Foundry Workers

Foundry Worker Asbestos Exposure
High-risk occupation for asbestos disease
Risk Level	High
SMR (Lung Cancer)	150 (Iron Foundries)
SMR (Pneumoconioses)	7,368
Peak Exposure Era	1920s-1980s
Primary Products	Asbestos PPE, furnace linings, Foseco hot tops
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Executive Summary

Foundry workers—including molders, casters, pattern makers, core makers, and sand mixers—experienced significant asbestos exposure through protective equipment, furnace insulation, and molding materials used throughout metal casting operations. The high-temperature environment of foundry work required extensive use of heat-resistant materials, with asbestos incorporated into protective gloves, aprons, leggings, and heat shields worn by workers handling molten metal. CDC surveillance data documented significantly elevated standardized mortality ratios reaching 7,368 for pneumoconioses among foundry workers, reflecting the intense dust exposure conditions in casting facilities. Foundry products from manufacturers including Foseco contained asbestos in coatings, mold washes, and refractory materials that workers encountered daily. According to Danziger & De Llano, foundry workers diagnosed with mesothelioma may pursue compensation through multiple trust funds and litigation against equipment and protective gear manufacturers.

The foundry industry's reliance on asbestos for heat protection created exposure throughout the metalcasting process. Molten metal operations required workers to wear asbestos protective equipment while working in close proximity to furnaces, ladles, and casting areas. Pattern makers encountered asbestos in core binders and molding materials. Furnace operators worked with refractory linings and insulation containing asbestos. Like Steel Mill Workers and Glass Manufacturing Workers, foundry workers operated in high-temperature industrial environments where asbestos was considered essential for thermal protection. Boilermakers and maintenance personnel who serviced foundry equipment created additional bystander exposure when disturbing insulation. The combination of direct protective equipment exposure and environmental contamination meant foundry workers accumulated significant cumulative asbestos exposure over careers spanning decades. Over $30 billion remains available in 60+ active asbestos trust funds, with average industrial worker settlements ranging from $1-1.4 million.

Foundry worker asbestos exposure at a glance:

• SMR 7,368 for pneumoconioses — foundry workers had one of the highest dust disease mortality ratios ever recorded in U.S. occupational health surveillance
• Asbestos was worn, not just worked near — unlike most industrial workers who encountered asbestos in building materials, foundry workers wore asbestos gloves, aprons, and leggings as standard protective equipment
• Foseco products were foundry-specific — hot tops, mold coatings, and refractory materials were engineered with asbestos specifically for metalcasting, creating exposure unique to this trade
• 2,500F+ working temperatures — foundries operated at temperatures so extreme that asbestos was considered the only viable heat protection for decades, guaranteeing daily worker contact
• Lung cancer risk doubled — iron foundry molders with more than 5 years of service showed relative risk of 2.08 compared to non-production workers in the same facilities
• 400+ documented Foseco job sites — the Foseco trust accepts claims from workers at over 400 specific facilities, with company records establishing exposure history
• Multi-pathway exposure was the norm — workers simultaneously breathed fibers from their own protective gear, surrounding furnace insulation, and Foseco casting products in enclosed spaces
• Pennsylvania, Ohio, Michigan, Illinois, Indiana — the five states with the highest concentration of foundry operations and the largest affected worker populations

Key Facts

Metric	Finding
Pneumoconioses SMR	7,368 — among the highest dust-disease mortality ratios documented in any U.S. occupation (CDC MMWR Surveillance)
Iron Foundry Lung Cancer SMR	150 — 50% excess lung cancer mortality in iron foundry workers vs. general population (IARC review)
Lung Cancer Odds Ratio (Under 65)	2.36 — more than double the lung cancer risk for foundry workers dying before age 65 (IARC, 1984)
Lung Cancer Relative Risk (Molders)	2.08 (CI 1.01–4.30) — iron foundry molders with 5+ years vs. non-production workers (Cohort Study)
Stomach Cancer Relative Risk	3.96 (CI 1.41–11.06) — nearly 4x the stomach cancer risk vs. non-production foundry workers (Cohort Study)
Pneumoconiosis Prevalence	3.7% — documented in Korean foundry worker radiographic screening study (Korean J Occupational Health)
Asbestos Glove Fiber Content	15–100% chrysotile — protective mitts ranged from blended to pure asbestos cloth (Manufacturer Records)
Hot-Top Asbestos Content	15–50% chrysotile/amosite — Foseco hot-top compounds used in steel ingot casting (Foseco Product Data)
Johns-Manville Trust Payouts	$5+ billion total — from initial $2.5B funding in 1988; covers foundry insulation and PPE claims (Trust Records)
Foseco Documented Job Sites	400+ — trust accepts claims from workers at over 400 specific foundry facilities (Foseco Trust)
Peak Exposure Era	1920s–1980s — before Nomex, Kevlar, and ceramic fiber alternatives replaced asbestos PPE
IARC Lung Cancer Risk Range	1.5x to 2.5x — consistently elevated across U.S., European, and Asian foundry cohorts (IARC Monograph)

What Asbestos Exposure Did Foundry Workers Face?

Foundry workers encountered asbestos through every aspect of the metal casting process, from personal protective equipment to facility infrastructure.

Protective Gear (Primary Direct Exposure):

Foundry workers wore extensive asbestos-containing personal protective equipment as standard practice:

• Asbestos Gloves: Provided thermal protection for handling hot molds and metal objects
• Heavy Asbestos Aprons: Protected the torso and upper legs from molten metal splashes
• Asbestos Leggings (Spats): Covered the lower legs and feet from radiant heat and splatter

These garments shed asbestos fibers continuously during use, particularly at stress points and seams. A 2005 study measuring asbestos exposure from wearing protective mitts documented very high fiber inhalation when asbestos gloves were used in hot environments.

Furnace Lining and Ladle Insulation:

Induction furnaces, cupola furnaces, and electric arc furnaces used asbestos-containing refractory materials as primary insulation. Workers installing, repairing, or replacing these linings created substantial airborne fiber releases. Transfer ladles used to pour molten metal were lined with asbestos insulation requiring regular maintenance.

"Foundry workers faced asbestos exposure from multiple sources simultaneously—the gloves they wore, the aprons protecting them, the furnace linings they maintained, and the Foseco products they used daily. This multi-pathway exposure created cumulative risks that far exceeded what any single source would produce."

— Rod De Llano, Founding Partner, Danziger & De Llano

Which Asbestos Products Did Foundry Workers Encounter?

Foundry workers encountered numerous asbestos-containing products throughout their careers:

Product Type	Asbestos Content	Manufacturers
Asbestos Gloves	15-100% chrysotile	Johns-Manville, Multiple PPE manufacturers
Asbestos Aprons	20-80% chrysotile	Industrial safety suppliers
Asbestos Leggings/Spats	30-70% chrysotile/crocidolite	Pyrotek, Silver Needle Inc.
Furnace Lining Materials	30-100% various types	Johns-Manville, Foseco
Hot-Top Compounds (Foseco)	15-50% chrysotile/amosite	Foseco
Ladle Insulation	40-90% chrysotile	Foseco, refractory manufacturers

Foseco Hot Tops and Products:

Foseco manufactured specialized asbestos-containing products for foundries, particularly "hot tops"—insulating plates placed on steel ingot molds during casting. Workers handling Foseco products during installation and replacement were documented to have higher rates of asbestos-related illnesses and deaths.

Where Were Foundry Workers Most Exposed?

Iron Foundries: The highest documented lung cancer SMR (150) was found in iron foundry workers, with molders exhibiting the highest risk after more than five years of exposure.

Steel Foundries: Workers in steel casting operations faced exposure to hot-top products and furnace insulation.

Geographic Concentrations: Major foundry states including Pennsylvania, Ohio, Michigan, Illinois, and Indiana had the highest concentrations of affected workers.

⚠ IARC Conclusion: The International Agency for Research on Cancer concluded that foundry work represents significant exposure to lung carcinogens, with elevated lung cancer risks between 1.5- and 2.5-fold observed consistently across multiple countries.

What Compensation Can Foundry Workers Receive for Mesothelioma?

Foundry workers diagnosed with mesothelioma may be entitled to substantial compensation through multiple sources.

Industry-Specific Trust Funds:

Foundry workers may file claims against multiple asbestos trust funds:

• Johns-Manville Asbestos Trust: Established in 1988 with initial funding of $2.5 billion; has paid over $5 billion total
• Foseco Products Trust: Claims accepted from workers at approximately 400 job sites where Foseco products were used
• Garlock Sealing Technologies Trust: Gaskets and packing materials used in foundry equipment

Key Defendant Manufacturers:

Primary defendants in foundry worker litigation include:

• Foseco (foundry-specific products including hot tops)
• Johns-Manville (protective equipment, insulation materials)
• Refractory manufacturers (furnace lining materials)
• PPE manufacturers (asbestos gloves, aprons, leggings)

"Foundry cases often involve Foseco products specifically designed for metal casting. The Foseco trust accepts claims from workers at over 400 documented job sites, and company records help establish exposure history even decades after the work occurred."

— Paul Danziger, Founding Partner, Danziger & De Llano

What Are Current Exposure Risks for Foundry Workers?

Legacy Exposure in Older Facilities:

Many foundries continue operating in buildings constructed during peak asbestos use periods (1920s-1980s). Aging furnace linings, deteriorated insulation on melting equipment, and asbestos-containing building materials pose ongoing exposure risks during routine maintenance and emergency repairs.

Demolition of Closed Plants:

The U.S. foundry industry has contracted significantly since its peak, with hundreds of facilities closing since 1980. Demolition of these plants creates secondary exposure risks for abatement workers and nearby communities.

OSHA Requirements:

Foundries must comply with 29 CFR 1910.1001 (general industry asbestos standard), requiring:

• Initial exposure monitoring when asbestos-containing materials are present
• Maintenance of worker exposures below 0.1 f/cc (8-hour TWA)
• Respiratory protection when exposures exceed permissible limits
• Medical surveillance for workers exposed above action level

✓ Documentation Tip: Foundry workers should gather employment records, Social Security earnings statements, and any photographs from their workplace. Coworker testimony about asbestos protective equipment and Foseco product use is particularly valuable for claims.

Frequently Asked Questions

What types of mesothelioma are most common in foundry workers?

Pleural mesothelioma (affecting the lung lining) is the most common type among foundry workers because their primary exposure route was inhalation of airborne fibers from protective equipment, furnace insulation, and Foseco products in enclosed, poorly ventilated casting facilities. Peritoneal mesothelioma (affecting the abdominal lining) also occurs, particularly in workers who ingested asbestos fibers through contaminated food and drink consumed in work areas where asbestos dust settled on surfaces throughout the shift.

How were foundry workers exposed to asbestos differently from other industrial workers?

Foundry workers had the unusual distinction of wearing asbestos directly against their bodies for entire work shifts, not just working near asbestos-containing materials. Asbestos gloves, aprons, and leggings were standard-issue protective equipment in metalcasting operations. These garments shed fibers continuously, particularly at stress points, seams, and areas abraded by contact with hot metal and molds. This body-contact exposure occurred simultaneously with environmental exposure from furnace linings, ladle insulation, and Foseco products — creating multi-pathway cumulative fiber loading unlike most other occupational settings.

Can foundry workers file claims if their plant closed decades ago?

Yes. Mesothelioma lawsuits and trust fund claims do not require the original employer to still be in operation. Most compensation for foundry workers comes from bankruptcy trust funds established by asbestos product manufacturers (Johns-Manville, Foseco, Garlock) rather than the foundry operator itself. The Foseco trust specifically maintains records of over 400 job sites where its products were used, and company documentation can establish exposure history even when the foundry has been demolished. Statutes of limitations typically begin at diagnosis, not exposure, giving newly diagnosed workers time to pursue claims.

What evidence do foundry workers need to prove asbestos exposure?

Key evidence includes employment records (W-2s, Social Security earnings statements, pension records), coworker testimony about the use of asbestos protective equipment and Foseco products, photographs showing workers wearing asbestos gloves or aprons, purchase records for asbestos-containing materials, and OSHA inspection reports from the foundry. Experienced mesothelioma attorneys maintain databases of products used at specific foundries and can often identify exposure sources through manufacturer records and prior litigation discovery materials.

Are foundry workers still at risk for asbestos exposure today?

Modern foundries have largely replaced asbestos PPE with alternatives such as Nomex, Kevlar, and ceramic fiber materials. However, legacy risks persist in older foundries still operating in buildings constructed during the peak asbestos era (1920s–1980s), where deteriorating furnace linings, pipe insulation, and floor tiles may contain asbestos. Maintenance and renovation work in these facilities can disturb dormant asbestos materials. Additionally, the demolition of hundreds of closed foundry plants across the Rust Belt creates secondary exposure risks for abatement and demolition workers.

How much compensation can foundry workers receive for mesothelioma?

Mesothelioma compensation for industrial workers, including foundry workers, typically ranges from $1 million to $1.4 million on average through combined trust fund claims, settlements, and verdicts. Many foundry workers qualify for claims against multiple trust funds simultaneously — Johns-Manville (insulation and PPE), Foseco (foundry-specific products), and Garlock Sealing Technologies (gaskets and packing) among others. Over $30 billion remains available across 60+ active asbestos trust funds. Trial verdicts in mesothelioma cases have occasionally reached tens of millions depending on the circumstances of exposure and the defendants involved.

Quick Statistics

• Furnace lining materials contained 30–100% asbestos by weight, requiring foundry workers to cut, fit, and replace refractory insulation throughout their careers
• Asbestos aprons protected against 2,800F+ molten metal splashes but continuously shed fibers at stress points and seams during every pour cycle
• Crocidolite (blue asbestos) was present in some foundry leggings and spats — the most carcinogenic asbestos fiber type, with higher mesothelioma risk per fiber than chrysotile
• U.S. foundry industry peaked at 6,000+ facilities before contracting to approximately 2,000 active plants, leaving thousands of contaminated former sites across the Rust Belt
• OSHA permissible exposure limit is 0.1 fibers per cubic centimeter (8-hour TWA) — historical foundry measurements routinely exceeded this threshold by orders of magnitude
• $2.5 billion initial funding for the Johns-Manville Asbestos Trust in 1988, which has since paid out over $5 billion to eligible workers including foundry employees exposed to J-M insulation and PPE
• Transfer ladle insulation contained 40–90% chrysotile asbestos and required regular replacement, generating heavy fiber release during maintenance by foundry workers
• Korean foundry worker screening found 3.7% pneumoconiosis prevalence through radiographic examination — suggesting widespread undiagnosed respiratory disease in foundry populations worldwide
• Iron foundry molders showed highest cancer risk after 5+ years of employment, with risk increasing with cumulative duration of production floor exposure
• Foseco hot-top compounds contained both chrysotile and amosite asbestos — the dual-fiber formulation increased carcinogenic potency for workers handling these products during steel ingot casting

Get Help Today

If you or a loved one worked in a foundry and has been diagnosed with mesothelioma, you may be entitled to significant compensation. The attorneys at Danziger & De Llano have decades of experience representing industrial workers exposed to asbestos.

Don't Wait — Time Limits Apply Foundry Worker SMR of 7,368 for Pneumoconioses Shows Extreme Risk Over $30 BILLION available through asbestos trust funds.

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