Foundry operative

Foundry operative manufacture castings, including pipes, tubes, hollow profiles and other products of the first processing of steel, by operating hand-controlled equipment in a foundry. They conduct the flow of molten ferrous and non-ferrous metals into moulds, taking care to create the exact right circumstances to obtain the highest quality metal. They observe the flow of metal to identify faults. In case of a fault, they notify the authorised personnel and participate in the removal of the fault.

Includes people performing the manufacture of jewerelly and bijouterie.

The duties of a foundry operative include, but are not limited to:

• Monitoring equipment and processes to ensure that they are functioning properly, so that production can continue without interruption
• Cleaning casting molds, furnaces, and other equipment used in the casting process
• Inspecting molds to make sure they are free of defects before pouring molten metal into them
• Using hand tools such as hammers and saws to cut metal into pieces that can be cast into ingots or other shapes
• Mixing chemicals used in the casting process, such as sulfuric acid or silica sand
• Operating cranes and forklifts to move raw materials into the foundry and finished products out of the foundry
• Monitoring furnaces and kilns to ensure that temperatures do not fluctuate too much or drift out of safe ranges
• Monitoring equipment to ensure that it is working properly, and making adjustments as needed to keep it operating efficiently
• Maintaining records of all materials used in the casting process, in order to accurately estimate costs and order supplies in the future

Foundry operatives are employed in foundries, which are factories that make metal products by pouring molten metal into molds. The molten metal is heated to a very high temperature, usually between 1,600 and 2,000 degrees Fahrenheit (870 and 1100 degrees Celsius), before it is poured into the mold. The mold is made of sand, clay, or a metal die. Once the metal has cooled and solidified, the mold is broken away to reveal the metal product.

Foundry operatives are exposed to high noise levels, high temperatures, and harmful fumes and dust. They must wear protective clothing, including gloves, aprons, and face shields, to avoid injuries.

Foundry operatives typically work 40 hours per week, but they may work overtime during busy periods.

The following job titles also refer to foundry operative:

metal molder
foundry process operator
foundry worker
metal caster
metal moulder
mould casting worker
foundryman
casting worker
ladleman
pourer and caster
foundry operator
molding and casting worker
casting operator
mold casting worker
caster
Central control caster
ladleperson
moulding and casting worker m,f,n)

No formal educational credential is required to work as a foundry operative. however, it helps a lot to have at least a high school diploma.

ISCO skill level is defined as a function of the complexity and range of tasks and duties to be performed in an occupation. It is measured on a scale from 1 to 4, with 1 the lowest level and 4 the highest, by considering:

• the nature of the work performed in an occupation in relation to the characteristic tasks and duties
• the level of formal education required for competent performance of the tasks and duties involved and
• the amount of informal on-the-job training and/or previous experience in a related occupation required for competent performance of these tasks and duties.

Foundry operative is a Skill level 2 occupation.

These occupations, although different, require a lot of knowledge and skills similar to foundry operative.

coquille casting worker
mouldmaker
casting machine operator
moulding machine operator
foundry moulder

These occupations require some skills and knowledge of foundry operative. They also require other skills and knowledge, but at a higher ISCO skill level, meaning these occupations are accessible from a position of foundry operative with a significant experience and/or extensive training.

metal furnace operator
pulp control operator
metallurgical technician
welding inspector
air pollution analyst

These skills are necessary for the role of foundry operative.

• Construct moulds: Construct moulds for the casting of objects in plaster, clay, glass, plastic or metal. Use casting machines and materials such as rubber, plaster or fibreglass.
• Select mould types: Select the appropriate type and size of mould based on the operation.
• Insert mould structures: Insert mould structures using the appropriate hand tools.
• Assemble metal parts: Align and arrange steel and metal parts in order to assemble complete products; use the appropriate hand tools and gauges.
• Troubleshoot: Identify operating problems, decide what to do about it and report accordingly.
• Fill moulds: Fill up moulds with appropriate materials and ingredient mixes.
• Repair mould defects: Repair mould malfunctions and damage, e.g. cracks or broken edges; use hand tools, mould boxes and patterns.
• Mix moulding and casting material: Measure and mix ingredients for casting and moulding materials, according to appropriate formula.
• Maintain mould parts: Carry out minor repair tasks and maintenance of moulds and mould parts.
• Extract products from moulds: Remove finished products from moulds and examine them in detail for anomalies.
• Move filled moulds: Replace filled-up moulds; understand how to load moulds into the oven and how to store filled-up moulds onto a rack.
• Ensure mould uniformity: Oversee uniformity of moulds; use casting equipment and tools such as hand press.
• Handle metal work orders: Interpret work orders in order to determine which metal parts should be produced.

This knowledge is sometimes, but not always, required for the role of foundry operative. However, mastering this knowledge allows you to have more opportunities for career development.

• Non-ferrous metal processing: Various processing methods on non-ferrous metals and alloys such as copper, zinc and aluminium.
• Ferrous metal processing: Various processing methods on iron and iron-containing alloys such as steel, stainless steel and pig iron.
• Jewellery processes: Materials and processes involved in creating jewellery items like earrings, necklaces, rings, brackets, etc.
• Types of metal manufacturing processes: Metal processes linked to the different types of metal, such as casting processes, heat treatment processes, repair processes and other metal manufacturing processes.
• Manufacturing of jewellery: The manufacturing of different type of jewellery such as rings or necklaces out of various metal types such as silver, gold, diamond and other precious stones.
• Precious metal processing: Various processing methods on precious metals such as gold, silver and platinum.

These skills and competences are sometimes, but not always, required for the role of foundry operative. However, mastering these skills and competences allows you to have more opportunities for career development.

• Attend to detail in casting processes: Attend in the metal processing casting work to specificities and details concerning the quality of the casting and moulds.
• Operate smelter: Operate heating machinery in order to melt various materials, or to bake filled-up moulds.
• Monitor gauge: Oversee the data presented by a gauge concerning the measurement of pressure, temperature, thickness of a material, and others.
• Record production data for quality control: Keep records of the machine’s faults, interventions and irregularities for quality control.
• Remove finished casts: Open mould and safely remove the finished cast from within.
• Manage time in casting processes: Work on castings with the necessary sense of timing in regards to quality, for example when measuring how long moulds must rest before they are used in further casting processes.
• Operate metal heating equipment: Use heating machinery to bake filled-up moulds or to melt steel, metal and other materials.
• Communicate using non-verbal language: Communicate with colleagues using body language and other non-verbal cues in order to ensure effective communication during operations.
• Mark a metal workpiece using punch: Handle and operate a punch and hammer to mark a metal work piece, for example for the purpose of carving a serial number, or for drilling to mark the exact place where a the hole should be places in order to keep the drill steady.
• Cut metal products: Operate cutting and measuring instruments in order to cut/shape pieces of metal into given dimensions.
• Smooth burred surfaces: Inspect and smooth burred surfaces of steel and metal parts.
• Insert reinforcement in mould: Insert chaplets and other kinds of reinforcing steel structures to a mould in order to fix different parts.
• Follow manufacturing work schedule: Follow the planning set up by manufacturing companies’ managers exactly to ensure one production process is not delayed due to another and they follow each other smoothly.

7211 – Metal moulders and coremakers

---

References

1. Foundry operative – ESCO
2. Foundry process operator | Explore careers – National Careers Service
3. Foundry Worker Job Description: Salary, Duties, & More – Climb the Ladder
4. Featured image: Photo by Kateryna Babaieva from Pexels