With more than five decades of experience in environmental health and safety (EHS) within the foundry industry, Jeet Radia has seen the evolution of regulations, technologies, and workforce dynamics firsthand. 

In this conversation, Radia, senior vice president at McWane Inc. and Chair of the AFS Air Quality Committee, shares insights on air quality, regulatory pressures, and the importance of knowledge transfer in sustaining the future of metal casting.

Modern Casting: Tell me a little bit about your background.

Jeet Radia: I’ve been in the foundry industry for over 50 years. I may look young, but I’ve really been in it that long. I studied metallurgical engineering in England and dreamed of becoming a leading expert in the field. But my first two jobs—first at the Steel Castings Research & Trade Association and then at the British Cast Iron Research Association—co-opted me into EHS work. The UK’s version of the Clean Air Act and OSHA had just been introduced, and they needed someone with a metallurgical background to help implement the changes in member foundries.

I was like, “Oh no, I want to work in metallurgical engineering.” But they told me I could not do that too. 

Once I started, I found EHS so interesting that I gave up my metallurgical ambitions to do this. And since I was still working with metallurgical industries, I could apply both skill sets. It was quite by accident, really. Like many people, I started in one direction and ended up somewhere unexpected—but deeply rewarding.

And now, so many decades later, I’m still in the field and still fascinated. About 22 years ago, I joined McWane to help build and oversee their EHS programs. That’s been my role ever since. 

MC: Why is EHS—and air quality specifi­cally—so important for foundries to consider?

Radia: Foundries have complex environmental footprints. We deal with materials like sand scrap and resins, and processes like electric melting, pouring, cooling, and shakeout—all of which generate air emissions.

The industry has made significant progress since the 1970s, using state-of-the-art technology to protect workers and communities. But as regulations tighten, it’s becoming harder to operate, expand, or build new facilities. A key example is the EPA’s PM2.5 rule—particulate matter smaller than 2.5 microns. In March 2024, the EPA lowered the allowable ambient air quality standard from 12 micrograms per m3 to 9. That three-microgram difference may seem small, but it has a huge impact on permitting and expansion.

MC: What’s the problem?

Radia: When a foundry wants to expand operations, they have to go to the state agency and the EPA to get a permit. Before issuing the permit, agencies conduct air dispersion modeling to simulate how emissions will spread based on weather conditions. They compare predicted ground level concentrations to the ambient air quality standard.

Because stacks are typically 30–50 feet tall or more, emissions spread over a wide area. What matters most is the concentration at ground level—what you and I would actually breathe. The models help determine whether those concentrations exceed the National Ambient Air Quality Standards (NAAQS) set by the EPA. While states can adopt stricter standards for certain toxic pollutants like benzene or antimony, the core NAAQS are federally mandated and consistent across states.

Under the old standard, if the background level was 8 mg/m3 and your operation added 2, you’d be at 10, still under the 12- mg/m3 limit. But now, with the standard at 9, that same scenario puts you over the limit. That means you’d need to implement costly mitigation measures—like raising stacks or installing costly, more stringent controls—which may not be feasible.
Many parts of the U.S. are already at, near or above 9 mg/m3, and natural dust sources such as agricultural and wildfires have made it worse by increasing background levels. So we’re competing with natural events just to operate.

MC: What technological advancements have helped improve air quality in recent years?

Radia: One major strategy is switching to electric melting. Foundries melt iron using both cupolas and electric furnaces because different product lines require different melting methods. For heavier castings like ductile iron pipe, cupolas are more efficient. But for lower tonnage needs, electric furnaces are more technically and economically feasible.  

The industry is gradually converting from cupolas to electric, which reduces greenhouse gas emissions from the melting process. Another avenue is raw material changes. For instance, switching to sand resins that emit fewer toxic contaminants. Suppliers continue to develop new alternatives that reduce or eliminate harmful chemicals.

Then there’s pollution control equipment—baghouses, scrubbers, and other systems that capture pollutants before they exit the stack. And finally, increasing stack height can help. Taller stacks result in more dispersion, so by the time emissions reach ground level, concentrations are lower.

Pollution control equipment has become more advanced—and more expensive. For example, in 2003, a state-of-the-art cupola baghouse cost around $10 million. Just a few years later, a similar system cost $15 million. That increase was due to both inflation and improved technology. Like buying a car, you pay for the added features and performance.

MC: So you have these external pressures to make changes. Are there challenges to getting internal buy-in for these efforts?
Radia: Change is never easy—especially when it adds work. We faced some initial resistance, but top-level commitment made all the difference. Our top leadership made it clear that we were serious about becoming industry leaders in EHS. Some people opted out, but many stayed, and we brought in new talent who were excited about the mission.

One powerful motivator is visibility. If there’s an incident—an injury or an unexpected emission—our digital systems immediately notify senior leadership. When the president of the company sends an email asking about a minor injury or a corrective action, it sends a strong message. People know leadership is watching and invested.

McWane has always prioritized industry-leading environmental, health, and safety programs. I was fortunate to have the opportunity to help develop those systems with a team of over 100 people. We modeled our standards on globally-recognized frameworks like ISO 14001 for environmental management and ISO 45000 for health and safety.

MC: What advice can you offer other foundries looking to improve their EHS initiatives?

Radia: If a foundry wants to get serious about EHS, the commitment must come from the top. Mid-level enthusiasm won’t be enough without executive support. They can invest in internal development or hire consultants, but it requires time, money, and leadership buy-in.

McWane’s policy has always been full transparency—with regulators and with peers. We’ve welcomed other foundries to benchmark our programs, and we’ve learned from theirs. It’s a collaborative effort.

Foundries face real challenges, but we also have real opportunities. With the right technology, training, and strategic planning, we can continue to operate responsibly and sustainably. I’m passionate about this industry and confident in its ability to adapt and thrive.