Document pe3M2JVB8zjLxzVJyODnO8Gy7

FROM E. E. RUMBERGER PITTSBURGH OFFICE TO 1982 February 16 RE: ASBESTOS REPLACEMENT The attached Asbestos Replacement Report is being distributed to plant Department Managers and Superintendents for Engineering, Procurement, Safety, Environmental Control and Industrial Hygiene. It comments on successful and unsuccessful substitutes for asbestos. Considerable progress has been made in the plants over the past two years in implementing safer substitute materials. This report should be helpful to you in knowing the results of the experiences at the other plants. It might also serve as a useful guide to be used in your next staff meeting to explore your success in making your plant as free from asbestos-containing materials as possible. We are asking that plant Engineering and Procurement Managers keep us advised of their results in seeking safer substitute materials. This will permit us to share the information throughout the plants. The very worthwhile efforts being made in the plants are much appreciated. E. E. RUMBERGER EER:mlf Distribution: Operations and Works Managers cc: Engineering Managers Procurement Managers Safety Managers - Domestic and International Environmental Control Contacts Industrial Hygienists - Domestic and International J. H. Sloane, Pittsburgh Office - 20 T. J. Sherman, Pittsburgh Office - 20 F. J. McGrath, Pittsburgh Office - 20 P. R. Atkins, Pittsburgh Office - 7 J. C. Fussell, 4th Floor - William Penn Hotel P. A. Haas, Pittsburgh Office - 20 J. M.-Me Collum, 3rd Floor - William Penn Hotel G. F. Leymeister, Pittsburgh Office - 19 C. E. Rhodes, Pittsburgh'Office -19' R. E. Edgington, Pittsburgh Office - 19 APC 003496 ALCOA Page 2 1982 February 16 Distribution: (Con't) M. J. Caprio, Pittsburgh Office - 19 V. R. Scorsone, Pittsburgh Office - 27 G. B. Scott, Pittsburgh Office - 23 E. B. Perry, Pittsburgh Office - 23 H, G. Reavis, Pittsburgh Office - 23 J. R. Clark, Pittsburgh Office - 23 R. J. Hosfeld, Pittsburgh Office - 23 R. D. Hornbeck, Pittsburgh Office - 30 K. W. Perry, Pittsburgh Office - 24 R. R. Hoffman, Pittsburgh Office - 30 E. M, Kasody, Pittsburgh Office - 28 W. Turbeville, Pittsburgh Office - 28 C. R. Gillespie, Cleveland Works R. C. Rawe, Lafayette Works R. A. G. Vines, Massena Operations W. C. Keith, Corona Works J. W. Martin, Lancaster Works N. W. Nielsen, Pittsburgh Office - 18 J. B. Geshay, Pittsburgh Office - 23 H. S. Evans, Pittsburgh Office - 24 P. L. Abernnethy, Jr., Pittsburgh Office - 17 R. Banks Smith, Pittsburgh Office - 29 H. L. Johnson, Pittsburgh Office - 14 C. P. Fletcher, ATC-C L. K. Hudson, ATC-C N. Jarrett, ATC-C P. R. Bridenbaugh, ATC-C J. D. Dowd, ATC-C R. E. Spear, ATC-C APC 003497 Industrial Hygiene Technical Bulletin NO. 82-3 Date: 1982 February 16 RE: ASBESTOS REPLACEMENT The Asbestos Replacement Program was initiated a number of years ago as a result of the health hazards associated with handling asbestos and asbestos-containing materials. The program is a cooperative effort between Production, Engineering, Procurement, Research, Safety and Industrial Hygiene at the plant and corporate levels. It continues to be Alcoa's objective to replace all asbestos with safer substitutes whenever possible. The only exception is that we do not encourage the immediate removal of affixed asbestos insulation so long as it is in good condition. When it does become necessary to replace worn asbestos-containing materials, safer substitutes should be used. When asbestos is being removed, proper precautions must be taken to protect employees from inhaling asbestos fibers. Considerable progress has been made in the past two years toward making Alcoa plants asbestos free. The attached report summarizes plant experiences and identifies successful substitutes. It also identifies unsuccessful products that have been tested and failed. The report contains sections on General Applications, Potroem Use, Carbon Ba'ke Use, Wire, Rod and Bar Use, and a List of Asbestos Replacement Manufacturers. This report should benefit each plant based on the experience in other plants. To continue to coordinate these efforts, it is important that Engineering and Procurement at each plant copy the Corporate Industrial Hygiene Division on all efforts made towards asbestos replacement . . . whether positive or negative results occur. Please review this present status report and advise us of any new experiences at your location. If we can be of any further assistance, please let us know. SCOTT M. ANDERSON SMA:mlf Distribution: See Page 2 H ALCOA APC 003498 INDUSTRIAL HYGIENE TECHNICAL BULLETIN 82-3 Page 2 1982 February 16 Distribution: Operations and Works Managers Engineering Managers Procurement Managers Safety Managers - Domestic and International Environmental Control Contacts Industrial Hygienists - Domestic and International Industrial Hygienists - Other Industrial Hygienists - Pittsburgh Office and ATC Attachment ppC 003499 ASBESTOS REPLACEMENT PROGRAM Contents General Applications Belting --Block or Brick -- Brake Linings Cement Patch Cloth and Paper -- Gloves -- Marinite Pump Packing Rope -- Tubing Tape Thermocouple Hire Potroom Use Cradle to Pot Shell Insulation Superstructure Foot Insulation Pot Cover Insulation Walkway Grating Insulation Bus Insulation -- Pot Exhaust Duct Exhaust Duct Gaskets -- Siphon Gaskets Ladle and Ladle Lid Seal -- Insulated Electrical Hire Carbon Bake Use Exhaust Duct Manifold Gaskets Wire, Rod and Bar Jarke Rack Liners Asbestos Replacement Manufacturers Page 1 1 2 3 4 5 6 6 7 8 9 10 11 12 12 13 APC 003500 v> Hf,' : / >Us *v. --XU33 rn 'Lfij-j 3 tv QOCMON ASBESTOS REPLACEMENT PROGRAM a) Johns-M anville "360" b) Keene C o rp o ra tio n "Super 1900' c) 48 In s u la tio n Super "48" 3 VI CO 3 O' 3 *coo c H .0 O VI o c 3 o 44 *o cCO T0D) VvC0O)iI (30 CC:*OO VI u (0 H VI CO Vi -COO VI tv c fH 06) 3 3 o CO CuO paH 0) 3 A H PC tv 3 pH 3 *H .* Vi 3 VI 3 2 aV Vi 0c0 o H 44 VI cOC 3 O H VI H 3 to * >s CO pH 0) 4J U C <0 3C |4 V< 3 Vi 3 3 44 .O U CO 00 4J C a VI <H 3 a *3 o 3 pH a eo *3 O O JC Vi eCO CL <0 3 0) O U H VI 3 C 3U O -O 3 o 44 pH JO CO 00 V>i o e c -vh> o VI 4) L H41 V 4uuC4O 0) 6 3e V3i H a3 c V3 PVi -C TO 44 3 Vi pH VI .30H 44 3 VI pH 3 VI 3 3 Vi VI 3e i <j VI H VI H H 3 6 VI 00 3 <0 C X Vi 0) 3 3 Vi o JO O O VI tv 3 tv .0 a 3 CM o < 0- sO Vi O3 4-1 *H VI ptHH G o> 3 o gH c 3 PQ 3 O3 3 J* Vi fH O O CL 3 3 Vi C Vi H *H /'S 33 VI O cn 0CM0 00 e VH 3 3 4J VI C3 V> tCvC H o 3 44 3 C SX3an* 00 5s co 3 H c o CL -0 H H H S *H i-9 3 oa 3. 3 o U Vi < 4S 44 o3 -3 3 O H CV H CQ 434' Vi Vi o 4O4 . 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CNI V 3 0 a U 0 1 0 N 0 VJ VI ou > 0 2 X o H 0 > H VI o 0 *3 o 0 H 0 o E v GO > 0 VI 0* X U (0 os X pH p4 0 XO 3 0 <Vi X 0 5K 3 0 Vi 0 O VI VJ 3 0 iH 3 3 Vi 0 3 O 0 X X e CO VI c pH 0 B 1 < (M 0 OX 0 Vi o 0a. o o OU VI e 0 -iH 8O (V 0 O M 1-4 o 0 VJ 0 pH X 0 60 *3 *3 > -H 3 0 00 > 0 pH 3 CM 0 1 5s a *S pH o pH u u 0 VI pH o 6 4) pH 4J 0 60 3 *n 00 e 0 a c 60 0 60 VI 0 0 0 3 e0c 0 0 pH X0 pH 0 e 0 iH VoM C H VI pH 3 0 IM 0 00o 0 Vl U 0 0 0 0 C VI *3 C >4 pH 0 H t4 0 H Vi 0 vi X H X 0 H 1 0 Up< VI 0 C 60 o 0 0 VI Vi 0 0 0 X H 0 a 3 VI 0 H & JO VI 0 o 3 0 X O G 0X e a m c 0 3 X VI 0 H 0a0 X uX VI 0 <54) **h e 0 0 e 0 0 i 0 0 Vi O 0 0 0 o H 3 0 X u- *H ,0 U 0 M 0 M o 60 0 ^ B 60 3 VI 00 c Tubing Tape fo r furnace seals 60 60 CC H *H X pH O (0 <a0 Vco Vi *3 iUO 0C APC 003504 X UUX33 XX<u CM OCON ASBESTOS REPLACEMENT PROGRAM 8 CO E 1 X co 0 o 3 (0 iH u CM O 4 3 3 44 CJ 8 B 4) 00 <44 * H 3 H 8 E O' -U 3 UH C3 pH O 3 0) ^ CO CO x ^4 O' 3 3 H 44 44 CJ o C *3 X 3 ZH H H *4 C <4-1 > *3 Cl 0) H ^c 3 3 3 OU *8 X H *H O CM 3 3 3 44 O pH u CO 3 Cu 3 O ag 3 H a B 3 1 4- o 3 O3 m oo g 44 e 3 CO pH H g3 3 3 X (0 o 3 3 H 3 3 X 3 *3 3 14 u3 00 3 CJ <-) X 3 CJ H 3 3 X *3 H TJ o 3X 3 33 3 Z M z a44 4) X u e 3 X 44 pH g aw 44 pH 3 CO rH 4) * U 33 pH X a. o 44 *3 Z/-s X O 3 X -X 4J 3 44 3 3 O X *3 m H o 44 4J o o 3 O 00 X cn pH X CO O 00 U 00 o 3 3 3 0) CO CD a w c 00 e o 3 *3 8 e x a goo 0 3 4) X H H OO 3 8 o <0 0 4J O 3 B r-l S3 uu CD u a. fH w 3 3 3X pH 44 O w pH 3 3 CO 3 H H 3 X pH 3 00 e SH X CO CO CO 3 E C 3X 3 C u< UU X *H 3 44 a8 a(0 CO CO CO 4-> U 3 o 3X 33 J- CO *3 3 rt 3 X U4 44 X e * C U u U 3 44 O CO 3 O 3 H 3 H H OO WH 3 os 4) O 00 3 *3 3 3 *3 a. -h U 4) 4) O /> 3 X C 3e (0 44 U CD *3 3 3 44 3 *3 00 3 V4 44 4J 0 c0 a O *3 00 O3 33 oCO pH 4) 3 H 3 e 44 3 X <H X X 3 a e H (4 *4 H H pH X H c4J a s 3 U O CM <0 3 CJ s S H X 3 ^ *M3 u 0 3 e 44 a*3 X 3a 3 H 3 CJ 3 X H H 3 CO 3 m 3 3 4J X 44 4J pH S V- B 1 z acj 3V *3 O *3 o CM CJ CO > (0 te 3 3 *H *n O 3 4J |4 H 41 3 41 4J *3 U 3e a 41 CO 3 3 *- C u O3 6533 H 4) CO O os CO X o CJ o o O' 3 3 * CM 3 <X Claoo3 ft : o AND APC 003506 ASBESTOS POTROOM USE SUBSTITUTES- M echanical E ngineering D iv is io n , P itts b u rg h , p re s e n tly s p e c ifie s ebony asbestos fo r th is Item Tests on o th e r m a te ria ls have not been successful O TO o TOpH pH H 3 CO * TO X *o Au W TO TO >H CO CO TO pH X TO Li TO L tuot X CM m CO- </> OI X u LI *d Li TO 00 G H A 9 O TO a* O O TO X X Li e TO CO H 9. 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X 3M ASBESTOS POTROOM USE SUBSTITUTES- 00 300 a3-* 4H-1 3U 5 eH C33Q e ooa 0c3M33 3 tCtO *33 CO 3 333C 5 3 C3 3 3 5 3e 3 3 3 5 XofHt X Z3 00 ft G H *3 ft 3a. 4J 3 *3 3 ft O O3- H 3 8 3 03 O CQ ; C M tfM 5 HH o. 3 cn ci X ft- ft* 2w ft- e X41 4-1 O X N f3t oftn X3 ft *3 O ft f0ts 3O ft4 ft- ft- CO 43J c fHt 3 2 *f3t 3 5O 00 CQ >N xe 3o 8 3 H HJ C ft M 3 33 5 Q O^ X3 g ft 8 36 XM JZ H CIh 4J oV* ft* 3 a U4) U0O4 P> in 2 ft* > aI *h3 33 XO O ,4 QC C aa 3 3 >C u t3ao AND A lj ^ i' - APC 003508 Xf5u3U93aK PM 0O0N * XXXLLCO3OiCi rPUl XXXX0P30 i(J0 CCOO XC0O0 CM 0 h XoCO 01 M0 T&03> * x3 35>S Xcd C to (Q fXo3t f>t X5k L3i zX ffoHH1 Q ft fH 3 L3i P3 COiJ 3 X3 XOLe3 fH3 c3m C3aO 033 zJoJ fIM3333H 3OO3 zLoI OO XX3p 3 LLC3ii X033c0 cm O 33 Cd 3 3 XfLHI 3 XL3i 3Lo O T ZEd Li X3 fH X3O X3c 3cj X *L3oi 3 rs6H 'XecB33 fH 3 ffHH 3 P3 Of3Ka fxCLH3UMi XL3I COM *f33ot oc 0cH0 XMC3 coa 00 CoLLOaOii X c3 >0) LCiL co CO 00 L3i X0fi0 >3Li* L3OI fCH O rfHSt fLOti 3 Ufa LU3i fet xe *0 XLi OO00 X3 00 fX3OOao fLLe33tIi X CoLf3aaJi XXCL4CO)i Xm X X3 X01 . 5eK xCoO O <L0i ex 3 00 Xc3e00 X o >s 3 XLcOsi LoceI 3 >> 3X L3i ofa XXLi *3Oo 3 X3 ON co X3fa f3Lai fa o oo n3 e3 o00 fX3ooa HXXf30U3a0*XXx330 C0O0 Xp tXPH xCoO XCC3OO co to o>Cs XLei 33 XXX X3ffaa 33 X>LOit X300 X33 XXfU3a Xx333 00 X3 X 33 X XX* C3LL39Jii M CO XM0) M0u) CO XOL3Oi rOX^N XXfMMCaO XMCoL0)i c O3" *CHO X XLCM0O1i McuCO CCOO XX3CO C O CO Li XXX3> XX333 a X300 3 x3> L33i X0330 Cd 33 X3X *30 X XU XX3C333UJ *3OC3oJ B3 XX 6 X3 XH fXUa 3uLi Z 33o XX33CJ 3333 *3o 3 3 X3 X O3 5k 1 *33o 3 X3> 3f3X3a 3 XXoe cCOJ Xe -3 C3(C30OO CCc3COOO f0(a00 Xo 0C0O X3 CO X Li 33 XL333i CfM*. fH X3 ; ZCM 2 X3 XLUC3Oi X C3O H , fa X43J Xe Li 3 X 'l fa XL3i *cL4 Xjg fH CJ ofa fXH fa1 C36J c Xo X CO MV Ha a . XX30 < XCO *aH C3O cm XU Va3J Xc CO 033 fXLCLoaOi X Xc *C33O XL3o3i 3C3 X XL3C3333i X o X5k XC3O 5 X3a r- fa OrHN fL3aI 0Li LLeoii f>a> X3 CcO oe 6 3 cs x *o ON (L0i C3 XXcoL<1i) CL3M. XLO XX L(0i fa cj . PRIVILEGE \ sDc APC003509 ASBESTOS POTROOM USE SUBSTITUTES- M echanical E ngineering D iv is io n , P itts b u rg h , presently sp e cifyin g Pyrotek T -l fe lt m aterial fo r th is a p p lic a tio n . iH C3M VI c . oo3 g g oo sVosJ c CUQ OH. 0) Vi H > rvHj C3M 3H X Cao3O U Vi XVO3i0 Vl **HVHi C. XVI X Vl VoHI CVhUI W T3 C *aH *ti Oh Ha <coHH e6V0l o5s a iH h> ag xa xvi Q *H r6CVl0i UO UoVHl <VOMi X Vl 6cCH0 ^a 60 V)> o 5 H>% U rH CH XO XX o cm h * h Oh hC a H a xU Q. n vV>i *3 ih3o X -h 6 3 mrH X1 rH U XHl (V X v0> CvV>voaHMi.l CO VI ooU33 a H XVI 6GH0 3 . H C3M rVHXI CCuu3J oaaua3C CVMi Vi a VI a3 e X3 k fVHXI *o e 3 OaM> e3 ua VV0oIi *V3I H cVHmI CO 3 C * V0I X a CVGMI O fH XVI z4oJ V0l B rVHQU3. C06cVQ)0 oC (o0 (e0(00) i-oJ 5 c0) 3 a rH 60 Vi 0) vi 3 X3 CO 0V). *3 < Pv M0) rHHI VI o vi M rH 0>kv bu XEHv CCMM| H XVI X OV>%l rvoHi PV u C*HO V3I X1 aO H aa XihH Vi n xH Vi (V cv X OB VI o oV>l%z0*0^ 0k rH 1 H 1Z O rVHI rH Pv H 1 rHI H v9 XVHi :CM Cv fH f*XrMHOH3H X iH CO 6Mk 1 VOI X< VI X Bu C0M u a X1 3 X1 n 7 ft tl APC 003610 u a CO 3 co 3 <0 UCO 3 G 3U 33 CO m *3 3 Vi 4J 3 /-n 3 CO ' vi B Gu 0) CO 3 00 CQ O. CO 3 3 3 Vi lm U 0) CO 3 3 3 * 4J V 4J 0) *3 c 3 O CJ O 3 *3 oo 6 e e 3 00 6 33 3 o AJ G o CJ C/3 4J G> 2 0-0 4uo4 U3 3 *T33 uCO oM; C3O VI VJ CQ CU E m 3U (0 C I ON V CO U 3CO 3 V > il U Q OM CsO >s 00 04 3 VI >> e c 00 o VI u C VI E c 3 3 3 > 4*4 U 3 C 44 O 3 3 CL U 00 3 3 a 3 Vi * U a3 V) 3 >s 44 pH 3 3 3 >s o 44 3H pH o 3 VI 3 3 eC33 3 3 3 Ui 3 3 3 33 3 CJ 3 3 > 3 3 3 3 Vi 3 5 C/3 2 Q. C/3 O 0) u CJ CO Cuu G 3 s 3 a to a *4 o 3 VI e X Vi O V> 3 3 44 3 V) 3 CO ASBESTOS POTROOM USE SUBSTITUTES- 3 O 3 o 3 3 rH VI H 3 O3 3 Vi 3 33 3 3 Vi 3 o 33 OO O3 is 3 3 3 2 2 CQ <2 CU ! pH TJ 3 Q. pH 3 3 H O o Vi 4m Vi 3 I 3 3 CM Fv *o O. : 3 o o 3^ 3 a 00 3 2 ^ cv a VI co O 3 3 *o 00 >4 3 3 3 3 3 1. 5 3 3 Vi V) 00 rH 1 0 3 H 3 3 3 Vi VI 3 3 3 O O 3 3 Vi 3 VI 3X Vi 33 VI 3 3 Vi 04 O 3 pH U 44 33 2 Vi CO CO < bu 00 M 04 Cu a u 3 a co 3 3 3 3 3 2 G oO w O a 3 eO 8 CU3O V0a)icOOsi Ce0l) H ao o > 60 CMO OO S P9H cms CM * oCm T3 3U v 00 3 C CQ u CJ CO Ui u * 3 3 co a if H3 CVoUJ 4VoJ. 0) o - mgu CM ,2 VI 6C CM CJ 3 < co V CU "> APC 003611 GOON sO 3u0o) >S UCO u4J o 3 3u01 tv oeve. XH cm QOO' CO oU0). IXd . >N >1 >s >< pH H 0H) <08) H CO CO 4) iHa to 0) CO CO a> 0>)s CuO (0 <u0 (VI <+4 C>O CuO CO v <4-1 <M .. >s H H H H CO CO atCO CO 4t CO CD <0 Vi CuO <M <VI . >N 0c0 iH pH 00 H CO flCO Vi 3 41 O OcCO > CO Vi * CM Vi CO 4<aJu CO 4J VC0O)I 0c) 0) 0 CJ 3 HO CwO H MHCOHOQ C3O VCOI c0) ogI CJ > VOVIi u MCUO <4CU0uVJOI >V>i IvOuCU>O >v VOVIi <ca4oH iVHCOI iVHCDI iH00 VI iVHcoI CCcOO 3CCeOO 3CcCOO 3cCcoO >VS VoI u >Us VoI o V>N VoI o OCO iH VCMO iVHCOI CCOO CO <V4CH-O1I CCOO <VCMHDI CCOO (V3I CC4U1OO u 3G 3G 3c 3 CO Id CO ASBESTOS CARBON BAKE USE SUBSTITUTES- /-- c Ci-MH p0C0uO)0 1v0-1i CooO pJ eCC0OO1 rCD -* 5g 00 Z3a Q o *VocHI CooO pj CCe0COOO) 2 e0C1O 9 29 e0(CcC0oOO) 2 CO G 4) 9 299 CO G0CCOO) co X CO CCG9OO 2 CeO C4COO1 32 co 6 2CC49OO1 Pd VI oO CQ O G H *OH 3V. VCHOI ICvO oa. r>t 6 SC 0) o v 3 u NO vi .X J. iH o> x 4C-O1 3 VI o Vi m C3O >1 Pu >f IOdS M 3 1 CO oH CO Id 00 CO < VCOi H> 4) fed 3VI O pH CJ 3VI o pH CJ <u T3 a Hco eCO CO C") M* pH CM 9CO 0> 9 Hcao CM HaCO a 4) Q. HCO CM lu o 0) VI -O fp Pu H pH *3 oc H 3CO Oo O in 3 VI iVHI 3CO C3O Jd Jd Jd Jd iH01 0) 4J V4)I 40J) V0I) EQ u0 O Vi ou O Vi >s Pu >s PU > PU *>4N Jd 0) VI o Vi CU I4 X 0) 4J Z3 CpHM X 41 4J 41 N CroM X V4)I 41 CM Co i-4 o H (VI VI CO C O *H rH a <a au CO VI 3 4) Q J* o CO (4fU-4 VI 3 CO CJ iH 3 O CO 3X aX co Id c o lU VI CO u piHH & ; <CL O i-4 <4H iH o 4) a co CO Vi 41 *e iH pJ X O CO Qd at jd Vi cO -) APC 003612 Product Pyrotex Fiberseal Products Refrasil Nor-Fab Yarns; Fabrics Fiberfrax Hi-Temp 270 Ceramic Fiber Products Marinlte and Other Products 1982 February 16 ASBESTOS REPLACEMENT MANUFACTURERS (Page 13) Supplier Newtex Industries, Inc. Railroad Avenue P. 0. Box 25 Victor, New York 14564 Pyrotek, Inc. East 9601 Montgomery Avenue Spokane, WA 99206 -0RBox 77 - R.D. #1 Claremont Road Carlisle, PA 17013 -0RSanta Fe Springs, CA HITCO Division of Armco Steel Middletown, Ohio 45042 Amatex 1032 Stanbridge Street Norristown, PA 19404 The Carborundum Company Insulation Division P. 0. Box 808 Niagara Falls, NY 14302 Penn Compression Moulding, Inc. Burton Street Pittsburgh, PA 15218 Kaowool Babcock & Wilcox Cem-Fll Corporation Two International Plaza Drive Nashville, TN 37217 Keller Glove Mfg. Co. Plumsteadville, PA 18949 Johns-Manville TheManviile Corporation Ken-Caryl Ranch Denver, CO 80217 Telephone No 716/924-9135 509/926-6211 717/249-2075 215/277-6100 716/278-6221 412/351-4004 615/361-4664 215/766-8818 303/978-2000 AFC 003513 PROM MICHAEL J. VAUDREUIL PITTSBURGH OFFICE TO MEMORANDUM 1980 August 14 RE: ASBESTOS REPLACEMENT UPDATE The following sections summarize the progress made over the past year in the search for asbestos substitute materials. The discussions are organized by asbestos product, and within each section by specific application. A supplemental list of substitute material suppliers is included. 1. Molten Metal Marinite There is presently only one necessary use for asbestos in ingot plant operations; that is, header applications. There are adequate replacements in Johns-Manville's Marinite I and Pyrotek's Pyrotherm B-2 board products and R-680 for all other melting and casting needs. Therefore, Molten Metal Marinite need not, and should not be used for dams, basins, troughs, etc. However, at present, the suitability of substitute materials for use as floats is questionable. Some header-related applications of asbestos have also been eliminated. After header design modifications, R-680 can be used for all FDC headers 635 mm (25 in.) and smaller. With this substitution, Lafayette, Vancouver and Massena should be asbestos free. Molten Metal Marinite must still be used for HDC and tool and jig headers. R&D programs at ATC will continue to address these areas. 2. Asbestos Rope Fiberseal A-l rope (Pyrotek, Inc.) can be used in place of asbestos rope for sealing the gap between the mold and bottom block in FDC casting operations. It prevents metal leakage and its good thermal stability allows it to be reused numerous times. It may also be used for sealing joints in pouring troughs. Z-5 treated fiberglass rope (Pyrotek, Inc.) can be used successfully as a crucible lid gasket on vacuum-type potroom tapping crucibles. It replaces the presently used Johns-Manville 872 or 702 asbestos gasketing material. However, Z-5 will not replace gaskets made of twisted aluminum foil. Plants using foil gaskets will in all probability have to continue that practice. 3. Transite Transite, a structural, fire-retardant asbestos/portland cement board, is used extensively in construction. ATC has tested glass-reinforced cement (GRC) sheet as a replacement for transite. 0ALCOA APC 003614 FROM MICHAEL J. VAUDREUIL PITTSBURGH OFFICE TO INDUSTRIAL HYGIENE CONTACTS DOMESTIC Si FOREIGN 1980 August 14 RE: ASBESTOS REPLACEMENT PROGRAM As part of Alcoa's asbestos replacement program, a listing of applications and substitutes for asbestos was compiled and distributed in August of 1979. Since that time, some headway has been made in the development of substitutes for several uses of asbestos. The progress to date is reviewed in the attached memorandum. An updated version of the original master listing is in preparation. Distribution of the revised registry is planned for 1980 November 01. However, critical to this effort is additional input from all Alcoa locations. Information on current plant asbestos use, as well as any successes (or failures) with substitute materials is requested. In order to meet the November 01 target date for release of the updated list, replies should be received by 1980 October 01. This ongoing exchange of information is necessary for the continued success of the program. With the assignment of Haig Sakoian as Senior Industrial Hygienist, Tennessee Operations, I have assumed the responsibility for overall coordination of the asbestos replacement program. Therefore, please direct all future correspondence to my attention. MICHAEL J. VAUDREUIL MJV:mlf Distribution: Location Managers - Domestic & Caribbean Location Managers - Subsidiaries & Allied Products Safety Managers - Domestic & Caribbean Safety Managers - Subsidiaries & Allied Products Location Engineering Managers Purchasing Agents J. H. Sloane - Pgh. K. W. Perry - Pgh. R. W. Wrenn - Pgh. T. W. Callaham - ATC T. J. Sherman - Pgh. E. B. Perry - Pgh. L. C. Drapela - Pgh. R. N. Sater - Pgh. F. J. McGrath - Pgh. R. C. McCormack - Pgh. T. I. Stephenson 0G. F. Lo\mM<5rer ALCOA - Pgh. - Pgh. APC 003516 SUPPLEMENTAL SUPPLIER LIST Product Nextel 312 TM (ceramic fiber) ZetexTM (a.k.a. Pyrotex j _Thermog,lass TM (fiberglass) HI FibeR (coated polyethylene fibers) Available Forms Supplier Phone No. 1. woven fabric Ceramic Fiber and tape Products/3M 2. braided sleeving 219-1 3M Center 3. bulk fiber St. Paul, MN 55101 612/733-1558 1. woven fabric Newtex Industries Railroad Avenue P. 0. Box 25 Victor, NY 14564 716/924-9135 1. twisted rope Amatex Corp. 2. braided sleeving 1032 Stanbridge St. 3. woven fabric Norristown, PA 19404 and tape 215/277-6100 1. fiber fillers for cement, caulkings, etc. Hill Bros. Chemical Co. One City Boulevard Suite 1521 Orange, CA 92668 714/634-3322 Cellox Fibers (polyacrylonitrile) *heat treatment 1. fabrics *2. conversion to pure carbon fibers Celanese Plastics & Specialities Co. 26 Main Street Chatham, NY 07928 201/635-2600 CER-WOOL (ceramic f.iber) 1. blankets 2. vacuum-formed boards 3. bulk fiber C. E. Refractories P. 0. Box 828 Valley Forge, PA 19482 412/351-4409 S11temp (fibrous glass) 1. cloth Haveg Industries, Inc. 900 Greenback Road Uilmington, DE 19808 1-800-441-7777 GRC Sheet (fiberglass reinforced cement) 1. flat and corrugated board GRC Products, Inc. 17051 I.H. 35N Schertz, TX 78154 512/651-6773 GRC Sheet (fiberglass reinforced cement) 1. flat and corrugated board TM Preox 1. woven fabric (polyacrylonitrile fiber) CEM-FIL Corporation 120 Spence Lane Nashville, TN 37210 Centex Corporation Carbondale, PA 18407 615/883-7563 717/282-3550 ,,Keilvartm ^ and Nomex (aramid fiber) 1. cloth E.I. duPont de Nemours 302/999-4693 2. rope & Co. 3. pump packings Textile Fibers Department 4. tapes and Wilmington, DE 19898 webbings 5. braided sleeving MICHAEL J. VAUDREUIL:mlf 80-08-05 APC 003618 Product Bulletin Thermocouple Insulation At last: a practical high-temperature insulating material that eliminates the two biggest causes of thermocouple failure. Dimensional stability and abrasion resis tance have always been big sources of trouble for high-temperature insulators. The most commonly used fibers- those made from vitreous silica - typically shrink, abrade, fray, or crumble to the point where wires become exposed This obviously creates a potential for inaccurate tempera ture readings. The traditional alternative, ceramic beads, solves the problem of ex cessive shrinkage and abrasion, but only at a high cost for labor. Now there's a better alternative: Nextel* 312 Ceramic Fiber from 3M Nextel 312 withstands operating temperatures of 1000* F. to 2600* F. continuously. It shrinks less and resists the combined effects of abrasion, flexing, and high temperatures better than asbestos, quartz, and vitreous silica fibers. It also offers good chemical resistance and immunity to thermal shock. Proven dimensional stability. A recent test compared the dimensional stability of Nextel 312 and vitreous silica by heating sleeves braided around separate lengths of wire for v? hour al 2000* F When the samples were removed from the fur nace. Nextel 312 still covered the wire completely, thanks to-shnnkage of less lhan 1 per cent The vitreous silica fiber had shrunken by roughly 12 per cent, leav ing anjnch ol wi/e exposed at one end Nextel 312 braided around a thermo couple wire and heated at 2000* F. tor Vi hour shrank 7% Vitreous silica handled the same way shrank 12%. Exceptional resistance to abrasion. In another test, a Duplan "silk-testing ma chine'' was used to compare filaments of Nextel 312 and vitreous silica. Blades were rubbed back and forth on the two products after they had been heated for Vi hour at 1000* F.. 1500* F. and 2000* F. Results showed that Nextel 312 lasted 2'/i to 5 times as long as the vitreous silica fiber This means that at 1000* F. Nextel 312 performed 400 per cent belter. The figures for 1500 F. and 2000* F. were 300 per cent and 166 per cent respectively. No residual acids or chlorides to cause etching of wires. Because Nextel 312 Ceramic Fibers con tain no residual acids or chlorides. Ihere s no chemical present to corrode or etch the wires. Even in a test involving exposure to 96 per cent relative humidity, no notice able electrolytic corrosion was detected. The test consisted of putting Nextel 312 fibers in contact with two unconnected bare #32 copper wires A 250-volt D.C. po tential was applied across the wires. After 20 hours, corrosion was determined by calculating the ratio of anode wire tensile strength to cathode wire tensile strength. Three test runs produced ratios above 0.99: since the maximum ratio possible was 1.00. there was essentially no elec trolytic corrosion Available from your local thermocouple supplier. Nextel 312 is being manufactured in pro duction quantities right now. For more information on how it can increase the ser vice life of your thermocouples, contact your supplier Or call 3M at 612-733-1558 (in Northeast locations call 201-575-2076) or write 3M at the address below N.M0TI-V1 5i |i Ceramic Fiber Products 3M 219-13M Center P*mI C CtAl APC 003619 litnOWUS A 3M ( FROM: GERALD D. HICKS - 30 TO 19 81 August 14 RECE/VED AUG 2 0 1981 RE: ASBESTOS REPLACEMENT PROGRAM Jndustrulhycene As part of'Alcoa's continuing program to reduce and ultimately eliminate all uses of asbestos in plant operations, it is necessary to conduct a rather detailed survey of asbestos uses still in effect at Massena. For such a survey to be of real value, we not only need to know where asbestos materials are still in use, but more importantly, what replacement materials have been tried and whether they are successful or not and why, if not. Our need to know where asbestos materials are still in use is to provide the industrial hygiene section with information to enable us to air sample all involved employees to document their levels of exposure. By OSHA regulation we are required to sample all such personnel each six months to confirm LOW or NO exposures. This report is also used to determine those personnel requiring a medical examination. From a health hazard and governmental regulation standpoint, the asbestos problem has not diminished in the least. Implications are that asbestos control regulations will become even more stringent in the future. Because the continued use of asbestos products may result in unnecessary health hazards and.concerns to our employees, as well as addtional costs to Alcoa to comply with specific provisions of the OSHA standard, it is believed to be in Alcoa's best interests to continue eliminating the use of asbestos products wherever possible. A systematic effort should be made to discontinue uses, when feasible and practical, by substitution or elimination. I have attached copies of an Asbestos Replacement Program Questionaire that I would appreciate each department to complete and return to me. Please use a spearate questionaire sheet for (1) each type of asbestos material and (2) each use made of the material. Please include a sheet for successful re placements. If asbestos materials are not used in your area, please note it on a form and return it to me. I will appreciate it if your response to the questionaire is completed by 1981 August 31. On the line for Materials please list the following: Cloth Paper Marinite Packing Rope. Sheet Gasketing Tape Thermocouple Wire Personal Protection APC0035SO On the line for Use please list such applications as: Insulation, Heat Insulation, Electrical Welding Blankets and/or Protection Coil Tray liners Heat breaks Molten Metal Casting Pump Packing (uncoated, noncompressed, braided asbestos) Cradle to Pot Shell Insulation Superstructure Fort Insulation Pot Cover insulation Walkway grating insulation Bus insulation Exhaust duct gaskets Siphon gaskets Ladle and Ladle Lid Seal Also list the Job Classification Exposed whenever the asbestos material is fabricated, applied, used in process or removed from service. By creating this listing and providing feedback to all people concerned we can hope to remove or eliminate our dependence on asbestos materials. Also attached to this letter is a list of asbestos replacement materials, their suppliers and telephone numbers. GERALD D. HICKS GDH:jmm Attachments cc: (w/attachments) R. A. G. Vines For information only G. H. Schneider - 303 - For information only G. L. McCullough - 28 - For information only R. H. Field - 8 - For information only J. R. Feeley - S9A - For information only Dr. M. J. Elder - 22 - For information only E, T. Klenske - 4 - For information only R. N. Peterson - 7 - For information only D. E. Jackson - 301 - For information only W. R. Duso/T. A. Reir.e - 2S - For information only J. D. Latvaitis/M. W. Clarke - 301 K. P. Bellor- 301 W. T. Burt - 201 . W. B. Parker - 204 W. H. Jochmann 60 Distribution continued on next page APC 003521 cc: (continued) R. J. Sharpsten - 207 W. J. Curtin - 59 D. E . Campbell - 44 J. V. Carroll - 59 F. R. Gero - 31 H. P. Besio - 75 J. L. Macintosh - 210 M. W. Wall - 60 C. W. Houlihan - 45 D. G. Martin - 60 R. J. Kopecky - 32A G. M. O'Brien - 30 R. J. Dougherty - 30 R. W. Flanagan - Pgh. H 6 P. H. Scott - Pgh. H 6 S file S APC 003522 ASBESTOS REPLACEMENT MANUFACTURERS Product Nextcl 312TM (ceramic fiber) Z7 e*tcx TM ^ (a.k.a. Pyrotex ; TM Thermoglass (fiberglass) HI FibeR (coated polyethylene fibers) Celiox Fibers (polyacrylonitrile) *heat treatment Available Forms Supplier 1. woven fabric Ceramic Fiber and tape Products/3M 2. braided sleeving 219--3 3M Center 3. bulk fiber St. Paul, MN 55101 Phone No. 612/733-1558 1. woven fabric Newtex Industries Railroad Avenue P. 0. Box 25 Victor, NY 14564 716/924-9135 1. twisted rope Amatex Corp. 2. braided sleeving 1032 Stanbridge St. 3. woven fabric Norristown, PA 19404 and tape 215/277-6100 1. fiber fillers for cement, caulkings, etc. Hill Bros. Chemical Co. One City Boulevard Suite 1521 Orange, CA 92668 714/634-3322 1. fabrics *2. conversion to pure carbon fibers Celancse Plastics & Specialities Co. 26 Main Street Chatham, NY 07928 201/635-2600 CER-W00L (ceramic fiber) 1. blankets 2. vacuum-formed boards 3. bulk fiber C. E. Refractories P. 0. Box 828 Valley Forge, PA 19482 412/351-4409 Siltemp (fibrous glass) 1. cloth Haveg Industries, Inc. 900 Greenback Road Wilmington, DE 19808 1-800-441-7777 GRC Sheet (fiberglass reinforced cement) 1. flat and corrugated board GRC Products, Inc. 17051 I.H. 35N Schertz, TX 78154 512/651-6773 GRC Sheet (fiberglass reinforced cement) 1. flat and corrugated board CEM-FIL Corporation 120 Spence Lane Nashville, TN 37210 615/883-7563 PreoxTM 1. woven fabric (polyacrylonitrile fiber) Gentex Corporation Carbondale, PA 18407 717/282-3550 TM Kelvar JM and Nomex (aramid fiber) 1. cloth E.I. duPont ae Nemours 302/999-4693 2. rope & Co. 3. pump packings Textile Fibers Department 4. tapes and Wilmington, DE 19898 webhings ' 5. braided sleeving APC 003523 Product TM Pyrotex Flbcrseal Products Refrasil Nor'Fab Yarns: Fabrics Fiberfrax Hi-Temp 270 Ceramic Fiber Products Kaowool Available Fo rms Supplier Phone No. Newtex Industries, Inc. Railroad Avenue P. 0. Box 25 Victor, NY 14564 716/924-9135 Pyrotek Incorporated 509/926-6211 East 9601 Montgomery Ave. Spokane, WA 99206 -or- Box 77 - R. D. Ill 717/249-2075 Claremont Road Carlisle, PA 17013 -or- Santa Fe Springs, CA 1. Cloth, tape and sleeving 2.- Bulk fiber 3. Cordage & yarn HITCO Division of Armco Steel Middletown, OH 45042 -orChamberlain Rubber Co. 1712 Erie Blvd. East Syracuse, NY 13210 315/478-0935 Amatex 1032 Stanbridge St. Norristown, PA 19404 215/277-6100 1. Bylk Fiber 2. Blankets 3. Cloth, tape and sleeving 4, Paper 5. Coating Cements 6. Boards 7. Tamping Mix 8. LDS Moldable 9. Vacuum Cast 10. Fiberwall The Carborundum Company Insulation Division P. 0. Box 808 Niagara Falls, NY 14302 716/278-6221 * Penn Compression Moulding, Inc. Burton Street 412/351-4004 Pittsburgh, PA 15218 1. Bulk Fiber 2. Blanket The Babcock & Wilcox Co. 716/662-9751 Refractories Division 3. Strip 3623 Eggert Road 4. Vacuum formed Buffalo, NY 14127 shapes -or- 5. Paper Refractory Products Co. 6. Rollboard P. 0. Box 309 7. Board 12 W. Main St. 8. Wet Felt Carpentersvilie, IL 60110 9. Surface Coatings APC 003524 Product Ceramic Fiber Products Available Forms Supplier Phone No. Cem-Fil Corporation 615/361-4664 Two International Plaza Dr. Nashville, TN 37217 Keller Glove Mfg. Co. 215/766-8818 PlumsteSdville, PA 18949 APC 003525 ASRESTOS REPLACEMENT PROGRAM SURVEY Department _Date Material: ___________________________________________________________ Use: __________________________________________________________________ Job Classification Exposed:____________________________________ Replacement Tested:Date_ Successful Not successful Comment: Replacement Tested:Date Successful Not successful____________ Comment Successful Not successful Comment Replacement Tested: Date Replacement Tested: Successful____________ Not successful Comment ` Questionaire Completed by: Date Phone: APC 003526 7'LP ZT; /l' . A- i < / ' ~ ` C' ' L RE: ASBESTOS IN CONSTRUCTION MATERIALS Mr. E. E. Rumberger, in his letter dated 1982 July 06, expressed some concern for the lack of construction participation in Alcoa's policy and objective to eliminate asbestos use in construction materials. Xou can be sure that, since 1969, construction managers and safety engineers have been informed of asbestos health hazards and the preferred use of substitutes in paints or insulation or in roof felt materials. Before asbestos substitutes were readily available on the Anaconda I Project in 1969, asbestos handling and dust control was given priority consideration. The fabrication of asoestos potlining materials was assigned to an isolated, enclosed area. Shop electric band saw cutting tables were equipped with dust collectors at the point of operation. Asbestos dust was collected in plastic bags and disposed of in designated hazardous waste sites. Workers in thevfabricating shop were supplied with appropriate respirators. In 1974, on the Northwest Alloys Project, asbestos dust control methods for the installation of ferro-silicon furnace gaskets required the Norwegian manufacturer to supply gaskets cut to size, pre-drilled, coated, and packaged in lots of five in plastic bags for safe handling at the point of installation. In the summer of 1980 at the Warrick location. Building 260, electrostatic precipitator rebuild, the sheeting and insulation material was removed wet. The insulation material was broken into small pieces, bagged, and removed to a designated hazardous waste area. Workers were supplied with paper suits, gloves and applicable respirators. APC 003527 T. I. STEPHENSON PAGE 2 1982 JULY 16 Field construction managers avoid the installation of materials containing asbestos. Occasionally the monitoring system fails, and asbestos can be found on a site. However, its use is stopped and a substitute is sought. At Point Comfort in May, 1981, the installation of felt paper pipe covering (containing asbestos) for washer tanks was stopped and delayed until the contractor found a suitable substitute. In addition to the above type of action, Alcoa Standards and Specifications play a leading role in controlling the use of hazardous materials at the site. Mr. Alkire is making the necessary standards changes when suitable substitutes are available. Site WBG:e f cc: T. M. Brown/R. G. Duhon - 2 AB APC 003528 E. E. RUMBERGER PITTSBURGH OFFICE - 6 FILE MR. J. W. DeWALT PITTSBURGH OFFICE - 2 MR. T. M. BROWN PITTSBURGH OFFICE - 2 1982 July 06 RE: ASBESTOS IN CONSTRUCTION MATERIALS Alcoa has had a policy and objective for the last several years to eliminate asbestos and asbestos-containing materials insofar as possible and practical considering the health hazard they represent to employees. This effort has been conducted primarily through Production, Engineering, Procurement, Research, Safety, and Industrial Hygiene personnel at both the plant and Corporate levels. The focus has been mainly on production and process uses. It would seem that we have been remiss in not being sure that Construction people also recognize this objective and participate as appropriate. We recently had occasion to learn of Warrick using a masonry paint that is approved under Engineering Standard 33.1.4 which contains 14% asbestos. We have now asked Tim Alkire to work with Procurement to determine what other coatings we have in our approved list which possibly contain non-essential asbestos as a filler instead of a safer non-cellulose type filler which is now available in many paints. So-called "encapsulated" fibers are suggested to be safe; and, while this might reduce fiber dissemination in air during application, it does not assure what happens during demolition or destruction of structures. We suspect there might be considerable generation of asbestos at that time from asbestos-containing paints. In any event, we believe it prudent to find safer substitutes wherever possible. The purpose of this letter is to ask that the Construction Department be cognizant of Alcoa's objective to be asbestos-free in our plants insofar as possible and practical. I would appreciate your communi cating this accordingly. Many thanks. E. E. RUMBERGER EER/eds cc: T. I. Stephenson - Pgh. 2 M I t /* APC 003629