Document 70eO33Xz8rNV36yErK7VXKLjE

FILE NAME Kaiser Gypsum KG DATE 1974 Mar DOC KG003 DOCUMENT DESCRIPTION Internal Manville Report - A Condensation of Environmental Facts on Asbestos and Health Presented at Customer Seminars ENVIRONMENTAL FACTS Asbestos kalnia ManvilleManville JJMM A Condensation of Environmental Facts On ASBESTOS and HEALTH Presented at a Series of Customer Seminars by MANVILLE CORPORATION PRODUCED JM - 83 For further information on this subject please contact Environmental Affairs Department Manville Greenwood Plaza Denver CO 80217 @ za, th 7 Rie ade cen: * TABLE OF CONTENTS { @ a , fi . i; \ Introduction to Asbestos and Health 2.0.0.0... eeecseeessssereeeetesssneensccensereneasoeesseeeeoneeeenees 1 Overview svotereneasessonseaescsacesenses 1 The Health Problem 1 Medical Aspects 2 Built Dust Defenses aes ceneeeceeeserees 2 Asbestos Diseases 3 Biological Reactions Asbestosis 4 Lung Cancer and Mesothelioma Leseceeeccesceceeeeeonsentenceesceeesensens 5 Fiber Differences Play Key ......... sosecccecsceeeccsseceetessseseuessesecseesneces 5 Dosage Standards 7 Dust Control How Effective 8 Smoking and Asbestos 9 Locked and Locked 10 OSHA Standards for Occupational Exposure to Asbestos sasasassenencsscessacetscscsesesssecscsussssseseseseaesesesesesesesesesecereeteeeneosse 11 12 Standards MonitoringVesccscessescescseocacsseceseoesesenesscnessessenssceseseeeeeeessssassaveraes 12 Methods of Compliance 12 Medical Requirements 13 13 Labeling EPA Standards for Airborne Asbestos . Emissions 13 M Fiber Handling Systems ceneueeeceneseeees 14 Bulk Fiber Handling Systems 14 Plant Fiber Handling Systems 15 Fiber Packaging 16 Shipping 16 New Concepts ae .... 17 Dust Control Through Engineering 18 Designing Dust Control for the Job cc eeetesersesrettsetensscesensceseeresseetsenseneneees 18 Some Dust Control Principles 19 Facing Tomorrow's Challenges 20 The Environmental Affairs Department 21 Biographies 23 Order Form for Printed Material ..................cccccecsssseosseseceeecsenenseatetesssessseneeeneneresensnsentees 25 This report was prepared by the Environmental Affairs Department of Manville in cooperation with the Asbestos Fiber Division Employee Relations Department and _ Environmental Engineering March 1974 INTRODUCTION With respect to asbestos and health -- at Manville we firmly believe that while it is dangerous to pretend there is no environmental problem and do nothing it is equally as dangerous to pretend the problem is so great that total abstinence is the only cure When } fi ; it comes to asbestos fiber and the health problems that can result from its improper use both apathy abstinence are extremes no one can afford Between the time any environmental health problem is identified and the time a cure or final solution is found there is always a period of prevention and control That is the fi \ period in which we find ourselves now with asbestos fiber It may well be that prevention , and control will be the final answer OVERVIEW Asbestos is used in some 3,000 products daily throughout the world almost indispensable in our modern society It has become Asbestos is the name given a family of fibrous minerals which have occurred naturally in our environment for as long as our planet has existed Characteristically asbestos fibers are resistant to extremes of heat and cold are flexible lightweight and durable Ay There are four fiasbestos accounts for commercially significant varieties in use today 97 of all the fiber used in the United States One variety chrysotile The other commercial forms are crocidolite amosite and anthophyllite It is important to remember that the latter three forms differ from chrysotile physically and chemically as well as in use Products containing asbestos are in our homes schools factories offices hospitals tye theaters spacecraft and more There is onomically or in quality of performance no one material that can outperform in the majority of these applications asbestos Indeed ec- with- out asbestos many products could not even be made nor do the job for which they were an intended Manville recently completed the expenditure of 75 million to expand mining and milling facilities at its Jeffrey Mine in Quebec Canada However asbestos fiber is so much in demand today that even this significant expansion will not enable M to meet all the demands of all of its customers at the present time The company expects to achieve that goal soon but has found the demand for fiber setting a faster pace than was expected THE HEALTH PROBLEM a For the past 50 years from the first indications that there were health problems involving workers who inhaled too much asbestos dust Manville has led the industry in working to solve those problems For many years along with other companies M has been active in asbestos health research in the U.S. and abroad The industry has funded and encouraged a great many studies and has worked with Federal State and Local governments to eliminate dust problems and set appropriate exposure standards -1- PRODUCED JM - 83 What was learned from these research and engineering studies was not always pleasant Frankly no industry likes to learn that because of a lack of knowledge not just on its part but on the part of the scientific community labor and government the health of some em- ployees had been unknowingly endangered in the past However it is to the industry's credit that it did not hide from the facts once they were known Again Manville assumed a leadership position in cleaning up plant and mine facili- ties . . . in controlling the occupational hazards that had been identified When equipment did not exist to control a particular situation M developed it Some of the equipment and systems developed and in use within M today are also being used by other industries with similar needs by it The corporate policy of Manville is simple and everyone in the organization lives It is our Company's policy to equip our plants for the highest degree of personal safety . provided it is technically possible and economically feasible to do so When technology is not available . . . or when it is not feasible economically from a competitive standpoint to make these installations . . . we will elect to discontinue a particular operation rather than knowingly endanger the health or life expectancy of a single employee The people of M know however that living by that policy within the confines of their own facilities is not enough They believe it is their responsibility to see to it that M customers and their employees are also made aware of potential hazards and how to control them a - MEDICAL ASPECTS | Asbestos can cause health problems if improperly used or handied When a person is subjected to high levels of airborne asbestos dust in the air serious health problems can result But if a person is protected - if normal prudent dust control systems are installed - a person's health _ can be protected and he or she will be able to work with asbestos fiber without danger Just about everything has a dose relationship when it comes to health and asbestos is no exception Every product we use in our factories or in our homes is potentially dangerous whether it is asphalt or asbestos used in our industrial processes or flour or table salt used in cooking at home They are all potentially dangerous substances if improperly used BUILT DUST DEFENSES All the air we breathe enters through the nasal passageways into the trachea The trachea separates into two main passageways called the bronchi The bronchi in turn get smaller as they go down the bronchial tree dividing into smaller passages until they reach the bronchioles These smaller and smaller air passageways finally terminate in a portion of the respiratory system known as the alveoli Figure ) While the trachea bronchi and larger bronchioles are visible to the naked eye the smaller air passageways and the alveoli are only visible with the aid of a microscope -2- PRODUCED JM - 83 . . > Figure 1 Anatomical Sketch of Air Passageways RESPIRATORY BRONCHIOLE ALVEOLAR ALVEOLUS TERMINAL BRONCHIOLE " ; ? It is in the bulb structures called the alveoli that the important action takes place as far as our respiratory system is concerned The alveoli are encapsulated with minute capillaries blood vessels - and it is here that the oxygen and carbon dioxide are exchanged There are 750 million alveoli in the normal human lung and several million could be destroyed without any ad- verse effect upon a person's normal respiration In a sense the human body has its own garbage collection system which begins with the small hairs in the end of our nose from entering the respiratory system These are filters - they prevent larger asbestos particles . \a a Be . * ae p> Additionally the inner nasal passageways down into the smallest bronchioles are lined with cilial cells These whiplike structures along the passageways sweep unwanted particles up from the lower depths of the bronchioles to the passageways of the upper respiratory system so they can be removed by expectoration Cilial cells are coated with a layer of mucous which captures the dust particles ASBESTOS DISEASES Asbestosis is a malignant fibrotic lung condition which may be caused by excessive inhalation of asbestos fibers over a long period of time It is one of several diseases classified as pneumoconioses such as 1. Siderosis - caused by inhalation of fumes or dust containing iron particles 2. Silicosis - caused by inhalation of free silica or quartz dust 3. Byssinosis - caused by inhalation of cotton fiber dust 4. Anthracosis - commonly known as black lung disease caused by inhalation of coal dust 5. Asbestosis - caused by inhalation of asbestos dust -3- PRODUCED JM - 83 These are all pneumoconioses normalities They are malignant cancerous pulmonary ab- Although asbestosis can occur anywhere in the lungs it usually occurs in the lower lobes and both lungs usually are affected Another disease that has been linked to asbestos to smoking and a few other substances is bronchogenic cancer While it can occur anywhere in the lungs it usually develops at the major junctions of the bronchioles - in the central part of the bronchial tree Bronchogenic or lung cancer is caused by many agents including asbestos One of the leading causes of bronchogenic cancer among both asbestos workers and the general public is cigarette . smoking 4 The third asbestos disease is called mesothelioma an extremely rare form of cancer which affects the lining of the pleural lung cavity or the peritoneal abdominal cavity Mesothelioma is by far the most serious of the three diseases because at this point in our knowledge once it is diagnosed it is inevitably fatal -- there is no known treatment Death usually occurs within 18 months after diagnosis Mesothelioma is not caused solely by asbestos In fact there are now more cases of mesothelioma listed in world medical registries in which asbestos has not been involved than there are cases in which it has been involved BIOLOGICAL REACTIONS ASBESTOSIS When an asbestos fiber is inhaled into the body and it is not captured and eliminated by the normal cleansing mechanisms two different actions can occur It can be encapsulated with rich protein -- in which case it is then referred to as an asbestos body or ferruginous body Or it can remain in a naked state -- uncoated If the fiber is encapsulated and becomes a ferruginous body it is for all intents and purposes harmless On the other hand if the fiber remains in a naked state in the lung then an almost uncontrolled growth of cells may begin resulting in the formation of collagen or scar tissue When collagen forms in the lungs it alters the normal tissue so that it no longer functions properly When this biological reaction occurs the body's vital capacity is greatly reduced Lungs cannot hold as much air as they did previously because a portion of the alveoli has been rendered inoperative With vital capacity thus reduced the oxygen dioxide exchange function within the lung is altered and the overall effect is poor ventilation and labored breathing which are signs of asbestosis Biological changes such as these can be detected by ray Another physical symptom which is characteristic of asbestosis is rales Rales is an unusual sound produced in the chest cav- ity which a physician can hear with the aid of a stethoscope PRODUCED -4- JM - 83 o| ) It should be noted that rales also can be caused by bronchitis the common cold or by pneumonia - One other physical symptom of asbestosis which might occur is clubbing of the fingertips Why this occurs still is a mystery although some scientific investigators believe it is related to the alteration in the oxygen dioxide exchange within the lungs LUNG CANCER AND MESOTHELIOMA The biological mechanisms involved in development of bronchogenic cancer and mesothelioma are not yet understood Like other forms of cancer there are many mysteries still to be unlocked fi FIBER DIFFERENCES PLAY KEY ROLE Asbestos fibers are not identical - there are both physical and chemical differences in the four commercially significant varieties Of these chrysotile white fiber is the most widely used | and is mined principally in Canada and Russia Crocidolite blue fiber is mined largely in Africa as is amosite brown fiber The fourth type anthophyllite comes from Finland and sees limited use principally in plastic reinforcement TYPES OF ASBESTOS fi an) Chrysotile Crocidolite Amosite Anthophyllite 1972 World Production Tons 4,000,000 Color White SI MG FE Composition 40 38 2 150,000 110,000 12,000 Blue 50 - 40 Brown 50 - 40 White 58 296 296 Sources . U.S.S.R. Canada S. Africa U.S.A. Italy S. Africa Cape Australia S. Africa Transvaal Finland Chemically the major differences in fibers are in their magnesium and iron content Chrysotile contains 38 magnesium while crocidolite and amosite have virtually none On the other hand crocidolite and amosite are rich in iron while chrysotile has little However it is the physical differences in fibers that appears to be of most significance in biological reactions Fibers of crocidolite and amosite are very harsh and shaped is wool in appearance tending to curl Chrysotile on the other hand ' Because of these physical differences the like fibers of crocidolite and amosite are more -5- PRODUCED JM - 83 Figure 2 DUST ELIMINATION RATES 10 MILGRAES TE a meg AMOSITAMOESITE CROCIDCOROLCII DOT LIE TE LUNG RAT IN DUST aay CHRYSOTILE 0 10 20 30 40 50 60 DAYS The weight of asbestos dust in rats lungs after 30 days exposure to dust clouds of similar respirable mass concentration and the subsequent loss of dust over the next 58 days Each point is the mean of 8 rats Equal numbers of male and female likely to pass through the bronchial passageways unimpeded while the wavy chrysotile fibers are more likely to impinge on the side of passageways where they are captured by the mucous lining of the cilial cell system and escalated up and out of the respiratory system Thus the physical characteristics of a fiber are extremely important in relation to its biological reaction In order to cause pulmonary disease a fiber or particle must penetrate deeply into the lungs In order to do this the particle must be below 3microns in diameter - although the length may vary considerably Scientific studies of fiber characteristics support the contention that chrysotile fibers are less likely to penetrate deeply into the lungs than the other fibers In one study a group of rats was exposed to crocidolite another to amosite and another group to chrysotile At the end of 30 days some of each group of rats was sacrificed and the amount -6- PRODUCED IM - 83 of fiber in their lungs measured The remainder of the rat groups were sacrificed and analyzed 30 days and 60 days later The results showed that chrysotile was more readily cleared from the lungs than either amosite or crocidolite Figure 2 ; Also significant is a comparison of studies by three different researchers ; fi chrysotile amosite In one study Dr. Irving J. Selikoff of Mount Sinai Hospital New York City studied 632 asbestos insulation workers men who cover pipes and boilers with asbestos insulation materials crocidolite and numerous other solvents and These workers were exposed to dusts The second study was done by Dr. Molly Newhouse in England and involved factory workers exposed to three different types of asbestos but not the mixed dust and other materials to which fi the insulation workers also were exposed The third study was done by Dr. J. Corbett McDonald head of the Department of Epidemiology at McGill University in Canada It involved 9,981 Canadian m: iners and millers exposed only to Canadian chrysotile asbestos a | , e : a a 3 ASBESTOS STUDIES Asbestos Insulation Applicators Dr. Selikoff No. of Men Studied No. of Deaths All Causes Lung Cancer Mesothelial Tumor 632 380 72 19 22 ( % Asbestos Factory Workers Dr. Newhouse 4,806 436 42 10 20( % Chrysotile Miners and Millers Dr. McDonald $ 9,981 2,143 97 % 3 0.1 ofIn analyzing the rate of lung cancer and mesothelioma in these different groups the higher rates disease appear in those groups of people exposed either to all three types of asbestos and other materials or all three types of asbestos alone Conclusions drawn from these studies tend to substantiate theories that Canadian chrysotile produces fewer cases of mesothelioma and lung cancer than other types of asbestos fiber DOSAGE STANDARDS Much discussion has surrounded the establishment by the U.S. Government of dosage stan- dards for asbestos dust inhalation However numerous studies have shown there is a dosage - or threshold level - for inhalation of asbestos below which there apparently is no significant increase in disease Dr. McDonald performed a number of studies in this area In one he surveyed almost 10,000 Canadian miners and millers of asbestos in Quebec's eastern townships Two separate - -7- PRODUCED IM - 83 Figure 3 Dosage Study Dr. J.C. McDonald Radiographic Changes - Prevalence rates % standardized for age and years in industry Males aged 36-65 at time of radiograph mpct - years fibres ml years THETFORD MINES Irregular Small Opacities - 0 -1 Pleural Thickening - Grade 1+ - Grade 2+ 10 23 10 23- Dust Group 100- 200- 400- 230 460- . 920- 800+ 1840+ Average 1.8 0.0 2.4 1.3 3.3 0.2 4.6 0.7 6.3 2.2 6.5 0.8 8.7 0.9 5.8 1.2 12.0 17.2 2.4 9.2 8.3 10.5 1.3 2.0 7.6 2.0 6.4 1.1 ASBESTOS Irregular Small Opacities - 0 -2 Pleural Thickening Grade - Grade 2+ 6.4 0.0 2.9 0.0 3.7 0.4 2.6 0.6 6.3 1.5 3.0 1.0 5.0 0.8 3.0 0.5 6.8 0.6 4.7 1.4 7.0 3.9 5.8 0.7 5.1 0.8 , 3.2 0.7 groups were used One at Thetford mines and the other at M's Jeffrey Mine Dr. McDonald's study are almost identical for the two groups Figure 3 The results of work level Using clearly exceeds both the illustrates 20 to 40 number of years of exposure and the exposure level itself McDonald's that the ill effects of asbestos exposure are not seen until the exposure fibers per cc It is only at the higher levels of exposure that significant health changes are detectable Figure 4 The latent period for asbestosis ranges from 15 to 20 years Bronchogenic cancer has and for mesothelioma the usual latent period is 25 to 35 a latent period of 20 or more years to remember that the disease being seen today in some time asbes- years Thus it is important result of exposures many years ago when dust control systems were not as effec- tos workers is the tive as they are today Furthermore these exposures occurred before the scientific commun- ity labor or government realized the nature of the asbestos health problem DUST CONTROL HOW EFFECTIVE An indication of how effective dust control systems can be in reducing the risk of asbestos- ea related disease was documented early in British study PRODUCED -8- JM - 83 Figure 4 Dosage Study Dr. J.C. McDonald Mortality Study - Equivalent average death 1000 Deaths to December 1969 Males Born Between 1891 - 1920 mppcf - years fibres years All causes Cancer of bronchus trachea lung , Abdominal Cancers Pneumoconiosis 10 23 365 10.3 18.0 1.6 10 23 355 13.1 13.6 1.5 Dust Group 100- 200- 230 460- 354 13.4 313 15.5 18.7 11.6 0.8 4.9 400- 920- 323 21.4 26.3 4.9 800+ 1840+ 395 32.1 28.7 23.6 Dr. John Knox then Medical Director for Turner Brothers Asbestos Company Ltd. in England studied workers employed over various periods of time in one TBA plant in Rochdale There was no dust control at this facility prior to 1933 when primitive dust control equipment was installed Dr. Knox divided his study group three ways those who had over ten years work experience in the plant prior to installation of dust control equipment those who had some exposure prior to 1933 when dust control began but less than ten years total exposure and those who had no ex- posure at all prior to 1933 and had only worked in the plant under dust control conditions All of the people in the three groups had at least 30 years of exposure with or without controls Comparing the death rate of these three groups to the standard mortality tables available from the British government and showing expected death rates for certain segments of the general population Dr. Knox was able to analyze the effects of dust control In the group with the heaviest exposure Dr. Knox found that while ten deaths would be the norm in reality there were 15. In group two with only some heavy exposure about eight deaths would have been expected but there were only six In the last group which had worked in the plant only after dust control equipment was installed the expected number of deaths was five but only two were recorded Figure 5 Dr. Knox study is a dramatic illustration of the effectiveness of dust control proving that the lives of employees can be protected even by the use of the simplest kinds of equipment SMOKING AND ASBESTOS Another important point that resulted from medical studies is that smoking and asbestos do not mix In his study Dr. Selikoff found that all but one of the cases of bronchogenic cancer were ~ -9- PRODUCED 7 JM - 83 ' Figure 5 Dust Control Study Dr. John Knox Distribution of Deaths with Exposure Before 1933 Standardized for Time since Completing 20 years Employment and Age Exposure Before 1933 yrs Distribution of Lung Cancer Deaths Observed Expected Distribution of Other Deaths With Asbestosis Distribution of Other Deaths Without Asbestosis Observed Expected | Observed Expected Over 10 Group 1 Up to 10 Group 2 None Group 3 15 9.8 17 11.38 16 16.91 6 8.41 5 8.07 12 12.98 2 4.78 0 2.55 13 11.12 All Groups Test of Significance of Trend 23 23.00 x 6.70 17 P 0.01 22 22.00 x= 9.63 = P 0.002 41 41.01 x= 0.52 1 P 0.47 among asbestos workers who also smoked cigarettes cigarettes had no greater rate of bronchogenic cancer Those asbestos workers who did not smoke than the normal smoking population Based on these hard facts about the carcinogenic effect of smoking and asbestos dust inhalation Manville and other asbestos companies strive to discourage smoking among em- ployees who work with asbestos Figure 6 LOCKED AND LOCKED While it is evident that excessive asbestos dust inhalation can be harmful this risk is confined almost exclusively to the occupational setting Asbestos products in general use may or may not pose a dust problem depending on their composition and handling Basically asbestos products fall into two groups - the locked products and the non- locked products In the locked products one must be concerned with the generation of dust However in those products in which the asbestos is locked by chemical physical or thermal means there is little cause for concern since the normal use of these products will not release significant amounts of asbestos fiber into the air While we know today that asbestos can cause health problems if proper steps are not taken -10- PRODUCED JM - 83 . . fi ay q - ke . Le {: ; : a : q 4. [7 L ; Ss aye spe pe. oa a ue 2 .a Figure 6 Smoking Study Dr. I.J. Selikoff Expected and Observed Deaths Among 17,800 US and Canada Asbestos Insulation Workers . January , 1967 - December 31 1971 Total No History of Cigarette Smoking History of Cigarette Smoking No. of men Jan. 1 1967 Persons Years of Observation Cancer All Sites Lung Cancer Pleural Mesothelioma Peritoneal Mesothelioma 17.800 86.300 Expected Deaths Observed Deaths 144.09 459 44.42 213 - 26 - 29 2.066 10.163 Expected Deaths 19.92 5.98 Observed Deaths 33 , 2 - 2 - 9 9.590 46,615 Expected Deaths 79.58 Observed Deaths 265 25.09 134 1 17 1 29 Cancer of Stomach 6.62 29 0.95 1 3.60 8 Cancer of Colon Rectum 17.51 26 2.52 4 9.53 14 " Cancer of Esophagus 3.21 13 0.44 0 1.80 7 Asbestosis All Other Causes F . 661 78 555 - 4 92.67 36 - 356.67 45 - 286 Total Deaths 805 63 1,092 112.59 73 436.25 596 pe se to reduce exposure we also know that exposures can be controlled and that there is a safe level of exposure Most members of the world scientific community believe that the levels established by the U.S. Government Department of Labor's Occupational Safety & Health Administration to limit asbestos exposure are safe levels and that asbestos diseases are preventable if proper dust control measures are taken OSHA STANDARDS FOR OCCUPATIONAL ASBESTOS EXPOSURE As 1974 began the asbestos industry learned that the Occupational Safety and Health Administration standard for occupational exposure to asbestos was under review Revised regulations are expected in late 1974 Current standards for asbestos exposure include these five major categories 1. Standards For airborne asbestos fiber concentrations in the workplace 2. Monitoring Method of determining whether or not dust standards are being met 3. Methods of Compliance 4. Medical 5.LaLbaebleilnigng -11- PRODUCED JM - 83 STANDARDS call for a maximum of Present OSHA standards for asbestos exposure than five micrometers in length per cubic centimeter Five fibers greater hour weighted average concentration and Ten fibers greater than five micrometers in length per cubic centimeter ceiling concentration Effective July 1 1976 the weighted average concentration standard becomes two fibers greater than five micrometers in length per cubic centimeter than five micrometers in length that can be In cases the standards refer to fibers greater seen by phase contrast light microscopy at approximately 430X magnification referred to as Threshold Limit Values TLVs These and other similar standards are generally substances and represent conditions under which TLVS refer to airborne concentrations of exposed day after day without adverse it is believed that nearly all workers may be repeatedly effect - - - American Conference of Governmental Industrial Hygienists @ @ MONITORING meets the required standards a system of monitor- To determine whether or not a workplace ing is required The asbestos standards require that a of the regulations June , 1973 every employer Within six months of publication released to be moni- shall cause every place of employment where asbestos fibers are to asbestos fibers + tored in such a way as to determine where every employee's exposure 4 is below the prescribed limits Monitoring usually is done by thethe membrane personal air sampler technique It requires which be obtained from a number of manufacturers that an employee wear an air sampler personal air onto a filter which collects the particulates and sampler draws workplace number of fibers counted The air air This filter is then placed under a microscope and the fibrous fibrous dust in the actual fiber concentrations expressed expresed as fibers per cubic centimeter of After the count is complete the air are calculated by formula Se, |ps! METHODS OF COMPLIANCE It is expected that future asbestos standards will place However the present standard pliance than the present ones controls It states that engineeringengineering controls such engineering shall be used exhaust ventilation and dust collection a greater emphasis on methods of comdoes include an important section on as but not limited to isolation enclosure This rule is a logical requirement for any dust generating -12- PRODUCED of whether or not IM - 83 it contains fiber since any dust in sufficient quantity is potentially hazardous Two good reference works on designing dust control systems are 1 American National Standards Institute ANSI Z9.2-1972 2. Industrial Ventilation by the American Conference of Government Industrial Hygienists . . oe Be , MEDICAL REQUIREMENTS medical standards require that the employer shall provide initial and annual compre- hensive Pmreedsiecnatl examinations to each of his employees engaged in occupations exposed to air borne concentrations of asbestos fiber ' NIOSH National Institute for Occupational Safety and Health a Division of the Department of Health Education and Welfare has recommended in its criteria for occupational exposure to asbes- of medical surveillance the term exposed to asbestos will be interpreted as tos that for the purpose above five fibers referring to weighted average exposures above one fiber per cc or peak exposures per cc The intent of the NIOSH recommendation was to eliminate the need for medical examina- tions when an employee's exposure was below half the TLV LABELING Present standards require that Caution labels shall be affixed to all products containing asbestos fibers or to their containers except that no label is required where asbestos fibers have been modified by a bonding agent coating binder or other material so that during no airborne concentrations of asbestos fibers in any reasonably foreseeable use excess of the prescribed limits will be released The required wording of the label is CAUTION Contains Asbestos Fibers Avoid Creating Dust Breathing Asbestos Dust May Cause Serious Bodily Harm EPA STANDARDS FOR AIRBORNE ASBESTOS EMISSIONS The Environmental Protection Agency on April 6 1973 published in the Federal Register national emission standards for three hazardous air pollutants - asbestos beryllium we - = The EPA standard for asbestos is unique because it contains no emission standards or ee PRODUCED numbers Instead the regulations are written around NO VISIBLE EMISSIONS -13- JM - 83 _ | { A visible emission is defined as any emission which is visually detectable without the aid of instruments and which contains asbestos particulate material that has no visible emissions is automatically in com- An asbestos manufacturing plant has visible emissions but they do not contain asbestos particulate If an asbestos plant However if an as- plidaentceermined by microscopic examination the operation also is in compliance as visible emissions then control devices must be in- bestos plant does have containing where stalled In this case the standard requires that a fabric bag filter be used in all cases except a ( the character of the emissions would render such filter unsuitable In that case a energy wet scrubber must be used < There are several exceptions from coverage under these EPA standards is field fabrication The apparent reasoning in this instance is that if important airborne emissions to operations conform to OSHA asbestos stand. ards possible One of the most field fabricating the atmosphere will be satisfactorily controlled M FIBER HANDLING SYSTEMS Corporation Manville produces and sells more than 775,000 tons of asbestos fiber each 100 miles east of from four mines The largest of these is the Jeffrey mine located about yMeoanrtreal in Asbestos Quebec Canada Jeffrey's production is in excess of 650,000 tons annually An indication of M's confidence in the future of asbestos fiber is apparent from the recently of 75 million to relocate and modernize crushing drying and concentrating completed expenditure facilities at Jeffrey and to expand mining operations more Each day six days a week some 35,000 tons of ore are hauled to the Jeffrey crusher than 100,000 tons of waste rock and overburden are hauled to the waste dump and The objective of the M Asbestos Fiber Division always has been to deliver fiber to customers in a form and a manner that creates no dust problem for the customer's employees ( BULK FIBER HANDLING SYSTEMS | One new method of shipping asbestos fiber is the bulk tank car which was developed by M with the Ford Motor Co. and Procor in Oakville Ontario M has been successfully in conjunction shipping short asbestos fiber grades in the bulk tank car for the last three years Approximately 150,000 was spent by Canadian Manville in development of this new car ( Each of the six bulk tank cars now supplying Ford holds 55 tons of asbestos fiber The car is _ At the receiving location air is loaded at the mine by pumping fiber into the seven compartments pumped into the car to fluidize the fiber and cause it to flow into storage silos ( varieties of storage silos that can be used and various makes of fiber pumps There are many are available -14- PRODUCED JM - 83 q . p ma - ry 4 x tll ra : BAGGED FIBRE STORAGE Figure 7 PROTOTYPE PLANT ASBESTOS FIBRE HANDLING SYSTEM . 3,500 DUST COLLECTION |, SYSTEM 3500 cfm Tt { ! 1 ! \/ \ 500 cfm cfm 800 500 \ 500 cfm / /\ / 2,000 + 7 \ \ 1,500 / CONV BAG _ b| BREAKING [\ / \- LS! STATION )PUMP SCALE 1,500 H T j | i | ! VALVE ! | DIVERTING { VALVE I K| 1,500 600 600 | | FLEX KLEEN KLEEN 4 600 600{ | FLEX KLEEN } |cfm 4 cfm 500 { 4500 " ALTERNATE cfm cfm 500 - Ny teen pn 500 1 4 ~A MIXER MIXER 14,500 PLUS PIPING Advantages of the bulk tank car system are No handling of bags and thus no contact with a fiber by employees lower handling costs and simplified monitoring of dust levels However the system does have limitations such as the tonnage that can be loaded into car depending on the length and openness of the fiber In addition the capital investment is about 100,000 and does not appear practical unless a customer's usage exceeds 2,000 tons annually PLANT FIBER HANDLING SYSTEM An plant fiber handling system has been developed and tested at Jeffrey Mine It includes ; *, a breaking station and fiber pump which conveys the fiber to mixers or weigh hoppers The entire system requires approximately 3,500 cubic feet of air and costs about 14,500 plus piping Figure 7 Aside from the fiber pump developed at Jeffrey there are other items of equipment on the market that can be used to transport fiber One is the Vanco Blower which has been used at Jeffrey to move 100 pounds per minute of Group 7 fiber 35 feet vertically and 2,000 feet horizontally with -15- PRODUCED JM - 83 Another Jeffrey development is the automatic bag opener which opens paper or polyethylene bags dumps the contents and deposits the empty bag all under dust control It requires 800 cubic feet per minute of aspirating air and costs from 9,900 to 12,500 depending on various controls Fairmount Engineering Inc. Hackettstown N.J. has developed a bag opener at a quoted price of 8,500 According to M calculations the entire cost of an plant fiber handling system including a Vanco blower automatic bag opener and a bag baler is approximately 30,000 plus the cost of ducts Figure 8 FIBER PACKAGING to At present M is supplying asbestos fiber the domestic market in three types of packages 1 Standard kraft multiwall paper bag six mil polyethylene film bag and the pulpable kraft multiwall bag The pulpable bag was developed for use in the asbestos paper industry so that both bag and contents could be dumped into a hydropulper or vat thereby eliminating the need for opening the bag In the same way the polyethylene bag is used in the asphalt paving industry and in limited cases in the floor tile industry where both the bag and contents are dumped into the pug mill or mixer Of course this concept is limited to suitable bag materials and the compatability of the bag composition with the product formulation SHIPPING M makes available to customers several alternatives in fiber shipping Unitized loads can be shipped on a cardboard deck sheet or a wooden pallet with all bags locked to reduce shifting and damage Palletized units also can be covered by shrink polyethylene film to prevent damage and - dust generation during shipment An added measure instituted by M to insure improved condition of asbestos shipments upon arrival is the assigned rail car been Over the past 18 months 450 rail cars - each 40 feet long with double doors - have in assigned service to M plants in the U.S. _ Palletized material in the assigned cars is kept secure by the use of inflatable dunnage two to a car placed between pallets in the doorway area to keep them from shifting during transit The company's experience with assigned cars and inflatable dunnage has been excellent - the condition of arrival of shipments has been greatly improved trial A limited number of assigned cars are available for shipment a customer decides this method is suitable test shipments to customers it will take approximately six If after a months to acquire the necessary cars and dunnage - 16 - JM - 83 Figure 8 DUST CONTROL 1 | r | i 1 1. BAG OPENER i | | i I \ } BAG BALER /, 7f SCHEMATIC PLANT HANDLING - BAGGED FIBER i i 1 \ i LY \ 1 FILTER RECEIVER i 1 i I an l 1 1 | I BATCH WEIGHER ! k | aN I I of | | Pia aoe | L MIXER 1s NEW CONCEPTS ; M's experimental work on improved asbestos fiber handling systems is continuing in two directions One new concept is the high density fiber block which measures " x 12 x 16 and has a density of 100 lbs per cubic foot The blocks are dust free and consume less space in shipment than normal pressure bags The second new concept is pelletized fiber Using a Waldron pelletizing machine asbestos pellets have been produced at Jeffrey Pellets have a loose density of 65 pounds per Mine with cubic foot Group 7 fiber using water as a binder and lend themselves well to shipment in closed hopper cars bags and other types of containers They are largely dust free Aside from these new developments and concepts the Asbestos Fiber Division is anxious to work closely with any of its customers in the development of a fiber handling system to meet individual requirements : PRODUCED -17 JM - 83 DUST CONTROL THROUGH ENGINEERING Because Manville asbestos dust for many years has the been in the business of company has developed handling asbestos fiber and controlling much expertise that may be valuable , to companies with similar problems Some of the systems developed by M to control operations may be adaptable to other companies or they asbestos may be dust exposure in its own viewed as concepts to work from duced While use of the assigned cars with double the dust problems associated with damaged doors and inflatable dunnage has railroad shipments there are four that should be followed in any asbestos unloading operation greatly re- basic rules 1 Upon arrival of a shipment check to determine if any loose fiber is on the bags or floor If there is the area should be vacuum cleaned before _. unloading 2 Immediately seal any broken or torn bags before unloading 3 . For manual unloading clean pallets should be used and after use the pallets should be vacuum cleaned or washed with water 4 All broken bags after resealing should be taken directly to the point of usage and not placed into inventory M's experience with adherence to these simple housekeeping marked reduction in fiber counts taken during unloading operations measures has been a sultant tectors plant storage of asbestos should be geared to preventing bag damage and the re- generation of dust Plastic covers can can be placed around pallets stored in be used for term storage and corner proa warehouse to prevent damage by plant vehicles Bag opening devices which protect personnel from dust during opening and feeding operations can bring about dramatic reductions in workplace fiber counts There are several types of bag opening devices designed for particular needs from simple to sophisticated Some of these systems also include a bag disposal section and bag baler to further prevent dust gen- eration DESIGNING DUST CONTROL FOR THE JOB If a manufacturing operation generates dust adequate dust control facilities should be designed and installed It is important that employees be protected from asbestos dust just as they should be protected from excessive heat and noise fumes toxic chemicals and other ma- , terials M has developed specialized yet simple dust control systems for many diverse operations from machining of Transite asbestos pipe and heavy duty brake blocks to shingle punch | presses PRODUCED -18- JM - 83 Two principles are important in designing dust control systems for particular operations Duct sizes should be a minimum of 4 to 5 inches in diameter with air duct velocities of 4,000 to 4,500 feet per minute and face velocities across the work station should be 200 to 250 feet per minute Cloth collectors are efficient systems of dust control and are in use in many M plants Such systems can be scaled up or down to meet particular needs However it is important that the air to cloth ratio be no more than 3 to 1 for a shaker type collector One of the largest cloth collectors in the world is located at M's Jeffrey Mine in Quebec This system encompasses the entire top floor of a story building and is under negative pressure There are 80,000 bags in this collector with thirty 350 motors driving fans that generate 5 million cubic feet of air per minute This sophisticated system has helped M keep dust counts in all work stations in the fiber mill at or below five fibers per cc with most below 2 fibers per cc In fact of 943 M asbestos fiber work stations in the U.S. 860 or 91 of them are at or below five fibers percc as of January , 1974 and 545 or 58 are below two fibers per cc Personal protective equipment is being used in those areas not yet below the fiber standard although the company is currently working on all stations to bring them below the pres- ent fiber TLV and to the two fiber standard due to go into effect on July , 1976 This reduction in fiber counts at M will be accomplished by improved housekeeping improved methods changes in processes and installation of improved dust control facilities SOME DUST CONTROL PRINCIPLES M's 30 years of experience in handling asbestos fiber and developing effective dust con- trol systems is available to M customers The following recommendations are designed as guides for those in need of dust control facilities and should be viewed as principles to work from not equipment one must have in order to solve a particular problem 1 A good job of industrial housekeeping usually is the first step An industrial vacuum cleaner should be used in areas where dust may be generated If a plant already has dust control facilities it is recommended that a vacuum cleaning system be used as a take from the present dust system by installation of a booster fan and a small cyclone M will provide a typical lay- out and schematic of such a system If asbestos fiber is used in an operation and there are no dust control facilities chances are there is a dust problem - and probably a fold one One would be exposure of employees to asbestos dust OSHA and the other would be exhausting asbestos laden air out of the build- , ing EPA It is not advised that a customer who has an operation without dust control make an industrial hygiene survey since this only will provide numbers for a need that is obvious Instead it is recommended that the customer arrange for an engineering survey which will result in a report with schematics and recommendations on how to correct dust problems inside and outside the -19- PRODUCED IM - 83 plant The survey should be adequate enough to provide cost estimates on the installation of a proper and effective dust control system on a fee basis along with a number of other re- 3 Manville conducts engineering surveys liable engineering firms Additionally M is equipped to handle the purchasing and installation of dust control facilities on a turn basis if desired There are many reliable firms providing similar services and M recommends a review of all before making a decision 4 The most appropriate times for an industrial hygiene survey are a If you already have dust control facilities an industrial. hygiene survey will determine how well your facilities meet OSHA standards b After installation of dust control facilities an industrial hygiene survey should be part of the installation agreement to establish the reliability of equipment and compliance with standards of Manville located in Denver Colo- The Environmental Control Systems Department to ensure the safest possible work environment for all rado is ready to work with M customers people handling asbestos fiber FACING TOMORROW'S CHALLENGES Much has been learned about asbestos problems in a short period of time due mainly to the initiative of the asbestos industry in facing a complex problem Many new facts were learned about asbestos and health at a major meeting on the subject held in October 1972 in Lyon France It was there that a majority of scientists from all over the world who were actively studying the biological effects of asbestos met under sponsorship of the International Agency for Research on Cancer a division of the World Health Organization There were 130 participants from 20 countries at the meeting In a report issued following that meeting the group's Advisory Committee on Asbestos Cancers reported There is no evidence of lung damage by asbestos to the general public ... There is no evidence of an increased risk of cancer resulting from asbestos fibers present _. in water beverages food or in the fluids used for the administration of drugs There is no detectable lung cancer risk above normal when occupational exposures have ... been low . . and these occupational exposures have almost certainly been much greater than the amount of asbestos to which the general public has been exposed There is evidence from population studies that a considerable number of mesothelioma . cases have no known association whatsoever with exposure to asbestos cath, -20- JM - 83 More came out of that meeting such as the incriminating evidence against cigarette smoking as a very probable carcinogen and the clear differences in risk with the type of fiber and nature of exposure In total it is now known that asbestos health risks are almost exclusively confined to the occupational environment ... ... ... that the effects of excessive inhalation of asbestos are both time and dose related . . that there are exposure levels that will not result in any increased risk of disease ... that the disease being found today among some time employees is not an indication of present day conditions rather it is a result of conditions existing decades ago when neither industry government or the scientific community knew much about the health effects of asbestos and even less about the proper means for their control THE M ENVIRONMENTAL AFFAIRS DEPARTMENT In its continuing effort to provide the widest field has established an Environmental Affairs Department As types and forms of information are made available to M of knowledge on asbestos and health M part of the department's services various customers and other interested parties A series of reports on asbestos and health problems is available free by filling out the order form Figure 9 and returning it to the M Service Center with the proper code number The printed materials available as of January 1974 are 1 Asbestos A Family of Minerals - describing the characteristics of the four commer- cially significant varieties of asbestos 376 2 Report of the Advisory Committee on Asbestos Cancers to the Director of the International Agency for Research on Cancer - outlining the major conclusions from the 1972 meeting in Lyon France of respected researchers from all over the world who were study- ing the biological effects of asbestos 374 3 Asbestos and Health - discussing the occupational health risks from asbestos dust and what M and the industry has done to eliminate or control them 375 4 Questions and Answers on Asbestos and Health - providing answers to the most commonly asked questions about the biological effects of asbestos 3711 5 Asbestos Water Pipe and Health - discussing the results of studies to determine if drinking water that has passed through asbestos water pipe poses any health risks 3711 6 Asbestos No Risk to the Public - reviewing asbestos health research to determine if there is any risk the public from the use or manufacture of asbestos products 3711 Other material available includes 2 7 What Every Employee Should Know about Asbestos - a pocket employee guide to asbestos and health including the responsibilities of both employer and employee in pro- viding a safe working environment 3711 -21- PRODUCED JM - 83 ay 8 Recommended Safety Practices for Handling Asbestos Fiber- an easy to read and follow list of accepted procedures for unloading storage handling and transporting of asbestos fiber as well as use of protective equipment and disposal of waste material tion is available on a color 11 x 14 poster on heavy gauge laminated order 3710 or in leaflet form Order 3711 This informacardboard g An extensive medical library on asbestos studies is open to interested parties To acquire copies of specific medical studies or for more information on additional material available through the Environmental Affairs Department write or call Walter A. Cooper Director Environmental Communications Manville Corporation Greenwood Plaza North Denver CO 80217 Telephone 770-1000 770-1000 Extension 2969 PRODUCED -22- JM- 83 BIOGRAPHIES This report was condensed from presentations made by the people listed below to Manville customers in series of seminars begun in 1973 F.J. JACK SOLON JR Vice President Environmental Affairs He earned a Bachelor of Science degree in Chemistry from the University of Notre Dame and studied at the Wharton Graduate School University of Pennsylvania He joined M in 1961. He has been Vice President for Advertising and Public Relations and prior to his present assignment was Vice President Corporate Relations WILLIAM B. REITZE Corporate Manager Accident Prevention and Industrial Health He earned a B.S. de- gree in Chemistry from Wagner College and has done graduate work in Physiology at the Columbia Uni- versity Medical School His experience includes many years of physiology and toxicology research Prior to joining M in 1969 he was Senior Industrial Hygienist for the New Jersey Department of Health As part of M's participation in the Insulation Industry Hygiene Research Program he was loaned to Mount Sinai School of Medicine as Chief of Field Studies and Industrial Hygiene EDMUND M. FENNER Director Technical Relations Environmental Affairs Department He is a graduate of Worcester Polytechnic Institute Worcester Mass with a B.S. degree in Mechanical Engineering A registered professional engineer he joined M in 1940. He previously was Director of Environmental Control for M He is Chairman of the Task Group on Naturally Occurring Inorganic Fibers of the American Society of Testing Materials Chairman of a subcommittee of the American National Standards Institute Chairman of the Technical Committee of the Asbestos Information Association America is a member of several professional and civic organizations NOEL W. HENDRY Vice President of Manville Sales Corporation and General Sales Manager for the Asbestos Fiber Division He earned a Bachelor's degree in Engineering from the University of British Columbia and a Master's degree in Geology from the California Institute of Technology He had extensive experience in mining and exploration before joining M in 1949 as Senior Mining Engineer He also served M as Senior and Chief Geologist and Exploration Manager before assuming his present responsibilities DONALD E. HILLIER Director of Environmental Engineering A graduate of the University of Michigan with a degree in Mechanical Engineering he joined M in 1944 as chief industrial engineer He has held a number of production engineering positions with the company His present responsibilities include direction of all M environmental control and environmental engineering activities -23- PRODUCED JM - 83 Figure 9 ENVIRONMENTAL AFFAIRS DEPARTMENT INSTRUCTIONS TO RELEASE INVENTORY -- CRD 1095 TO BILL EDMONDS M SERVICE CENTER 1601 23RD STREET DENVER COLORADO SHIP TO PRINT QUANTITY FORM DESCRIPTION IF NO FORM NO SPECIAL INSTRUCTIONS X43301 88 728 X43301 88 705 ISSUED BY DATE RELEASE # THIS FORM FOR ENVIRONMENTAL AFFAIRS DEPARTMENT USE ONLY -25- PRODUCED JM - 83 JM Manville Greenwood Plaza - Denver Colorado 80217 475 4 Printed in USA * is able eee Board of Directors E. E. TREFETHEN JR Vice Chairman of the Board Officers HENRY J. KAISER Chairman of the Board EDGAR F. KAISER Chairman of the Board THE COVER Emerging from the production line sacks and bundles of building materials give scant hint of their exciting potential But in use the Company's many products are the cells and sinews of construction bones flesh and skin which shape man's world It is that vibrant role of Permanente products in action that the mood construction photographs on these pages portray They were made specially for this report by nationally published Los Angeles photographer Leigh Wiener CONTENTS: Management Year Brief .. . . Chairman and President's Comments Financial Summary . . Growth . . 2. 2... Research & Development Products & Markets . . Facilities . . . . . . Production Technology . Financial Statements . Year Comparisons . No No 4 5 11 13 16 17 19 22 WALLACE A. MARSH President PETER S. HASS Executive Vice President WILLIAM MARKS Vice President & Secretary ALLEN D. CHRISTENSEN Mining and . Industrial Consultant Palo Alto H. W. MORRISON Chairman Morrison Co. Inc. Boise : GILBERT J. SHEA President J. F. Shea Investment Co. Los Angeles JAMES K. BEATTY Vice President Cement KENNETH A. CONNINGHAM Treasurer ROBERT A. COSTA Vice Presid Asst General Mar. Gypsum MELVIN E. ERLAND Vice President Sand & Gravel JOHN M. GAROUTTE Vice Operations Cement JAMES J. HAGUE Vice President Gypsum CLAUDE E. HARPER Vice President & General Manager Gypsum RONALD G. HOHNSBEEN Controller Cement WILLIAM P. JACKSON Vice President & General Manager Sand & Gravel CARL R. OLSON Vice President ERNEST H. SCHAL Vice President Gypsum BRYCE W. SIMPSON Controller