Indoor Air Quality Issues for Foundries
Introduction
An estimated 2,950 foundries are
located throughout the U.S. and employ
more than 225,000 people. These
foundries cast a variety of metals into
products that touch our lives everyday.
Although the industry consists of many
smaller operations serving specific
market niches, there are also a few large
“captive” foundries producing substan-
tial volumes of castings for markets such
as the automotive sector.
The foundry industry is changing. In
the last decade, there have been enor-
mous shifts in metal mix, increased
government regulation, more interna-
tional competition, and the introduction
of new materials and process technolo-
gies. Along with these changes have
come requirements to minimize environ-
mental emissions both inside and outside
the casting facility. The focus of this
report is indoor air quality; a look at the
important issues, and some suggestions
leading to workable solutions.
Background
In 1999, American foundries shipped 14.4
million tons (13.1 million metric tons) of
Perc ent of
Tonnag e S hipped,
S tate 1999
Oh io 16%
I n d ia n a 12%
Wis c on s in 12%
Al a b a m a 11 %
M ic h ig a n 10%
P e n n s y lv a n ia 6%
I llin o is 6%
Te n n e s s e e 4%
Ca liforn ia 4%
Te xa s 3%
S o u rc e : A F S
Table 1. Geographic Distribution of
Foundries - Top Ten States
products valued at $29 Perc ent of
billion. The industry is E nd-Us e Markets Cas ting s S hipped
centered in the Midwest, Au tom otiv e & L ig h t Tru c k 35%
P ip e & P ip e F ittin g s 15%
though there are foundries
Con s tru c tion , M in in g & Oil F ie ld E q u ip m e n t 6%
located in all 50 states. Table
In te rn a l Com b u s tion E n g in e s 5%
1 shows the top ten foundry R a ilroa d 5%
states and the percent of total Va lv e s 5%
tonnage shipped in the U.S. F a rm M a c h in e ry 3%
M u n ic ip a l Ca s tin g s (m a n h ole c ov e rs ,
Historically, locations for 3%
g ra te s , e tc . )
metal casting establishments
P u m p s & Com p re s s ors 2%
were selected for their Oth e r M a rke ts 21%
proximity to raw materials S o u rc e : A F S
(iron, steel and other Table 2. End-Use Applications for Foundry
metals), coal, and water for Projects
process cooling and trans-
portation. In recent years, the geo-
projected to increase 4 percent annually
graphic concentration of the industry is
for the next ten years. The metal mix in
changing as facilities are built where
the foundry industry for 1999 is shown
scrap metal and electricity are available
in Figure 1.
at a reasonable cost and there is a local
market for cast products. Metal castings are used in a variety of
applications. More than 90% of all
The overall market for metal castings is
manufactured goods and capital equip-
projected to grow just under 2 percent
ment use castings as engineered compo-
annually for the forseeable future.
nents or rely on castings for their
Efforts to reduce weight in parts cast for
manufacture. Nearly one-third of all
the automotive sector are not only
metal castings is produced for the
changing the metal mix from iron and
automotive and light truck market.
steel to aluminum and magnesium, they
Other major end-use markets include
are also opening the door to high
pipe & fittings, construction mining and
performance plastics and composites. In
oil equipment, internal combustion
1980, every domestically produced car
engines, railroad, and valves. A
used an average of 600 pounds (272 kg)
breakdown of these markets is shown in
of cast iron. By 1999, the average
Table 2.
amount of cast iron per vehicle dropped
to 325 pounds (147 kg). By 2006, it is The SIC codes included in the foundry
expected that the amount of cast iron per industry are listed below.
car will slip further to 230 pounds (104
SIC 3321 – Gray and Ductile Iron
kg).
Foundries
Though iron castings
Steel
made up nearly 75 Malleable Iron Aluminum
2% 10% 12% Other
percent of all castings
produced in 1999, this Ductile Iron
5%
number is expected to 29%
decline as the market
shifts to lighter metals.
The principal growth
Gray Iron
market is in aluminum 42%
castings, which are
Figure 1. 1999 Casting Shipments - Percent of Sales
1
 SIC 3322 – Malleable Iron Foundries
SIC 3323 – Steel Investment Casting
Foundries
SIC 3325 – Steel Foundries, not
elsewhere classified
SIC 3365 – Aluminum Foundries
SIC 3366 – Copper Foundries
SIC 3369 – Nonferrous Foundries, not
elsewhere classified
According to the U.S. Census bureau,
more than 50 percent of all foundries
operating today have less than 50
employees, and 80 percent employ
fewer than 100 employees. Only 6
percent employ more than 250 people.
Notable among the larger facilities are
the “captive” foundries operated by
original equipment manufacturers,
including General Motors, Ford,
Chrysler, John Deere, and Caterpillar.
Economic Trends and
Development Needs
The U.S. metal casting industry experi-
enced an unprecedented drop in produc-
tion during the 1970’s and 1980’s, but has
been recovering since the early 1990’s.
Between 1993 and 1994 alone, the U.S.
increased its share of world metal casting
production from 18 to 20 percent. The
increases in production came primarily
from increases in capacity utilization at
existing facilities rather than the construc-
tion of new facilities.
To stay competitive, the industry has
identified the following priority areas
for research and development to
improve its processes and products:
• improved casting technologies
• development of new casting materials
(alloys) and die materials
• development of higher strength and
lower weight castings
• improved process controls
• improved dimensional control
• improved the quality of casting
material
• reduced casting defects (DOE, March
1996)
• development of environmentally
improved materials to meet today’s
regulations.
2
Challenge
Today it is critical that the industry be
familiar with the environmental hazards
that employees are subjected to in the
workplace. Emission levels for foundry
operations have been thoroughly
reviewed by the Environmental Protec-
tion Agency (EPA), the Occupational
Safety and Health Administration
(OSHA), and Burgess (Health Hazards
in Industry, 1995). Exposures to
mineral dusts, metal fumes, products of
combustion, resin bonding systems,
physical noise, heat and vibration
hazards may seriously impact the health
of workers in foundries. Silica, a major
component of sand, can be converted to
forms that cause silicosis in workers.
Data from several hundred foundries
found airborne concentrations above the
OSHA Permissible Exposure Limit
(PEL) in 31 to 54 percent of the samples
taken. The challenge that foundries face
today is to produce a cost competitive
product while taking all necessary
precautions to protect the health and
safety of its workforce.
In addition, the Department of Energy’s
Office of Industrial Technologies has
prepared a Technology Roadmap of the
Metalcasting Industry as part of the
Industries of the Future program. This
roadmap notes that environmental needs
are one of the four key needs for the
future of that industry. This roadmap
was developed with the support of the
metal casting industry, including the
American Foundrymen’s Society, the
North American Die Casting Associa-
tion and the Steel Founders’ Society of
America.
Environmental
Standards and
Regulations
On November 15, 1990, President Bush
signed into law the first changes to the
Clean Air Act in 13 years. The new
legislation affects smaller foundries that
were not previously regulated. Any
metal caster producing more than 10
tons (9.1 metric tons) of air toxics per
year, or more than 25 tons (22.7 metric
tons) per year of a combination of listed
chemicals is included under the new
standards. The EPA established a list of
source categories of toxic air pollutants
as one that emits 10 tons (9.1 metric
tons) per year of a single substance or
25 tons (22.7 metric tons) per year of
any combination of substances.
Exposure sources and chemicals of
concern taken from EPA reports,
including the latest version of AP-42,
are summarized in Table 3. The types
of emissions generated, by process
operation, are also listed in Table 3.
The green sand molding process is the most
common molding process, accounting for
nearly 90% of castings produced in the
U.S. An example of emissions by process
operation is shown in Figure 2.
Investigation into OSHA records for the
most recent 100 facility audits for the Iron
and Steel foundries provides some addi-
tional insights into the air quality issues
affecting foundries. Foundries reported
an incident and injury rate of 21.5 per 100
workers in comparison to the national av-
erage of 8.8 for all manufacturers. The
foundry SIC codes range from a low of
12.8 injuries (SIC 3324) to a high of 25.4
injuries (SIC 3322) per 100 workers.
In reviewing 400 audits, 1,392 violations
were sorted by reported violation. Viola-
tions pertaining to indoor air quality (IAQ)
are summarized in Table 4.
Approximately 23% of the total violations
are related to airborne contaminants in the
workspace. The chemicals of concern in-
clude asbestos, organics, metal fumes and
particulates such as silica dust.
There were 52,500 reported lost workday
cases for SIC 33 in 1998 for a total indus-
try employment of 714,200 workers. The
foundry industry employs about 110,000
workers with lost time of just over 8,000
work days. Assuming each worker costs
$30/hour, and that 15 - 25% of the lost
days were related to IAQ, the annual cost
for the industry approaches $1 - 2 million
per year. And this is just the reported
cases.
Indoor Air Quality
Regulations
Many different organizations have regu-
lations and/or standards that are used to
determine the adequacy of the indoor air
environment. These organizations, their
pertinent rules and/or regulations and the
areas of indoor environment they address
are summarized below.
 Indus trial
Proc es s Air E mis s ions
Pattern Making Vola tile Org a n ic Ca rb on s (V OCs ) from g lu e s , p la s tic re s in s , u re th a n e a d h e s iv e s ,
e p oxie s a n d p a in ts
Mold and Core Preparation and Pouring
G re e n S a n d S ilic a a n d oth e r p a rtic u la te s , m e ta l oxid e fu m e s , c a rb on m on oxid e , org a n ic
c om p ou n d s , h y d rog e n s u lfid e , s u lfu r d ioxid e a n d n itrou s oxid e . Als o, b e n z e n e ,
p h e n ols , form a ld e h y d e s a n d oth e r h a z a rd ou s a ir p ollu ta n ts (HAP s ) if c h e m ic a lly
b on d e d c ore s a re u s e d . P a rtic u la te e m is s ion s a re g e n e ra te d d u rin g m ixin g , m old in g
a n d c ore m a kin g op e ra tion s s . Wh e n g re e n s a n d a d d itiv e s a n d c ore s a n d b in d e rs
c om e in to c on ta c t with th e m olte n m e ta l, th e y p rod u c e g a s e ou s e m is s ion s s u c h a s
c a rb on m on oxid e , org a n ic c om p ou n d s , h y d rog e n s u lfid e , s u lfu r d ioxid e , n itrou s
oxid e , b e n z e n e , tolu e n e , xy le n e s , p h e n ols a n d oth e r HAP s .
P e rm a n e n t M old Com p a re d to s a n d c a s tin g op e ra tion s , re la tiv e ly little wa s te is g e n e ra te d in th e
p e rm a n e n t m old p roc e s s . F u g itiv e s ilic a d u s t a n d wa s te s a n d /p la s te r (p a rtic u la te s
a n d m e ta llic oxid e fu m e s ) a re g e n e ra te d if c ore s a re fa b ric a te d of s a n d or p la s te r
re s p e c tiv e ly.
P la s te r M old Wa s te m old p la s te r a n d fu g itiv e d u s ts (p a rtic u la te ) a n d m e ta llic oxid e fu m e s c a n b e
g e n e ra te d u s in g th is m old in g p roc e s s .
In v e s tm e n t/L os t Wa s te re fra c tory m a te ria l, wa xe s a n d p la s tic a re th e la rg e s t v olu m e wa s te s
Wa x g e n e ra te d . Air e m is s ion s a re p rim a rily s ilic a p a rtic u la te s a n d m e ta llic oxid e fu m e s
from th is p roc e s s .
L os t F oa m L a rg e q u a n titie s of p oly s ty re n e v a p ors a re p rod u c e d d u rin g los t foa m c a s tin g . Th e y
c a n b e fla m m a b le a n d m a y c on ta in m e ta llic oxid e fu m e s , m e th a n e , a c e ty le n e ,
c a rb on m on oxid e , h y d rog e n a n d h a z a rd ou s a ir p ollu ta n ts (HAP s ) s u c h a s b e n z e n e
a n d s ty re n e . S a n d p a rtic u la te s a re a n oth e r s ou rc e of a ir e m is s ion s .
Ch e m ic a l B in d in g S ilic a p a rtic u la te s , c ore oils , u re a form a ld e h y d e , p h e n ol form a ld e h y d e , fu ra n , a lky d
S y s te m s is oc y a n a te , p h e n olic is oc y a n a te , p oly e s te r u re th a n e , p h os p h oric a c id ,
tolu e n e s u lfon ic a c id a n d b e n z e n e s u lfon ic a c id .
Furnac e Charg e Preparation and Metal Melting
Ch a rg in g a n d Cu p ola , re v e rb e ra tory a n d e le c tric a rc fu rn a c e s m a y e m it p a rtic u la te m a tte r, c a rb on
M e ltin g m on oxid e , h y d roc a rb on s , s u lfu r d ioxid e , n itrog e n oxid e s , s m a ll q u a n titie s of c h lorid e
a n d flou rid e c om p ou n d s , a n d m e ta llic fu m e s from th e c on d e n s a tion of v ola tiliz e d
m e ta l a n d m e ta l oxid e s . Cu p ola fu rn a c e s e m it th e m os t org a n ic a n d in org a n ic toxic
e m is s ion s of a ll m e ltin g fu rn a c e s . In d u c tion fu rn a c e s a n d c ru c ib le fu rn a c e s e m it
re la tiv e ly s m a ll a m ou n ts of p a rtic u la te s , h y d roc a rb on , a n d c a rb on m on oxid e
e m is s ion s . Th e h ig h e s t c on c e n tra tion of fu rn a c e e m is s ion s oc c u r wh e n fu rn a c e s a re
op e n e d for c h a rg in g , a lloy in g , s la g re m ov a l a n d ta p p in g .
F lu xin g a n d S la g P a rtic u la te s , m e ta llic oxid e (e . g . , m a g n e s iu m oxid e s ) fu m e s , s olv e n ts , h y d roc h loric
a n d Dros s a c id .
R e m ov a l
P ou rin g E m is s ion s of p a rtic u la te s , le a d , a rs e n ic , c h rom iu m , h a log e n a te d h y d roc a rb on s a n d
a rom a tic h y d roc a rb on s
Quenc hing , Finis hing , Cleaning and Coating
P a in tin g a n d R u s t V OCs . F in is h in g op e ra tion s m a y g e n e ra te p a rtic u la te a ir e m is s ion s . Cle a n in g a n d
In h ib itor c oa tin g m a y g e n e ra te a ir e m is s ion s of V OCs from p a in tin g , c oa tin g a n d s olv e n t
Ap p lic a tion c le a n in g ; a c id m is ts a n d m e ta l ion m is ts from a n od iz in g , p la tin g , p olis h in g , h ot d ip
c oa tin g , e tc h in g a n d c h e m ic a l c on v e rs ion c oa tin g .
S h a ke ou t, Coolin g S ilic a d u s t a n d m e ta llic p a rtic u la te s ; V OC a n d org a n ic c om p ou n d s from th e rm a l
a n d S a n d Ha n d lin g s a n d tre a tm e n t s y s te m s . S h a ke ou t, c oolin g a n d s a n d h a n d lin g op e ra tion s g e n e ra te
wa s te s a n d a n d fin e s p os s ib ly c on ta in m e ta ls .
C le a n in g , V OCs , s ilic a a n d oth e r d u s ts a n d m e ta llic p a rtic u la te s
Qu e n c h in g ,
G rin d in g , Cu ttin g

Table 3. Air Emissions by Foundry Process Operation

3
 Make-up Sand Raw Materials Inputs Raw Materials Inputs
Sand Metal Scrap or Ingot
Binders Alloys
Fluxing Agents
Particulates Hydrocarbons,
carbon monoxide,
smoke
Sand & Binder
Mixing Scrap & Charge
Preparation
Particulates
Particulates, nitrogen oxides,
carbon monoxide, metal oxide
Core fumes, sulfur dioxide
Forming Metal Melting
VOCs & HAPs Cupola Furnace
Electric-Arc Furnace
Induction Furnace
Reverberatory Furnace Spent
Core Crucible Furnace Refractory
Particulates Material
Forming

Particulates,
Mold Mold & Core metal oxide fumes,
carbon monoxide,
Making Assembly Particulates, nitrogen oxides,
VOCs, HAPs
carbon monoxide, metal oxide
fumes, sulfur dioxide
Particulates,
organic compounds,
VOCs, HAPs Tapping, Treatment,
Mold Pouring, Slag & Dross
Cooling Removal
Sand Preparation Particulates
& Treatment
Lump Knockout Sand
Screening Casting Slag, dross, spent
Metal Removal refractory material
Shakeout
Thermal Treatment
Wet Scrubbing Particulates
Other
Scrap Metal, spent
tools, abrasives
Riser Cutoff &
Gate Removal Waste cleaning
water with solvents,
Particulates, oil & grease,
Wet scrubber VOCs suspended solids
wastewater with
high pH
Cleaning, Finishing
& Coating Spent solvents, abrasives,
coatings, wastewater
Treatment sludges
Waste sand, fines &
Lumps, metals

Inspection &
Shipping

Figure 2. Sources of Emissions from Green Sand Foundry Operations (EPA/310-R-97-004, 1998)

• American Conference of Governmental

S IC Industrial Hygienists (ACGIH), Thresh-
Number of
OS HA Violation 3321 3322 3324 3325 Violations % old Limit Values (TLVs) sets limits for
Air Con ta m in a n ts (n ot
acceptable 8-hour exposure to over 600
10 14 14 15 53 3.8 chemicals.
s p e c if ie d )
As b e s tos 0 1 0 4 5 0.4
• American Society of Air Conditioning,
F la m m a b le /Com b u s tib le
L iq u id s
1 5 10 9 25 1.8 Heating and Refrigeration Engineers
Ch e m ic a ls (a c e ty le n e , le a d ,
(ASHRAE), 55-1992, Thermal Environ-
c a d m iu m , form a ld e h y d e , 17 19 19 4 59 4.2 mental Conditions for Human Occu-
m e th y le n e d ia n ilin e ) pancy publishes standards for combina-
Nois e 4 20 14 9 47 3.4 tions of temperature and humidity de-
P e rs on a l P rote c tiv e pending on time of year and clothing
2 16 17 18 53 3.8
E q u ip m e n t (P P E ) - G e n e ra l worn.
R e s p ira tory P rote c tion 10 13 24 27 74 5.3
Ve n tila tion 0 1 3 0 4 0.3
• ASHRAE, 62-1999, Ventilation for Ac-
TOTALS 44 89 101 86 320 23. 0
ceptable Indoor Air Quality publishes
standards for acceptable ventilation rates
Table 4. OSHA Indoor Air Quality Related Violations, Iron and Steel to residential and commercial spaces to
Foundries minimize the buildup of indoor air con-
taminants.

4
• Key sections in the Environmental Pro-
tection Agency (EPA), 40 CFR Parts
50-99, Clean Air Act are the National
Emission Standards for Hazardous Air
Pollutants (NESHAPs) - 40 CFR 61
Subpart M.
• EPA, 40 CFR Parts 302, 355, 370 and
372, Superfund Amendments and Reau-
thorization Act (SARA) Emergency Plan-
ning and Community Right to Know Act
(EPCRA) of 1986 provisions requires
certain facilities to collect data and pre-
pare reports on certain materials [usu-
ally greater than 5 tons (4.5 metric tons)]
for the State Emergency Response Com-
mission (SERC) and the Local Emer-
gency Planning Committee (LEPC).
These include the annual Forms 311,
312 and R.
• EPA, 40 CFR Parts 700-799, Toxic Sub-
stances Control Act (TSCA) contains
provisions regarding the manufacturing
and use of certain substances, including
asbestos, lead, PCBs and radon.
• National Institute for Occupational
Safety and Health (NIOSH), Recom-
mended Exposure Limits (RELs) has
RELs for over 160 hazardous sub-
stances.
• OSHA, 29 CFR Part 1910.1000, Ac-
ceptable Levels for Air Contaminants
and Mineral Dusts, Tables Z-1, Z-2 and
Z-3, June 7, 1988, rule proposed to add/
amend 402 substances to these tables (to-
tal of about 430), mainly adding ACGIH
values. New tables are expected to be-
come law in 2 to 5 years based on July
30, 1999 notice.
• OSHA, 29 CFR Part 1910.94, Ventila- These solutions revolve predominantly
tion. publishes occupational ventilation
requirements.
• OSHA, 29 CFR Parts 1910.95, Occu-
pational Noise Exposure publishes ac-
ceptable noise levels with/without hear-
ing protection.
• OSHA, 29 CFR Parts 1910.119, Pro-
cess Safety Management (PSM) of
Highly Hazardous Chemicals is a com-
panion rule to EPA’s Risk Management
Plan (RMP) rule. It publishes broad re-
quirements on certain hazardous or
flammable chemicals stored in certain
quantities in the workplace.
• OSHA, 29 CFR Parts 1910.120, Haz- hot environments (melting, pouring,
ardous Waste Operations and Emer- shakeout) to minimize the effects of heat
gency Response (HAZWOPER) defines stress. The feasibility of this type of
training and responses safely handling ventilation must be considered on a case
hazardous wastes. by case basis.
Local Exhaust: Local exhaust/ventila-
Of all these regulations, the OSHA Table
Z PELs are likely to have the most impact tion, in contrast to general ventilation, is
on the foundry industry. Air contaminants designed to evacuate contaminated air
found in foundries and their Permissible from a specific area. A local exhaust
Exposure Limits (PELs) are summarized system consists of a capture hood,
in Table 5. connecting ductwork, air-cleaning
device and fan. Local exhaust systems
Legislation has also been written that come in various designs depending on
subjects foundries to Maximum Achiev-
the type of operation that needs to be
able Control Technology (MACT) controlled.
standards. These standards require
foundries to install technology particular The size of the work area may limit the
to the foundry industry that is providing use of a local exhaust system because
the most effective reduction of environ- costs escalate and efficiency becomes
mental emissions. There has been limited as the size of the system in-
considerable debate with regard to creases.
MACT standards which has delayed Overall, local exhaust ventilation is
their implementation. It should also be more efficient in controlling contaminant
noted that MACT standards are jointly levels than general ventilation. There
designed by the EPA and foundry are a variety of suppliers who produce
operators and apply principally to dust, fume, mist and smoke collectors
outdoor air quality. The first MACT designed for foundry applications. To
draft for the foundry industry is due to
be released by December, 2000.
CHE MICAL OS HA PE L (mg /m3)
Solutions and Ac role in 0.25
Recommendations B e nz e ne 10 ppm
C a d m iu m f u m e 0.1
There are four principal methods to C a d m iu m d u s t 0.2
improve air quality that have been Ch rom iu m c om p ou n d s 0.5
utilized in the foundry industry. C op p e r f u m e 0.1
Iron oxid e fu m e 10
• General (Dilution) Ventilation
M a g n e s iu m oxid e fu m e 15
• Local Exhaust
M a n g a n e s e fu m e 5
• Worker Specific Protection
Nu is a n c e Du s t
• Process Modification - R e s p ira b le fra c tion 5
- Tota l 15
around the use of electrotechnologies, Oil m is t 5
including motor driven fans for P h e n ol 19
ventilation and induction for melting. S ilic a
- Qu a rtz (re s p ira b le ) 1 0 / (% S iO2 + 2 )
General Ventilation: The principle of
- Qu a rtz (tota l d u s t) 3 0 / (% S iO2 + 2 )
general ventilation is to dilute airborne
- Cris tob a lite h a lf of v a lu e s for q u a rtz
contaminants through air turnover.
- Trid y m ite h a lf of v a lu e s for q u a rtz
General ventilation, to be effective,
has to move large amounts of air. This S ilic o n
method is costly because of the volume - R e s p ira b le fra c tion 5
of air that has to be moved, especially - Tota l 15
during winter when heated make-up air S ty re n e 100 ppm
must replace exhausted air. S u lfu r d ioxid e 13
Tolu e n e 200 ppm
General ventilation is not the most
Te llu riu m a n d 0.1
effective means for controlling dust or c om p ou n d s
vapors from localized areas. It can be Table 5. Foundry Air Contaminant
used to provide cool air to workers in Permissible Exposure Limits (PELs)
5
match the appropriate equipment to the
application, it is suggested that system
design be professionally evaluated.
Examples of ventilation/filtering
technologies include fabric, cyclone,
downdraft benches and workcenters,
smoke-fume, bag-dump stations, and bin
(silo) vents.
Local ventilation can be used to remove
dust/particulate at the following source
locations: melting, metal casting/
pouring, investment casting, annealing,
quenching, tempering, abrasive blasting,
finishing, degreasing, shakeout,
coremaking, mold making, and sand
reclamation.
Worker Specific Protection: Worker
protection such as respirators are often
used as a temporary measure while a
long term solution is in the design/
installation phase. Other protection such
as gloves, special clothing and eye
protection serve very specific purposes
and can be effective when used in
combination with other measures to
minimize the potentially harmful effects
of a foundry environment.
Air purifying respirators and air
supplying respirators must be NIOSH/
MSHA approved. Also, the cartridges
and filters in air purifying respirators
have limited capacity to absorb/trap
contaminants and must be changed on a
regular basis.
The toxicity effects of harmful sub-
stances, handling information, and
recommended worker protection
measures are listed on the material
safety data sheets (MSDS). An MSDS
sheet must, by law, accompany the
shipment of any regulated substance as
defined by NIOSH. The MSDS must be
displayed and easily accessible to
employees.
Applicable SIC Codes:
3321, 3322, 3323, 3325, 3365, 3366, 3369
EPRI Center for Materials Production
614.421.3440 •
EPRI Corporate address • 3412 Hillview Avenue, Palo Alto, CA 94304 • PO Box 10412, Palo Alto, CA 94303 USA
800.313.3774 • 650.855.2121 • askepri@epri.com • www.epri.com
Process Modification:
• Induction furnaces and crucible
furnaces emit relatively small amounts
of particulates, hydrocarbons, and
carbon monoxide emissions. It may be
possible to replace older cupola,
reverberatory or electric arc furnaces
with induction or crucible melting.
• Modify the binder additive used in the
sand molds. A new generation of
binders has been developed to
minimize phenol/formaldehyde
content and subsequently lower VOC
emissions. Binder emissions are a
significant contributor to poor indoor
air quality.
• Use binders that incorporate esters
dissolvable in water rather than those
based on phenolic compositions.
• Use furans or free radical-cured
acrylic binders to reduce phenol/
formaldehyde emissions.
• Use “cold box” processes and no-bake
sands with higher molecular weight
esters, yielding lower VOC emissions.
• Replace silica sands with olivine,
zircon and chromite sands that have
lower toxicity.
• Keep sand moisture content above
25% during molding.
Acknowledgements
Stephen Petty of Energy and Environ-
mental Services, Inc. and Joe Fox of
Ashland Chemical provided reference
materials and valuable technical input.
Resources
The following OSHA publications are
available free of charge:
To order additional copies of this
publication call 800.313.3774 or e-mail
askepri@epri.com.
• 1251 Dublin Road • Columbus, OH
cmp@tarateccorp.com
OSHA – 2056. All About OSHA
OSHA – 2098. OSHA Inspections
OSHA – 3021. OSHA: Employee Workplace
Rights
OSHA – 3084. Chemical Hazard Communication
OSHA – 3047. Consultation Services for the
Employer
OSHA – 3071. Job Hazard Analysis
OSHA – 3077. Personal Protective Equipment
OSHA – 3079. Respiratory Protection
OSHA – 3085. OSHA Computerized Information
System (Chemical information file)
Hazard Communication Standard, Title 29, Code
of Federal Regulations (CFR) Part 1910.1200
Contact: OSHA Publications Office, Rm
N 3101, 200 Constitution Avenue NW,
Washington, D.C. 20210 Phone: (202)
523-9667
The following OSHA publication is
available for a fee:
OSHA – 3104. Hazard Communication
Compliance Kit – Contact Superinten-
dent of Documents, US Government
Printing Office, Washington, DC 20402
Phone: (202) 783-3238 ($18 fee)
Other resources:
American Foundryman’s Society (AFS),
505 State Street, Des Plaines, IL 60016
Phone: (800) 537-4237 www.afsinc.org
Ashland Chemical Safe Foundry
Manual, available through the Foundry
Products Division, 5200 Blazer Memo-
rial Parkway, Dublin Ohio 43017
Phone: (614) 790-3333
Casting Emissions Reduction Program
(CERP), McClellan Air Force Base,
5301 Price Avenue, Bldg 238,
McClellan AFB, CA 95652-2502
Phone: (916) 643-1090 www.cerp-
aiger.org
Metal Casting Industry Roadmap, Office
of Industrial Technologies, DOE, 1000
Independence Ave. SW, Washington,
DC 20585 Phone: (202) 586-9235
www.oit.doe.gov/metalcast
 2000 Electric Power Research Institute (EPRI),
Inc.
All rights reserved, Electric Power Research
Institute and EPRI are registered service marks of
the Electric Power Research Institute, Inc. EPRI.
POWERING PROGRESS is a service mark of the
Electric Power Research Institute, Inc.
Printed on recycled paper in the United States of America.
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