Table B2-2
Control Measures - Metalworking
ID
Metalworking
Technique
Ingestion
Hazard
Inhalation Hazard
1
WELDING, BRAZING, & SOLDERING
2
Oxyacetylene
Welding Fire
Hazards
3
Oxyacetylene
Welding
Cylinder
Precautions
4
Oxyacetylene
Welding
Safety
Hazards
Skin Contact Hazard
Other Hazards
Fire and explosion
hazards
Recommended Control
Measures
Welding surface should be
fireproof, made of steel or
firebrick; don't use asbestos
sheeting; wooden floors &
walls should be covered
with fireproof materials;
remove
combustibles/flammables;
don't weld on containers
that have held
combustibles/flammables
Don't move cylinders w/out
valve protection cap; make
sure hoses can't be tripped
over/don't contact grease;
make sure connections are
gas tight; use proper tools
to open valves away from
self-purge lines to remove
mixed gases; close valves
before relighting
Thermal burns
B2-2-1
Hot metal, flying
sparks, infrared
radiation can cause
severe thermal
burns on exposed
skin
Wear leather gloves, longsleeve 100% wool or flameretardant cotton shirts,
pants, leather apron to
protect from burns; don't
wear flammable clothing
Table B2-2, continued
ID
Metalworking
Technique
Ingestion
Hazard
Inhalation Hazard
Skin Contact Hazard
Other Hazards
Recommended Control
Measures
w/cuffs, pockets; wear hightop leather boots w/out
rubber/crepe soles & do
have safety toes
5
Oxyacetylene
Welding
Health
Hazards
6
Arc Welding
Safety
Hazards
7
Arc Welding
Health
Hazards
Phosgene extremely toxic;
carbon dioxide, acetylene
cut off oxygen to lungs;
carbon monoxide &
fluoride flux fumes highly
toxic; metal fume fever;
metal dusts irritating; metal
fumes highly toxic
Ozone highly toxic/causes
lung irritation/congestion/
chemical
UV can cause skin
cancer, eye damage,
sunburn; can react w/
chlorinated
hydrocarbons to form
phosgene
Eye damage from uv
light
B2-2-2
Visible light can
cause eye
strain/headaches;
infrared radiation
can cause skin
burns/ chronic eye
inflammation/ heat
cataracts; copper/
zinc/ iron/ nickel/
magnesium can
cause metal fume
fever; lead/
cadmium/
manganese/
chromium/ beryllium/
nickel highly toxic
Wear welding goggles
w/shade #4-8; don't store
chlorinated hydrocarbons
where UV light can reach;
know composition of
metals/rods; use dilution
ventilation of at least 2,000
cubic feet/minute/welder;
use local exhaust system,
NIOSH-approved respirator
Increased risk of fire,
thermal burns from
sparks, heat stress;
high risk of electric
shock due to large
electric currents
used
Wear protective
clothing/leather
leggings/sleeves; prevent
fire; install & ground electric
arc welders according to
manufacturer; cables/
connectors should be of
proper size, regularly
inspected, & properly
secured; inspect electrode
holders, cables
Chromates may
cause lung irritation,
allergies, nasal
Use fireproof UV radiation
screens around welding
units; coat walls w/zinc
Table B2-2, continued
ID
Metalworking
Technique
Ingestion
Hazard
Inhalation Hazard
Skin Contact Hazard
pneumonia/chronic
bronchitis, can be fatal;
nitrogen dioxide highly
toxic/causes chemical
pneumonia, emphysema;
metal
fumes/manganese/fluoride
fumes highly toxic
8
FOUNDRY
9
Mold Making
High-silica sands, silica
flour, investment plasters
highly toxic (can cause
silicosis); formaldehyde
extremely toxic;
isocyanates highly toxic;
asbestos extremely toxic;
ethyl silicate highly toxic
10
Burnout of the
Pattern
Carbon monoxide highly
toxic; wax decomposition
fumes highly irritating;
styrene, hydrogen cyanide
gases highly toxic
11
Melting the
Metal
Carbon dioxide & carbon
monoxide (highly toxic)
from furnace; lead fumes
from lead metal & bronze
highly toxic; zinc fumes
from bronze & brass
moderately toxic; nickel
Formaldehyde
moderately toxic;
hexamethylenetetramine
causes skin irritation by
decomposing to
formaldehyde
Other Hazards
Recommended Control
Measures
septum ulceration,
lung cancer; plasma
arc welders produce
much higher
concentrations of
ozone, nitrogen
dioxide, metal fumes
& produce high
noise levels
oxide to reduce reflection;
leave 20 inches at bottom
of screen for ventilation;
wear welding helmet over
impact-resistant flash
goggles (#10-14); use local
exhaust ventilation
Formaldehyde
known carcinogen;
asbestos can cause
lung cancer,
mesothelioma,
stomach/intestinal
cancer; french chalk
can contain high
amounts of free
silica
Use foundry sand for
molds, not high-silica
sands; use local exhaust
ventilation when mixing
silica, or use NIOSHapproved respirator; avoid
formaldehyde/polyurethane
resins; wear gloves,
goggles; DO NOT use
asbestos/silica flour/French
chalk; use graphite
Ventilate with local exhaust
system (canopy hood over
burnout furnace)
Natural gas/propane
gas cause
fire/explosion
hazards; nickel
fumes/dusts can
cause lung/nasal
cancer; using alloys
B2-2-3
Gas furnaces should be
connected by gas
company; use alloys of
known composition only;
avoid nickel/lead; use local
exhaust ventilation; wear
infrared goggles, face
Table B2-2, continued
ID
Metalworking
Technique
Ingestion
Hazard
Inhalation Hazard
Skin Contact Hazard
fumes may be extremely
toxic (nickel carbonyl can
be in it)
12
Pouring the
Metal
Hazardous metal fumes
released during pouring;
thermal decomposition of
organic materials release
formaldehyde, carbon
monoxide, acrolein,
cancer-causing
substances; polyurethane
foam can release
hydrogen cyanide gas
(extremely toxic)
13
Removing the
Mold
Intense temperatures
convert normal quartz
sand to highly hazardous.
silica; sandblasting can
cause silicosis in a few
years exposure
14
FORGING & METAL FABRICATION
15
Cutting,
Piercing, &
Molten metal splashes
can cause severe
thermal burns
Small metal filings can
damage skin, eyes;
B2-2-4
Other Hazards
Recommended Control
Measures
of unknown
composition can
result in exposure to
other toxic metals;
furnace can cause
heat stress; infrared
radiation causes
skin burns
shield, long-sleeve wool
shirt, insulated leggings,
jacket, apron, gloves
Manual pours limited
by weight of crucible
& person's strength;
molten metal
splashes on cement
result in heat
vaporizing water in
cement, causing it to
violently break apart
in steam explosion
Make sure you can lift
crucible; don't pour by
yourself; use two-person
shank and ring/mechanical
lifting equipment; embed
molds in damp sand 18
inches deep, enclosed in
metal; foundry floor should
have raised metal
grate/covered w/sand; use
canopy hood
Abrasive blasting
creates loud
amounts of noise,
which can cause
hearing loss
Wear NIOSH-approved
toxic dust respirator;
vacuum/wet mop; don't use
sand for abrasive blasting;
use alumina/silicon
carbide/walnut shells; avoid
foundry slags w/arsenic;
inspect blasting machine
often; wear hearing
protection, protective
clothing; blasting hood
Electric drills can
cause electric
Wear ANSI-approved
goggles to protect eyes
Table B2-2, continued
ID
Metalworking
Technique
Ingestion
Hazard
Inhalation Hazard
Filing Metals
16
Forging
Furnaces for hot forging
give off large amounts of
carbon monoxide and
other highly toxic fumes &
gases
17
Annealing
18
SURFACE TREATMENT OF METALS
19
Mechanical
Treatment
Benzine (VM&P naphtha)
moderately toxic
Skin Contact Hazard
Other Hazards
Recommended Control
Measures
saws, drills, metal snips
can cause cuts
shocks if they're not
properly grounded
against flying metal
pieces/filings; make sure
electrical equipment
properly grounded & wiring
is in good condition; handle
tools w/sharp edges
carefully; fasten metal piece
in vise; put tools away after
use
Careless handling of hot
objects can cause
thermal burns; furnaces
produce infrared
radiation, which is an
eye & skin hazard
Noise is a hearing
hazard in both
hot/cold forging;
large amounts of
heat from furnaces
can cause heat
stress
Do forging in separate
room; wear ear plugs/ear
muffs; equip all furnaces
w/chimneys/canopy hoods;
use exhaust fan; wear
protective goggles (shade #
1.7-3.0); wear long-sleeve,
cotton shirt, leather gloves,
safety shoes, face shield;
keep room cool
Sulfuric acid/other acids
& Sparex highly
corrosive to skin, eyes;
diluted acid less
hazardous., but can
cause burns
Use of torches
involves flammable
gases, such as
propane &
acetylene, and
oxygen/compressed
air (fire & explosion
hazards); furnaces
can cause heat
stress
Use precautions w/gas
torches, fuel-fired furnaces;
wear protective goggles,
gloves, apron; add acid to
water; use Sparex; avoid
acids; if acid splashes on
skin, rinse w/water, if in
eyes, rinse for 15-20
minutes; neutralize acid
w/sodium bicarbonate
Benzine moderately
toxic; hot pitch is skin
irritant & frequent,
Heating pitch & use
of benzine to
remove pitch from
Don't smoke/have open
flames; store solvents in
safety cans, store rags in
B2-2-5
Table B2-2, continued
ID
Metalworking
Technique
Ingestion
Hazard
Inhalation Hazard
Skin Contact Hazard
Other Hazards
Recommended Control
Measures
prolonged contact can
cause skin cancer
the metal creates
fire hazards;
engraving tools can
cause cuts if used
improperly
disposal cans & remove
each day; use adequate
exhaust system; use gloves
when handling hot pitch or
benzine; handle engraving
tools carefully; cut away
from yourself
Methyl cellosolve
acetate can cause
adverse
reproductive effects,
kidney damage,
anemia; methyl
cellosolve acetate &
xylene flammable;
carbon arcs emit
ultraviolet radiation,
which cause
sunburn, eye
damage; hot pitch is
fire hazard.
Wear gloves, goggles,
protective apron, NIOSHapproved organic vapor
respirator; add acid to
water; if acid splashes on
skin, rinse w/water, if in
eyes, rinse for 15-20
minutes; use local exhaust
system; use commercial
resists; don't use carbon
arcs
20
Etching &
Photoetching
Nitrogen dioxide gas highly
toxic, causing pulmonary
edema, pneumonia,
emphysema; methyl
cellosolve acetate highly
toxic; xylene highly toxic;
carbon arcs give off
nitrogen oxides, ozone,
metal fumes (highly toxic)
Nitric acid/other acids
highly corrosive to eyes,
skin; methyl cellosolve
acetate highly toxic;
xylene moderately toxic;
hot pitch can cause
burns
21
Electroplating
&
Electroforming
Sulfuric acid is respiratory
irritant; lacquer vapors &
mists highly toxic
Risk of electrical shock;
caustic soda, sulfuric
acid highly corrosive;
sulfuric acid skin & eye
irritant; lacquer vapors
moderately irritating
22
Electroplating
&
Electroforming
Send pieces to commercial
electroplater; wear rubber
gloves, goggles, protective
apron, NIOSH-approved
respirator, rubber-soled
shoes; add acid to water; if
acid splashes on skin, rinse
w/water, if in eyes, rinse 1520 min.; use local exhaust
system
Install ground fault circuit
interrupter; install
electroplating unit on
B2-2-6
Table B2-2, continued
ID
Metalworking
Technique
Ingestion
Hazard
Inhalation Hazard
Skin Contact Hazard
Other Hazards
(continued)
Recommended Control
Measures
wooden/non-conducting
surface, not on metal; don't
use metal chair; don't touch
bath, wires, electrodes
w/bare hands; unplug
power before adjusting
bath; use special
rectifiers/tape
23
Anodizing
Hydrofluoric
acid can be
fatal
Trisodium phosphate
alkaline & can cause
respiratory irritation;
hydrofluoric acid highly
corrosive to lungs
Trisodium phosphate
alkaline & can cause
skin, eye irritation;
hydrofluoric acid highly
corrosive
Titanium & tantalum
are combustible;
their filings & dust
will burn; burns can
occur without pain
hours after exposure
to hydrofluoric acid;
hydrofluoric acid can
cause chemical
pneumonia, chronic
bone/teeth or kidney
damage; risk of
electrical shock
Wear insulating rubber
gloves, goggles, protective
apron, face shield; AVOID
hydrofluoric acid, use wet
sand & emery paper; only
use hydrofluoric acid in lab
hood or w/acid gas
respirator; if contact
w/skin/eyes, flush for 15
min. & call doctor right
away
24
Patinas
Patinas
highly
poisonous;
concentrated
acids highly
corrosive;
benzine
moderately
toxic
Chlorinated solvents highly
toxic; patinas highly
poisonous; spray mists
hazardous.; concentrated
acids highly corrosive;
potassium cyanide forms
poisonous hydrogen
cyanide gas; benzine
moderately toxic, lacquers
highly toxic
Chlorinated solvents can
be absorbed through
skin; patinas corrosive;
concentrated acids
highly corrosive;
benzine, lacquers
moderately toxic
Chlorinated solvents
probable
carcinogens; if
heated w/torch,
decompose to
poisonous phosgene
gas; diluted acids
cause skin, eye
irritation; oxidizing
agents can cause
fires/explosions;
benzine, lacquer
solutions flammable
Use mineral
spirits/detergent solutions
to clean/degrease metals;
don't use antimony/ arsenic/
cyanide/ mercury; wear
goggles, gloves, protective
apron; don't add acids to
sulfides when coloring;
store oxidizing agents away
from solvents
B2-2-7
Table B2-2, continued
ID
Metalworking
Technique
Ingestion
Hazard
Inhalation Hazard
25
Patinas
(continued)
26
Niello
Lead sulfide
dust from
grinding
highly toxic
Lead fumes emitted from
melting of lead highly toxic;
lead sulfide dust from
grinding highly toxic
27
Gilding
Mercury
metal poorly
absorbed
Mercury metal highly toxic
Skin Contact Hazard
Other Hazards
Recommended Control
Measures
Use glove box, local
exhaust ventilation, NIOSHapproved toxic dust
respirator; don't eat, drink,
smoke in studio; dip/brush
patinas instead of spraying;
don't have smoke/open
flames in working area;
dispose of waste solvents &
rags daily
Do all melting & heating in
local exhaust system; wear
NIOSH-approved respirator;
don't eat, drink, smoke in
studio; wash hands
carefully after work; wet
mop surfaces; heat
ammonium chloride paste
inside a hood
Mercury metal highly
toxic
B2-2-8
Acute mercury
poisoning is
accompanied by
metallic taste,
excessive salivation,
swelling of
gums/mouth,
vomiting, bloody
diarrhea, kidney
failure, bronchitis,
pneumonia; chronic
mercury poisoning
affects central
nervous system
DO NOT USE mercury
amalgams; store mercury
under water in closed
containers; if mercury used,
make amalgam on tray to
contain spills; use local
exhaust ventilation; clean
up spills w/mercury spill kit;
wash contaminated
surfaces w/ferric chloride
Table B2-2, continued
ID
Metalworking
Technique
Ingestion
Hazard
28
CLEANING, POLISHING, & FINISHING
29
Pickling
Ammonium
bifluoride
highly toxic
30
Grinding,
Polishing, &
Other
Mechanical
Techniques
Leadcontaining
dusts highly
toxic
Inhalation Hazard
Recommended Control
Measures
Skin Contact Hazard
Other Hazards
Nitric & sulfuric acids
highly toxic; hydrofluoric
acid highly corrosive;
potassium dichromate
highly toxic
Nitric & sulfuric acid,
ammonium bifluoride
highly toxic; hydrofluoric
acid highly corrosive;
sodium bisulfate
moderately corrosive;
potassium dichromate
moderately toxic
Boiling acid
solutions can be
very hazardous due
to danger of
splashing;
dichromates are
probable
carcinogens;
hydrofluoric acid can
cause lung irritation,
chemical
pneumonia, chronic
bone/teeth/kidney
damage; may be
fatal
Wear gloves, goggles,
protective apron, respirator,
face shield; if acid splashes
on skin, rinse w/water; if in
eyes, rinse for 15-20 min.;
cover acid baths; use local
exhaust ventilation; use
bifluoride pastes; neutralize
acid w/sodium bicarbonate
Lead-containing dusts
highly toxic; free silica
highly toxic, causing
silicosis; formaldehyde
highly irritating; silicacontaining abrasives may
cause silicosis from
chronic inhalation
Cutting fluids may cause
dermatitis
Flying metal
particles can cause
eye damage;
synthetic,
semisynthetic,
soluble cutting oils
contain
nitrosamines, which
cause cancer in
animals
Wear goggles, face shield,
respirator; grinding wheels
should have eye shields;
don't wear loose clothing;
don't use sandstone
wheels; use silicon
carbide/alumina; use wet
techniques; use local
exhaust ventilation; use
cutting oils w/out
amines/nitrites
B2-2-9