9-1

Chapter 9 OverviewChapter 9 Overview

Specific hazards working in die casting plantSpecific hazards working in die casting plant By being aware, they can be avoided, By being aware, they can be avoided,

ensuring a safe work environmentensuring a safe work environment Obvious hazards are liquid metal and large Obvious hazards are liquid metal and large

powerful machinespowerful machines

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Chapter 9 ObjectivesChapter 9 Objectives

Correctly identify personal protective Correctly identify personal protective equipmentequipment

List eight hazards in the die casting List eight hazards in the die casting workplaceworkplace

List seven steps to safely use compressed List seven steps to safely use compressed airair

List six steps to safe handling of castingsList six steps to safe handling of castings

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Safety in the WorkplaceSafety in the Workplace

Safety is a defensive attitudeSafety is a defensive attitude Pursuit of safety requires top management to Pursuit of safety requires top management to

be fully committed to safetybe fully committed to safety Hazards occurring in the die casting plant:Hazards occurring in the die casting plant:

• Pinch, snag, strike, burn, electric shock, pierce, Pinch, snag, strike, burn, electric shock, pierce, slip-fall, trip-fall and fireslip-fall, trip-fall and fire

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Protective ClothingProtective Clothing

Wear natural vs. synthetic clothingWear natural vs. synthetic clothing Cover upCover up

• Shirts with long sleeves, Shirts with long sleeves, buttoned at the wristbuttoned at the wrist

• Long pantsLong pants• Molder’s bootsMolder’s boots• GlovesGloves• Safety glassesSafety glasses• Helmut, if requiredHelmut, if required

9-5

Machine SafetyMachine Safety

DCM has:DCM has:• Moving parts, pinch and shear points, lubricants, Moving parts, pinch and shear points, lubricants,

hydraulic fluid, and electrical controlshydraulic fluid, and electrical controls Particular areas of the machine may be hotParticular areas of the machine may be hot Die casting dieDie casting die

• Hot at operating temperatures, can have pinch and Hot at operating temperatures, can have pinch and shear pointsshear points

Auxiliary equipment has specific safety Auxiliary equipment has specific safety considerationsconsiderations

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Work Environment:Work Environment:Trip-fall HazardsTrip-fall Hazards

Must keep area Must keep area neat and cleanneat and clean

Tripping obstacles Tripping obstacles can cause injurycan cause injury

Machines have components Machines have components that project outthat project out• These are trip-fall hazardsThese are trip-fall hazards• These items should be painted with standard OSHA color These items should be painted with standard OSHA color

coding to make them more visiblecoding to make them more visible

9-7

Work Environment:Work Environment:NoiseNoise

Excessive noise can be a hazard that can result in Excessive noise can be a hazard that can result in hearing losshearing loss

The combination of noises make it wise to use The combination of noises make it wise to use hearing protectionhearing protection

At minimum, earplugs are recommendedAt minimum, earplugs are recommended

9-8

Work Environment:Work Environment:Slip-fall HazardsSlip-fall Hazards

Lubricants, release, cooling Lubricants, release, cooling agents often get on the floor agents often get on the floor and cause a slip-fall hazardand cause a slip-fall hazard

Follow good house-Follow good house-keeping practiceskeeping practices

Use surface-drying Use surface-drying compounds on spills compounds on spills

Follow rigid equipmentFollow rigid equipmentmaintenance and preventative programsmaintenance and preventative programs

9-9

Work Environment:Work Environment:Floor ClutterFloor Clutter

Floor clutter creates Floor clutter creates slip-fall hazardsslip-fall hazards • Electric cords, cables, Electric cords, cables,

and hoses running and hoses running across the flooracross the floor

• Process debris such as Process debris such as scrap, biscuits, runners, scrap, biscuits, runners, overflows, spruesoverflows, sprues

All hoses, pipes and cables at floor level should be in All hoses, pipes and cables at floor level should be in a trench that is properly covereda trench that is properly covered

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Work Environment:Work Environment:Operator Platforms and Operator Platforms and ControlsControls

Operator PlatformsOperator Platforms• These establish the These establish the

proper working height and proper working height and prevent fatigueprevent fatigue

• Should be of uniform Should be of uniform height for similar machinesheight for similar machines

• Need to provide a non-Need to provide a non-skid surfaceskid surface

• Proper working heights minimize physical strainProper working heights minimize physical strain ControlsControls

• Must be at the proper height to avoid fatigueMust be at the proper height to avoid fatigue

9-11

High Pressure AirHigh Pressure Air

Escaping air can be noisy and an air blast Escaping air can be noisy and an air blast can carry small particles of dirt or metalcan carry small particles of dirt or metal

Air connections should be secured by strong Air connections should be secured by strong couplings and connectorscouplings and connectors

Air hoses should be arranged to prevent Air hoses should be arranged to prevent tripping hazardstripping hazards

9-12

Steps of High Pressure Air Steps of High Pressure Air SafetySafety

Check all air hose connections before Check all air hose connections before turning on the air or pressurizing the linesturning on the air or pressurizing the lines

When turning air on or off, hold nozzle end of When turning air on or off, hold nozzle end of the hose to prevent whipping of the air linethe hose to prevent whipping of the air line

Shut off the air before adjusting air toolsShut off the air before adjusting air tools Never point an air nozzle at anyoneNever point an air nozzle at anyone

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Steps of Steps of High Pressure Air Safety High Pressure Air Safety cont.cont.

Do not use air to dust off hair or clothing, or Do not use air to dust off hair or clothing, or to sweep the floorto sweep the floor

Wear safety glasses when using high-Wear safety glasses when using high-pressure airpressure air

Inspect air hoses regularly and request Inspect air hoses regularly and request prompt repair of defective lines prompt repair of defective lines

9-14

Material HandlingMaterial Handling

Inspect materialsInspect materials Get a firm grip on the objectGet a firm grip on the object Keep fingers away from pinch pointsKeep fingers away from pinch points Keep hands away from the ends of long objects Keep hands away from the ends of long objects

to prevent pinching handsto prevent pinching hands Wipe off greasy, wet, slippery or dirty objects Wipe off greasy, wet, slippery or dirty objects

before trying to handle thembefore trying to handle them Keep hands free of oil and grease Keep hands free of oil and grease

9-15

Working with Metals:Working with Metals:ExplosionExplosion

If any liquid containing If any liquid containing water gets under the water gets under the surface of the liquid surface of the liquid metal, the water will turn metal, the water will turn to steam, causing the to steam, causing the metal to explode and metal to explode and spray out of the furnacespray out of the furnace

When water turns to steam, it rapidly expands to 1500 When water turns to steam, it rapidly expands to 1500 times its volumetimes its volume

Can be a secondary explosion, more violent than the Can be a secondary explosion, more violent than the firstfirst

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Industry SafetyIndustry Safety

Incidence rate for lost work injuriesIncidence rate for lost work injuries• In aluminum die casting at 7.8 per 100 workersIn aluminum die casting at 7.8 per 100 workers• 6.4 per 100 workers in “other non-ferrous die 6.4 per 100 workers in “other non-ferrous die

casting”casting” These rates are almost double those for all These rates are almost double those for all

manufacturing sectors at 4.2 incidents per manufacturing sectors at 4.2 incidents per 100 workers 100 workers

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SummarySummary

Many hazards are associated with working in Many hazards are associated with working in a die casting planta die casting plant

Safety is a defensive attitude, requiring Safety is a defensive attitude, requiring commitment from top management downcommitment from top management down

Personal protective clothing and accessories Personal protective clothing and accessories helps minimize your risk to certain hazardshelps minimize your risk to certain hazards

Several places on the DCM can cause injury, Several places on the DCM can cause injury, including hot dies, pinch and shear pointsincluding hot dies, pinch and shear points

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SummarySummary

Work environment hazards include cords, Work environment hazards include cords, hoses, floor clutter, and obstacleshoses, floor clutter, and obstacles

High pressure air can be hazardous; follow High pressure air can be hazardous; follow safety guidelines when using itsafety guidelines when using it

Always follow the safety guidelines when Always follow the safety guidelines when handling materialshandling materials

Liquid metals can explode if any water is Liquid metals can explode if any water is mixed into the melted metalmixed into the melted metal