PSR for Foundry Operations and Molten Material Handling
Ensure Compliance & Protect Workers Around High-Temperature Processes
Understanding the Hazards of Molten Materials
Working with molten metals such as aluminum, steel, or alloys presents some of the highest-risk scenarios in industrial environments. These materials, often exceeding 1,000°C, pose severe dangers:
Molten metal spillage or splashing during pouring, transferring, or equipment failure
Violent reactions with moisture or incompatible substances
Fires, burns, and explosions from uncontrolled releases or ignition sources
Thermal radiation injuries in confined or poorly ventilated areas
Under Ontario Regulation 851, workplaces introducing or modifying processes that handle molten material—such as furnaces, ladles, or casting equipment—must complete a Pre-Start Health and Safety Review (PSR) before operation.
When Is a PSR Required for Foundries?
A PSR is triggered under the OHSA when new or modified installations involve:
Melting, casting, or transferring aluminum, steel, or ferrous alloys
Use of furnaces, crucibles, holding tanks, or ladle transport systems
Secondary processes like slag removal or additive mixing
Any equipment or process that increases worker exposure to thermal, fire, or chemical risks associated with molten material
HITE Engineering ensures your operation meets all PSR obligations with a focus on real-world safety and practical engineering controls.
Components of Our Engineering Review
Our PSR process for foundries and molten material systems includes a comprehensive assessment of:
Containment & Guarding Systems
Equipment enclosures and shields
Spill and splash protection
Safe pour zones and restricted access areas
Emergency Controls
Emergency shut-off switches
Alarm systems and egress paths
Fail-safe cooling and inerting methods (if applicable)
PPE and Worker Protection
Engineering confirmation of appropriate PPE standards
Face shields, insulated gloves, aprons, leggings
PPE signage and placement review
Process Layout & Material Flow
Logical separation of hot zones and personnel areas
Cross-traffic and hazard proximity mapping
Equipment spacing for thermal and operational safety
Structural Integrity
Furnace, ladle, or crucible support systems
Heat-resistance and mechanical strength of containment vessels
Load ratings and thermal fatigue considerations
Codes and Standards We Apply
HITE Engineering applies a robust combination of regulatory and best practice guidance when performing molten metal PSRs, including:
Safety data sheets (SDS) for metals, fluxes, and additives
Ventilation layout (if present)
Photos or drawings of the facility layout
If you’re unsure of what’s required, our team will guide you step-by-step during onboarding.
What You Receive from HITE Engineering
Upon completing our engineering review, you’ll receive:
A PSR Report of Findings identifying any gaps in safety or code compliance
Recommendations for risk mitigation, engineering controls, and best practices
A PSR letter sealed by a licensed Professional Engineer, as required under OHSA
Optional follow-up guidance or training for safe molten material handling
Why Choose HITE for Foundry PSRs?
With decades of experience in thermal hazard environments, HITE Engineering provides a practical, hands-on approach that ensures your operations are both safe and compliant.
We’ve helped dozens of Ontario manufacturers and foundries:
Upgrade their casting lines
Retrofit furnaces and transfer equipment
Ensure worker safety in legacy and newly commissioned systems
You’ll get clear, actionable reports that prioritize your operations while meeting Ontario’s strictest safety standards.
Stay Safe. Stay Compliant.
Contact us today to book a PSR for your foundry or molten material system. Our team will help you meet OHSA requirements and reduce risk from day one.