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Tcufnal dJ^ J-mciusW\al <*, TuJLg, ii 34 "I# er*S. HEALTH HAZARDS IN THE FOUNDRY INDUSTRY* W. J. McConnell, M.D. A*ritl*ni Mriiral Dintlar, Dintlar, Indutlriai Htalth Artliit AMO J. Wii. Feknel, B.Sc. Cktmirt in Chart*, Indiutrial Hytitn* Laboratory Mtlropolilan Lift Intvranet Company, Ntv York Introduction ef the following individuals in making N APRIL, 1831, the Wisconsin I Manufacturers Association, through Mr. Harold S. Falk, Chairman of the Association's com < mittee on dust, fumes, vapors and gases, requested the Metropolitan Life Insurance Company to extend a health survey, undertaken for a group of its own policyholders, to include Dr. F. V. Meriwether, Surgeon, U. S. Public Health Service. Dr. A. J. Lansa, Assistant Medi cal Director, Metropolitan Life Insurance Company. Mr. P. A. Petriek, Laboratory Assistant, Metropolitan Life In surance Company. representative foundries in the State Score and Technic or the Survey of Wisconsin for the purpose of de termining the extent and nature of Although a total of 41 foundries the health hazards in the industry, has been surveyed by the Industrial with the object of recommending Health Section to date, twenty-ono measures for better and more sanitary foundries were selected for this study working conditions. as representative of the industry. The proposed study was discussed The various types of foundries were with Mr. F. M. Wilcox, Chairman of classified in four general groups, the Industrial Commission for the namely: State of Wisconsin, who endorsed tho A. Grey iron foundries; Association's request that the Metro B. Steel foundries; politan Life Insurance Company un C. Malleable iron foundries; dertake tho survey. This request D. Non-ferrous metal foundries. met with the approval of Mr. F. H. The first group (A) is represented by Ecker, President of the Metroplitan plants A to L inclusive. Plant J of Life Insurance Company, who directed this group manufacture both iron and the Industrial Health Scetion to sicel castings, and Plant K manu conduct the study. factures grey iron and malleable iron Acknowledgment is gratefully made eastings. The former, therefore, may for the counsel and technical assistance oc classified in groups A and B, and the latter in groups A and C. * Received for publication, June 1,1934. The second group (B) is represented ow ot\ 0* 'MA O1 > ill j t< it-. --3 o v: .0 5 r -n I l 1 *s r>; o mmm 228 THE JOURNAL OF INDUSTRIAL HYGIENE [rai, no. i by plants M to P inclusive; the third pyrotannic acid method, but the re group (C) by plants Q to T inclusive; sults of these analyses were negative. and the lourth group by plant U. Air sampling for dust was made with Plant Q manufactures steel and mat* the impinger (1) method which collects Icablo iron eastings and may be the dust by aspirating the sir and classified in groups B and C. impinging ft onto a flat surface covered The survey includes plants of all by a liquid in a container; and with sites and those considered good, aver* the sisetrie precipitator (3), an instru age and poor. Therefore, the selection ment designed upon the principle of a Is representative of the industry, os Cottrell precipitator. Both are stand far as site and plant conditions are ard methods used in America for concerned. Although physical exami determining duat concentrations and nations were not made, exempt where particle aisc. these were the routine of the plant, 215 The impinger was placed in close X-ray examinations of the cheats of proximity to the largest groups of workers exposed to foundry dusts were workmen and at a height correspond made. These workers were selected ing to the breathing level of these from locations where the dust con workers. The liquid used in the con centrations were highest. Dust tainer of the impinger consisted of samples were taken at various places of distilled water. The impingere were employment and in the line of travel actuated by suction supplied by steam * in each department. To secure a ejectors operated by compressed air. picture of working conditions and, if The rate of air flow, during sampling, .possible, sources of health hasards, was measured by means of a small process analyses were made, and sani vacuum gauge inserted into the suction tary conditions and personal sendee line. The entire set-up, in tum,%hod facilities were noted. previously been standardized against a standard wet meter. Wherever Meascwen-o Instruments and Meth ods or Collecting Samples masks or respirators were worn by the workmen, a connection was made either into or under the helmet by The measuring instruments used in means of rubber tubing which was the survey were the foot candle meter connected to the impinger. Each for determining the illumination at sample collected by the impinger the working levels; the sling peyehrom- method represented a sample of dust eter for measuring the dry and wet from a volume of air amounting to bulb temperatures; flasks for collecting from 50 to 100 cubic feet. gas samples which were analysed for The electric precipitator was placed carbon monoxide; and the impinger in a position similar to that of the :nd electrical precipitator for collect impinger. The air is drawn through ing dust samples. this instrument by means of a small Air samples were collected around rotary fan, run by a motor, the quan the cupolas and in the vicinity of tity being measured by a flow meter. freshly poured molds. These were Each ample collected by the electric analysed for carbon monoxide by the precipitator repreaented a volume of July, 1931} HEALTH HAZARDS IN FOUNDRY INDUSTRY 229 lr of from 10 to 50 cubic feet. These samples were used for determination of particle sise. Particle size measurements were made by taking microphotogmphs at a known magnification of the dried preparation of dust, as described by Green (I), and then enlarging the negative further by projecting the images upon a screen by means of a rence as abscissae (3, 4). It is a simple procedure to interpolate from these plots, which develop into straight lines, the frequency of occurrence of any sised dust particlo less than 10 microns present in the particular dust under investigation. It has been demonstrated repeatedly that no silica particles exceeding 10 microns (5) in greatest diameter enter Fio. 1.--Composite Griph of General Air Sample* from 13 Foundries of Which 3 srs Steel, S Grey Iron and 4 Malleable Iron Foundries stereopticon. The longest diameters of the images of the dust particles were then measured upon the screen. From tho results of a sufficient number of these measurements n curve was plotted of the size frequency relations on Haxens' logarithmic probability paper, the logarithms of the function measured in microns plotted as ordi nates, snd the probability of oeeur- the lung tissue, and for this reason it has been the general practice to count only dust particles under 10 microns. Figure 1 indicates that 90 per cent, of the dust particles were lea than 10 microns and 53 per cent, were less than. 3 microas in greatest diameter. Dust Coomts The reader is referred to the March >***. A'lMk* / 230 THE JOURNAL OF INDUSTRIAL HYGIENE [zvi, no. J 18, 1932 number of Public Health . also ran higher by the modified method Reporta (6) for a detailed description than by the standard light field pro of methods for standardizing and cedure. It was found later that this cleaning equipment and necessary procedure of modified dark field count precautions for accurate work. Ac ing is identical with the method used curate tcehnio is acquired only by on the Wltwatersrand in South Africa observation and diligent work under since July, 1923. The advantages of the guidance of a qualified technician. the modified dark field over the The method of dust counting used by standard light field Illumination are the United States Public Health Service illustrated in the photographs here is an empirical or rule-of-thumb technic reproduced of identical fields using 3 devised to measure the extent of air micron silica, the only difference dustiness. This method was idemon- being the type of illumination (Figs. strnted to be effective in the Service 2 and 3). study of the granite industry at It has been demonstrated that the Barre, Vt. (7). employment of the dark field method In 1928, one of us, J. W. F. (8), enables one to count readily particles while conducting a study of the of 0.5 micron in size, while with the hazards of rock drilling on building standard light field method particles and subway construction work in under 1.5 microns are frequently New York City, experienced difficulty missed. Both methods were used in in cheeking with this standard pro this study and it wss found that the cedure of counting and after consulta modified dark field method gave results tion with other technicians it was consistently twice as gTeat as the learned that certain modifications standard light field procedure. The were introduced, such as tilting or results obtained by the standard light shading the microscope mirror, thereby field method are here reported..' modifying the light. With the in crease of the free silica content of the dust the difficulties in counting by the Fotrcroar Botloinos arm Plant PnoczasBS standard procedure increased. It was The general condition and appear definitely demonstrated by experi ance of foundries have been improved mentation that as the dust approached and they have, therefore, become more the pure form of free silica, the re desirable plaoes in which to work. fraction approached that of the lens The foundry buildings for the most system of the microscope, making it part are large and high, with a great difficult to fofcus the image clearly. amount of window space available. Therefore, a modification of the illu Brick, stone, corrugated iron and mination was tried by using a Plank steel are the usual materials used in ton or fixed stop condenser, which construction, although a few foundries resulted in marked improvement. A of frame construction were found. series of counts was conducted by both Foundry work requires the use of standard and the modified illumina ponderous machinery. Industrial tion, and it was found that the counts railways, cranes, hoisting accessories checked more consistently, but they and certain types of foundry machin- 4] IIKAf/nr HAZARDS IN foundry industry m f interest from the viewpoint its, but need not be discussed port which is confined to the ition of health hnxards. Plant Hvoxenk ntion. --While most of the studied have a large window .s permitting the use of luminatlon In the vielnlty of ows, the majority require advantageously. The use of bare lamps is to be discouraged from the standpoint of operating economy and on account of the glare, which is annoying to workers. Steel reflectors having a porcelain enamelled reflecting surface are well adapted to foundry work. Special treatment of foundry illumination is almost a necessity, owing to the darkness of the materials used, which absorb a great deal of Ti ' .t V> Min. .d0 in i. -.rx o. r-*. 2.--Standard Light Field Flo. 3.--Modifird Dark Field tern of artificial lighting, ngnirod that an adequate natural light is desirable Itl be more generally used by a systematic mrthisl of f windows. It was noticed ;omc instances, whore the acre not denned for a king 10 glass had become rustd almost opaque, resulting ismission of very little light. 11 light is not always used light, and on account of the smoke, steam and dust in the air, through which the light must penetrate. A large volume of light is required anil can be secured by large lamps or dusters of smaller units, hung low enough and equipped with reflectors and diffusing globes which direct the light downward in order to distribute properly the light on the work. Where bench work or mnchinc mold ing is done, the general illumination K H oo- o S 3 ^3 l*r**--' i1 ***.* . a m** * - s thk Jorn.VAi, or rNncsritiAi. rrvGiK.vr: [j-n, no. 4 should be reinforced with local illu blast equipment. It is a fact, how mination. The cleaning o/ these units ever, that most of the dust incident to at frequent intervals is important. foundry work results from defective The painting of the interior} of found* equipment and lack of proper main ries n-ith lifeht colored paints will tenance. facilitate light distribution. The dusts encountered in foundries Ventilation.--The visual ventilation have a high free silica content, aver of foundries is by means of windows. aging between 50 per cent, and 90 per A system of forced draft, either for rent, free silica, which makes control general ventilation or for the ventila of these dusts a necessity. tion of individual rooms, is used in Puitif procc**e*.--The health hazard some instances. The general ventila from the Inhalation of foundry* dust tion is. supplemented, as a rule, by results chiefly from three foundry ventilating hoods at specie points. operations: The ventilation of foundries, so far as 1. Sand conditioning and concey- supplying pure air for breathing is ing.--The conditioning of the sand concerned, is quite difficult on account which is accomplished by the addition of the smoke, fumes, and dust incident of binders, such ns flour, molasses to foundry* work. Where these can be and water in proper proportions, collected and exhausted at the point together with sieving, mixing and the of origin. .he problem of their control preparation of the mold facing sand, is is simplified, but unfortunately this usually done in the central area of the * cannot always be effectively ac foundry. The sand is - carried back complished. and forth by means of mechanical Air duttinea.--The introduction of conveyors. Although by centralizing new methods, new apparatus, and new these operations, the raw materials protective measures ha* greatly amel and conditioned sand ore convened a iorated the atmosphere in foundries. minimum distance, the dusts that The mechanical cleaning of castings in are created are distributed through conjunction with suitable exhausts, the out the entire foundry. Marked use of tumbling operations and dust- improvement, from the viewpoint tight sand blast rooms, the hydraulic of dustiness, would be noticeable washing of castings, and tlje provision were these operations to be carried of positive air pressure helmets for out in a separate department com workers engaged in sand blasting are pletely isolated from the foundry all measures designed to control the proper, and a considerable amount of health hazard* resulting from the dust could be confined by enclosing inhalation of dust. Certain types of the sand cunveyora. foundry work must be done by the 2. Shakeout operation!.--These op- older methods, particularly large cast cmtions are usually located ncur the ings where the production is so sand conditioner, but may be carried infrequent as not to warrant the nit in any convenient space in the e-Miensc of suiid blast equipment, or foundry- When a sand cutter is used where the size or character of their for sand conditioning, it is customary cures will not admit the use of sand to shake out eastings wherever poured. i | i s , j j | i July, J9341 HEALTH HAZARDS IN FOUNDRY INDUSTRY 233 Because of the hot dry sand end the mechanical maintenance of a good mechanical means of handling castings type of sand blast cabinet, together subjected to the shaking out opera with the use of. an efficient type of tions, clouds of fine silica dust arc set respirator by operators, will greatly up which penetrate the entire foundry aid in safeguarding the workers. atmosphere, thus exposing practically every worker to the dust. In found HsjtKroLKtss or Silica Dust ries where heavy castings are shaken Tht btsard of silica dust with special out by means of suspending the mold reference to the lungs has long been with a crane and applying a vibrator appreciated. It baa been firmly estab hammer, fewer workmen would be lished that the inhalation of this dust exposed to the dust if the operations results in a fibrosis of the lungs, which were carried out in a separate room or, disease is known as "silicosis," and ita preferably, outside the foundry proper. 'presence, for some reason yet ill- Is the case of small castings, the defined, results in extraordinary pre shaking out operation can be done disposition to pulmonary tuberculosis. over a grate attached to an exhaust or It should be borne in mind that sili in a separate room. Where the mold cosis develops very slowly, taking from ing is done on the foundry floor and a five to fifteen and even twenty to sand cutter is used for sand condi twenty-five years to become estab tioning, the shaking out operation lished. This rate of progress is in should be begun preferably at the fluenced mainly by the dosage of silica end of the working period, thua ex which the lungs receive and this posing the least number of foundry dosage, in turn, depends upon three workers to the resulting dust. Suf variables: the amount of silica in the ficient time would elapse for the dust to dust, the quantity and particle size of lettle before the beginning of the next dust in the air, and the extent of vorldng day. exposure. Individual idiosyncrasy Cores are now effectively removed might be included sa a fourth variable. rom castings by washing with high However, little ia knows of the varia ressure streams of water inside a tions in susceptibility in those exposed abinet or outdoors. This operation to dust. iiminates the dust hazard due to * In an investigation of granite cut and removing and cleaning. ting plants (7), conducted by the 3. Cleaning operations.--Casting United States Public Health Sendee, leaning by mijans of chipping, grind- most of the workers were found to bo ig, and sand blasting is sometimes exposed to an average of about irried on in a separate department, 60,000,000 particles of dust of less it U is common practice to conduct than 10 microns in greatest diameter, esc operations in the foundry proper per cubic foot of air. The dust con almost any convenient location tained about 70 per cent, silica, of it has the advantage of the least which about 36 per cent, was in the tount of handling. Proper hoods form of quarts or free silica. Under i exhausts for entrapping dust such conditions, there was an almost ling from grinding wheels, and universal occurrence of silicosis among it IV i! t-Vn~:I>< 3 i >v->* Mw *0 'A 2% " -j --M -oo,~rl <il^ nH >2< 5 h i*: SS N m [* r* ^D V H a>- a i*i 8 VP 3 $ 1 July, 193i] HEALTH HAZARDS IN FOUNDRY INDUSTRY 237 / /. , ,^ T3 V> 3 ;n0 rJ ,3 to o Is 9 11 % 3r* io :-o= ?J!ioiarL< jo a m .iy j y xoOa rv-w s m au' ico jo io iii: z ita is v s r t 23& THE JOURNAL OF INDUSTRIAL HYGIENE [xri, no. 4 TABLE I-CmtiMMJ Steel foumlriee < viowi <i MaOrable fouadma. Noa-fnoua w i l l TABLK 1-Cenetudtd 240 THE JOURNAL OF INDUSTRIAL HYGIENE [an, no. * touadnu--Condudtd Is \{ 8 t i > e ! 'W i i K p ; t 2 i T E 2i > -M * 9 s .s 0 * *S 9 * * s --K s 8 * s -r 2 8S e R see 3 Si- l , e 3^8 21-S IJmm a- H f-5 |! *]1 lMi IT El -5 x 22 Jj K 9# 33 E July, 1W1 HEALTH HAZARDS IN FOUNDRY INDUSTRY 241 in the foundrymen's work witch operates to produce a high incidence of respiratory affections among them. What few statistics there are on the incidence of disabling sicknesses and of the incidence of physical impair ments among these workers, support respiratory disease mortality of foundrymen. In the following paragraphs, we shall discuss the main findings of these investigations: Combined group mortality experi ence.--19tt-19S0 (10).--Table V was compiled from the report entitled ournoi TABLE II Aoa Oiem tna KAUtinj ItOR imu 1 } 1 \ 2t a t t | t e a t t 1 i ii X fmrt SO sad over a e 13 5 1 3 i 0 2 0 0 0 40-19 30-39 14 7 39 11 3 9 0 1 0 t 1 0 7 fl 33 7 0 13 a 1 3 0 0 3 90-39 Under 30 Not given 0 0 1 0 13 3 10 2 0 5 0 0 0 0 0 1 0 0 0 0 0 01 0 0 00 0 0 a 0 4 0 0 3 Total txatninad... 33 30 73 37 8 29 7 2 9 1 1 TABLE III Ysans or Exroeoas OUT (HI ma IUUIAU rnoii BOR.rUBOOB MSTAE I J 1 1 J 1 1 it 1 e2 i1 t e a I a i t 1 2 21 1 J 1 Z ' 15 and over 10-15 5-10 Under 5 Not (iven 19 9 IS 13 2 S i 2 l i 1 3 5 3 13 ' 5 1 7 3 0 i 0 0 1 5 7 29 8 ' 1 7 3 0 3 0 0 o 3 1 IS 3 3 . 7 1 0 3 0 0 0 0 0 00 0 0 0 0 3 0 0 0 Total examined... 33 30 75 27 39 7 2 9 1 1 * the findings of the mortality inves tigations. Three recent mortality investiga tions, made by American Ufe insurance companies, and a report of the Reg istrar General of England and Wales show dearly how unfavorable is the "Combined Group Mortality Experi ence 1023-1030" published by the Committee on Group Mortality In vestigations, July 17, 1031. The Committee analysed the mortality records of employees of industrial concerns insured under Group Life tt v> .* IbS *3 V> M o cn *o \7> J r: r* -c1i " Z) i: i ><; 1 !i It t f. 3< * j) | sri 9. k oM ". VO j 1 r>*. l ! io>---ii o Si s\ Ov/ $ 242 THE JOURNAL OF INDUSTRIAL HYGIENE [xvi, no. 4 Insurance contracts written by six Large American and Canadian insur ance companies. AH employees of a particular company, regardless of oc cupation, are classified under but one industry. It is more than twice that for workers in any of the industries selected for comparison. More than one-third of all the deaths among foundry workers were caused by some respiratory disease, whereas but little morev than TABLE IV Bt Occupation MITIMf vni MAUlillJ ***111091 IWI IVTtt Iat 1 I 2 t i I 2-I3 2 r 11 t 1 3 2 t 21 1tz 1 1 t 1 zI r 3 g 53 s0 1 3 1 1 1 s a i 40 30 1 1 0 0 1 0 0 0 00 10 0 0 0 0 0 0 0 3 s 1 s0 0 1 0 0 0 1 3 9 31 10 0 1 0 0 1 Tumbler operators..................... 0 1 0 0 0 0 3 0 3 0 0 0 1 0 0 00 00 0 0 0 0 0 fitnri nitler .............................. I 0 0 0 0 0 1 0 0 0 0 0 0 | 0 00 00 0 0 0 0 0 0 0 0 00 0 t 0 1 0 0 0 0 0 0 00 0 0 0 00 1 j 7 2A 10 0 0 100 0 40 0 A 00 00 n 0 0 A Grinding (swing or stand)............ 3 0 & a 0 3 I 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 .0 0 0 0 0 0 1 0 0 0 0 O' 0 0 0 0 01 00 0 Q 0 0 0 Foundry laborer............................ 0 0 1 0 0 0 0 0 00 0 1 0 31 0 0 0 10 0I 0 0 0 0 0 01 0 0 0 0 0 40 0 0 0 0 0 10 0 0 0 0 0 Welding.......................................t. 0 0 0 3 0 0 0 0 0 0 0 0 Granitic raoa Ubortf.................. 1 I 1 0 0 0 0 0 0 0 0 0 1 0 .3 0 0 0 0 0 0 0 0 0 0 0 2 00 00 0 0 0 0 0 Painter___-.................................... 0 0 1 0 0 0 0 0 0 0 0 0 M g 33 0 0 0 0 0 1 0 0 0 Total examined........................ 33 30 73 37 ft 39 7 3 9 1 i 3 The death rate for respiratory diseases (including all forms of tuber culosis and influensa) for iron and steel foundry workers, is shown to b* about two and one-third times that for workers in all industries combined. one-fifth of the deaths of workers In other industries were due to these causes. Table VI is also based upon the Combined Group Mortality Experi ence. It presents death rates by ages 244 THE JOURNAL OF INDUSTRIAL HYGIENE (xri, no. 4 losis is lower only st central ages 18 and 23, while their rate for other diseases of the respiratory system is markedly in excess at all ages. Comparing the crude death rates for all ages combined, it is found that the influenza death rate for fotindrytncn exceeds the average by about 90 per osnt, while their rate far tuberculosis is M per cent la excess. Most out* is largely responsible for the high rate reported in this investigation for other diseases of the respiratory system. Evidence of the excessive mortality among foundrytnen will be found in the graphic presentation of the data em bodied in columns 2 and 3 of Table VI. This is crudely presented in ths graph shows is Fig. 4. Joint occupation tiudy--193$ (11).---- Flo. 4.-rAll Respiratory Disensas Deaths per thousand life yean exposed. Intercompany group mortality experience 1322-1930. Employees of steel sod iron foundries 490,013 years. All occupation* 20,333,309 years. standing it the high rate for other respiratory diseases (pneumonia, bron chitis, etc.) where the foundrymen'a rate was nearly three times that for all workers combined. Unfortu nately, deaths from pneumonia were not separately distinguished. Other studies have indicated that this disease is the leading cause of death among foundryrocn. Undoubtedly this eause This study covers persons insured in twelve large life insurance companies under Ordinary plaas (81,000 or more) during the years 1915-1026. As a measure of the effect of employment on the mortality rate, the ratio of actual to expected deaths was used. The number of deaths which-would bo expected to oeeur from respiratory diseases among the group of persons July, 1934) HEALTH HAZARDS IN FOUNDRY INDUSTRY 251 Decennial Supplement, 1931: Part II. Occupational Mortality, Kertility, tad Infant Mortality. H. M. Sta tionery Office, London, 1937. It. U. 9. Public Health 8erriee, Public Health Bulletin No. 205: Lead Pol. eooiot in a 8tor*e Battery Plant. Qorertunent Printinc Office, Waeh- leftea, 0, C, INSt p. 15 15. U. 8. Public Health Serriee, Reprint No. 1370 front PubUe Health Reporta, Vol. 45, No. It, May 3, 1930, pp. 197-1009: Effect of Radiant Energy on the BUn Temperaturoe of a Oronp of Steel Vorhen. Ooeernmnt Print ing Office, Weihinfton, D. C. I i i I/ i i I r vIi m :!5 '-`.e o fA m .no r* -i r* <' kZ 't i* * \ f. *3< OH is 1 53 en \ 23 * si " r n A Iv i'.r Or .'D D IC IiE FQfC FOSrCSE OF ii I I m : I 1 1 mm