Posted By Phil Grace
Francis,
It's 20 years since I left the aluminium industry so am a bit "rusty" - no pun intended. It's almost to big a topic to set out here and you will NOT be able to use a RA prepared by another party/person.

Crane: Capacity/testing etc Inspection regime may need modifying for environment
Ladle: Presume will have refractory lining - this will need checking and replacement from time to time.
Safe System of Work: RA will indicate what you have to do in terms of PPE, procedures, keeping back bystanders, roles of three people you mention - their training to work together and what to do when one of them is away on hols..!!
Work area: Smnooth, level, free from trippping hazards, able to withstand small metal spills etc etc
Moulds: These wil need to be checked, perhaps coated with a release agent and pre-heated so they are dry/moisture free

You do not say what metal you are casting - this has significance because steel is hotter than aluminium than non-ferrous.

I've not covered everything but hopefully made it clear that an "off the shelf" solution is not going to solve your problems
Phil

Posted By Phil Grace
Francis,
Now we're talking...

Overalls: In Aluminium industry we had to fight HSE belief that we should use wool (like steel industry) rather than (flame retardant) treated cotton. We won - eventually. You may consider FR cotton with heavy leather apron to be acceptable alternative to wool.
Shirts/Undergarments were all company issue - no synthetics 'cos it melts into the burn. You may have difficulty in enforcing a "no synthetics" rule if you do not issue company clothing
Footwear: Quick release foundry boots plus gaiters to cover lower leg.
Leather gloves/gauntlets:
Eye/Face: I would suggest that you use a combination of specs plus vizor. I would not regard this as overkill but sensible approach to protecting sight and face.

Hope that gives you a start. Does sound like you'll have an uphill taks overcoming years of poor practice. Don't hesitate to get in touch directly if you want to disucss.

Posted By wilki
Francis,
Having over 30 years steel meltshop experience I have a good understanding of the hazards associated with steel making, pouring and casting.
I endorse what Phil has indicated. The woollen 'Melton' coat and trousers is certainly the standard for steelmaking operations. I would also recommend a 'kepi' attached to the rear of the helmet to protect the back of the neck from any splashes/sparks.
It is very important moulds are free from any moisture.
There should be emergency procedures in place in case you have a metal breakout from the ladle, and these procedures should be simulated from time time so the guys know and understand exactly what to do without panicking.

Ian Wilkinson