Document xMgNGVna9gOpvaX4d8r4DRxb

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 UJ ALCOA ARD 003551 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 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 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, Potroom 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 E! ALCOA ARD 003553 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 ARD 003554 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 Wire 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 Wire 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 ARD 003555 ASBESTOS REPLACEMENT PROGRAM GENERAL APPLICATIONS 1982 February 16 Material & Use Belting for Drip Casting Replacement Status Fiberseal Fabric was tested and found to be inadequate. Block or Brick for furnaces Ceramic fiber refractory block is an acceptable substitute. There are no asbestos products currently being installed in melting furnaces, holding furnaces, or heat-treat furnaces. Brake Linings A possible (but untested) replacement for asbestos brake linings is RF-28-3D Truck Blocks (4602-FF) from Limpco Manufacturing in Greensville, PA. Cement Patch for Boiler Maintenance Two grades: 1. Hydraulic-setting cement - contains mineral wool and Portland Cement; temperature range up to 1000F. Suppliers: a) Johns-Manville "375" b) Keene Corporation "Super Powerhouse" c) 48 Insulation "Quick-Set Cement" 2. High-Temperature Grade - contains mineral wool; temperature range 1000F to 1900F. Suppliers: a) Johns-Manville "360" b) Keene Corporation "Super 1900" c) 48 Insulation Super "48" ARD 003556 1982 February 16 Material & Use Cloth and Paper for Insulation and Welding Protection ASBESTOS REPLACEMENT PROGRAM (Page 2) Replacement Status Cloth substitutes include: Pyrotek Fabrics, Refrasil, Nor-Fab, Kelnit Welding Blankets Paper Substitute: Johns-Manville - Cerawool Paper (Note: Paper should not be used for welding protection.) Gloves Flame-resistant terrycloth gloves can be used for temperatures up to 700F. Some substitutes successfully used at ATC include Kevlar Mittens (up to 400F) and Kevlar Gloves (up to 900F). These products are available from Kranso Glove & Mitten, Milwaukee, or A-Best Products, Cleveland. Other products are Kelnit 29, Keller Gloves, Pyrotex, Textoglass Gloves, and Pre-ox Gloves. Marinite and Marinite Floats for Molten Metal Casting For most HDC and FDC ingot operations, Johns-Manville's (J.M.) asbestos-free Marinite-C board should replace the asbestos Molten Metal Marinite. The applications for Marinite-C include molten metal transfer troughs, baffles, basins and floating skimmers. In certain applications, an acceptable alternate for Marinite-C is Pyrotek's asbestos-free Pyrotherm B-3 manufactured by Cape Boards of England. Johns-Manville's asbestos-free Marinite-I is not recommended for molten aluminum operations. (Marinite is continued on Page 3.) ARD 003557 ARD 003558 Material & Use Pump Packing 1982 February 16 ASBESTOS REPLACEMENT PROGRAM (Page 3) Replacement Status An asbestos-free material for the critical HDC and FDC header applications (sheet ingot headers at Tennessee South Plant and Warrick, Hunter caster tips at Badin, small round HDC headers at Badin, and tool and jib plate headers at Vernon) has yet to be developed for commercial use. Until this product is available, we will continue to use asbestos header grade molten metal Marinite. . Almost all asbestos uses in FDC ingot operations can be replaced by Alcoa's R-680. In most cases, pump packing materials are bonded in rubber or some other coating compound. These usually generate little potential for fiber exposure and need not be substituted. However, some packings, such as uncoated, noncompressed, braised asbestos may offer a potential for exposure and should be replaced. The plant industrial hygienist should be consulted when there is a question of whether or not a material should be replaced. Since specific needs and equipment types vary dramatically, pump packing and general packing materials are purchased at the plant level. Suitable replacements should be sought by plant Purchasing by direct contact with manufacturers and suppliers. ARD 003559 Material & Use Rope for packing and sealing Tubing Tape for furnace seals and general insulation ASBESTOS REPLACEMENT PROGRAM (Page 4) Replacement Status 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. Fiberseal K-2 (Pyrotek, Inc.) has been used successfully by Massena as a replacement for the asbestos rope which was used to pack bottom blocks. Another alternative is Thermo-Ceram Rope by Garlock. Tape replacements include Pyrotex, Refrasil, Fiberfrax, and Nor-Fab. 1982 February 16 Material & Use Thermocouple Wire ASBESTOS REPLACEMENT PROGRAM (Page 5) Replacement Status Sleeves made of Refrasil or Fiberfrax material may be used in place of asbestos-coated wire in some cases. Tennessee has successfully used a fiberglasscoated, braided, and wrapped thermocouple wire from Thermoelectric Co., Saddlebrook, N.J. - P/N Q/Q/20-J (Standard Grade) in their ingot preheat and a two conductor 20 gauge premium grade thermocouple wire Q/TW-20-JJ in their annealing furnace. Warrick has found two thermocouple wire substitutes: 1. J type lead wire 6A16 gauge by Thermoelectric. 2. K type 16 gauge wire made of fused teflon, polyvinyl and fiberglass by Claud S. Gordon Co. A ceramic fiber product from 3M, Nextel 312, has been tried, but it has not held up during use. 1982 February 16 ARD 8 01 ASBESTOS - POTROOM USE SUBSTITUTES (Page 6) 1982 February 16 Specific Application Cradle to Pot Shell Insulation Substitute Location Quarry Tile Wenatchee Curit Fiberglass Fill Board Warrick Cerawool Fill Board Warrick Cem-Fil GRC Sheet Warrick Cem-Fil GRC Massena J-M Asbestos-Free Millboard Massena Comments Good replacement Seems OK Will test Didn't hold up Not successful Installed on some pots and appears OK. Will be used on all future pot rebuilds. Mechanical Engineering Division, Pittsburgh, specifies Johns-Manville Cerawool Millboard as a substitute for JM-106 Millboard. Compressive strength and insulating quality are comparable. Cost for Cerawool Millboard is $1.50 each for 1/4" x 3" x 48" pieces in lots of 250, or $1.25 each in lots of 500. This is less than the $5.00 per piece you are paying for Chem-Fil board. ARD 003561 Superstructure Foot Insulation Cem-Fil GRC 9"x7"xl" Marinite P - 1/2" sheet R-680 Badin Massena Badin Badin Product was not even and resulted in rocking of the superstructure. To be tested Crushed Currently testing Mechanical Engineering Division, Pittsburgh, presently specifies ebony asbestos for this item. Tests on other materials have not been successful. ASBESTOS - POTROOM USE SUBSTITUTES (Page 7) 1982 February 16 Specific Application Pot Cover Insulation - Substitute Almac Plastic Industries' High-Temp. Glass Marinite P - 1/2" sheet Pyrotek Fiberseal H-3 Fabric Amatex-Thermoglass //G-36P752 Location Massena Massena Badin Massena Warrick Wenatchee Badin Comments To be tested Not successful Double the fabric; works well for repairs. Not successful Works well; now standard; also works for sideshield insulation. Satisfactory Will use in all new pot covers. Mechanical Engineering Division, Pittsburgh, has eliminated use of Asbestos by wrapping Amatex-Thermoglass //G-36P752 around an aluminum bar. In other installations, fiberglass fabrics have been used as the insulating material. ARD 003562 1982 February 16 ASBESTOS - P0TR00M USE SUBSTITUTES (Page 8) Specific Application Walkway Grating Insulation Substitute Pyrotek E-40 Pyrotek Phenolic Paper Pyrotherm G-5 Insulating Board Marinite P - 1" Board Marinite P - 1/2" Board GRC Cem-Fil 1/4" & 3/8" M-50 Pyrotherm Dense Board Chem-Fil Fiberboard by Louisville Insulation Location Bad in Bad in Bad in Bad in Bad in Massena Massena Massena Warrick Comments Crumbled Currently testing; easy to work with but expensive To be tested Not satisfactory Not satisfactory Not successful Not successful Unsuccessful; it crumbles. Currently trying this cement-fiberglass product Mechanical Engineering Division, Pittsburgh, specified Chem-Fil fiber reinforced cement for the new Badin and Noranda potlines. Previously specified Koppers NCX (fire-retardant) treated wood. The disadvantage of wood is that it still chars when exposed to molten bath. The cost of Chem-Fil and treated wood are comparable. ARD 003563 ASBESTOS - P0TR00M USE SUBSTITUTES (Page 9) 1982 February 16 Specific Application Bus Insulation Substitute Marinite P - 1" sheet Marinite P - 1/2" sheet Cem-Fil GRC 1/4" & 1/2" Location Bad in Massena Massena Pot Exhaust Duct Pyrotek Pipe Hetron 197 ( Warrick Bad in Wenatchee Hetron 92 Wenatchee Fiberfrax Laminate Tubes by Carborundum, Inc. ATC Comments Crumbles Not successful Not successful Mechanical Engineering Division, Pittsburgh, eliminated use of transite by substituting an aluminum bar with a 1/16" layer of glass fabric epoxy, NEMA Grade G-ll, taped to each side of the bar. Looked good in preliminary testing; continuing testing with interior coatings to prevent corrosion. Looks good on 9 pots; changing to this product. Fiberglass pipe with antimony and dynel liners failed, and replaced by normal transite. Fiberglass pipe with antimony and asbestos linings satisfactory. Currently testing Mechanical Engineering Division, Pittsburgh, has conducted extensive tests on Hetron 197 at Wenatchee and Warrick. This material is quite expensive and may not be as durable as transite. ARD 003564 ASBESTOS - P0TR00M USE SUBSTITUTES (Page 10) 1982 February 16 Specific Application Exhaust Duct Gaskets Substitute Pyrotek Fiberseal Felt T-l Pyrotek T-22 Fiberglass Cloth Location Massena Massena Siphon Gaskets Pyrotek Fiberseal M-13 1/8" Compressible Board Fiberseal Felt G- 1 1/2" & T-l - 1/4" J-M Asbestos-Free Millboard J-M Ceraform Heat Seal Massena Badin Massena Badin Massena Rockdale Comments Not successful Successful; replacing asbestos as pots are rebuilt. Mechanical Engineering Division, Pittsburgh, is specifying asbestos impregnated sheet material; however, Garlock's Gylon material would probably work for this application. Satisfactory Currently using this product. Unsuccessful . Tested and proved OK, but prefer Fiberseal M-13. Satisfactory, presently in use. Not as stable as asbestos; needs to be replaced more often. Mechanical Engineering Division, Pittsburgh, presently specifying Pyrotek T-l felt material for this application. ARD 003565 ASBESTOS - POTROOM USE SUBSTITUTES (Page 11) 1982 February 16 Specific Application Ladle & Ladle Lid Seal Substitute Silicon Red Rubber Air Hose - 3/4" Location Warrick Fiberseal Rope F-10, 1-1/2" Massena Refrasil-wrapped around rubber hose Bad in 1" Fiberseal Rope D-l Anaconda Pyrotek Treated Z-5 Tape Massena High Temperature Exposure Insulated Electrical Wire P-75, P-225 Potwiring, P-225 Jackmotors, Calrod heaters High Temperature Silicon Braid Copper Conductor, 1000 V., 200C Massena Comments Standard usage (but different seal than other plants) Unsuccessful No good; rubber melts; seal breaks Uses 600 ft. per month of D-l Successful; presently in use. Mechanical Engineering Division, Pittsburgh, presently specifying Pyrotek Z-5 material. Several layers of this material are used for one seal. Satisfactory. Limited replacement practice. ARD 003566 ASBESTOS - CARBON BAKE USE SUBSTITUTES (Page 12) 1982 February 16 Specific Application Exhaust Duct Manifold Gaskets Substitute Pyrotek Composition Boot V-5, M-6, H-3 Fabric Location Massena Comments To be tested. Expect shipment October 1981. ASBESTOS - WIRE, ROD AND BAR USE SUBSTITUTES Specific Application Jarke Rack Liners Substitute Pyrotek 747 Cloth Pyrotek F-l Cloth Pyrotek T-23 Tape Pyrotek Glass and Kevlar Blend Pyrotek T-22 Tape Newtex Fabric Tape Zetex 1200 Tape Zetex 32500 Location Massena Massena Massena Massena Massena Massena Massena Massena Comments Unsatisfactory; frays easily. Unsatisfactory; frays easily. Unsatisfactory; frays easily. Unsatisfactory; frays easily. Unsatisfactory; frays easily. Unsatisfactory; frays easily. Unsatisfactory; frays easily. Successful so far; encouraging. ARD 003567 Product Pyrotex Fiberseal Products Refrasil Nor-Fab Yarns; Fabrics Fiberfrax Hi-Temp 270 Ceramic Fiber Products Marinite and Other Products 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 -0R- Box 77 - R.D. #1 Claremont Road ' Carlisle, PA 17013 -0R- Santa 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-Fil Corporation Two International Plaza Drive Nashville, TN 37217 Keller Glove Mfg. Co. Plumsteadville, PA 18949 Johns-Manville The Manville Corporation Ken-Caryl Ranch Denver, CO 80217 1982 February 16 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 ARD 003568