Document a41OBbBgVQjVQwDJ39KJpeKB9

CertainTesd Date January 9, 1981 Sibject Hillsboro A&B Plant Industrial Hygiene Survey FINAL REPORT To J. McGinley From O\ jl U ^iA] J. L. Woodson Location and mail code 2125/2B Location and mail code 1125/4 cc: D. Hall - 2125/2B B. Blakeslee - 2126/00 0. Kittllstad - 1125/4 Attached find the final report for the Industrial Hygiene Surveys made at the Hillsboro A/C Pipe Plants A&B, May 27-30 and November 12-14, 1980. Please contact me if you have any questions or comments. JLW/tmf 01-26-0009 10/77 CTD020692 Industrial Hygiene Survey Hillsboro A/C Pipe Plant #257 May 27-30, 1980 November 12-14, 1980 Introduction Two Industrial Hygiene Surveys were conducted at the Hillsboro AsbestosCement Pipe Manufacturing location by Janis Woodson during May 27-30 1980 and Novemher 12-14 1980. The first survey. May 27-30, 1980 was conducted in the "A" Plant to supple ment the on-going in-plant fiber exposure surveillance program and to measure the employees exposure to noise. A preliminary report and log of sample results was distributed to the plant on July 14, 1980. The first initial start-up of Plant B was in December of 1979 with production running through March 1980. During the period March - October 1980 there was no production in B Plant. Since B Plant was not in operation at the time of the May survey a return trip was made November 12-14, 1980. Air samples and noise levels were obtained during this second initial startup and shakedown period of B Plant, with some follow up work done in A Plant. A preliminary report and log of sample results was distributed to the plant on December 18, 1980. This report discusses the results of the two surveys at the Hillsboro A & B Plants, by devoting a separate section to each plant. The appendices to the report document the air sampling methodologies, the analysis techniques, and the current standards used in evaluating the data. The field notes and in-house laboratory documentation of this survey are on file in Corporate Health and Safety. This report is an "Employee Exposure Record" as defined in 29 CFR 1910.20 and must be retained for at least 30 years in the plant and made available upon request to those authorized access to employee records as specified in 29 CFR 1910.20(d) and the CertainTeed Corporate Procedure Manual, section AD011. CTD020694 Table of Contents A - PLANT Introduction Manufacturing Schedule Discussion Asbestos Fiber Samples Noise Measurements A-Plant Summary B - PLANT _ Introduction Manufacturing Schedule Discussion Asbestos Fiber Samples Noise Measurements B-Plant Summary FURTHER AIR MONITORING RESPIRATORS FURTHER NOISE WORK HEARING PROTECTION RECOMMENDATIONS A-Plant B-Plant General TABLES A-Plant I Personal Dust Exposures (May) II Environmental Dust Samples III Personal Dust Exposures (Nov.) IV Departmental Breakdown V Audiodosimetry Results Page 1 2 3-7 7-11 11 12 13 14-16 16-17 17-18 18 19 20 20 21-22 22 22-23 24-28 29 30 31 32-34 CTD020695 TABLES (Cont'd) B-Plant VI Personal Dust Exposures VII Environmental Dust Samples VIII Departmental Breakdown IX Audiodosimetry Results EXHIBITS I-III A-Plant Noise Survey IV-V B-Plant Noise Survey APPENDICES I Monitoring/Analytical Procedures II Key elements of a Respirator Program 35-36 37-38 39 40 41-44 45-46 47-48 49-51 CTD020696 -1- Hillsboro "A" Plant One hundred-five air samples and 36 personal audiodosimetry samples were obtained during the week of May 27-30 1980. Of the 105 air samples, 100 were personal samples covering 32 job positions and establishing 34 time weighted averages. The other 5 air samples were taken in different areas of the plant. During the November 12-14th survey some follow up work was done in plant A Finishing Department with 8 air samples obtained and sound pressure level measurements taken throughout the area. CTD020697 -2- Hillsboro A/C Pipe Plant "A" Manufacturing Schedule May 27-30 1980 November 14, 1980 Tuesday 5/27/80 Manufacturing Dept. Finishing Dept. 1st Shift 1st Shift 2nd Shift 12 & 16" 150 pipe 12"150 cplgs. Epoxy Dept. 1st Shift Wednesday 5/28/80 16" 150/200 pipe 12" 150 pipe 8" 150 FM's Thursday 5/29/80 8" 150 pipe 6" 200 TBIC 4 & 16" 150 couplings 8" 1/2 FM's 4"150 cplgs. Friday 5/30/80 16" 150 pipe 16" 150 cplgs. 6" 150 pipe Friday 11/14/80 6" sewer couplings 6" 1/4 FM's 20" couplings 6" rework CTD020698 -3- Industrial Hygiene Survey Hillsboro A/C Pipe Plant #257 May 27-30, 1980 November 12-14, 1980 ASBESTOS FIBER MEASUREMENTS Table I shows the results of the 100 personal fiber samples giving individual sample results, and Time Weighted Averages where applicable. Table II shows the results of the 5 Environmental samples taken throughout the plant, and Table III gives the results of the follow-up samples taken in the Finishing Department during the November survey. A departmental breakdown of the samples and results can be further exemplified by Table IV. In reviewing the sampling results, all results fell within the current OSHA 8-hour Time Weighted Average (TWA) asbestos standard of 2.0 f/cc, although a few samples/areas need further discussion, which follows. Manufacturing Department Twenty four samples were taken in this Department with a range from 0.015 to 0.53 f/cc. The average fiber count was 0.20 f/cc. The fiber warehouse was found to have a level of 0.02 f/cc (Sample 101). One pallet of fiber was found tipped over with torn bags. This spill was cleaned up and bags were taped. With the doors open and the normal breezes that flow through the building any open bags would cause fiber to be carried throughout the area. It is recommended that all incidents such as this, be immediately cleaned up and bags taped. Also, any employee involved in the cleanup and working in the area should be wearing a respirator. The Automatic Bag Opener is located between the fiber warehouse and the Manufacturing Department. The bags of asbestos are loaded on the conveyor from the warehouse. The Bag Opener opens the bags and transfers the raw fiber into the mixers and eliminates human contact with the fiber. At the time of the survey, ventilation at the opener was tested by using a smoke tube. The system seemed to be working effectively, which is also shown by the result of the air samples taken in the work area. It is recommended that two things be corrected for more efficient use of the bag opener, (1) a slitted curtain be added to the bag opener where the bags enter the opener on the conveyor, (2) several latches were missing from the plexiglass doors. It is recommended that all latches be in working condition and used by the operator in order to make the best possible seal. All trash generated from this process is properly labeled and disposed of. CTD020699 -4- Industrial Hygiene Survey Hillsboro A/C Pipe Plant it257 May 27-30, 1980 November 12-14, 1980 The mixer operator makes approximately one dump per hour, (depending on the type of pipe being manufactured). Each dump consisted of approximately 30 bags. Since this is where raw fiber is introduced into the, system, a greater possibility of accidental exposure to raw fiber exists, therefore it is recommended that respirators continue to be required in this area during the operation of the Bag opener, when staging the fiber and when cleaning the area. The TWA for this job position was 0.10 f/cc (Samples 001-004) with one 38 minute peak exposure sample of 0.06 (Sample 002). An area sample at the bag opener disclosed a level of 0.03 f/cc (Sample 102). Three brooms and one oil mop were found in the area of the bag opener and were used for cleaning in the area. It is recommended that all brooms in all areas of the plant be eliminated and alternate methods for clean up be used. Oil mops, vacuums, and any wet method would be acceptable. Three samples were taken in the area of the pipe machine to characterize the concentration during the manufacturing process. One sample (#103) located at the wetting screw had a level of 0.03 f/cc, another sample (#104) located at the recirculating ditch had a level of 0.068 f/cc. Sample #105 was located at the pipe machine roll-up chart and yielded a 0.015 f/cc. It was noted that used felt is cut into strips and used as padding for machine parts that come into contact with pipe and is sometimes used as a curtain at the entrance to the curing tunnel. The felt inherently contains asbestos fibers and upon drying can be expected to release asbestos fibers when abraided. Although there isn't sampling data that condemns this practice, it is recommended that use of the used felt be discontinued and that old discarded felt be totally disposed of. Personal exposures for the Machine Tender (#005-007), Press Operator (#008-010), Mandrel Handler (#011-013) and Utility (Relief) Person (#017-019) all positioned at the wet end of the machine, were found to be well within the OSHA standard. This plant has an automatic pipe stripper therefore no sampling data was obtained for this area. The Tray Loader (#014-016) was also found to be well below the current standard. Finishing/Fitting Department Sixty-three samples were collected in this department yielding a range of 0.011 to 2.52 f/cc with the average fiber count being 0.30 f/cc. The 8 samples obtained during the November survey yielded a range of 0.0780.55 f/cc. CTD020700 -5- Industrial Hygiene Survey Hillsboro A/C Pipe Plant #257 May 27-30, 1980 November 12-14, 1980 On May 27 and 28 Lathe Line #2 and 3 were sampled while running 12" and 16" 150 pipe respectively. Each job position was sampled, with all sample results being well within the 2.0 f/cc standard. Samples on Line #2 and 3 included the positions of the Lathe Operators (#020-029), Inspector (#030-032), Hydrotester Operators (#033-039), Bellers (#040-044), Pipe Handler (#045-047) and the Truck. Driver (#048). Although the exposure levels on the Lathe lines, was acceptable, general housekeeping at the lines should be upgraded. The major problem seemed to be when finished pipe rolled down the lathe table and the tester table to the Tester Operator, the pipe would bump against each other and any dust or tailings left In the pipe would be released and fall to the floor. At the end of the_shift only some of this dust would be cleaned up. It is recommended that the work area get a more thorough clean up at the end of each shift in order to eliminate any build up of dust in the area over time. The Coupling Tester Operator (Samples 049 and 050) and the 1/4 Tester Operator (Sample 051) were both within the OSHA limit, as was the Crusher Operator (Samples 053-056) with a range of 0.096 - 0.95 f/cc for these positions. The sample with results of 0.95 f/cc (#056) was a 21 minute peak exposure sample taken on the Crusher operator. The crusher is located outside the plant next to the Finishing Department and has a canopy over it to protect the complete system from the weather. All rejected pipe, end pieces, etc. are taken to the crusher to be recycled into fines and used in manufacturing new pipe. During damp weather the system tends to block up therefore a minimum amount of crushing is done. It is not known what may have increased the crusher operators exposure during sample 056 but the Crusher System itself could be the source. The crusher area is posted as a required respirator area. The employee wears a 3M 8710 respirator during a block up (usually caused by damp weather), during clean-up, and while crushing during extra dry weather. It is recommended that the operator be required to wear a respirator at ill times while in the area so that we can be assured his exposure remains below 2.0 f/cc. More sampling should be done to determine and document the levels of exposure for this position. The small Coupling Cut Off Saw Operator (Samples 061-063), #3 Boring Mill Operator (Samples 069-072), Coupling Stacker (Samples 073 & 074), Fittings Inspector (Samples 075 & 076), #2 & 3 FM Lathe Operator (Samples 081-083) and the Fittings Maker (Samples 093 & 094) all fell well within the OSHA 8-hour Time Weighted Average (TWA) Asbestos Standard of 2.0 f/cc. CTD020701 -6- Industrial Hygiene Survey Hillsboro A/C Pipe Plant #257 May 27-30, 1980 November 12-14, 1980 The #1 Boring Mill Operator (Samples 064-067) had a TWA of 1.79 f/cc during the survey in May with individual samples being >2.52, 0.31, >1.83 and 0.73 f/cc while running 4" couplings. At this time it was recommended to the plant that this job position be resampled by the plant personnel in order to determine exactly what was causing the exposure. It was also recommended that respirators be worn by employees in the area and that a disposable suit also be worn while operating the #1 Boring Mill. Plant sample results yielded unacceptable levels while running 8" MHA's. A study of the ventilation system led to the relocation of an exhaust line to the left side of the mill. The floor beneath the coupling conveyor was also wiped with oil to help control dust. The plant sampled this job position again after the changes were made and found the levels to be reduced to 0.69 f/cc & 0.72 f/cc while running 12" 150 couplings. Follow up sampling done by Corporate Health & Safety on November 14, 1980 yielded levels of 0.29 & 0.24 f/cc with a TWA of 0.27 f/cc (Samples 142 & 143) while Boring 6" couplings. These results show that a great improvement has been made in the dust collection system and work practices of the employee. Although these levels are now well below the current OSHA limit it is still recommended that respirators be worn in this area until we can be assured that exposures will remain at these low levels for all sizes and ages of couplings. Since we have documented low levels of exposure on 6" and 12" couplings it is recommended that more testing be done on the other sizes of couplings run on this mill, also noting the date of manufacture for those couplings. During the May survey the #1 FM Lathe Operator was sampled (Samples 079 & 080) and found to be well within the standard, although some work was needed on the ventilation at the lathe itself. These samples were taken before major changes were made to this operation. A 1/4 length saw was added in line before the lathe and the FM tester has been moved to the area so that this is now one complete operation. The ventilation system was redesigned to include the saw and to give better suction at the Lathe. Samples taken during the follow up survey in November revealed, again, levels well within the standard for the FM Lathe Operator (Samples 144 & 145) and the FM Lathe Helper (Samples 146 & 147). The large coupling saw was sampled and found to have levels of >1.85, 1.46 and 1.15 f/cc with a TWA of 1.56 f/cc while sawing 16"150 couplings. It should be noted that the operator wore a respirator at all times while operating the saw. CTO0J0702 -7- Industrial Hygiene Survey Hillsboro A/C Pipe Plant #257 May 27-30, 1980 November 12-14, 1980 The hood design and ventilation at this saw is poor but it is understood that this saw is to be replaced in the near future with a saw designed to cut from underneath, the same as the Small Coupling Saw and the new 1/4 length FM Saw are designed, both of which have good readings. Meanwhile, cleanup at the Large Coupling Cut-Off Saw should be upgraded in order to eliminate the dust that accumulated on the floor and the saw itself in the course of the work day. Another contributing factor to this problem could be the location of the Large Coupling Saw and Rework Saw (Samples 090-092) both are located close to an exit door which stays open most all the time. When the wind is blowing from the south there seems to be a constant breeze coming into the plant. With this breeze, any dust on the floor or equipment could become airborne and carried throughout the Finishing/Fittings Department, this being one reason that a good and thorough cleanup is necessary. Epoxy - Miscellaneous Departments Areas that fall under this heading include Shipping and Laborers, Maintenance and Epoxy Departments. One shipping department employee was sampled while banding trucks in the yard the sample #099 was for 310 minutes with results of 0.0036 f/cc. Two employees classified as laborers worked in B Plant Finishing Department rebanding 8"150 Pipe on second shift (Samples 057-060). Their TWA's for the shift were 0.32 and 0.065 f/cc. A Maintenance Shift Mechanic was sampled and found to have a TWA of 0.017 f/cc (Sample 100). Most of his time was spent in the Maintenance Department area with a few trips made back to the Manufacturing Department. The Epoxy Department was sampled while running 4" pipe and couplings. The pipe cleaning station operator is also the pipe epoxy coating operator. Levels of 0.013 and 0.03^ f/cc (Samples 095 & 096) with a TWA of 0.026 f/cc were found for this operator. The Coupling Coater Operator (Sampled 097 & 098) had a TWA of 0.12 f/cc. NOISE MEASUREMENTS The noise survey was conducted by using Dupont Audiodosimeters set at 90 dB, during the survey of May 27-30, 1980. The employees wore the dosimeters throughout the day while working at their normal jobs. The audiodosimeters are noise measuring devices which measure and accumulate CTD020703 -8- Industrial Hygiene Survey Hillsboro A/C Pipe Plant if257 May 27-30, 1980 November 12-14, 1980 the total noise dose above 90 dBA for the total time during which the employee wears the instrument. The resulting value is recalculated to determine the 8-hour exposure based on the assumption that the employee's work is fairly consistent throughout the day. This 8-hour value is compared to the OSHA 8-hour acceptable limit of 100%. The audiodosimetry results are given in Table V. Followup work for noise was done during the November 12-14, 1980 survey using a sound level meter at locations throughout the A-plant Finishing and Fittings Department. The survey consisted of sound pressure level and octave band analysis measurements. These measurements provide insight into the nature of the noise problems and means of engineering controls. The diagrams and results are presented in Exhibit I through III of this report. The results of the audiodosimetry survey indicated that 8 of the 36 job positions sampled had excessive noise levels. These 8 job positions were all located in the Finishing/Fittings Department. Excessive noise levels were found for Lathe line #2 Lather Operators and Hydrotester operators tested on both the first shift and second shift. The results are shown in Table V, Samples #113, 114, 115, 117, & 118. First shift on 5/28/80, Lathe Line 2 was running 8" & 12"150 pipe for 6 1/2 hours then changed to line 3 and ran 16"150 pipe for 1 1/2 hours. The Lathe operators levels were measured to be 91%, (Sample 112) 149% (Sample 114) and the Hydrotester (Tester) operator had 293% (Sample 117). Noise levels as measured by the sound pressure level meter on 11/14/80 disclosed levels of 94-95 dBA for the Lathe operators when lathing 6" sewer pipe with a peak of 107 when pipe bang together on the lathe table and levels of 87-92 at the tester operators position. Second Shift this day ran 12"150 on line 2 for the full shift. The Lathe Operators results were found to be 187% (Sample 113) & 235% (Sample 115) and 120% (Sample 118) for the Tester Operator. Line 3 was tested 5/30/80 while running 16"150 pipe. The audiodosimetry results were 178% (Sample 123) for the Lathe Operator and 120% (Sample 124) for the Hydrotester Operator. Lathe Line 3 was not running during the November survey so sound pressure levels were not obtained for those job positions. CTD020704 -9- Industrial Hygiene Survey Hillsboro A/C Pipe Plant if257 May 27-30, 1980 November 12-14, 1980 The main source of the noise for the 3 operators was the lathe itself while actually lathing the pipe ends and the air noise created when the lathe moves back from the finished pipe. The installation of air silencers at the lathe would help the noise problem considerably. A contributing factor at the lathe is the type of pipe and its hardness, which is due to a manufacturing process change. The harder the pipe the more noise that is created by the tools lathing the ends. Another factor adding to the overall problem is the pipe rolling on hard surfaces and bumping together. These levels contributed to high levels found in other areas of the Finishing/Fittings Department. The Small Multiple Coupling Cut-Off Saw was found to have sound pressure level measurements of 91 dBA while both saws were in operation, another contributing factor to the noise level would be the truck traffic in this area. The audiodosimeter sample obtained during the May survey was voided due to a malfunction in the instrument. Although a noise dose was not obtained on this operation it seems from the other measurements taken in this area that this employee could be overexposed to noise. The #1 Boring Mill had results of 151% (Sample 131) while boring 4" & 6" couplings with Sound Pressure level measurements of 91-92 dBA while boring. This job position is located between #1 and #2 Boring Mills, therefore excessive noise levels were created while both mills are running plus the other operations in the department. The operator's noise dose would also depend on the size of the coupling and its age/hardness plus the employee's work speed. Two means of noise reduction could be utilized - a panel or wall made of a sound absorbing material could be installed between #1 and if2 Boring Mill to cut down on noise generating from if2 plus an application of absorbing foam inside the 2 mills. The if3 Boring Mill operators results were found to be 77% (Sample 132), as was the #1 FM Lathe Operator (#135), although, Sound Pressure level measurements for the #1 FM Lathe Operator & Helper work stations were found to have a range of 91-97 dBA while the FM Saw, lathe and tester were in operation. The #2 & 3 FM Lathes Operator was found to have 99% (Sample 136) on the audiodosimeter test, which is almost the OSHA limit of 100%. The PAD adapter lathe and the Large FM Lathe were found to have sound pressure level measurements of 91-94 while machines were in operation. The coupling tester operator (Sample 125) had a reading of 82% while running 16"150 couplings during the May survey, which is acceptable by OSHA. Sound pressure level readings ranged from 85 (background noise) to 96-102 dBA. While in operation (16" couplings) the main source seems to be air noise created when actually testing the coupling. CTD020705 -10- Industrial Hygiene Survey Hillsboro A/C Pipe Plant #257 May 27-30, 1980 November 12-14, 1980 The Large Coupling Saw was found to have 134% reading on the audiodosimeter (Sample 137) while sawing 16"150 couplings. This saw was not in operation during the November noise survey therefore sound pressure level measurements were not obtained. The Rework Saw was sampled for noise during the May survey (Sample 138) in which the employee wearing the dosimeter ran both the Large Coupling Saw and the Rework Saw at different intervals throughout the day. His exposure was 133%. Sound pressure level measurements revealed a background level of 87 while the saw was not in operation and a range of 93-96 dBA while the saw was in operation. A peak of 93 dBA was found when raising cut pipe from saw to roll on the table. The Large Coupling Saw and Rework Saw are similar in design and therefore seem to have the same source of noise to be corrected. The operators for both saws work very close to the saw, manually pulling the blade down onto the piece being cut. The operator is in a direct line with noise generated during the cut. To reduce the noise exposure at the rework saw, it is recommended that a sound absorbtive barrier panel (with a plastic viewing window) be built into the saw handle so that when the blade is brought into position on the piece, the panel would absorb and reflect noise to reduce operator exposure. It is understood that the Large Coupling saw is to be replaced in the near future with a saw designed to cut similarly to the Small Coupling Saw & FM Saw already in operation. Until the new saw is installed hearing protection should be required for operators in this area. If the installation of the new Coupling Saw is to be delayed somewhat, it is recommended that the same panel as described for the rework saw, be installed on the Large Coupling Saw. The Fittings Maker had a 144% (Sample 139) reading on the dosimeter while running 6" pipe on the fittings Lathe. This equipment was not in operation during the November survey, therefore no sound pressure level measurements were taken. The Crusher Operator was sampled and found to have a reading of 269% (Sample 127). The exposure or noise dose received by the Crusher Operator largely depends on the speed at which the individual works. Sound pressure levels were not taken on November 14, because the operation was down due to rainy weather. Observations made of the Crushing Operation reveal that reduction of the noise level could be accomplished by lining non-wearing surfaces inside the crusher (especially the hood around the crusher entrance) with sound absorbing acoustic foam. CTD020706 -11- Industrial Hygiene Survey Hillsboro A/C Pipe Plant #257 May 27-30, 1980 November 12-14, 1980 When levels are analyzed and the overall picture is considered, the Lathe lines are the prime source with diminishing levels being found at greater distances from the lathe. The lathes, when in operation, affect employees exposures at other areas in the department. The audiodosimeter samples taken illustrate this, although each of the individual machines, themselves, are a source. Reduction of noise exposure in the department could be accomplished by installation of absorptive barrier walls or curtains throughout the area. In review, there is no fast and easy solution to the problem of noise in the Finishing/Fittings department. OSHA requires that noise be controlled by feasible administrative or engineering controls. Only when these methods fail to reduce sound levels to acceptable limits is it appropriate to utilize a permanent hearing protection program. Reduction of noise levels by engineering and administrative controls can be accomplished for nearly all the job positions found to be excessive by the audiodosimeter survey. "A" Plant Summary The results of this survey disclose that all Time Weighted Averages of the 32 job functions sampled presently fall within the current OSHA 8-hour Time Weighted Average (TWA) asbestos standard of 2.0 fibers per cubic centimeter of air (f/cc). One 155 minute sample of 4 samples (#064-067) taken on the #1 Boring Mill Operator was found to be >2.52 f/cc (Sample 064) resulting in a TWA of 1.79 f/cc for this position. This was the only sample taken in plant "A" found to be above 2.0 f/cc. Plant management was notified of these results and asked to resample this job function. Further sampling was done along with some changes made to the dust collection system to bring the fiber levels down to 0.29 & 0.24 f/cc with a TWA of 0.27 f/cc (Samples 142 & 143). Personal Audiodosimeter Measurements reveal a number of job positions exceeding the current OSHA Noise limit of 90 dBA. Areas in need of improvement include: The Boring Mill, Large Coupling Saw, Crusher, Fittings Maker, and the finishing lathe lines, mainly the lathe themselves. Improvements made at the lathes would help to reduce the noise levels throughout the Finishing/Fittings Department. CTD020707 -12- Hlllsboro "B" Plant The first initial start-up of Plant B was in December of 1979 with production running through March 1980. During the period March - October 1980 there_was no production in B Plant. Since B Plant was not in operation at the time of the May survey a return trip was made November 12-14 1980. Air samples and noise levels were obtained during the second initial startup and shakedown period of B Plant. Forty air samples and 5 personal audiodosimetry samples were obtained during the week of November 12-14, 1980, in the Manufacturing Department. B-Plant Finishing Department was not in operation at the time of this survey. Of the 40 air samples, 21 were personal samples covering 8 job positions and establishing 6 Time Weighted Averages. The other 19 air samples were taken in different areas of the B-Plant. One thing to keep in mind when reviewing all of the sampling results from this survey, is that these samples were taken during a shakedown period with manufacturing interruptions for engineering changes, breakdowns and repairs, and that these levels are not necessarily the same levels that would be found during normal operations. CTD020708 -13- Hillsboro A/C Pipe Plant "B" Manufacturing Schedule November 12-13, 1980 Wednesday 11/12/80 Thursday 11/13/80 Manufacturing Dept. 6" 150 pipe 6" 150 pipe CTD020709 Industrial Hygiene Survey Hillsboro A/C Pipe Plant #257 May 27-30, 1980 November 12-14, 1980 -14- ASBESTOS FIBER MEASUREMENTS Table VI shows the results of the 21 personal fiber samples giving individual sample results, and time weighted averages where applicable. Table VII shows the results of the 19 environmental samples taken throughout B-Plant. A departmental breakdown of the samples and results can be further exemplified by Table VIII. In reviewing the sampling results, all areas seem to fall within the current OSHA 8 hour Time Weighted Average (TWA) asbestos standard of 2.0 f/cc, although a few samples need further discussion, which follows. Manufacturing Department Thirty-five samples were taken in this department with a range from 0.0004 to 4.6 f/cc. The average fiber count was 0.36 f/cc. The fiber warehouse was found to have a level of 0.05 f/cc (Sample 173). The mixer operator was stationed mainly at the bag opener (Samples 150 154) and had a TWA of 1.1 f/cc covering 7 3/4 hours. Sample #150 for 60 minutes had a level of 4.6 f/cc. This sample was taken while the employee was involved in a cleanup at the Bag Opener flat conveyor. One 20 minute sample (#171), taken on a maintenance person also involved in this repair/ cleanup, was heavily loaded with particulate. An exact count was not possible, however, in order to determine an exposure level an attempt was made to count the sample. The results were found to be in excess of 61 f/cc, which is above the current OSHA ceiling concentration of 10 f/cc. Two samples were taken on this employee covering 73 minutes which was insufficient sampling time to calculate a TWA for this employee. The cleanup and repair of this block up at the Bag Opener flat conveyor involved the Maintenance person in the pit unclogging raw fiber and putting it in plastic bags, while the mixer operator was on the upper level emptying the bags back into the Bag Opener. All the employees in the area wore 3M 8710 air purifying respirators. While the current OSHA Asbestos Standard 1910.1001 d2(i) of the Federal Register requires only air purifying respirators for levels from 10-100 f/cc short term exposures, it is our recommendation that when a block up of this type occurs or when an exposure of this level is expected or unknown the employees involved should be outfitted with powered air purifying respirators or supplied air respirators (continous flow or pressure demand). CTD02Q710 -15- Industrial Hygiene Survey Hillsboro A/C Pipe Plant #257 May 27-30, 1980 November 12-14, 1980 The Hillsboro plant has three 3M White Cap units available for use. It is recommended that these units be stored and available for use in the areas of both plants where they are most likely needed, such as the mixer room/ area for block ups, at the Dust Collectors for use upon entry into the Dust Collector and at the Crusher in case of a block up. The employees should be instructed in the proper use and care of these units and a regular check should be made of all units, to be assured they are clean and in working order. Continuing on with the Mixer Operator job position, the Bag Opener was not working with 100% efficiency this day, the slitters were not cutting the bags completely so the Mixer Operator was having to slit some of the bags by hand, which meant having the plexiglass doors open for access into the opener. The employee wore a 3M 8710 respirator throughout the shift. Area samples (#174-179) taken at the bag opener revealed levels with a range of 0.23 - 0.70 f/cc. These 6 samples characterized the areas at the bag compactor and control panel with all doors open, down to 1 door open, during dumps and without dumps. Specific notes for each sample can be found on table VII under the remarks column. Other area samples taken in the mixer room (#180-188) had a range of 0.13 - 0.32 f/cc. These samples all are well within the OSHA standard of 2.0 f/cc. A small leak was found at the willow mill yielding a level of 0.24 f/cc which was fixed immediately lowering the level to 0.13 f/cc. The Machine Tender has a TWA of 0.20 f/cc (#155-157). The Control Operator had a TWA of 0.026 f/cc (#158-160) with area samples taken in the control operator work area revealing levels of 0.023 and 0.047 f/cc (#189 & 190). Two of the three samples taken on the Mandrel Handler were voided (#162 & 163) as were the 2 area samples (#191 & 192), all due to heavy particulate concentration. A possible contributing factor to the uncountability of the samples could be the steam in the air, the samples that were voided showed a minimal fiber concentration. One sample of 5 taken in this area that was countable (#161) and revealed a level of 0.11 f/cc, it was a 171 minute sample. The plant has been asked to resample this job position to better determine the exposure levels in this area. The Take Off Person had a TWA of 0.022 (#164-165) and the Relief Person had a TWA of 0.14 f/cc (#166-167). An area sample at the stripper revealed a level of 0.0004 f/cc. All the above samples are well within the OSHA standard. CTD020711 62870 VROFOSZO RULES \ o _o 0 1 o 3 ou >v- i3ii Cr aa*od > c -KSS* %* KJa"8|2; 5Sq^ `||ao t 3 1^3=? 3-8 % 11| I-a rspsisf v <3 . b IClis"S"i 3 A~* _, CO :Sill?5'g8 ist ] | S5i ss &| 0,3 S " 8 ssEsr 3 a 91 ** s a-2 la,-*! 516' ft S.X3 U ft afciSi 1l|JPI?l! fSoliisl'S|iIa0- Hi lSH\mi1l!l.I*0SBiSCjS> s*J a^ o s m1 8 " g*-8 5|a3S&'g; t ti m nS 51 ***11*3*: v8t,5|ao^-o3-c :ils.S |ee?sgigld ?=-aS,,aS5 alia I" B-3J5-2 3 Ilgl'sIS'S 2il5 H a a o 5 g S$ t sfcgg mm tripEiS iJ0.1V3I t>O<, Qwj C" L VO u ? jsps *g P- P 4> S c H ft, u 3 ^5 iib ^ a3Ss _ 3S HaS" xeo?73*aS5rj jos Swna^gl8o2e,, si a tJ-So 5t- eosg |"s=* J0a.2 & C y 3 > 3 w ^ f0l fl 0} Mk A> C01 u^5&31 S3 *3E vct ? g io5s S6 - -g rSf iP SsygS&i s|s..s !l|g" ssa^s ^<5 wO Saj aTJ 5 Sog"55 a5 2 ia S n| S S"li ^ cob.S3b h ** n P s.C ZSs l 5Sf ll|g .Ijil l|l|s- J>5 "a? 3 a ! s||| 5?| 5:1 aa33,,g3 Ijjll^l ES Cn ti V O: E=ges! n ,, -81 5ci oo> .s|afio5.c IU s-gr s^-gs, -=ds*slhsJ _c g- o5 g SjO 15 j E 5* S?2-3ggv^g! <-o e ci x? <8v?oo So . ftJ5 P2 B3 i 2 ^s^rtEa-M-Sd) q 83Sr &*,.& 2S --3 &s ~ 8 ~ I-H-f I5 t ** 13! "Ss||l3||| 3 a8.^Iia3 Mlfiiiii 8fi3St*S J5S-S*,gsiJa3 --0 vl|s5i!^Sg '^palts^e S=C3S"g=o= Sg2^S8=;8| .iI llslsiisl!a!=li|il!ll| o 8^ * L-rSge*?13 i 8__fS I-3 0_c 8 ^ft<w1*L ^Pw *0C ssel;H'a . * . a !I||I 2-0 j|o " 2e .-S8?Et-: :SVi2VlSgS"?fJ* c4 ua0 .s;i? 'sit S8S S8SfiJ' r,n> :-rti :5JI 8 "SEai ^ 1 1 M- ix 1 nil? III! ? |i S?33 s* A. ITm. II o II nilrfidg 11 CTD020712 11 1 Hillsboro A/C Plant Industrial Hygiene Survey November 12-14 1980 Table Environmental Dust Exposures "B" Plant No. 80 184 185 186 POSITION/ LOCATION (Date) Fiber Scale 11/12/80 2nd Floor Mixer 11/12/80 NAME/AREA Area Area 187 188 Mixer F4/ Wetting Screw 11/12/80 Area 189 190 Control Operator's Station 11/12/80 Area 191 Mandrel Handler's Station 11/12/80 192 Area 193 Stripper Station 11/12/80 Area ANALYSIS FOR TIME MIN. Fiber 2:46p 4:12p 86 Fiber Fiber Fiber 1:10a l:57p 167 l:57p 4*15p 138 11:13a 1:58p 165 l:58p 4:07p 129 11:30a 2:40p 190 Fiber 2:40p 4:16p 11:35a 2:40p 96 185 2:40p 4:17p 97 Fiber 12:00N 4:20p 260 RESULT TWA for Sample period REMARKS 0.13 -- pump setting 3' from floor on fiber scale 0.25 0.21 -- pump located on 2nd floor hanging 3* from platform 20' above 1st floor 0.32 0.20 -- pump setting 1* from #4 mixer 2' above covered wetting screw. 0.023 0.047 pump approx 5' from Roll-up/Press Section at operators station VOID VOID -- 0.0004 -- pump approx 5' from Roll-up/Press Section at operators station Void sample - heavy particulate Void Sample - heavy particulate. No employees In area pump setting on Mandrel Return side on control panel approx. 4' from stripper CTD020713 "lllsboro A/C Plant iustrial Hygiene Survey jvember 12 - 14 1980 !\ V c? TABLE Audiodosimetry Results "B Plant" NO. R0 position/ LOCATION (Da te) NAME Manufacturing Department 194 Mixer Operator (11/13/80) R. Lacy TIME Min. 10115a 3: 50p 335 RESULTS Eight Hour % Dosimeter 8 5 dflA | 9 0 dBA 87% 195 Machine Tender (11/13/80) _ 196 Control Operator (11/13/80) 197 Mandrel Handler (11/13/80) J, Owens H. Cox C. Salinas 10:22a 3t 55p 333 10:30a 3: 5 Op 320 10:33a 3:55p 322 85% -- 185% 198 Relief Person 11/13/80 R. Pavelka Miscellaneous Departments 199 Crusher Operator 11/13/80 C. Harris 10:26a 5: OOp 394 10:36a 12:00N 164 1:30p 2 50p 111% 193% REMARKS 6"ISO pipe employee in Mixing Room-normal operations 6"150 pips VOID SAMPLE 6"150 pipe Mandrel Return behind employee accounting for most of his exposure. Hiis job position requires work in all areas of the Manufacturing Department CTD020714 -16- Industrial Hygiene Survey Hillsboro A/C Pipe Plant #257 May 27-30, 1980 November 12-14, 1980 The Crusher Operator had a TWA of 0.78 f/cc (#168-170) with sample #169 being 1.7 f/cc. There was a block-up in the crusher system earlier that day (not on this sample) which might have reoccured again during this sample although its not noted. The operator wore a 3M 8710 respirator during his shift. Because of the possible block-ups in the Crusher System it is recommended that this job position be posted a required respirator area. NOISE MEASUREMENTS The noise survey was conducted by using Dupont Audiodosimeters set at 90 dB, during the survey of November 14, 1980. The employees wore the dosimeters throughout the day while working at their normal jobs. The audiodosimeters are noise measuring devices which measure and accumulate the total noise dose above 90 dBA for the total time during which the employee wears the instrument. The resulting value is recalculated to determine the 8-hour exposure based on the assumption that the employee's work is fairly consistent throughout the day. This 8-hour value is compared to the OSHA 8-hour acceptable limit of 100%. The audiodosimetry results are given in Table IX. A sound level meter was used at locations throughout B-Plant Manufacturing department. The survey consisted of sound pressure level and octave band analysis measurements. The diagrams and results are presented in Exhibit IV and V of this report. The results of the audiodosimetry survey indicated 3 of the 5 job positions sampled had excessive noise levels. These job positions were in the Manufacturing department. (The Finishing Dept, was not in operation during this survey.) The 3 positions are Mandrel Handler 185% (#197), Relief Person 111% (#198) and the Crusher Operator 193% (#199). The other 2 samples taken on the Mixer Operator and Machine Tender were under the 100% allowable dose. The control operator sample (#196) was void due to an equipment failure. The mixer room was measured with the sound level meter and found to have levels of 82 - 85 dBA. The noise levels at the pipe machine, presented in Exhibit V, show that general operating conditions produce 87 to 95 dBA. The levels at the pipe machine increase to 110/120 dBA when the mandrels clang together on the mandrel return conveyor. Air release noise was noted as a major source of noise when the press section moves up and the new mandrel rolls into position. Altogether, these are sources contributing to the Mandrel Handlers and control operators overexposure. CTD020715 Industrial Hygiene Survey Hillsboro A/C Pipe Plant if257 May 27-30, 1980 November 12-14, 1980 -17- Reduction of these noise exposure levels should start by installing air mufflers on all pipe machine air cylinders. Also, considerable noise is generated by the empty mandrel as it rolls into position within the pipe machine. Reduction of some of this noise could be accomplished by installing neophrene pads on metal to metal Impact and roll surfaces. In the interim we recommend these employees wear hearing protectors. The Relief_Person works throughout the Manufacturing dept. Therefore he receives noise from many different sources. He does relieve the Mandrel Handler so a large percentage of his dose could be from the Mandrel return conveyor. The Crusher Operator sample of 193% (//199) was taken during a full day work shift. During the shift the employee was involved in a block-up and helped to repair it. Sound level measurements were not taken at this operators station because it was not In operation November 14, due to damp weather. Observations made of the Crushing Operation reveal that a reduction of the noise level could be accomplished in much the same manner as the A-Plant Crusher by lining non-wearing surfaces inside the crusher (especially the hood around the crusher entrance) with sound absorbing foam. The 3 job positions, Mandrel Handler, Relief Person and the Crusher Operator that exceeded 100% OSHA noise dose should be required to wear hearing protection until the noise levels are reduced by engineering or administrative controls. B-Plant Summary The results of this survey disclose that all time weighted averages calculated on the job positions sampled, fall within the current 8 hour Time Weighted Average of 2.0 f/cc. One sample (#171) taken on the maintenance person for 20 minutes exceeds the 10 f/cc ceiling concentration for a peak exposure sample. The 3M White Cap units should be made readily available to those employees involved in breakdowns and clean-ups such as this. CTD020716 -18- Industrial Hygiene Survey Hillsboro A/C Pipe Plant #257 May 27-30, 1980 November 12-14, 1980 The plant personnel should be sampling the air in B-Plant on a daily basis while the plant is in the shakedown stage. A permanent schedule for sampling should be established once the plant is operating normally. Three job positions exceed the 100% allowable noise dose, those were the Mandrel Handler, Relief Person and the Crusher Operator. These 3 positions should be required hearing protection work areas until engineering or administrative controls are instituted. FURTHER AIR MONITORING A-Plant The present fiber exposure surveillance program in A-Plant should be continued but expanded to include more frequent sampling in all areas of the plant with more emphasis on 8 hour Time Weighted Averages for those employees sampled. It is recommended that the areas with samples exceeding 1.0 f/cc (Large Coupling Saw Operator) and any other area that possibly could exceed 1.0 f/cc be monitored on a regular basis in order to be assured that levels remain below the current limit of 2.0 f/cc established by 0SHA. It is also recommended that whenever any changes - minor or major - are made to the manufacturing process/system, in the Finishing/Fittings Dept, and the Crusher Area, fiber exposure measurements should be made and followup work done to assure that exposures are well within standards at all times. B-Plant A fiber surveillance program should be established for the new B-Plant, with frequent sampling done during the start-up and shakedown period. One purpose of samples taken during this period is to document the fiber levels during engineering and manufacturing process changes and to show the improvements in the exposure levels brought about by those changes. Once the plants functions are considered normal manufacturing operations, then the program for sampling can be put on a regular sampling schedule, with emphasis placed on 8 hour shift sampling with Time Weighted Averages. CTD020717 -19- Industrial Hygiene Survey Hillsboro A/C Pipe Plant #257 May 27-30, 1980 November 12-14, 1980 Tables IV and VIII show the number of samples taken in each deparment of A and B Plants and the average airborne fiber concentration for each department. On the right side of the table there are 3 columns, one is headed - Percent >2.0 f/cc. This gives the percentage of samples taken during this survey that exceed the current OSHA limit of 2.0 f/cc. The other 2 columns are headed - Percent >0.5 f/cc and percent >0.1 f/cc. These columns were included in the table to give an idea of the percentage of samples exceeding the levels now under consideration by OSHA. This table was also included to give an idea of where most work would be needed to bring the plant into compliance with the new level. RESPIRATORS- It is necessary that a written respirator program be established to formally address the use of respirators at the plant. Respirators are required in areas where a level exceeding 2.0 f/cc is found, until engineering or other changes are made and an acceptable level is achieved. Currently, 3M 8710 respirators are used at locations throughout the facility where required and by employees who choose to use one. A very large drawback with the 3M 8710 is that employees cannot be properly fit tested to assure us that when an employee is wearing the respirator, he is being properly protected. Undetected leaks around the nose or face due to facial contour lead to a false security that the respirator is in fact offering protection. It is especially important that all employees who are required to wear respirators be fit tested. The respirator protection program should be upgraded to incorporate toxic dust filters for all job positions where we require the use of respirators. A single use respirator, 3M 9900, as well as other permanent half-mask respirators approved by NIOSH for protection against asbestos containing dusts should be utilized. These should also be made available to those employees who request a respirator. It is recommended that a "Personal Respirator Control" Unit Program be developed using the concepts presented in section C of the CT Health and Safety Manual and Appendix I to this report. CTD020718 Industrial Hygiene Survey Hillsboro A/C Pipe Plant #257 May 27-30, 1980 November 12-14, 1980 -20- FURTHER NOISE WORK A-Plant In discussing the areas with noise problems, some suggestions have been made to help reduce the noise levels. A more extensive analysis should be made by engineering personnel to determine the exact cause of the noise and the necessary steps to be taken. B-Plant A more detailed study of the noise problems in B-Plant should be made after the plant is operating at normal production, this should also include the Finishing Line and the Crusher. HEARING PROTECTION Until noise levels are reduced to acceptable limits, all employees whose job positions were found to exceed 100% (audiodosimeter results) should be required to wear hearing protection. It is recommended that several types of hearing protectors be made available to employees so that they can choose the one most comfortable. These machines and job positions should be posted with signs requiring the use of hearing protection. These employees should also be provided with annual audiometric examinations. If engineering controls cannot reduce the levels to 90 dBA, consideration should be given to administratively control the noise by having the employees change work positions. Administrative control means that a person's exposure is controlled by limiting the amount of time he is exposed to noise. By rotating the employees through job positions on an hourly basis, and by engineering reductions, it may be possible to reduce all employee exposures to less than 100%. Until such time as the 8-hour exposures are less than 90 dBA, these employees must wear hearing protection. CTD020719 Industrial Hygiene Survey Hillsboro A/C Pipe Plant #257 May 27-30, 1980 November 12-14, 1980 -21- RECOMMENDATIONS A-Plant 1. A slitted curtain should be added to the bag opener, where the bags enter the opener on the conveyor. 2. All latches on the bag opener should be repaired and used by the Mixer Operator. 3. General Housekeeping should be upgraded at the Lathe Lines, Rework Saw and Large Coupling Saw to include a thorough cleanup at the end of each shift. 4. The Engineering Department should be consulted for the improvement of the dust collection system at the finishing lathe lines to remove tailings and dust from inside pipe. The job positions in this area should be sampled regularly to measure the effect of the changes made. 5. Further sampling should be done at the Crusher and #1 Boring Mill on all sizes of couplings run at this mill. 6. The Large Coupling Saw should be replaced as soon as feasibly possible, otherwise, the present dust collection system should be redesigned for better efficiency. 7. The fiber surveillance program should be expanded to include more frequent sampling throughout the plant with more emphasis on full day sampling and 8-hour Time Weighted Averages. 8. Posted required respirator areas should be the Automatic Bag Opener, Crusher Area, the #1 Boring Mill and the Large Coupling Saw. 9. Air Silencers should be installed at the lathe lines. 10. A wall made of sound absorbant material should be installed between #1 and #2 Boring Mill and/or an application of sound absorbing foam inside each mill. 11. A sound absorbant panel should be added to the Rework Saw handle. This should also be done to the Large Rework Saw if it is not replaced in the near future. CTD020720 -22- Industrial Hygiene Survey Hillsboro A/C Pipe Plant #257 May 27-30, 1980 November 12-14, 1980 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. A sound absorbant foam should be applied to non-wearing surfaces at the Crusher including the hood at the entrance to the Crusher. An installation of sound absorbant barrier walls or curtains should be made throughout the Finishing/Fittings area. Posted required hearing protection areas should be: The Lathes & Testers #2 & 3, the Crusher, #1 Boring Mill, Large Coupling Saw and the Fittings Machine. B-Plant The Mandrel Handlers job position should be resampled immediately to better determine the exposure levels in this area. A constant (daily) surveillance of fiber levels should be made in the B-Plant until the Manufacturing operation is considered normal and all levels are within OSHA limits. When normal manufacturing operations are achieved a regular surveillance program should be established. A posted required respirator area should be at the Crusher Area and the automatic Bag Opener. A more detailed and extensive study should be made of the noise levels in the B plant, including the finishing line and Crusher. Posted required hearing protection areas should be at the Mandrel Handler's job position and the Crusher Operator's job position, which would include the Relief Operator when he is in these areas. A sound absorbant foam should be applied to non-wearing surfaces at the Crusher, including the hood at the entrance to the crusher. General All fiber spills should be cleaned up immediately and all torn bags taped. All brooms in all areas of the plant should be eliminated and alternate methods such as oil mops, vacuums and any wet method should be used for cleanup. The use of old felts should be discontinued and old discarded felts should be totally disposed of. CTD020721 -23Industrial Hygiene Survey Hillsboro A/C Pipe Plant #257 May 27-30, 1980 November 12-14, 1980 25. Areas with samples exceeding 1.0 f/cc or any area that could possibly exceed 1.0 f/cc should be sampled on a regular basis. 26. 3M white cap units should be in working order and stored in areas of the plant where they would most likely be used. Employees should be educated in the use and cleaning of this equipment. 27. A review and upgrading of the present Respirator program should be made. CTD020722 Page 24 Industrial Hygiene Survey 'llsboro Plant y 27-30, 1980 No. POSITION 80 LOCATION (Date) MANUF lCTURING DEPARTMENT NAME/AREA 001 Mixer Operator 5/28/80 J. Chambers 002 003 004 005 006 Machine Tender 5/28/80 R. Rodrigues 007 i 009 Press Operator 5/28/80 R. Pavelka 010 OIL 012 Mandrel Handler 5/28/80 J. R. Wood 013 014 015 Tray Loader 5/28/80 G. Sulak. 016 017 018 Utility (Relief) Person 5/28/80 J. A. Uood 019 u20 021 Line #2 Lathe Operator 5/27/80 K. Lentz 022 TABLE I PERSONAL DUST EXPOSURES A-Plant ANALYSIS FOR TIME MIN. RESULT (f/cc) TWA (f/cc) REMARKS Fiber Fiber Fiber Fiber Flbc. Fiber Fiber 8:17 a 10:20 a 10:20 a 10:58 a 10:58 a 2:01 p 2:01 p 3:55 p 8:20 a 10:50 a 10:50 a 2:05 p 2:05 p 3:50 p 8:10 a 10:25 a 10:25 a 2:15 p 2:15 p 3:25 p 8:10 a 11:00 a 11:00 a 2:05 p 2:05 p 3:57 p 8:25 a 11:20 a 11:20 a 2:07 p 2:07 p 3:45 p 8:52 a 11:22 a 11:22 a 2:00 p 2:00 p 3:55 p 123 0.059 38 <0.057 183 0.18 114 0.028 150 0.32 195 0.53 105 0.38 135 0.28 230 0.29 100 0.46 170 >0.46 185 0.19 112 0.50 175 0.062 167 0.085 98 0.11 ISO 0.093 158 0.36 US 0.17 L6"150 pipe Hade 2 dumps L dump made 0.098 (24 min.) 16"150 pipe 0.43 16"150 pipe Fans Operating 0.32 / 16*150 pipe 0.36 i/dl 16"150 pipe 0.082 ' .0 1J> 0.21 :n Unrolled old felt from Handrel (S min.) Emptied sweeper twice 10:57 a 128 0.14 1:05 p 12*150 pipe 1:05 p 105 0.24 0.16 2:50 p CTD020723 2:50 p 3:55 p 65 0.058 Line 3 16"150 pipe Industrial Hygiene Survey Hillsboro Plant May 27-30, 1980 TABLP. I (con't) PERSONAL DUST EXPOSURES A-Plant Page 25 No. POSITION 80 LOCATION (Date) FINIS i INC DEPARTMENT (coi NAME /AREA Inued) 023 024 Line #2 Lathe Operator 5/28/80 2nd Shift R. Banik 025 026 027 028 Line #2 Lathe Operator 5/27/80 C. Flaherty 029 030 Line #2 Inspector 5/27/80 R. Jones ANALYSIS FOR Fiber Fiber Fiber 032 033 034 Line #2 (1) Hydrotester Operator 5/27/80 L. Sonnenberg 035 036 037 Line #2 (1) Hydrotester Operator 5/28/80 2nd Shift L. Humphrey 038 039 040 04 L Line f2 (1) Beller 5/27/80 A. Huse 042 044 Line #2 (1) Beller 5/27/80 J. Blackman Fiber Fiber Fiber Fiber TIME MIN. RESULT (f/cc) TWA Cf/cc) REMARKS 5:35 p 7:35 p 7:35 p 9:35 p 9:35 p 9:52 p 9:52 p 11:10 p 10:55 a 1:05 p 1:05 p 2:50 p 2:50 p 3:55 p 10:58 a 1:07 p 1:07 p 2:50 p 2:50 p 3:55 p 10:58 a 1:09 p 1:09 p 2:51 p 2:51 p 3:50 p 5:45 p 7:37 p 7:37 p 9:57 p 9:57 p 10:12 p 10:12 p 11:05 p 10:45 a 1:04 p 1:04 p 2:45 p 2:45 p 3:50 p 10:50 a 1:04 p 1:04 p 1:35 p 120 120 17 78 130 105 65 129 103 65 129 102 59 112 140 15 53 139 101 65 134 31 0.13 0.10 0.052 0.14 0.057 0.41 0.12 0.049 0.14 0.14 0.11 0.22 0.12 0.31 0.15 0.87 0.39 0.028 0.13 0.15 0.016 0.12 12" 150 pipe 0.12 loathed 14 pipe 0.20 12"150 pipe Line 3 16"150 pipe 12"150 pipe Line Fl Tester 0.10 iX\ 12"150 pipe Line ll Tester 0.15 7 Line #3 16"150 pipe 12"150 pipe Line #1 Tester 0.28 12"150 pipe 0.086 'jjh Line #3 16*150 pipe 12*150 pipe 1.0399 CTD020724 Industrial Hygiene Survey Hillsboro Plant May 27-30, 1980 No. POSITION NAME/AREA LOCATION (Date) FINISi INC DEPARTMENT (co i tlnued) 045 046 Line #2 Handler 5/27/80 (1) C. Cavltt 047 048 049 050 Finishing Truck Driver 5/30/80 Coupling Tester Operator 5/30/80 R. Cortinaa G. Granner 051 052 1/4 Tester Operator 5/28/80 2nd. Shift J. Wooten Crusher Operator 5/29/80 054 C. Harris 055 056 057 058 Laborer 5/28/80 2nd. Shift J. Neff 059 060 Laborer 5/28/80 2nd. Shift F. Schnltzlus 061 062 Small Coupling Cut-Off Saw Operator 5/29/80 L. Hill 063 Page 26 TABLE I (con't) PERSONAL DUST EXPOSURES A-Plant ANALYSIS FOR TIME MIN. RESULT (f/cc) TWA (f/cc) REMARKS Fiber Fiber Fiber Fiber Fiber Fiber Fiber Fiber 10:45 a 1:03 p 1:03 p 2:45 p 2:45 p 3:50 p 9:00 a 2:20 p 138 102 65 320 0.057 2"150 pipe 0.13 0.23 0.12 50^ .ine #3 16"150 pipe 0.031 0.031 Running Line #3 16"150 pipe 8:30 a 10:55 a 10:55 A 2:00 A 5:10 p 7:40 p 7:40 p 9:57 p 8:50 a 11:22 a 11:22 a 1:18 p 1:18 p 2:25 p 2:55 p 3:01 p and 3:20 p 3:35 p 5:20 p 7:45 p 7:45 p 11:02 p 5:22 p 7:46 p 7:46 p 11:02 p 8:05 a 11:17 a 11:17 a 2:45 p 2:45 p 3:45 p 145 185 150 137 152 116 97 21 145 197 144 196 192 208 60 0.35 0.20 0.19 -- 0.26 0.24 0.096 0.95 0.011 0.55 0.027 0.091 0.034 0.077 0.043 0.27 16"150 pipe Void sample Pump Problems 0.25 V 0.32 In Plant B Rebanding 8"150 pipe In Plant B Rebandlng 0.065 8"150 pipe 4"150 couplings 0.055 'K 6-200 TBIC CTD020725 Page 27 Industrial Hygiene Survey ''lllsboro Plant ;y 27-30, 1980 No. POSITION NAME/AREA LOCATION (Date) FINISH ING DEPARTMENT (cotitlnued) 064 065 #1 Boring Hill Operator 5/29/80 J. Slovk 066 067 068 069 070 #3 Boring Mill Operator 5/29/80 M. Clements <171 072 073 074 Coupling Stacker 5/27/80 C. Brown 075 076 Fittings Inspector 5/27/80 077 078 #1 FM Lathe Operator 5/28/80 2nd. Shift Scott A. Coaster 079 080 081 082 #2 6 #3 FM Lathe Operator 5/29/80 W. Poston '3 084 085 Large Coupling Saw Operator 5/28/80 2nd. Shift 086 C. Flaherty TABLE I (con't) PERSONAL DUST EXPOSURES A-Plant ANALYSIS FOR TIME MIN. RESULT (f/cc) TWA (f/cc) REMARKS Fiber Fiber Fiber Fiber Fiber Fiber Fiber 8:00 a 10:35 a 10:35 a 10:50 a 10:50 a 1:15 p 1:15 p 2:47 p 2:47 p 3:50 p 7:55 a 10:20 A 10:20 a 10:35 A 10:35 a 1:15 p 1:15 p 3:45 p 11:05 a 1:11 p 1:11 p 4:00 p 11:00 a 1:10 P 1:10 p 3:50 p 4:25 p 6:40 p 6:40 p 9:10 p 9:10 p 9:26 p 9:26 p 11:30 p 8:20 a 11:20 a 11:20 a 2:30 p 2:30 p 3:50 p 4:30 p 6:40 p 6:40 p 6:52 p 6:52 p 7:42 p 155 >2.52 15 0.31 145. > 1.83 92 0.73 X-- 145 0.33 15 0.22 160 0.082 150 < .011 126 0.29 169 0.34 130 0.22 160 0.18 135 -- 150 -- 16 0.070 124 0.056 180 0.035 190 0.14 80 V 70 -- 12 -- so -- 4M150 Couplings Bore 33 Couplings 1.79 Void - Pump problems 16*150 couplings 0.14 Bore 17 couplings yvi s 0.32 x? 12"150 Couplings 0.19 12N150 Counllnaa CTD020726 - Void - pump problems Void - pump problems 0.058 Machined 11-8"150 FM'a l'a 8" 1/2 Length FM's and 16" FAD adaptora 0.090 -b Void - pump problems Void - pump problems -- Void - prop problem. Void - pump problem* Page 28 Industrial Hygiene Survey *Mllaboro Plant t 27-30, 1980 No. POSITION NAME/AREA LOCATION (Date) FINII HING DEPARTMENT (c mtlnued) 087 086 Large Coupling Saw Operator 5/29/80 J. Foster 089 090 091 Rework Saw (Random Saw) Operator 5/29/80 J. Poster 092 093 Fittings Maker 5/30/80 094 or LINE 095 096 Cleaning Station Operator 5/29/80 097 098 Coupling Coater Operator 5/29/80 SHIP ING DEPARTMENT 099 Bander 5/30/80 K. Estes G. Miller M. Smith D. Raulston 100 Manufacturing Shift Mechanic 5/30/80 T. Woodruff TABLE I (con't) PERSONAL DOST EXPOSURES A-Plant ANALYSIS FOR TIME MIN. RESULT TWA REMARKS Fiber Fiber Fiber Fiber Fiber Fiber Fiber 8:00 a 10:55 a 10:55 a 11:14 a 11:14 a 1:16 p 1:16 p 1:31 p 1:31 p 2:52 p 2:52 p 3:40 p 8:55 a 10:55 a 10:55 a 2:25 p 175 >1.85 19 1.46 16** 150 pipe/couplings 1.56 Made 20 cuts 122 1.15 15 0.16 81 0.14 48 0.57 8"150 random Lengths Made 20 cuts 0.29 I'M 120 <0.011 6" Pipe operating the <0.0083 Fittings Lathe 210 <0.0068 9:12 a 11:27 a 11:27 a 3:35 p 9:12 a 11:57 a 11:57 a 1:33 p 135 <0.013 278 0.032 0.026 4"150 pipe i9 165 0.20 96 0.002 0.12 .. 4M1S0 Couplings 9:10 a 2:20 p 310 0.0036 0.0036 10:20 a 2:10 p 230 0.017 0.017 CTD020727 Page 29 Industrial Hygiene Survey llsboro Plant ay 27-30, 1980 No. 101 102 POSITION LOCATION (Date) Fiber Warehouse 5/30/80 Bag Opener 5/30/80 NAME/AREA Area Area 103 Wetting Screw 5/30/80 Area 104 Recirculating Ditch 5/30/80 >5 Roll Up Chart 5/30/80 Area Area Table II ENVIRONMENTAL DUST SAMPLES ANALYSIS FOR Fiber Fiber Fiber Fiber Fiber TIME 9:32 a 11:00 a 9:25 a 10:20 a MIN. RESULT f/cc TWA f/cc REMARKS 88 <;0.023 pump 5' from floor In -- warehouse 55 <0.033 pump setting 4' from floor on Bag Opener -- above Bag Compressor (Manufacturing 16"150 pipe) 9:40 a 11:05 a 85 0.030 pump setting 4' from -- floor on mixer motor 4' from Screw (manu facturing 16** 150 pipe) 11:05 a 1:15 a 130 0.068 at feed flow Trough 4` -- above pit (nanufacturlng 16'150 pipe) (1:00 a 1:15 p 135 0.015 pump 5* from floor V from rollup charts -- 30' from press section (manufacturing 16N150 pipe) CTD020728 Page 30 ilaboro A/C Plant industrial Hygiene Survey November 12 - 14 1980 Table III Personal Dust Exposures "A" Plant No. 80 142 143 POSITION/ LOCATION (Date) 11 Boring Hill Operator (11/14/80) NAME/AREA J. Slovk 144 145 #1 P H Lathe Operator (11/14/80) A. Coaster 146 .7 fl F H Lathe Helper (11/14/80) T. Brown 148 Large Coupling Saw and Rework Saw Operator (11/14/80) J. Foster 149 ANALYSIS FOR TIME MIN. Fiber 7:50a 11:45a 235 11:45a 3:00p 195 RESULTS F/CC TWA REMARKS FOR SAMPLI PERIOD 0.29 Boring 6" cplgs 0.27 0.24 *0 Fiber 7.55a 10:00a 125 10:00a 3:05p 305 0.10 0.078 0.084 6" 1/4 length FM's Fiber 8:20a 10:00a 100 10:00a 3:10p 310 0.11 0.16 0.15 6" 1/4 length FM's vM ^ Fiber 8:00a 1:35p 335 VOID 1/4 hour Coupling Saw 3 1/4 hrs. putting rings In couplings 1 1/2 hrs Rework Saw Void sample heavy particulate l:35p 3:05p 90 __________ 0.55 6" Rework CTD020729 Page 31 Table IV Hillsboro A/C Pipe Plant ("A") Survey of May 27-30 1980 ** Department No. Samples Manufacturing 24 Mean Percent >2.0 f/cc 0.20f/cc 0 Percent >0.5 f/cc 8 Percent >0.1 f/cc 54 Finishing/ Fittings _ Epoxy Lining 63 4 0.30f/cc 0.02f/cc 2 0 14 0 65 0 Miscellaneous 6 (Shipping, Crusher) Plant 97* 0.12f/cc 0 0.25f/cc 1% 0 11% 33 58% * 8 of the 105 samples taken were voided due to problems in the field. ** Eight samples taken in the Finishing Department during the November survey are not included in this table. CTD020730 Page 32 Hillsboro A/C Pipe Plant "-`dustrlal Hygiene Survey / 27-30 1980 No. POSITION/LOCATION (Date) MANUFAC1'URING DEPARTMENT 106 Mixer Operator 5/28/80 107 Machine Tender 5/28/80 108 Control Operator 5/28/80 109 Mandrel Handler 5/28/80 no Tray Loader 5/28/60 in Utility Person 3/28/80 finish: NG DEPARTMENT Line #2 Lathe Operator 5/27/80 113 114 Line #2 Lathe Operator 5/28/80 2nd Shift Line #2 Lathe Operator 5/27/80 115 116 Line #2 Lathe Operator 5/28/80 2nd Shift Line #2 Inspector 5/27/80 117 Hydrotester Operator Une #2 (1) 5/27/80 118 Line #2 Tester Operator 5/28/80 2nd Shift 119 Une #2 (1) Beller 5/27/80 Table V AUDIODOSIMETRY RESULTS A-Plant NAME TIME MIN. J, Chambers R. Rodriguez R. Pavelka J. R. Wood G. Sulak J. A. Wood 8:17 a 3:55 p 8:20 a 3:50 p 8:10 a 3:55 p 8:10 a 3:57 p 8:25 a 3:45 p 8:52 a 3:55 p 458 450 465 467 440 423 Results for 8 hr X D08l meter 85 dBA 90 dBA 10 53 23 85 14 38 K. Lentz 10:57 a 3:55 p 298 91 R. Banlk C. Flaherty 5:35 p 11:10 p 10:55 a 3:55 p 335 300 187 149 J. R. Curry R. Jones 5:35 p 11:10 p 10:58 a 3:55 p 335 297 235 43 L. Sonnenberg 11:00 a 3:50 p 290 293 L. Humphrey A Huse 5:45 p 11:05 p 10:45 a 3:50 p 320 305 120 34 REMARKS 16"150 Pipe 16-150 Pipe 16-150 Pipe 16`ISO Pip. 16-150 Pipe 16*150 Pip. 8" & 12"150 Pip. 1/2 hr Line 3 16-150 Pipe 12-150 Pipe 8- & 12"150 Pipe 1 1/2 hr Line 3 16-150 Pipe 12-150 Pipe 8* 6 12*150 Pip. 1 1/2 hr Line 3 16-150 Pipe 8" 4 12-150 Pipe 1 1/2 hr Line 3 16"150 Pipe 12"150 Pipe 8' 6 12*150 Pipe 1 1/2 hr Lina 3 16-150 Pipe CTD020731 ; Hillsboro A/C Pipe Plant iustrlal Hygiene Survey y 27-30 1980 No. POSITION/LOCATION (Date) FINISH I!G DEPARTMENT (continued) 120 Line #2 (1) Seller 5/27/80 121 Line t2 (1) Handler 5/27/80 122 123 124 125 . *6 127 128 Line #3 Lathe Operator 5/30/80 Line #3 Lathe-Operator 5/30/80 Hydroteater Operator Une #3 5/30/80 Coupling Tester Operator 5/30/80 1/4 Tester Operator 5/28/80 2nd Shift Crusher Operator 5/29/80 Laborer 5/28/80 2nd Shift 129 Laborer 5/28/80 2nd Shift 130 131 132 133 * Small Coupling Cutoff Saw 5/29/80 #1 Boring Kill Operator 5/29/80 #3 Boring Mill Operator 5/29/80 Coupling Stacker 5/28/80 Fittings Inspector 5/27/80 Page 33 t? .o Table V (con't) AUDIODOSIMETRY RESULTS A-Plant NAME TIME MIN. Results for 8 hr X Dosl seter 85 dBA 90 dBA Je Blackman 10:50 a 1:35 p 165 62 C. Cavitt 10:45 a 3:50 p 305 91 K. Lantz C. Flaherty L. Sonnenberg G. Granner J. Wooten C. Harris J. Neff 9:00 a 2:25 p 9:00 a 2:25 p 9:05 a 2:25 p 8:30 a 2:00 p 5:10 p 11:05 p 8:50 a 3:35 p 5:20 p 11:02 p 325 325 320 330 355 228 342 72 178 120 82 77 269 24 F, Schnitxius 5:22 p 11:02 p 340 24 L. Hill J. Sloult M. Clements C. Brown Scott 8:05 a 3:45 p 8:00 a 3:50 p 7:55 a 3:45 p 9:00 a 4:00 p 11:00 a 3:50 p 460 470 470 420 290 152 77 67 - REMARKS 8" 6 12"150 Pipe 1 1/2 hr Line 3 16-150 Pipe 8" 4 12-150 Pipe 1 1/2 hr Line 3 16-150 Pipe 16'150 Pipe 16*150 Pipe 16-150 Pipe 16*150 Couplings 8-150 FM'a In B Plant Rebandlng 8"15Q Pipe In B Plant Rebandlng 8-150 Pipe Void Sample 4-150 -6 1/2 hra 6"200 -1 1/2 hra 16*150 Couplings 16*150 Couplings Void - Problems with Dosimeter CTD020732 Page 34 llaboro A/C Pipe Plant Justrlal Hygiene Survey May 27-30 1980 No* POSITION/LOCATION (Date) FINISH NC DEPARTMENT (continued) 135 #1 FM Lithe Operator 5/28/80 2nd Shift 136 #2 & #3 FM Lathes Operator 5/29/80 Table V (con't) AUDIODOSIMETRY RESULTS A-Plant NAME TIME MIN. Results for 8 hr X Dosimeter 85 dBA 90 dBA A. Coaster 4:25 p 11:30 p 425 77 W, Poston 8:20 a 3:50 p 450 99 137 138 Large Coupling Saw Operator 5/28/80 2nd Shift Large Coupling Saw & Rework Saw Operator 5/29/80 C. Flaherty J. Foater 4:30 p 7:42 p 6:00 a 3:40 p 192 460 134 133 139 Fitting Maker 5/30/80 OCY EPARTMENT 140 Epoxy Cleaning Station 5/29/80 R* Eetes G. Miller 8:55 a 2:25 p 330 9:12 a 3:35 p 383 144 64 141 Boiler Operator 5/28/80 J. Wilson 9:05 a 4:15 p 415 48 REMARKS 8-150 1/4 Length FM'a 8"150 1/2 Length FM'a & 12" Pad Adaptors 16"150 Couplings 16*150 Couplings 5 1/4 hra 6*150 Randoms 2 3/4 hra Running 6" Pipe On Fittings Lathe 4-150 Pipe Cleaning 3 1/4 Hra Plant B CTD020733 Hillsboro A/C Pipe Plant Industrial Hygiene Survey November 12 - 14 1980 TABLE VI Personal Duet Exposures "B" Plant Page 35 No. POSITION/ NAME/AREA 80 LOCATION (Date) Manufacturing Department 150 Mixer Operator 11/13/80 R. Lacy 151 152 153 154 -- ' 15 156 Machine Tender 11/13/80 J. Owens ' 157 158 Control Operator 11/13/60 159 H. Cox 160 161 Mandrel Handler 11/13/80 162 C. Salinas 163 ANALYSIS FOR TIME MIN. Fiber 8:05a 9:05a 60 9:05a 9:35a 30 Fiber Fiber Fiber 9:35a 11:20a 11i20a I:40p 105 140 l:40p 3:50p 130 8:15a ll:0la 166 11:01a l*45p 1:45p 3:55p 164 130 8:07a 11:00a 173 11:00a l:42p 162 l:42p 3:50p 128 8:10a 11:01a 171 11:01a I:46p 165 l:46p 3:55p 129 RESULT F/CC TWA REMARKS FOR SAMPLE PERIOD 4.6 0.26 0.36 >**150 pipe Helping unblock bucket el^ys t orj^t Bag opener^ _ _ Bag opener not working with 100Z efficiency having to slit Bags by hand One window to Bag opener open all the tine 1.1 1.0 0.46 Employee wore a 3M 8710 Respirator throughout the entire shift. 0.21 6*150 pipe 0.17 0.23 0.20 ^^ 0.025 0.027 0.026 6*150 pipe vlsable mist at press section 0.026 0.11 6*150 pipe VOID VOID -- Void sample - heavy particulate Steamy area feel mist In air Void sample - heavy particulate CTD020734 Page 36 Hillsboro A/C Pipe Plant Industrial Hygiene Survey 'ember 12 -- 14 1980 Table VI (con't) Personal Dust Exposures Plant No. 80 164 165 POSITION/ LOCATION (Date) Take off Person 11/13/80 NAME/AREA J. Payne ANALYSIS FOR TIME MIN. Fiber 10:35a 1:35a 180 l:35p 5:00p 205 RESULT F/CC TWA REMARKS 0.022 0.022 0.022 6"150 pipe Trayloader 166 167 Relief Person 11/13/80 R. Pavellca Miscellaneous Departments 168 Crusher Operator 11/13/80 C. Harris > 170 Fiber 10:26a 1:52p 206 l:52p 5:00p 188 Fiber 8:45a 10:36a 111 10:36a 12:00N l:30p 2:50p 84 80 0.13 0.15 0.14 f 6"150 pipe 0.36 1.7 0.37 0.78 Secondary Crusher Block-up 8:45a - 9:30a / -1 ) n. Employee wore a 3M 8710 Respirator throughout entire shift 171 Maintenance Person 11/13/80 M. Ruda Fiber 8:42a 9:02a 20 >61* Working on a mixing system Block-up at flat conveyor for the Bag opener. All employee. In the area wore 3M 6710 Respirators 172 9:02a 53 0.32 at water treatment 9:55: slurry tank. * Note - filter heavily loaded with particulate actual count would be greater than 60f/cc. CTD020735 Hillsboro A/C Plane Industrial Hygiene Survey "ovember 12 - 14 1980 Ho. 80 173 POSITION/ LOCATION (Date) NAME/AMA Fiber Warehouse 11/12/80 Area 174 175 Bag Opener at Compactor 11/12/80 Area 176 Bag Opener at Control Panel 11/13/80 177 Area 178 179 ISO Mixer Operator's Desk 11/12/80 181 Wlllov Kill 11/12/80 182 Area Area 183 Willow Mill 11/13/80 Area Pag* 37 Table VII Environmental Dust Samples "B" Plant ANALYSIS FOR TIME MIN. RESULT TWA for Sample period REMARKS Fiber 1 ;04a 2:03p 179 0.050 -- pump 4' from floor setting on a pallet of ML 6 fiber located near the Bag opener. all doors In area open Fiber 11:00a l:47p 167 0.39 Fiber 1:47p 4:13p 8:30a 9:02a 146 32 0.41 0.23 9:02a 35 0.65 9:37a 9:37a 11:15a 98 11:15a l:37p 142 0.43 0.70 -- 6*150 pipe 2 windows on Bag Opener open, pump sitting on Bag Compactor 1' from window 2* from platform -- no dump made. 1 window, nearest control panel, open. one dump made 1 window nearest control panel open pump setting at control panel 1' from window 4' from platform Fiber 11:52a 2:46p 174 0.16 pump setting 41 from floor after dean up of #l-#2 mixer area Fiber 10:56a 44 0.24 11:40a 2:03p 4:10p 127 0.13 small leak In Willow Mill -- -- 11:30 leak fixed 11:30 - 11:50 block up/ cleanup #2 mixer area _ _ sample taken to measure effectiveness of repair work made to stop leak on Willow Mill Fiber 8:27a 10:21a 114 0.22 more sealing/repair work done on Willow Hills CTD020736 Hillsboro A/C Plant Industrial Hygiene Survey November 12 - 14 1980 Table VII (con't) Environmental Dust Samples "B" Plant Page 38 No. 80 184 183 186 POSITION/ LOCATION (Date) Fiber Scale 11/12/80 2nd Floor Mixer 11/12/80 name/area Area Area 187 188 Mixer #4/ Wetting Screw 11/12/80 Area >89 190 Control Operator's Station 11/12/80 Area 191 Mandrel Handler's Station 11/12/80 192 Area 193 Stripper Station 11/12/80 Area ANALYSIS FOR TIME MIN. Fiber 2:46p 4:12p 86 Fiber 11:10a l:57p 167 Fiber Fiber l:57p 4;15p 138 11:13a l:58p 165 1:58p 4:07p 129 11:30a 2:40p 190 Fiber 2:40p 4:16p 96 11:35a 2:40p 185 Fiber 2:40p 4:17p 97 12:00N 4:20p 260 RESULT TWA for Sample period REMARKS 0.13 -- pump setting 3' from floor on fiber scale 0.25 0.21 -- pump located on 2nd floor hanging 3' from platform 20* above 1st floor 0.32 0.20 -- pump setting 1' from #4 mixer 2* above covered wetting screw. 0.023 0.047 pump approx 5* from Roll-up/Press Section at operators station VOID VOID 0.0004 -- pump approx 5* from Roll-up/Press Section at operators station Void sample - heavy particulate Void Sample - heavy particulate No employees in area pump setting on Mandrel Return side on control panel approx. 4' from stripper CTD020737 -39- TABLE VIII Hillsboro A/C Pipe Plant ("B") November 11-14, 1980 Department No. Samples Mean Percent >2.0 f/cc Manufacturing 35 0.36 f/cc 3% Miscellaneous (Crusher, Maintenance) 5 12.8 f/cc* 20% Percent >0.5 f/cc 11% 40% Percent >0.1 f/cc 80% 100% Plant' 40** 1.9 f/cc 5% 17% 94% * Exceedingly high due to one sample of >61.0 f/cc. ** A total of 52 samples were taken: 8 in A-Plant - 1 sample voided* 44 in B-Plant - 4 samples voided* (The 5 samples were voided due to heavy particulate concentration.) CTD020738 Pge 40 Hillsboro A/C Plant industrial Hygiene Survey member 12 " 14 1900 Table IX Audiodosimetry Results *B Plant" "1" NO. R0 position/ LOCATION (Date) NAME Manufacturing Department 194 Mixer Operator (11/13/00) A. Lacy 195 Machine Tender (11/13/80) _ 196 Control Operator i (11/13/00) 1 ] | 197 Mandrel Handler (11/13/80) J. Owens H. Cox C. Salinas i i j _ 198 Relief Person 11/13/90 ! i \t 1 Miscellaneous Departments 199 Crusher Operator 11/ 13/80 t | " -- R* Favelka C. Harris TIME Min. 10:15a 3: 50p 335 RESULTS Eiqht Hour % Dosimeter S5 dBA | 9 0 dBA 87% 10t22a 3t 55p 333 10:30a 3:50p 320 10:33a 3: 55p 322 85% -- 185% 10:26a 5: OOp 394 10:36a 12:0 ON 164 1 3 Op 2:50p 111% 193% REMARKS 6"150 pipe employee in Mixing Room-normal operations 6"150 pipe VOID SAMPLE 6*150 pipe Mandrel Return behind employee accounting for most of his exposure* This job position re<iulres work in all areas of the Manufacturing Department CTD020739 i i '1 ^9'W'J v.,LvJui: Lii v-.^wj u.jJ CRUTAINTEED CORPORATION ITT-MifcMMlil >! r*r^wwr,iifc> DATE /t//4/st> J015 DESCRIPTION: PLANT: ^/<L NOISE SURVEY SHEET Page 42 REF. 0.0002 MICROBAR EXHIBIT f :iZL SHKET A '&&U<Zz OF EXPOSURE: DEPT. CONDITIONS: INSTRUMENT: . // (LG<^Q^iCA<lJ B 6 K 2220099 1F*SSISMHl V /, , w.^: COM JP<2/ . ENGINEER: 1613 OCTAVE FILTER MICROPHONE: B&K PROTECTOR: CALIBRATOR: B 6 K CALIBRATION DATE: BEFORE AFTER STA. NETWORK PEAK OCTAVE C ENTER FKEO. (Hz. ) HO. TIME EMPLOYEE A LIN. HOLD 31.5 63 125 250 500 IK 2K 4K 8K 16K 9/&*.0 -aftSMnfJL /TLuJttAfdsj 9* ft % TL & Sf 75 % % i6 HotHL HfA/JUl) t*U^2V. 0) f/u. ft/ft)OUslQj 9* iftj$iiLu&vLy t^-Jy/nocC&O&L > 97 % %%o If $7 ZL /3 7$ fru y JzHru^fhjdbL c tvl 'WlA 3 (6 A9! . &L fLC' Hi %s & UsU IZyj. 'JLu. ftc^focruM* ftluul f/ 9i n% % u SL <& & XL 'Ll djfe&erK <'<horridotrL, kh tiZ yin 9'*% , o wn at4% ii n & 1L 72- 7L /J- '-AsmiJ f SKETCH - REMARKS <$) L K Multiple. Cpl^ 5au) E3@13@ if' zj'lm * \r. FOI Url\ c. C7D020741 CStS^SdLD CERTAINIKED CORPORATION RJTHfiai r. IM nt rm l'LANT: JOB DESCRIPTION': NOISE SURVEY SHEET Page 43 REF. 0.0002 MICROBAK EXHIBIT P MMlMMaMMMiMiMMAl T feenjB SHEET AJ* Ilf4 OF EXPOSURE: DEPT. CONDITIONS: . __________ a^a INSTRUMENT: B 6/$Jf 222025 1i'*SLM ' ^-- / 7 iR\jEirF., tA\jfRi\:; . y^\ rE.lNGINEER: xy B~& K 1613 OCTAVE -FILTER MICROPHONE: B&K CALIBRATOR: B & K STA. NO. TIME fyi EMPLOYEE /&@S#JinsrT\ /'Jurm^ PROTECTOR: CALIBRATION BEFORE DATE: AFTER NETWORK PEAK OCTAVE CIENTER l'itEO. (Hz. ) A LIN. HOLD 31.5 63 125 250 500 IK 2K 4K 8K 16K w Jo} ft 37 ?2- 9z 2a 7/ SS 70 7 9. ft). d&u)^CLpMjeJt&r* ft ^2A$ais*n 3 <Jztf7P(^S^L 7V /fiffa 0LjQl4O$6C*i 91 7/ /O! 90 93fa -S3 ft i/ lo fa ?z *i~Tf & fa 3o_ % % f3 Jo fa 30 7? 7 li-rt /ft66 n //A> % n 7/v 3r fa n 1%o %> fa & ?> ft ft 333? 3%1 fa 35 3o 7> 73 >4 % & ?5 38 ft % fa 7o SKETCH - REMARKS ,--------- , Pj 1 r//yo pfj) fil)APT0 J_ ,. ^EAb Lme I Fl<fe'A--*=-!<) <9 oFFice- & kgS5tf A. La.the. (0 5 & f/A CTD020742 cnm- (Qp'Tlf Pv.^/r*] i 1 U ViVV:-^vv j i_ . jj CERTAINTEED CORPORATION DA'l'l NOISE survey sheet Page 44 REF. 0.0002 MICROBAU EXHIBIT f XEL_ ^JOB DESCRIPTION: V ZrLvt^jaJt CONDITIONS: X? , f / KXP05HJRE: T\OtCsi<. A? _ <7 REF. A/K: . DEPT. ENGINEER; INSTRUMENT: hCB J6pJKL'22c0Z$/fvCl$M(lA*^7UrtCr wy (A/iUMABr^4l&K v1L6^13j?OsCTrAsXC^iFXILTHg/ / MICROPHONE: ^ PROTECTOR: D O l\CALIBRATOR: D , ,, STA. NO. TIME / /ffr 2 r--/*--* EMPLOYEE CALIBRATION DATE: BEFORE AFTER NETWORK PEAK OCTAVE CENTER FKEO. (Hz.) IKA LIN. HOLD 31.5 63 125 250 500 2K 4K 8K 16K fc H, 46 2 *& % lz f2 $2.2 & JL 73 10 =J /36> /Ztortol) xldu) Lqms. % 7/ $&1uJZ&VCs (//-frAJhLs jiz |Z ic I* $JL & > 1 J 3 /:% <>I&t6L.SZ40XS? t 3 i-\M, UjfosUdJLe^ta 'htFOO'sd&J 7 ti? SKETCH REMARKS 0 Q-jP 19. te.-Sfe.K- *'W- SftoY 'ReuW.k. SAiA t por n\ Op?K " or' I h i -i j L" euooX c7D0207-43 <r. F rT ' "1 V^t'/1j L iCu : U l! L U V .v V' ^** \v j *_ . j i J CERTAINTEED CORPORATION DATE: PLANT: NOISE SURVEY SHEET Page 45 REF. 0.0002 HICKOBAU EXHIBIT 0 IK "sheet job descrii >T10SN:fS (* ?M^r '#SU) ^ 6"A&CONDITIONS: jazjS 'i / , REF- A/R: ____________________ L/ H^GTNEER: INSTRUMENT: 1! , K 2209 l'SLM B & K 1613 OCTAVE FILTER 'MICROPHONE: CALIBRATOR; B&K D b. ,,k STA. NO. TIME CD a2:2 EMPLOYEE fXLk -> PROTECTOR: CALIBRATION DATE: BEFORE AFTER NETWORK PEAK OCTAVE CENTER FREO. (Hz.) A LIN. HOLD 31.5 63 125 250 500 IK 2K 4K 8K 16K % Z'2 CZ^b fto. C^uomuO ?2 Crvoft: SKETCH remarks To yipE Aia.C.i\i kJ A to 11 Ou> Mills O'<3 ;ti ffciL \ -VSroe_' a.tt'tv ^^2 GpAte.;u~]_ CTD020744 ni aw mm wtwm tefeinSeoO CERTAINl.'lililJ CORPORATION DATE: Ilk PLANT noise survey sheet ^age 46 REF. 0.0002 MICROBAU JZLEXHIBIT 0 6 ~ @6&tcL SHEET OF EXPOSURE: C0",T,raW^^W INSTRUMENT: E b K 2209 l'SLM B & K 1613 OCTAVE FILTER ? MICROPHONE: CALIBRATOR: B&K BR STA. HO. TIME EMPLOYEE PROTECTOR: CALIBRATION DATE: BEFORE AFTER NETWORK PEAK OCTAVE CENTER FKEO. (Hz.) A LIN. HOLD 31.5 63 125 250 500 IK 2K AK 8K 16K 0), klShitJ (ICfAjlt&t*[?/ 93 22 & lo 95 1C 11 &L >d^dL^Zy(SbT^{^UJo^ 0 1 XLLcCc&tA-; &cMup\ (0 lllyMMsm Lcp (2) /07 > & % /Umja* t//ozjc SKETCH - REMARKS l UiJME (3> PlA/JtiR. L 2o>JVCyox^ q----= -5ecioA ey cvdt ei*Ls CD RovO TfLw--Cj&'. * 0- _T <D CTD020745 Page 47 APPENDIX I Monitoring/Analytical Procedures and Current Standards Asbestos Personal samples. Area samples which reflect employee exposure levels, and Engineering j&re^rsamples mHi cW'Ar> ompi nyoa ovpncurM were obtained on Millipore 0.8 micrometer Mixed Cellulose Ester Filters (MCEF). DuPont P4000 air sampling pumps were calibrated before and after each sampling day to approximately 2 liters per minute (1pm). In most cases, a series of 3 or 4 different filter samples were obtained for the person or area to establish an eight hour time weighted average concentration (TWA). The analysis was conducted according to the USPHS/NIOSH Membrane Filter Method for Evaluating Airborne Asbestos Fibers (P&CAM 239) by an experienced fiber counter who was trained by NIOSH. Fibers were counted on a Nikon Model 96982 phase contrast microscope at 400X magnification. The current OSHA standard is given in 29 CFR1910. 1001. It calls for an employee TWA airborne limit of two fibers, longer than 5 micrometers, per cubic centimeter of air (f/cc). Also, no employee shall be exposed at any time to airborne concentrations in excess of 10 f/cc. Noise DuPont Model D-376 audiodosimeters utilized during this survey were set at the 90 dB cutoff mode. The audiodosimeters were calibrated before and after each day of dosimetry sampling utilizing the DuPont Audiodosimeter Calibrator Model C114 by the direct reading method. Before and after each survey week the audiodosimeters were calibrated by the timed calibration procedure utilizing the DuPont calibrator Cl14 and the Model R225 readout. This calibration was done for 5 minutes, 10 seconds at 114 dB to give an expected 30% +/- 4% result. The Permissible noise exposure given in OSHA 29 CFR 1910.95, ranges between 90 decibels for 8-hours per day through 115 decibels for a maximum duration of 1/4 hour per day according to the table below. Also, exposure to impulsive or impact noise should not exceed the 140 decibel peak sound pressure level ceiling value. The maximum permissible audiodosimeter dose is 100%. -7 5^ CTD020746 Appendix I Monitoring/Analytical Procedures and Current Standards Page 48 Permissible Noise Exposures Duration per day, hours dBA, slow response 8 6 4 32 1 1/2 1 1/2 1/4 or less 90 92 95 97 100 102 105 110 115 CTD020747 Page 49 APPENDIX II KEY ELEMENTS OF A RESPIRATOR PROGRAM The Occupational Safety and Health Administration (OSHA) provides regulations for the use of respirators in OSHA standard, 29 CFR 1910.134. OSHA indicates that harmful levels of atmospheric contamination of dusts, fogs, fumes, mists, gases, smokes, sprays and vapors shall be prevented as far as feasible by accepted engineering controls. When effective engineering controls are not feasible or when they are being instituted, appropriate respirators are to be used. It is required that employers provide respirators which are applicable and suitable for the purpose intended. The employer is responsible for the establishment and maintenance of a respiratory protective program which includes the following eleven items. 1. Written Operating Procedure. The respirator procedures must be written and should address the selection and use of respirators. The location's procedures for items 2 through 11 should be discussed and explained in detail. Responsibilities for specific aspects of the program should also be specified in the Location's written respirator program. 2. Proper Selection. The selection of the appropriate respirator is based on the physical state of the substance (gas, vapor, particulate, etc...) the warning properties of the chemical, the toxicity of the agent involved, the protection factor of the respiratory device, and the airborne level of the agent. Other factors to be considered include permissible exposure levels, oxygen deficiency, and approved equipment. 3. Training and Fitting for the Employees. It is required that employees are instructed and trained in the proper use, limitations, selection, and maintenance of respirators. Employees should be trained in the nature of the hazard. The employee must be trained to check the fit of the respirator each time it is used. Fitting through the use of quantitative fit testing (isoamyl acetate or irritant smoke) is also required. 4. Exclusive Employee Use. Where practicable, the respirators should be assigned to individual workers for their exclusive use. cro28748 Page 50 KEY ELEMENTS OF A RESPIRATOR PROGRAM - Cont'd... 5. Cleaning and Disinfecting. Respirators are to be regularly cleaned and disinfected. This must be done thoroughly after each use for respirators used by more than one worker. For respirators assigned to one worker, respirators must be cleaned and disinfected daily when they are routinely used throughout the day. 6. Storage. Respirators shall be stored in a convenient, clean, and sanitary location. It is especially important that rubber parts are stored so that they do not lose their original shape. A misshapen mask is essentially broken and no longer holds its approval. 7. Inspection and Maintenance. Respirators used routinely must be inspected during cleaning. Worn or deteriorated parts must be replaced. Respirators for emergency use such as self-contained devices shall be thoroughly inspected at least once a month and after each use. 8. Work AREA Surveillance. Appropriate surveillance of work area conditions and degree of employee exposure shall be maintained. It is necessary to review the work area to identify contaminants and assess the degree of hazard on a regular basis. 9. Inspection and Evaluation of the Program. Regular inspections are required to. insure that respirators are properly^selected, used, cleaned, and maintained. 10. Medical Examination. OSHA indicates that an employee should not be required to use a respirator unless a physician has determined that the employee is physically able to perform the work and use the equipment. The respirator user's medical status should be reviewed periodically. 11. Approved Respirators. Approved (NIOSH/MSHA) respirators are to be used when they are available. The approvals on respirators apply to the respirators as whole units. The approval is valid for the whole unit in good condition. It is nullified by the mixing of components and by use of non-approved components. CTD020749 Page 51 KEY ELEMENTS OF A RESPIRATOR PROGRAM - Cont'd... This is a condensed summary of the OSHA regulations on the use of respirators. Background information on respirators is given in the following sources: A Guide to Industrial Respiratory Protection, John A. Pritchard, Los Alamos Scientific Laboratory, HEW Publication No.(NIOSH) 76-189, 1976. Practices for Respiratory Protection, ANSI Z88.2, 1969, American Standards Institute, Inc., 1430 Broadway, N.Y., N.Y., 10018. OSHA Standard Method for Determination of Respiratory Protection Program Acceptability, Industrial Hygiene Field Operations Manual, OSHA Instruction CPL 2-2.20, April 2, 1979, Office of Field Coordination. CTD020750