Document DdmzdzX6kpQgBpR4rmG5q7aeQ

FILENAME: Flintkote (FLK) DATE: 1969 DOC#: FLK059 DOCUMENT DESCRIPTION: Internal Report - Report of Investigation: The Flintkote Company-Tiletex Plant - American Liability Insurance Co. if AMEI u :'.' 1UAL LI ABU-HT INSURANCE COMPANY REFORT OF INVESTIGATION THE FLINTKOTE C0.3?ANY - TILETEX'PLMiT KcKinley Avenue Chicago Heights, Illinois I I I By Leon D. Horowitz Chief, Industrial Hygiene Section ENGINEERING DEPARTMENT S E X H IB IT ^ * l(o IIf4/O-IO2K.H-*. ACiaiCr.JLZDGEKSNT The author of this report wishes to acknowledge the courtesy extended to him of Ur. E.A. Opila, Plant Manager, and Mr. Fred Swansop, Assistant Plant Manager, during his visit to this plant on March 10, Hfril " He also acknowledges the help given to hir, during this study, of Mr. J. T. Crista of the Chicago Office of American Mutual Liability Insurance Company. PURPOSE To evaluate the control of the potentially hazardous dusts, esbestos, talc, and limestone at the floor tile manufacturing operations. Keither the visit of our representative under the terms of our policy nor the making of this report constitutes an undertaking to determine or warrant .that your premises or operations are safe. CONCLUSIONS Airborne dust concentrations were excessive in the Scrap Crinding Area and at the Ho. 7 Dry Mix Feed. ' ANALYSIS OF ENVIROIS-ZNTAL DUSI J Air samples for dust count were obtained in tte Scrap Crinding Area and the Dry Mix Peed hoppers of No. 1, 6, and 7 lines. The results of these dust counts are shown on the attached Air Analysis Table. The Threshold Limit Value (T.L.V.) of 14.0 million particles per cubic foot (mppcf) is based on the formulation of toxic mineral dusts going into feed mixtures. Although approximately 3 to 5 bags of pure asbestod are added to each bctch at the feed stations, it is of short duration and the batch loadings are intermittently spaced rather than continuous. Sox: investigators might apply the more stringent T.L.V. of 5.0 mppcf (or the newly proposed 2.0 mppcf). However, It is our opinion that the exposure observed does not warrant such strict interpretation. Note that the three air samples which did not exceed the T.L.V. of 14.0 mppcf were also close to or below the T.L.V. of 5.0 mppcf used for asbestos alone. DESCRIPTION OF PROCESS AND DUST EXPOSURE Dry Mix Feed to Tile Machines , Number 6 and Number 7 Dry Feed Mixers are loaded from raw material paper bags through hinged doors at the top of the mixers. Two-inch slotted hoods at each end of each pair of doors provide 350 feet per minute slot velocity. Thus, the air movement at the front of the feed opening is less than 100 feet per minute and Is, therefore, inadequate to provide the required control of dust during dumping. I These slots have been damaged by heavy bags, etc., and are, therefore, restricted at several points. The Dry Mix Teed for the Chip Manufacturing Line (Specialty Line) is controlled by a large enclosing hood with duct take off at one end with very lev air move* csent into the duct (200 feet per minute air velocity), therefore, providing practically no air movement for dust control at the feed opening when bags are dumped into the mixer. Scrap Grinding Area All reject and waste tile are brought to this area in steel drums for grinding and eventual use in the tile manufacture. The drums are dumped, by mechanical means, into a hopper and belt-conveyed to a grinder after which it'is belt-con veyed to bins at one end of the room. Although some dust collection is provided, it is very inadequate. The drum dumping created a great deal of dust as does the grinder, belt- conveyors, belt transfer points, and belt dumping into the bins. Employees do not wear dust respirators during any of these operations. RECOMMENDATIONS <> 1. The exhaust slots at Do. 6 & 7 Dry Teed Mixers should be repaired and the exhaust volume provided by the dust collecting system should be increased. One method to provide adequate air velocity control of the dust created at this location is to provide slots at both sides of each feed opening Instead of across two feed openings. This method is used at the Tile-Tex plant in Mew Orleans where air velocities provided at a similar slot-type exhaust hood was much greater than at this location. The door hinged at the rear between the two slots on both sides effectively helps provide an air velocity away from the operator and dumping operation. Another effective method of providing adequate air velocity for controlling dust at this dump operation is to exhaust air directly from the mixer whenever the doors are opened. This would provide an inward movement of air vhich could effectively prevent the dust from rising up to the operator's breathing zone. 2. Although dust counts were not excessive at the .Dry Mix Feed dumping operation for the Chip Manufacturing Line, exhaust ventilation at both dump hoods should be Improved. This would require an evaluation of-the dust collecting system . which is not providing adequate air movement and a better hood enclosure. The hood opening should be made smaller so that the inward air movement provided by an improved dust collecting system would be most effective at the source'of dust contamination, namely at the feed opening of the mixer. 3. It appears that a new dust collecting system must be provided at the Scrap Crinding Operation. The drum dump hopper must be completely enclosed end ventilated to prevent dust from escaping Co the room air. All belts must be enclosed and provided wich exhaust ventilation to prevent dust escape to room air. All beltd transfer points must be redesigned to prevent spillage 4 3 and exhaust hood enclosures oust be used at these points to prevent escape of dust to the room atmosphere. The grinder must be enclosed or provided with exhaust ventilation to prevent atmospheric contamination. The bins must also be vented to the dust collecting system. This dust collecting system should include a cloth bag-type dust collector with automatic shaking device and provisions to return collected dust to the manu- lecturing process if so desired. Exhaust air must be discharged to the outside. 4. All operators exposed to dust concentrations vhich exceed the established T.L.V. must wear only respirators approved by U.S. Bureau of Minos for pneumoconiosis dusts. A respirator progran{ to maintain and keep individual respirators clean,, must be instituted. 5. Annual (as well as preemployment) chest X-rays (14" x 17") must be made on all employees working in toxic dusty areas. 6. Housekeeping must be maintained in the Mixer Feed tareas as well as the Scrap Grinder Area. 1 ; ATR 3-10-09 PLANT F l l n t k o le - T iletex r ia n t _____ _____ __ LOCATION ..ffSKAnley Ave . , Chicago Heig h t s .IT Tme Mint. AIP. A N A L Y S I S T A U L E Location and Eventa Asbestos, Talc, Lineatone, Mixture Concentration (C) 10______ Breathing ".one Scrnp Grinding Area 26.7 10______ Cenerai Air Scrnp Crine* 1ng Area 27.0 * 10 I Dry Kix Teed - No. 6 5.3 BN-25 BN-16 BN-26 10______ Dry Mix Feed Mo. 7 Manual Shoveling in Calendar 10 I No. 1 Line Calendar Roll 10______ No. 1 Line Dry Mixer (Room! 19.3 2.0 4.0 Threshold limit Volue A--Mittirami per Cubic Meter B-- Parti per MiRion C--.Miltion Particle per Cubic Foot 14.0 tnppcf * - Exceeds T.L.V.