Document N29jkG53XjXk15ON5VO91yp2E

FROM E. E. RUMBERGER PITTSBURGH OFFICE TO LOCATION MGRS. - DOMESTIC & /v CARIBBEAN ^j LOCATION MGRS. - SUBSIDIARIES & ALLIED PRODUCTS 1979 August 27l PLAINTIFFS EXHIBIT AL-241 RE: ASBESTOS The attached memorandum on the status of Alcoa's asbestos replacement program was recently released to all location Industrial Hygienists. Because of the impact of asbestos use on each of our locations, I felt it important that you be aware of this information. Works Safety, Environmental, and Purchasing Managers are included in the distribution of this letter. The asbestos problem, from a health hazard and governmental regulation standpoint, has not diminished in the least. In fact, implications are that asbestos control regulations will become even more stringent in the future. For these reasons, we are currently stepping up our coordination of this program to find substitute materials wherever possible. ' The corporate Industrial Hygiene staff will monitor feedback on the testing of replacement materials and maintain the continuity of the . program. Technical expertise on asbestos substitutes will be provided by each of the following personnel in the areas indicated: H. G. Sakoian (Pgh.-Ind-. Hygiene) -- Overall Coordinator M. J. Caprio (Pgh. Office-Purchasing) -- General Insulation; Molten Metal Marinite J. M. McCollum (Pgh. Office-Mechanical -- Potroom Replacements Engineering) D. St. Jacques (ATC-Safety) -- Personal Protective Equipment . Please distribute this information to other appropriate personnel on your staff as you see fit. E. E. RUMBERGER EER/eds Attachment Distribution: See Page 2 on Reverse Side 0ALCOA ARCH 020032 FROM HAIG G. SAKOIAN PITTSBURGH OFFICE TO MEMORANDUM 1979 July 30 RE: ASBESTOS SUBSTITUTION Attached is a summation of asbestos materials currently in use at Alcoa locations. Included in the listing are: - The material and its use - The number of plants using the material - Whether or not there is a potential for employee exposure - Potential replacements, if available -- and manufacturers (Page 10) Much effort has been extended to reduce and eliminate asbestos uses in most locations. However, as can be seen by this report, many uses still exist. Because the continued use of asbestos products may result in unnecessary health hazards and concerns to our employees, as well as additional costs to Alcoa to comply with specific provisions of the OSHA Standard, we believe it is in Alcoa's best interest to continue eliminating the use of asbestos products wherever possible. This does not mean that all existing asbestos should be removed immediately which, as in the case of sprayed-on insulation, could create unnecessary exposure potentials. Rather, a systematic effort should be made to discontinue uses, when feasible and practical, by substitution or elimination. By creating this listing and maintaining frequent updating via feedback from all locations, each plant can be provided with the information hecessary to attain this goal. Mr. J. M. McCollum, Pittsburgh Office Mechanical Engineering, has been coordinating such an effort for asbestos replacements in potrooms. A list illustrating Alcoa's experience with potroom replacements is shown on Pages 7, 8, and 9. It is hoped that this type of registry will be extended to cover all asbestos uses for all locations. To achieve this, it is asked that each location copy this office on all efforts made towards asbestos replacement... whether positive or negative. This information will then be disseminated to all locations on a periodic basis so that each plant can profit from the experience of the others in the Company. Any questions, comments, or additions to the attached would be appreciated. HAIG G. SAKOIAN HGS/eds Attachments Distribution: See Paqe 2 Qalcqa ARCH 020033 4,. ARCH 020034 ASBESTOS REPLACEMENT SUMMARY -- BY USE MATERIAL/USE Deltlng/Drip Casting Conveyors . POTENTIAL EXPOSURE Potential for exposure during maintenance and removal. * (2 plants s 3, 7) __________REPLACEMENTS AVAILABLE______________ UNTESTED. Potential candidate: Fiberseal Fabric (NOTE: Must determine operating temperatures and strength/durability requirements for engineering.) Block or brick/ Furnaces Potential for exposure during installation, and especially during removal, even though this is infrequent. * (1 plant : 23) Ceramic refractory block and brick. Brakes/Vehicles & Equipmen t Recent studies indicate,, some asbestos fibers survive from brake use and are not destroyed, as presumed previously. However, the percentage of fibers not degraded by heat and friction is unknown. * (All plants) NONE. Should reemphasize requirement of not using air to blow out brake drums and linings. Vacuum systems are available and should be used. (NOTE: Recommend air sampling for asbestos to document and confirm LOW or NO exposures: 1. Vehicle brake mechanics 2. Extruder brake, mechanical presses, or other equipment brake changers) Cement Patch/Boiler Maintenance Potential employee exposure. Two grades: * (2 plants : 18, 24) 1. Hydraulic-setting cement -- Contains mineral wool and Portland cement; temperature range up to 1,000F. Suppliers: --Johns-CTanville - "375" Keene Corp. - "Super Powerhouse" 48 Insulation - "Quick-Set Cement" 2. High-Temperature Grade -- Contains mineral wool; temp, range: 1,000F to 1,900F. Suppliers: Johns-Manville - "360" * Number of plants using material. Keene Corp.- "Super 1900" 48 insulation - "Super 48" (Cont.) I ARCH 020035 MATERIAL/USE Cloth/Insulation, Welding Blankets t-'Personal Protec tion/Gloves, Mittens, Pads, Coats, & Pants ASBESTOS REPLACEMENT SUMMARY -- BY USE POTENTIAL EXPOSURE i REPLACEMENTS AVAILABLE Plants indicate'NO potential or unknown exposures. In many cases, the cloth is used wet and would, indeed, pose little potential for dust inhalation. However, as several plants indicated, there may be some cases where the exposure is unknown. * (6 plants : 12, 13, 16, 17, 20, & 24) There may or may not be a potential for exposure depending on the type of material, i.ei, whether it is aluminized `or coated; lined or unlined; and the frequency of use. In general, lined, aluminized protective equipment should not generate a potential for dust inhalation. However, noncoated, unlined materials may pose a problem and should be replaced, preferably with a nonasbestos substitute. * (All plants) Pyrotek Fabrics (used in Warrick) Pyrotex. Refrasil Nor*Fab Keller Gloves Kelnit Welding Blankets These apply for some applications, not all. Many times asbestos gloves are used in cases where the temperatures encountered do not warrant the need for asbestos. For example, flame-resistant terrycloth gloves can often be effective replacements where up to 700F temperatures are encountered. For temperatures up to 1,000F, gloves made of duPont1s Kevlar fiber may be acceptable. However, past Alcoa experience indicates that in certain applications the seams of these gloves do not hold up. For this reason, each case should be treated separately. Please keep us advised of your results. "Kelnit 2$" Keller Gloves Pyrotex"1 I * Number of plants using material. (Cont.) r~ ft ARCH 020036 ASBESTOS REPLACEMENT SUMMARY -- BY USE Page 3 MATERIAL/USE POTENTIAL EXPOSURE REPLACEMENTS AVAILABLE Marlnlte and Marinite Floats/ Molten Metal Casting Because of the special problems associated v/ith Marlnlte In Ingot casting, it is being treated separately. * (11 plants: 1, 7, 9, 13, 16, 17, 19, 20, 21, 22, & 24) A Alcoa Research Laboratories and our suppliers, in conjunction with plant personnel and Primary Products, have been working for some time to find replacements for molten metal Marinite. Due to this effort, replacements are now available for many -- but not all -- of its uses. Many plants are now using these replacements; however, for one reason or another, many plants continue to use Marinite even in those cases with potential replacements. These reasons include initial cost factors, and increased costs associated with lost or decreased production in ingot casting. Considering the increased costs associated with compliance requirements, i.e., medical exams, protective clothing, disposal requirements, ventilation controls, etc. -- in addition to the less tangible, but more serious costs of potential impairment of employee health -- every effort should be made to institute the replacements now available and to continue the search for those uses not yet replaceable If it is still considered that the costs associated with replacement remain prohibitive to the location, continue the control program and continue the search for a more feasible replacement. This decision must be arrived at only after careful examination by both management and Medical. * Number of plants using material. ' (Cont.) ARCH 020037 ASBESTOS REPLACEMENT SUMMARY BY USE Page 4 MATERIAL/USE___________ POTENTIAL EXPOSURE ypacking/ General pump packing In most cases, pump packing materials are bonded in rubber or some other coating compound. As indicated by the plants, these generate little potential for fiber exposure. However, some packings, such as uncoated, noncompressed, braided asbestos may offer a potential for exposure and should be replaced. * (All plants) REPLACEMENTS AVAILABLE Since specific needs and equipment types vary dramatically, pump packing and general packing materials are purchased at the plant level. Suitable replacements should be handled by plant Purchasing by direct contact with manufacturers and suppliers. Paper/Welding protection, electrical insulation Should be replaced. . * (6 plants: 1, .3, 7, 13, 17, 6 20) Johns-Manville - Cerawool Paper (NOTE: Asbestos paper should not be used for welding protection. Substitutes available for this application can be found in the section dealing with "Cloth".) 7 Ro |e/Furnace nsulation L^hhieet Gasketing/ General Plants are divided on the extent of potential dust hazards. Uncoated material may pose a problem during removal and disposal and should be replaced. * (15 plants; 1, 3, 6, 8, 12, 13, 15, 16, 17, 18, 19, 20, 21, 23, & 24) Pre-cut compressed gaskets should pose little potential for employee exposure, especially if they are resin or rubber bonded. Sheet gaskets which must be cut out at the plant may create a dust hazard during cutting, installation, removal, and disposal. Since the requirements for gasketing material vary depending on the MUST BE TESTED. Johns-Manville - Ceraform Pyrotek - Fiberseal Rope + Others Rope (used in Warrick) * Number of plants using material. (Cont.) AFtCli 020038 ASBESTOS REPLACEMENT SUMMARY -- BY USE *"2'- MATERIAL/USE Sheet Gasketing (Cont.) Tape; Tubing/ Furnace seals, general insulation ^Thermocouple Wire / POTENTIAL EXPOSURE REPLACEMENTS AVAILABLE application, each use should be carefully considered. Care should be taken to insure that maintenance personnel do not have on hand and use indiscriminantly such sheet gasket material. Storerooms and users should be carefully monitored to; 1. Determine and document exposures. 2. Evaluate housekeeping. 3. Insure proper disposal of waste material. * (All plants) .. Majority of plants'do`not consider this to be a potential dust hazard. However, certain uses may generate free fibers. * (10 plants.; l, 3, 6, 9, 13, 16, 17, 18, 20, & 23) Due to deterioration and fraying of the asbestos insulation on thermocouple wire, potential fiber exposure may exist. * (7 plants: 1, 6, 7, 9, 15, & 19; probably more) ` Tape Replacements: Pyrotex77" Refrasil Fiberfrax Nor Fab Sleeves made of Refrasil or Fiberfrax material may be used in place of asbestos-coated wire in some cases,' otherwise, no replacements available. I I * Number of plants using material. Page 6 KEY TO ALCOA LOCATIONS 1 - ATC 2 - ARKANSAS 3 - BADIN 4 -- CHILLICOTHE (Wear-Ever Aluminum) 5 - CLEVELAND 6 - CORONA 7 - DAVENPORT 8 - FT. MEADE : 9 - LAFAYETTE ' 10 - LANCASTER -. 11 - LEBANON 12 -- MARSHALL (ACPC) 13 - MASSENA 14 - MOBILE 15 - NORTHWEST ALLOYS (ADDY) 16 _ PT. COMFORT 17 - REA MAGNET WIRE 18 - RICHMOND, INDIANA 19 - ROCKDALE 20 - TENNESSEE 21 - TIFTON ` 22 - VANCOUVER 23 - VERNON 24 -- WARRICK ARCH 020039 Specific Application Cradle to Pot Shell Insulation ASBESTOS Substitute Quarry tile Cem-Fil GRC Sheet Cem-Fil GRC POTROOM USES Location Wenatchee Warrick Massena Superstructure Fort Insulation Cem-Fil GRC - 9" x 7" x Marinite-P -- V sheet Massena Massena Pot Cover Insulation Almac Plastics Inc. 's-v" High-Temp Glass ' ' Marinite-P -- *j" sheet Pyrotek's Fiberseal H-3 Fabric (Same as above) (Same as above) Amatex - Thermoglaso #G-36P752 Massena Massena Massena Badin Warrick Wenatchee Walkway Grating Insulation M-50 Pyrotherm Dense Board GRC Cem-Fil - V and 3/8 Marinite-P -- Jj" sheet Marinite-P -- 1" board Pyrotherm G-5 Insulating Board Kaowool M Penn Hi-Temp 270 Massena Massena Massena Badin Badin Warrick Warrick (Cont.) Page 7 Comments Tested; proved to be good replacement. Installed and seems okay; will get back with update. Currently testing (just started). Received material to be tested. Received material to be tested. Testing. To be tested. To be tested for P-75 pot covers. Double the material; works well. Works well; now standard; works for side shield insulation. Satisfactory. also Tested; unsuccessful; it crumbles. To be tested on P-225. To be tested on P-225. Currently testing; not optimistic. To be tested. Does not stand up (no good). Looks good in preliminary tests; to be tested further; limitation might be that it's too expensive. ARCH 020040 ARCH Specific Application Bus Insulation ASBESTOS Substitute Marinite-P -- 1" sheet Cem-Fil GRC - V and Jj" Marinite-P -- V' sheet -P--O--TROOM USES Location Badin Massena Massena Page b ct o o O Comments Currently testing (but it crumbles) To be tested. To be tested. Exhaust Duct Insulator Pyrotek Pipe Hetron 197 Hetron 92 . ,? Fiberfrax laminate tubes by Carborundum, Inc. Exhaust Duct Gaskets Pyrotek's Fiberseal Felt Warrick Wenatchee Wenatchee ATC i Massena Looks good in preliminary tests; . now have 8 in use with a *" wall; have ordered 8 more 3/8" and 8 more >t" for testing. Fiber glass pipe with antimony and dynel liners have failed and have been replaced with normal transite. Fiber glass pipe with antimony and asbestos linings -- satisfactory. No plans. Siphon Gaskets Pyrotek1s Fiberseal Felt G-l - V' and Fiberseal Felt T-l - h" (Shme as above) Fiberseal M-13 - 1/8" Compressible board J-M Ceraform Heat Seal Badin Massena Massena Rockdale (Cont.) Tested and proved okay. Tested on P-225 siphon gasket and crucible cover plate , gaskets; found unsatisfactory To be tested on P-225 siphon gasket and crucible cover plate gaskets. Not as stable as asbestos; needs replaced more often. i 1 1 1 1 Application Ladle & Ladle Lid Seal ASBESTOS - POTROOM USES Silicon Red rubber air hose - 3/4" Refrasil - wrapped around rubber hose 1-V' Fiberseal rope - F-10 1" Fiberseal rope - D-l 1-Jj" Fiberseal rope - F-10 Warrick . Badin Badin & Massena Anaconda Pt.' Henry Page 9 Standard (but different seal from other plants). No good; rubber melts; seal breaks On order. Uses 600 ft./mo. of D-l V PRODUCT____________ PyrotexTW Fiberseal Products Eefyasjl Nor*Fab Yarns; Fabrics Fiberfrax Hi-Temp 270 Ceramic Fiber Products ASBESTOS REPLACEMENT MANUFACTURERS SUPPLIER Newtex Industries, Railroad Ave. P.0. Box 25 Victor, NY 14564 Inc. Pyrotek Incorporated East 9601 Montgomery Ave. Spokane, WA 99206 - or Box 77 - R.D. #1 Claremont Rd. Carlisle, PA 17013 - or Santa Fe Springs, CA HITCO Division of Armco Steel Middletown, OH 45042 Amatex 1032 Stanbridge St. Norristown, PA 19404 The Carborundum Company Insulation Division P.O. Box 808 Niagara Falls, NY 14302 Penn Compression Moulding, Inc. Burton Street Pittsburgh'-,' PA 15218 Kaowool ` Babcock & Wilcox Pace 10 TELEPHONE 716/924-9135 509/926-6211 717/249-2075 215/277-6100 716/278-6221 412/351-4004 Cem-Fil Corporation Two International Plaza Drive Nashville, TN 37217 Keller Glove Mfg. Co. Plumsteadvilie, PA 18949 615/361-4664 215/766-8818 HAIG G. SAKOIAN 1979 July 20/eds ARCH 020043