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MANHATTAN RUBBER MFG. DIVISION
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RAIBEST05-MANHATTAHf INC. RtBB.alg.. Jj2
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A study of the health hazards, if ary, incident to the inhalation
of dust and fumes at the plant of the Manhattan Rubber lifg* Division of Raybes-
tos-Manhattan, Inc. at Passaic, N.J was made between September 24, 1934 and
November 1, 1934 hy the Industrial Health Section of the Metropolitan Life
Insurance Company.
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c PLANT CONSTRPCTIOH '
This plant consists of a number of buildings constructed of brick,
concrete and steel. The ground floors are of concrete and the remaining floors
are of wood. t Natural illumination is furnished by clear glass windows. Artifi
cial illumination is furnished by incandescent electric lights equipped with
reflectors*
PLANT PROCESSES
I
Products manufactured in this plant involving the use of asbestos
are: brake lining, brake blocks, and dutch facings.
Three types of brake lining are made. These are lining made from
woven asbestos cloth, dry process lining, and wet process lining.
C The asbestos cloth is made outside of this plant. The doth is
treated with rubber, cut into strips and folded to the size desired. The fold
ing is done in Department 36 on machine #1513. This lining is cut to length
in Department 8 on machine #1382. The dry process lining is made from a mixturi s
of asbestos, rubber, resin, litharge and cotton. The mixture is made up in
Department 531 in a rotary mlxar. Canadian asbestos is used. The asbestos as
received is put through a hammermlll and then through a picker and over a shake *
screen. The other materials are kept in containers. After the mixture is
completed, it is taken to Department 53* She mixture is weighed and pressed
into sheets in a heated press. Several of these .sheets are heated in a press
for a given time. The sheets are then cut into strips to the desired width
on a
planer. The btrips are ground to the desired thickness in Gardner
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C surface grinders. They are then eat to length and formed to a given radius in a
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heated press. Holes are drilled in the lining on a gang drill machine. The
ends are chamfered on abrasive wheels. The shipment.
is inspected ami packed for
The wet process lining is made from a mixture of asbestos,rubber,
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litharge and waste material from the finished product of Department 53* This
mixture is made up in Department 53T. The different materials are kept in con
tainers in stalls. A movable scale is equipped with an exhaust system so arranged
that two stalls and the scale are exhausted at the same time. When the material!
from the two stalls are weighed, the scale is moved to the next two stalls. The
workman weighing out these materials is very careless in the handling of the
lead used. He uses a hand scoop and manages to get the lead on his hands and
C clothes and on the' floor. His weans a Willson silica respirator.
Gasoline is used as a solvent for the rubber. The mixing is accom
plished in a
vith rotating paddles. The material is then taken to Depart
ment 53 where it ia formed into strips by means of an hydraulic press and a mold
The strips are dried in heated presses, ground to size in the Gardner Grinders
and cut to length with an abrasive wheel. The lining is then formed on heated
mandrels to the desired radius. Holes are drilled and the corners are cham
fered. The UtiIti; is inspected and packed for shipment.
Th brake blocks are made from & mixture of asbestos, rubber, resin,
lead, etc. This mixture is made in Department 53T. The blocks are formed in
heated molds
in a steam press in Department 32. The blocks are then turned
to size on a lathe and cut to width on a band saw. They are finally put into
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a sandblast cabinet and the surfaces are blasted. Soles are drilled and the finished block is inspected before shipment.
Dry proosss clutch facings are made from a mixture of asbestos, rubber lead, resin, sulphur, carbon black and waste from Department 39 These materialt are mixed in Department 53T in a rotary mixer end the mixture is carted to Depari ae ment 39. The material is weighed and the clutch facings are formed in heated molds and presses. The facings are then ground to the desired thickness, holes are punched, and the facings are inspected before shipment.
One cloth type clutch facing is made from woven asbestos doth treated with rubber. The cloth is folded and circled on a coning machine. The folded cloth is cut and the ends are fastened together. The facing is then put into heated molds and pressed in a steam press. After coming from the molds, the facing is ground to the thickness desired and holes are punched.
The other type of cloth clutch facing is made by punching the rubber treated cloth to size and then putting several thicknesses into the molds. The separate pieces are molded together and then they follow the same processes as the other facings.
The base stock of the rubber used throughout the different department! is compounded in Department 1. Che raw rubber is received in wooden boxes and Btored on the third floor of the building. As the rubber is needed, the boxes are opened and the mass of rubber from each box is placed in a power cutter that cut8 .the rubber mass into six places. These pieces are carried on a conveyor
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to the second floor where they are weighed into mixes for different base stocks along with different compounding materials.
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natter*
Ib sons of the products the rubber oust be free from any foreign
The raw rubber is put through Bills anH then put through a
to take out foreign matter*
The compounding materials such as litharge, sine oxide, sulphur,
rosin, clay, and oils are leapt In a roe of hoppers and tanks that discharge
on the first floor. A traveling scale Is mounted on a small track that runs
under the length of the row of hoppers. The batches of compound are weighed
into open containers as desired for the different bases.
The hoppera are filled fron the second floor. Some of the materials
are sifted through a shaker screen before entering the hoppers. The litharge f (D-70) is received In metal drums. It is dumped from the drums through a
grating into a bln. This dumping is done In a small corrugated Iron died loca
C ted on the north side of the storage building and receiving department. An open belt conveyor carries the litharge to the second floor of Department 1 where it
i enters the hopper. A cloth screened box Is used to allow the air to escape from the hoppers and keep the litharge dust from the atmosphere. One man does the
dumping and wears a Uillaon Dustite respirator.
Two Banbury mixers and six compounding mills are used to make up the
various base stocks. As the rubber comas from the compounding mills, it is
placed on a conveyor and carried to the center of the building where two colored
men remove it, dust it with soapstone and stack it o&to skids. Each base is
tagged and finally stacked Into open racks until needed or taken directly to
\ the department where it la to be used.
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Molded rubber products are mads In Department 4* The base stock is reworked in rubber mills* Xt is out into strips apd put in tube machines that produce solid strips* These strips are out into pieces and placed in metal molds. The molds are heated and pressed Tor a certain time, setting the rubber to the shape of the molds. The molds are stripped and the finished rubber is trimmed and inspected before packing for shipment*
Rubber bonded abrasive wheels are produced in Department 2. The base stock rubber is malted and mixed with asbestos, litharge, carbon, sulphur and abrasive materials in an open container, i colored man does the weighing and mixing. Hie does not wear a respirator while handling the dry materials. The mixture is molded to the desired sizes in molding machines. The molded wheels are then put into ovens where tba solvents are driven off and the wheels set. The wheels are trued on lathes and grinders. These machines are exhausted. The smaller wheels have Babbitt centers. These centers are poured from a hand ladle. The Babbitt is melted in a pot under an exhausted hood.
Large rubber sheets used for flooring and floor protection are iPdw up in Department 26. The base stock is rolled to the desired thickness and put into large heated presses where the rubber is cured or set. Hats of various designs and colors are made by cutting out sections and inserting or inlaying sections of different shapes and colors.
Rubber tubing is made in Departments 5, 51, 6, 31, and 7A. Tubing is produced for various purposes and of various sizes. The base stock is usually reworked in each department before entering the tube machines where the tube is produced. The tubes are cured on metal rods to give the desired inside diameters. The tubing is dusted with soapstone, wheat flour or rice
7.
flour as it comes from the tube machines to keep it from sticking to adjacent
tubing. \ In some cases the tubing passes through braiders where a fabric cover
ing is braided around it. Departments 71 and 6 do this type of work. Some
types of tubing have various layers of fabric. This is accomplished by wrapping
the tubing with cloth impregnated with rubber and allowing the rubber to set
at the same time. The rubber of the cloth and tubing join together and the
result is a solid tube with layers of fabric. This type of tubing is nuoh
stronger than plain rubber tubing.
The 7 type belts are made of a solid rubber core with a fabric cover
ing. This fabric covering is applied to the core and cured in heated molds to
assure the shape and size desired.
Elat belts are made of cloth impregnated with rubber. The doth is
folded mechanically and cured on heated mandrels, the edges being sealed
i together by a strip of rubber applied after the folding process. In the ease of long belts the curing is accomplished in heated presses.
In Department 54 metal pipes, pipe joints and tanks are lined with
rubber. Tha rubber is applied over a coating of rubber cement in thin layers
to the desired thickness. This is uncured rubber and is applied with hand
rollers. After the rubber is in place, it is cured in heated tanks making a
solid rubber lining out of the several layers applied.
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In Department 5 rubber tubing of various sizes is cut to length and
placed on mandrels in lathe grinders. The outside diameter is ground to the
size required. Other products are ground to size in this department also.
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Wool scouring rings and Mintura Vacuus dryer strips were ground at .the tima of
the surrey*
Grinding of rubber rolls of large dimensions, such as paper rollst Is done In department 28. 3be majority of these grinding machines have 63 haust systems. PERSONAL FACILITIES
Drinking water Is supplied throughout the plant by bubbler fountains of the electrically cooled type* Wash rooms and toilets are adequate and are
kept clean. PLANT HOUSEKEEPING
Housekeeping is good in most departments* At the time of this survey portable vacuum cleaners mere used In cleaning the rafters before painting. METHODS OP SAMPLING AMD ANALYSIS
Atmospheric dust and fume samples mere taken with the impinger('1 & 2)
at the breathing zone of the 'workmen at representative operations. This instru ment, developed by the United States Public Health Service, is the standard method used in this country. Air is drawn in through a glass tube at the rate of one cubic foot per minute. The tube ends in a constricted orifice under the surface of distilled water contained in a flask. The air passes through the orifice and impinges upon a glass plate which breaks up the air stream, allowing
the dust particles to be vet and entrapped in the water in the flask.
c/yV'ni i8 added to the sample as a preservative to Inhibit the solo-
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tlon of tha fine silica particles and alna to prevent the formation of aggre(1)Comparative Tests of Instruments for Determining Atmospheric Dusts, Public Health Bulletin #144, U.S. Public Health Service, Tress. Dept. Wash. D.C.Jan. 19^5 (2)The Impinger Rampling Apparatus as Used ty the U.S. Public Health Service, Public Health Reports, March 18, 1932, Vol. 4V* U.S.P.H.S., Treasury Dept. Wash. D.C.
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gates of the fine particles by clumping. Suction is supplied for drairing the sir sample through the lmplnger
by means of an ejector, or else an electrically driven pump where compressed air is not available to actuate the lmplnger*
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The dust counts were made by the methods and technique developed and used by the United States Public Health Servioa. Particle size measurements war t made of the dust by a direct projection method* The results are tabulated and appear In the graphs attached at the rear of the report* It will be noted that from 87 to 95*1$ of the particles are less than 10 alorons In greatest diameter*
The following table gives the results of analyses of air samples taken at representative points*
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Lead is present In most of the processes in combination with a number of other substances* but with the exception of lead* these substances are not in
large enough quantities to be hazardous. Asbe6tosis will be discussed in general report.
TOXICITY OF LEAD
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Lead poisoning is the commonest of the industrial intoxications.
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The toxicity of lead depends upon a number of factors such as: the fora of lead
taken into the body - vapor, dust or solid; the solubility of the lead compound
in human tissues; the mode of entry of lead into the body - inhalation, ingestioi or skin absorption; the extent of exposure; individual susceptibility which is
heightened by numerous conditions particularly by previous attacks of poisoning.
Among the most readily toxic of the inorganic lead compounds are the
oxides* the carbonate* the sulphate and the Chromate. Lead is a cumulative poison and* with a few exceptions* industrial
lead poisoning is usually a chronic condition caused by the inhalation or in
gestion of small amounts of soluble lead over long periods of time. This procesi
of poisoning may go on elovly for a long period without manifesting any of the
characteristic acute symptoms. Lead inhaled* however* is far more rapidly and surely toxic than lead ingested, since it reaches the blood stream more directly
and comparatively little is eliminated unabsorbed. There is little agreement in the estimates made by various authori
ties' on the wrtMmmn amount of lead which can cause p oisoning if taken into the body. For practical guidance, however, it can be assumed that from 1 to 2
milligrams
in daily over a period of months or years may cause poisoning.
A number of factors also enter into the estimation of the amount of air breathed by a man at active work during the working day. Ten cubic meters of air in a
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c ten hour day is an^estiaate which very probably errs on the safe side for the average workman. Ob the basis of these calculations, the lead content of the
( air of workrooms where men are continuously exposed should be kept as low as 0.1 of a milligram per cubic meter of air or else strict measures for protectloi
should be Installed to prevent poisoning.
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The symptoms of chronic lead poisoning are many and may manifest them
selves through the gastro-intestinal tract as in the familiar "lead colic" or
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the neuro-musculer system or both. Among the symptoms most commonly noted are
colie, metallic taste in tbs mouth, obstinate constipation and loss of appetite,
muscular weakness, particularly of the bands and wrists, neuritis and joint
( pains, loss of weight, headache, dizziness, nausea or vomiting, gastric distress or fatigue are among the minor symptoms that may or may not be present.
The principal diagnostic signs for the detection of lead poisoning
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in its early stages or of lead absorption, which is essentially pre--clinical
poisoning before the onset of symptoms, are ashen pallor of the skin, tremor, i
lead line on the gums, stippling or basophilic degeneration of the red blood
cells, hematoporphyrin in the urine and mild secondary anemia. Other abnor
malities in the blood which are characteristic of lead poisoning are polychro*
matophllia, changed relative proportions of lymphocytes and polymorphonuclear
leukocytes, increased mononuclear cells and increased reticulocytes.
Repeated physical examinations should be made of workers exposed to
lead at fairly short intervals' of from two to Six months, depending upon the
severity of exposure. It is important to prevent the occurrence of lead poison
ing, since, even though it is not often fatal under modern conditions, it fre
quently results in premature development of chronic'degenerative conditions in
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-17the circulatory system.
The pfayBiochemistry of lead poisoning and the treatment to he pursued (3)
have been the subject of intensive experimentation and study by Aub and his (4)
associates at the Harvard School of Public Health and by Kehoe and his colleagues of the University of Cincinnati.
(3) Lead Poisoning; J. C. Aub, et el; Williams and Wilkins, Baltimore, Md. 1926, to. 265. (4) 0n the Normal Absorption and Excretion of Lead, I--IT, K. A. Eehoe, 7. Thamann, J. Cholak, Journal of Industrial hygiene. Sept. 1933*
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CONCLUSIONS AND RECOMMENDATIONS
The dust counts are low with the exception of sample #4 In Depart
ment 53* This concaving and bending unit is not exhausted. Although this oper
ation is Intermittent, precautions should be taken to eliminate any hazard by
adequately entrapping and exhausting the arising dust.
Samples #26 and #34 In Department 2 and sample #61 in Department It
these operations should be dons under exhausted hoods to prevent the dispersion
of dust throughout the rooms. The operator at these and all other batch
operations should be taught and compelled to handle the materials carefully to
prevent the spilling of the materials on their clothing and on the floors.
Samples #87 in Department 5 and sample #88 in Department 6t careful
handling of the soapstone and flours used and proper application of exhaust
hoods over the pans and at the discharge ends of the tube machines would greatly
reduce the dust concentration created at these points. It will also be noticed that where there Is an increase in dust
counts and where lead compounds are present, as in samples #4, #26, #34, #61
ftwd #88, there is a considerable increase in the concentration of lead compound
4yt TVi *11 wrtr\a+.4 rm nf
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ate the lead compound concentration.
In addition to the samples listed in the preceding paragraph, the
following were found to contain excessive amounts of leadt sample #41, Depart
ment 53} samples #30, #31 and #36, Department 2; sam# ples #39 and #43, Departmen1 53T; sample #76, Department 28} samples #82 and #84, Department 5. Although
these operations are exhausted, they show an excess of lead concentration which
may be due to the fact that the hoods are not properly placed or the suction is
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C not adequate to remove the arising dust. Sample #50, Department 261 If possible, exhaust should be applied to
gun cutting operations to eliminate the lead concentration.
Samples #53, 57, $8, 59, 60 in Department Is The Banbury mixers and rubber compounding mills where lead compounds are used should be exhausted to
eliminate the lead compound dust generated. The pollution of the air at the
east end of the department where the raw rubber is cleaned is probably due to
the Banbury mixers and compounding mills located near this section. The opera
tors should be'warned to handle the lead carefully.
Sample #102, Department Is This sample was taken under the respirator
of the workman while he was dumping drums of litharge through a grate * onto a
belt conveyor which conveys the litharge to the hoppers. A mechanical means
c. should be installed,, if possible, for the dumping of litharge at this place or the workman should be supplied with a positive pressure respirator and an ex
haust hood applied properly* It was noted that clouds of litharge were blown
from the shed and platform and there is a possibility that this lead would be
carried into adjoining buildings. This would create an unnecessary hazard.
Sample #103,
floor. Department It The lead concentration at this
point was excessive. An exhaust should be applied to the open belt conveyor and
at the hopper end to prevent the pollution of the air in this room. The present
method does not keep the finer particles from being dispersed into the atmos
phere of tba room* Ramplm #68, 2nd floor, Department 8s This sample shows a slight
excess of lead concentration. This may be due to the working of the belting material while the rubber is still in the uncured state or may be due to pollu-
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tion from sources outside of this room. Exhaust hoods could be applied to the
tables.
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Sample #88, Department 6t The base stock is reworked in a -m and
then put through the tube machines.' The
and the tube machines could be
exhausted to eliminate the lead hazard at this point.
The workmen should be taught that lead compounds are harmful when the
dust is breathed into the lungs and to handle it carefully. It was noticed thal the workmen were careless in putting their hands into the lead compound and
brushing it on their clothes.
Operations where there is an excess of lead and where exhaust systems
4
are not practicable should be isolated and efficient respirators supplied to
the workmen. Lunch rooms should be maintained and separated from the departments
where lead is used. Vorkmen should not be allowed to eat lunch in the depart
ments.
Samples of material used in the different products were obtained and
analyzed to determine harmful elements. The following results were obtained:
Lead compound (D-70) - 93.45* lead
(D-80) -
94.34* "
Haste material from Dept. 53 (Hr-56) - 24.65* lead} 13.91* total silica
, m w m (1^7) ,, 27.32* lead; 12.94* "
Samples of dust from three grinding operations were obtained and
analyzed. Dust from rubber grinding. Dept. 25, machine #11-746 -- 7.85* lead
black rubber. Dept. 5, machine #1240 - 1.15* "
* green rubber. Dept. 5, machine #1311
- 12.48*
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c Samples of dust from rafters irere taken In various departments and analyzed. The following results were obtained!
Dept 2, dust from over batch mixing operations - 5.48* lead
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531,
weighing - 7.1# lead; 25.5# total silica
6, at end where tube machines were located - .38* lead
25-26, 55(4th floor) 11 32 31
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26 (1st floor)
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SAMPLE HO. 6 , ept. 53
Grinding machine #2050, one nan chamfering ends of brake lining on emery wheel
Ihe Mahhattan-Bubber Mfg. Dir* of Raybestos-Manhattan, Inc*
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SAMPLE SO. 2 Dept. 53
Cutting operation with carborundun wheel; cutting wet prooe88 brake lining to length
The Manhattaa-Rubber Mfg. Dir. of Raybestos-Manhattaa, Inc.
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Gardner surface grinder #2, machine #L510 dry process lining
The Manhattan Rubber Mfg. Div.
SAMPLE wn. Dept. 53
Circular grinder while grinding inside surface of brake lining
The, Manhattan Rubber Ufg. Div.
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Dept* 51
Panning rubber tubing
The Manhattan-RUbber Mfg. Div, of Raybe8toB-Uanhattan, Inc.
sawpt.ks jjQ. 2L b& 12 Dept. 39
Grinding clutch facing
The Mahhatta&-Rubber Mfg. Dir. of
Eaybestos-Hanhattan, Inc.
Dept. 53-T
Balghlng robber for eet process nixtore
The Manhattan-Rabber llfg. Div. of Bsybestos-Uaohattan, Inc.
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SAMPLE HO. 15 Dept. 39
Sandblasting molds for pressing dutch, facings
The Manhattan Bobber Hfg. Div.
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The Manhattan Rubber Mfg. Dir. of
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The Kanhattan-Rubber Mfg. Div. of
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Sept. 5 West End Soon
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The Uanhattan-Kubber Mfg. Div of
Baybestos-Manhattan, Inc.