Document QgOzJ7qvojgOnnG4yrNYXeQLR

UNION CARBIDE CHEMICALS COMPANY institute plant r o box cm in i rj, i i virgi ji', ',WNu,n'' Mr. G. J. Ratcliffe t; Industrial Relations 20 July 1962 Medical Department - Plant 512 Amwor'ing loll or dolo Mr. L. N. Dickinson Mr. G. H. Daniels Mr. N. S. Eastman Mr. R. A. Huber Mr. B. F. King Mr. F. B. Snyder Dr. C. U. Dernehl Dr. E. M. Best Subil,c' Mr. E. G. Heinz Mr. P. E. Henry Mr. R. A. Neal Mr. D. R. Matheny^^ Mr. N. H. Ketcham Insulation Block Dust Survey Construction Insulation Shop Plant 511 Enclosed is an industrial hygiene report by Mr. R. E. Peele on the potential huzardousneoG of "new and improved" "Thermobestos" insulation blocks submitted by the manufacturer for evaluation by band saw processing in the Construction Department's Insulation Shop. The report points out that the three "new and improved" sample blocks, subjected to test conditions identical with those in use and reported upon in March of thiB year, are an improvement somewhat, but these blocks too, release quantities of asbestos dust particles into the working environment considerably above the acceptable safe limits (i.e., the T.L.V.). Therefore, definitely, the processing of "new and improved" blocks also constitute a hazard to health. Mr. Peele recommends that "Thermobestos" blocks not be processed in the Construction Department Insulation Shop until they meet acceptable standards and I concur fully. Very truly yours, I. Enclosure R. VS Sexton, M.D. Plant Medical Director INDUSTRIAL HYGIENE SURVEY CONSTRUCTION INSULATION SHOP - BUILDING 311-2018 REPORT 62-IH-2-G-1 PLAINTIFFS EXHIBIT Colo}. Q Pq.SL SUMMARY: In March of thin year, following an industrial hygiene survey, it van recommended that band saw fabrication of "Thennobestos" insulation blocks in the Construction Department Insulation Shop at Plant ^12 should cense completely and permanently unless the blocks, or the dust control techniques used in fabricating the blocks, are improved so that atmospheric dust concentrations are found to be within acceptable 3afe limits. In the following month of April, three new "Thermobestos" insulation blocks were submitted to Plant 511 for evaluation under environmental conditions identical with those experienced heretofore. Critical analysis of the data obtained on this more recent survey revealed the existence of some degree of improvement in the dust contamination associated with the fabrication of theBe particular "Thermobestos" insulation blocks. However, the magnitude of the improvement did not reduce the atmospheric dint concentrations to within the recommended safe acceptable limits of 20 mppcf (million particles per cubic foot) of air. Therefore, the recommendations remain exactly as those stated in the report of the survey of March, ]QC'2*. INTRODUCTION: It was established unquestionably, in an industrial hygiene report submitted in March of this year, i.e,, Report 62-IH-l-G-l, that, an inhalation hazard to health is produced within the Construction Insulation Chop whenever "Thermobestos" insulation blocks are fabricated. Furthermore, it was recommended also that the fabrication of "Thermobestos" insulation blocks should cease until at least one of the following two conditions arc- met: First, that the atmospheric dust problem is reduced to below 20 mppcf of air through the use of ventilation, etc., or, second, that, if a new insulation block should bo manufactured by the producer of "Thermobestos" blocks that, it would be subjected to testing under identical conditions as before thereby establishing the fact that it will not release, upon fabrication with a band saw, dust concentrations in excess of 20 mppcf of air. The Industrial Hygiene Department's recommendations met exact rcmnlinnce by those' responsible persons in the Construction Insulation Shop, in that no "Tlvrmobes Los" insulation blocks have been fabricated with band saws for use in this plant since the date of the issuance of these recommends tion.a. However, some change in procedure was indicated when, on 2S Apr I.J 1002, this dop-> rtment vn n contacted by Mr. D. R. Mntheny, General Foreman of Mm* .Insulation Shop. At that time, Mr. Matheny requested an ovaluot Ion of a now lhormoboal.ps" insulation block which had boon developed by the mnufnctup'r, in an cffoj-t ha comply with the specifications as sbated in tlv so ond part, of the above listed recommendations. "Insula i.J on block Dust Survey, Construction Insulation Shop, Plant dll, Report C2-JH-1-G-1. PLAINTIFF'S EXHIBIT Col 3.. D Pq-3 DIuC'Uta'J.UH: Mr. Matheny's request for services was immediately acted upon at which time two basic decisions were made: First, Friday, the 27th of April, would be the most opportune time for obtaining the information needed in the performance of this evaluation and, second, two atmospheric dust samples of each condition should be obtained with each one being taken in identical locations so as to provide greater reliability. These sampling plans hai to be altered somewhat, however, on the site, when it was discovered that the manufacturer had provided only three insulation blocks each of which differed in the precise manner in which it had been produced*. Tliis shortage of material, with identical characteristics, complicated the sampling and evaluation procedures Bomewhat, since it was impossible, therefore, to obtain more than one sample of atmospheric du3t being produced by any one material (in actuality, a total of only three atmospheric dust samples were collected during the test period). However, this complication was not so severe as to render the sample data of no use, as is revealed in the condeused explanation of the sampling procedure selected on this date which is as follows: First: The data contained on page 8 of Report 62-TH-'l-b-l revealed clearly that the greatest concentrations of atmospheric dust were produced at the band saws, and that:, location //3, i.e., r/2 band saw while sawing, definitely provided the greatest hazard to health. Consequently each of the three samples, under consideration in thl3 report, i.e., 62-IH-2-G-1, were taken at this 6ame location. Second: All of the results revealed Ln the preceding report, i.e., fj2-ilI-l-G-l, were obtained during the late fall and winter, therefore, the doors to the building were closed for purposes of heat conser vation. These environmental conditions were duplicated during the performance of this second survey. Third: The operator of the $2 band saw employed sawing techniques as nearly identical with those in evidence during the preceding periods of evaluation as were possible to duplicate, i.e., position of the block with respect to the saw blade, speed of finding the block. Into the saw blade, position of the operator's head with respect, to the block, etc. Fourth: Each of the dust samples obtained during the 1.1 me performing the initial survey were held in the operator's breathing rr no. 'lliin feature was also duplicated for this second survey, ol'-lH-2-O-1. h'.'A i .1 l.vr i i dl: Kwh of Ur three samples collected were evnlun teal in Urn .laboratory in with recommended and proscribed, light field, m i <: rosoonl < counting U-chn tqnes ns referred to and identified in Report 02-IH-l-G-.l . it should be noted that, no effort was expended to obtain anything more than a knowledge of the concentration of dust in the air since the composition aid particle s ze of ttiis material should not be expected to deviate to any d i g ree from tdi ' prior recorded values. This supposition was based on two facts, (l) the 5in accordance wTTFi in/'ennation received from the manufacturer each block was composed of ]dnntically the norm materials and was formed in the same general manner, I.e., by tin - "Fan Method". However, the similarity in pi eduction differed (km here on v'th the manufacturer being the only one in possession of the exact dec.-'rip' ion and the specific alterations incorporated in each metical. PLAINTIFFS EXHIBIT foloLO 3- chemical make up of these mater Lais was reported as being identical with tin-' "Themobestos" materials reported on in the prior survey and, (?) the sawing techniques utilized on both occasions were identical in nature. PHOCKDUREo: Both sampling and analytical methods were identical in detail with those described in the earlier report, with sampling being accomplished through the use of the Mine Safety Appliance Company's Midget Impinger Pump and Apparatus nnd the analysis taking place in accordance with light field microscopic counting techniques. PiKSULTS: Analysis of the physical data contained on page 5 reveals that the atmospheric dust concentration in rappef (million particles per cubic foot) of air for each of the three new materials wa3 (a) 3^.8 mppcf of air for J.M. //21, (b) 48.1 mppcf of air for J.M.//22, and (c) 44.1 mppcf of air for J.M. //23. CONCLUSIONS: (1) None of these three samples revealed a concentration as high as that recorded in the previous report for "Thermobestos" exposures in this position, i.e., 101.4 mppcf of air for Location $3- However, by the same token, none of the present three samples revealed a concentration as low as that recorded for "Kaylo" exposures in this position, i.e., 17.1 mppcf of air for Location #3* (2) Each of the three values exceeded the established T.L.V. (Threshold Limit Value) of 20 mppcf of air by a substantial amount. (3) None of the three insulation materials, i.e., J.M.//21, J.M.//22, and J.M.//?3, as submitted by the manufacturer of "Thcrmobestos", should be fabricated with band saws in the Insulation Shop by our employees unless the manufacturer complies exactly with the following conditions: The physical and/or chemical characteristics and composition of them.: mater Lais are improved to the degree that some further fut ure evaluation might reveal them to be incapable of releasing concentrations of dust, into the atmosphere that are in excess of the T.L.V. Ki:<k .'HKNOAi'.l mN.'I: No not fabricate the 1.0" x 36" x 4" "Tliennobestos" Insulation blocks (J. M.~$21, .I.M.//22, J.M.#23) with existing equipment unless - (l) Hie pn-iucer of this material can further improve his prelect, to the point that it will not release, upon fabrication with our ventilated band saws, dust concentrations in excess of 20 mppcf of air, or, h. (2) The atmospheric dust problem can be reduced to below 20 mppcf of air through the use of improved ventilation techniques, or other safeguarding measures. REF:gl 15 July 1962 Submitted by: Robert E. Pcele Industrial Hygienist 4- INDUSTRIAL HYGIENE SURVEY EVALUATION OF ATMOSPHERIC DUST CONCENTRATIONS AT HIE CONSTRUCTION INSULATION SHOP Atmospheric Dust Concentration Data on Three "Thermobestos" Materials An Collected with the Midget Impinger Pump and. Apparatus TYPE OF DUST MATERIAL LOCATION Rate in cfm Time In Min. SAMPLE Vol. in C.F. Blank n Dilution Particles Factor Count Ji Particle:; Cone. in mppe f of Air JM //21 //2 Rand Saw, Breathing 0.1 Level of Operator 10 1.0 0-3 100 n4. 8 36.8 JM 7/22 JM #23 Same nn Above Same as Above 0.1 10 0.1 10 1.0 1.0 8.3 6.3 250 57.0 200 65.O 48.1 44.1