Metal has been melted and poured for casting for many centuries but this has not diminished the serious risks associated with these activities. In this blog article, we zoom in on the most common hazardous substances involved in the melting and casting of metal.

Want to find out how you can protect yourself against these substances? We will take you through the risks of each hazardous substance and explain how you can protect yourself.

Some hazardous substances call for extra care:

• Berrylium
• Carbon dioxide
• Chromium and hexavalent chromium
• Lead
• Manganese
• Aromatic hydrocarbons
• Sulphur dioxide

Exposure during metal production and metal processing/on the work floor.

How could you be exposed and what must you be aware of?

Berrylium

• Inhalation: dust and smoke that are released during beryllium production and processing, as well as during the welding, grinding, cutting, drilling and polishing of beryllium alloys can all be inhaled.
• High-energy processes such as cutting, grinding and polishing metal can create metal particles and oxides which can be inhaled easily.
• Contact with skin: direct skin or eye contact with liquid beryllium or substances that contain beryllium can penetrate the skin or cause wounds.
• Swallowing: employees may accidentally swallow beryllium if their hands become contaminated, e.g. while eating, drinking, smoking or biting their nails.

Did you know… labourers are also exposed to the risk of inhaling the spray from beryllium salts?
Exposure to beryllium can also occur when the skin is exposed to soluble salts and metal elements/splinters when working with metal and alloys which contain beryllium.

Carbon dioxide

• Inhalation: the most common exposure situation with respect to carbon dioxide in the metal production and processing environment is the inhalation of the gas that is created as a by-product of the combustion of organic materials (such as during the production of cokes and anodes), as well as emissions from blast furnaces, oxy-steel furnaces and degassing processes during the production of primary metals and other industrial processes.
• Skin contact: contact with carbon dioxide in a liquid or solid form can be damaging for the skin and eyes.

Did you know… Metal processors, and especially welders, have an increased risk of developing lung infections.

Chromium and hexavalent chromium

• Inhalation: the inhalation of dust and smoke, primarily originating from the production and processing of chromium and hexavalent chromium alloys. There may be exposure during metal processing, including when welding, grinding, cutting, drilling and polishing alloys which contain these elements.
• High energy processes such as cutting, grinding and polishing metals can also create particles of metal and metal oxides and these can also be inhaled easily. Employees may also be exposed if they work with galvanised metals or metals with a superficial coating containing chromium or hexavalent chromium. Substances, mists or vapours of chromium and hexavalent chromium may also be created in other industrial settings, e.g. when handling or using chemical substances containing these elements, in powder or liquid form.
• Skin contact: contact with the skin or eyes, primarily when chromium and hexavalent chromium are present in a liquid form. These can easily penetrate the skin or cause skin problems.
• Swallowing: Employees can accidentally be exposed to chromium and hexavalent chromium via ingestion, e.g. while eating, drinking, smoking or biting their nails when their hands are contaminated with this substance.

Lead

• Inhalation: dust and smoke which are released during the production and processing of lead and lead alloys can be inhaled, primarily during processes such as the welding, grinding, cutting, drilling and polishing of lead alloys.
• High-energy processes may release small particles of metal and metal oxides, which can then easily be inhaled. In other industrial situations, lead vapours, mists or dust may be created, e.g. when handling powder or liquid chemicals containing lead.
• Skin contact: contact with the skin or eyes, primarily when lead is present in a liquid form, can constitute exposure because the lead can penetrate or injure the skin.
• Swallowing: employees may accidentally swallow lead, e.g. while eating, drinking, smoking or biting their nails when their hands are contaminated with lead.

Did you know… An important factor to consider when managing the exposure to lead is minimising the risk of swallowing it? This can be achieved by implementing good hygiene practices such as washing, changing and shower facilities.

Manganese

• Inhalation: inhaling dust and smoke when working with manganese and manganese alloys, e.g. when welding, grinding, cutting, drilling and polishing.
• High-energy processes may release particles of metal and metal oxides which can then be inhaled. In other industrial situations, manganese vapours, mists or dust may be created when handling chemicals that contain manganese.
• Skin contact: contact with the skin or eyes, primarily when manganese is present in a liquid form, may constitute exposure because the lead can penetrate or injure the skin.
• Swallowing: employees may accidentally swallow manganese, e.g. while eating, drinking, smoking or biting their nails when their hands are contaminated with manganese.

Did you know… manganese oxide is used in many welding products? Specifically in:

• A flux in the coating of shielded metal arc welding electrodes
• In the liquid core of arc welding electrodes
• As an alloying element used in electrodes.

Aromatic hydrocarbons

• Inhalation: inhaling dust and smoke when working with PAHs (polycyclic aromatic hydrocarbons) and PAH alloys, such as welding, grinding, cutting, drilling and polishing during metal processing.
• Skin contact: direct contact with the skin or eyes, primarily when PAHs are in a liquid form. This can lead to exposure because they can easily penetrate or injure the skin.
• Swallowing: employees may accidentally swallow PAHs, e.g. while eating, drinking, smoking or biting their nails when their hands are contaminated with a PAH.

Sulphur dioxide

• Inhalation: inhalation of the gas, which is often created as a by-product of metal production or other processes.
• Skin contact: contact with sulphur dioxide vapours or liquids with the skin or eyes, whereby liquid sulphur dioxide can easily penetrate or damage the skin.

How can I protect myself?

Both employers and their employees have a role to play in guaranteeing safety on the work floor when working with hazardous substances.

1/ RIE

First, the employer must conduct a thorough risk inventory and evaluation (RI&E) to identify potential hazards and tackle them systematically. This helps to minimise the risk of work-related health issues and accidents.
According to the Health & Safety at Work Act, measures must be taken to tackle the source of the problem; this is known as the labour hygiene strategy.
This can vary from collective solutions, such as extraction systems, to individual personal protective equipment (PPE).

2/ The provision of suitable PPE

Specific PPE, which may include respiratory protection (Respiratory Protection Equipment or RPE), may be required alongside other management measures during certain work, e.g. welding.

Below is an overview of which respiratory protection is needed for which substances.

3/ Training employees

As well as choosing the right PPE, it is essential to manage your staff effectively. Employees who wear PPE must be aware of:

• The nature of hazardous substances that are present in the workplace and their potential impact on health
• The correct use and limitations of PPE
• The right way to put on and wear PPE
• How to inspect, maintain and clean PPE, as well as being able to recognise defects and how to deal with these

4/ Provide regular, good quality maintenance

The regular inspection and maintenance of personal protective equipment is important to ensure optimum protection. Find out more about the options for maintenance and repair by Vandeputte.