Article originally published in the Foundry Trade Journal Issue December/January 2024-2025
2024 Review – What Happened?
The past year has highlighted the ongoing need for personal protective equipment (PPE) in the metals and foundry industries, as the hazards of high temperatures, molten metal splashes, and airborne contaminants cannot be overlooked.
Respiratory Hazards: Choosing Effective Protection
In 2023, an estimated 12,000 lung disease deaths in the UK were linked to past exposure to hazardous substances in the workplace, emphasizing the critical need for effective respiratory protection both presently and moving forward.
Airborne contaminants, including silica dust, welding fumes, and harmful gases, pose significant health risks in foundries. The long-term effects can lead to conditions such as asthma, lung disease, and silicosis. The choice of respiratory protective equipment (RPE) is vital and depends on various factors including the type of contaminant, the duration of exposure, and the tasks being performed.
For short tasks disposable FFP3 masks may suffice, but for extended periods of work like fettling, or when workers have facial hair, powered respirators offer superior protection and also provide a flow of clean air to the wearer, reducing fatigue and ensuring comfort. Given that HSE guidance also recommends regular breaks for unpowered masks, the benefits of powered air systems become clear.
High Heat Protection: The Role of Aluminised Clothing
In the metals industry, workers face intense radiant heat and the risk of molten metal splash, making aluminised clothing an important component of PPE. This specialised gear reflects over 90% of radiant heat and allows molten metal splashes to slide off, reducing the risk of severe burns.
The level of protection required depends on the specific activity and associated risks. Aluminised garments come in various forms, including aprons, jackets, trousers, and full hoods. Notably, different types of molten metal require different levels of protection; for instance, molten aluminium, despite its lower melting point compared to molten iron, poses unique risks due to its viscosity.
High Heat Hand Protection: Gloves for Every Task
Hand injuries are among the most common in the metals industry, making high-heat gloves essential for protection against burns and abrasions during metal handling and finishing processes. Choosing the right gloves begins with understanding the specific risks involved in each task. Factors such as temperature, dexterity, and potential exposure to cuts or punctures must be considered.
Glove options vary significantly, from durable aramid gloves that withstand temperatures from 250°C to 1000°C, to flexible leather gloves designed for precision tasks such as grinding. Innovations in glove technology now allow for thinner materials that maintain high levels of cut and heat resistance, ensuring that workers can perform their tasks safely without sacrificing dexterity.
Footwear, clothing and other PPE:
The most common protection method might be to wear foundry boots and D3, E3 clothing to protect against molten metal spatter and other industry hazards. Choosing the right type to fit the level of risk and the demands of the job is critical though and might involve some trials. Accessories such as aprons, gaiters, sleeves, neck capes and more can play a large role in both increasing the level of protection and increasing the lifespan of critical PPE.
This is where MF Safety can help:
The correct protection is needed for every task. It is vital to choose a supplier who can give advice, a good service level, and communicate clearly at every stage of the process.
MF Safety & Workwear is a PPE and clothing supplier based centrally in the UK in the Midlands. Family owned and run, the company has been established in PPE and safety since 1991. They provide the following:
- Aluminised clothing,
- High heat protective gloves,
- High heat head and face protection,
- Specialist foundry boots,
- Molten metal splash clothing,
- Respiratory protection,
- Hand cut protection.
MF Safety & Workwear supply across the UK foundry, castings and forging sectors, providing information and guidance as well as the products to help companies protect staff with a service that can be trusted.
Contact MF Safety & Workwear:
Tel: +44 (0)115 925 2261
Email: [email protected]