Page 8 - OHS, October 2024

P R O T E C T I V E A P P A R E L
Could Your PPE Be Making Molten Splash More Dangerous?
How the right PPE protects from molten splash hazards.
BY MARY ANN MERIKOSKI
imagine splashes of molten metal or a dramatic in-
When most people hear “molten splash,” they might
dustrial incident. But molten splash hazards are far
more nuanced, and the hazards are more complex
and dangerous than just high temperatures. While many are famil-
iar with fi re-retardant PPE and fabrics, fewer understand the critical
role of how these materials interact with the substances involved —
and that’s where the real challenge in protecting workers begins.
Molten splash, also known as hot splash, involves not just ex-
treme heat but direct contact with highly reactive and caustic sub-
stances that can aggressively attack PPE materials. Imagine molten
metals like iron or aluminum, or chemicals like sodium hydroxide,
not just burning through fabric but also corroding it, causing rapid
degradation and rendering the protective gear ineff ective. It’s not
just about the heat—the real danger is in how these substances
interact with PPE, turning a protective barrier into a potential li-
ability. Th is is why selecting the right PPE material isn’t just im-
portant—it’s a critical decision that directly impacts worker safety.
What Causes Molten Splash?
Molten splash occurs when water, moisture, or any liquid meets
molten substances, typically metals like iron, aluminum, or zinc. But
it’s not limited to metals; molten splash can also result from non-
metallic substances such as asphalt, pulp and paper liquors, or slur-
ries. Even a hot furnace exposed to water can trigger this hazard.
When molten splash contacts a person, it can burn through cloth-
ing and cause severe or even fatal injuries. Workers oft en rely on mul-
tiple layers of heat-resistant PPE, which provides a critical shield of
protection until help arrives or immediate actions can be taken.
How Does PPE Material Affect Protection?
Th e choice of material is crucial to protect against molten splash.
Diff erent fabrics have unique properties that determine their eff ec-
tiveness against specifi c substances, heat levels and temperatures.
Some key fabrics used for molten splash protection include:
■ Aluminized fabrics off er protection against high radiant heat
and certain molten metal splashes but lack breathability.
■ FR cotton works well for secondary protection in routine
steel production tasks. But workers in high-risk zones need pri-
mary protection from more materials such as aluminized fabrics.
■ Technical fabrics are designed with shedding properties.
Th ey may include wool for its natural metal-shedding and thermal
insulation, or vinal fi bers for chemical resistance, off ering protec-
tion without needing a second layer like aluminized fabrics.
Inherent Fibers vs. Treated Fibers vs. Coated Fabrics
Safety managers have options among FR garments made from in-
herent fi bers, treated fi bers or coated fabrics.
Inherent fi bers have built-in fl ame resistance that does not
degrade with use or washing. Treated fi bers, like FR cotton, have
limited durability compared to inherent fi bers but still meet safety
standards. Coated fabrics, on the other hand, can be made of ei-
ther inherent or treated fi bers, which are then coated in silicone or
some other treatment to enhance their shedding properties.
Th e primary diff erences lie in performance, weight and comfort.
Inherent fi bers like aramids are stronger, allowing for a lighter weave,
which makes garments lighter and more comfortable for extended wear.
Th ink of inherent fi bers like a solid metal fence: strong and reli-
able on its own, requiring less material to do the job eff ectively. In
contrast, treated fi bers are more like a wooden fence with a protec-
tive paint layer. It still works, but it needs extra protection to with-
stand the elements, making it heavier and less durable over time.
Standards Governing Molten Splash PPE
Several standards guide the design and use of PPE for molten
splash protection. Key standards include:
■ ASTM F955. Th is standard evaluates heat transfer through
protective clothing when exposed to molten substances. It involves
pouring 1 kg of molten metal onto fabric from a height of 305 mil-
limeters, with temperature adjusted for each metal type. Th e fabric
sample is positioned at a 70-degree angle to simulate draping and
tested for heat resistance, damage, and substance adhesion.
■ NFPA 1990. Th is standard covers protective ensembles for
hazardous materials, with design and testing guidelines for manu-
facturers. Requirements include that garments must protect torso,
arms and legs; gloves must protect from fi ngertips to at least one
inch beyond the wrist crease; garments should be tested for liquid-
tight integrity; and seams and closures must resist penetration.
Molten Splash: A Manageable Hazard
Although molten splash is a serious hazard, its risks can be sig-
nifi cantly reduced by understanding molten behavior, temperature
exposures and selecting the right PPE. However, PPE alone is not
suffi cient; proper safety procedures and practices are essential.
Many incidents occur when workers, despite having the correct
PPE, suff er severe injuries due to improper use, such as leaving
fastenings open or wearing incomplete sets.
Stay Safe with the Right Materials and Practices
Mitigating molten splash hazards goes beyond just wearing any
PPE. It’s about selecting materials that can withstand extreme heat
and reactive substances. Inherent fi bers, treated fabrics and alumi-
nized options each play a role, but their eff ectiveness depends on
proper use and comprehensive safety practices. Understanding the
properties of these materials and ensuring proper use signifi cantly
reduces the risk of injuries and maintains a safer workplace.
Mary Ann Merikoski is the Director of Product - Apparel at Mechanix
Wear.
REFERENCE
1. OSHA 1910.134(d)(1)(iii): tinyurl.com/y74k86z9
8 Occupational Health & Safety | OCTOBER 2024 www.ohsonline.com