Document RpJNXvweORBmemJyjZaOxbgzz

PLAINTIFF'S EXHIBIT AL-831 61. G eneral correspondence // ^ov^nov=JL Elle Sasinoski FILE i MR. J. B. FERRAZ SAP LUIS, BRAZIL 1982 Sept. 22 RE: JOAN E. SANDER'S 1982 SEPT. 10 LETTER -- PRECAUTIONARY MEASURES FOR FABRICATION OF ASBESTOS FIBRE-CEMENT ROOFING AND SIDING Enclosed you will find the booklet which promised to forward to you, "Recommended Work Practices for Field Fabrication of Asbestos-Cement Sheet". I If we can be of any further assistance, please do not hesitate to call Joan on Ext. 2597. t~ {,. 7" - ELLE SASINOSKI Secretary to Joan E. Sander /eds Attachment i> I ( I JOAN E. SANDER PITTSBURGH OFFICE DRAFT MR. R. D. SCHULTZ SAO PAULO, BRAZIL MR. J. B. FERRAZ SAO LUIS, BRAZIL i 1982 September 07 RE: Ref: Earl PRECAUTIONARY MEASURES FOR FABRICATION OF ASBESTOS FIBRE-CEMENT ROOFING AND SIDING R. Sharkey/E. E. Rumberger's 1982 August 31 Telegram_______ OU+liKt Rumberger has asked me to CniAAni ymi in^mnii mit otecrvt *tAe precautionary steps to Luli'i iw during the fabrication of thio -to W u sad i t-i asbestos-cement material finrs-fetae construction of Building 035. Because working with asbestos products involves a real and serious potential health hazard, certain recommended work practices and procedures should be followed to minimize employee exposures to asbestos dust. For all fabrication operations, one must assume that airborne asbestos concentrations are excessive unless air monitoring demonstrates otherwise. To control these asbestos exposures, I have offered some suggestions below, and have enclosed some booklets which I hope will be helpful to you. I. WORK PRACTICES A. Good housekeeping should be followed to maintain a working environment free from the accumulation of asbestos dust. B. Clean-up of asbestos dust should be performed by vacuum cleaners or wet methods to prevent generation of dust clouds. Loose material should never be dry swept. (MORE) Messrs. R. D. Schultz and J. B. Ferraz 1982 September 07 Page 2 C. The asbestos waste and scrap material should be disposed of in impermeable sealed bags or containers. D. The enclosed booklet, "Recommended Work Practices for Field Fabrication of A-C Sheet", offers some guidelines for fabrication of asbestos materials. This booklet is published by the Asbestos Information Association and is a good reference for specific procedures involving the different types of operations involved in the construction process. II. PERSONAL PROTECTIVE EQUIPMENT A. Respirators 1. Since exposure levels are unknown, but likely to be excessive, respiratory protection will be required of those involved in the fabrication of the fiber-cement roofing and siding. 2. There are several respirators suitable for the control of asbestos dust. The enclosed 3M brochure illustrates three such respirators: the 3M 8710, 9900, and 9910. There should be comparable products available in Brazil. B. Protective Garments 1. Further asbestos exposure to the worker or his family may result from wearing the asbestos-laden clothing home and, also, in the laundering of the work clothes. To prevent this type of exposure, those employees working in areas which may produce visible asbestos dust with fwnprl I' | Messrs. R. D. Schultz and J. B. Ferraz 1982 September 07 Page 3 B. Protective Garments (Cont.) subsequent accumulation on the clothing should be provided with protective garments. 2. DuPont manufactures Tyvek , a spunbound olefin used in disposable protective garments as a barrier against asbestos dust. Their Sao Paulo Office will be glad to assist you in locating vendors who sell protective garments made of Tyvekw . I am enclosing some literature on the product for your information. For further assistance, you may contact: J. T. Muniz DuPont Company Do Brasil S.A. Al. Itapicuru 506 Cixa Postal 26 Alphaville 06400 Barueri, Sao Paulo Telephone: 11-421-8229 III. RECORDKEEPING Fibers of asbestos in asbestos-cement sheet products are normally "locked in" to a cement binder. However, during fabrication and demolition operations, there is a significant potential for fiber generation. With future considerations in mind, it is imperative to maintain accurate records as to where asbestos products have been used in construction. This will help to insure that proper precautionary measures are followed during modification, demolition, etc., of the areas using A-C sheet products. (MORE) Messrs. R. D. Schultz and J. B. Ferraz 1982 September 07 Page 4 If I can be of any further assistance, please do not hesitate to call me in the Pittsburgh Office at 412/553-2597. JOAN E. SANDER JES/eds Enclosures v. FROM E. E. RUMBERGER PITTSBURGH OFFICE TO 1982 February 16 RE: ASBESTOS REPLACEMENT The attached Asbestos Replacement Report is being distributed to plant Department Managers and Superintendents for Engineering, Procurement, Safety, Environmental Control and Industrial Hygiene. It comments on successful and unsuccessful substitutes for asbestos. Considerable progress has been made in the plants over the past two years in implementing safer substitute materials. This report should be helpful to you in knowing the results of the experiences at the other plants. It might also serve as a useful guide to be used in your next staff meeting to explore your success in making your plant as free from asbestos-containing materials as possible. i We are asking that plant Engineering and Procurement Managers keep us advised of their results in seeking safer substitute materials. This will permit us to share the information throughout the plants. The very worthwhile efforts being made in the plants are much appreciated. E. E. RUMBERGER EERrmlf Distribution: Operations and Works Managers cc: Engineering Managers Procurement Managers Safety Managers - Domestic and International Environmental Control Contacts Industrial Hygienists - Domestic and International J. H. Sloane, Pittsburgh Office - 20 T. J. Sherman, Pittsburgh Office - 20 F. J. McGrath, Pittsburgh Office - 20 P. R. Atkins, Pittsburgh Office - 7 J. C. Fussell, 4th Floor - William Penn Hotel P. A. Haas, Pittsburgh Office - 20 J. M. Me Collum, 3rd Floor - William Penn Hotel G. F. Leymeister, Pittsburgh Office - 19 C. E. Rhodes, Pittsburgh Office - 19 R. E. Edgington, Pittsburgh Office - 19 alcoa Page 2 1982 February 16 Distribution: (Con't) M. J. Caprio, Pittsburgh Office - 19 V. R. Scorsone, Pittsburgh Office - 27 G. B. Scott, Pittsburgh Office - 23 E. B. Perry, Pittsburgh Office - 23 H. G. Reavis, Pittsburgh Office - 23 J. R. Clark, Pittsburgh Office - 23 R. J. Hosfeld, Pittsburgh Office - 23 R. D. Hornbeck, Pittsburgh Office - 30 K. W. Perry, Pittsburgh Office - 24 R. R. Hoffman, Pittsburgh Office - 30 E. M. Kasody, Pittsburgh Office - 28 W. Turbeville, Pittsburgh Office - 28 C. R. Gillespie, Cleveland Works R. C. Rawe, Lafayette Works R. A. G. Vines, Massena Operations W. C. Keith, Corona Works J. W. Martin, Lancaster Works N. W. Nielsen, Pittsburgh Office - 18 J. B. Geshay, Pittsburgh Office - 23 H. S. Evans, Pittsburgh Office - 24 P. L. Abernnethy, Jr., Pittsburgh Office R. Banks Smith, Pittsburgh Office - 29 H. L. Johnson, Pittsburgh Office - 14 C. P. Fletcher, ATC-C L. K. Hudson, ATC-C N. Jarrett, ATC-C P. R. Bridenbaugh, ATC-C J. D. Dowd, ATC-C R. E. Spear, ATC-C Industrial Hygiene Technical Bulletin NO. 82-3 Date: 1982 February 16 RE: ASBESTOS REPLACEMENT The Asbestos Replacement Program was initiated a number of years ago as a result of the health hazards associated with handling asbestos and asbestos-containing materials. The program is a cooperative effort between Production, Engineering, Procurement, Research, Safety and Industrial Hygiene at the plant and corporate levels. It continues to be Alcoa's objective to replace all asbestos with safer substitutes whenever possible. The only exception is that we do not encourage the immediate removal of affixed asbestos insulation so long as it is in good condition. When it does become necessary to replace worn asbestos-containing materials, safer substitutes should be used. When asbestos is being removed, proper precautions must be taken to protect employees from inhaling asbestos fibers. Considerable progress has been made in the past two years toward making Alcoa plants asbestos free. The attached report summarizes plant experiences and identifies successful substitutes. It also identifies unsuccessful products that have been tested and failed. The report contains sections on General Applications, Potroom Use, Carbon Bake Use, Wire, Rod and Bar Use, and a List of Asbestos Replacement Manufacturers. This report should benefit each plant based on the experience in other plants. To continue to coordinate these efforts, it is important that Engineering and Procurement at each plant copy the Corporate Industrial Hygiene Division on all efforts made towards asbestos replacement . . . whether positive or negative results occur. Please review this present status report and advise us of any new experiences at your location. If we can be of any further assistance, please let us know. SCOTT M. ANDERSON SMA:mlf Distribution: See Page 2 a ALCOA INDUSTRIAL HYGIENE TECHNICAL BULLETIN 82-3 Page 2 1982 February 16 Distribution: Operations and Works Managers Engineering Managers Procurement Managers Safety Managers - Domestic and International Environmental Control Contacts Industrial Hygienists - Domestic and International Industrial Hygienists - Other Industrial Hygienists - Pittsburgh Office and ATC Attachment ASBESTOS REPLACEMENT PROGRAM Contents General Applications Belting --Block or Brick -- Brake Linings Cement Patch Cloth and Paper -- Gloves -- Marinite Pump Packing Rope -- Tubing Tape Thermocouple Wire Potroom Use Cradle to Pot Shell Insulation Superstructure Foot Insulation Pot Cover Insulation Walkway Grating Insulation Bus Insulation -- Pot Exhaust Duct Exhaust Duct Gaskets -- Siphon Gaskets Ladle and Ladle Lid Seal -- Insulated Electrical Wire Carbon Bake Use Exhaust Duct Manifold Gaskets Wire, Rod and Bar Jarke Rack Liners Asbestos Replacement Manufacturers Page 1 1 2 3 4 5 6 6 7 8 9 10 11 12 12 13 \0 U XU33 3 Pm CM 0O0N ASBESTOS REPLACEMENT PROGRAM a) Johns-M anville "360" b) Keene C o rp o ra tio n "Super- 1900' c) 48 In s u la tio n Super "48" OpM a) o jj Ss (0 cd <h o> 3 4-1 o rH o Oo O 1--1 * rH cr G to CO & o 3 cd 3 Vi 3 CO f*4 3 rH 3 <4-1 V (4 H *3 O ,43 1 3 Ua 33 -- rH 3 3 60 co cvj <5 0) JJ (0 C cd O PH 3 H 0) a> U CO 3 CP P iH VO a 60 33 3 o o Vi sf O a 3 r-l o w a> JJ o a o <4-1 r-l 3 O -G , 0) rH c 3 id 3 Vl H O= A 4-1 V4 G 0) 0) iHa Pm 3o to -a u 4-1 -bC 1-1 3 E r-l c O 4-1 JJ H H CM 3 o u oi ai O id Vl VI 3 < CJ iH 4-1 (0 -3 0) c o a) CD Vi Vl | a> 0) 01 cv co OO O JJ M 3 at m r-l cj o a. 3 1 iJ 3 a 3 as 4J E r cn jd 1 Pm PH o a >4-i 0) Vi G 3 o> ui r o o PH *3 H (0 Vi H iH 3 60 JJ OC ^ O 60 3 4-1 6 3 * fi i-l co e s s o O' 3O *3 O 3o iJ CO C in one O JJ i-i - U rH -dj 3 M 4J 0> 1 i-l 3 oj vi O ap2 JJ O 0) r-l 3 4-1 CO Vi 60 3 i--i cd G 3 W JJ V4 0) 3 CO N 3 3 rH Vl O 3 60 Z CO u 0 6 a 0) 1 VI H 3 -H O iH Pi 3 Ed 3 3 3 lu b u jj O > CV VI 33 O 00 M 0J G 3 c Pd cd 4J e vi cd jj Pi 3 MM Vi i-l M 3 <4-4 3 *3 d OH 3 4J 3 cd i-l 3V 3 M js n M-l 01 3 4-i in e 33 13 So 3 1 CO M3 3 Pi jj M CO X 3 JJ Pm H 4) M r-l JJ 3 r-l 3 jO <0 3 35 -a co S N--' co aO H 3 0J c a 3 3 *H JJ M G G M JJ Pi rH M 3 JZ 0) 33 3 3 O H o oi oo H Pi iH 3 H V 4J U 0J 1-1 o 3 3 Pm rH 1 3 *H a0) r-l 3 0) 3 CM VI (0 JJ 3C 1 o VI i-l JJ r-i e a. -i-oi ir--il i-El 3M *o -3 *3 3 >, 3 ad *3 CP a a Wa 3 n n n iH 3 3 o3 H iH 3 CO rJ U 3 CO d 3 ci 33 jj m cd Pt 6 VI 60 3 10 0) 00 rH 3 a pO 3 H eeS Pm 3 a> a XI M .a i-i 3 3 4) M O (0 .43 O aO^idi oB V4 Vl <314 o5 H rH CM 3 Pi 3Q 60 Pi 3 HJ O H Mm U rH 3 3 DC 3 iH 3 O Pi H 3 JJ JJ rH 33 Z CQ C0O) o 3 OC H Pi P 3 CQ U-i oU Pi O Mm r^ ou *H CQ 3 DC 3 H C hJ 3 3 Pi CQ ooccd 3 3 Poi MM rC a jj 3 Pu jj 3 3 a 3 a vO >la-1ij 9l-i 43 f0n) CM 00 CT\ X(0J 4>3> *o 3 0) O XJ c co XJ 3X 3 co cd 3 * rH c C CX d H T3 0> 0 ,0 C H Cd fH cd PQ m a> uu o cd xj *o rH 43 9S CD cd d o cd 0) cd M-i rH -a co d o H XJ aV>i m00 03) 1C-1 to *3 3 o cv u VoI x* <+4 U3 v CO H cd rH CX rH *3 CO cd O H O 0) > 00 ua cd XJ o a cd fH 0) XJ o xj 4: Vi rH co 3 fH a) -3 u XJ xj d o O co co 0) H o > cd 0) XJ 3 c60 o 3 ucd 0) a o XJ O 00 oco <0 3 O X to VI to S <44 3 C <vi 3 3 O Vi 300 H T_dJ HO c _c rH a. o tt> CO -H O *0 3 g <4-1 60 a) o o .O u3 co>% xj (u0 3 > co 0) H a>* u 3 XJ XJ 4J (60 C 3 6 CO 43 43 d 3 *0 3 o 3 3 o v 0 3 rH 3 00 3 3 an*TM\ XJ H 43 O o a 00 XJ 60 tH 03 0 3 rH 0 CX d rH XJ aco XJ 3 *0 u XJ p V0 3 e xj 3 O 3 cr 3 Cx H Do d u 3 XJ 3 O cx 3 pH | H c 3 a fH Vt fH M 3 o 3 o 3 d PQ XJ 3 VI 3 3 X V 3 0oUo 00 CM 43 0 3 40 d 00 cd XJ *0 3 3 XJ 3 cr 3 a3 Put 3 EC XJ XJ rH 3 rH w 3 3 43 3 H 3 m d o o 3 Vi 3 3 43 fH o ex XJ CX M 0 fH 3 CX 3 XJ rH o 'w' 3 * >v XJ 33 44 0O *0 *0 rH 43 3 iH 3 44 3 3 3O a u 3 XJ o CM d 3 rH d 3 3 Vi Vi a 3 Vi 3 rH 3 33 3 0) rH H u H Vi 0 3 V XJ H 3 o H 3 3 fH 0 3 0 rH 0. x: XJ XJ d rH 3o 3 H *0 XJ rl U a 43 XJ XJ VI XJ 3 o 3 XJ 43 43 3d 0 3 XJ u 3 d O iH 3 3 6 3 3 3 /N XJ d O 3 a ES 43 d iH XJ ,0 a0. 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CM 0CT0V x0:) 4-1 O 0) o. X W fa H r>H Hfa rfHa rl H H H CO CO CO CO cO > cO CMM cfOa Vi CM r>H> rfHa rHfa iH iH H CO CO CO cO CO CO a> ) oo Ho CO fHHHCHfafO3l CO CO 4s<g3JU COJ >u* o 4OcCMOJQ *H 4CCc3JOO fa 4VcoaOJi CCHMO 4Ccc-3OO1 uoafUa (0 CCMO H o4cCsOJO fua 4oacOJ CCMO MH Ccs3OO fa Vi 4OacOJ CCrMOl 4CCs-3OO1 Vfai 4o-1 CCOCMDO 4H-1 cCsO3O fuoa 4-1 MOCCHOO *4cCH-OO1 3 33 fa CO3 ASBESTOS CARBON BAKE USE SUBSTITUTES- CM col c0 rH MH c sca0> csO 01 cs<dU csO Q> c3aO> c03O1 z cO CO CO CO CO O CO CO CO CO CO CO CO CO CO CO Q O O CO eg cfl CO j 2 2 2 2 J23 2 eg 2 * -u oo PQ o CO Vi T4--1t XC3O H fa CoO CO fa 1 4<-u1 Bw cO_> . 43J iH vO fa 1 a> 2 U x0) 4oJ * mm fa 1 CO fa > Cwd s i CO Ho CO fPaQ C<O u rcHO >0) fa 0) f4a- O roH PN. f4oa-1 iaM rH 0C)u HcO m CM "c0 cO CO CO cO <Ouu CO a. HcO 01 H CCMM a MH D. CO H 4<-D1 43J H M CO f3a CO *0* fa M0) o M fa fa fa fa H fa ro-l Ts> fa 10-)i 0) 4ouJ 4<o-U1 Vi 4a->1 pq oU fa fa ffaa ffaa i H XCO) fa fa 4aou->1 ffaa X 40-1) >ai z Oo CM rH X 40-1) M4) Massena Zetex 32500 c rH oO iH VM 4-1 *H CO C O (0 iH rH a 4-1 CO a < o 3 4c-u1 Q o CO H 4-1 ca VM (0 a iH 3 a cO <u JS aX CQ w c o iH 4-1 (0 CO M o H 0) c rH iH o. _3 a < O o CO 0^ H a) O <U M & cO 00 *"3 Product Pyrotex Flberseal Products Refrasil Nor-Fab Yarns; Fabrics Flberfrax Hi-Temp 270 Ceramic Fiber Products Marinite and Other Products ASBESTOS REPLACEMENT MANUFACTURERS (Page 13) Supplier Newtex Industries, Inc. Railroad Avenue P. 0. Box 25 Victor, New York 14564 Pyrotek, Inc. East 9601 Montgomery Avenue Spokane, WA 99206 -0RBox 77 - R.D. #1 Claremont Road Carlisle, PA 17013 -0RSanta Fe Springs, CA HITC0 Division of Armco Steel Middletown, Ohio 45042 Amatex 1032 Stanbridge Street Norristown, PA 19404 The Carborundum Company Insulation Division P. 0. Box 808 Niagara Falls, NY 14302 Penn Compression Moulding, Inc. Burton Street Pittsburgh, PA 15218 Kaowool Babcock & Vilcox Cem-Fil Corporation Two International Plaza Drive Nashville, TN 37217 Keller Glove Mfg. Co. Plumsteadville, PA 18949 Johns-Manville The Manville Corporation Ken-Caryl Ranch Denver, CO 80217 1982 February 16 Telephone No. 716/924-9135 509/926-6211 717/249-2075 215/277-6100 716/278-6221 412/351-4004 615/361-4664 215/766-8818 303/978-2000 FROM' MICHAEL J. VAUDREUIL PITTSBURGH OFFICE TO MEMORANDUM 1980 August 1A RE: ASBESTOS REPLACEMENT UPDATE The following sections summarize the progress made over the past year in the search for asbestos substitute materials. The discussions are organized by asbestos product, and within each section by specific application. A supplemental list of substitute material suppliers is included. 1. Molten Metal Marinite There is presently only one necessary use for asbestos in ingot plant operations; that is, header applications. There are adequate replacements in Johns-Manville's Marinite I and Pyrotek's Pyrotherm B-2 board products and R-680 for all other melting and casting needs. Therefore, Molten Metal Marinite need not, and should not be used for dams, basins, troughs, etc. However, at present, the suitability of substitute materials for use as floats is questionable. Some header-related applications of asbestos have also been eliminated. After header design modifications, R-680 can be used for all FDC headers 635 mm (25 in.) and smaller. With this substitution, Lafayette, Vancouver and Massena should be asbestos free. Molten Metal Marinite must still be used for HDC and tool and j ig headers. R&D programs at ATC will continue to address these areas. 2. Asbestos Rope Fiberseal A-l rope (Pyrotek, Inc.) can be used in place of asbestos rope for sealing the gap between the mold and bottom block in FDC casting operations. It prevents metal leakage and its good thermal stability allows it to be reused numerous times. It may also be used for sealing joints in pouring troughs. Z-5 treated fiberglass rope (Pyrotek, Inc.) can be used successfully as a crucible lid gasket on vacuum-type potroom tapping crucibles. It replaces the presently used Johns-Manville 872 or 702 asbestos gasketing material. However, Z-5 will not replace gaskets made of twisted aluminum foil. Plants using foil gaskets will in all probability have to continue that practice. 3. Transite Transite, a structural, fire-retardant asbestos/portland cement board, is used extensively in construction. ATC has tested glass-reinforced cement (GRC) sheet as a replacement for transite. ESalcoa MEMORANDUM Page 2 1980 August 14 Although GRC boards are not suitable for high temperatures (>320C) or molten metal contact, they can be used in fire resistant components, pipe work, furnace shells, etc. Physical properties are similar to transite except that GRC board has lower shear strength. However, proper engineering design can compensate for this deficiency. 4. Thermocouple Insulation Finding a suitable replacement for asbestos-coated thermocouple wire has been particularly troublesome. Many substitutes have been rejected because of low abrasion resistance and/or friability at high temperatures. A new ceramic fiber product from 3M, Nextel 312, purportedly exhibits excellent abrasion resistance and Immunity to thermal shock. The attached brochure provides more complete product information. If physical properties of Nextel 312 are as claimed, it should prove to be a suitable substitute for asbestos coated wire. Comments and additions to the information presented are encouraged. FROM MICHAEL J. VAUDREUIL PITTSBURGH OFFICE TO INDUSTRIAL HYGIENE CONTACTS DOMESTIC & FOREIGN 1980 August 14 RE: ASBESTOS REPLACEMENT PROGRAM As part of Alcoa's asbestos replacement program, a listing of applications and substitutes for asbestos was compiled and distributed in August of 1979. Since that time, some headway has been made in the development of substitutes for several uses of asbestos. The progress to date is reviewed in the attached memorandum. An updated version of the original master listing is in preparation. Distribution of the revised registry is planned for 1980 November 01. However, critical to this effort is additional input from all Alcoa locations. Information on current plant asbestos use, as well as any successes (or failures) with substitute materials is requested. In order to meet the November 01 target date for release of the updated list, replies should be received by 1980 October 01. This ongoing exchange of information is necessary for the continued success of the program. With the assignment of Haig Sakoian as Senior Industrial Hygienist, Tennessee Operations, I have assumed the responsibility for overall coordination of the asbestos replacement program. Therefore, please direct all future correspondence to my attention. ' / 1 iJ MICHAEL J. VAUDREUIL MJV:mlf Distribution: Location Managers - Domestic & Caribbean Location Managers - Subsidiaries & Allied Products Safety Managers - Domestic & Caribbean Safety Managers - Subsidiaries & Allied Products Location Engineering Managers Purchasing Agents J. H. Sloane - Pgh. K. W. Perry - Pgh. R. W. Wrenn - Pgh. T. W. Callaham - ATC T. J. Sherman E. B. Perry - Pgh. - Pgh. L. C. Drapela - Pgh. R. N. Sater - Pgh. F. J. McGrath - Pgh. R. C. McCormack - Pgh. T. I. Stephenson - Pgh. QG. F- i sr er ALCOA - Pgh. INDUSTRIAL HYGIENE CONTACTS DOMESTIC & FOREIGN 1980 August 14 Page 2 Distribution (con't): Industrial Hygiene Mailing List Environmental Managers E. L. Rooy - Pgh. J. Z. Nelson - Pgh. G. F. Stephens - Pgh. D. D. McGregor - Pgh. R. L. Graves - Pgh. M. J. Caprio - Pgh. J. M. McCollum - Pgh. D. St . Jacques - ATC cc: T. B. Bonney, Pittsburgh Office - 7 E. E. Rumberger, Pittsburgh Office - 7 V. L. Hammersmith, ATC-B V. W. Rieke, Pittsburgh Office - 2 R. M. James, Pittsburgh Office - 7 R. W. Flanagan, Pittsburgh Office - 6 C. Dixon, Pittsburgh Office - 6 P. H. Scott, Pittsburgh Office - 6 B. L. Siceloff, Pittsburgh Office - 6 Attachments SUPPLEMENTAL SUPPLIER LIST Product Next el 312TM (ceramic fiber) ZetexTM (a.k.a. Pyrotex oTnh- ermog,lass TM (fiberglass) HI FibeR (coated polyethylene fibers) Available Forms Supplier 1. woven fabric and tape 2. braided sleeving 3. bulk fiber Ceramic Fiber Products/3M 219-1 3M Center St. Paul, MN 55101 Phone No. 612/733-1558 1. woven fabric Newtex Industries Railroad Avenue P. 0. Box 25 Victor, NY 14564 716/924-9135 1. twisted rope 2. braided sleeving 3. woven fabric and tape Amatex Corp. 1032 Stanbridge St. Norristown, PA 19404 215/277-6100 1. fiber fillers for cement. caulkings, etc. Hill Bros. Chemical Co. One City Boulevard Suite 1521 Orange, CA 92668 714/634-3322 Celiox Fibers (polyacrylonitrile) *heat treatment 1. fabrics *2. conversion to pure carbon fibers Celanese Plastics & Specialities Co. 26 Main Street Chatham, NY 07928 201/635-2600 CER-WOOL (ceramic fiber) 1. blankets 2. vacuum-formed boards 3. bulk fiber C. E. Refractories 412/351-4409 P. 0. Box 828 Valley Forge, PA 19482 Siltemp (fibrous glass) 1. cloth GRC Sheet (fiberglass reinforced cement) 1. flat and corrugated board Haveg Industries, Inc. 900 Greenback Road Wilmington, DE 19808 GRC Products, Inc. 17051 I.H. 35N Schertz, TX 78154 1-800-441-7777 512/651-6773 GRC Sheet (fiberglass reinforced cement) 1. flat and corrugated board CEM-FIL Corporation 120 Spence Lane Nashville, TN 37210 615/883-7563 PreoxTM 1. woven fabric (polyacrylonitrile fiber) Gentex Corporation Carbondale, PA 18407 717/282-3550 ,,Ke.lvarTM ^ and Nomex (aramid fiber) 1. cloth E.I. duPont de Nemours 302/999-4693 2. rope & Co. 3. pump packings Textile Fibers Department 4. tapes and Wilmington, DE 19898 webbings 5. braided sleeving MICHAEL J. VAUDREUIL:mlf 80-08-05 Product Bulletin Thermocouple Insulation At last: a practical high-temperature insulating material that eliminates the two biggest causes of thermocouple failure. Dimensional stability and abrasion resis tance have always been big sources of trouble for high-temperature insulators. The most commonly used fibers- those made from vitreous silica - typically shrink, abrade, fray, or crumble to the point where wires become exposed This obviously creates a potential for inaccurate tempera ture readings. The traditional alternative, ceramic beads, solves the problem of ex cessive shrinkage and abrasion, but only at a high cost for labor. Now there's a better alternative: Nextel* 312 Ceramic Fiber from 3M Nextel 312 withstands operating temperatures of 1000 F. to 2600* F. continuously. It shrinks less and resists the combined effects of abrasion, flexing, and high temperatures better than asbestos, quartz, and vitreous silica fibers. It also offers good chemical resistance and immunity to thermal shock. Proven dimensional stability. A recent test compared the dimensional stability of Nextel 312 and vitreous silica by heating sleeves braided around separate lengths of wire for v2 hour at 2000 F. When the samples were removed from the fur nace. Nextel 312 still covered the wire completely, thanks to shrinkage of less than 1 per cent. The vitreous silica fiber had shrunken by roughly 12 per cent, leav ing an inch ol wire exposed at one end Nextel 312 braided around a thermo couple wire and heated at 2000 F. lor 'h hour shrank 1%. Vitreous silica handled the same way shrank 12e/o. Exceptional resistance to abrasion. In another lest, a Duplan "silk-testing ma chine" was used to compare filaments of Nextel 312 and vitreous silica. Blades were rubbed back and forth on the two products after they had been heated for Vs hour at 1000 F.. 1500 F. and 2000 F. Results showed that Nextel 312 lasted 2'/2 to 5 times as long as the vitreous silica fiber This means that at 1000 F. Nextel 312 performed 400 per cent better. The figures for 1500 F. and 2000* F. were 300 per cent and 166 per cent respectively. No residual acids or chlorides to cause etching of wires. Because Nextel 312 Ceramic Fibers con tain no residual acids or chlorides, there's no chemical present to corrode or etch the wires. Even in a test involving exposure to 96 per cent relative humidity, no notice able electrolytic corrosion was detected. The lest consisted of putting Nextel 312 fibers in contact with two unconnected bare #32 copper wires. A 250-volt D.C. po tential was applied across the wires. After 20 hours, corrosion was determined by calculating the ratio of anode wire tensile strength to cathode wire tensile strength. Three test runs produced ratios above 0.99: since (he maximum ratio possible was 1.00. there was essentially no elec trolytic corrosion Available from your local thermocouple supplier. Nextel 312 is being manufactured in pro duction quantities right now. For more information on how it can increase the ser vice life of your thermocouples, contact your supplier Or call 3M at 612-733-1558 (in Northeast locations call 201-575-2076) or write 3M at the address below. N-M8T1-3(110.5)11 Ceramic Fiber Products/3M 219-1 3M Center St Pat!I Mtnnptnt.'j ^101 UlHQlNUS A GERALD D. HICKS - 30 TO: MEMORANDUM- d -- (j^b. U ^jk 0 1*981 August 14 RECEIVED Aug 2 0 7987 RE: ASBESTOS REPLACEMENT PROGRAM Industry hygiene As part of "Alcoa's continuing program to reduce and ultimately eliminate all uses of asbestos in plant operations, it is necessary to conduct a rather detailed survey of asbestos uses still in effect at Massena. For such a survey to be of real value, we not only need to know where asbestos materials are still in use, but more importantly, what replacement materials have been tried and whether they are successful or not and why, if not. Our need to know where asbestos materials are still in use is to provide the industrial hygiene section with information to enable us to air sample all involved employees to document their levels of exposure. By OSHA regulation we are required to sample all such personnel each six months to confirm LOW or NO exposures. This report is also used to determine those personnel requiring a medical examination. From a health hazard and governmental regulation standpoint, the asbestos problem has not diminished in the least. Implications are that asbestos control regulations will become even more stringent in the future. Because the continued use of asbestos products may result in unnecessary health hazards and concerns to our employees, as well as addtional costs to Alcoa to comply with specific provisions of the OSHA standard, it is believed to be in Alcoa's* best interests to continue eliminating the use of asbestos products wherever possible. A systematic effort should be made to discontinue uses, when feasible and practical, by substitution or elimination. I have attached copies of an Asbestos Replacement Program Questionaire that I would appreciate each department to complete and return to me. Please use a spearate questionaire sheet for (1) each type of asbestos material and (2) each use made of the material. Please include a sheet for successful re placements. If asbestos materials are not used in your area, please note it on a form and return it to me. I will appreciate it if your response to the questionaire is completed by 1981 August 31. On the line for Materials please list the following: Cloth Paper Marinite Packing Rope Sheet Gasketing Tape Thermocouple Wire Personal Protection oo< k>Ov>' On the line for Use please list such applications as: Insulation, Heat Insulation, Electrical Welding Blankets and/or Protection Coil Tray liners Heat breaks Molten Metal Casting Pump Packing (uncoated, noncompressed, braided asbestos) Cradle to Pot Shell Insulation Superstructure Fort. Insulation Pot Cover insulation Walkway grating insulation Bus insulation Exhaust duct gaskets Siphon gaskets Ladle and Ladle Lid Seal Also list the Job Classification Exposed whenever the asbestos material is fabricated, applied, used in process or removed from service. By creating this listing and providing feedback to all people concerned we can hope to remove or eliminate our dependence on asbestos materials. Also attached to this letter is a list of asbestos replacement materials, their suppliers and telephone numbers. GERALD D. HICKS GDHijmm Attachments cc: (w/attachments) R. A. G. Vines For information only G. H. Schneider - 303 - For information only G. L. McCullough - 28 - For information only R. H. Field - 8 - For information only J. R. Feeley - 59A - For information only Dr. M. J. Elder - 22 - For information only E, T. Klenske - 4 - For information only R. N. Peterson - 7 - For information only D. E. Jackson - 301 - For information only W. R. Duso/T. A. Reine - 25 - For information only J. D. Latvaitis/M. W. Clarke - 301 K. P. Bellor - 301 W. T. Burt - 201 . W. B. Parker - 204 W. H. Jochmann 60 Distribution continued on next page cc: (continued) R. J. W. J. D. E. J.,V. F. R. H. P. J. L. M. W. C. W. D. G. R. J. G. M. R. J. R. W. P, H, file Sharpsten - 207 Curtin - 59 Campbell - 44 Carroll - 59 Gero - 31 Besio - 73 Macintosh - 210 Wall - 60 Houlihan - 45 Martin - 60 Kopecky - 32A O'Brien - 30 Dougherty - 30 Flanagan - Pgh. H 6 Scott - Pgh. H S S ASBESTOS REPLACEMENT MANUFACTURERS Product TM Nextel 312 (ceramic fiber) _Ze.tex TM (a.k.a. Pyrotex ; Thermoglass TM (fiberglass) HI FibeR (coated polyethylene fibers) Celiox Fibers (polyacrylonitrile) *heat treatment Available Forms Supplier 1. woven fabric Ceramic Fiber and tape Products/3M 2. braided sleeving 219-1 3M Center 3. bulk fiber St. Paul, MN 55101 Phone No. 612/733-1558 1. woven fabric Newtex Industries Railroad Avenue P. 0. Box 25 Victor, NY 14564 716/924-9135 1. twisted rope Amatex Corp. 2. braided sleeving 1032 Stanbridge St. 3. woven fabric Norristown, PA 19404 and tape 215/277-6100 1. fiber fillers for cement, caulkings, etc. Hill Bros. Chemical Co. One City Boulevard Suite 1521 Orange-, CA 92668 714/634-3322 1. fabrics *2. conversion to pure carbon fibers Celanese Plastics & Specialities Co. 26 Main Street Chatham, NY 07928 201/635-2600 CER-WOOL (ceramic fiber) 1. blankets 2. vacuum-formed boards 3. bulk fiber C. E. Refractories P. 0. Box 828 Valley Forge, PA 19482 412/351-4409 Siltemp (fibrous glass) 1. cloth Haveg Industries, Inc. 900 Greenback Road Wilmington, DE 19808 1-800-441-7777 GRC Sheet (fiberglass reinforced cement) 1. flat and corrugated board GRC Products, Inc. 17051 I.H. 35N Schertz, TX 78154 512/651-6773 GRC Sheet (fiberglass reinforced cement) 1. flat and corrugated board CEM-FIL Corporation 120 Spence Lane Nashville, TN 37210 615/883-7563 PreoxTM 1. woven fabric (polyacrylonitrile fiber) Gentex Corporation Carbondale, PA 18407 717/282-3550 KelvarTM TM and Nomcx (aramid fiber) 1. cloth E.I. duPont ae Nemours 302/999-4693 2. rope & Co. 3. pump packings Textile Fibers Department 4. tapes and Wilmington, DE 19898 webbings 5. braided sleeving Product Pyrotex TM .Fiberseal Products Refrasil NorFab Yams: Fabrics Fiberfrax Hi-Temp 270 Ceramic Fiber Products Kaowool Available Forms Supplier Phone No Newtex Industries, Inc. Railroad Avenue P. 0. Box 25 Victor, NY 14564 716/924-9135 Pyrotek Incorporated 509/926-6211 East 9601 Montgomery Ave. Spokane, WA 99206 -or- Box 77 - R. D. #1 Claremont Road 717/249-2075 Carlisle, PA 17013 -or- Santa Fe Springs, CA 1. Cloth, tape and sleeving 2.- Bulk fiber 3. Cordage & yam HITCO Division of Armco Steel Middletown, OH 45042 -or- Chamberlain Rubber Co. 1712 Erie Blvd. East Syracuse, NY 13210 315/478-0935 Amatex 1032 Stanbridge St. Norristown, PA 19404 215/277-6100 1. Bijlk Fiber 2. Blankets 3. Cloth, tape and sleeving 4. Paper 5. Coating Cements 6. Boards 7. Tamping Mix 8. LDS Moldable 9. Vacuum Cast 10. Fiberwall The Carborundum Company Insulation Division P. 0. Box 808 Niagara Falls, NY 14302 716,/278-6221 Penn Compression Moulding, Inc. Burton Street 412/351-4004 Pittsburgh, PA 15218 1. Bulk Fiber The Babcock & Wilcox Co. 716/662-9751 2. Blanket Refractories Division 3. Strip 3623 Eggert Road 4. Vacuum formed Buffalo, NY 14127 shapes -or- 5. Paper Refractory Products Co. 6. Rollboard P. 0. Box 309 7. Board 12 W. Main St. 8. Wet Felt Carpentersvilie, IL 60110 9. Surface Coatings Product Ceramic Fiber Products Available Forms Supplier Phone No. Cem-Fil Corporation 615/361-4664 Two International Plaza Dr. Nashville, TN 37217 Keller Glove Mfg. Co. 215/766-8818 Plumsteadville, PA 18949 ASBESTOS REPLACEMENT PROGRAM SURVEY Department _____Date Material:_______________________________________________ Use: _____________________________________________ ___________________ Job Classification Exposed:________________________________ Replacement Tested:Date_ Successful___________________ Not successful Comment: Replacement Tested:Date Successful Not successful' Comment Replacement Tested: Date Successful Not successful Comment Replacement Tested: Successful Not successful Comment Date Questionairc Completed by: Phone: i' r A- /7 /-j~ * < / RE: ASBESTOS IN CONSTRUCTION MATERIALS Mr. E. E. Rumberger, in his letter dated 1982 July 06, expressed some concern for the lack of construction participation in Alcoa's policy and objective to eliminate asbestos use in construction materials. Xou can be sure that, since 1969, construction managers and safety engineers have been informed of asbestos health hazards and the preferred use of substitutes in paints or insulation or in roof felt materials. Before asbestos substitutes were readily available on the Anaconda I Project in 1969, asbestos handling and dust control was given priority consideration. The fabrication of asbestos potlining materials was assigned to an isolated, enclosed area. Shop electric band saw cutting tables were equipped with dust collectors at the point of operation. Asbestos dust was collected in plastic bags and disposed of in designated hazardous waste sites. Workers in thet fabricating shop were supplied with appropriate respirators. In 1974, on the Northwest Alloys Project, asbestos dust control methods for the installation of ferro-silicon furnace gaskets required the Norwegian manufacturer to supply gaskets cut to size, pre-drilled, coated, and packaged in lots of five in plastic bags for safe handling at the point of installation. In the summer of 1980 at the Warrick location. Building 260, electrostatic precipitator rebuild, the sheeting and insulation material was removed wet. The insulation material was broken into small pieces, bagged, and removed to a designated hazardous waste area. Workers were supplied with paper suits, gloves and applicable respirators. f T. I. STEPHENSON PAGE 2 1982 JULY 16 Field construction managers avoid the installation of materials containing asbestos. Occasionally the monitoring system fails, and asbestos can be found on a site. However, its use is stopped and a substitute is sought. At Point Comfort in May, 1981, the installation of felt paper pipe covering (containing asbestos) for washer tanks was stopped and delayed until the contractor found a suitable substitute. In addition to the above type of action, Alcoa Standards and Site Specifications play a leading role in controlling the use of hazardous materials at the site. Mr. Alkire is making the necessary standards changes when suitable substitutes are available. WBG:e f cc: T. M. Brown/R. G. Duhon - 2 AB E. E. RUMBERGER PITTSBURGH OFFICE - 6 FILE MR. J. W. DeWALT PITTSBURGH OFFICE - 2 MR. T. M. BROWN PITTSBURGH OFFICE - 2 1982 July 06 RE: ASBESTOS IN CONSTRUCTION MATERIALS Alcoa has had a policy and objective for the last several years to eliminate asbestos and asbestos-containing materials insofar as possible and practical considering the health hazard they represent to employees. This effort has been conducted primarily through Production, Engineering, Procurement, Research, Safety, and Industrial Hygiene personnel at both the plant and Corporate levels. The focus has been mainly on production and process uses. It would seem that we have been remiss in not being sure that Construction people also recognize this objective and participate as appropriate. We recently had occasion to learn of Warrick using a masonry paint that is approved under Engineering Standard 33.1.4 which contains 14% asbestos. We have now asked Tim Alkire to work with Procurement to determine what other coatings we have in our approved list which possibly contain non-essential asbestos as a filler instead of a safer non-cellulose type filler which is now available in many paints. So-called "encapsulated" fibers are suggested to be safe; and, while this might reduce fiber dissemination in air during application, it does not assure what happens during demolition or destruction of structures. We suspect there might be considerable generation of asbestos at that time from asbestos-containing paints. In any event, we believe it prudent to find safer substitutes wherever possible. The purpose of this letter is to ask that the Construction Department be cognizant of Alcoa's objective to be asbestos-free in our plants insofar as possible and practical. I would appreciate your communi cating this accordingly. Many thanks. E. E. RUMBERGER EER/eds cc: T. I. Stephenson - Pgh. 2 Af f r A /- V D-R. D. SCHULTZ Sao Paulo Office --W Aug/o PA=;a. Mr. ROBERT SHARKEY Pittsburgh Office - Room 628 C - A Re: FIBRE-CEMENT ROOFING AND SIDING We are attaching with this letter two samples of the fibre-cement material we propose to use for special roofing and siding for this project. As we discussed during our 3-way conversation with T.I. Alkire these samples are for testing to see if the material is acceptable for use. Mr. Alkire's wire indicates that we are not to order Building 035 siding until the material receives Pittsburgh approval. We await your comments so that an acceptable material may be immediately ordered. Note that the corrugated section is the material proposed for the roofing and siding for Building 035. The other section is similar to the roofing of most of the substations and control rooms in the Port,Refinery and Smelter areas. a - Cs* c.c.: G.L. Anderson/D.W. Barnes A. Pasalo J.L. McKinstry - 3^, T.I. Alkire - J/3 RDS/rbv. /i D. SCHULTZ ALCOA ^ L. F. DIBLE PITTSBURGH OFFICE 28 TO dr. w. Bruckner ALCOA LAB6^ATORIES pr /E.O StP Z 4198^' v // // ?_- / / - T INDUST WAI-HYGIENE .- - "2- 2"2-1-/-7 *7 -- -- - --^5^3- o//^ RE: MARINITE MACHINING INHALATION PROTECTION Alconor, Igarassu, Brazil_______ MR. T/J.RANDALL ROCKDALE WORKS / 981 JULY 10 H &S Industrial Hygiene BDP, ccon TBB RMJ BIS PHS -MJV- co rH =5 MLF RWF CD DB ^>We observed these operations and .judged the concern and precautions to_be_ inadequate. We mentioned this to Mr. Pitts and on 1981 July 01, I reported our observations to Mr. Alain Belda and Mr. Scorsone. I have also reported to Mr. Boak and he in turn has had a _discuss.ion mth Mr. Rumberger. fjJ I told Mr. Rumberger that ATC had selected some non-asbestos material for caster tips (Marinite C) and suggested that he check with you and Virginia r-JHammersmitTi. I believe you should stand ready to give whatever technical /rt~ il) ' assistance may be needed. We had some prior involvement with Igarassu on tip material, but they advised us that they had gotten some help from Seal and believed their material was superior to the USA material. -=^ Mr. Rumberger will pursue this matter with Alconor, and recommend remedia1 action. > I am requesting that Mr. Rumberger also treat a commercial situation. Our corrugated sheet gets strong competition from corrugated castasbestos cement. The asbestos cement product is cheaper and dominates the market. I told Messrs. Belda and Scorsone that the asbestos awareness in Brazil was shocking to me compared to the control and elimination activities here. He and Mr. Scorsone are somewhat oewildered by it too. In this connection, Mr. Belda would like whatever information you can put together on asbestos bearing products. He has two objectives: make sure Alcoa Aluminio is doing the right things, and do whatever outside missionary work that seems appropriate on the hazards of asbestos products - products like cast asbestos cement v corrugated sheet. L. F. DIBLE LFD:db CC .---.-- r-. r-- . yE. E. Rumberger 6 j:-' . T.I.S.Boak - 14 S.D.Pitts - Igarassu, Brazil Alain Belda, V.R.Scorsone - Sao Paulo E.M.Kasody - 28 G.B.Scott/E.B.Perry - 23 A.J.Sartschev - 3 WPH Virginia L. Hammersmith - ATC ^ ALCOA Jj i i