How to ensure safety for castable mixing

Refractory 1/4
PR RFR P06-12 V1

Introduction
ƒ The hazards associated with castable mixer operations include health and safety hazards. Health hazards
are primarily due to the material properties of the castable. Safety hazards are generally physically
hazards due to the work equipment.
ƒ Such hazards can be eliminated or controlled by appropriate prevention measures. Unless these measures
are taken, the hazardous situations can easily give rise to personal injury and/or property damage.
Objectives
ƒ The purpose of this guideline is to recognize the specific hazards related to castable mixer such as
paddle-type mixer or auger mixer and to outline the necessary requirements for this type of work:
ƒ noise
ƒ dust and particulates
ƒ flying objects
ƒ pneumatic energy

ƒ This guideline is applicable to all the employees and contractors of Lafarge.

Prerequisites
ƒ Operators should be registered and certified by the employer. Pre-testing may need to be conducted to
verify their competency in the work requirements. Apprentices and helpers should work under the
supervision of a qualified person.
ƒ All the operators must be taught how to stop the machine quickly in case of emergency.

Procedure Template developed by

 How to ensure safety for castable mixing

Refractory 2/4
PR RFR P06-12 V1

Basic rules

1. General
ƒ Ensure that Personal Protective Equipment is worn

Electrical Precaution
ƒ The equipment should be connected to a properly grounded electrical outlet.
ƒ Lock out and tag all machines before working on them. Disconnect equipment from their power source
before changing the blade. This is to ensure inadvertent or accidental start-up.
ƒ Don’t use joint wire on the circuit.

Lighting
ƒ Sufficient lighting must be provided to ensure a safe work environment.

2. Specific
Equipment pre-testing
ƒ Visually inspect all metal blades prior to operation. If there are any signs of damage or unusual wear, do
not use the blade.
ƒ Mount the blade solidly and firmly. The equipment must be stopped during fixing of blade.
ƒ Make sure the blade is not contacting anything before starting the engine.
ƒ After changing a new blade, it is required that the equipment be run at operating speed for a few
minutes prior to start mixing. Take note of any abnormalities and take necessary corrective actions. Do
not allow anyone to stand in front or in line with the equipment during this test. The protective guarding
must be intact.
ƒ When first starting, always stand aside until the equipment reaches its normal running speed. Thereafter,
check for abnormal wobbling and vibration.
ƒ Replace back the protective guard before commencing mixing.

Procedure Template developed by

 How to ensure safety for castable mixing

Refractory 3/4
PR RFR P06-12 V1

ƒ Ensure the emergency switch is working

A castable mixer with a protective metal wire mesh

Mixing operation
ƒ Operate the machine only in well-ventilated areas.
ƒ Pour dry castable into the equipment when the switch is in the ‘off’ position.
ƒ Water should be added only with the protective guarding intact.
ƒ Mixer should be operated at low speed setting.
ƒ Keep all parts of the body away from the blade and other moving parts of the equipment during
operation.
ƒ Do not stand directly in front of equipment whenever it is running.
ƒ Do not try to check the quality of mixing during rotation.
ƒ Ensure rotation of paddle as per blade maximum operating speed.
ƒ Off the machine ‘main switch’ when it is left unattended.

Always pour dry castable and water (if possible) when the equipment is in non-operable position

Procedure Template developed by

 How to ensure safety for castable mixing

Refractory 4/4
PR RFR P06-12 V1

Appendix

1. Castable mixer Checklist

Items To Be Checked Conditions Remarks

Item Description Yes No
Blade The metal blade is in a good working
condition.
Protective Guard There is a protective guard to cover
the mixer.
Electrical The electrical cable is well-insulated
and in a good working condition.
Emergency Switch There is an emergency switch and it
is in a good working condition.
Trolley Wheel The trolley wheel is in a good
working condition and balancing the
equipment properly.

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