Molten metal spills can be prevented and managed by following safety precautions and emergency procedures. These include containment strategies, appropriate personal protective equipment (PPE), and knowledge of first aid measures.

To prevent molten metal spills:

• Ensure equipment used to deliver molten metal is equipped with a warning device that is activated during delivery and at the beginning of a pour.
• Preheat and dry cold or damp metal ingots before adding them to molten metal.
• Use a metal chute to fill the holding furnace to avoid splashes.

[12] [12] [12] If a molten metal spill occurs, implement these emergency procedures:

• Evacuate the area.
• Keep unnecessary personnel away and upwind of the spill/leak.
• Eliminate ignition sources, and use non-sparking tools.
• For large spills, stop the flow of material if it is safe to do so and dike the spilled material where possible.
• Contain the spill by covering the spill area with a fire-extinguishing foam and then with absorbent materials such as bentonite or vermiculite, working from the edges inward.
• Collect the spilled material using non-sparking tools and place it in a metal container approved for transportation by authorities.
• Clean the residue with an appropriate solvent, ensuring the area is well-ventilated, and follow safety precautions on the solvent label and SDS.
• Seal the container and dispose of the collected material according to local, regional, national, and international regulations.

[1] [2] [5] [2] [5] Appropriate PPE:

• Eye protection with side shields for operating a die-casting machine or tending a melting or holding furnace.
• Face shield for handling molten metals or tending a furnace (except for cold chamber machine operators).
• Clothing that covers arms to hands and legs to feet, with hard-soled shoes for manually tending a die-casting machine or melting or holding furnace.
• Spats or leggings for employees manually ladling a cold chamber die-casting machine, tending a melting or holding furnace, or transferring molten metal (unless wearing molders shoes with pant legs covering the tops).
• Use personal protective equipment.

[6] [6] [6] [2] [4] [7] [8] [9] [10] [11] First aid measures include:

• Inhalation: Move to fresh air and call a physician if symptoms develop or persist.
• Skin contact: Wash off with soap and water and get medical attention if irritation develops and persists; treat cuts or abrasions promptly with thorough cleansing of the affected area and seek medical attention for severe cuts or abrasions.
• Eye contact: Rinse with water and get medical attention if irritation develops and persists; if the eye is cut or otherwise damaged, seek medical attention.
• Ingestion: Rinse mouth and get medical attention if symptoms occur.

[5] [5] [3] [3] [5] [5] Relevant safety regulations include:

• General Industry Safety Standard Part 33 "Personal Protective Equipment,"
• R 408.14502 MIOSHA referenced standards.
• R 408.14507. Employer responsibility.
• R 408.14508. Employee responsibility.
• Cal/OSHA Regulations §5188. Molten Salt Baths.

[6] [6] [6] [6] [13]