Document gbYd7akRkk8wv0R5zwyqr3v1q

INDUSTRIAL HYGIENE REPORT v V .V `J ? Inland Manufacturing Division Dayton, Ohio March 16, 17 and 18, 1960 I b V. **r-" 'i. t <1 im r H4 . t 4* 4mhM **4* L>W *| GENERAL MOTORS CORPORATION PERSONNEL STAFF f 1 >*^^ >.-ry~_ r-~'~ J.*r- Industriol Hygiene Department Vincent J. Castrop--Director ^J. Inland Manufacturing Division Dayton, Ohio March 16, 17 and 18, 1960 Trichloroethylene Asbestos Dust Chromic Acid Toluene Diisocyanate (TDI) No. 6031 Reported by: G. C. Stoeclcer r ^ u,o rfrrm Toluene Dlisocyanate (TDI) Toluene diisocyanate (TDI) is used in the polyurethane foam production for crash pads and seat pads. Crash pads are process ed in the building adjacent Building 25. Seat pads are produced in Building 28. - . $ The potential hazards of TDI are well recognized and the pro cesses are well controlled by enclosures and local exhaust at points where exposures are likely to occur. It is understood that good control is enhanced by air sampling for TDI performed by personnel of the chemistry laboratory. A record of air analy ses will be of value in the event of alleged illnesses Which may be attributed to TDI exposures. However, periodic scheduling of such tests, rather than an occasional survey, should be consider ed. Such tests should also be made when production schedules are increased or new equipment put into operation. Tests for TDI were made at several locations in Department 75, Building 28. The tests were taken under present production \- Ew\ un jn un un i Toluene Diisocyanate (Cont'd) Page 7. rates with only the south side of the seat cushion line in opera tion. The results, recorded below, are well below the permissi ble limit for exposure to TDI. Permissible Limit for TDI The permissible limit for exposure to TDI is 0.1 part per million parts of air by volume (ppm). Results of Tests for TDI Test No.Location and ConditionsTDI in ppm i[ 15 Breathing zone of foamer operator. Ex ! haust slots along conveyor near this location None Detected 16 Breathing zone along conveyor in area of mold covering operation. Exhaust slots behind conveyor None Detected 17 Breathing zone at unloading station after first pass through oven None Detected 18 General condition in area of transfer of pads from roller squeezer to convey or for final cure oven None Detected 19 General condition along conveyor Where cloth strips are applied to finished \ pads Less than 0.01 i l EXPLANATORY NOTES Test Methods \ ~ ....... Trichloroethylene vapor was determined with a Davis Halide Meter. ir k t 3 ` M,. Inland Manufacturing Division Dayton,.Ohio August 28, 29 and 30, 1961 Toluene Diisocyanate (TDI) Solvent Vapor Trichloroethylene Cement Solvent Asbestos Dust Boise Reported by: J. R. Vender Roost lo: -jjci.. f.-VT;/ ' bn* c ' > ' :7 ~. rf >v , 11 (o \ C- i ' '3 *: DISCUSSION Toluene Piisocyanate (TDI) Crash pads and seat pads are produced from polyurethane foam containing toluene diisocyanate (TDI). Crash pads a^e produced in Department 76, Building 28, on four foaming machines. Once the foaming machine is started, the necessary amount of foam is automatically released through a noz zle. After the proper amount of foam has been deposited between the fabric and backing, the parts are placed in a mold on a con veyor which carries them through an oven for curing. When the olds emerge from the oven, the parts are removed and packed for hlpment after inspection. Slot exhaust ventilating ducts -rere located below the nozzles of the foaming machines, along the con veyor and at the openings of the oven. Toluene Dlisocyanate (Cont'd) Seat pads are produced on both sides of a wide conveyor in Department 75, Building 28. Foam runs into the molds continuous ly from a nozzle on each side of the conveyor. A thin sheet of plastic and a perforated metal lid are then placed over the mold in that order. After passing through the curing oven the lids are removed and the pads are taken out of the molds and placed on an adjacent conveyor. Flashing is trimmed from the pads prior to the final cure oven. Two ten feet long exhaust slots, parallel to and above the center of the conveyor, were located just ahead of and behind the foam nozzles. A similar duct has been position ed above the conveyor where pads cure removed from the molds and the molds are cleaned with a scraper and a compressed air jet. There was also a slot exhaust duct on the pad conveyor where pads are placed after removal from the molds. A flexible exhaust duct, six inches in diameter, had been provided for the scrap drum, near the nozzles, on each side of the conveyor. No toluene diisocyanate was detected in any of the tests made at various operations in both Departments. Information was offered that low results from tests at these operations were also obtained by plant personnel. Ventilation appeared to be adequate and no changes are suggested. It was stated that the prepolymer foaming method, formerly used, had been replaced by a "one shot" method. The changeover resulted in the elimination of objectionable fumes that emanated from the curing oven at times. Installation of a similar but larger seat pad production unit, located just south of the present unit, was in the final stages. Exhaust ventilating equipment appeared to be ample, al though it was not in operation. Permissible Limit for Toluene Diisocyanate (TDI) The commonly accepted limit for TDI is 0.02 part per million parts of air by volume. gsults of Tests - TPI `eat Ho,TDI In ppm___________________________ Remarks........................................... samples 1 through 3, inclusive, taken along south conveyor of the jorth seat pad installation with both sides of the conveyor in jperation. Building 28, Department 75, 1 None Detected Breathing zone of roan clamping lids on molds after cutting plastic sheet with heat knife. Exhaust slot ten feet long over center of conveyor. t. 2 None Detected Breathing zone of man cleaning molds with scraper and air jet after pads had been removed near exit of oven. Twenty- four inch pedestal fan directed west causing gusty air flow. 3 None Detected Sample taken in breathing zone of man on north side of south trimming table. NO local exhaust ventilation at this operation. No objectionable odors. Sample 4 through 5, inclusive, taken at crash pad production oper ations in Building 27, Department 76. 4 None Detected Breathing zone of No. 4 foaroer operator producing Pontiac Bonneville crash pads. Exhaust slot below nozzle and above waste box. General air flow 50 feet per minute from open monitor in north wall. & Nbne Detected Sample taken in breathing zone of No. 3 foaroer operator. Local exhaust duct in back of nozzle. 6 None Detected Breathing zone of man unloading crash pads from molds on conveyor near oven exit. Exhaust slots at oven exit and along conveyor where parts are removed. I r Page 4. INDUSTRIAL HYGIENE REPORT > V GENERAL MOTORS CORPORATION PERSONNEL STAFF ** * " ` , ^ lNl#lli#| I*. M n Industrial Hygiene Department Vincent J. Castrop-- Director Inland Manufacturing Division Dayton, Ohio June 18, 19 and 20, 1962 Solvent Vapors Toluene Diisocyanate (TDI) Reported by: j. r. vender Roest n a ~i n uuuu un Ov CJ ui Toluene Dllsocyanate (TDI) Polyurethane foam containing toluene diisocyanate is used in the production of crash pads and seat pads. Both operations have been described in detail in a previous report. Production of crash pads had been transferred to Building 31, Department 176. Although the equipment has been rearranged in the present layout, the exhaust ventilation appeared to be adequate. Seat pads are produced in the same location in Department 75, Building 28. Line 1 on the original production unit and bines 3 and 4 on the new production unit were in operation. The sequence of operations on both units was essentially the ae. Exhaust ventilation on the new unit was similar to that n the older unit and appeared to be satisfactory. i T.- ; *'1 .i >` ` Page 5. Toluene Dllsocyanate (Cont*d) Results of tests taken at representative operations in both Departments were below the permissible limit except for three tests taken near the foamers on the new unit. Two of the tests taken in the breathing zones of men placing lids on molds on Lines 3 and 4 were above the permissible limit and or.e test in the breathing zone of a roan temporarily stationed just east of the foaroer on Line 4 was equal to it. Since the last survey, two tempered air supply units each providing 80,000 cubic feet per minute had been installed between the two production units. Information was offered that branch ducts were to be addod to the west supply unit to deliver fresh air to the areas near the foamers on Lines 3 and 4. Additional air supplied at these oper ations should dissipate the vapors to acceptable levels. Permissible Limit for Toluene Dllsocyanate (TDI) The generally recognized limit for TDI is 0.02 part per million parts of air by volume. Results of Tests - TDI Test No. TDI In ppm Remarks All samples taken in breathing zone of employees at locations noted. Samples 1 through 4, inclusive, taken at crash pad pro duction operations in Building 31, Department 176. 1 None Detected No. 2 foaroer operator producing Pontiac Catalina crash pads. Ex haust slot below nozzle and a new flexible exhaust duct above waste box. 2 006 No. 1 foaroer operator producing Pontiac Bonneville crash pads. Local exhaust on unit as in Test No. 1. 3 None Detected Man unloading pads from molds just after exit from curing oven. t * 1 " 1* , i i \ Results of Test8 - TDI (Cont' dj Test No. TDI In ppm Remarks 4 None Detected Qnployee deeming Pontiac Bonne ville crash pads at bench. Samples 5 through 10, Inclusive, taken at seat pad operations on Lines 3 and 4 In Department 75, Building 28. 5 .09 Man placing lids on molds at foamer on Line 3. Air flow 100 feet per minute toward 14 foot exhaust 8lot between Lines 3 and 4. There was also a slot behind the foaroer and a flexible exhaust duct over a waste drum. o -- o K> 4k 6 Man placing lids on molds at foamer on Line 4. Air flow 0 to 100 fpm toward center exhaust slot. Other exhaust ducts as in Test 5. 7 Man checking temperature of molds just east of foamer on Line 4. Very light air flow at thio loca tion. 8 Less them .005 Man removing lids from molds on Line 4. Turbulent air flow from 24 inch pedestal fan blowing west 400 to 600 fpm. 9 None Detected Man removing lids from molds on Line 3. Air flow greater than 600 fpm from east air supply unit. There was a large exhaust slot be tween Lines 3 and 4 at this oper ation. 10 None Detected Man trimming seat pads at table on Line 3 - adjacent to trimming table on Line 4. Air flow variable in direction and rate. Page 7. n i~i n n n Results of Testa - TDI (Cont'd) Test N-__________TDI in ppm _____________________ Remarks 11 Hone Detected Man placing lids on molds at foamer on Lino 1. Air flow 125 to 175 fpm toward exhaust slot between Lines 1 and 2. There was a flexi ble exhaust duct over an adjacent scrap barrel. 12 None Detected Man removing lids from molds on Line 1. Air flow gusty and in ex cess of 600 fpm from pedestal fan. 13 Leas than .005 Trimming operation at table on Line 1. EXPLANATORY NOTES INDUSTRIAL HYGIENE REPORT Inland Manufacturing Division Dayton, Ohio ^ September 26 and 27, 1962 i i tf * * TV-' I,.. **V- i &fAt* V :\ ms *.% *> "': * '. i /* -* p&xteeihSSS*. * "* 7. * i *J5 *V* % -.'Vi r __ _ _ ,__ ' Inland Manufacturing Division Dayton, Ohio September 26 and 27, 1962 Toluene Diisocyanate (TDI) Solvent vapors **>. 6293 i Reported by: j. p. Stephens ii n n n- n L in . uuuu u 0 J u * _ *'' % Toluene D1Isocyanate (TDI) The production of seat and safety pads using polyurethane foam in Buildings 28 and 31, respectively, have been adequately described in previous reports. Branch ducts had been added to the west air supply unit in Building 28 to deliver fresh air to areas near the fearners on Lines 3 and 4. A similar exten sion of the east air supply unit was planned. Production was normal on Lines 3 and 4 at the time of this survey, and air tests for TDI were made in some detail. The results demonstrated virtual absence of this contaminant. Al though the building was relatively open, the prevalence of ef fective supply air and local exhaust systems encourage the opinion that control will also be adequate during winter months. Building 31 was also reviewed under essentially normal Production conditions. This building was more closed, but its mechanical ventilating facilities proved beneficial and control va adequate. No suggestions for change are offered relative to TDI control in these areas. The use of trichloroethylene to flush foam nozzles in Gliding 31 was observed incidentally to the TDI tests. Except r No. 8 foamer, see TDI Tests 12 and 16, the escape of sol- vapor was not apparent. The No. 8 foamer was a manually 'Pirated engineering unit that was soon to be removed from the Page 2 Results of Tests - TDI (Cont*d) Test Parts TDI per No.______Million Parts of Air______________________Remarks 6 N.D. Same as Test 5 above except on Line 3. Compare with Test 9, Report No. 6276. 7 N.D. Trimming operator at end of lines, repeating Test 10, Report No. 6276. Except for Tests 13 and 15, Tests 8-16 below involved sampling in the breathing zone of employees at locations noted in Build ing 31, Department 176 - building generally closed. Test 13 and 15 conditions sure described. 8 N.D. Man at No. 2 foamer safety pad filling operation. Effective exhaust slots behind foam noz zle and at lip of waste box. Good general ventilation through out building. Trichloroethy lene nozzle flushing not done. 9 N.D. Man at No. 1 foamer safety pad filling operation. Local ex haust on unit as in Test No. 8. Trichlor flushing of nozzle done involving about a five second flush with about eight ounces of liquid each minute. 10 N.D. Man at No. 5 foamer. Trichlor flush done and local exhaust ventilation provided. 11 N.D. Man at No. 7 foamer (old No. 6) filling pads, Trichlor used. Page 4 Results of Testa - TDI (Confd) Test No. 12 13 Parts TDI per Million Parts of Air N.D. N.D. Remarks One of two men at No. 8 foamer, temporarily used by engineering personnel. Foamer was manual ly operated, trichlor flushing was done with some odor of es caping vapor apparent at tiroes. Fairly effective exhaust duct at box, but none at nozzle. Possible source zone (not breath ing zone) test at south end of last oven where positive pres sure caused out-flow. Employ ees infrequently present at this location for brief inter vals. 14 N.D. One of several men cleaning foam from inserts at south end of second long table from east oven. 15 N.D. General condition sample col lected among men unloading molds at end of east oven (good indraft) and at unloading table near west oven. 16 N.D. Repetition of Test 12 at No. 8 foamer. Page 5. n n i*v a u u.u u