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Tranemo Safety Expert Guide

RISK ASSESSMENT METALLURGY A practical guide to identifying risks and designing the right safety measures for working in smelting plants and foundries.

RISK ASSESSMENT METALLURGY Radiant heat and the risk of splashes from molten metal or minerals – when working in smelting plants and foundries, there are high-severity risks that can have serious consequences if not managed correctly. Under the PPE Regulation, splashes from molten metals are classified in the highest category, Category III – high risk of injury. To protect against these potential risks, knowledge of the metals and minerals used, an understanding of the risks, and a risk management method are required. Knowledge of fabrics and materials, as well as testing in a real-world working environment, is also essential. In this guide, we go through the various steps involved in carrying out a risk assessment. We also provide recommendations for protective clothing suitable for working with different types of metals and minerals. © 2026 Tranemo Workwear | Risk Assessment Metallurgy

RISK ASSESSMENT METALLURGY

Keep an eye on the metals

Understand the risks

Apply EN ISO 11612

Test in a real-world environment

Be aware of the design requirements

Select a collection and garment

1. KNOW WHICH METALS YOU ARE WORKING WITH The design of safety systems for work in smelters and foundries is based on the specific metal or mineral used in the process. It is therefore essential that you know which metals and alloys you and your colleagues are handling. Red and white metals are two distinct categories in metallurgy, characterised by their unique properties and the specific risks they pose.

RED METALS AND ALLOYS

WHITE METALS AND ALLOYS

MINERALS

Iron, steel, copper, bronze, brass, etc.

Zinc, aluminium, silver, lead, etc.

Melting point: Often 900–2000 °C

Melting point: Approximately 400 °C

Molten glass, molten rock, cryolite, etc.

Behaviour: Volatile, ‘nervous’ behaviour. Does not stick when molten, but simply wants to ‘run off’.

Behaviour: Sticky when molten and may stick to clothing if splashed

EN 116122 code letter: E

EN 11612 code letter: D

Melting point: 1000–2500 °C EN 11612 code letter: D

2. UNDERSTANDING THE RISKS IN METALLURGY SPLASHES OF MOLTEN METAL A drop or splash of molten metal or mineral may penetrate protective clothing if the metal or mineral accumulates on the garment or does not run off quickly enough. The temperature, density and behaviour of the metal and mineral are therefore important factors that must be taken into account in risk analysis. 1.

Is there a risk of molten metal or mineral splashes?

Which part of the body is at risk?

How likely is it that the splash will run off, given the properties of the metal/mineral and the functionality of the garment?

Can the risk of splashes be reduced or eliminated?

Is additional or different protection needed?

RADIANT HEAT The working environment in smelting plants and foundries is generally very hot. In addition, there are usually high levels of radiant heat. When working in high temperatures and wearing heavy protective clothing, the body’s natural cooling process – sweating – becomes less effective. This can lead to physiological heat stress and pose various health risks depending on the degree of strain.

OTHER RISKS

» Heat and flame » Arc flash (certain occupational groups) » Road traffic accidents (limited risk)

3. APPLY STANDARD ISO 11612 The EN ISO 11612 standard specifies protective clothing for work where there is a risk of the garments coming into contact with heat and flames. To protect against risks in the metallurgical industry, protective clothing certified to this standard is required. The standard is divided into different categories, with code letters indicating which requirements the garments meet. A – flame spread

D – molten aluminium

Code letter A indicates the fabric’s ability to limit the spread of flames. A1: Surface ignition. A2: Edge ignition.

Code letter D indicates the fabric’s ability to protect against molten aluminium under certain specified conditions.

B – convective heat

E – molten iron and steel

Code letter B indicates the fabric’s ability to block convective heat (open flame).

The code letter E indicates the fabric’s ability to protect against molten iron and steel under certain specified conditions.

C – radiant heat Code letter C measures the ability to block radiant heat. The tests provide two values: the time it takes before you feel the heat through the fabric (perception time RHTI12), i.e. a temperature increase of 12°C, and the time it takes for skin temperature to rise by 24°C (radiant heat index RHTI24) . The reaction time is the time the user has to react and move away from the heat source to avoid a burn. See the illustration on the right.

F – contact heat The code letter D indicates the fabric’s ability to protect against contact heat.

Radiant Heat Index (RHTI24) Perception time (RHTI12) Initial temperature

Reaction time +12°

+24°

4. TEST THE FABRICS IN A REAL-LIFE SETTING Fabric testing in real-world conditions is a crucial step in designing the right protective solution. In this type of test, molten metal is poured onto the fabric to see whether the metal sticks or runs off. If the metal sticks, it will quickly burn through the fabric, which would cause the wearer very serious burns. These tests are important to carry out as laboratory tests do not always reflect the reality of your working environment.

5. BE AWARE OF THE DESIGN REQUIREMENTS REQUIREMENTS Molten metal or minerals that become trapped in the garment can cause burns. To minimise the risk of injury, EN ISO 11612 Parts D and E specify certain design requirements, such as closed pockets and concealed metal fittings (as metal conducts heat). The protective clothing must also be constructed in accordance with the ‘waterfall principle’, with overlapping fabric layers designed to allow molten metal/mineral to run off the garment.

RECOMMENDATION In these environments, there is also a risk of heat stress. We therefore recommend a system comprising two or three thin layers that insulate against heat radiation and enhance protection, as the air gaps between the layers shield the user from heat and energy. © 2026 Tranemo Workwear | Risk Assessment Metallurgy

6. CHOOSE COLLECTION AND ITEM Work in smelting plants and foundries usually requires protective clothing with a high level of flame resistance that complies with EN ISO 11612. The garments must also be certified with the correct code letter – D or E – depending on the metal or mineral being used. As mentioned earlier, code letter D is associated with aluminium, whilst E relates to molten iron and steel. On the following pages, we present various collections of protective clothing certified for working with different types of metals.

IRON AND STEEL When working with molten iron or steel, clothing certified to EN ISO 11612 E1–E3 is required, with E3 being the highest level. If the fabric can withstand molten iron and the metal does not adhere to the surface, it will usually also withstand molten copper, molten phosphor bronze and molten brass.

ALUMINIUM When working with molten aluminium, clothing certified to EN ISO 11612 D1–D3 is required, with D3 being the highest level. If the fabric can withstand molten aluminium and the metal does not stick to the surface, it will usually also withstand molten aluminium bronze and molten minerals.

ZINC When working with molten zinc, clothing certified to EN ISO 11612 is required, made from a fabric with a degradation temperature higher than 420°C (the melting point of zinc). Tranemo’s Apex collection features an outer layer of aramid that does not break down even if zinc sticks to the fabric. To block radiant heat and enhance protection, Apex also features double fabric on the front of the jacket and trousers.

OTHER METALS Other molten metals and alloys have different melting points, viscosities and production processes, which place different demands on protective clothing. If you work with other molten metals, please contact Tranemo to find the right solution for your specific operations.

EVERYONE WHO GOES TO WORK HAS THE RIGHT TO COME HOME SAFE AND SOUND. KEEP AN EYE ON METALS. UNDERSTAND THE RISKS. For more detailed information on risk assessments, standards, certifications and sustainability, please visit our website tranemo.com.