Document MoEx7ppkVKmyeY2RQdboBbg4k

KEARNEY ASBESTOS REPORT SYNOPSISi AOTCMOTIVB SEGMENT Recently much emphasis has been placed upon the handling of toxie and hazardous materials. Asbestos, one such material, has been a major point of conoern. In an effort to provide the Consumer Produot Safety Commission with fundamental information concerning asbestos, Kearney Management Con sultants have released a 300 page report. This report, "Review 0f Asbestos Use in Consumer Products," attempts to identify and describe produots, resolve amounts and methods of asbestos usage, determine if and how asbestos might be released, and estimate the consumer presenoe during conditions or activities which might release asbestos. This report deals with a broad range of produots which lnolude asbestos usage. A brief summary of produots, basio market information, and related viewpoints whioh specifically apply to the automotive Industry is shown on the following pages. FWW/mah Vehicle Materials Engineering June, 1978 8002 SCF-ALLF-07271 PRODUCED BY FORD Market Size Over the paat decade the U.S. hae consumed between 608,000 and 876,000 short tons of asbestos annually. Each year, approximately 15$ of the asbestos usage la pro duced in the U.S.- with the remaining amount being Imported primarily from Canada. The asbestoa industry divides sales data Into several oatagories. Cf these cate gories, only four) p&oklng and gaskets, friotion produots, coatings and sealants, and relnforoed plastics, aotually pertain to the automotive industry. Psoking and gasket use of asbestos fiber is cited by the Bureau of Mines to average about 25,000 short tons per year. This volume, however, probably understates the . actual usage sinoe asbestos paper is frequently converted to gasket material. The total value of the various grades of fiber used is estimated, by an industry contact, to be approximately $10,000,000 yearly. Westons' and CCNSAD estimate the annual value of shipments to be near $140,000,000. . Friotion products containing asbestos, such as; clutches, brake shoes and pads, are not under the jurisdiction of the CPSC. The annual fiber use for ooatings and sealants, at $110 per ton, is estimated to range between $4,500,000 and $8,600,000. However the value of shipments, estimated by CCNSAD and Weston, range from 250 million to 275 million dollars. Asbestos usage in relnforoed plastios is reported by the Bureau of Mines to be 20,000 short tons valued at $2,500,000 per year. Market Structure In 1976, according to the Bureau of Mines, there were five U.S. asbestos mining and milling operations yielding a total U.S. employment of under 400. All but one of these operations was controlled by small businesses specializing in asbestos mining and milling. U.S. produces* typically sell their production to other manu facturers while Canadian operations are oontrolled by major international corpora tions, five of which are U.S. based, who further process much of their own produc tion. The asbestos fiber producers or miners and mill operators sell fibers through whole sale distribution channels or dlreet to primary manufacturers. Although these out lets typically do not sell to consumers, it is possible for consumers to obtain loose fibers^ Paoking and gasket manufacturers are medium-sized companies who impregnate or lami nate the primary asbestos produot which is purchased from larger manufacturers. The paoking* and gaskets are then sold through various distribution channels as finished products. Both finished and unfinished paoking and gasketing material is sold through channels whloh sell to consumers. X/ "Teohnologioal Feasibility and Eoonomlo Impaot of OSRA Proposed Revision to the Asbestos Standard"j Weston Environmental Consultants - Designers, West Chester, PA., 1976 8002 1402 PRODUCED BY FORD Market Structure (continued! Manufacturers of frlotlon produots fabrioate loose fibers or buy these produots from the primary manufacturer. The frlotlon product is then fabricated and generally sold dlreotly to an automotive manufacturer or through automotive channels, however, consumers oan easily purchase friction produots. The majority of coating and sealant manufacturers are composed of several small - firms who either- sell through -the-wholeaale/retail channels or sell in large quantities to major firms with a vide distribution area. The plastlo molding material is typloally compounded from loose fibers by relatively large firms. The molding material is either used internally or sold to various small speolalty molding firms. The finished molded plastlo produots are widely used by the oonsumer and are sold to original equipment manufacturers. Trends The U.S. asbestos usage is apparently increasing at a rate equalling economic growth. An annual growth rate of 1 tq 38 le predicted by the Bureau of Mines for the remainder of the oentury. Significant fluctuations in asbestos use, related to oonstruotlon aotlvity, are expected to oontlnue in the future. Continued asbestos utilisation is affected by three major factors. First, asbestos has unique properties and any efforts to substitute other materials for asbestos have generally resulted in a cost penalty. Second, the oost of asbestos has in creased over the past several years with no break expected in the future.. Finally, Btringent pressure to limit the hazards associated with asbestos use has been plaoed upon the industry. These pressures have brought about an inorease in the oost of asbestos oausing firms to eliminate asbestos usage in their produots. Alternative materials to asbestos in frlotlon produots were found to be impractical from both a oost and performance point of view. Many of the asbestos related ooating and sealant products intended for the con sumer market are being reformulated. However, produots intended for use by pro fessionals have not been reformulated due to the more severe performance demands placed on these produots. Asbestos usage ae a reinforcement in molded plastios has diminished considerably over the past, two years.- This reduction is attributed to the availability of asbestos, increased oost, demanding OHSA controls, and deletion of asbestos from industrial wort area* and produots. The selective removal of asbestos as a produot constituent appears to be the future trend in produots where asbestos is not oritioal to produot acceptance and where asbestos is considered to be hazardous. However, produots, in vhioh there is diffioulty in duplicating the attributes of asbestos and for vhlob there are no eoonomloally feasible alternatives, oontlnue to be produced. 8008 1403 PRODUCED BY FORD ASBESTOS FACT SHEET Product Automotive Mufflers Automotive Undercoatlng Custom Auto Bod/ Filler Mawrtgn Asbestos Concentration Asbestos sheet is uasd between the Inner aod outer shell of standard mufflers be cause of Its heat raslstanoe and sound deadening properties. The sheet varies between .030 and .090 Inches thick. Suita ble asbestos substitutes have not been Identified. However, through design phanges asbestos can be eliminated from the product. An Industry respondent Indicated that the two largest domestic auto makers will purchase no asbestos containing mufflers after 1978. V To 90* Undmoatlng on automobiles, trucks, and other vehicles are applied to retard rust and to help prevent stone damage to the bod/. These undercoatings are asphalt or wax based and designed to remain semlvlecous. The costings ere applied by the manufacturer or by specialty undercoating garagea. 5 to 80* Published sources report that It Is not uncommon for these body fillers to con tain asbestos. Of those contacted only one Indicated any current use of asbestos fibers. 5* Friction Materials Clutch plates and brake linings contain aabestoe bound In realns. Respondents Indicated that fibers are aechanloally and thermally altered to a non-flbrous form during product use. However, some sources Indicate that unaltered fibers can be emitted during use of the product. 30-70* 1/ Ford Is currently using mufflers where the asbestos has been replaced with fiberglass. Method of Incorporation Paper . Scenario for Fiber Release Puncture or deterioration of Inner or outer shell. Consumer Contact In presence of damaged muffler during engine use or muffler repair. Fibers thoroughly mixed In seml-vlscous matrix. Industry sources report that fiber release is highly unlikely. Product widely used In consumer environment, Thoroughly mixed In viscous matrix vhlch becomes hard after application. Sanding of hardened filler material. Fibers generally In felt or cloth form Impregnat ed with resin. taring use fibers may be emitted to the atmosphere or emitted and retained by related mechanical parts and released to atmosphere during repair or replace ment operations. Product available for purchase by consumers. Consumers occasionally repair product incorporating asbestos friction materials! consumers may be present during cosmerclal repair activity. PRODUCED B Y FORD 8002 !*<>*  i i Product Metal Deadensr Molded Plenties Phenolic Laminatea Radiator Sealant Discussion Closely related In ooapoaltlon to autonoblle undercoating. Metal deadsner la knovn as Dub-Dub" In the trade, la uaed on the In side of fenders, doors, hoods, etc.. It aerrea to auffle road, vibration, and engine noises. The product is designed to remain seal-viscous. ' Asbestos fibers are uaed In Bolded plaatlea to Impart lnpect and tensile strength, heat and ohenlcal resistance. Industry contacts Indicate a dranatlo reduction In the use for this purpose. Substitutes Include talc which aay contain asbestos contaminates. This category Includes a large group of industrial sheeting aaterlals. Asbestos cloth as well as paper, cotton fabric, etc. serve as a structural element for phenolic resins. The sheeting Is cut or stamped Into a nultltude of ltms such as washers, bear ings, spacers, and sotor vanes. Industry respondents reported that the trend is away froa the use of asbestos In lanlnatee. Asbestos Is Included In the formulations of sobs automotive radiator sealants. The fibers serve to fora a minute network at. the area of the leak, thus sealing It. w Asbestos Concentration 10* Method of Incorporation Thoroughly sized In asphalt. Scenario for Fiber Releeae Abrasion If material hardened. 2 Consumer Contact Applied to automobiles during manufacture. 5 to 50* Up to 85* Fibers are thoroughly adzed In hard to brittle aatrlx. Thoroughly eocapeolated In pleatlo matrix. Sanding or abrading; no product Identified which would be sanded or abraded In foreseeable use. Abraalon destruction. Products widely used In coneuser environment. Asbestos phenolic* are generally fo: Industrial use; however they aay s as component* of consumer product* such as lawn care and home shop equipment. 3* Mixed with Hone Identified. liquid cheoloals. Product directed to conatmer aarket 2/ Ford radiator aaalanta do not contain asbestos i I : CD o IV t* VP I I Vehicle Materials Engineering June, 1978 PRODUCED B Y FORD ) PROJECT Brake * Clutob Emissions Generated During Vshlole Operation. 3A* Kay 1*-l8,1973 Asbestos Missions from Broke Dyomacmotor Teste. SAX K- 1i-l8,1973 Asbestos Exposure During Brake lining Kalnenanos and Repair. Dm. 10, 1975 Project Re-Funded ASBESTOS MISSIONS APIH0B3 H.G. Asto-Bnrilz R.T. Da Cherae-Bendlx A.X. Andaman, R.U Gealor, R.C. EsCnna and J.W. Spryeford Kotor Co. SHOOK! COHCLUSICSS This report outlines the study eonduoted on dim A drun brakee A clutches utllialng dyns-aoostar testing A actual driving oyclaa la the Detroit araa. (fa the average greater than $9.7% of tba asbestos is converted to foeterlte, Olivias, polymerlo A carbonaceous Materials. Tbs contribution to tba etsoepbere Is 3-21 of the total asbestos missions. This report concludes that moat of tbs lining asbestos vas found to be converted to a non fibrous material by tbs high flash temp, of tbs braking aurfeoe. less than .02? of tbs lining mar vas rsleased as asbestos fibers. Tba concentration of aabaatoa fibers In the urban atm. due to brake usage, was estimated at less than .07110"g/e3. The ocaiblned total to brake and clutch friotion material worn away annually is 117 billion lba. for brakes A 6.56 Million lbs. for dutches. Tbs total debris Is 123.6 Million lbs. Asawtng tba asbestos content Is a Maximus of 61 by vt. tbs amount of asbestos worn away as friotion Material debris la approximately 7k Million lbs. Observations relating to emission trends were tbs follovliyt * Asbestos esdeelooe were bigher for new friotion surfaces aid decreased with use. * Drum brakes produced aore asbestos amission than tba disc ' brake with the difference deereasing as tbs friction aaterlale continued in use. ' ' Heavy duty did not necessarily give a higher percent of asbestos; tbs large amount of debris produoed, however, gave a significant rise la asbestos emissions. * for the disc pads them vas an increase in asbestos emissions with increased asbestos oonteat. Ho such trend existed for the dm Materials. Observational * laterfaoial temperatures during braking could be high enough to doocopose the cbryaotUe aabestos Into non fibrous them! degradation products. - * Asbestos crudes (largo bundles) vers calculated to roach their rapid dscoepoeltlen temperature daring normal braking speeds between 18-56 *pb. and above. * Local flash temperature and Severn aecbanloal action am aajor faotoro In the breakdown of asbestos fibers for brake usage. Baiatnation of lining surfaces revealed the presenoe of non fibrous aagnesiu* sUlcata in both crystalline (ferstorite) and aaorphoua phases. l.K. Rcbl, A.K. Laager, M.3. Wolf, A J. VelaaanMt. SSoal School of Hedlclas Tbs projeot demonstrated the pressnoe of unaltered fiber A fibrils of cbrysotlle ranging from 2-1531 la brake drat dusts (ev. 3-6)0. Shear causes structural strain A tubetruetural fragmentation producing Material fatigue which, with binder pyrolysis, oaa oauae lining disintegration at temp, far below those required for cbrysotlle dehydroxylation (65O-6800C). At lower temperature foratarite baa been noted to fora during prolongad atatle beating Vehicle Material* Engineering Deesaber 1977 PRODUCED BY FORD BOOZ IUQ0