Document LJGK50QL1pnypk1Y8z0aRLVwQ
ENGINEERING REPORT for
Certain Teed Products Company
Pipe Plant
Ambler, Penn.
^
e$0i,
Asbestos Evaluation
^g
prepared by
Robert C. Benafehski The Travelers Insurance Cos, One Tower Square Hartford, Conn. 06115
J
Date(s) Surveyed December 13th and 14th, 1977
THE TRAVELERS ENGINEERING DIVISION
PLAINTIFF'S EXHIBIT CT-1215
Engineering Services Protecting People and Property Since 1894
C-1 7 i 6? 1 Ppintco in u.S.a.
CTD018600
1. Distribution; 1 cc Asst Claims Mgr. Syrek - Philadelphia Claims Dept. 1 ec Eiig. Acct. Mgr. Wilms - Philadelphia Engineering 1 cc Certain Teed 1 cc Sect. Hatch, CP Claim, H.O. 1 cc File (H.O.) 1 cc Reg. Asst. Yekenchik - CP Claim - 8 PB
CTD018601
TABLE OF COMTENTS Introduction Summary Discussion of Results and Evaluation 1. Crusher Operation , 2. Fibre mixing 3. Boring Mill (JO") 4. Coupling cutoff saw 5. Lehman Short Lathe 6. Rework Saw (dry) Sampling, Analytical Procedures and Standards A. Sampling Procedure B. Analytical Procedure C. Standards Data A. Industrial Hygiene Survey Data Sheets B. Laboratory Analysis Results
CTD018602
3
I. INTRODUCTION
On December IJth and 14th, 1977. the Certain Teed Pipe Division Plant in Ambler, Penn., was surveyed. The purpose of the survey was to determine if the plant workers were exposed to asbestos as a result of their work environment.
Our Home Office Claim Department requested we survey this location to determine the extent of asbestos exposures to the plant workers. This in-plant air sampling and survey of operations was done during the days of December ijth and 14th, 1977, and completed by the following Travelers' representatives:
L. Wilms, Eng. Acct. Mgr. - Philadelphia Eng R. C. Benashski, Asst. Dir. - H.O. Eng.
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II. SUMMARY
Air samples were taken in the workers breathing zone and collected on membrane filters of 0.8 micron pore size mounted in an open face filter cassette. The asbestos fibres longer than 5 microns and with an aspec-1" ratio of 3:1, found on the membrane filter, were counted by phase contrast microscopy at 450 magnification
Swipe samples using a membrane filter, were also taken of selected workers clothing to determine whether their clothes were contaminated with asbestos.
Samples of settled dust were taken at selected operations to determine the presence of Asbestos fibres and also the percentage of quartz in the settled dust.
t
General area samples were taken for respirable dust at two locations to determine the concentration of respirable quartz dust near the operators work area.
Workers are exposed to asbestos fibres in the workplace as well as taking contaminated clothing home, since no change of work clothes was observed at this plant.
We met with Plant Manager Benhardt for a short time before and after our survey.
Mr. Magers, the plant engineer and safety manager accompanied U3 during our entire sampling program.
Mr. Arthur Ileilson, an Industrial Hygiene Consultant met Mr. Wilms and I on the second day of the visit for about an hour (11:00 AM to 12:00) and left. He was not observed to have sampled. He represented Fred S. James Insurance Agency.
CTD018603
TABLE I SUMMARY OF ASBESTOS SAMPLES
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6 73 5
Fibre mixer (A. Semioes) Fibre mixer (W. Edleman) Rework Saw (W. Ball) Lehman Short Lathe (J. Silva) Crusher Operation (Gullo) 2nd shift Crusher Operation (R. Johnson) 1st shift 30" Boring Mill (C. Handsekin) 30" Boring Mill (C. Handsekin) Coupling Cut-off Saw (E. Wharton)
00
CM
Asbestos Concentration Fibres/cc
3.4 0.6 ^ 3.9 ^ 5.3 ^ 2.4 0.9 ^ 0.3 0.7
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s-
SA** 'J'f A
Swipe Sample (C. Handsekin) Swipe Sample (R. Johnson)
Settled Dust (Boring Mill) Settled Dust (Vacuum box crusher)
Asbestos fibres present Asbestos fibres present
Asbestos fibres present Asbestos fibres present
4
CTD018604
TABLE II
RESPIRABLE QUARTZ DUST CONCH 1TRATION
ptc viO
1 fAIPJ
8 JA
A 4 Crusher Machine (afternoon)
Concentration 0.61 mg/m^
1A
Crusher Machine (morning)
0.63 mg/n?
1-)A
JO" Boring Mill
0.15 mg/m^
saP A
Settled Dust (Boring Mill) Settled Dust (Vacuum Box-Crusher)
-- -
# Quartz 5-3* 6.1#
12.2#
15# 10#
CTD018605
6
III. DISCUSSION OP RESULTS AND OBSERVATIONS
The Certain Teed plant in Ambler, Penna., is engaged in the manufacture of cement asbestos pipe of various sizes. The operation consists of charging raw materials, cement, asbestos and water to a mixer producing a slurry which is transferred to a pipe machine which forms the various size pipes. They are then dried and cooked in an autoclave and finished in lathes and milled to couplings and fittings of various sizes by saws and milling machines.
Also, scrap pipe material is sent to the Crusher Operation where the pipe is reduced to a powder to be reintroduced in the process to be added to the raw slurry.
1. Crusher Operation
The crusher operation handles scrap pipes of various sizes and feeds them to the crusher to reduce them to a fine dust size for re-use in the pipe manufacturing process.
Two different shifts were sampled on a representative or typical work cycle basis. This is a three shift operation, and shifts one and two were sampled to determine any differences in work styles.
Shift one showed.an air concentration of 2.4 fibres per cc., while shift two average 5*3 fibres per cc. The time sampled was 67 minutes and 55 minutes, respectively. The results are typical of their respective exposures for an 8-hour day since the work style did not vary during the observed process work.
The first shift operator's clothing was swipe tested and asbestos fibres were found on the membrane filter used and analyzed by the phase contrast microscopy technique.
Two general area samples for respirable dust was also taken and both air concentrations were below the T.L.V. (Threshold limit value) or allowable level. However, the quartz.percentage of the dust was found to be over five percent and therefore, a possible silicosis hazard could exist.
Settled dust samples showed asbestos fibres present as well as 10 per cent quartz.
Both of these workers wore street clothes which were obviously contaminated with asbestos fibres. There was no change of clothes before leaving work.
CTD018606
.K
V
Respirators were also worn (3M disposable) but not properly. This is a two strap mask and only one strap was used allowing unfiltered air to-be brought around the chin of the wearer.
Observed was the use of an air hose to blow off the dust on the workers clothing. A broom and shovel were also used to clean up settled dust.
1-A y
2. Mixing Operation
The workers in this operation move various typeB of asbestos bags (--100 lbs) and dump them into an enclosed and ventilated dump station. They are also responsible for weighingS&perations to be sure proper mixing and addition of the asbestos has occurred in the batches.
Two shifts were sampled. A 13 minute sample was taken on the second shift to represent the dumping of asbestos for one batch,
20 one hundred pound bags. The level measured was 3*4 fibres per cc which is below the allowable peak level for a 15 minute period. The first shift worker was measured for 64 minutes at the breathing zone in the morning and the result found was 2.8 fibres per cc.
This was indicative of an average exposure over an hour period during and after dumping and very similar in concentration to the shorter term sample. This would indicate that the average concentration would be over the allowable level of 2 fibres per cc since 8 to 10 batches are dumped per shift.
These workers also wore street clothing and 3 M approved respirators incorrectly (one strap). They were observed using the vacuum system to clean themselves of the dust. Also avail able to them was an air hose which was not observed to be used.
The respirators were stored cup face up on the electrical switches. These respirators had settled dust in them from the process.
3. Rework Saw
Pipe is cut dry for reuse and the operation was sampled for
50 minutes at his breathing zone for asbestos fibre concentration.
The concentration measured was 0.6 fibres per cc. He also wore
street clothing and a
approved respirator. The respirator
was also worn incorrectly (one strap used).
4. Lehman Short Lathe
Dry pipes are finished at the lathe by cutting the rough ends of the pipe. An hour and 30 minutes sample was taken to
CTD018607
1*. Lehman Short Lathe (Cont'd)
represent his eight-hour exposure and a concentration of 3*9 fibres per cc was found on the breathing zone sample. A respirator was not worn during the operation. Also street clothes were worn.
,j
5. Coupling Cut-off Saw
The saw operator was sampled in his breathing zone for one hour and 18 minutes with a resultant concentration of 0.7 fibres
per ec. He wore a yi approved respirator and also street clothing.
6. 30" Boring Mill
Grooves are cut in pipe fittings and two breathing zone samples were taken for 27 minutes and 1 hour and 32 minutes with a resultant fibre count of 0.9 fibres/ec and 0.3 fibres per cc.
He did not wear a respirator and wore his street clothes. A swipe sample of his clothes was taken using a membrane filter and asbestos fibres were found when analyzed by phase contrast microscopy.
Also settled dust was taken from the machine and asbestos was detected in this dust as well as 15# quartz. A general area sample on the machine at breathing zone height was taken for , respirable dust and the concentration was found to be 0.15 mg/m^ containing 12.2# quartz.
EVALUATION
All samples for asbestos were taken in the workers breathing zone and attached to the workers. Samples were taken to represent their ,eight hour-work style, since the workers were at the stations and operating their equipment on a consistent basis except for short breaks. It is felt therefore, the samples represent 8-hour concen trations of asbestos fibres. The fibre mixing operation, Lehman short lathe and the crushing operation personnel are all exposed to asbestos fibres above the allowable 8-hour concentration of two fibres per cc, but no sample revealed a high short term peak (15 minutes) of 10 fibres per cc.
However, all workers are exposed to asbestos fibres as witnessed by the air samples the lowest of which was 0.3 fibres per cc, the swipe samples, observed dust on the workers clothing, and asbestos observed in the settled dust.
CTD018608
9.
Our asbestos air Samples v:ere generally higher than those recorded by the plant who maintains a log of their results.
Though all operations tested had exhaust ventilation, some of the piping had holes in it, the workers tended to lean into the exhaust air and dust did settle around areas of poorly designed exhaust systems. This was evidenced by the contaminated clothing.
The respirable dust samples showed high quartz percentages as did the settled dust. There could be a potential silicosis exposure which should also receive further review and sampling by the plant, on a personal sampling basis.
IV. SAMPLING. ANALYTICAL PROCEDURES AND STANDARDS.
A. Sampling Procedures
Bendix permissible pumps with 0.8 micron membrane filters were used in collecting asbestos air samples at 2 liters per minute at workers breathing zone.
The general area respirable samples were taken with a Bendix per missible pump and size selective cyclone with PVC filters of o.5 micron pore size. The size selector filters out the non-respirable dust at 10 microns and above allowing the respirable dust to be collected by the filter.
Swipe samples of workers clothes for asbestos were collected on membrane filters which are also used to collect air samples.
Bulk samples at various points of the process were collected and analyzed by our laboratory for the presence of Asbestos and Quartz.
B. Analytical Procedures
The membrane filters were analyzed in our laboratory for asbestos fibres longer than 5 microns and with an aspect ratio of 3:1 by phase contract microscopy at ^50 magnification as recommended by OSHA. The % quartz determination was made by x-ray diffraction following NIOSH criteria.
C. Standards
The 8-hour time weighted average concentration of a3be3tos fibres currently permitted by OSHA is two fibres per cc. A ceiling value or peak level of 10 fibres per cc is permitted for 15 minutes. However, OSHA has proposed a rule to lower the above levels to an exposure limit at 8 hours (TWA) of 0.5 fibres per cc larger than 5 microns and a ceiling of 5 fibres per cc for a 15 minute sampling period. NIOSH wa3 requested to study this proposal on December 2, 1975- The resultant criteria document of December 1976 concurs with the above OSHA proposal.
CTDO18609
10.
The threshold limit value for respirable dust recommended by the American Conference of Governmental Industrial Hygienist is developed by calculation based on the percent of quartz found on the filter sample; such that the eight-hour time weighted average is:
TLV (TWA) =
10
% quartz + 2
therefore, a 10 quartz concentration would give an allowable concentration of
TLV (TWA) = 10 = K) = 0.83 mg/m5
10+2
12
R. C. Benashski
CTD018610
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CTD018620
INDUSTRIAL HYGIENE ANALYSIS REPORT
ANAlv^S hC.
.629-77 (16-20)
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ANALYST
MIMj DAR
AA Filters : PVC Filters: Bulk Samples; Svdpe Samples
SAMPLE NUMBER
time
Af/<V
144g
M
LOCATION
Fibre Mixer (dumping) (A. Semioes)
TEST RESULTS
T HREbliOcL/ LIMIT VALUE .1 LVi
Asbestos 2.8 fibers/cc
Asbestos* 2 fibers/cc
95G H Fibre Mixer (dumping) (W. Edlemen)
157G
J
Rework Saw (dry) (Wm. Ball)
152G
10
Lehman Short Lathe (Joada Silva)
Asbestos 3.4 fibers/c.c
IO t/cc.
Asbestos 0.6 fibers/cc
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Asbestos 5.3 fibers/cc
Resp. Part. 0.6l mg/m2
Resp. Part. 1.37 mg/m3
Quartz Less than 5.3#
Resp. Part. 0.13 mg/m3
Quartz Less than 12.3S
Resp. Part. 0.70 mg/m3
ANALYTICAL MCTMOD
Microscopy X-ray Diffraction
*OSHA Limit Page 1
C-15449 NEW 1-72 PRINTED IN U.S.A.
TRAVELERS INSURANCE COMPANIES
HARTFORD. CONNECTICUT
22
CTD018621
INDUSTRIAL HYGIENE ANALYSIS REPORT
AN A L t 5 * V,.
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, 629-77 (16-20)
sample sini et
Certain Teed
OATE RECEIVED
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12-16-77
1-4-78
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LOCATION
TEST RESULTS
1 HREihCLL LILMT VALUC ' T LV1
82P
Bulk Sample of Settled Dust on Boring Mill
Asbestos Fibers Present
Quartz
15#
92G
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50M Boring Mill (C. Handsekin)
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30" Boring Mill (C- HAnoSSKim)
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Asbestos 0.9 fibers/cc
Asbestos 0.3 fibers/cc
Asbestos*
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Swipe Sample of Clothing (C. Handsekin)
Crusher Machine
Asbestos Fibers Present
Reap. Part. O.63 mg/m?
Quartz Less than 6.1#
Resp. Part. 1.23 mg/m?
98g
C.J
Crusher Oper. (R. Johnson)
79A Bulk Sample of Settled Dust on ' Vacuum Box
ANALYTICAL ML1H00
Microscopy X-ray Diffraction
Asbestos
Asbestos*
2.4 fibers/cc 2 fibers/cc
Asbestos Fibers Present
Quartz 10#
*OSHA Limit
Page 2
C-1S449 NEW 1-72 PH IN TED IN U.5.A.
TRAVELERS INSURANCE COMPANIES
HARTFORD, CONNECTICUT
23
CTD018622
INDUSTRIAL HYGIENE ANALYSIS REPORT
AKA I t < m\
| li.K'Lt'
( AL'tpMl is
629-77 (16-20) i
SAMPLE SENT e*
Certain Teed
____________ Ambler, Pa.
DATE RECEIVED
DAli RE PUR ICO
analyst
' ' Benashski/Wilms
RlAl A. . . l C
12-16-77
1-4-78
MTK; DAR
AA Filters; PVC Filters; Bulk Samples; Swipe Samples
SAMPLE number
LOCATION
I' L C V : I L' - , 'j" i iON w I 1
TEST RESULTS
1 HR LbriC.*-C Llf.MT VAIUC T L '
87G
-r i,i/cr
93G
Swipe Sample of Clothes (R. Johnson)
Asbestos Fibers Present
Coupling Cut Off Saw (E. Wharton)
N
Asbestos 0.7 fibers/cc
Asbestos* 2 fibers/cc
I
I I -I
ANALYTICAL MLThOD
Microscopy X-ray Diffraction
C-1S449 NEW 1-72 PRINTED IN u.S.A.
*0SHA Limit
Page 3
TRAVELERS INSURANCE COMPANIES
HARTFORD,CONNECTICUT
2L
CTD018623