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Points to keep in mind during the forging process
Release date:
Nov 14,2025
Abstract
1. The forging process includes: cutting the material to the desired size, heating, forging, heat treatment, cleaning, and inspection. In small-scale, handcrafted forging operations, all these steps are carried out collaboratively by several blacksmiths working in a confined space. They are collectively exposed to the same hazardous conditions and occupational risks; meanwhile, in large-scale forging workshops, the risk factors can vary depending on the workstation location.
Working conditions, while varying depending on the type of forging, share certain common characteristics: moderate-intensity physical labor, a dry and hot microclimate, noise and vibration, as well as air pollution from smoke.
2. Workers exposed simultaneously to high-temperature air and thermal radiation experience a buildup of heat within their bodies. The combination of environmental heat and metabolic heat production can lead to impaired heat dissipation and subsequent pathological changes. During an 8-hour work shift, sweat rates vary widely—typically ranging from 1.5 to 5 liters, or even higher—depending on microclimatic conditions, physical exertion levels, and the degree of thermal adaptation. In smaller forging workshops or areas farther from heat sources, the Behar II Heat Stress Index usually falls between 55 and 95; however, in larger forging facilities, particularly at workstations near heating furnaces or drop hammers, it can soar to as high as 150 to 190. This situation may increase the risk of electrolyte depletion and heat cramps. Meanwhile, during colder seasons, moderate shifts in microclimatic conditions can partially aid adaptation—but rapid and frequent changes may pose significant health risks.
Air pollution: Workplace air may contain particulate matter, carbon monoxide, carbon dioxide, sulfur dioxide, or acrolein, with concentrations depending on the type of fuel used in the heating furnace, impurity levels, combustion efficiency, airflow, and ventilation conditions.
Noise and Vibration: Forging hammers inevitably generate low-frequency noise and vibrations, though they may also include some high-frequency components. The sound pressure level typically ranges from 95 to 115 decibels. Prolonged exposure to forging vibrations can lead to physical and functional impairments, reducing workers' ability to perform tasks effectively and compromising workplace safety.
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