Safety Resources

Respirable Crystalline Silica

OSHA's respirable silica regulations are affecting almost every foundry in the United States. NFFS has provided a comprehensive silica compliance program and resource page designed specifically to help YOUR FOUNDRY with meeting the new silica regulations.

Written OSHA Compliance Programs

Many times, OSHA regulations require a WRITTEN program in additional to employee training and other requirements. Here is a listing of the most commonly requested written OSHA template documents. These documents must be edited by your firm prior to implementation in order to customize them and make them representative of your own organization:

  • Asbestos Program - A program for those who do NOT use asbestos in the manufacturing process but may have this mineral in the materials used in the building (such as the floors and ceilings).
  • Bloodborne Pathogens Program - A program developed by an OSHA area office for those companies that do NOT have persons on staff as primary health care providers. This program covers employees who provide first aid or assistance as a collateral (not primary) part of their jobs. The full text of the OSHA standard is included.
  • Cadmium Program - A written compliance program for foundries that utilize materials containing Cadmium metal.
  • Confined Space/Permit-Required Confined Space - A program to help foundries manage their confined spaces and their permit-required confined spaces
  • Electrical Safety Program - A written electrical safety program for foundries.
    Emergency Action Program - A program for the emergency response to fires, floods or other situations that require evacuation of the foundry.
  • Entry Policy - A template entry policy designed to help manage admission of inspectors into the foundry, including who is authorized to admit entry into the plant and what to do if that person(s) is not available. Template entry policy is available on page 2.
  • Hazard Communication Program - A written Hazard Communication Program template.
  • Hazard Communication Program - GHS Supplement - A written supplement to the Hazard Communication program to align the program with the requirements of the Globally Harmonized System (GHS) of Hazard Communication
  • Lead Program - A full program that includes an example of the 'facility description' section that describes how lead enters the plant, how employees are exposed, control methods and compliance programs. It is for all facilities including separate sections for large and small foundries, and includes the full text of the OSHA lead standard including appendices.
  • Lockout/Tagout Program - A program developed by an OSHA area office to meet the lockout/tagout standard. It includes the written program and checklists for equipment and evaluation of the program. The full text of the OSHA standard is also included.
  • Medical Access Program - A brief program outlining the standard and a notice for posting. The full text of the OSHA standard is also included.
  • Personal Protective Equipment (PPE) Program - A written personal protective equipment program. All of the PPE standards (except respiratory protection which has its own program) and forms which can be used to evaluate the facility and certify compliance. Sample forms for specific foundry jobs can be found at the end of this program. This document is for guidance only, actual PPE requirements will vary from facility to facility depending on the scope and magnitude of the hazards encountered in each facility.
  • Respiratory Protection Program - A full program to document the respiratory protection program in the foundry. This includes sections on who must be included, types of respirators, proper selection, maintenance, fit testing, medical evaluation and recordkeeping. Sample forms are provided to document compliance. The standard is included as an appendix.
  • Written Silica Control Plan Template - A written respirable silica dust program for foundries.
Safety Training Programs 

A suite of different training programs developed by NFFS  under the Susan B. Harwood Grant Program in cooperation with the Occupational Safety and Health Administration or OSHA (DOL). These program are available for free and have been developed specifically for the foundry industry. Topics include the following:

  • Lead Hazards in the Foundry - The OSHA Lead standard is one of the most commonly cited sections in the metal casting industry. Often times, ineffective lead programs are caused by poorly trained workers and incomplete written compliance programs. Utilizing up-to-date- training materials and compliance programs can increase the effectiveness of your own lead program, resulting in a safer workplace and a smarter workforce.Make sure your Lead Program is up to date!
  • Lockout/Tagout (Control of Hazardous Energy) - The OSHA regulations addressing the control of hazardous energy, also known as Lockout/Tagout, are critical for ensuring the worker safety in the foundry. This comprehensive lockout/tagout training program was specifically designed to train employers and employees in the cast metals industry about the principals of controlling hazardous energy in order to prevent work-related fatalities and accidents. 
  • Workplace Emergency Planning - Every year, emergencies exact their toll on both business and people alike.The costs, in terms of both lives and dollars, can be substantial. However, by planning ahead, most foundries can limit injuries, reduce facility damage, and return to operations much faster after an emergency strikes. Is your facility prepared to handle a fire or explosion? What about a tornado, or an armed employee? When do you evacuate, and when do you simply move to a safe part of the plant. The answers to these and many other questions are just a training program away!
  • Foundry Noise Exposure - According to OSHA, approximately 30 million people in the United States are occupationally exposed to hazardous noise levels every year. Noise-related hearing loss has been listed as one of the most prevalent occupational health concerns in the United States for more than 25 years. The exposure levels in the foundry industry is of particular concern to OSHA. Now is the time to make sure your noise exposure program is properly implemented and up to date!
  • Foundry Air Contaminants - During the manufacturing process, foundries and die-casters can release potentially hazardous contaminants into the workplace. The types of contaminants potentially emitted is dependent on the materials and process used to make castings. It is important for the management of these facilities to protect their employees from the hazards presented by these contaminates, not only to provide a safe work environment, but to also avoid potentially severe fines and criminal penalties from federal regulatory agencies.
  • Hazard Communication aligned with GHS (Globally Harmonized Standard) - Our training program addressing the new Globally Harmonized System of Classification and Labeling of Chemicals (GHS) is now available. Developed specifically for non-ferrous foundries, this program will provide all of the employee training materials necessary for your foundry to successfully transition to the new GHS system of hazard communication.
  • Electrical Safety/Arc Flash - Electrical hazards are the fourth leading cause of occupational fatalities in the U.S., killing approximately one worker per day, permanently disabling 3,600 workers per year, and injuring untold thousands of additional workers with electrical shocks and severe burns. The costs in lives, medical expenses and company liability are staggering.
NFFSummit Safety, Health and Environmental Webinar Archives 

These  archives allow NFFS members to review previous monthly NFFS webinars on demand. Have a question related to Occupational Safety, Health and Environmental topics? The answer is likely in our archives and just a click away! 

Regulatory Compliance Hotline for NFFS Members

Have you ever had a safety or environmental question, and wished you could call someone for a quick answer? NFFS has you covered! Joseph A. Guimond & Associates has worked with NFFS members for over 25 years as OSHA and EPA Compliance Specialists. Skip and Martha Guimond are well known as industry experts in providing no-nonsense compliance assistance and advice. They are available to assist NFFS members with specific regulatory questions or problems via the NFFS Regulatory Compliance Hotline. All conversations are private and confidential.