Solutions for the Prevention

of Musculoskeletal Injuries 

in Foundries

OSHA 3465-08 2012
Occupational Safety and Health Act of 1970

“To assure safe and healthful working conditions 

for working men and women; by authorizing 

enforcement of the standards developed under 

the Act; by assisting and encouraging the States in 

their efforts to assure safe and healthful working 

conditions; by providing for research, information, 

education, and training in the field of occupational 

safety and health.”

Material contained in this publication is in the 

public domain and may be reproduced, fully or 

partially, without permission. Source credit is 

requested but not required.

This information will be made available to 

sensory-impaired individuals upon request. 

Voice phone: (202) 693-1999; teletypewriter 

(TTY) number: 1-877-889-5627. 

Cover photo: Elena Finizo, Braintree, Massachusetts Area Office.
Solutions for the Prevention

of Musculoskeletal Injuries 

in Foundries

Occupational Safety and Health Administration

U.S. Department of Labor

OSHA 3465-08 

2012

OSHA would like to thank the following foundries for their 

hospitality, time, and effort during OSHA’s site visits to the 

plants: Neenah Foundry, ThyssenKrupp Waupaca Foundry, 

Brillion Iron Works, Roloff Manufacturing, Manitowoc 

Grey Iron Foundry, and Wisconsin Aluminum Foundry in 

Wisconsin, as well as the Clow Valve Foundry in Iowa. OSHA 

greatly appreciates these foundries’ cooperation and willingness 

to share with the Agency information on the improvements 

made in their plants, the statements from the workers and the 

management, and their comments on the draft publication. 

OSHA’s National Office is grateful to the OSHA Area Office in 

Appleton, Wisconsin and the Wisconsin Health Consultation 

Program for their participation in the design of this publication 

and their contributions to the Agency’s efforts to reduce 

musculoskeletal injuries in the workplace. 
2 occupational safety and health administration

Contents

Executive Summary . . . 3

Introduction . . . 5

A Process for Protecting Workers . . . 6

Providing Management Support . . . 6

Involving Workers . . . 6

Providing Training . . . 7

Identifying Problems . . . 7

encouraging and utilizing Reports of Injuries . . . 8

Implementing Solutions . . . 9

Evaluating Progress . . . 9

Solutions . . . 10

Facility-Wide Solutions . . . 11

Melting Solutions . . . 25

Mold Preparation Solutions . . . 26

Casting Solutions . . . 33

Shakeout and Core Knockout Solutions . . . 37

Cleaning and Handling Solutions . . . 44

Additional Sources of Information . . . 51

References . . . 52

OSHA Assistance, Services and Programs . . . 53

Regional Offices . . . 56 

How to Contact OSHA . . . 57
Solutions for the Prevention of Musculoskeletal Injuries in foundries 3

Executive Summary

Many proactive initiatives undertaken by the 

foundry industry, including establishing ergonomic 

processes, incorporating ergonomic principles into 

new projects, and conducting facility walkthroughs 

to identify injury risks have resulted in a reduction in 

worker injuries and illnesses (1). Employees working 

in foundries are often exposed to ergonomics-related 

injury risks, such as lifting heavy items, bending, 

reaching overhead, pushing and pulling heavy loads, 

working in awkward body postures, and performing 

the same or similar tasks repetitively (1). The 

physically demanding tasks performed during foundry 

operations may be responsible for the musculoskeletal 

disorders (MSDs) developed by workers in this 

industry. Foundry workers have higher MSD

injury rates than workers in general industry and 

construction (2).

Although many ergonomics-related risk factors exist 

in foundries, this industry has found ways to make 

the work less stressful through ergonomic solutions. 

The successful efforts of some foundries to address 

this important issue provide a sufficient basis for 

replicating these actions to better protect foundry 

workers.

This publication provides recommendations for 

foundries to help increase employer and worker 

awareness of ergonomics-related risk factors, alleviate 

muscle fatigue, increase productivity, and reduce the 

number and severity of work-related MSDs.

In developing these guidelines, OSHA visited six 

foundries in Wisconsin (Neenah Foundry, Waupaca 

Foundry, Brillion Iron Works, Roloff Manufacturing, 

Manitowoc Grey Iron Foundry, and Wisconsin 

Aluminum Foundry) and the Clow Valve Foundry in 

Iowa to review the foundries’ ergonomic programs, 

observe existing ergonomic practices in action, 

talk with managers, interview workers and union 

members, and take pictures of the engineering 

solutions. Whenever possible, OSHA also obtained 

photos of foundry tasks prior to implementation of 

the ergonomic solutions. Moreover, some photos 

were retrieved from PowerPoint presentations 

designed by the foundries visited. In addition, OSHA 

reviewed available scientific information regarding 

foundry activities that may benefit from implementing 

ergonomic solutions. 

The general information in this publication is 

intended to provide foundry employers and workers 

with effective and practical solutions. It also aims 

to be a useful reference source when determining 

the need for ergonomic assistance for specific jobs, 

such as melting, mold preparation, casting, shakeout 

and core knockout, and cleaning and cut off. The 

recommendations and information presented here are 

intended to be a flexible framework to be adapted to 

the needs and resources of each individual foundry. 

The solutions recommended in this publication may 

also be beneficial in other industries, such as those 

that handle heavy materials, use tools for multiple 

processes, and work on parts of widely varying sizes 

and shapes (3).

OSHA realizes that some foundries, particularly 

small ones, may need assistance with certain 

ergonomic solutions. This may include developing 

and implementing an ergonomic process or tailoring 

a recommended solution to a specific situation. 

Therefore, employers are encouraged to take 

advantage of OSHA’s free consultation services to 

address these needs.

This publication presents ergonomic solutions that are 

already implemented within some foundries. OSHA 

recommends that foundries consider these solutions 

in the context of a broader, systematic process that 

includes the elements described in this publication. 

Such a process will make it more likely that any 

solutions implemented will be both cost-effective and 

successful in reducing injuries.

This document includes an introduction, a process 

for protecting workers, solutions that employers can 

use to help reduce MSDs in foundries, and additional 

sources of information on ergonomic applications in 

foundries.

 David Michaels, PhD, MPH 

Assistant Secretary of Labor for

Occupational Safety and Health
4 occupational safety and health administration

This guidance is advisory in nature and informational in 

content. It is not a standard or regulation, and it neither creates 

new legal obligations nor alters existing obligations created 

by OSHA standards or the Occupational Safety and Health 

Act of 1970 (OSH Act.) Pursuant to the OSH Act, employers 

must comply with safety and health standards and regulations 

issued and enforced either by OSHA or by an OSHA-approved 

state plan. In addition, the Act’s General Duty Clause, Section 

5(a)(1), requires employers to provide their employees with a 

workplace free from recognized hazards likely to cause death 

or serious physical harm. 
Solutions for the Prevention of Musculoskeletal Injuries in foundries 5

Introduction

A foundry is a site where castings are made 

from molten metal, according to an end user’s 

specifications. Foundry work often includes the 

following processes: creating casting patterns, 

making and assembling molds, melting and refining 

the metal, pouring the metal into molds, and 

cleaning the finished part (i.e., removing adhering 

sand and redundant metal from the casting) (5).

Numerous potential hazards are present in a foundry 

work environment. These include both chemical and 

physical hazards, such as exposure to dust, silica, 

lead, noise, heat stress, and gases (e.g., nitrogen 

dioxide, sulfur dioxide, and carbon monoxide) (3, 

6, 7). However, this publication addresses only the 

ergonomics-related risks to which foundry workers 

are most often exposed. These risk factors include the 

following: 

• Exerting high levels of force to handle or move 

materials; 

• Doing the same or similar tasks repetitively;

• Working in awkward postures;

• Maintaining static (i.e., nonmoving) body postures 

for long periods;

• Coming in contact with sharp edges that press into 

the skin; and

• Being exposed to vibrating tools and work 

surfaces.

Injuries to the low back and upper limbs are common 

MSDs among foundry workers. These may arise from 

doing work repetitively or for prolonged time periods, 

exerting excessive force to move or grip objects, or 

using vibrating tools such as chipping hammers and 

hand-held or rotary grinders (1). Early symptoms 

of MSDs include pain, restricted joint movement, 

soft tissue swelling, numbness, and tingling. MSDs 

typically develop gradually, over time, as a result of 

intensive work (10).

To develop these guidelines, OSHA visited several 

foundries that formed the NorthEastern Wisconsin 

Foundry Ergonomics Partnership (NEWFEP) to 

address ergonomic issues and implement ergonomic 

solutions. The foundries specialize in different 

products and represent a broad range of employment 

(from several dozen to more than a thousand 

employees). Work-related MSDs were considerably 

reduced by the Ergonomics Partnership members. 

These companies also found that the solutions they 

implemented lowered absenteeism rates, increased 

worker productivity and efficiency, and improved 

product quality. Workers reported that by working in 

a safer and more comfortable work environment, they 

experienced less fatigue and improved morale (1, 11).

“By promoting good workplace ergonomics 

we accomplish a cost saving, but on top of 

that we have shown our employees that we 

do truly care about them and the quality of 

lives they have.”

John Smith, Ergo team member, 

ThyssenKrupp Waupaca
6 occupational safety and health administration

A Process for Protecting 

Workers

For many foundry operations, the number 

and severity of MSDs resulting from physical 

overexertion, as well as their associated costs, can 

be substantially reduced by applying ergonomic 

principles (9). OSHA recommends that employers 

develop a process to systematically address ergonomic 

issues in their work environments and incorporate it 

into their existing safety and health programs. In fact, 

many foundries surveyed by OSHA have integrated 

an ergonomic process into their overall safety 

and health program (1). To be most effective, the 

process should be tailored to an individual foundry’s 

operations. 

Foundry management should consider the general 

steps discussed below when establishing and 

implementing an ergonomic process. It should be 

noted, however, that each foundry will have different 

needs and limitations that should be considered 

when identifying and addressing workplace 

concerns. Foundries may implement different types 

of programs and activities and may assign staff from 

a variety of departments to accomplish the goals 

of an ergonomic process. Every foundry is unique; 

thus, the approach taken to incorporate ergonomic 

solutions within its operations should consider the 

foundry’s size, structure, and culture.

Providing Management Support

“Ergonomics is a key component of our 

safety culture, with management and labor 

working together in developing creative 

solutions to unique challenges in our die 

casting business. We have been able to apply 

many of these best practices elsewhere in 

our operations as well.”

Jim Sutton, Safety Manager, 

Mercury Marine

A strong commitment by management is critical to 

the overall success of an ergonomic process (9). In 

the development stages, OSHA recommends that 

foundries define clear goals and objectives for the 

ergonomic process, discuss them with their workers, 

assign responsibilities to designated staff members, 

and communicate clearly with the workforce. 

Management should promote and help establish a 

joint worker-management ergonomic team, ensure 

that regular committee meetings are held, and 

address workers’ concerns in a timely manner. A 

participatory ergonomic approach, where workers 

are directly involved in worksite assessments, 

solution development, and implementation is the 

essence of a successful ergonomic process. The 

structure of the team will differ, based on a facility’s 

size and its available human resources. An effective 

ergonomic process requires a sustained effort, 

the coordination of activities, and the resources 

necessary to ensure that the objectives of the 

ergonomic process are met.

An ergonomic process should be viewed as an 

ongoing function that is incorporated into the 

daily workings of the facility, the same as safety 

and production issues, rather than as an individual 

project. Management should strongly encourage 

worker involvement in the ergonomic process and 

in the decisions that affect their safety and health. 

Employers also should clearly define procedures 

that encourage workers to present their concerns to 

management and provide responses to worker input. 

Many foundries have successfully integrated other 

workplace strategies along with an ergonomic 

process into their business operations. One example 

is the “lean manufacturing” strategy, which focuses 

on providing “the right material, to the right 

place, at the right time, in a proper manner” (1, 

13). These strategies attempt to eliminate steps 

in the manufacturing process that add no value, 

such as “wasted walking” or “wasted motion” to 

pick up parts. Ergonomics is a good fit with these 

strategies because ergonomic principles help identify 

and control activities that detract from worker 

performance and may lead to MSDs.

Involving Workers

“Solving ergonomic problems has become 

part of our culture at Manitowoc Grey 

Iron Foundry. Employee involvement and 

continuous improvement are the cornerstone 

of our mission.”

Robert Peaslee, President, 

Manitowoc Grey Iron Foundry, Inc.
Solutions for the Prevention of Musculoskeletal Injuries in foundries 7

Workers can identify and provide important 

information about hazards in their workplaces. 

Their opinions and suggestions for change also 

are valuable, particularly in such a difficult and 

complex work environment. As such, employees 

should be included in the early stages of planning 

an ergonomic process. Workers can also assist in 

the ergonomic process by voicing their concerns and 

suggestions for reducing exposure to risk factors 

and by evaluating the changes made as a result of 

an ergonomic assessment. Workers can participate 

in other ergonomics-related activities, such as 

being part of task abatement groups and lean 

manufacturing teams, or responding to management 

surveys and questionnaires. They should be encouraged to provide early reports of MSD symptoms 

related to a job, which can accelerate the job assessment and improvement process, helping to prevent or 

reduce the progression of symptoms, the development 

of serious injuries, and subsequent lost-time claims.

Active participation by workers on ergonomicsrelated issues helps their acceptance of job changes 

made as a result of an ergonomic assessment 

and enables a better understanding of ergonomic 

principles both on and off the job (1, 12).

Workers involved in ergonomics-related activities 

within their own plant are able to share their 

experience and ideas with other foundries, thus 

increasing the dissemination of their successes. For 

example, the workers who served on the Ergonomics 

Partnership Committee provided ergonomic 

abatement recommendations to the Partnership for 

consideration by other foundry member sites.

Providing Training

Training is an important element in the ergonomic 

process. It ensures that workers are aware of 

ergonomics and its benefits, become informed about 

ergonomics-related concerns in the workplace, 

and understand the importance of reporting early 

symptoms of MSDs. Training should be conducted 

in a manner and language that all workers 

understand and is best provided by individuals who 

have experience with ergonomic issues in foundries. 

Training prepares workers to actively participate in 

many aspects of the ergonomics process, including 

problem identification, solution implementation, and 

process evaluation. When training is effective the 

workers will: 

• Learn the principles of ergonomics and their 

applications; 

• Learn about the proper use of equipment, tools, 

and machine controls; 

• Use good work practices, including proper lifting 

techniques;

• Become more aware of work tasks that may lead 

to pain or injury; 

• Recognize early symptoms of MSDs; 

• Understand the importance of addressing early 

indications of MSDs before serious injury 

develops; and

• Understand foundry procedures for reporting 

work-related injuries and illnesses, as required by 

OSHA’s injury and illness recording and reporting 

regulation (29 CFR Part 1904).

Workers will benefit from an orientation and jobspecific hands-on training before they begin their 

tasks, especially on jobs with potential ergonomic 

risk factors. Workers should also be notified of 

workplace changes, instructed on using new equipment, and informed about new work procedures.

Identifying Problems

An important part of the ergonomic process is a 

periodic review of the facility, specific workstation 

designs and work practices, and the overall 

production process, from an ergonomics perspective. 

This includes identifying existing problems, which 

can be obtained from reviewing the company’s 

OSHA 300 injury and illness logs, 301 reports, 

workers’ compensation records, and worker reports 

of problems. However, a more forward looking 

approach, to be used in combination with reviewing 

injury and illness records, is to be proactive in 

identifying potential ergonomic issues that have gone 

unnoticed or resulted from facility changes, before 

they result in MSDs.

 
8 occupational safety and health administration

Observations of workplace conditions and work 

processes, ergonomic job analyses, workplace 

surveys, and worker interviews are common 

proactive methods for identifying ergonomicsrelated injury risks. Risk factors that may lead to the 

development of MSDs include: 

• Exerting excessive force (4) – Using high levels 

of physical effort to perform a task, such as 

manually pouring molds or pushing a loaded 

rack, or to maintain control of equipment or 

tools, such as breaking risers from castings. 

• Performing the same or similar tasks repetitively 

(4) – Performing the same motion or a series 

of comparable motions frequently or for an 

extended period of time, such as grinding 

finished castings. 

• Doing work in awkward postures, or being in the 

same posture for long periods of time (4) – Using 

postures that place stress on the body. Examples 

include: reaching above the shoulders to load 

racks; bending forward, to the side, or twisting 

to lift castings from containers; kneeling or 

squatting to inspect the core or mold; or staying 

in one body posture for a prolonged period, 

such as standing at a grinding machine for an 

entire shift.

• Localized pressure into the body – Having objects 

press on the body or a specific body part, such as 

holding a file with a sharp edge or using the hand 

as a hammer to align parts. 

• Coming in contact with vibrating surfaces –

Using vibrating tools such as sanders, chippers, 

drills, grinders, or reciprocating saws.

• Combined exposure to several risk factors –

Being exposed to a combination of several risk 

factors that may place workers at higher risk 

for MSDs than exposure to individual risk 

factors. The risk of MSD injury depends on 

the frequency the task is performed, the level of 

required effort, the duration of the task, as well 

as other factors (8). 

Another proactive means of identifying ergonomicsrelated issues is to observe worker behaviors. For 

example, are workers making modifications to their 

tools, equipment, or work area to address potential 

risk factors; are they shaking their arms and 

hands; are they rolling their shoulders; or bringing 

products, such as back belts or wrist braces, into the 

workplace.

encouraging and utilizing Reports

of Injuries

Comprehensive injury reporting is important to 

the success of an ergonomic process. The goal 

of this effort is to properly assess, diagnose, and 

treat MSDs that occur in foundry operations. This 

allows the foundry to correctly identify work areas 

or specific tasks where injuries frequently occur or 

are most severe. This information helps direct the 

activities of the ergonomic team as well as to guide 

healthcare providers in making return-to-work and 

light-duty work decisions. 

Encouraging and utilizing reports of injuries: 

• Reinforces worker training on recognizing MSD

symptoms;

• Encourages early reporting of symptoms of 

MSDs; 

• Allows prompt medical evaluations for diagnosis, 

treatment, and follow-up care;

• Reduces injury severity, the numbers of workers’ 

compensation claims and associated costs, and 

the likelihood of permanent disability;

• Provides guidance on return-to-work and workplacement restrictions during the healing process; 

• Guides job modifications;

• Provides a mechanism to track and trend 

foundry-wide MSD injuries; and

• Enables assessment of the effectiveness of work 

changes.

Note: Federal and state laws prohibit discrimination 

against workers who report a work-related injury or 

illness [29 U.S.C. 660(c)].

Healthcare professionals are important ergonomic 

team members. They help injured workers 

recover more quickly and return to their jobs 

with appropriate restrictions and less risk for 

reinjury. It is necessary that these professionals are 

knowledgeable about foundry operations and work 

practices. Their knowledge of the facility will allow 

them to assist the injured worker during the healing 

process and in post-injury work placement (1).
Solutions for the Prevention of Musculoskeletal Injuries in foundries 9

Implementing Solutions 

“The new automated grinders have 

eliminated the vibration and stress on 

my wrists and forearms that used to be a 

problem when we did it the old way on stand 

grinders. I now go home and my arms don’t 

hurt and I am also cleaner than before.”

Dale Faris, Barinder Grinding Operator, 

Brillion Iron Works, Inc.

There are several types of ergonomic solutions 

that are not only feasible, but have already been 

implemented within foundry operations. Examples 

of these potential improvements are located in the 

“Solutions” sections of this publication, and they 

cover both facility-wide recommendations and 

solutions for specific operations within foundries.

Evaluating Progress

Established evaluation and corrective action 

procedures need to be in place to periodically assess 

the effectiveness of the ergonomic process and to 

ensure its continuous improvement and long-term 

success. 

As an ergonomic process is first developing, 

assessments should include:

• Determining whether goals set for the ergonomic 

process have been met;

• Determining the success of the implemented 

ergonomic solutions;

• Evaluating whether: 

o The time between hazard identification and 

implementation of appropriate solutions has 

been reduced

o The number of jobs analyzed and risk factors 

reduced or eliminated has increased

o More workers have been trained on 

ergonomics

• Reviewing facility first-aid reports, absenteeism 

rates, job transfer requests, or other similar 

indicators to determine if ergonomics-related 

efforts have had an immediate impact;

• Obtaining feedback from workers, supervisors, 

and involved healthcare professionals regarding 

such issues as any change in their understanding 

of ergonomics, their enthusiasm or acceptance 

of the facility’s ergonomic process, and worker’s 

attitudes toward their own safety and well-being; 

and

• Discussing how the ergonomic process should be 

improved.

For small foundries, the success of an ergonomic 

process might best be based on interactions with 

workers and observations of the work environment. 

A more formal evaluation, including measuring 

activities and outcome measures to indicate process 

performance, may be needed for larger foundries. 

For more established ergonomics processes, 

evaluations should focus on long-term trends, such 

as changes in:

• The numbers of OSHA-recordable MSDs or the 

facility’s MSD incidence rate;

• Workers’ compensation claims and the average 

workers’ compensation costs per MSD; and 

• Medical costs associated with work-related 

MSDs. 

Facilities can use the findings from an ergonomic 

process evaluation to modify process goals, 

establish new priorities, and justify the existence 

of the process.
10 occupational safety and health administration

Solutions

Many foundries have successfully implemented 

ergonomic solutions in their facilities as a way to 

address their workers’ MSD injury risks. These 

interventions have included purchasing new 

equipment or modifying existing equipment, making 

changes in work practices, and purchasing new tools 

or other devices to assist in the production process. 

Making these changes has reduced the physical 

demands of foundry work, eliminated unnecessary 

movements, lowered injury rates and their associated 

workers’ compensation costs, and reduced employee 

turnover. In many cases, work efficiency and 

productivity have increased as well (1).

The ergonomic solutions presented in this publication 

have already been implemented in several foundries. 

These suggested improvements are not intended 

to address all ergonomic challenges that foundries 

face, nor does OSHA expect that every solution 

presented here will be applicable to each foundry. 

OSHA recommends that employers first consider 

using engineering controls, where feasible, to address 

foundry-related ergonomic issues.

OSHA recognizes that implementing engineering 

solutions may present certain challenges within a 

foundry environment, which often involves work 

that has been performed in a similar way for decades. 

However, foundry personnel are encouraged to use 

the examples in this document as a starting point for 

developing innovative solutions tailored to the specific 

ergonomic challenges in their individual facilities.

 

These solutions are grouped according to the jobs to 

which they most frequently apply:

Facility-Wide Solutions

Melting Solutions

Mold Preparation Solutions

Casting Solutions

Shakeout and Core Knockout 

Solutions

Cleaning and Handling Solutions
Solutions for the Prevention of Musculoskeletal Injuries in foundries 11

Hoists/Balancers to Transfer Heavy Loads

Description:

Devices (powered or non-powered) used to lift 

and reposition heavy objects

Advantages:

•	 Replace manual handling of heavy objects

•	 Reduce the manual force needed to lift and

position heavy objects or tools throughout the 

work area

•	 Reduce fatigue from frequent lifting

Notes:

•	 Workers must be trained on proper hoist/

balancer use

•	 Safer hoist/balancer use may initially slow

down transfer time 

•	 Several hoist control design trials may be

needed before finding the one that works 

most effectively

•	 Many makes and models of hoists/balancers

are commercially available (e.g., pneumatic, 

electric, or computer controlled)

•	 Powered hoists/balancers:

o Are much more efficient than chain pulls

o Eliminate manual pulling on a chain

o Reduce repetitive arm motions

o Reduce extended arm and shoulder 

movements

o	 Require more workplace setup than nonpowered units

•	 Ensure the hoist is rated for the load weight

•	 Implement polices requiring hoist use when

transferring loads that exceed a set weight 

limit (e.g., 50 lbs.)

Facility-Wide Solutions

Before After

Reduce lifting, pushing, and pulling forces
12 occupational safety and health administration

Powered Trolleys or Roller Conveyors

Description:

Systems that use mechanical means to transfer 

heavy or hot items from one location to another

Advantages:

•	 Minimize forceful pushing, pulling, and

carrying

•	 Move workers farther away from high heat

areas or dangerous pinch points

Notes:

•	 Gravity-fed conveyors may also assist with

transfers but will require more handling and

effort by workers

•	 May require a rearrangement of surrounding

work areas

•	 Design should not introduce a trip hazard or

contact injuries

Facility-Wide Solutions

Reduce manual pushing of materials
Solutions for the Prevention of Musculoskeletal Injuries in foundries 13

Lift Tables

Description:

Devices used to raise or lower the height of 

materials for easier handling

Advantages:

•	 Vertically adjust materials to minimize

bending and keep the load close to the body

•	 Help keep neutral body posture

•	 May reduce task cycle time

•	 May increase productivity

Notes:

•	 A wide variety of lift tables with different

features are available:

o Tables on springs or inflatable bladders 

that automatically adjust height; good 

when the weight of items is consistent

o Power tables, which allow the operator to 

raise and lower materials as needed; better 

when the weight of items handled varies

o Platforms that tilt

o Platforms that rotate

•	 If bins are used on lift tables, they should have

drop-down sides to improve access to items 

near the bottom of the bin

•	 The rotating platform feature is especially

useful to reach materials that are located near 

walls or other obstacles

•	 Lift tables can be installed directly into the

floor 

•	 Floor mounted cylinder-like pneumatic lifts

can be used to raise carts and pallets

Facility-Wide Solutions

Before After

Reduce bending, reaching and walking
14 occupational safety and health administration

Tilters

Description:

Mechanical devices that lift and tilt to adjust 

materials for easier handling

Advantages:

•	 Move the load closer to the worker, which

reduces extended reaches

•	 Reduce the forward bending required to

handle castings

•	 May increase productivity

Notes:

•	 Tilting features minimize access restrictions

caused by bin sides 

•	 Workers will require training on using the

powered device to lift/tilt heavy containers

(e.g., with scrap and ingots)

Facility-Wide Solutions

Reduce bending and reaching

Before After
Solutions for the Prevention of Musculoskeletal Injuries in foundries 15

Modifications of Work Heights to Raise 

Workers to More Comfortable Heights

Description:

Continuously adjustable elevation of workers to 

more comfortable heights

Advantage:

•	 Reduce the amount of above-shoulder

reaching required to do work

Notes:

•	 Any height adjustments should consider both

the facility’s workforce and the products being 

manufactured

•	 Precautions should be taken to make certain

that trip hazards are not created

Facility-Wide Solutions

Reduce reaching
16 occupational safety and health administration

Facility-Wide Solutions

Reduce awkward body postures

Permanently Raised Standing Work Areas Before After

Description:

Modification of the work surface to raise the 

worker

Advantages:

•	 Allow workers to work at their preferred

height

•	 Allow working in a neutral body posture

•	 Eliminate or reduce extended reaching in front

of the body 

•	 Provide stability

•	 May be made in-house using inexpensive

materials

Notes:

•	 The platform should not present a trip or fall

hazard

•	 Should be implemented in locations where

shorter workers must work with raised arms

•	 In areas where multiple people work, the

portable platform should be easily removed 

and replaced 
Solutions for the Prevention of Musculoskeletal Injuries in foundries 17

Platforms or Stack of Pallets to Increase 

the Height at Which Items are Handled

Description:

A permanently raised area or stacks of pallets 

that serve as a low-cost replacement for lift tables

Advantages:

•	 Allow workers to work in a more upright

position

•	 Reduce the amount of bending by workers

•	 Reduce forward reach distance

•	 May shorten task time

•	 May increase productivity

•	 Are less expensive than lift tables

Notes:

•	 This solution works best when work height

does not change

•	 This solution is not practical if workers are

exposed to above-shoulder reaching

•	 Pallets should be in good condition to provide

a stable working surface

•	 Changing work height by adding or removing

pallets may be time-consuming

•	 Pallets are heavy and difficult to handle

manually

Facility-Wide Solutions

Before After

Reduce bending and reaching
18 occupational safety and health administration

Facility-Wide Solutions

Reduce awkward body postures

Height-Appropriate Work Surfaces Before After

Description:

Work tables and benches that can be easily 

raised or lowered to accommodate workers of 

different heights

Advantage:

•	 Reduce awkward working postures of the

arms and trunk

Notes:

•	 For proper height adjustment, workers should

focus on the height of the work being done, 

not the height of the work surface

•	 If a workstation is shared, height adjustment

should be possible without the use of special 

tools or devices

•	 If a workstation is used primarily by a single

worker, hand cranks or motors for rapid 

adjustment may not be necessary
Solutions for the Prevention of Musculoskeletal Injuries in foundries 19

Fixtures that Rotate Parts 

during Production

Description:

Devices that allow parts to be easily turned in 

multiple directions

Advantages:

•	 Are adjustable for varying work processes

on the same part or for differing work 

preferences

•	 Introduce more flexibility for performing tasks

•	 Reduce extended reaching and awkward

postures

Notes:

•	 This solution may be limited to smaller or

lighter-weight items

•	 The loading and unloading of parts onto the

fixture may impact work cycle time

•	 Make sure that the fixtures are stable and

that they prevent unintended movement or 

rotation of the parts

Facility-Wide Solutions

Reduce reaching and awkward postures

Cut-Outs in Work Tables

Description:

Modified work surfaces to allow workers to 

perform tasks more easily

Advantages:

•	 Reduce the reach needed for handling parts,

tools, and equipment

Notes:

•	 The cut-out should not create sharp edges

•	 The width and depth of the cut-out depends on

the locations of parts and tools being handled

•	 This solution should be considered only if

the removed space does not limit the needed 

working space Reduce reaching distances
20 occupational safety and health administration

Powered Dollies

Description:

Worker-controlled, motorized devices to move

loads

Advantages:

•	 Require less manual effort to push/pull loads

•	 Shorten task time

•	 May increase productivity

Notes:

•	 Many types of dollies are commercially

available

•	 Consider dolly features that allow it to be used

for the:

o	 Heaviest loads

o	 Frequently moved loads

•	 Powered dollies may be especially useful

when loads must be moved up or down 

ramps or when loads are moved long 

distances

Reduce physical effort

Before After

Facility-Wide Solutions
Solutions for the Prevention of Musculoskeletal Injuries in foundries 21

Reduce the amount of manual pushing 

and pulling

Before After Systems to signal the location of 

materials that need to be moved using 

powered equipment

Description:

A signaling method, which uses lights installed at 

the end of each workstation. These lights turn on 

to alert forklift drivers that racks/carts need to be

moved

Advantages:

•	 Reduce the amount of manual pushing

and pulling 

•	 Reduce the amount of forklift traffic

Notes:

•	 Workers should receive training to learn how

to use the alert system most effectively

•	 An inefficient system may impact productivity

Facility-Wide Solutions
22 occupational safety and health administration

Sit-Stand Stools

Description:

Devices that workers can lean against, which are 

taller than chairs

Advantages:

•	 Reduce fatigue

•	 Allow workers at standing workstations to

easily change their work postures (e.g., from 

standing to leaning on stool)

•	 Workers can get closer to the work since

space for the knees is not required

•	 Promote more comfortable body posture and

reduce extended reaches 

•	 Improve blood circulation

•	 Are relatively low cost

Notes:

•	 Most sit-stand stools are height-adjustable to

meet the needs of workers of varying heights

•	 Sit-stand stool supports differ by manufacturer; ensure that those used provide stability

•	 Must ensure that stools are stable, so they do

not scoot out from under workers when they 

sit; casters cannot be used

Reduce fatigue and extended reaches

Before After

Facility-Wide Solutions
Solutions for the Prevention of Musculoskeletal Injuries in foundries 23

Floor Mats in Areas Where Workers 

Stand for Long Periods of Time

Description:

Cushioned material that softens hard standing 

surfaces

Advantages:

•	 Reduce worker fatigue

•	 Improve overall worker comfort

Notes:

•	 Provide beveled edge mats to eliminate a trip

or fall hazard

•	 Secure the mats in place

•	 Regularly clean around and under floor mats

•	 Replace worn out mats

•	 Care must be taken where sparks or hot metal

may fall on cushioning material

•	 Selection of the floor mats should be made

in accord with industry specifications and 

standards

Reduce fatigue and discomfort

Before After

Facility-Wide Solutions
24 occupational safety and health administration

Grabbers to Handle Full Barrels

Description:

Mechanical devices, usually attached to fork 

trucks, that can move and manipulate full barrels

Advantages:

•	 Reduce the physical demands required to

perform tasks

•	 Minimize the chance of dropping or spilling

Note:

•	 Workers need to be trained on proper use of

the grabbers

Reduce physical effort

Before After

Handles or Hand Grip Materials on 

Tools that are Difficult to Hold

Description:

Handles or material added to tools that form a

secure and comfortable grip

Advantages:

•	 Added handle or material makes tool gripping

and manipulating easier

•	 Reduce use of forceful pinch grips

Note:

•	 The added handle material may wear out and

may need to be replaced periodically

Improve tool grip

Before After

Facility-Wide Solutions
Solutions for the Prevention of Musculoskeletal Injuries in foundries 25

Mechanical Devices to Dump Raw 

Materials into Top-Loading Furnace

Description:

Handling system to assist with top-loading

furnaces

Advantages:

•	 Reduce the manual handling of materials and

the physical demands

•	 Eliminate manual lifting and tossing of

materials

•	 Reduce back and shoulder injuries

•	 Reduce exposure to heat

•	 Minimize the potential for hand contusions,

fractures, and burns

•	 May increase productivity

Note:

•	 Equipment costs may be recouped in one year

or less

MELTING Solutions

Reduce lifting forces, fatigue, and 

exposure to heat

Mechanical Devices to Load 

Materials into Furnace

Description:

Handling system with a pneumatic ram to feed

ingots into side-loading furnaces

Advantages:

•	 Reduce the manual handling of materials and

the physical demands 

•	 Eliminate manual lifting and tossing of

materials

•	 Reduce back and shoulder injuries

•	 Reduce exposure to heat

•	 Minimize the potential for hand contusions,

fractures, and burns

•	 May increase productivity

Notes:

•	 Materials may still need to be loaded

manually onto the device

•	 Equipment costs may be recouped in one year

or less

Reduce fatigue and exposure to heat

Before After
26 occupational safety and health administration

MOLD PREPARATION Solutions

“Lazy Susan” Type Turntable Systems 

for Inspecting and Finishing Cores

Description:

A device that allows cores to be easily inspected 

and finished during the work process

Advantages:

•	 Reduce the amount of force to repeatedly

move the cores

•	 Reduce physical demands on worker’s hands/

wrist and shoulders

•	 Can reduce the number of times a core is

lifted for finishing and inspection

•	 Can place the part closer to the worker

•	 Allow work on the entire circumference of the

core without having to reposition the core

•	 Core can be viewed from different sides

without manipulating

•	 May improve productivity

Notes:

•	 May take up a lot of floor space

•	 Ensure that the design of the turntable is

load rated for the cores being handled

Reduce physical exertions, awkward 

postures, and reaching
Solutions for the Prevention of Musculoskeletal Injuries in foundries 27

Shorter and Wider Product Storage Racks

Description:

Shorter and wider racks to improve access to the 

molds 

Advantages:

•	 Reduce overhead reaching

•	 Reduce extended forward reaching

Notes:

•	 Redesigned racks should hold the same

amount of molds as those racks being 

replaced 

•	 Redesigned racks may need more storage

space

•	 Introduce an administrative control rack

loading policy to minimize the use of long

reach distances to place products on the rack 

shelves 

MOLD PREPARATION Solutions

Reduce awkward postures and 

extended reaching

Rack Shelves with Roller Wheels

Description:

Rack shelves with integrated roller wheels to 

reduce force needed to pull patterns out of 

storage racks. The patterns rest on wheels 

instead of a shelf surface so they “roll” out of the 

racks instead of “sliding” out of the racks.

Advantages:

•	 Rollers reduce the push/pull forces required to

drag heavy patterns over the shelves

•	 Workers have better access to patterns during

transport

Notes:

•	 Retrofit existing racks or install new racks

•	 Roller mechanisms should be regularly

maintained to ensure push/pull forces are

minimized

•	 Ensure that the rack shelves are rated for the

load weight

Reduce physical exertion

Before After
28 occupational safety and health administration

Automatic Molding Machine

Description:

Machine to join mold halves together

Advantages:

•	 Reduces awkward postures and pinching

hazards associated with moving, flipping and

joining mold halves together

•	 Substantially reduces the amount of physical

effort needed to lift and carry molds

•	 May improve productivity and quality

Notes:

•	 This system may require reconfiguration of

the work area

•	 Automation requires machine guarding and

development of hazardous energy control

procedures

Reduces physical exertion and 

awkward postures

MOLD PREPARATION Solutions

Hoists to Dip Cores

Description:

Overhead systems to lift and lower cores during 

handling

Advantages:

•	 Reduce the physical effort required to lift and

lower cores

•	 May improve productivity

Notes:

•	 Hoist may require a customized hook or

device to attach to each core

•	 Hoist priority should be given to the heaviest

cores or those with greater production runs

•	 Ensure that the hoist is rated for the load

weight

Reduce physical exertions
Solutions for the Prevention of Musculoskeletal Injuries in foundries 29

Grab Bar on Hook Used to Remove 

 Mold from Core

Description:

Grab bar added to the handling hook, which 

provides better mechanical support to disengage 

mold from the core when using an overhead 

hoist 

Advantages:

•	 Allows workers to use a more secured grip

while removing mold from core

•	 Provides greater control of the hoisted

material

•	 May increase productivity

Notes:

•	 Grab bar should be oriented so the hand/wrist

is in a neutral position

•	 Hook/grab bar designs may need to be

customized for the parts

•	 Grab bar design should consider wrist posture

and pinch points

MOLD PREPARATION Solutions

Allows for more controlled gripping
30 occupational safety and health administration

Motorized Hand Carts for Racks

Description:

Worker-controlled, powered devices that 

mechanically maneuver heavy, wheeled carts 

or racks

Advantages:

•	 Reduce the manual force needed to push/pull

wheeled carts

•	 Reduce back and shoulder injuries

•	 Reduce travel time to perform task

•	 May improve productivity

Notes:

•	 Many types of powered hand carts are

commercially available

•	 Priority should be given to frequently moved

racks or racks moved over long distances

•	 Commercial motorized hand carts may need

to be customized

MOLD PREPARATION Solutions

Before After

Reduce physical effort

Lifting Devices to Remove Jacket Sleeves

Description:

Mechanical methods to remove sleeves from 

molds

Advantages:

•	 Reduce physical demands on the back and

shoulders

•	 Reduce back and shoulder injuries

•	 May increase productivity

Note:

•	 The cost to implement may be recouped in

two weeks since a two-man job can now be 

accomplished by a single worker

Before After

Reduce physical exertion and 

awkward posture
Solutions for the Prevention of Musculoskeletal Injuries in foundries 31

Handles Added to Mold Weights

Description:

Hand grips on weights used on molds as they

cool. The old weights were simply metal plates, 

which were difficult to lift and place on molds. 

Advantages:

•	 Reduce the amount of bending needed to

reach weights

•	 Make moving weights easier, because the

handle allows workers to use a comfortable 

power grip 

Notes:

•	 Handles for the weights can be made in-house

•	 Ensure that handle openings are wide enough

to fit gloved hands

MOLD PREPARATION Solutions

Reduce bending and improve power grip
32 occupational safety and health administration

Pistol Grip Air Guns to Clean the 

Mold Patterns

Description:

Right-angle shaped tools with a trigger to 

activate air flow in a horizontal direction

Advantage:

•	 Reduce the awkward positioning of hand/wrist

when performing task

Notes:

•	 The shape or orientation of the mold being

cleaned may determine the appropriate air 

gun 

•	 Using an overhead balancer to hang the air

gun can further reduce the physical effort 

MOLD PREPARATION Solutions

Reduce awkward hand/wrist postures

Inline Drills to Establish Vent Holes 

in Mold Patterns

Description:

Tools with trigger bars aligned in the activation 

direction 

Advantages:

•	 Promote neutral wrist posture by reducing

bending of the wrist

•	 Neutral wrist posture makes it easier to exert 

the necessary force 

Notes:

•	 The best application of the tool is for

horizontal work surfaces

•	 Using an overhead balancer to hang the air

gun can further reduce the physical effort 

required for the task

Reduce bending of the hand/wrist 
Solutions for the Prevention of Musculoskeletal Injuries in foundries 33

CASTING Solutions

Ceramic Ladles

Description:

Ceramic ladles, which are lighter than iron ladles

Advantages:

•	 Lighter-weight ceramic ladles are easier to lift

•	 Reduce physical exertion of the back and arms

Notes:

•	 The cost of ceramic ladles is comparable to

iron ladles

•	 The cost of ceramic ladles may be recouped in

one day

Before After

Reduce physical effort

Balancer Systems to Bear the 

Weight of the Pot/Ladle

Description:

Overhead devices to support the weight of the 

pouring pot/ladle

Advantages:

•	 Reduce the physical effort required of operator

to perform the task

•	 Increase the ability to control pouring pot/

ladle movement

•	 Reduce fatigue

•	 May improve productivity

Notes:

•	 Balancer systems may be constructed

in-house

•	 Training will need to be provided

Before After

Reduce physical exertion
34 occupational safety and health administration

CASTING Solutions

Slip-Resistant Ladle-Pouring Handles

Description:

Friction-increasing materials (e.g., grip tape) or 

modified handles (e.g., knurling) to improve grip 

Advantages:

•	 Increase the control during the ladle-pouring

process

•	 Improve pouring accuracy and reduce

spillage

•	 Reduce the grip force, which must be exerted

to turn the wheel 

Note:

•	 Slip-resistant material should cover the entire

handling surface and may need to be replaced 

frequently

Improve grip 

Powered Devices to Raise and 

Lower Ladles

Description:

Mechanical equipment to replace using hand

wheels to manually reposition ladles

Advantages:

•	 Reduce repetitive movements of the arms

and shoulders

•	 Reduce the physical demands of ladle

handling 

Note:

•	 Controls should be properly located to

minimize awkward shoulder positions

Before After

Reduce physical effort and 

repetitive movements
Solutions for the Prevention of Musculoskeletal Injuries in foundries 35

CASTING Solutions

Spout Extensions Used to Fill Ladles 

Description:

An extension to the spout on brass furnaces

Advantages:

•	 Reduce forward reaching needed to move

worker away from heat

•	 Reduce awkward shoulder postures

•	 Reduce stress on shoulders

Note:

•	 Ensure that the extension does not produce

an impact hazard

Before After

Reduce forward reaching distance and 

awkward postures

Rounded Handles on Metal Pouring Ladles

Description:

Ball-shaped handle securely attached to the 

current lever 

Advantages:

•	 Allow worker to operate ladle using a stronger

grip

•	 Improve operator’s control of the pouring

ladle

•	 Eliminate sharp edges that could press into an

operator’s hands

•	 May reduce spillage

Note:

•	 Handle ends could be round or oval in shape

to suit the needs of the task and worker 

preferences 

Improve grip and reduce contact stress
36 occupational safety and health administration

CASTING Solutions

Elevated Platforms along Pour Lines

Description:

Stable platforms to elevate workers while 

pouring 

Advantages:

•	 Reduce the amount of vertical reaching

required to pour molds

•	 May lower the amount of molten metal

spillage 

Notes:

•	 Precautions should be taken to make certain

that trip hazards are not created

•	 If platforms are higher than 4 ft. from the floor,

rails should be installed

Reduce over-shoulder reaching 

Elevated Locations to Rake Slag

Description:

A raised position where a worker can remove 

slag from the perimeter of holding tanks 

Advantage:

•	 Reduce overhead or forward reaching 

Notes:

•	 Ensure that any raised positions do not create

trip/fall hazards

•	 Consider how the raised location may impact

one’s ability to view the task

Reduce reaching 
Solutions for the Prevention of Musculoskeletal Injuries in foundries 37

Impactors for Shakeout Work

Description:

Mechanical impactors supported by balancers 

that can remove sand, gating, and metal from 

castings

Advantages:

•	 Reduce manual force needed for spruing and

eliminate sledge hammer use 

•	 A balancer supports the weight and makes it

more maneuverable

•	 May increase productivity

Note:

•	 Workers will require training on using

impactors/wedges

Before After

Reduce physical exertion and fatigue

Shakeout and Core Knockout Solutions
38 occupational safety and health administration

Hydraulic, Pressure-Powered Wedges 

to Remove Risers

Description:

Mechanical impact tools supported on tool 

balancers that replace sledgehammers

Advantages:

•	 Reduce awkward shoulder and trunk postures

•	 Eliminate the forces needed to grasp, swing,

and hold sledgehammer 

•	 May reduce task cycle time

Notes:

•	 Different wedges may be needed for different

castings

•	 Wedges need to be supported on the balancer

in the frequently used position

Before After

Reduce physical exertion and awkward postures

Shakeout and Core Knockout Solutions
Solutions for the Prevention of Musculoskeletal Injuries in foundries 39

Reduce physical exertion and awkward postures

Shakeout and Core Knockout Solutions

Mechanical Devices to Open Dies

Description:

Powered equipment to open dies, which replaces

manual opening with pry bars

Advantages:

•	 Eliminate manually prying apart dies

•	 Reduce body fatigue

•	 Reduce the amount of awkward postures

•	 Reduce the risk of burns

•	 May increase productivity

Note:

•	 Cost to implement system may be recouped

within a few months
40 occupational safety and health administration

Reduce manual handling and physical exertion

Shakeout and Core Knockout Solutions

Mechanical Devices to Assist 

in Core Removal

Description:

Powered devices that support core weights 

during lifting and transporting between the rack 

and the shakeout pan

Advantages:

•	 Reduce the manual handling of cores

•	 Reduce physical demands on the back and

shoulders by eliminating lifting and carrying 

Note:

•	 Workers will need training on proper use of

the equipment
Solutions for the Prevention of Musculoskeletal Injuries in foundries 41

Diverters to Channel the Direction 

of Castings

Description:

A sturdy add-on to shaker tables to guide casting 

movement towards the worker

Advantage:

•	 Reduce the extended reaching and torso

bending required to access and handle

castings 

Notes:

•	 These guides can be installed at little cost

•	 Diverter may need to be adjustable for

castings that differ greatly in size or shape

Before After

Reduce reaching

Shakeout and Core Knockout Solutions
42 occupational safety and health administration

Extension Slide at the Output of Shaker 

Table to Automatically Drop Parts into Bins 

Description:

A modification to existing equipment, which uses

gravity to automatically transfer parts

Advantages:

•	 Eliminates use of repeated hook and pull

•	 Reduces the handling of castings

Notes:

•	 Workers may need to monitor bins to prevent

overflow of parts

•	 Defective parts may still need to be handled

manually

Reduces physical exertion

Shakeout and Core Knockout Solutions
Solutions for the Prevention of Musculoskeletal Injuries in foundries 43

Powered Conveyors to Transfer and 

Dump Molds to Shakeout Pans

Description:

A motorized method to move molds to shakeout

pans

Advantages:

•	 Eliminate need to manually push molds along

the production line

•	 Reduce the physical demand on the back

and shoulders to manually lift molds from 

conveyor and break them 

•	 Reduce work in awkward body postures

•	 Reduce fatigue

•	 Reduce burn risk to workers

•	 May increase productivity

Notes:

•	 Existing lines need to be replaced or

retrofitted

•	 Implementation costs may be recouped

within six-to-twelve months

Before After

Reduce physical exertion

Shakeout and Core Knockout Solutions

Rounded Edges Added to the Sides 

of Shakeout Lines

Description:

Smooth surfaces that do not press into workers’ 

bodies when leaning against equipment 

Advantage:

•	 Reduce contact pressure from sharp

equipment edges 

Notes:

•	 Ensure that new edges do not extend

away from the conveyor resulting in 

over-extended reaches

•	 Modifications can be made in-house

Reduce pressure against body 
44 occupational safety and health administration

Grinders with User-Friendly Features

Description:

Pneumatic tools with task-enhancing features 

such as vibration dampening properties, lighter 

weight and more effective grinding heads

Advantages:

•	 Lighter weight may reduce grinding effort/

fatigue

•	 Reduce awkward postures of the hands/wrists,

elbows, and shoulders during activity

•	 Improve control over the grinding task

•	 Reduce exposure to vibration

•	 May improve access to different areas of the

casting

•	 May take material off faster and improve

grinding efficiency, productivity, and quality

Notes:

•	 New equipment costs may be recouped

within four-to-twelve months 

•	 Many newly-designed grinders are

commercially available; test different grinding 

wheels before making a purchasing decision

•	 Alternative grinder attachments may be

placed on currently used grinders (e.g., pads 

that can grind more rapidly)

•	 Ensure proper guarding of the wheel on all

handheld grinders

Before After

Cleaning and Handling Solutions

Reduce physical exertion and 

awkward wrist postures
Solutions for the Prevention of Musculoskeletal Injuries in foundries 45

Mechanical Lifts to Move Cast Materials

Description:

Hoists that bear the weight of the casting being

handled

Advantages:

•	 Minimize the manual transfer of parts

•	 Reduce physical stress on back and shoulders

•	 Reduce whole-body fatigue

•	 May lower the risk of burns

•	 May increase productivity

Note:

•	 Custom attachments may be needed to handle

different parts 

Before After

Cleaning and Handling Solutions

Reduce manual lifting 
46 occupational safety and health administration

Portable Conveyors to Move Materials

Description:

Wheeled portable transfer system that can 

be readily moved from location to location as 

needed 

Advantages:

•	 Reduce bending and other awkward postures

while handling materials 

•	 Reduce the amount of carrying of material

•	 May reduce work cycle times

•	 May improve productivity

Notes:

•	 Portable conveyors that incline can further

reduce the manual handling of materials by 

allowing transport to different elevations

•	 Consider floor surface and load weight when

selecting wheels for conveyors

Cleaning and Handling Solutions

Reduce physical exertion and 

awkward postures
Solutions for the Prevention of Musculoskeletal Injuries in foundries 47

Automated Casting Trim and Finishing

Description:

Powered machines to replace hand or stand 

grinders for finishing work

Advantages:

•	 Minimize grinder usage and exposure to

hand/arm vibration

•	 Decrease the time operators must work while

looking down

•	 Reduce manual parts handling

•	 Reduce task cycle times

•	 Minimize potential exposure to flying debris

and airborne metal contamination

•	 Improve product quality and consistency

•	 Reduce noise levels

•	 In some cases, can eliminate need for a

ventilation helmet

•	 May improve productivity 

Note:

•	 Implementation costs may be recouped within

one year 

Before After

Cleaning and Handling Solutions

Reduce exposure to vibration 

and awkward postures
48 occupational safety and health administration

Automated Finishing Equipment

Description:

Automated equipment to replace hand grinders

and finishing tools 

Advantages:

•	 Eliminates grinder use and exposure to hand/

arm vibration

•	 Improves operator work posture

•	 Serves as a barrier to protect operators from

flying debris and sparks

•	 Controls noise from process

•	 Improves product quality and scheduling

Notes:

•	 Equipment may require more floor space

•	 Ensure that parts loading and unloading does

not require extended reaching

Reduces physical exertions

Cleaning and Handling Solutions

Presses to Assemble Parts

Description:

Mechanical presses to set parts instead of using 

manual pounding

Advantages:

•	 Reduce physical effort required for manual

pounding 

•	 Eliminate use of hand tools

Notes:

•	 Presses may be designed and made in-house

•	 May improve parts quality and reduce scrap

•	 Individual presses may be needed for each

type of part produced

Before After

Reduce force 
Solutions for the Prevention of Musculoskeletal Injuries in foundries 49

Fixtures to Affix Parts

Description:

Fixture to automatically insert and affix clamps, 

and position castings on forging tools, which 

replaces manual power with machine power

Advantages:

•	 Reduce physical demands on workers’ hands/

wrists and shoulders

•	 Utilizes mechanical force instead of muscle

force

•	 May improve productivity

Notes:

•	 A customized fixture may be needed for each

assembled part

•	 Implementation costs may be recouped within

one month 

•	 Consider creating a fixture that can position

the casting in various orientations

Before After

Reduce physical exertions 

Powered Drivers to Assemble 

Components

Description:

Pneumatic or electric tools that replace hand 

tools for assembling finished parts

Advantages:

•	 Reduce repetition and awkward postures to

the hands/wrists and shoulders

•	 Improve productivity

Note:

•	 Implementation cost may be recouped within

one week

Before After

Reduce physical exertion, repetition 

and awkward postures

Cleaning and Handling Solutions
50 occupational safety and health administration

Box-Taping Machines

Description:

Equipment that automatically tapes boxes

containing finished castings

Advantages:

•	 Reduce physical demands required to staple

boxes manually 

•	 Reduce awkward postures during finished

castings packing

•	 Produce a higher quality shipping container

•	 May improve productivity

Notes:

•	 Worker will need to be trained on using the

machine

•	 Implementation cost may be recouped within

one month

Before After

Reduce physical exertion 

Cleaning and Handling Solutions

Plastic-Wrap Machines to 

Enclose Materials

Description:

Automatic means of wrapping pallets of finished 

product 

Advantages:

•	 Substantially reduce the amount of physical

effort to wrap finished product manually

•	 Reduce awkward postures and extended

reaching

•	 May increase productivity

Note:

•	 The machine will require more floor space

Reduce physical effort and awkward postures
Solutions for the Prevention of Musculoskeletal Injuries in foundries 51

Additional Sources of

Information 

The following sources may be useful to those seeking 

further information about ergonomics and the 

prevention of work-related MSDs in foundries.

• Elements of Ergonomics Programs, U.S. 

Department of Health and Human Services, 

National Institute for Occupational Safety and 

Health, (NIOSH), Publication # 97-117, 1997, 

http://www.cdc.gov/niosh/docs/97-117. The 

document describes the basic elements of a 

workplace program aimed at preventing workrelated MSDs. It includes a “toolbox,” which 

is a collection of techniques, methods, reference 

materials, and sources for other information that 

can help in program development. 

• Many states and territories operate their own 

occupational safety and health programs under 

plans approved by Federal OSHA. Information on 

specific state foundry initiatives and compliance 

assistance, as well as state standards that may 

apply to foundries is available on OSHA’s website 

at: www.osha.gov/dcsp/osp/index.html.

• Free On-site Consultation Services for Small 

Business. OSHA’s On-site Consultation Program 

offers free and confidential advice to small and 

medium-sized businesses in all states across 

the country, with priority given to high-hazard 

worksites. On-site consultation services are 

separate from enforcement and do not result in 

penalties or citations. Consultants from state 

agencies or universities work with employers to 

identify workplace hazards, provide advice on 

compliance with OSHA standards, and assist 

in establishing safety and health management 

programs.

For more information, to find the local On-site 

Consultation office in your state, or to request a 

brochure on Consultation Services, visit http://

www.osha.gov/dcsp/smallbusiness/consult.html, or 

call 1-800-321-OSHA [6742].

• Seven foundries in OSHA’s Region V formed the 

NorthEastern Wisconsin Foundry Ergonomics 

Partnership to address ergonomic hazards in a 

foundry setting. This initiative reduced injury and 

illness rates, increased awareness of ergonomic risk 

among workers and management, and significantly 

increased productivity and/or reduced workers’ 

compensation costs. More information on the 

Partnership’s successes can be found at: https://

www.osha.gov/dcsp/success_stories/partnerships/

region5/261_fep_success.html. 

• Through their Alliance (http://www.osha.gov/dcsp/

alliances/afs/afs.html), OSHA and the American 

Foundry Society (AFS) encourage AFS members 

and others, including small businesses, in the 

metalcasting industry to increase worker access 

to safety and health information and training 

resources on workplace issues. AFS provides and 

promotes knowledge and services that strengthen 

the metalcasting industry for the ultimate benefit 

of its customers and society. 
52 occupational safety and health administration

References 

(1) Reports of OSHA site visits to foundries. 

(2) Bureau of Labor Statistics. U.S. Department of 

Labor, November 2011. 

 

(3) Ramsey, J., J. Eisenberg. 2008. Ergonomic 

Evaluation of Workers at a Piston and Cylinder 

Liner Manufacturing Plant. NIOSH Health 

Hazard Evaluation Report HETA 2007-0124-

3060.

(4) Da Costa, B.R., E. R. Vieira. 2010. Risk factors 

for work-related musculoskeletal disorders: A 

systematic review of recent longitudinal studies. 

American Journal of Industrial Medicine,

Vol. 53, pp. 285-323.

(5) Steel Founders’ Society of America at: 

http://www.sfsa.org/sfsa/cstintcp.php.

(6) Armstrong, T. J., M. M. Marshall, B. J. Martin, 

J. A. Foulke, D. C. Grieshaber, G. Malon. 2002. 

Exposure to forceful exertions and vibration in 

a foundry. International Journal of Industrial 

Ergonomics, Vol. 30, Issue 3, pp. 163-179.

(7) Muzammil, M., A. Ali Khan. 2007. Effect 

of noise, heat stress and exposure duration 

on operators in a die casting operation. 

Occupational Ergonomics, Vol. 7, No. 4, 

pp. 233-245.

(8) Musculoskeletal Disorders and Workplace 

Factors – A Critical Review of Epidemiologic 

Evidence for Work-Related Musculoskeletal 

Disorders of the Neck, Upper Extremity and 

Low Back. 1997. U.S. Department of Health 

and Human Services. National Institute for 

Occupational Safety and Health (NIOSH), 

Publication No. 97-141.

(9) National Research Council and Institute of 

Medicine. 2001. Musculoskeletal Disorders 

and the Workplace – Low Back and Upper 

Extremities. National Academy of Sciences. 

Washington, DC: National Academy Press.

(10) Hoozenmans, M.J.M., A. J. van der Beek, 

M. H. W. Frings-Dresen, L. H. V. van der 

Woude, F. J. H. van Dijk. 2002. Pushing and 

pulling in association with low back and 

shoulder complaints. Occupational and 

Environmental Medicine 59, pp. 696-702.

(11) https://www.osha.gov/dcsp/success_stories/

partnerships/region5/261_fep_success.html. 

(12)Marras, W.S. 2000. Occupational low back 

disorder causation and control. Ergonomics.

Vol. 43, No. 7, pp. 880-902.

(13) Butt, S.E., T. K. Fredericks, S. Amin-Kumar, 

S. Ramrattan. 2009, Safety and Ergonomics 

Revisited: How has the Industry Changed in 

10 Years? No. 09-115, Transactions, American 

Foundry Society, Vol. 117, pp. 847-856. 
Solutions for the Prevention of Musculoskeletal Injuries in foundries 53

OSHA Assistance, Services

and Programs

OSHA offers free compliance assistance to employers 

and workers. Several OSHA programs and services 

can help employers identify and correct job hazards, 

as well as improve their injury and illness prevention 

program.

Establishing an Injury and Illness 

Prevention Program

The key to a safe and healthful work environment is a 

comprehensive injury and illness prevention program.

Injury and illness prevention programs are systems 

that can substantially reduce the number and severity 

of workplace injuries and illnesses, while reducing 

costs to employers. Thousands of employers across 

the United States already manage safety using illness 

and injury prevention programs, and OSHA believes 

that all employers can and should do the same. 

Thirty-four states have requirements or voluntary 

guidelines for workplace injury and illness prevention 

programs. Most successful injury and illness 

prevention programs are based on a common set of 

key elements. These include management leadership, 

worker participation, hazard identification, hazard 

prevention and control, education and training, and 

program evaluation and improvement. Visit OSHA’s 

illness and injury prevention program web page 

at www.osha.gov/dsg/topics/safetyhealth for more 

information.

Compliance Assistance Specialists

OSHA has compliance assistance specialists 

throughout the nation located in most OSHA 

offices. Compliance assistance specialists can provide 

information to employers and workers about OSHA 

standards, short educational programs on specific 

hazards or OSHA rights and responsibilities, and 

information on additional compliance assistance 

resources. For more details, visit http://www.osha.gov/

dcsp/compliance_assistance/index.html or call 1-800-

321-OSHA [6742] to contact your local OSHA office.

Free On-site Consultation Services for 

Small Business

OSHA’s On-site Consultation Program offers free 

and confidential advice to small and medium-sized 

businesses in all states across the country, with 

priority given to high-hazard worksites.

Each year, responding to requests from small 

employers looking to create or improve their safety 

and health management programs, OSHA’s On-site 

Consultation Program conducts over 29,000 visits 

to small business worksites covering over 1.5 million 

workers across the nation. 

On-site consultation services are separate from 

enforcement and do not result in penalties or 

citations. Consultants from state agencies or 

universities work with employers to identify 

workplace hazards, provide advice on compliance 

with OSHA standards, and assist in establishing 

safety and health management programs.

For more information, to find the local On-site 

Consultation office in your state, or to request a 

brochure on Consultation Services, visit http://www.

osha.gov/dcsp/smallbusiness/consult.html, or call 

1-800-321-OSHA [6742].

Under the consultation program, certain exemplary 

employers may request participation in OSHA’s 

Safety and Health Achievement Recognition Program 

(SHARP). Eligibility for participation includes, but is 

not limited to, receiving a full-service, comprehensive 

consultation visit, correcting all identified hazards and 

developing an effective safety and health management 

program. Worksites that receive SHARP recognition 

are exempt from programmed inspections during the 

period that the SHARP certification is valid.

Cooperative Programs

OSHA offers cooperative programs under which 

businesses, labor groups and other organizations can 

work cooperatively with OSHA. To find out more 

about any of the following programs, visit http://

www.osha.gov/dcsp/compliance_assistance/index_

programs.html. 

Alliance Program

Through the Alliance Program, OSHA works with 

groups committed to worker safety and health to 

prevent workplace fatalities, injuries and illnesses. 

These groups include trade or professional 

organizations, employers, unions, consulates, faith- 
54 occupational safety and health administration

and community-based organizations and educational 

institutions. OSHA and the groups work together to 

develop compliance assistance tools and resources, 

share information with workers and employers, and 

educate workers and employers about their rights and 

responsibilities.

OSHA Strategic Partnership Program (OSPP)

The OSPP provides the opportunity for OSHA to 

partner with employers, workers, professional or 

trade associations, labor organizations, and/or other 

interested stakeholders. OSHA Strategic Partnerships 

(OSP) are formalized through unique agreements 

designed to encourage, assist, and recognize partner 

efforts to eliminate serious hazards and achieve model 

workplace safety and health practices.

Challenge Program

OSHA Challenge provides interested employers 

and workers the opportunity to gain assistance 

in improving their safety and health management 

programs. OSHA Challenge is available to general 

industry, maritime and construction employers in 

the private and public sectors under OSHA’s federal 

jurisdiction.

Voluntary Protection Programs (VPP)

The VPP recognize employers and workers in private 

industry and federal agencies who have implemented 

effective safety and health management programs and 

maintain injury and illness rates below the national 

average for their respective industries. In VPP, 

management, labor, and OSHA work cooperatively 

and proactively to prevent fatalities, injuries, and 

illnesses through a system focused on: hazard 

prevention and control, worksite analysis, training, 

and management commitment and worker 

involvement. To participate, employers must 

submit an application to OSHA and undergo a 

rigorous on-site evaluation by a team of safety and 

health professionals. Union support is required for 

applicants who are represented by a bargaining unit. 

VPP participants are re-evaluated every three to five 

years to remain in the programs. VPP participants are 

exempt from OSHA programmed inspections while 

they maintain their VPP status.

Occupational Safety and Health Training

The OSHA Training Institute in Arlington Heights, 

Illinois, provides basic and advanced training and 

education in safety and health for federal and state 

compliance officers, state consultants, other federal 

agency personnel and private sector employers, 

workers, and their representatives.

In addition, 25 OSHA Training Institute Education 

Centers at 44 locations throughout the United States 

deliver courses on OSHA standards and occupational 

safety and health issues to thousands of students a 

year.

For more information on training, contact the 

OSHA Directorate of Training and Education, 2020 

Arlington Heights Road, Arlington Heights, IL

60005; call 1-847-297-4810; or visit www.osha.gov.

Susan Harwood Training Grants

OSHA awards grants to nonprofit organizations to 

provide workers and small employers with safety 

and health training and education about hazard 

identification and prevention. Grants focus on small 

business, hard-to-reach workers and high-hazard 

industries.

Grantees develop programs that address safety and 

health topics selected by OSHA, recruit 

workers and employers for the training and 

conduct the training. They are also expected to follow 

up with students to find out how they have applied 

the training in their workplaces.

For more information on training grants, contact 

the OSHA Directorate of Training and Education by 

calling 1-847-297-4810 or visiting www.osha.gov.

OSHA Educational Materials

OSHA has many types of educational materials in 

English, Spanish, Vietnamese and other languages 

available in print or online. These include:

•	 Brochures/booklets that cover a wide variety of job

hazards and other topics;

•	 Fact Sheets, which contain basic background

information on safety and health hazards;

•	 Guidance documents that provide detailed

examinations of specific safety and health issues;
Solutions for the Prevention of Musculoskeletal Injuries in foundries 55

•	 Online Safety and Health Topics pages;

•	 Posters;

•	 Small, laminated QuickCardsTM that provide brief

safety and health information; and

•	 QuickTakes, OSHA’s free, twice-monthly online 

newsletter with the latest news about OSHA 

initiatives and products to assist employers and 

workers in finding and preventing workplace 

hazards. To sign up for QuickTakes visit OSHA’s 

website at www.osha.gov and click on QuickTakes

at the top of the page.

To view materials available online or for a listing of 

free publications, visit OSHA’s website at www.osha.

gov. You can also call 1-800-321-OSHA [6742] to 

order publications.

OSHA’s website also has a variety of eTools. These 

include utilities such as expert advisors, electronic 

compliance assistance, videos and other information 

for employers and workers. To learn more about 

OSHA’s safety and health tools online, visit www.

osha.gov.

NIOSH Health Hazard

Evaluation Program

Getting Help with Health Hazards

The National Institute for Occupational Safety and 

Health (NIOSH) is a federal agency that conducts 

scientific and medical research on workers’ safety and 

health. At no cost to employers or workers, NIOSH 

can help identify health hazards and recommend ways 

to reduce or eliminate those hazards in the workplace 

through its Health Hazard Evaluation (HHE)

Program. 

Workers, union representatives and employers can 

request a NIOSH HHE. An HHE is often requested 

when there is a higher than expected rate of a disease 

or injury in a group of workers. These situations may 

be the result of an unknown cause, a new hazard, or 

a mixture of sources. To request a NIOSH Health 

Hazard Evaluation go to www.cdc.gov/niosh/hhe/

request.html. To find out more about the Health 

Hazard Evaluation Program:

•	 Call (513) 841-4382, or to talk to a staff member

in Spanish, call (513) 841-4439; or

•	 Send an email to HHERequestHelp@cdc.gov.
56 occupational safety and health administration

OSHA Regional Offices

Region I

Boston Regional Office

(CT*, ME, MA, NH, RI, VT*) 

JFK Federal Building, Room E340

Boston, MA 02203

(617) 565-9860 (617) 565-9827 Fax 

Region II

New York Regional Office

(NJ*, NY*, PR*, VI*)

201 Varick Street, Room 670

New York, NY 10014

(212) 337-2378 (212) 337-2371 Fax

Region III

Philadelphia Regional Office

(DE, DC, MD*, PA, VA*, WV)

The Curtis Center

170 S. Independence Mall West

Suite 740 West

Philadelphia, PA 19106-3309

(215) 861-4900 (215) 861-4904 Fax

Region IV

Atlanta Regional Office

(AL, FL, GA, KY*, MS, NC*, SC*, TN*)

61 Forsyth Street, SW, Room 6T50

Atlanta, GA 30303

(678) 237-0400 (678) 237-0447 Fax

 

Region V

Chicago Regional Office

(IL*, IN*, MI*, MN*, OH, WI)

230 South Dearborn Street 

Room 3244

Chicago, IL 60604

(312) 353-2220 (312) 353-7774 Fax

Region VI

Dallas Regional Office

(AR, LA, NM*, OK, TX)

525 Griffin Street, Room 602

Dallas, TX 75202

(972) 850-4145 (972) 850-4149 Fax

(972) 850-4150 FSO Fax

Region VII

Kansas City Regional Office

(IA*, KS, MO, NE)

Two Pershing Square Building

2300 Main Street, Suite 1010

Kansas City, MO 64108-2416

(816) 283-8745 (816) 283-0547 Fax

Region VIII

Denver Regional Office

(CO, MT, ND, SD, UT*, WY*)

1999 Broadway, Suite 1690

Denver, CO 80202

(720) 264-6550 (720) 264-6585 Fax

Region IX

San Francisco Regional Office

(AZ*, CA*, HI*, NV*, and American Samoa, 

Guam and the Northern Mariana Islands)

90 7th Street, Suite 18100

San Francisco, CA 94103

(415) 625-2547 (415) 625-2534 Fax

Region X

Seattle Regional Office

(AK*, ID, OR*, WA*)

300 Fifth Avenue, Suite 1280

Seattle, WA 98104

(206) 757-6700 (206) 757-6705 Fax

* These states and territories operate their own 

OSHA-approved job safety and health plans and 

cover state and local government employees as well 

as private sector employees. The Connecticut, Illinois, 

New Jersey, New York and Virgin Islands programs 

cover public employees only. (Private sector workers 

in these states are covered by Federal OSHA). States 

with approved programs must have standards that 

are identical to, or at least as effective as, the Federal 

OSHA standards.

Note: To get contact information for OSHA area 

offices, OSHA-approved state plans and OSHA 

consultation projects, please visit us online at 

www.osha.gov or call us at 1-800-321-OSHA (6742).
How to Contact OSHA

For questions or to get information or advice, 

to report an emergency, report a fatality or 

catastrophe, order publications, sign up for 

OSHA’s e-newsletter, or to file a confidential 

complaint, contact your nearest OSHA office, 

visit www.osha.gov or call OSHA at 

1-800-321-OSHA (6742), TTY 1-877-889-5627.

For assistance, contact us.

We are OSHA. We can help. 
For more information

www.osha.gov (800) 321-OSHA (6742)

Occupational

Safety and Health

Administration

U.S. Department of Labor