Document 8Rr55zwxkYoZw0BjmMveDJ3Ey
FILE NAME: Abex (ABX) DATE: 1972 Feb DOC#: ABX002 DOCUMENT DESCRIPTION: NIOSH Inspection Report
SPECIAL ASBESTOS DUST S
PRELIMINARY INDUSTRIAL HYGIENE SURVEY
ABEX CORPORATION American Brakeblok Division
Winchester, Virginia
Survey Conducted By:
John Dement Patrick Shuler Ralph Zumwalde
Report Prepared By;
John Dement Patrick Shuler
Environmental Investigations Branch Division of Field Studies and Clinical Investiga Rational Institute for Occupational Safety and Health.
1014 Broadway Cincinnati, Ohio 452G8
February 7-11, 1972
INTRODUCTION
During the week of February 7-11, 1972, a special asbestos dust survey
and a preliminary industrial hygiene were conducted at the American Brakeblok Division of the Abex Corporation, Winchester, Virginia. The main purpose of the asbestos dust survey was to evaluate the asbestos sampling technique used by the U.S. Public Health Service.
To date, the samples which were collected have not been analyzed; how ever, from past U.S.P.H.S. surveys and the present industrial hygiene survey, several conclusions can be drawn. The following paragraphs discuss plant operations and industrial hygiene practices along with conclusions and recommendations.
DESCRIPTION OF THE PLANT
The plant is located south of the city of Winchester and employs approx imately 655 blue collar workers and 119 white collar workers. There is a doctor employed by Abex Corporation but he only visits this facility once or twice a year. A nurse is on duty full time however. A complete pre-employment physical is given and is repeated every two years. Chest X-rays are taken every year. Blood and urine samples are taken twice a year from those in the mixing area to check for lead. Abex employs an industrial hygienist full time. The Personnel Manager acts as the Safety Director and works through the foremen to implement safety programs.
The plant was constructed by Abex in 1947 for the purpose of manufacturing asbestos friction products. The total plant site consists of 44 acres with four main buildings amounting to 440,000 square feet. The buildings are two story structures with the mixing operations and dust collectors being located on the upper level.
Products of the plant include automotive, aircraft and industrial braking materials, ABK industrial bearings, and sintered, metallic material for production of metallic, friction products. Approximately 50 different braking material mixes are made by the company in order to comply with varying customer needs and specifications.
DESCRIPTION OF THE PROCESSES
Both extruded and dry process brake linings are made along with ABK. bear ing material. Sintered metallic materials are made in a separate building
and does not involve the use of asbestos. The following paragraphs give a brief description of the operations which make use of asbestos fibers.
A. Dry Process Brake Linings
The process by which dry process brake linings are made consists
of the following steps:
1.
Mixing
2.
Preforming and Blending
3.
Hot Pressing
4.
Cutting and Trimming
5.
Curing
6.
Final Grinding and Drilling
Raw material mixing is materials used in each which thoroughly mixes on the first floor.
done on the second floor. mixture are dumped into a the materials and empties
The various "Nauta" type to conveying
raw mixer carts
After the materials are mixed they are taken to preform stations where initial forming takes place. Preforming consists of placing a pre scribed amount of mix into a mold and pressing with a hydraulic press until the materials cling together as one mass.
Following the preforming operations, the brake blocks are placed in a hot press for a period of approximately two hours. Hot pressing serves the purpose of allowing the resins to further bond the materials into a rigid body.
Finally, the blocks are ground to the proper thickness, drilled with the proper holes, inspected and packaged for shipment. Blocks are labeld with a brander machine.
B. Extruded Brake Linings
Extruded brake linings are made in the following steps:
1.
Raw Material Mixing Grinding
.
2.
Extruding
3.
Baking .
4.
Cutting
5.
Final Curing
6.
Final Grinding and Drilling
Raw material mixing is done in a manner similar to dry process lining productions, the only difference being that oils are added to form a damp paste. After the materials are mixed, they are emptied into conveying carts on the ground floor.
After mixing, the raw materials are extruded in the form of a tape which is wound into a coil. The coil is then placed in an oven for initial curing.
Following the initial curing operation, the coils are surface ground and cut to length on band saws. Depending on customer specifications, the lining may undergo another curing operation.
Finally the linings are drilled with the proper holes, finish ground, inspected, and packaged for shipment.
C. ABK Industrial Bearings ABK industrial bearings are special wear and heat resistant bear
ing made by the company. The bearings are made by first impregnating a cloth with various resins and then winding this cloth or hot press ing it to form the product. These bearings are used quite extensively in iron and steel foundries.
SURVEY PROCEDURES
The main purpose of the asbestos dust survey conducted at the plant was to evaluate the asbestos sampling technique currently used by the U.S. Public Health Service. To do.this, simultaneous samples were taken C85 pairs on the same side of the man and 23 sets on opposite sides) to check the reproducibility of the asbestos sampling under field conditions with relatively low concentrations. The majority of the sampling was conducted at the same machines in the cutting, grinding and drilling of auto linings for three consecutive days on the first and second shift in order to also supply data on variations of concentration of asbestos with the shift and day of week. The remainder of the samples came from the preforming and hot press, areas. A special study was done to determine the effect of heavy background on sample results.
A preliminary industrial hygiene survey of the plant was also conducted to try to evaluate general housekeeping and ventilation systems..
INSPECTION OF THE PLANT
Potential Health Hazards: The major potential
were;
1. Exposure to ashestos dust
2. Exposure to lead from mixing operations
health hazards
encountered
Caution needs to be exercised toward some of the raw materials (see Table 1) that are encountered. Indiscriminate use of such things as carbon black, litharge, and hexamethylenetetramine would be haz ardous. Also, noise levels could be excessive in some areas.
Personal Protection: Hie only worker in the plant seen wearing a respirator was in the hot press area. Safety clothing such as rubber aprons and ear protection are provided where appropriate. Safety glasses are required of everyone inside the manufacturing area. There is a program to finance the purchase of safety shoes, but this is voluntary.
Ventilation: Local exhaust ventilation is used quite extensively with ductwork at almost all operations. The contaminated air is vented to 22 American Air Filter "Roto-Clone" type "N" wet dust collectors with a total design capacity of 314,740 cfm. Design specifications are given in Table 3. None of this air is recycled. The sludge from the wet collectors is taken through, a series of three settling ponds to clear the water. A pumping station is located at the last pond to recycle some water. The water is evaporated and absorbed so none of it is allowed outside company property. Sludge is cleaned from the ponds about once a year and piled in mounds on company property.
Mcblcc- up
Fr~'" A'
V > i+ UUW
n J W U
, r r h "f"
WJ I W U
1 ^
I
pressure inside the plant. The- total capacity of the make-up air is
155,000 cfm from 10 units.
Ventilation layouts of areas sampled during the special survey are shown in diagrams 2 and 3. Table 4 gives the results of the ventilation survey.
The method used to make the mixes is good in that raw materials are not handled by hand. A cart goes down a rail and under a series of hoppers each containing a part of the mix. The mixer stops the cart at the appropriate hopper and puts in that chemical. Each hopper is ventilated individually. The nice part about this system is that the chemicals are loaded by vacuum lines into the hoppers. Unfortunately asbestos cannot be included in this method since it is not a loose powder and is broken into the mix cart at the end by hand.
It appeared that the collection and disposal part of the ventilation system is adequate and performing as designed, but improvements could be made in the duct work and especially the hooding. The duct velocities are quite high, but more emphasis should be placed on using enclosed or flanged hooding as near the source of dust evolution as possible.
Housekeeping: In general the housekeeping was good. There is usually sufficient space in the aisleways. Painting and a general cleanup was in progress during the time of the survey. Brooms and a large vacuum floorsweeper were used for cleaning. The major problem in housekeeping was the frequent use of compressed air to blow off machinery.
CONCLUSIONS AND RECOMMENDATIONS
From this and past surveys, it appears that the areas of potentially excessive asbestos dust exposures are the mixing and preforming areas. The following are recommendations for some changes which are necessary to improve conditions at the plant:
1. A method needs to be developed for loading asbestos into the
mixers which would eliminate hand loading. Until such a method
is developed, asbestos mixers should wear Bureau of Mines approved
respirators.
I12*4
2. Ventilation improvements are indicated at the preforming stations.
One such improvement would be to place hoods closer to the area of
dust generation and use a more enclosing type hood. Another method
would be to automate the block preforming operation as has been done
for disc brake preforming.
. 3. More make-up air should be provided to prevent ventilation systems
from being starved for air.
4. Once the modifications have been done on the ventilation systems
and the systems are balanced, all blast gates should be welded in
position to prevent them from being altered.
TABLE #54321
1 2 3 4 5
APPENDIX
TITLE
Potentially Hazardous Raw Materials Abbreviations Used in Ventilation Diagrams Dust Collector Design Data Results of Ventilation Survey Results of Past Surveys
' FIGURE
1 2 3
' TITLE
Diagram of Plant Layout Ventilation in Preform Area Ventilation in Finishing Area
TABLE I
POTENTIALLY HAZARDOUS RAW MATERIALS USED BY
ABEX CORPORATION AMERICAN BRAKEBLOK DIVISION
Asbestos Fiber Litharge Lead Powder Hexamethylenetetramine Phenolic Resin Polyrez Resin Paints Carbon Black Coal Zinc Dust & Zinc Powder Nuisance Dusts '
TABLE I I
ABBREVIATIONS USED IN VENTILATION DIAGRAMS
Abbreviation
DP EG MD PF R S SG
Meaning
Drill Press Edge Grinder Multipress Drill Preforming Station Ripper Band Saw Surface Grinder
The following ventilation diagrams use the above codes and denote where the sampling was done during the special survey at Winchester in the preforming and finishing area.
TABLE I I I
W IH CKESTER DUST CO LLECTO RS
E N G IN E E R IN G B U L L E T I N - -149
S e e PP.-W 404
OC *rl
D epartm ent
- CJ
-U
S e rv e d
o
p
q
EG7 S trip i B a lco n y F in is h in g
5J K 6
2n d
K
6J I -.7 ii Q 2nd ! fa'J-:C9
II We t
! 4- 2nd
!
n j r .9
Com pounding
1 5 2nd
O ld ie )
1 ^ i '*
b .ik 9 2n d
;;ry Com pounding
i
100:111 B l o c k
V B a lc o n y Com pounding
IC 'D n l 1 B lo c k o B a lco n y P re fo rm in g
i
B lo ck
! 9 6Z Z A 7 . F i n i s h i n g
j !~
16:0-17 A . r.1. ?r.
1 13P Q 14 P i l o t ..
J! 12 2n d
Pi nn t
T 3: u r c ~ C o a l
13
G rin d in g
1 12.1C A E 1 s B l a n k e t
! m i TzH ti ! `-1 1 GZZA7
! ic
ii
/ZZ;vo
i 17
Ij -r n 1 i0
o C i)/ Ba lco r.y
P rc co n n in g C lo ck F in ish in g
B lo ck F i n i s h i n [:__ a ld e r F in i a ilin g bcnp F in ish in g
1j1 ]1C',.
i B ia m ca t ' P re fo rm in g
P-I
16N 60 11 60
i: 50 it 50
2W AO 16N 50 16N . 60 16N 60 16N 50 20N _ 75_ 12W 10 6N 15 1.6M 50 3.6M 50 7.0N 60 2ON 60
1 2CM 60
* J1 16M !50
M otor t^ d
1200 1200 1800 1800 1200 12C 0 1200 1200 1750 1750 1160 1725 1750 865 1750 1750 1800 1800
Type & S iz e j B lo w p i p e i]
I n s t a l l e d i|
COl ~"""-
Fan
r-J
-60 pu* fc--?1 .'**t
2
o
|
a
?-
ru ,
P-l
8 * H O pi
d
75 18 10A 2 16.000
70
10A 2 16,000
66
1039 16,000
60
1015 15,000
1A 30 9,200
65
107 A 15,000
65 8 1160 15,940
65 8 1008 16,500
63 17 1060 16,000
90
... 11.2.1_ 22,000
12
7.150 3.000
14
A 80 5,500
65 16 10A 2 16,000
52 17 1039 16,000 68 17 _ 1071_ 2.0 , Q00 58 17 1073 20,300
18 1073 20,300
55 16 1042 16,000
3 -OO4 4<-L dto 4J -oH Mci cCc CO rC-ti 4rJj ud /: f~<u`.\ J--d\ cuo --- 1r
Pump
r*0"14 p i CO s i
6.15
2L 6- C D 0 5
6 .3 4
B - 6-6 5 _ "
6 .0 1 2L 6-C D O 5
3.5
B - 6-6
3
5 .4
G ra v ity
5 .0
B - 6-6
5
5 .2
K
2
3.6 4 B - 6-6
5
7.2 5
,6U 2_ . .8 4 .1
G ra v ity D rag Out
G ra v itv
6 .0
2L 6- C D 0 5
4 .8 6 7 2L 6-C D Q 5
3.88 9 G r a v it v
5.84_ .1,6 G r a v i t y . 5.04 6 G r a v it v 6.42 1/7 2L 6-C D Q JC
5 .4 2 10 |v2:L 6.-*^J`|-C'DQ: 5
S' *
i-- ! .
1J R S ! F ile !' #
--Uo< -tc1-oi uC oo CVZ
1.200 ! --1IT* j
950 ! - n e
'
li
1800 i!i - 11D n
1800 - l i
.
.
. . ..
`i
-n
950 j - l i
1200 - n .
1200 - 11F
. -H E
1- 11.A 1
-9
U 228 Sh 6
r
W228 Sh 3 K 228 Sh 4
1800 -10
W223 1200 -14 S h 3
-15 1i
-16 ;! .......
.- --16A ; ' .1200 1- 16B-
H
IT W228 Sh 5
It
1200 j - 16C II
ou tC' H C
1 gO - sd t
ri*
rn--i an
c--
p
W405
S h 2A-3 170
W405
Sh 2
' 70
W405
S h 3 '70
M214
S h 1 '55
W219
Sh 2
'55
*55
W405
S h 19 '55
W405
S h 13 '67
M405
S h 14 : 67 W405 ^ /
S h I n ' 67
W266
Sh 7
`_53
,
' 59
W405
S h 7 '67
1)405 .
S h 14 '67
1 l
II '.7503 Sh 2 T405 Sh 7
' 67 -- L 6.Z_
'10 '67
U o
r3 c;
J 1--1
tn!
(OJ c
*r--il ACCJ r J
pO 1--c1 0 i
.ill!
,_ 1 L 1
'60
:
'55 3 :i
If 4 :!
'55 ! 5 ij
' 55 5 1 /!
. 60 7 j
7_/5_5 . 3 ! il
' 6--4-- i 9 i ' 65 10 '*ii
!i ...335 14.J2IB J|,1!|
' 59 -- 1i 3 jI
163 141! ' ii
' 63 -- 1--5-->`*f
..'.6. 6..
' 66 -- --- : 70
'66
L a*i,( 17 - l l :| 1 8 1J
Collector #
Location
TABLE I I I ( c o n t i n u e d )
Type
Motor H.P.
Fan C.F.M.
Design Inlet Static
20
New Addition
16 N
50
16,000
4,69
21
Metallic Sintering Building
4 N
4,000
2.50
22
New Addition
20 N
60
20,000
4 -6
Total Desig-aed Exhuast Volume - 314j 740 cfm
TABLE I V
RESULTS OF VENTILATION SURVEY
Machine
Machine Code
,
'
0 0 yP8
Volume CFM
Duct Diameter
Vented to Collector #
Multiple Drill #4 Multiple Drill #5 Multiple Drill #6 Drill Press #5 Drill Press #8 Surface Grinder #4
Edge Grinder #1 Surface Grinder #5
Surface Grinder #6
Lining Ripper #1 Cut-Off Saw #1 Cut-Off Saw #3 Cut-Off Saw #4 Preform Station #1
Weigh Station Overhead Preform Station #20 Weigh Station Overhead
MD- 4 MD- 5 MD- 6 DP- 5 DP- 8 SG- 4
EG- 1 SG- 5
SG- 6
R - 1 S -1 S -3 S -4 PF- 1
PF-.20
Underneath Underneath Underneath At Drill At Drill Wheel Underneath Underneath At Wheel tUIwl,lUJ V----X-----U----V- c llU At Wheel & Underneath Underneath Blade & Underneath Blade Underneath Blade Underneath
Slot Grate
Slot
"
Grate
315 438 411 151 151 223 751 771 680
--
813 1297
522 1269
166 416
250 700
5"
2
5"
2
5"
2
4"
18
4"
18
4" 18
6"
6"
18
7"
18
7"
18
5"
2
5"
3
5"
3
5"
3
1 " X 15" 10" X 15" . 19
1 " X 15" 19
10 " X 15"
I
: - 3 'T
Sivlii' 8
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r*',{
H
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9
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w
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8 .aspic i-
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Mixing & Contini; Cent inued
Auto R oller Oper, -- I'arsenal (Co:n td .)
Hand RoHer--Personal
Sleeper--Personal
Service l'an--Personal Q uality Control--r e n e ;iuH.
Prefers:--?ers m a l
Forcing
Hand R o ll Operator--3S
13?
c,h
Radius R oll--r
353
C.ii
291
0.6
Personal
Prol'orr. Cpcrntor--BZ
&
1.3
137
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0.1 0.3 0.0
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210
25.0 0.9 0.1
211
n.9 1.6 0.U
212
2.-1 0.5 O f;\J
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2 Hi
1.1 0,1
19
0.6 0.6 0.2
20
0.7 0.6 C.h
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-} y.1.0 0-3
7
i.li 1.0 0.6
1!i0
2.5
0.6
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2.7 2.0 1.0
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1 .5 0.5 0.3
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3.1
1.0
133
7.6
1,6
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Inni:
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nppcf
Forcing (Confr&d)
rroXorn Cper-atesWiS
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Ui7
1.9
13
0,li
176
3.?
Percenal
-
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Hand Holl Cperctor-~3Z
13?
indivis Roll-- HZ '
.
353
2?1
Personal
i
Prefera Operator--- !
Si
137
Ui7
.
162
176
0.U 0,!> 0.6
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carpio #
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177
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155. -1 il'!.
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2,9
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293 297 3'-i3
12.9
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0,6
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2.7 2.0
U.2 1.4
1.5 0.5
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52 133
U3
163 177
3.1 7.6
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11.05
3.6
1 .0
1.6 H.5
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American Brake Shoe Ccsnoejiy
Operation
Ini?:*'T*V*
Ssrrple #
Kppcf
4
4*4 *
Ko:- e r m o Fx.!
S a n i e ,{' Total
>> <" I0 (
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F o m i n s (Continued) F r e i e m Operator-**Personal
Kot Pressing
.
S'-ocper-- Pcrcoril
Scr\'iccaan~-?ci'sor: el
Cinehirr; F o m s ^ P c r s c n a l (l'era Ititi'.r)
/J5X S Veos Cper.-B3
Book Pres Ooor-- 153 (Iloi).
Personal
Service lan, Kot Press
S* 165
1 ii2 . M
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157
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7.1 6.1 2.7 r* 1.7 1.0
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2.7 1.4 0.6 3.7 1.4 C.5
5
American BrsHc Shoo Carpcarr
Operation
V>r`*.V*
Earsple it. isppcf
Hot Froosir ( Continued )
Hob J^eso 0por.~32 Personal
63
1.0
73
0.1
'
Hairing
Oven C/p';r*~*-3'j Ctsrveyov
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O.u
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