Subchapter E. FOUNDRIES
GENERAL PROVISIONS Sec.
47.151. Definitions.
47.152. Scope.
47.153. Penalty.
SPECIFICATIONS
47.161. Entrances and windows.
47.162. Gangways.
47.163. Smoke, steam, gases, and dust.
47.164. Lighting and heating.
47.165. Sanitary conveniences.
47.166. Lockers.
47.167. Maintenance.
47.168. Employment of women.
47.169. Brass foundries.
47.170. Future cellar or basement foundries.
47.171. Existing cellar and basement foundries.
Authority The provisions of this Subchapter E issued under the act of June 2, 1913 (P. L. 396, No. 267) (71 P. S. § 1442); and the act of May 18, 1937 (P. L. 654, No. 174) (43 P. S. § § 25-1—25-15), unless otherwise noted.
Source The provisions of this Subchapter E adopted August 16, 1929, amended through May 1, 1967, unless otherwise noted.
GENERAL PROVISIONS
§ 47.151. Definitions.
The following words and terms, when used in this subchapter, have the following meanings, unless the context clearly indicates otherwise:
Basement—A story partly, but not more than 1/2 below the level of the ground surrounding the building and shall be considered the first story of such building.
Brass foundry—A place where brass, aluminum, copper, tin, zinc, gold, silver, or composition metals containing any of the foregoing metals are melted or poured into molds in the making of castings, except that foundries where only aluminum is melted shall be covered by regulations governing iron and steel foundries.
Cellar—A story more than 1/2 below the level of the ground surrounding the building.
Entrance—A main doorway opening directly to the outer air.
Gangway—A well-defined passageway dividing the working floor of the foundry but not the spaces between molds. Spaces between molds shall be divided into three classes, which shall be known as bull-ladle aisles, hand-ladle aisles and buggy-ladle aisles.
Iron or steel foundry—A place where iron or steel or both metals are melted and poured into molds in the making of castings, together with cleaning, core making, drying, washrooms and toilet rooms, used in connection with the castings.§ 47.152. Scope.
This subchapter sets forth rules to safeguard the lives, limbs and health of workers in foundries, and places the responsibility of complying with these rules upon both employer and employe.
§ 47.153. Penalty.
Any person who violates this subchapter or any regulations of the Department or who interferes with the Department or its duly authorized representative in the enforcement of these provisions or regulations shall be penalized under the provisions of section 15 of act of May 18, 1937 (P. L. 654, No. 174) (43 P. S. § 25-15).
SPECIFICATIONS
§ 47.161. Entrances and windows.
Entrances to foundries shall be protected from November 1 to April 1 of each year by a covered vestibule, either stationary or movable, which shall be constructed so as to eliminate drafts and of such dimensions as to answer ordinary purposes, such as the passage of wheelbarrows, trucks and small industrial cars. This requirement does not apply to entrances used for railroad or industrial cars handled by locomotives or motors, or for traveling cranes, horse-drawn vehicles or automobiles. The entrances may remain open only for such time as is necessary for the ingress and egress of such cars, trucks, cranes, horse-drawn vehicles or automobiles. No locomotive shall remain inside the foundry during the loading or unloading of the cars.
§ 47.162. Gangways.
(a) Main gangways, where metal is carried by hand, bull or truck ladles, shall be not less than 5 feet wide. Truck-ladle gangways, which are not main gangways, shall be not less than 4 feet wide. Bull-ladle aisles between floors shall be not less than 3 feet wide. Single hand-ladle or buggy-ladle aisles between floors shall be not less than 18 inches wide. When trolleys are used over molding floors for pouring metal, the aisles shall be of sufficient width to permit the safe ingress and egress of employes and the safe use of the ladles. When it is necessary to occupy the central portion of the floor space in the production of castings, continuous gangway space shall be provided.
(b) During the progress of casting, each gangway or aisle shall be kept entirely free from undue dampness or obstruction of any kind. Each gangway shall be kept in good condition at all times. Each gangway used for industrial trucks shall be constructed of a hard material of substantial character, and the top of the rail shall be flush with the floor.
§ 47.163. Smoke, steam, gases, and dust.
(a) Ventilation. When smoke, steam, gases or dust, arising from any of the operations of the foundry, are dangerous to health or eyes, and when a natural circulation of air does not carry off such smoke, steam, gases or dust there shall be installed and operated hoods, ventilators, fans or other mechanical means of ventilation.
(b) Castings. The cleaning and chipping of castings shall be done in separate cleaning rooms, except that in existing installations where traveling cranes or cars are used for conveying castings into the rooms, a separating partition shall be erected not less than 12 feet in height. In existing installations, where the crane cage or crane girders do not permit the erection of a 12 foot partition, the height of the partition may be reduced sufficiently to permit the clearance of cranes and cars. Large castings may be chipped or cleaned by hand in the molding and casting room, if sufficient protection is furnished by the use of a curtain, screen, or some other means equally good to protect employes who are otherwise employed in the cleaning rooms. This requirement does not apply if mechanical contrivances are used for cleaning castings, and the dust and particles arising from it are effectively removed at the point of origin by an exhaust system.
(c) Exhaust systems. When tumbler mills are used, exhaust systems shall be installed to carry off effectively the dust arising from the cleaning of castings, except when the mill is operated outside the foundry. This requirement shall not prohibit the use of a water barrel to clean castings. Sand blast operations shall be carried on in the open air or in a separate room solely for such purposes. The milling of cupola cinders, when done inside the foundry, shall be carried on by an exhaust or water mill.
(d) Floor slope. The floor beneath and immediately surrounding the cupola shall slope and drain away from the base of it.
(e) Compressed air. Cores shall not be blown out of castings by compressed air, unless such work is done outside the foundry or in a special room or dustproof enclosure. Men employed in cleaning castings by compressed air or sand blast shall be provided and wear approved head and eye protectors.
§ 47.164. Lighting and heating.
(a) Lighting. The lighting of foundries shall conform to the requirements of Chapter 27 (relating to lighting).
(b) Heating. Proper and sufficient heat shall be provided and maintained in each foundry. Open fires may be used for the drying of molds or cores if coke containing less than 1% of sulphur is used. Also charcoal, gas or oils may be so used. If practicable, such drying of molds or cores shall be done at night.
(c) Drying of ladles. All hand and bull ladles shall be dried in ovens or outside of the foundry. A sufficient number of sheet-iron shields shall be available in iron foundries for use in covering hand and bull ladles.
(d) Clothes of employes. Suitable facilities shall be provided for the thorough drying of the clothing of employes. The facilities may be located in the washroom, the locker room or in a room used exclusively for this purpose.
§ 47.165. Sanitary conveniences.
(a) Toilet rooms. Each foundry employing ten or more persons shall provide and maintain for the use of the employes, in a place conveniently accessible and connected with the foundry making it accessible without exposure to the open air, a toilet room of suitable size in which the employes may change their clothes. The toilet rooms shall have washbowls or washtroughs so arranged that water does not stand in them, of sufficient capacity adequately equipped with hot and cold water service. The washrooms shall be kept clean and sanitary and properly heated during cold weather. Each foundry shall establish and maintain separate from such toilet rooms, a suitable water closet. The toilet room and the water closet shall be connected with the foundry building making them accessible to it without exposure to the open air. They shall be properly heated, ventilated, cleaned and protected from the dust of the foundry. The requirement of the covered passageway between the foundry and the toilet rooms shall not apply to employes who as an ordinary part of their occupation work out of doors at all seasons of the year.
(b) Toilet facilities. Each foundry shall provide water closets or chemicals closets of an approved type, separate for each sex, in accordance with the following table:
Number of Persons Number of Closets Ratio 1—10 1 1:10
11—25 2 1:12 1/2 26—50 3 1:16 2/3
51—80 4 1:20 81—125 5 1:25 (c) Additional employes. For each additional 45 employes, or part of that number, the foundry shall provide one additional water closet.
(d) Number of employes. If less than 30 males are employed at one time, there shall be provided one individual urinal. If more than 30 and less than 80 males are employed, two urinals shall be provided, and thereafter one individual urinal shall be provided for every 80 men, or part of that number, employed. At least two linear feet of trough or slab urinal shall be considered the equivalent of one individual urinal.
(e) Washbasins. Washbasins with faucets for hot and cold water shall be supplied in accordance with the following table:
Number of Persons Number of Wash Basins Ratio 1—8 1 1:8
9—16 2 1:8 17—30 3 1:10
31—45 4 1:11 1/4 46—65 5 1:13
(f) Additional employes. For each additional 25 employes, or part of that number, at least one additional washbasin shall be supplied. Two feet of trough and two faucets supplying hot and cold water, so arranged that the water supply may be mixed to the desired temperature, shall be considered the equivalent of a washbasin as setout in subsection (e). If it is desirable to mix the water supply at some location remote from the trough, an outlet for the mixed supply shall be provided for at least every 2 feet of trough.
(g) Shower baths. Washrooms installed after 1927, where 20 to 50 men are employed, shall be provided with at least one shower bath with an ample supply of hot and cold water. For each additional 50 men, or part of that number, at least one additional shower bath shall be provided.
(h) Passageway. If workmen are employed in heated rooms or buildings of foundries, and the required toilet facilities are provided in adjacent buildings or rooms, a covered passageway leading to such facilities shall be made to protect the workmen from a sudden change of temperature.
(i) Calculation. In using the tables of this section for calculating the number of facilities required, the maximum number of persons using the facilities at any time may be considered rather than the total number of persons employed.
§ 47.166. Lockers.
Individual lockers, arranged for locking, shall be provided for employes and placed in a room used exclusively for such purpose, such as the washroom, the drying room, or at convenient places in the molding room. In cases of dispute, the necessity for, and the number of, such lockers shall be determined by the Board.
§ 47.167. Maintenance.
(a) Inspectors. Ladles, shanks, tongs, slings, yokes, skimmers, and slag hoes used in the pouring of molten metal shall, prior to their use, be inspected daily as to their safety by the men preparing and using them. A regular inspection as to their safety shall be made once a month by a man designated for that purpose. A monthly inspection shall also be made of the chains and cables on counterweights used in connection with drying ovens, and a record kept of such inspections.
(b) Fireways. Fireways connected with drying ovens, when built in the floor, shall at all times be protected by either a substantial protecting cover or a standard railing as defined in Subchapter G (relating to railing, toeboards, open-sided floors, platforms and runways).
(c) Trapdoors. Trapdoors shall be guarded when open, either by standard railings as defined in Subchapter G or by watchman. All pits shall be covered or railed when not in use and sufficiently guarded at other times.
(d) Passageways and stairs. Passageways, stairways, inclines, runways, charging decks and platforms shall be properly lighted and have tread surfaces so constructed and maintained that persons walking on them do not slip or trip, and safeguarded with standard railings as defined in Subchapter G.
(e) Worm gears. All ladles pouring from the lip of 2,000 or more pounds capacity shall be equipped with a worm geared device for tilting the device. Ladles not so equipped shall be changed to conform with this requirement. All crane truck and trolley pouring ladles shall be so constructed that the center of gravity is below the bail, unless ladles are equipped with a geared device and a clip to prevent overturning.
(f) Trunions. Trunions on flasks shall sustain the loads they are required to handle. Trunions constructed after 1927 shall be carefully designed to carry the load they are to handle and constructed with a factor of safety of at least ten including bolts when they are used. The diameter of the button shall be equal to the diameter of the groove plus 1 1/2 times the diameter of the sling used to handle the flask. Inside corners shall be well filleted, and, in order to prevent the sling slipping off or riding the button, the radius of the corner between groove and button shall be approximately equal to the radius of the sling used with the remainder of the inside edge of the button straight. All trunions constructed after October 1, 1915, shall bear the date of their construction.
(g) Explosives. The use of high explosives on the foundry premises for the breaking of castings is prohibited unless effective protection is provided.
(h) Drop. The breaking of castings by the use of a drop inside the foundry during working hours is prohibited.
(i) Drop outside the foundry. When a drop is used for the breaking of castings or scrap outside of the foundry, a permanent shield of heavy planking or other effective protection shall be provided.
(j) Safety devices. Each employe shall use safety devices furnished for his protection by the employer, when there is a hazard connected with his employment.
(k) Legs and feet. Persons employed in iron or steel foundries who remove or handle pots or ladles containing molten metal from furnaces shall be provided with protection for the legs and feet and worn at all times while engaged in such work.
(l) Head and eye. Each employe whose head, eyes or neck is subject to injury from flying particles, heat or glare, or from the handling of molten metal shall be provided with and use protection as specified in Chapter 39, Subchapter C (relating to head and eye protection).
(m) Tumbler barrels. Tumbling barrels shall be guarded as follows:
(1) All drive belts, gears and shafting shall be guarded as required by Chapter 29 (relating to mechanical apparatus—miscellaneous) on all types of tumbling barrels.
(2) Horizontal revolving and reciprocating tumbling barrels operated singly or in a single line shall be guarded as follows:
(i) Loading and unloading sides shall be guarded either by a guard 6 feet high with not more than 1/2 inch mesh, such guard rising vertically or inclined, or a hood over the barrel supported by counterweights. In either method it shall be interlocked with a belt shifter.
(ii) When a clearance of 15 inches on all sides of the barrel is obtained and the barrel revolved upwards from the loading and unloading sides with all projections pointed downward, no enclosure is required.
(3) When barrels operate back to back there shall be a platform over the shaft.
§ 47.168. Employment of women.
(a) When rooms in which core ovens are located adjoin rooms where cores are made by females, and where the making of cores and the baking of cores are simultaneous operations, the partition between the rooms shall be constructed of concrete, hollow tile, brick, metal or other similar material, and there shall be in the partition only openings that are required by the nature of the business.
(b) Openings in partitions between the core oven room and the room in which females are employed shall be vestibuled with a revolving device, or double doors which shall be self-locking, or any other self-closing device equally effective. The device shall be kept in a condition that gases, fumes and smoke are effectively trapped.
(c) No female shall handle cores which have a temperature of more than 110°F.
§ 47.169. Brass foundries.
(a) Generally. The regulations relating to dust, smoke, gases, fumes, ventilation, sanitation, heat, light, gangways, aisles, safety appliances, washrooms, cleaning rooms, drying and locker accommodations, as specified for iron and steel foundries, shall apply to brass foundries, except that main gangways shall be not less than 4 feet wide and gangways between molds on spill troughs not less than 3 feet wide.
(b) Platform. When the crown plate of an upright melting furnace is elevated above the surrounding floor in excess of 12 inches, the furnace shall be equipped with a platform guarded with a standard railing. The platform shall be constructed of metal or other fire-resistive material, extend along the front and sides of the furnace flush with the crown plate, be at least 4 feet in width, and be clear of all obstructions during pouring time. If the platform is elevated above the floor in excess of 12 inches, the lowering from the platform of crucibles containing molten metal shall be by mechanical means.
(c) Crucibles. When the combined weight of a crucible, tongs and molten metal exceeds 100 pounds, it shall be removed from the furnace and deposited on the floor by mechanical means.
(d) Smoke boxes. When smoke finish is desired on molds made on benches or tubs, smoke boxes which shall effectively trap the smoke shall be used and connected with flues to the outer air.
(e) Molders. When molders work side by side, at least 5 feet of space sideways shall be allowed for each employe, and a clear space of 3 feet shall be provided back of each employe.
(f) Ventilators. Hoods shall be provided directly above all brass melting furnaces using gas or oil as fuel, which effectively trap all gases and fumes generated in the melting of the metal. The hoods shall be provided with outlet pipes to lead the gases or fumes to the outer air. Ventilators shall be provided over all other furnaces used for melting brass or composition metal to effectively remove the gases above the furnaces.
(g) Light. Brass foundries shall be provided with natural light from at least two sides, or from at least one side with skylights in the roof.
(h) Legs and feet. Persons removing or handling pots containing molten metal from furnaces shall be provided with protection for the legs and feet.
(i) Dirt riddling. Gangway dirt and floor scrapings shall not be riddled in the room where workmen are employed, unless it is dampened so as to prevent the rising of dust.
(j) Stoves. When stoves for drying molds are located in the rooms used by workmen they shall be surrounded by a casing of fire-resistive material to the full height of the stove.
(k) Ceiling. No brass foundry shall be constructed after November 1, 1915, with a clearance less than 14 feet between the lowest point of the ceiling and the floor, except that where a peak, saw-tooth, monitor or arch roof is constructed, the side walls may be of a minimum height of 12 feet.
§ 47.170. Future cellar or basement foundries.
No foundry shall be located after November 1, 1915, in a cellar or basement unless both the ceiling is at least 14 feet in height, measured from the finished floor to the under side of the ceiling, and proper and adequate provisions are made for lighting and ventilation. In addition to these two requirements if the foundry is, or is intended to be, located entirely in the front part of the building, the ceiling shall be in every part at least 6 1/2 feet above the curb level of the street in front of the building; or, if the foundry is or is intended to be located entirely in the rear part of the building or to extend from the front to the rear the ceiling shall be not less than 3 feet above the curb level of the street in front of the building and the foundry shall open upon a yard or court which shall extend 6 inches below its floor level.
Cross References This section cited in 34 Pa. Code § 47.171 (relating to existing cellar and basement foundries).
§ 47.171. Existing cellar and basement foundries.
If any foundry that was operated in a cellar or basement on October 1, 1915, is or was discontinued or closed by the Department, it may not be reopened as a foundry unless there is strict compliance with § 47.170 (relating to future cellar or basement foundries). The occasional use of a foundry for the purpose of evading this requirement shall not be deemed a continuance of use of the foundry.
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