Document MG0zzXgNpDxVZ3nRjp86mKewj

PLAINTIFF'S EXHIBIT SS'JSTRIAL KVGISZ SLr.VSf Construction Insulation Shop - Building 511-2 CIS r' Report 63-IH-3-G-1 SUGARS' The Construction Insulation Shop (Building 2C1S), Plant 512 location, routinely fabricates- large quantities of insulation block with ventilated band saws. This core efficient procedure of fabrication has replaced an older, tit* honored, practice of using- simple handsaws to do the job. However, it has, at the same time, created a health hazard resulting from exposure to excessive concentrations of atmospheric dust. The hazard to health has been evaluated and reported oreviously1'* with the result that one material, "Thermobestos" was clearly* identified with the hazard (exceeded TLV) and another material, "Kaylo", was safe to fabricate (within TLV). The present report (the third on this subject) was initiated in an attempt to supply answers to three basic questions: (1) was there any error in the original evaluation cf "Kaylo", (2) can supplementary exhaust ventilation reduce the "Thermobestos" hazard to within safe acceptable limits, and (3) is a hazard to health produced in the fabrication of a third material, i.e., "Carav- Tenp". The information uncovered in the present evaluation reveals the . following facts: \ 1. "Kaylo" insulation blocks can be safely fabricated with the existing equipment. \r^ 2. "Thermobestos" insulaticn blocks cannot be safely fabricated at the present time with existing equipment, .but could be safely fabricated if the exhaust ventilation is improved. 3. The TLV (Threshold Limit Value) for "Carey-Temp" is identical with that established-for both "Kaylo" and 'Thermobestos", i.e., 20 nppcf (million particles per cubic foot) of air. 4. "Carey-Temp" also cannot be safely fabricated with the existing equipment, but ccula be if improvements are made in the ventilation system. 5. The original "downdraft" exhaust ventilation rates, on either band saw, do not meet the reccomended capture velocity rate of 4,000 fpm (feet per minute). 6. The supplementary "overhead" exhaust ventilation ch both banc saws, is an improvement and the rates do meet tha recommended capture velocity rate of 4,000 fpm. i.H. Reports 62-IH-l-C-l'and 62-IK-2-G-1 v~ u * r. lJ'" '-.Tft. rit _______dJjjlUil__ vf " ~ \/ - **v tI INTRODUCTION: r' The manufacturer and Union Carbide's Purchasing Deparrxr.t expressed a great deal of concern about the findings revealed in this initial repcrt when it was uncovered that the manufacturer' s Research Department also had evaluated these materials and was not able to produce results comparable with those contained, in the report of March 1952. That is to say, the sodspheric dust concentrations reported by the manufacturer, when processing !nherrobestcs" insulation blocks, were substantially higher than those revealed in Repcrt 62-IH-l-G-l. This revelation disclosed the need for a more extensive evaluation of this problem so as to resolve all differences of opinion relative to the atmospheric dust exposures inthis environment. This decision in favor of further evaluation, -promoted the production of a much more extensive study than was originally planned, a study which eventually encompassed three separate intervals of dust sampling, analysis, and evalution before all of the unanswered health problems could be resolved. DISCUSSION : Tnese three investigations were actually initiated for the general purposes of tJoth clarification-and identification - purposely-for clarification cf-ohe . . actual hazard to health (if any) connected with the fabrication of three different insulation materials and identification of acceptable measures fcr use in reducing... all exposures to within safe acceptable limits. .However, each investigation, occurred for clearly-identifiable reasons as explained below: The investigation of 24 Jan S3 was conducted because: 1. The Johns Manville Company submitted a report, compiled by their Research Department, which contained data that conflicted with that submitted by this department in Repcrt 62-IH-I-G-l. 2. This'department desired to clarify the reasons for the discrepancy between the two reports and to identify positively, the actual conditions as they exist in the working environment.. The investigation of 25 and 26 Feb 63 was conducted .because: 1. In the preceding investigation, the two insulation materials in question, i.e., "Themcbestos" and "Kaylo,r were evaluated inadvertantly during the same afternoon, a procedure which was not in keeping with an attempt to stimulate the conditions of the original report.. In the original report, each material was evaluated on separate occasions so as to preclude the possibility that any one sample might contain dust produced by both operations. * 4* 2. The "Kaylc" insulation material had to be re-evaluated. 3. The Construction Insulation Shop requested that a new insulation r* material ,*i.e., "Carey-Temp", be evaluated. The investigation of 6 Mar 19S3 was conducted because 1. The Construction Insulation Shop recently had installed supplementary exhaust ventilation on both band saws and desired to know if this additional control method would reduce the "Thertcbestos" dust concentrations to within safe acceptable limits. A comparison of the reasons listed above discloses that each was different in content and concerned actually with different investigations but all were interrelated in part, i.e., each was concerned with the same environment, the same location and the same specific methods of fabrication. Consequently, the sampling procedures,'Utilized in each, instance, basically were identical and in accordance with the following condansed explanation: .. First: Two methods of fabrication,.i.e., cutting and edging, and cutting a.radius, were evaluated at each band saw . since this is standard practice'followed in the' fabrication of any insulation material. in n r Second: The environmental conditions of both preceding reports, i.e., 62-IH-l-G-l and 62-IH-2-G-1, were duplicated in that _ all outside..doors to the building were closed. Third:. 'Each.dust sample was collected in the operator's breathing . rcne'.as he. worked in the fabrication process; - -- Fourth:. The complete fabrication of "Carey-Tamp'.'.insulation blockswas evaluated in two ways: - First, -with all available vantilaticn in operation and second,-with only`the-original downdraft ventilation in operation. Specialized sampling procedures were utilized also during portions of the latter two investigations, in an andeavcr to evaluate the supplementary exhaust ventilation system which had been installed as recommended. These were as follows: First: The complete fabrication'of "Thermobestos" insulation blocks was evaluated in two ways: First, with all available ventilation in operation and second,with only the original downdraft ventilation in operation. Second: The complete fabrication of "Carey-Temp" insulation blocks was evaluated while utilising all available exhaust ventilation. It is necessary to explain that "Kayla" insulation blocks were not included as a part of this evaluation since the initial investigation" (-^rforrad ^ without supplementary exhaust ventilation) disclosed only one exposure exceeding" the TLV of 20 mppcf ef air and, therefore, it could be assured that ny vr.tilati: that eight be added should be mere than adequate in ccntrcliing the hazard EVALUATIONS: ' A. Atrcspheric dust exposures: 1. The concentrations of inhalaile dust, present in the breathing zone when fabricating any cne of the three types of insulation materials, were determined in accordance with the following procedure: a. Three locations and nine different conditions of exposure, as described on Page 9, were selected-for evaluation.* b. Atmospheric dust samples were collected through t'na usa of the impingement* principle of air sampling. .-The midget impir.ger apparatus (described on Page S ) served as the instrument of usa. c. The concentration of dust collected in each sample was established, through the use of standard-light field microscopic counting techniques as described bn 'Page- -5 . J 2. 'The size of the particles of inhaled dust was determined, fer both "Kayla and "Thermobestos", in the initial survey, of 1952 in accordance with the procedure described on Page' 5 : Consequently, no effort was expended tc ' .* repeat the determination for any of. the insulation materials since -the sawing techniques-as'well as equipment, i.e., saw blades with three teeth to the inch operating at 2200 linear feet per minute, were-identical cn both occasions and, therefore, the size of the particles should not ta expected to deviate to any great, degree from, the prior recorded values'. 3. The-composition of. the dust, i.e., percentage crystalline' free silica cr percentage asbestos was determined for both "Kaylo" and "Thermobestos" in the initial survey of 1962. Consequently, no effort was expended to repeat this determination .since the materials used on both occasions, war reported as being identical in composition. However, since the composite of*"Carey-Temp" was not established at any earlier.date it was deemed imperative that -it.be determined and reported at this tine. This was accomplished as described on Page 5. B. Local exhaust ventilation controls: . 1. The velocity of the air being exhausted through tha ventilation hoed openings on both band saws (#1 and #2) was measured through the use of a Model SO Anemotherm air meter. 2.Four variable conditions.of interest were evaluated: a. The velocity of air through the downdraft hood on both saws with all ` other hoods on the system closed off. *This means to strike against, as (in this application) the striking cr dashing of atnesphs * ust particles against the better, cf a small Lmpinger flask containing a specific volume of dust-free water as a collecting medium. b. The velocity cf air through the downdraft hoed on both saws with all other hoods on the system open. c. The velocity of air through the supplementary overhead hoed on both saws with all other hoeds on the system closed off. d. The velocity of air through the supplementary overhead hoed cn both saws with all other hoods on the system open. P.-JEDUPZS: Beth sampling and analytical methods were as follows: SAMPLING: 1. All samples used in determining the actual ccncantraticns in air were collected with a midget impinger apparatus, sampling 0.1 cubic feet cf air per minute through impinger flasks containing 15 milliliters ox double distilled dust-free water. 2. - All samples used in obtaining particle size distribution data were collected cn millipore filters .connected to a smell battery-operated pump. ANALYTICAL: 1. Each dust sample was evaluated through the use of a courting procedure referred to as the light field microscopic counting technique'. - 2. The particle sizing techniques were derived from two separate sources. 7^ First,-the sample-was prepared for sizing in accordance with a permanent mounting.method.+-. Second, the actual sizing was accomplished in accordance with the recomended .technique depicting the use of a filar micrometer and a standard microscope while using_bcth the 4 3X (high and dry) and the 97X (oil inversion)'objectives.* 3. The.evaluation and free silica determination of "Carey-Temp" material was accomplished through the use of two methods'. .-First, through information supplied by ht*. E. D. Ermanc, Director of Researoh'of the Philip Carey Manufacturing Company and second, through contracted analysis performed- by Mr. Thomas M. Durkan, Cnief Chemist for the Trudeau Foundation, Inc., Sarenak Lake, N. Y. RESULTS: See Pages 8, 9, 10 and 11. Drinker and Hatch: "Industrial Dust" 2nd Edition, pp. 152-153, McGraw-Hill Book Company, Inc. New York, 1954. Pautus, H. J., Talvitie, N. A., Frase ', D. A., and Keenan, R. G.: "Use cf Membrane Filters in Air Sampling", A.I.H.A. Quarts ly, Vcl. IS, p. 252, September, 1257. t 'inker and Hatch: "Inaustnal Dust" 2nd Edition, pp. 155-179, McGraw-Hill Book Company, Inc., New York, 1954. CCHCUU5IGNS: Relative to dust exposures from Graph fl Tables on Fages 3 S: 1. "Thermobestos" insulation blocks should not be fabricated whan using cnlv the original downraft exhaust ventilation. 2. "Kaylo" insolation blocks could be fabricated safely when using only the original downdraft exhaust ventilation if existing leaks, obser/ed cn the #1 band saw, are corrected. 3. "Kaylo" insolation blocks definitely ray be safely fabricated when using the entire exhaust ventilation facilities now available, i.e., hoods above the blocks as well as below. From Graph #26 Tables on Pages 8 9: 1. Methods of handling "Thercobestos" blocks (preparatory to sawing) and scraps (after sawing) contribute, greatly to specific individual exposures as demonstrated by the following facts: a. The fabrication process, which always begins at the 2 band saw with the simple cutting of each-18" x 38" x 4" block into three sraller blocks about 18" x-12". x 4", is normally the least dusty .of all the . fabrication operations as revealed by the samples.taken on 24 Jan IS:I : . b. .However', cn .8 liar 1SS3, this operation was revealed as being one of the dustiest, regardless of the ventilation being used... . 'c. There was only one major variable between the samples taken cn the two dates, i.e., the method of handling the blocks preparatory to sawing. . Consideration of the procedure used on these dates reveals: . (1) that on 24 Jan 1983, the blocks were rolled up to the saw after _ having been removed from their shipping -cartons and stacked cn a "dolly".for easy individual removal and (2) -on S Mar 1953,.the blocks were not removed from their shipping cartons until needed .by the worker. A large amount of dust is produced when blocks are removed individually from the cartons as a result of the natural abrasion produced whan cne block is. pulled over the surface of the ether. Consequently, the dust concentrations on this date at this location were greater than normal. 2. The supplementary overhead ventilation (added since the time cf the preceding two reports) does successfully reduce the dust exposures. However, it does not reduce "Thermobestos" dust exposures to within*safe - acceptable limits wnen cutting radii. From Graph #3 Table cn Page 9: 1. "Carey-Temp" dust concentrations for each exposure was substantially greater than the comparable "Thermobestos" dust concentrations and in excess of even the most lenient TLV established for human exposures, i.e., 50 mppcf of air. n T / 2 The existing exhaust ventilation system as installed on both band saws is incapable cf reducing the dust hazard, associated with the fabricat on of "Carey-Temp", to within safe acceptable Units, i.e., 20 .tppcf cf a Relative to the exhaust ventilation system.: 1. The duct velocity in the dswndraft ventilation system cn both band saws is far below the recccranded value cf <*000 fpm. 2. The duct velocity in the overhead ventilation system cn both band saws is equal to or core than the reccncenced value of U0C0 fpr.. 3. The velocity in the downdraft ventilation systems fcr fccth band saws could be increased by patching all holes, leaks, etc., now in existence. RZCOttSIDATIONS: 1. Do not fabricate 13" x 35" x 4" "Carey-Temp" cr "Theroabestos" insulation materials unless: a. The atmospheric dust problem can be reduced to below 20 npccf cf air through the use cf improved ^ventilation techniques or repairs to the existing system, or ' b. The manufacturers of the two makes cf insulation materials are able to produce a product*which will not release, upon fabrication with a band saw, dust concentrations in excess of 20 mppcf cf air. r* HE?:hl 23 October 1363 Submitted by: --31." rTTssle ------------ Industrial Hygienist IISUSTRIAL WSI5IZ SURVEY 8 Evaluation of Atmospheric Dust Conditions at the Construction Insulation Shoo Table #1 * Acrospharic Dust Concentration Data rN Collected When Using Only Fartial Ventilation, i.e., Only Below the Blacks Date 25 Feb 63 24 Jan 63 6 Mar 63 25 Feb 63 24 Jan 63 6 Mar 63 Cutting Edging Insulation Elocks Type of Material Kaylo Thermobestos II Kaylo Thermobestos It Description of Location #1, i.e.. South Side of the #2 Band Saw w ` if fi ti if tt n nw if it it n it - 92, i.e., South Side of the #1 Band Saw |2 " n n n it it it tt 12 11 nn ` it it it it Concentration in rapcf 3.32 10.00 51.50 17.32 26.36 42.70 Date- Mar 62 25 Feb 63 Mar 62 24 Jan 63 6 Mar 63 Mar 62 25 Feb 63 Mar 62 24 Jan 63 6" Mar 63 Cutting a Padius on Insulation Blocks Type of Material Description of Location KaIyt lo ThermIof bestos ft KaIyI lo Thermobestos II It . , 13, #3, , 9 3, i.tel ., ft tv If Sofut th tt If If SidIte It It If of II ft If n the tf ft It it #2 tt It If If Band II If tt 1 Saw If ft If If , 14, i.Ife., SoIuI th SidIfe oIft thIfe #1II BanItd Saw It #4, If 11 If If It fl It ft If tl tf fl II It tf If #4, If II It. tl If If tl ft Concentration in raped 17.10 3.33 101.40 63.53 36.82 3.06 23.35 83.30 66.63 70.00 Table 02 Atmospheric Dust Concentration Data CoLIacred When Using All Available Ventilation, i.e., Both Above S Belov the Sleeks Cutting . Edging Insulation Blocks a Date 6 Mar 63 . 26 Feb 63 6 Mar 63 26 Feb 63 Type of Material Theraobestos Carey-Terp Theraobestos Carey-Tesp Description of Location j0S1Ta^, i.ie., S onuth Sicfte. onf thne 02n Bannd Snaw 02a, i.e., South Side of the 91 Band Saw 2a, " n 1 ft n tt ti it i Ccncantrati: In "per 30.20 51.70 17.59 63.20 Cutting a Radius on Insulation Blocks 0* Date Type of I-iaterial Mar 63. "'6 Mar 3 26 Feb 63 46 Feb 63.',. Thercobestos:... Theraobestos Carey-Terp- i Carey-Ternp Description of Location ` t #3a, i.e., South'Side of:the 02.Band.Saw : 04a, i.e., South Side of/the 01 Band Saw l{& it ii ti a u ti it it 05a,-i,e.. North Side.of the #1 Biand Saw " Concentratir in mpeef , 22.42 51.70 85.40 100.' 90 Index for Graphs #1, 12. S #3 fl = South Side 12 Band Saw - Cutting Blocks - Ventilation Only Below #2 = tl ti 01 It - Edging " - tl II 13 = n ti #2 It - Cutting a Radius - II It #4 01a = it ti ti 01 ti 02 II If _ ft tl fl _ - Cutting .Slocks ^ . ft It II Both Above if 2a =: ft 03a ii ti it 01 02 19 II - Edging " - Cutting a Radius - ft II II It fl ft 04a = ti 01 It II tt If Eslcw tl 05a = North Side 01 Band Saw - Cutting a Radius - Ventilation Both Above 6 Eeiow n 99 n 1---------------------Trial # Table *3 Determination of Percentage Crystalline Free Silica Present in "Tbemcbestos", "Kayla" t "Carey-Ter.?" as Quarts by the "Talvitie" Method "Theraobestos" (As Contained in Report 62-IH-l-G-l) Wj, in Grams W2 in Grans W3 in Grats % Free S1O2 1 0.5002 0.0390 0.0069 6.42 2 0.5000 0.0347 0.0063 5.53 3 0.50C2 0.0396 0.0082 6.23 Average Percentage Crystalline Free S1O2 = 6.4 "Kaylort . (As Contained in Report 62-IB-l-G-l) Trial. # ' i_ :2 ;3 : in Grans W2 in_ Grans W3 in_ Grans % Free St 02 ^ 0.5000 : 0.5000, . o.sooo 0.08070.0730,.-.0.0563 0.0433' : 0.0364 - ! 0.0190" : ' 7.48 , 7.32 7.46 Average Percentage Crystalline Free'Si^' s'7.4 "Carey-Tatp'.' . (As Reported by Mr. Thomas M. -IXnrican) 4 October 1963 Components Soluble in Hcl Other Components Soluble in Phosphoric Acid 1 Percentage Crystalline Free S3O2 as Quartz 10.3% 88.8% 99.6% 00.4% n :.w` i,: TT7TT T- VST Table #u Ventilation Races on Tuo Sand Saws 11 Hood Being .ate Sand Saw Checked Description of Condition Ventilation Rat. in fpn 25 Feb 63 6 Mar S3 25 Feb 63 6 Mar 63 25 Feb 53 _6 Mar 63 #2 #2 n n #2 #2 Downdraft II II fl II II 25 Feb 63 Mar 63 25 Feb 63 5 Mar 63 n #2 - #2 #2- " Overhead - - _- fl H 25 Feb 63 =8 Mar S3 25 Feb S3 ^Mar 63 * Feb S3 6 Mar 63 i t #1 - #1 - #1 : #1 : #1 #1 - - Downdraft ,H .r ft ft i * ft ft 25 Feb 63 "6 'Mar 6325 Feb 63 j> Mar 63 * #i ' n #i i . Overhead. = , -. i If , - If at Only Downdraft System in Operation It ft If ft If Downdraft 6 Overhead System in Ooeraticn ft ft fl ft ft Every Hood, in the System Open It It ft II fl fl Downdraft .Overhead System in Operation ft ft tl It ft If Every Hoed in the System Open ' ft If ft ft ... ft fl I Only Downdraft System in Operation- If ft If II II Downdraft 6.Overhead System in Operation j .It If ft ft .11 If Every Hood in the System-Open - It fl It II ** It fl Downdraft`6-Overhead System in Ooeraticn J II ft It II -If If 7 Every Hood-in the System Open - ti it it it it if i 1500 1450 1200 1200 950 900 6500 4800 4000 * ;2100 :1S00_ . . 1500' -- `1150 1100 iSOO ;4SOO 4200 rn TT. . 'ji. T 2T7T 75.JK"^W _>.r T n cs d 9 < a O n A _ Zf ** n / IB .n d J.W g .o it S.w nd -Sw f l Bn S :oz 5 aa 6 > Ui wo LU a 3wo o CXixi hwo 3 Q r' Wit**!'*?* * -o 3 B 4 **? Bf t in d S / I OCX.-2. f' xcy jo joddui ux uota?Jivra3uoo n----- !.