Document 65qbOq9w6Ow4dwJNqgNyo6b8g
C1
f; PLAINTIFF'S EXHIBIT
AB- 1 3-4 "
ABEX CORPORATION INDUSTRIAL HYGIENE SURVEY AMERICAN BRAKEBLOK DIVISION
WINCHESTER. VIRGINIA OCTOBER 2-6/ 1972
Original; CC:
/C B. Mallory
C. C. Blackwell/ Jr., M.D.
C. H. Borcherding, Jr. A. A. Borin
E. H. Feierabend D. K. Rennie G. L. Romine
F. E. Taylor
J. J. Walsh - IC Industries G* A. Zanis - The Travelers
SPNY 000527
ABEX CORPORATION INDUSTRIAL HYGIENE SURVEY AMERICAN BRAKEBLOK DIVISION
WINCHESTER VIRGINIA OCTOBER 2-6, 1972
PURPOSE
This survey provides coverage of the majority of operations in the plant to determine the extent of asbestos exposure to plant personnel. One additional survey will be scheduled in the near future to complete the evaluation.
Several of the asbestos samples collected from locations pro cessing lead compounds were also selected for analysis to determine airborne lead concentrations at various operations.
SUMMARY
Personal samples were collected at a majority of operations throughout the plant including Strip Finishing# Block Preform# Block Press# Block Finish# Block Inspection & Packaging# Com pounding# Book Preform# and Disc Brake Manufacturing, in addition# a personal sample was also taken from the operator of the mobile Tennant sweeper during routine sweeping opera tions. The sweeper was emptied of collected dust twice during the 66-minute sampling period.
To verify that airborne asbestos levels were below permissible limits# general air samples were collected from work and traffic areas in Shipping and Receiving and in the Machine Shop.
Referring to the results in the Analyses of Air Samples for Asbestos# 24 of the 72 samples reported exceeded the 5 fiber/ml exposure limit. Of these 24 samples# seven (7) were in excess of the 10 fiber ceiling "C" limit.
Although the majority of the exposures were confined to Book Preform# Block Preform# and the Block Finish Department# ex cursions were also encountered at the automatic preform machines in Disc Brake Manufacturing, and at the controls of the Tennant Sweeper.
SPNY 000528
As pointed out in our previous reports, the eight hour time weighted average exposure limit established by OSHA will be reduced from 5 fibers/ml to 2 fibers/ml on July 1* 1976. During this survey, a total of 60 personal samples, represent ing 83% of all samples collected, exceeded this projected exposure limit. The plant should anticipate the 1976 reduction of the permissible limit. Plans for expansion of existing exhaust ventilation systems or provision of additional engineer ing controls should be based on the projected 2 fiber limit.
Analysis of the personal samples for lead disclosed no con centrations exceeding the proposed or '`intended" threshold limit of .15 mg/M^. In most instances, a number of samples from each of the designated work areas were tested. None contained more than trace concentrations of lead. Control of exposure to airborne lead appears to be adequate at the present time.
DISCUSSION
Block Preform samples were collected on both the first and second shifts. As indicated, highest concentrations were encountered at Block Preform Machine No- P-4 operated by . D. Jeffries. -^Refer to sample numbers 45, 52, and 56.) Three samples were collected in series over three short time inter vals to avoid filter loading and resultant masking of the fibers during analysis. This work station was selected for short term sampling because of the poor personal hygiene exhibited by the operator. Spillage, scattering, and genera tion of airborne particulates was most noticeable at this location.
Excessive concentrations encountered in the Block Preform Department may be partially attributed to the personal work habits and housekeeping practices of the individual operators. However, local exhaust systems at all work stations should be improved to affect maximum capture of airborne contaminants. Present design at each Block Preform unit consists of a flared exhaust hood suspended above the preform bench. Al though face velocity is adequate, the design and location of the hood permits capture of only a fraction of the airborne material being generated during the preform cycle. In addition, an open, branch exhaust trunk is connected to the ventilation duct above the flared hood, but is serving no useful purpose at the present time. No ventilation is provided for the adjacent mix bin and weigh scale where a large share of the manual opera tions are conducted..
2- -
SPNY 000529
As point source collection of airborne asbestos fibers is not feasible due to the inherent design of the Preform units, en closure of the presses and/or redesign of the existing hoods above the preform benches may be an acceptable alternative. Exhaust ventilation should also be provided at the mix bins and weigh scales. Intimate handling during this phase of the preform cycle contributes significantly to the total exposure.
Automation of all or any part of the preform cycle should be investigated as a possible means of eliminating exposures.
Samples numbered 25 through 32 were collected at representative work stations throughout the Block Finish Department, including Inspection and Packaging and the Printer Machine. As Indicated, four of the eight samples exceeded the 5 fiber limit. Ex posures in this department can be primarily attributed to continuous handling of the dusty brake shoes, although grind ing and drilling may be contributing incidentally to the air borne concentrations. Please note the increased concen trations collected from Inspection and Packaging where exposure is caused exclusively by handling.
To control asbestos exposures in Block Finishing, the blacks should be thoroughly cleaned by brushing, vacuuming, and/or the use of enclosed air pressure prior to extensive handling in the Block Finish Department. Final removal of loose material should also be done after block, finishing and before the shoes are inspected and packaged for shipment.
None of the samples collected in General Compounding exceeded the 5 fiber limit, although two of the samples closely approached it. (Refer to sample Nos. 20 & 57) Also please note that all but three of the Compounding samples exceeded the projected limit of 2 fibers/ml.
To aid iri reducing airborne asbestos fibers throughout General Compoundihg, the feasibility of bulk storage of asbestos should b% investigated in conjunction with enclosed conveyance or vacuum transport of the fibers. The elimination of bagged asbestos would decrease required handling and at the same time limit personnel exposures. It is our understanding that as bestos in compressed pellet form is available as a possible replacement for the loose fibrous product. If adaptable to brake shoe manufacturing processes, use of the pelletized product should be seriously considered.
3- -
SPNY 000530
Referring to pages 5 and 6 of the Appendix* Book Preform samples exhibited higher concentrations than those encountered during previous surveys. This condition may have resulted from cold weather closure of exterior openings supplemented by direct air disturbance from the Dravo make-up air unit adjacent to the Preform machines. However* the reduced sampling time of the more recent samples may also be a factor. Prolonged collection tends to overload the filter* masking the fibers during analysis of the sample. Filter loading is especially common in areas where increased concentrations of airborne particulates are generated.
Reduction of elevated asbestos concentrations in Book Preform will require increased enclosure of the existing hoods above the preform units. All sides including a portion of the open front should be enclosed. In addition* the sides of the hoods should be extended downward to provide greater capture of as bestos dust generated during the pressing cycle. Adequate hooding should also be considered for the mix bins and weigh scales where intimate handling is a problem. Design and engin eering considerations should include the possibility of automation of all or any part of the preform cycle as a means of reducing or eliminating exposures.
In Disc Brake Manufacturing* two automatic preform machines were sampled. Both units disclosed concentrations exceeding the 5 fiber limit. Intimate handling is a problem at these locations* and provision of additional ventilation should be considered.
A personal sample was collected from the Tennant sweeper operator during normal sweeping operations. The mobile sweeper was emptied of collected dust at least twice during the sampling period.
It is apparent that the majority of the exposure to the opera tor is incurred while emptying the unit. Heavy concentrations of airborne dust are generated while this activity is in progress.
Until further samples can be collected to determine sweeping and dumping exposures separately, the operator should be re quired to wear respiratory protection. In addition* the Tennant Sweeper should be emptied outside the plant in a pro tected area where scattering or spreading of airborne asbestos can be minimized.
4- -
SPNY 000531
Methods of compliance, and required control measures were dis cussed in our previous Industrial Hygiene Survey Report dated August 14-18, 1972. Please note that the requirements outlined at that time apply to all areas listed in this report where asbestos concentrations exceed 5 fibers per milliliter.
A copy of the Occupational Safety and Health Standards in digest form is attached.
Our thanks to Charlie Mallory, Bob Brown, Charles Curtis, and associates for the cooperation extended during the survey.
12/27/72
SURVEY CONDUCTED BY:
APPROVED BY: fT
.
Mgr.Ind.Hyg./Loss Prevention
SPNY 000532
INDUSTRIAL HYGIENE SURVEY ABEX CORPORATION
BM-approved BZ . cfm dB
fpm GRA mg/m? mppcf ppm PS TLV
Ventilation
GLOSSARY
- Approved by the United States Bureau of Mines
- Breathing zone
- Cubic feet per minute
- Decibels-symbol denoting the relative intensity of sound pressure levels (re 0.0002 dyne/square centimeter)
- Feet per minute
- General room atmosphere
- Milligrams per cubic meter of air
- Million particles per cubic foot of air
- Parts per million by volume
- Personal sample
- Threshold limit value for an 8-hour daily exposure
- The terms ventilated, ventilating, or exhaust imply the use of mechanical means such as a fan for air movement, unless otherwise noted.
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DATE ANALYZED: 1 0 /1 9 /7 2
ANALYST: M. Desoukey
T L V j.1 5 mg/M^ (In te n d e d )
SPNY 000541
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