Document DMBzO3JeB9vGeZMjNryQnagja

FILE NAME Brakes BRK DATE 1972 Aug DOC BRK206 DOCUMENT DESCRIPTION NIOSH Report - Air Sampling & Industrial Hygiene Survey - Rayloc AIR SAMPLING INDUSTRIAL HYGIENE SURVEY GENUINE PARTS COMPANY RAYLOC DIVISION ATLANTA GEORGIA Survey Conducted By JOHN M. DEMENT PATRICK J. SHULER Report Prepared By JOHN M. DEMENT PATRICK J. SHULER Division NATIONAL Environmental Investigations Branch of Field Studies and Clinical Investigations INSTITUTE FOR OCCUPATIONAL SAFETY & HEALTH 1014 Broadway Cincinnati Ohio 45202 August 1972 GP0004492 INTRODUCTION During the week of July 17-21 1972 an industrial hygiene survey and air sampling for asbestos and lead dusts were conducted at the Rayloc Division of the Genuine Parts Company Atlanta Georgia From the sample results and 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 west of Atlanta and employs approximately 540 people operating on three shifts Of these workers about 50 come into contact with brake linings or clutch e facings on a routine basis This facility was constructed by Genuine Parts Company in 1959 for the purpose of rebuilding , various automotive parts The plant is enclosed under one roof * additions having been made over the years to the original plant site GP0004493 PLACE VISITED Rayloc 4200 Gordon Road Atlanta Georgia Phone # 404-691-3780 DATE OF TRIP July 17-19 1972 PERSONS MAKING TRIP : John M. Dement Patrick J. Shuler PERSONS CONTACTED PURPOSE OF TRIP Mr. Edward Kipling Plant Manager Nr Thomas Damiel Production Manager To conduct an industrial hygiene survey and take asbestos and lead dust samples In the plant GP0004494 Genuine Parts Company provides consultation consultation to assist Rayloc and their other divisions with any safety and industrial hygiene problems These services are also provided by Sentry Rayloc's insurance company The production manger is responsible for safety in the plant and is chairman of a five member safety committee which meets each month The union Teamsters Local . 528 is also actively involved in the safety program in the plant The medical program consists of local physician retained as a time consultant and workers trained in first aid who are always in the plant A employment physical is given which includes a chest ray and blood and urine analysis _ No pulmonary Function tests or further physical examinations are given Products of the plant presently include rebuilt starters generators alternators water pumps fuel pumps clutch pressure plates and relined clutch discs and brake shoes Clutch disc and brake shoe relining has been done here since the plant opened , X in 1959 ' DESCRIPTION OF THE PROCESSES The processes sampled were the relining of riveted and bonded brake shoes and clutch discs GP0004495 A. Brake Shoe Relining The used brake assemblies are first sorted according to size The old worn linings are removed next Riveted linings are sheared off and bonded linings are burned off Next the shoes are degreased by heat if necessary then cleaned in a Wheelabrator which uses high velocity steel shot to abrade the surfaces The shoes are then dipped in a corrosion inhibitor and straightened if needed Next the new linings are either riveted or are bondetdo the shoe All relined assemblies are then surface ground to provide the correct radius of curvature The finished products are given a final inspection and packed for shipment B. Clutch Disc Relining The used clutch discs are first wheelabrated with the old friction pad still on to insure that the thin metal torque members are not damaged Next the old friction surface is removed by deriveting the clutch disc with either a drill drill or punch press A new pad is riveted on the disc the whole assembly is inspected and boxed for shipment . SURVEY PROCEDURES The actual sampling for asbestos fibers and lead dust was confined to the brake and clutch rebuilding areas since these GP0004496 were the only areas using these materials No other potential exposures were noticed in the rest of the plant with exception to toluene in the starter rebuilding rebuilding area Personal samples were collected on workers at each of the steps in the process of relining brakes and clutches in order to determine which jobs if any pose potential health problems Samples were collected on a Millipore Type AA cellulose ester membrane filter at a calibrated flow of 1.7 minute . The type of pump used was a MSA permissible personal air sampler Analysis for asbestos fibers was done by counting fibers greater than 5 um in length under a phase contrast microscope at a magnification of 430x The amount of lead was determined by chemical analysis on the same filters as the asbestos concentration was evaluated An industrial hygiene survey of the plant also conducted to try to evaluate general housekeeping and ventilation systems . LY INSPECTION OF THE PLANT . Potential Health Hazards The potential health hazards which were noticed during the Survey are as follows follows _ GP0004497 1 Exposure to asbestos dust during brake and clutch relining 2 Lead exposure from lining materials during brake and clutch relining 3 Toluene exposure during Insulation coating of various various armatures Measurements were made of both asbestos dust and lead exposure In each of the friction operation . exposure were made No measurements of solvent Personal Protection Safety glasses are required in certain areas of the plant Approximately 40 of the plant employees wear safety glasses Respirators are not required in production operations however respirators are required when cleaning or repairing the bag dust collectors Safety shoes are not required but the company does have a program to aid in their purchase A noise study has been conducted in the plant recently by Sentry Insurance Mr. Kipling indicated that the only operation near the 90 dba present standard was grinding No hearing protection is required at the present time os Ventilation Local exhaust ventilation is provided on all 3 brake lining grinders and on all 5 Wheelabrator cleaning machines These machines are vented to 6 Wheelabrator bag dust collectors GP0004498 Figure 1 shows a layout of the friction products area of the plant along with locations of the dust collectors and their respective capacities Velocity measurements at the entrance to the grinder hoods showed velocities ranging from 600 fpm to 1100 fpm No ventilation is provided at the clutch deriveting operation Housekeeping In general the plant was quite well kept with sufficient sufficient | room to minimize overcrowding All Floor cleaning is done with vacuum sweepers on a continual basis Compressed air is used for cleaning but all outlets have low pressure nozzles Results and Discussion The results of this survey are presented in Table 1 The present standard for asbestos was published in the Federal Register on June 7 1972. In essence the standard is as follows The hour weighted average airborne concentration of asbestos fibers to which any employee maybe exposed shall not exceed _ five fibers longer than five micrometers per cubic centimeter of air as determined by the membrane filter method at 400-450x magnification 4 millimeter objective phase contrast illumination No employee shall GP0004499 be exposed at any time to airborne asbestos fibers in excess of ten fibers longer than five micrometers per cubic centimeter of air On July 7 1976 a new standard of 2.0 fibers greater . than 5 micrometers in length per cubic centimeter of air will be effective None of the 45 samples exceeded the present standard for asbestos the highest value being 4.8 fibers fibers greater than 5 micrometers in length per milliliter milliliter There were only three samples that exceeded the future asbestos standard of 2.0 fibers All of these samples were taken on person deriveting old clutch facings by drilling out the rivets A total of four samples were taken at this operation the mean being 2.6 fibers Surface grinding produced the second highest average exposure its value being 1.4 fibers All other operations had an average value at or below 1.0 fibers a . Lead concentrations were very low except for the clutch deriveting and brake shoe sorting operations The present standard for lead dust exposure is 0.15 mLead results are also given in Table 1 GP0004500 Sy CONCLUSIONS AND RECOMMENDATIONS From the sample results and the industrial hygiene survey the following conclusions and recommendations are made 1. There was no operation that had asbestos exposures in excess of the present standard of 5 fibers The only operation in excess of the future standard of 2.0 fibers was the removal of old clutch facings by drilling This operation also had lead exposures in excess of the present standard of 0.15 mg Particle size estimates of the lead particles has shown that 80 of the particles were less than 3.5... in diameter and would therefore by respirable Due to the high lead exposures local exhaust ventilation should be added at these drills immediately 2. Lead concentrations in the old shoe sorting operation were also above the present standard of 0.15 mg Particle size estimates on these samples has shown that 85 of these particles were smaller than the 3.5 respirable diameter The high concentrations appear to be the result of brake lining wear dust clinging to old brake shoe assemblies Our past experience has shown that most wear dust contains approximately _ % lead by weight Two possible solutions to this problem would be to either first wet or vacuum off the brake assemblies before sorting GP0004501 3. There was a detectable toluene odor in the area of the armature dip tank Although this odor was present it is highly 4 possible that toluene concentrations are well below the present standard of 100 ppm the odor threshold for toluene is only 2.1 ppm In any event toluene concentrations should be determined for this area and local exhaust ventilation installed installed If levels are found excessive 100 ppm 4. Due to the elevated lead exposures found in the brake shoe sorting operation and clutch deriveting operation blood . lead levels should be determined for workers in these areas A program of periodic blood lead checks should be established GP0004502 REFERENCES " Edwards G.H. and J.R. Lynch The Method Used by the U.5 Public Health Service for Enumeration of Asbestos Dust on Membrane Filters Am Occup Hyg 1-6 1968 2 Keenan Robert etal The U.S.P.H.S. Method for Determining Lead in Air and in Biological Materials Am Ind Hyg Assoc Journal 481-491 1963 Interoffice Report on Garage Lead Exposures March 16 1972 GP0004503 . FIGURE 1 FRICTION PRODUCT LAYOUT WITH COLLECTORS " DEBONDERS . WATER PUMP : ome . Ront Lo. FRAKE SHOE ASSEMBLY F=> |\ | - 152 COLLECTOR COLLECTOR CAPALITIES 1-6250CFM 1-6250CFM 2-1600 2-1600 18 3-1100 3-1100 A 1100 " S- 1600 11 6-1600 6-1600 oy. GP045 STORE CLUTCH |- DEPT DEPT CLUTCH DIX SUP DISASY Ore. j DELAY Lica 4 HOLD +