Document NGd7LXV5JM1k9k7gwxxkVn50Q

'JiN CARBIDE CHEMICALS COMPANY INSTITUTE PLANT P. 0. BOX 2'il. CHL.lLSTO.';. WEST VIRGIN Mr. S. C. Gianbruno *r Industrial Relations 0e,, U December 1962 D,pt Medical Department Aflivrinp UfJtr ^lc Plant 512 Mr. L. K. Dickinson Mr. G. E. Daniels Mr. N. S. Eastman Mr. R. A. Huber Mr. 3. F. King Mr. F. 3. Snyder 'Dr. E. M. Best, Jr. Mr. E. G. Heinz s`,fc',ri Mr. ?. E. Henry Mr. R. A. Heal Mr. D. R. Matheny-'sc* Mr. N. H. Ketcham Dr. C. U. Dernehl . Insulation Block Dust Survey Construction Insulation Shoo Plant 511* Tvo reports by Mr. R. E. Peele have been issued on this subject (21 March 1962 and 20 July 1962) and sent out under ny signature. On i6 May 1962, a copy of a letter from Doctor Hale to the UCC Central Purchasing Department in New York pertaining to this subject was sent to some of the people on the above distribution list. Undoubtedly, Johns Manville is extremely interested in having our Construction Department use their "Thermobestos" blocks. However, I believe that possibly unnecessary pressure is being applied to us from several sources. The enclosed report by Mr.. Peele includes information on an invitation for Mr. Peele to visit Manville, New Jersey, at Johns Manville's expense to evaluate their industrial hygiene studies. Mr. Peele points out in this report also that he has been contacted recently by the Design and Construction Department at the Technical Center who have implied that Mr. Peele should comply with Johns Manville*s proposal. `It is my opinion that we should continue to do surveys, with limitations, on samples of ''thermobestos" blocks that are of a new formula and are submitted to our Construction Insulazion Shop at the Institute Plant for evaluation. However, I am sot in favor of Mr. Peele accepting Johns Manville1s invitation and would appreciate approval or disapproval for this trip from my supervision so that Mr. Peele can be Informed accordingly. Very truly yours, rs RJS:gh Enclosure R.LT. Sexton, M.D. Plant Medical Director PLAINTIFFS | EXHIBIT 1 UC-1441 X >** ur:iON GAneisc A IHTCRUAL. OORRCCPOKDCHCC ic '/'?i mcj UNION CARDIOE CKERSICALG COMPANY fMCTmrrt rmtrr f. o. box 23i. chiotck. wot virch. * (Nm*1 R. J. Sexton, M.D. iarwHta Medical Department - Plant 512 0.1. 29 November 1963 O.pl. Industrial Hygiene - Plant 512 C*r to Mr. L. N. Dickinson Mr. N. S. Eastman Mr. S. C. Giambruno Mr. R. A.' Huber Mr. B. F. King Dr. E. M. Best Dr. C. U. Dernehl Mr. J. W. Perry Construction Insulation Shop Mr*. P. E. Henry Buildine 511-2018 Mr. R. A. Neal . Mr. D. R. Matheny-<=" Mr. N. H. Ketcham Mr. L. B. Weddell - Safety Dept. Mr. F. G. Comerford In accordancewith Hr. P..E;.Henry's"request of Thursday; 7 Nov 63, I have investigated the fabrication of "Carey-Temp"-.pipe covering.' This operation is carried out with band saws -and, on the basis of visual observation alone, it has been decided that there should be no health hazard associated with this particular type-of operation. This investigation took place during the morning of Thursday, 14 Nov 63, in the company of Hr; K. B. Lanham, Foreman of the Fabrication Insulation Shop, and consisted merely of observing the process of-the cutting. __ of half sections of eight inch diameter "Carey-Temp"-pipe cpvering.-with.-a_. _ band saw. No effort was'made,-at that time; to determine the actual concentration of atmospheric-dust being produced during this-operation. It should not be necessary to perform this specific test so long as_working conditions are not altered appreciably from those.observed on-this date. However, a more thoroughevaluation of these conditions will be performed if Cl) it is'specifically requested, (2) employees begin.complaining about reactions such as nose bleed, etc., (3) a thicker material, i.e.,more -than two inches in diameter.is substituted for fabrication, or (4) the fabrication shop begins cutting each curved half-section frcm large blocks of "Carey-Temp". Very truly yours, REP:hi . r' R. E. Peele Industrial Hygienist AU307C I- ITE It N! AL COf'^ESI'CNOEKCt r iVriU-- HELICALS Division l\JTt" JTt r.SKT r'jiw x-S /O 7 V/ Wicj chwjsw .m;i v-:-i' ^ sv_* K. b. Lankan r * ."*ii ulaticit Faoricaticn . . . slur,, ill - root 2CIS ? 2n August 1SS5 w-industrial Hygiene - riant i.12 tt>r .* M, . 1 v* 0* .M* Ccii.eiford fallen hr. *v rL* Harry . iM, tK*<^* h. rW. * ti. ** here*'.2m hatl.any J. lextm Vs-. Frank Snaf. er `A, L. b. Weddell f'A*. Frad .Villi^ms ;aJST SA,25LI"'" OF "C-iCf-TL,"!?" IhTL ..'e have receives results frcra the cast sampling series ccr-ducted In your stop while the head grinder machine was being used to cut "Carey-Tamr" insulation bloc*-.. These results indicate that the hazard to health frar. dust exposure .luring this operation is. very slight and should not present any serious res-irator uroblums tc the machine ooeratcr if conducted.in a similar .manner to the tast runs Luring cur conversation, you rnantiened that you anticipate rwi machine to anotlier location in the shop and also makinz certain codifications uchine and dust exhaust system. It is cur reccnriandation tnat these d^an-ccurried out to their caooletion in the near future sc as to further add to the -.dcquacy cf the system. in order tc completely fiiializa t:.i.c investigation, w . would like ow another series of sampling v:hon more "Carey-Ierp" insulation is a v.ilabie and *f*L-r the above changes and modifications have beer. made. If, in the interim period, you have any questions r .ests, please notify this department. these Vary -truly yours, . I ll I..JI I ll.u l JUffrU rt A03077 Si i ,,,CN CARBIDE CHEMICALS COMPANY institute plant p,, o0.. eE::x iE3', CHARLESTON, V.IST VIP- HO#*) R. J. Sexton, M.D. t*r Medical Department Oat* ^ December 1962 Originsling o.pi. Industrial Hygiene - Plant 52J Ani^iriAf lIUr dat* Subject Johns Maryville "Thermobestos" On 21 March 1962, an Industrial Eygiene Report, i.e., 62-IK-1-6-1 identified the existence of a hazard to health in the Construction Insulation Shop during such times as vhen insulation blocks canufactured by the Johns Manville Company are being fabricated vith exhausted band saws. It was reccmmen at that time that 18" x 36" x V' "Thermobestos" insulation blocks* should net be fabricated vith the existing equipment unless -- (a) The atmospheric dust problem could be reduced to below 20 mppcf of air through the use of ventilation, etc., or (b) The producer of this product begins manufacturing an insulation n block which will not release upon fabrication vith a band sav, dust concentrations in excess of 20 mppcf of air. In accordance vith these recommendations, the Construction Insulation Shop discontinued almost immediately the purchase of ''Thermobestos" insulation blocks. On 20 July 1962, a second Industrial Hygiene Report, i.e., 62-EJ-2-G-1, was submitted subsequent to an evaluation of three nev insulation materials supplied by the Johns Manville Company. This report concluded that these materials were improved over the original. However, the dust concentratic produced upon fabrication of these insulation blocks were substantially in exces of the recommended safe concentrations of 20 mppcf of air. Therefore, the recommendations contained in this report remained exactly as those stated in th initial report of March, 1962. On 20 November 1962 the author was contacted by Mr. D. R. Mathen:General Foreman of the Insulation Shop, who stated that three Johns' Manville representatives, i.e., Messers. F. E. Saxer, N. Gordon, and H. E. Kaufman, were present and had requested' a meeting vith the Flant Industrial Hygienist. This meeting was held in the lobby of Building 2, at which time Mr. Saxer produced the accompanying copy of portions of a report submitted by the Johns Manville Industrial Hygiene Laboratory located at Manville, N.J. Mr Saxer stated that, in accordance vith this report, they were not able to produce results which agr' with those contained in the reports submitted by this department. Therefore, they were concerned and interested in learning if their methods of reproducing *The Johns Manville trade name for their insulation blocks 403070 R. J. Sexton, M.D. 3 December 19&2 Rase 2 our envlronaental conditions, sampling and evaluating the dust concentrations contained therein were subject to question. At this point he stated also that uhis conclusion'was prcaoted on the basis cf their analysis cf the ataospheric dust conditions produced by their coapetitors product, (i.e., Kaylo cr Itea * 5AT in the report) vhich in no way agreed with the data submitted in the industrial Hygiene Report--35-62-I-G-1. It was explained at this point, that this department's interest in this problea is always' confined solely to the environmental conditions as they effect the health of our workers, and that no part of the investigation should be construed as an attempt to arbitrarily prenote the use of one conpany's product over that of another. Upon conpletion of this statement, Mr. Saxer proposed that Mr. D. R. Matheny and the Plent's Industrial Eygienist make a trip to Manville, New Jersey, at Johns Manville's expense and at a time selected by Union Carbide. This visit would be for the specific purpose of observing, scrutinizing and comparing their method of atmospheric dust evaluation with that as utilitized by the Institute Plant's Industrial Hugiene Department. It was Mr. Saxer's opinion that such a visit would permit a more positive approach to the problem and remove the possibility of misunderstandings, etc., that results frem written correspondence. At this point, Mr. Saxer was assured that there would be no personal objection on my part to the performance of such a service. However, .a proposal of this nature would have to be submitted to the Plant Manager, Mr. L. N. Dickinson, through appropriate channels before a final decision could be made. In conclusion, it should be stated that a phone call was received from Mr. P G. Comerford of Design and Construction on the morning cf 21 November 1962, who requested that he be brought up to date on this specific problem. This request was immediately satisified both by verbal explanation and by the promise that copies of both reports, i.e., 62-IE-I-G-I and 62-IH-2-G-1, would be mailed to him immediately. Mr. Comerford further stated that we should not back down on our requirements, but that it probably might be vise to consider their proposal in light of the many ramifications of the problem as it affects the whole company structure, i.e., purchasing, sales, manufacturing, etc. Very truly yours, REP: gh Enclosure Robert 2. Peele Industrial Hygienist -f rjjwiiin* .i AU307 tor? 09AS U'U '1 CCGC CI)*r*Gwn *3G G '*."."3 ".GC*3 C3 wG *w w 1T - j ' C9i -c*'. * c. ur--n _^ c f-brientior. oi insulation bis-sis oa ihs DO-ALL >lodci L-K-V cnnii cuu in .r.il:.rza Cun'.-r Materials Test!-? i.-.Lsr.:aer:' t.-.:-.ple p.-t<pi,-i.ti in rsax. Too i'aiisr.al Cendiarsnoo of Govorsataiul Industrial Hypicnists Test >Lctr.eel '--as i'cllovod usizj tho Grccaburgi-Szith iariajer. Testa vers csnciuotoc by Mr. T. F. sodr-as'chui: of tbo T-M Industrial Hj-icau Laboratory at Manvillc. To cbtaLa coaparatiro data, tbo rooa ventilation vns adjusted to Giro rare tbaa tbo usual auount of ataosphoria dust. Too teat sat up is shout: ix tic photo graph bo low. i i r i t 1 I ) f rs y7" ;'W t.1 ">' . ,i A 0303C P 1,1 iB ...iliUkU1 1 f "J1 T.g"U 1 II1 1 > M".W .".'1 c /* ."3 vt -- i'u 2"0:*; b) c) iLrj'Lzz - O. it cu C- . ' - C. _l...V.. 'c aui sc 'H. rj * * * J V. *: e 1:;. paa css* bl - - --A.+* `--I * t 2 ^ Cf . 1C tr-rs .1 70 per c: 95-1CO ct -- j ,-- * * ^ " Usisz c ,,*.va oi ov 1^*-* **-* VT ita- -0 then la a- si .4 /CV^^..Ai g A.# % c a`w ccrpaai/iica, 2 W---- * ***--* or V* * * ^ ^A * Ciw r\ A030o 1 7" TT T wrr .........r / industrial hygiene evaluation and survey FRQJECT NO. 7 // "e*. e /- J / ' Tine /' Project ("* erartacr.t / '' ^ Lcoation ."e quested by Reason i' General Conidiittioi onnss: f .j f /V f .S-f `/c Z * V..' .O' A/ ^</y Aj *'r, -- J-.7'.' 7 s- /V / ' sldg. No. /v/-' r/ / /4/ ^ v *./ " //* Sampling Method and Eo.uipnent v V / ->- . /, // f ? .*/ ,*.*. -. . ^ _ .*'7-.. , r, s', 7 ^ Shift: oar-pie /)ur'.ber / 1 rs 7* Cay ___ Eve. ___ file I.'o. Employees' Sampled by //*/'' 7~ Sampling Zone Use-Kin. /V / /U. b't / Flov C0KCEK3ATI0N . Special Conditions Rate r i itp rr.je.? /-.-r/ , V. <0.1 < c.:s /<> J- O/", /i . /~/ - ; /. J' / /,___r./-/-, ./..I.-- -r'/ / /'' ~ / /.it o.i. A 5 :/ / ./ ; v. O.f *.Q 5 jr J h i. Calculation: -r /A/ ^/ ?.y o.Z - //" o.o .// ^ - - /.<*> , #''// , "V** - /.u v .v < -- Z".. ,/ ^ /'/ > & f 'c1. ? ,/ /*.. . ' c ^ f y - v- - - - / ....../c s *.< > /a <3./ <0.25 <^--+. <i <*/(7 . *7 f> cnnrks: t, I r, * f S /' J ~^T~77P . '^Sch - See Reverse Side. Reference Mo. 7Jri& 4-5 Analyzed by DGte orv <~^ze <X_ INDUSTRIAL KYU-IENz EVALUATION ACT SURVEY Tiae /Q 'r-: ^~-rra*e = t ~[)t f( "/ /.% X t'r' PROJECT 1 V" Cepartsent c______ Location sfjS/pstv' S/sq//js^<f,) Sldg Requested by 3<J>* v ^ v/ Reason :L..iercl Conditions 3 'k/oc/rr f?" * ") IT T *~/ 1^-ffec^esf) fa>; v San^p_l_in__g Method end Equipment__/_/_A._f*__o_ A''-)r"/ ** .'Jr-* ,y-<V C ~ rV ~/`CuL-tS .-to cl'lL K rg7^ : oTc / /r'^J /j^' Shift; Day ___ Eve. ___ Mid . ,77No. Eaployees X Sampled by /St/ '</- C Sample Number / Sampling Zone Time-Hin. /o flow Rate Z,S */r+ concentration- c/.a / nrrc, - Ao <c./ <0.25 ... Special Conditions ft d~ X/ . C/t*-- >' \ > /o c*#--y ~T// /'* 0.8 Z.o *" I J>S 7 TG- / 3 /O 2,y /.& 2.1 5.5 /> Calculation: A .`marks: K JO * T'ZV X fO _ /.<y ^ toK Sketch - See Reverse Side. Reference No. &JNJ) 10 Analyzed by A0300.3 PARTICULATE KATTER I3i AIR II r Dust Breathed by the Employees while Cutting and Installing "Reylo" Insulation Plant-wide Surrey - Plant 514 Figure 1. Sowing block'sections. Breathing rone level air senple -being collected in the background. n BLlf- Figure 2 Applying insulation block. Ereathing rone level air sacple being collected in the foreground. A M U3084 . b /, * m'j1. r late ll-le-64 . 1-19-65 2-15-65 r' 3-1-G5 ' 3-22-65 5-16-65 G-14-E5 tad*:; i PARTICULATE MATTER. IK AIR lust Breathed =7 Employees while Cutting and Installing ''Zaylo" Insulation 1 Z GIUp 1 6 1 Uuaber 1 1 2 3 4 5 6 7 8 9 ID 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 ampling C onditi ons at Breathing Level Humber cf Emo3 ovccs 5-min. cutting, 5-min. application inside building Sane Sane 7-min. cutting, 3-min. application * 2 2 2 Cutting and application during entire sampling period - inside building . Sane Same 6 6 6 Seme Seme Application of insulation - no hand saw cutting Some 2 2 2 1 Cutting and application during sampling period - outside building Seme .Same 2 2 2 Application of insulating - no cutting - inside building Same 7-min. cutting; 3-min. application 3 3 1 Clean up of insulation from floor sweeping and shoveling - inside bit g. Same Same 2 2 2 Cutting and application during sampling period - inside building Sumo Saras Same 2 2 2 2 Dust Count H??r? (1; rT 2.8 1.7 3.0 22.5 17.0 22.S 2.0 1.5 C. 2 D.l 7.S 2.4 4.0 1.9 13; .[)> 1 | U.U U.l 2.5 i.O 1 5. ij 1 2.5 1.1 (1) Hilli cn particles per cubic fcot of oir. j.D-14-55 U3Q3!, n- jiticuiais matter u; air n n Doctor Hull, Plant Hedisal Director, requested a plant-vidu industrial hygiene study to determine the potential exposure of insulators to asbestos fiber dust concentrations. Toble I gives the results cf seven separate tests, including 24 breathing zone level air samples and shovs an average dust concentration cf 5.2 Billion particles per cubic foot cf air. A ''threshold linit value" of 20 nppcf of air has been suggested.* When three employees, or less, hend-cut and apply "Kaylo" insulation, the concentration of dust is considered safe from tho health standpoint; however, vith S aan the dust count exceeds the 1L7. It is at this phase of the operation that exhaust ventilotion should be used. Excessive dust concentrations can be expected when the insulation is removed from piping and tanks. Agcin, exhaust venti lation should be used to move the_dust away fron the employees, if possible; otherwise, respirators_are advised. "Zaylo" insulation contains 12 to 13% asbestos and 5.S to 7.4% crystalline-free silica. This material is received in block and pipe form and the insulator measures and marks the material into appropriate sizes and cuts it with a hand saw. Ihe insulation material is wired into position around the tank or pipe. Ihe tasks of cutting and apply ing the "Zaylo" insulation are shown in Figures 1 and 2. The air samples were collected vith a.midget impingcr end a Uivl-jet sampler, drawing 0.1 cubic fcot of air per minute through impingcr flasks containing 10 milliliters of distilled water. Dust counts, made by the Light Field Microscopic Counting Technique, appear in Toble I. This study has revealed that further research work is needed to: 1. Attain cn established figure for the "threshold limit value". 2. Utilise exhaust ventilation to remove the dust from the work area. 3; Determine the particle size of the asbestos fiber where the Gust count exceeds 5 appef. 4. Obtain Range Finding Tests on animals exposed to different percents of asbestos fiber. 5. Continue our plant-wide study in support of'these conclusions. 1. Cook, V/urrcn A., and Foclo, Robert E., Lottcr doted February 12, 10GC Tha University of Michigan School of Public Ilcolth. 2. l'ceio, n. E., Industrial ilvgicno Survey - Construction Insulation Shop, Building 511-2010. Report B2-IH-1-G-1 (March 21, 1902). a0308j;