Evaluation of Worker Exposures to Noise, Metalworking ...Exposures to Noise, Metalworking Fluids, Welding Fumes, and Acids During Metal Conduit Manufacturing Manuel Rodriguez, MS,

Evaluation of Worker Exposures to Noise, Metalworking Fluids, Welding Fumes, and Acids During Metal Conduit Manufacturing

Manuel Rodriguez, MS, CIH, CSP

Republic Conduit Louisville, Kentucky April 2008

National Institute for Occupational Safety and Health

Christine A. West, RN, MSN/MPH

Scott E. Brueck, MS, CIH

Health Hazard Evaluation Report HETA 2006-0332-3058

DEPARTMENT OF HEALTH AND HUMAN SERVICES Centers for Disease Control and Prevention

Workplace Safety and Health

https://www.cdc.gov/niosh/hhe/reports

http://www.cdc.gov/niosh/hhe/

http://www.cdc.gov/niosh/hhe/

The employer shall post a copy of this report for a period of 30 calendar days at or near the workplace(s) of affected employees. The employer shall take steps to insure that the posted determinations are not altered, defaced, or covered by other material during such period. [37 FR 23640, November 7, 1972, as amended at 45 FR 2653, January 14, 1980].

Contents

RepoRt Contents

Abbreviations........................................................................ ii

Highlights.of.the.NIOSH.Health.Hazard.Evaluation............. iii

Summary..............................................................................v

Introduction...........................................................................1

Assessment..........................................................................2

Results.&.Discussion............................................................3

Conclusions........................................................................11

Recommendations..............................................................12

References.........................................................................15

Appendix A Tables.................................................................................17

Methods..............................................................................23Appendix B

Appendix C Occupational.Exposure.Limits.and.Health.Effects..............25

Appendix d Confined.Space.Entry.Program..........................................37

ACknowledgments Acknowledgements.and.Availability.of.Report....................39

Health Hazard Evaluation Report 2006-0332-3058 Page �

ABBReviAtions

ACGIH® AmericanConferenceofGovernmentalIndustrialHygienists AG Acidgas AL Actionlevel ANSI AmericanNationalStandardsInstitute CIH CertifiedIndustrialHygienist CO Carbonmonoxide CSP CertifiedSafetyProfessional Cr(III) Trivalentchromium Cr(VI) Hexavalentchromium CT Charcoaltube dB Decibel dBA Decibels,A-scale GA Generalarea HCl Hydrochloricacid HHE Healthhazardevaluation HL Hearinglevels Hz Hertz JSA Jobsafetyanalysis LOTO Lockout/Tagout Lpm Litersperminute µm Micrometer µg/m3 Microgramspercubicmeter mg/m3 Milligramspercubicmeter mL Milliliter mm Millimeter MSDS Materialsafetydatasheet MWF Metalworkingfluid NIOSH NationalInstituteforOccupationalSafetyandHealth OEL Occupationalexposurelimit OSHA OccupationalSafetyandHealthAdministration PBZ Personalbreathingzone PEL Permissibleexposurelimit PPM Partspermillion PPE Personalprotectiveequipment PTFE Polytetrafluoroethylene PVC Polyvinylchloride REL Recommendedexposurelimit SAR Suppliedairrespirator SCBA Self-containedbreathingapparatus SLM Soundlevelmeter STEL Shorttermexposurelimit STS Standardthresholdshift TLV® Thresholdlimitvalue TWA Time-weightedaverage

Page �� Health Hazard Evaluation Report 2006-0332-3058

HigHligHts of tHe

niosH HeAltH

HAzARd evAluAtion

Health (NIOSH) received

This HHE was requested because of concerns

conducted site visits in

2007.

The National Institute for Occupational Safety and

a confidential employee request for a health hazard evaluation (HHE) at Republic Conduit in Louisville, Kentucky.

about exposures to acids, unsafe confined space entry procedures, and inadequate personal protective equipment. NIOSH investigators

November 2006 and March

What NIOSH Did ● Welookedatconduitmanufacturing.

● Wetalkedtoworkersabouttheirconcernsaboutworkplace hazards.

● Welookedatpreviousairsamplingrecords,injuryandillness records,andmaterialsafetydatasheets.

● Wesampledforacidmists,metalworkingfluids(MWFs), elements,andhexavalentchromium.

● Wemeasuredworkers’noiseexposures.

● Welookedathearingtestrecords,writtenconfinedspace entryprocedures,andtherespiratoryprotectionprogram.

What NIOSH Found ● Workerswerenotoverexposuredtoacidmists,elements,or

hexavalentchromium.

● Mostworkerswereoverexposedtonoise.

● Someworkersworetheirhearingprotectionincorrectly.

● ThreeworkershadMWFexposuresatorabovetheNIOSH recommendedexposurelimit.

● Therespiratoryprotectionandconfinedspaceprogramswere incomplete.

● GradeDbreathingairwasnotavailableforsuppliedairrespirators.

● Lockout/tagoutruleswerenotfollowed.

● Workerssaidtheyhadupperrespiratorysymptomscausedby acidandhandinjuriescausedbycontactwithconduit.

● Workerswereconcernedaboutimproperpersonalprotective equipmentandpoorventilation.

● Workersmentionedalackoftrainingandpoorhazardcommunication.

What Republic Conduit Managers Can Do ● Reducemetaltometalcontactnoise.

● Haveworkerswearhearingprotection.

● Startahearinglosspreventionprogram.

● Enclosethemillsandinstalllocalexhaustventilation.

Health Hazard Evaluation Report 2006-0332-3058 Page ��

HigHligHts of tHe

niosH HeAltH

HAzARd evAlution (Continued)

● Developanentrychecklistforeachconfinedspace.

● ProvidegradeDbreathingairforsuppliedairrespirators.

● FollowtheOccupationalSafetyandHealthAdministration’s (OSHA)lockout/tagoutrules.

● UsetheOSHA Small Entity Compliance Guidetowritearespiratoryprogram.

● Provideworkerspersonalprotectiveequipment.

● Writeanincidentresponseprogramforemergencies.

● FollowOSHA’sHazardCommunicationsstandard.

● EducateandtrainworkersaboutMWFs.

● Startanemployee-managementhealthandsafetycommittee.

What Republic Conduit Employees Can Do ● Followalllockout/tagoutprocedures.

● Wearpersonalprotectiveequipmentwhenworkingaround acids.

● Wearhearingprotectioninnoisyareas.

● Wearbothearplugsandearmuffswhenworkingnearthe hotdipareaorthesteamcannon.

● Reportanywork-relatedsymptomsorsafetyconcernstoyour supervisor.

● Talktoyourdoctorifyouthinkyoursymptomsarework-related.

Page �v Health Hazard Evaluation Report 2006-0332-3058

summARy

at concentrations equal to or greater than the

concentrations of acids were either not

NIOSH recommends that

implemented to reduce

Noise exposure measurements for 94% of the workers evaluated were above the NIOSH REL. Three workers were exposed to MWFs

NIOSH REL. Airborne

detected or were much lower than their OELs.

engineering controls be

exposures to noise and MWFs below their NIOSH RELs. Recommendations are also provided for improving the confined space entry and respiratory protection programs.

OnAugust8,2006,NIOSHreceivedaconfidentialemployee requestforanHHEatRepublicConduitinLouisville,Kentucky. Therequestorsexpressedconcernsaboutworkplaceexposuresto acids,unsafeconfinedspaceentryprocedures,andinadequatePPE forhandlingacids.WeconductedaninitialsitevisittoRepublic ConduitonNovember13,2006,duringwhichweperformed awalk-throughofthefacilityandinterviewedworkers.Based onourobservations,workerswerepotentiallyexposedtoacids, Cr(VI),MWFs,weldingfumes,andnoise.Ofthe13employees whoweselectedformedicalinterviews,tworeportedacuteupper respiratorysymptomsandexacerbationofasthmasymptoms relatedtoabriefexposuretoHCLduringaleak.Fourreported injuriesnotassociatedwithacidexposure,whichincludedback pain,skinirritation,lacerations,andcrushedfingers.Areview ofOSHA’sForm300LogofWork-RelatedInjuriesandIllnesses for2006revealedthatof21entries,11listedcrushedfingersor lacerationscausedbycontactwithconduit.

Weconductedafollow-upsitevisittoRepublicConduitduring March5–8,2007,tosampleforacidmists,MWFs,elements fromweldingfumes,andCr(VI)fromchromicacid;conduct noisedosimetry;andreviewthecompany’swrittenhealthand safetyprograms.AllsamplingresultswerebelowapplicableOELs exceptfornoiseandMWFs.Ofthe35personalnoiseexposure measurementstakenduringthisevaluation,33exceededthe NIOSHRELof85dBA.BecauseOSHAusesdifferentcriteriato measurenoiseexposure,onlysixexceededtheOSHAPELof90 dBA,though29exceededtheOSHAALof85dBA.Threeof21 PBZsampleresultsequaledorexceededtheNIOSHREL-TWAfor MWFsof0.4mg/m3(thoracicparticulatemass).

DuringtheMarch2007sitevisit,weprovidedall168production workersonthreeshiftsasurveyformaskingabouttheirworkplace exposures,useofPPE,hazardcommunication,andconfined spaceentryprocedures.Sixty-nineworkers(41%)completedthe voluntarysurvey.Ingeneral,workerswereconcernedabouttheir workplaceexposures,specificallytoacidsandzincoxidedust.

BasedonPBZairsamplingconductedduringthisevaluation,we recommendthatRepublicConduitenclosethemillsandinstall localexhaustventilationtoreduceairborneMWFconcentrations belowtheNIOSHREL.Werecommendmilloperatorsuse respiratoryprotectionuntilairborneconcentrationsofMWFsare belowtheNIOSHREL-TWA.Afterthecontrolsareinstalled,

Health Hazard Evaluation Report 2006-0332-3058 Page v

summARy (Continued) additionalPBZairsamplingshouldbeconductedtodetermine iftheairborneconcentrationofMWFshasbeenreducedandif respiratoryprotectionisstillneeded.Controlsshouldbeinstalled toreduceimpactnoisegeneratedbymetaltometalcontact,and hearingprotectionshouldbeusedproperlytoreducetheriskof hearingloss.Wealsoproviderecommendationsforprotecting workerswhileperformingmaintenanceonsystemswithacids, reducinginjuries,andrevisingthewrittenrespiratoryprotection andconfinedspaceentryprograms.Furtherrecommendationsare providedintherecommendationssectionofthisdocument.

Keywords: NAICS.332813.(Electroplating,.plating,.polishing,. anodizing,.and.coloring),.nitric.acid,.sulfuric.acid,.hydrochloric.acid,. metalworking.fluids,.MWFs,.welding,.noise,.hearing.loss,.impact. noise,.confined.spaces,.hexavalent.chromium,.Cr(VI)

Page v� Health Hazard Evaluation Report 2006-0332-3058

intRoduCtionOnAugust8,2006,NIOSHreceivedaconfidentialemployee requestforanHHEatRepublicConduitinLouisville,Kentucky. Therequestorsexpressedconcernsaboutworkplaceexposuresto acids,unsafeconfinedspaceentryprocedures,inadequatePPEfor acidexposures,andwork-relatedthroatirritation.TwoNIOSH industrialhygienistsandanurseepidemiologistconductedan initialsitevisittoRepublicConduitonNovember13,2006. Duringthesitevisitweinterviewedworkersandconducteda walk-throughtourofthefacility.Weobservedthatworkerswere exposedtooneormoreofthefollowingchemicalandphysical hazards;acids,MWFs,weldingfumes,zincoxide,Cr(VI),and noise.

Basedonourobservationsduringtheinitialsitevisit,we conductedasecondvisittoRepublicConduitduringMarch5–8, 2007,tosampleairborneforacidmists,Cr(VI),MWFs,andmetals fromweldingfumes;conductnoisedosimetry;andreviewthe healthandsafetyprograms.

RepublicConduitoccupiesa400,000squarefootbuilding thatwasconstructedin2005andispartofTenaris,aglobal manufacturerandsupplieroftubularproducts.Atthetimeof thisevaluationtheplanthad168productionemployees.All productionworkersatRepublicConduitwearsafetyglasses, hearingprotection,safetyshoes,andhardhats.Someworkerswear Kevlar,leather,ornitrilegloves,basedontheirjobrequirements.

Process Description

RepublicConduitreceivesrollsofsheetmetalthatareslit intostrips,withthestripwidthcorrespondingtothedesired circumferenceoftheconduit.Thestripsaremanuallyaligned, andtheendsweldedtoensureacontinuousfeedofsheetmetal stripsthroughthemills.Asthesheetmetalstripsmovethrough themillsonconveyors,themillsformthestripsintotubing,weld theseam,andcutthetubingtothedesiredlength.Atthetimeof thisevaluation,onlytwoofthefivemilllineswereinoperation. SyntheticMWF(amixtureof6%neatfluidaddedtowater)isused tocoolthetubingduringtheformingandweldingprocess.

Smallerdiameterconduitisgalvanizedbypicklinginanacidbath (nitric,sulfuric),thenelectroplatedwithzinc.Thegalvanizedpipes aredippedinachromebathanddriedinanoven.Achrome coatingisthensprayedinsidetheends.Theinterconnected


intRoduCtion (Continued) galvanizingandelectroplatingtanksareenclosedbyvinylstrip curtainsandfansoverthepicklingandcoatingtankscaptureand exhausttheacidmistthroughascrubber.

Largerdiameterconduitiscleanedbydippinginanenclosed, ventilatedHCltank,andthencoatedbydippinginmoltenzinc. Aftercoating,excesszincisblownoutfromtheinteriorofthe conduitusinghighpressuresteam,thentheconduitissprayed withdilutedchromicacid.Theconduitendsarethreadedand recoatedwithzinc(remetalized),thenheattreated.Workersin thethreadingareausedaerosolspraycanstoapplyazinccoating onpartsofthetubingthatwerenotadequatelytreatedduring remetalization.

Atthetimeofthisevaluationtwoorthreeworkerswereatthehot diptank.Theseworkersmanuallyadd60poundbarsofzinctothe kettleandstirthemoltenzinc,requiringthemtobeclosetothe kettle.Zincfumescapturedbyacanopyhoodatthehotdiptank passthroughabaghousefilter.

Assessment Afterthewalk-throughtouroftheplant,wedevelopedasampling strategybasedonpotentialworkerexposuresandaddressing therequestors’concerns(seeTable1).Basedonourdiscussions withRepublicConduitmanagementpersonnelandemployees wedeterminedthatexposureswouldprobablybegreateronday shiftandthattherewasnodifferenceintheproductionprocesses conductedduringdayandnightshifts,hencewecollectedPBZ airsamplesondayshiftemployeesonly.Wealsocollectedtwo GAsamplesforHClinthehotdipenclosure,twosamplesfor elementsnearmills,andoneinthethreadingarea.Wesampled employeesaccordingtotheirworkplaceexposuressothatthose workingnearthemillsweresampledforMWFsandelementsfrom weldingfumes,personnelworkingaroundacidsweresampled forinorganicacidswhichincludedHCl,sulfuric,andnitricacid. Personnelworkingnearchromicacidtanksweresampledfor Cr(VI).MostemployeesonwhoPBZairsamplingwasconducted werealsosampledfornoise.SamplingresultsforMWFs,acids, Cr(VI),elementsfromweldingfumes,noiseareprovidedintables A1-A6inAppendixA.Inadditiontotheresults,thetablesprovide thesampledworker’sdepartmentandjobtitleaswellasthesample time.Detailsonthemethodsusedforairsamplingandnoise measurementsareexplainedinAppendixB.TheOELsandhealth

Page � Health Hazard Evaluation Report 2006-0332-3058

Assessment (Continued) Table1:SummaryofEmployeesWorkplaceExposures Department Exposures

Maintenance

HotDip

Welding/Mills Threading LabTech

AcidMists(HCL,Sulfuric,Nitric), MWFs,Cr(VI),Noise AcidMists,Cr(VI),ZincOxide, Noise MWFs,WeldingFumes,Noise Zinc Oxide, Noise

AcidMists,Noise

Results & disCussion

effectsarediscussedinAppendixC.Allsampleswerecollected duringafullshift(generally8-10hours)withtheexceptionoftwo STELareasamplesforHCLcollectedinthehotdipenclosure. Wealsousedventilationsmoketubestoobserveairflowpatterns aroundenclosuresforhazardousoperations.

Duringourinitialsitevisit,RepublicConduitrepresentatives provideduswitharosterofemployeesworkingatthefacility. Wechoseeveryfifthemployeefromtherosterforinterviews abouthealthsymptoms.Employeeswerechosenfromthehot dip,galvanizing,maintenance,andweldingareasfromfirstand secondshift.WereviewedOSHA’sForm300LogofWork-Related InjuriesandIllnessesfor2006andthewrittenguidelinesforthe confinedspaceentryandrespiratoryprotectionprograms.

Weprovidedasurveyformtoall168productionworkerson threeshiftsaskingabouttheirworkplaceexposures,useofPPE, hazardcommunication,andconfinedspaceentryprocedures. Participationwasvoluntaryand69(41%)ofthe168production workerscompletedthesurvey.

Air Sampling

ThePBZairsamplingresultsforMWFsbyjobclassification arepresentedinTableA1(AppendixA).Onlyonemillwas inoperationinthemorningduringthe2daysweconducted airsamplingandnoisedosimetry.Generally,twomillsarein operationatthesametimeduringtheentireday,whichmayresult inahigherreleaseofweldingfumesandMWFmist.Wecollected atotalof16PBZairsamplesforMWFs.OneMWFsample collectedonamilloperatorexceededtheNIOSHREL-TWAof 0.40mg/m3.Theremaining13samplesmeasuredexposuresbelow


Results And disCussiontheREL.Anothermilloperatorandendfinisherhadexposures (Continued)thatequaledtheREL.InadditiontotheMWFsthetotalthoracic particulatemassincludesotherparticlessuchaselementsfrom weldingfumesandambientdust.TheextractedMWFrepresents theairborneconcentrationofMWF,howevertheNIOSHREL appliestothetotalthoracicparticulatemass.

m

AirsamplingresultsforacidmistsarepresentedinTableA2.We collectedatotalof21PBZairsamplesforacidmistsand2GA samples.Samplingresultsforacidmistsdidnotexceedapplicable OELs.Nitricacidhasthelowestdetectionlimitandwasthemost commonlydetectedacid.Thehighestairborneconcentrationof nitricacidwas0.1mg/m3,whichismuchlessthantheOSHA PEL-TWAorNIOSHREL-TWAof5mg/m3.Withtheexceptions ofonePBZairsample(0.29mg/m3)andoneSTELareasample (3.1mg/m3)HClwasnotdetected.Thesesampleresultswere belowtheNIOSHRELandOSHAPELceilinglimitof7mg/

3.Sulfuricacidwasalsonotdetectedorwasdetectedintrace concentrationsatlessthan0.09mg/m3,whichisbelowtheOSHA PEL-TWAorNIOSHREL-TWAof1mg/m3.Linebreakingand replacementofcomponentssuchaspumpsandvalveswerenot performedbymaintenancepersonnelduringthisevaluation.There isapotentialforhigherexposurestoacidswhileperformingthose tasks.PriortothisHHE,threeworkershadbeensplashedwith HClwhenapressurizedlineruptured.

AirsamplingresultsforCr(VI)collectedonPVCfiltersare presentedinTableA3.Wecollected4PBZairsamplesforCr(VI) fromweldingfumesonmilloperators,2onendfinishers,and2 onendwelders.ResultsforCr(VI)collectedonquartzfiltersare presentedinTableA4.Atreatedquartzfilterwasusedinthis areatopreventtheCr(VI)frombeingreducedtoCr(III).We collectedatotalof15PBZairsamplesonemployeesworking nearthehotdipandgalvanizingareasandontwomaintenance workers.ThehighestairborneconcentrationofCr(VI)0.3µg/m3 wasobtainedonasamplecollectedonagalvanizinglineworker. AllotherCr(VI)sampleswerelessthan0.1µg/m3,whichisbelow theNIOSHREL-TWAof1µg/m3andtheOSHAPEL-TWAof5 µg/m3.

Airsamplingresultsforelementsinweldingfumesarepresentedin TableA5.Wecollectedatotalof15PBZairsamplesonemployees workingnearthemills,threading,orhotdipareas.Wealso collectedtwoGAairsamplesbythemillsandthreadingarea.The


Results And disCussion airsamplescollectedonemployeespotentiallyexposedtowelding (Continued) fumesorzincwereanalyzedfor31elements,primarilymetals.The predominantmetalsdetected,ironandzinc,werepresentinall16 airsamples.Theconcentrationsofironrangedfrom0.02to0.38 mg/m3;concentrationsthatweremuchlowerthantheNIOSH REL-TWAof5mg/m3andtheOSHAPEL-TWAof10mg/m3. Zincconcentrationswhichrangedfrom0.01to1.5mg/m3,were belowtheNIOSHREL-TWA(forzincoxidedustorfume)of5 mg/m3andOSHAPEL-TWAof5mg/m3forzincoxidefume. Otherelementsdetectedinquantifiableconcentrations(but wellbelowtheirrespectiveOELs)includedaluminum,barium, calcium,copper,magnesium,manganese,molybdenum,silver, andtitanium.Althoughanexposurelimitfortotalweldingfumes hasnotbeenestablishedbyeitherOSHAorNIOSH,NIOSH recommendsmaintainingexposurestoweldingfumesaslowas technicallyfeasible[NIOSH1988,2005].

Noise

Personalnoiseexposuremeasurementresultsarepresentedin TableA6.Ofthe35personalnoiseexposuremeasurements,33 exceededtheNIOSHRELof85dBA,whichisequivalenttoa noisedoseof100%.Thenoisedosefor29noisemeasurements wasgreaterthan200%(twotimesgreaterthantheNIOSHREL). Thenoisedosefor16measurementsexceeded500%(fivetimes theNIOSHREL).BecauseOSHAmeasuresnoiseusingadifferent criteriathanNIOSH,only6measurementsexceededtheOSHA PELand29measurementsexceededtheOSHAAL.Although theNIOSHRELfornoiseisnotalegallyenforceableregulatory standard,NIOSHconsidersittobemoreprotectiveinthe preventionofhearinglossthanOSHA’snoiseexposurelimits. Table2providesasummaryofnoisemeasurementresultsforeach jobtitle.

Metalimpactisasubstantialsourceofnoiseintheproduction area.Specifically,metalconduitrollingintoordroppingonto otherpiecesofconduitduringprocessingcausesimpactnoise. Impactnoisealsooccurswhenconduitstrikesstopplates(end finisher)orotherpiecesofmetalontheproductionequipment. Theproductionequipmentitselfalsogeneratesnoisewhenitis running.


Results And disCussion (Continued)

Table2:RangeofPersonalNoiseDosimetryMeasurements

Department JobTitle Numberof Measures OSHAALa

PercentDose

OSHAPELb NIOSHRELc

Galvanizing Bundler 2 90.8–113.3 73.7–97.3 620.0–961.5

Extractor 2 160.2–217.3 131.9–191.9 2536.4–5961.1

HotDip Operator

Laborer

1

1

205.6

90.8

186.5

45.4

4215.7

649.3

Loader 2 66.9–123.1 51.4–116.5 356.2–837.1

Maintenance Maintenance 4 19.8–95.9 8.5–79.0 93.3–1491.1

Shipping MaterialHandler 6 55.1–77.9 33.4–49.3 214.3–565.3

PackagingOp. 2 48.0–73.7 23.7–39.5 170.1–876.7

Threading SawOperator 2 77.9–104.2 57.4–77.9 418.7–552.4

Inspector 1 58.2 38.4 303.0

Bander 4 83.5–211.4 67.8–197.2 578.5–1635.5

EndFinisher 3 41.2–155.8 33.0–141.4 148.1–1712.8 Welding

MillOperator 2 44.8–69.7 16.3–39.0 155.1–317.3

Utility 1 15.0 59.9 46.7 aOSHAAL=Adose=50%(an8-hourTWAof85dBA,usinga5dBexchangerate). bOSHAPEL=Adose=100% (an8-hourTWAof90dBA,usinga5dBexchangerate). cNIOSHREL=Adose=100%(an8-hourTWAof85dBA,usinga3dBexchangerate).

Inthehotdipdepartmentahighlevelofimpulsenoiseis createdwhenthesteamcannonisactivated.Ofparticularnote werethenoiseexposuresoftheoperatorsandextractorsinthe hotdipdepartment,whichrangedfrom99dBAto102dBA basedonNIOSHmeasurementcriteria.Soundlevelandoctave bandmeasurementstakeninthisareashowthatpeaklevels aresometimesgreaterthan136dBwhenthesteamcannonis activated.Becauseofnoisemonitoringequipmentlimitations, thesevaluesmayactuallyunderestimatethetruepeaknoiselevel fromthesteamcannon[Kardous2004].

Mostemployeesworeoneofthefollowingfourtypesofhearing protection:E-A-R®Classic®(NRR29),MoldexPurafit®(NRR 35),HowardLeightLaserlight®(NRR32),orBilsom®Thunder® T3H(NRR27)earmuffs.Weobservedthatsomeworkersdidnot


Results And disCussion wearearplugsproperly.Specifically,thefoamearplugshadnot (Continued) beeninserteddeeplyenoughintotheearcanal.Improperlyworn orinsertedearplugsreducetheeffectivenessoftheearplug.

Weobservedthatsomeworkerswerenotwearinganyhearing protection.Whenaskedaboutthereasonfornotwearinghearing protection,oneworkerrespondedthatthenoisedidnotseemtoo loudandwasnotasloudasnoiselevelsexperiencedinaprevious job.Wealsoobservedsomecontractweldersnearthezinckettle andsteamcannonwhowerenotwearinghearingprotection.

AudiometrictestingisdoneoffsitebyBaptistWorxwhenworkers arehiredandthenrepeatedonayearlybasis.RepublicConduit beganoperationsandhiredmostoftheworkforcein2005and 2006.Atthetimeofourevaluationmostworkershadonly receivedbaselinehearingtests.However,56productionworkers hadabaselineaudiogramandsubsequentyearlyaudiogram. Ofthese,fiveworkershadanSTS.OSHAdefinesanSTSasa changeinanemployee’shearingthreshold,relativetothebaseline audiogram,ofanaverageof10dBormoreat2000,3000,and 4000Hzinoneorbothears.TheoccurrenceofaSTSindicates thatworkersexposedtohighnoiselevelsarenotadequately protectedeitherbecausetheyarenotwearinghearingprotectionor arenotproperlywearinghearingprotection.

Ventilation

Weusedsmoketubestovisualizeairflowcurrents.Smoke releasedneardoorsintheadministrativeandbreakroomareas flowedrapidlyintotheproductionarea,indicatingthatthe productionareawasundernegativepressurerelativetothose twoareas.Thisisafavorableconditionbecauseitmeansthat aircontaminantsreleasedintheproductionareawillnotflow intotheadministrativearea.Smokereleasednearthegalvanizing tanksfloweduptotheexhaustfans.Smokereleasedbythehot dipenclosureandtheremetalizerflowedintotheirrespective enclosures,indicatingtheywerebothundernegativepressure. Despitemissingseveralenclosurepanels,whichmayreducethe effectivenessofthetank’sexhaustventilationsystem,smoke releasedintothechromicacidtankflowedintotheenclosure. Thetankfarmlocatedwithintheplantnearthehotdipareawas underpositivepressure,anundesirableconditionbecauseifaleak occurredthevaporscoulddisperseintotherestoftheplant.The HClhotdipenclosurehadavariableairflowexhaustsystemto


Results And disCussionmaintaintheenclosureundernegativepressurewhenconduitwas (Continued) transferredinandoutofthetanks.

Weobservedanaccumulationofdustinthethreadingarea, indicatingthatthelocalexhaustventilationsystemwasineffective orneededmaintenance.

Themillsarenotenclosed,andlocalexhaustventilationisnot used(Photo1).RepublicConduithadappliedforaconstruction permitinSeptember2006toinstallanexhaustsystemonthemills andwasawaitingapprovalbytheLouisville/MetroAirPollution ControlDistrict.

ldi

l

ill i l l

We ng fumes and MWFs.

Note no enc osure

Photo1:M formscondu toutofsheetmetaandwe dstheseam

Respiratory Protection Program

Thewrittenrespiratoryprotectionprogramwasnotsitespecific. Forexample,itdidnotspecifythetypeofrespiratoryprotection requiredforhazardousoperationssuchascleaningtanksor enteringtheHClhotdipenclosure.Additionally,therespirator programnotedthattheuseofsuppliedairrespiratorswasrequired forlinebreaking,butasourceofGradeDbreathingairwasnot availableatthefacility.

Employee Interviews

Duringtheinitialsitevisit,November2006,weinterviewed13 (21%)of71employeesworkingfirstandsecondshiftinthehot dip,galvanizing,maintenance,andweldingareas.Employees


Results And disCussion interviewedreportedajobtenureof2monthsto1year.Two (Continued) oftheworkersinterviewedreportedacuteupperrespiratory symptomsandexacerbationofasthmasymptomsrelatedtoabrief exposuretoacidduringaleak.Fourotheremployeesinterviewed reportedbackpain,skinirritation,lacerations,andsmashing injuries.Alongwithhealthsymptoms,generalsafetyissuessuch aspersonnelnotfollowingproperproceduresforconfinedspace entryandlockout/tagoutwerereported.

Thesymptomsreportedbythe13workersinterviewedandthose ontheOSHA300LogofWork-RelatedInjuriesandIllnesseswere notassociatedwithaspecificcausativeagent.However,someof thesesymptoms(e.g.,eye,noseandthroatirritation,skinirritation, andrespiratorysystemdistress)areconsistentwithacidexposure andcouldbecausedorexacerbatedbyshort-termexposureto acids,evenifexposuresarenotabovetheOELs[NIOSH1981, 2005].Ofthe21entriesforinjuriesorillnessesontheOSHA Logsin2006,2ofthemechanicsreportedthroatirritationfrom exposuretochemicalvapors.Otherentriesincluded6crushing/ smashinginjuries,6lacerations,4sprains/strains,and2fractures. Theoccupationmostoftenlistedfortheseinjurieswasend finisher.

Employee Survey

DuringtheMarch2007sitevisitweprovidedallproduction employeesasurveyformwithquestionsaboutworkplaceexposures anduseofPPE.Althoughthesurveyhadonly41%participation fromtheworkforceand,thus,maynotrepresenttheentire workforce,wewereabletoobtainusefulinformationfromit. Workerswereconcernedaboutpotentialhazardswithintheir workareas.Milloperatorswereconcernedaboutweldingfumes; threadersandhotdipoperatorsaboutzincoxide;andworkers atthegalvanizinglineaboutacids.Thirty-fiveoftherespondants saidtheyhavesmelledacidintheirworkarea,and16saidthey havehadskincontactwithacids.Allrespondantssaidtheywear assignedPPE.Withfewexceptions,respondantssaidtheywere familiarwithMSDSsandthattheyhadbeeninformedabout chemicalhazardsintheirworkplace.Otherconcernsmentionedto usbyseveralsurveyedworkersincludedemployeesnotfollowing LOTOrules;containersbeingunlabeledormislabeled;forklift operatorsdrivingtoofast;keroseneorgaspoweredheaters beingusedininadequatelyventilatedworkareas;enteringacid tankfarmswithoutpre-entryairtestingandwithouttrainingon


Results And disCussionthepotentialtankentryhazards;andremovingconduitfrom (Continued)acidbathswithoutdonningtheproperPPE.Someindividual employeesmentionedthatsmokewouldfillthefacilityduring maintenanceonthescrewfeedersonthehotdipkettles,andthat thespillwarninglightwasnotfunctioningonthehotdippit. Althoughwedidnotcheckthevalidityofallofthesecomments, weareprovidingthisinformationbecausesomeoftheseconcerns maywarrantmanagementattention.

Observations

DuringthisHHEweobservedthefollowingworkpracticesthat couldresultinseriousinjuriesand/orpropertydamage:

● Threeemployeeswereperformingrepair/maintenance workonamillbutonlyonelockwasusedto“lockout”and preventstart-upofthemillduringrepair.Eachemployee workingontheequipmentisrequiredtoplacealockonthe energysource[CFR1996].

● Wenotedthatthecontainmentdoorsonthezinckettlewere notalwaysloweredtopreventmoltenzincfromsplattering ontonearbyunprotectedworkers.

● Weobservedfluidswhichhadspilledontotheworkplace floor,increasingtheriskthatemployeesmaysliporfall.

● Wesawsomeforkliftoperatorsnotwearingtheirseatbelts, andseveraldriversappearedtobetravelingtoofastanddid notconsistentlyusetheforklifthorntosignalwhenthey werebackingup.

● Anemployeeusinga40-tonoverheadcranetomoveametal coilwasobservedstandingtooclosetotheload.Intheevent offailureorexcessiveswingoftheloadtheoperatorwould beatriskofinjury.

Page �0 Health Hazard Evaluation Report 2006-0332-3058

ConClusionsOurnoisedosimetryresultsindicatethatRepublicConduit workersareatriskofhearinglossfromexposuretohighnoise levelsintheproductionareas,andfromourreviewofhearing testrecords,someemployeeshavealreadyexperiencedhearing loss.Whileemployeesusedhearingprotection,someworeit improperly.Metalimpactwasthemainnoisesourcenearthemills, andimpulsenoiseproducedbythesteamcannonwasthemain noisesourcenearthehotdiparea.Earplugsalonecannotprovide adequateprotectionfromthehighimpulsenoiselevelsinthehot diparea.

Employeesworkingnearthemillsmaybeatriskofdeveloping respiratoryproblemsfromexposuretoMWFmist.Three employeeswereexposedtoairborneMWFconcentrationsator abovetheNIOSHREL.Onlyoneortwoofthefivemillswere operatingonthedayswesampledforMWFs,sothenumberof overexposedemployeesmayincreasewhenmoremillsoperate andtheproductionrateincreases.Workerswerenotoverexposed toairborneacidmist,metals,orCr(VI)duringtheNIOSH evaluation;however,overexposuretoacidscouldoccurwhen removingcomponentsordisconnectinglinesfromasystem containingconcentratedacid(linebreaking).

Wefoundthatrequiredorrecommendedproceduresfor severalhealthandsafetyprogramswerenotbeingfollowed,and employeeswereconcernedabouttheirhealthandsafety.For example,thewrittenconfinedspaceentryguidelinesdidnot addresshazardsassociatedwitheachconfinedspace,whilethe writtenrespiratoryprotectionprogramdidnotlistthetypeof respiratoryprotectionrequiredforeachhazardousoperation. RegardingtheLOTOprogram,wenotedthatnotallemployees hadplacedalocktoisolatetheenergysourcewhenworkingonthe samemachine.Finally,duringourinterviewsandsurvey,workers wereconcernedaboutreceivingemergencyresponsetrainingso theywouldbepreparedintheeventofanotheracidtankspill, inadequatePPE,lackoftimelinessinprovidingchemicalsuitsand respirators,poorventilationinacidroomsandzinckettleareas, lackoftrainingandidentificationofchemicalsusedintheplant, pooruseoflock-outprocedures,andlackofsafetylinesforthefall protectionprogram.


ReCommendAtionsWeencourageyoutoreviewthestandardsandpublications mentionedinourrecommendationsandconductaselfassessment toensureemployeesareadequatelyprotectedfromsafetyand healthhazards.Basedonourfindingsandobservationsduringthis evaluation,weofferthefollowingrecommendationstoimprove employeesafetyandhealth:

1. Improvetheexistinghearingconservationprogram.

a. Continuetorequirehearingprotectioninthe productionareas.Supervisorsshouldberesponsible andheldaccountableforensuringtheproperuse ofhearingprotectionintheirworkarea.Hearing protectionuseshouldalsoberequiredforoutside contractors.

b. DuetothehighpeaknoiselevelsandTWAnoise exposuresthatexceed100dBAforemployeesworking atthesteamcannonorashotdipoperators,require thattheyusedualhearingprotection(i.e.,the combinationofinsert-typeearplugsandearmuffs)while thesteamcannonisinoperation.

c. Implementahearinglosspreventionprogramfor allemployeesinjobtitlesthathavenoiseexposure levelsgreaterthantheNIOSHRELof85dBA.We recommendusingtheNIOSHRELfordetermining whichemployeestoincludeinahearingconservation program.RefertotheNIOSHdocument“Preventing OccupationalHearingLoss:APracticalGuide”for moredetailedinformation.Thisdocument(NIOSH publicationnumber96-110)isavailableontheNIOSH websiteat[http://www.cdc.gov/niosh/96-110.html].

d. Reviewandtrackhearinglossatallaudiometric testfrequencies.Specifically,NIOSHrecommends usingaconfirmed15-dBhearingthresholdshiftat anyfrequencytodeterminewhetheremployeeshave experiencedaSTS.

2. Implementnoisecontrolmeasurestoreduceimpactnoise. Consultwithanexperiencednoisecontrolengineerfor helpininvestigatingtheseandothernoisecontroloptions.

a. Reducethedistancethatmetalconduitrollsordrops beforestrikingotherconduit.

b. Decreasethespeedatwhichconduitrollsbefore strikingotherconduit.


ReCommendAtions (Continued) c. Addrubberornylondampingonthepick-upsonthe

E-Galvloaderarms.

d. Constructapartialenclosureorbarrieratthesteam cannontoreduceoperatornoiseexposure.

e. Increasethethicknessofthemetalstopplatesatthe endfinishertodampennoisecreatedwhenconduit strikestheplate.

f. Replacemetalpickupsontheendfinisherchain conveyorwithnylonpick-ups.

3. Enclosethemillsandinstalllocalexhaustventilationto reduceexposurestoMWFs.IftheconcentrationofMWFs isnotreducedbelowtheNIOSHRELthenworkersmust continueusingrespiratoryprotection.

4. Assesseachconfinedspace.Includeinthewritten proceduresaninventoryofallconfinedspaces,their location,associatedhazards(aircontaminantandphysical hazards),entryprocedures,PPErequired,LOTO/isolation requirements,atmospherictestingrequirements,and modeofentryandegress,includingemergencyegressin accordancewithOSHAStandard29CFR1910.146Permit-required Confined Spaces [Permit-requiredconfinedspaces -1910.146].AppendixDincludesalistofrecommendations toreducerisksassociatedwithconfinedspaceentry.We alsorecommendthatimplementingincidentresponse trainingforeveryemployeeintheplant,andcoordinate trainingandcommunicationwiththelocalemergency service.

5. Updatethewrittenrespiratoryprotectionprogramsothat itspecifieswhattypeofrespiratoryprotectionisrequired foreachhazardousoperationperformedatthefacility.The writtenprogramshouldincludeachange-outschedulefor cartridges.OSHA’sSmall Entity Compliance Guideprovides guidelinesforwhatisrequiredinthewrittenprogram. Thisguideisavailableonlineat[http://www.osha.gov/ Publications/secgrev-current.pdf].

6. UsesuppliedairrespiratorsoraSCBAforprotection againstconcentrationsofnitricacidthatexceedthe NIOSHRELunlesstherespiratormanufacturerspecifies thatthecartridgesprovideprotectionagainstnitricacid.

7. ProvideworkersasourceofGradeDairorSCBAsfor linebreaking.TheJSAwewereprovidedrequiredtheuse


ReCommendAtions (Continued) ofsuppliedairrespiratorsforlinebreakingbutasource

ofGradeDbreathingairwasnotavailableatthefacility duringourevaluation.

8. Useasupplied-airrespiratororSCBAwithafull-face mask,glovesandprotectiveclothingforlinebreaking untilitisdeterminedthroughairsamplingthatalower levelofrespiratoryprotectionisadequate.Butylrubber orneopreneglovesandSaranex,Barricade,orResponder suitsaresuitableforHCl(<37%)andnitricacid(<70%) [ForsbergandMansdorf2007].

9. Investigatewhydustaccumulatesinthethreadingarea.A particlecountercanbeusedtotraceleaksintheventilation systemandtoidentifythepointofdustgeneration.The clothsealsonwastedrumsinthebaghouseweretorn, allowingzincoxidedusttoescape.Thesesealsmustbe maintainedandreplacedwhennecessary.

10.Rinseoffchemicalprotectiveglovesandstorethemina cleanareawhennotinuse.

11. Implementtheserecommendationstoimproveemployee safety:

a. Operateforkliftsatasafespeed.

b. Usesafetybeltswhendrivingaforklift.

c. Useforklifthornswhenapproachingintersectionsand tosignalthattheforkliftisbackingup.

d. Cleanupfluidsthathavespilledontotheproduction floor.

e. Keepdoorsonthezinckettleloweredtoprevent splashingorsplatteringofmoltenzinc.

f. ReviewtheOSHALOTOStandard29CFR1910.147, Thecontrolofhazardousenergy(lockout/tagout).- 1910.147,toensurethatproceduresspecifiedbyOSHA arefollowed.

g. Instructcrewsofworkerswhoserviceormaintain equipmentthateachauthorizedemployeemustaffix apersonalLOTOdevicetothegrouplockoutdevice, grouplockbox,orcomparablemechanismwhenworkis started.TheLOTOdevicecanonlyberemovedwhen theauthorizedemployeestopsworkingonthemachine orequipmentbeingservicedormaintained[29CFR 1910.147(f)(3)(ii)(D)].


ReCommendAtions (Continued) h. Standatleastasfarawayfromaloadsuspendedby

anoverheadcraneasthedistanceofitsheightincase theloaddropsfromthecraneandtipsover.Theload shouldalsobekeptatthatsamedistanceawayfromany otheremployees.

i. Ensurethatalltoolrestsandtongueguardsonabrasive wheelgrindersaremaintainedattheappropriate distancefromthegrindingwheel.

j. Instructworkerstouseatooltomoveconduitandnot placetheirhandsbetweenpipes.

12.Encourageworkerswhoareexperiencingrespiratory problems,skinirritation,orotherhealthproblemsto reportexposurestheyfeelmaybework-relatedtothesite healthandsafetymanager.Becausethework-relatednessof certainhealthconcernsmaybedifficulttoestablish,each personwithpossiblework-relatedhealthproblemsneeds tobefullyevaluatedbyaphysician,preferablyonefamiliar withoccupationalmedicine.Acompleteevaluation includingafullmedicalandoccupationalhistory,a medicalexam,areviewofexposures,diagnostictestsif warranted,andcompletefollow-uptonotetheprogressof theaffectedworkershouldbeconductedasdeterminedby theattendingphysician.

13.Meetingswithemployeesandmanagementshouldbe convenedonaregularbasistoaddresshealthandsafety issues.Werecommendthatyouestablishahealthand safetycommitteetoaddressemployeehealthandsafety concerns.

RefeRenCesCFR[1993].29CFR1910.146,permitrequiredconfinedspaces. CodeofFederalRegulations.Washington,DC:U.S.Government PrintingOffice.

CFR[1996].29CFR1910.147.Thecontrolofhazardousenergy (lockout/tagout).CodeofFederalRegulations.Washington,DC: U.S.GovernmentPrintingOffice,OfficeoftheFederalRegister.

ForsbergK,MansdorfSZ[2007].Quickselectionguidetochemical protectiveclothing,5thed.Hoboken,NJ:Wiley-InterScience.


RefeRenCes (Continued) KardousCA,WillsonRD[2004].Limitationsofusingdosimeters inimpulsenoiseenvironments.JOccupEnvironHyg1(7):456-462.

NIOSH[1981].Occupationalhealthguidelinesfornitricacid; chromicacidandchromates;hydrogenchloride;andsulfuric acid.Cincinnati,OH:U.S.DepartmentofHealth,Education, andWelfare,PublicHealthService,CenterforDiseaseControl, NationalInstituteforOccupationalSafetyandHealth,DHHS (NIOSH)PublicationNo.81-123.

NIOSH[1988].Criteriaforarecommendedstandard: Occupationalexposuretowelding,brazingandthermalcutting. Cincinnati,OH:U.S.DepartmentofHealthandHumanServices, PublicHealthService,CentersforDiseaseControl;National InstituteforOccupationalSafetyandHealth,DHHS(NIOSH) PublicationNo.88-110.

NIOSH[2005].NIOSHpocketguidetochemicalhazards. Cincinnati,OH:U.S.DepartmentofHealthandHumanServices, PublicHealthService,CentersforDiseaseControl,National InstituteforOccupationalSafetyandHealth,DHHS(NIOSH) PublicationNo.2005-149.


Appendix A: tABles

TableA1:PBZAirSamplingResultsforMWFs(March6-7,2007) Concentrationmg/m3

Department JobTitle SampleTime TotalThoracic Minutes ParticulateMassa ExtractedMWF

Maintenance Maintenance Maintenance

Maintenance Maintenance Maintenance Maintenance Maintenance Maintenance

418 0.37 0.18 469 0.28 0.16 441 0.30 0.16 475 0.29 0.17 431 0.31 0.16 445 0.17 NDb

464 0.22 0.22 425 0.23 ND

BanderBanderBanderBanderEndFinisherEndFinisher

Welding EndFinisher EndWelder MaterialsHandler MaterialsHandler MillOperator MillOperator Utility

NIOSHREL-TWA

430 0.33 0.22 463 0.31 0.19 490 0.38 0.26 431 0.30 0.21 159 0.23 ND 469 0.40 0.35 434 0.23 0.15 367 0.24 0.15 496 0.25 0.11 447 0.22 0.16 599 0.50 0.32 561 0.40 0.24 489 0.34 0.22

0.40 a TheNIOSHREL-TWAforMWFaerosolsof0.4mg/m3ofairisbasedonthetotalthoracicparticulatesand nottheextractablefractionofMWF.Thetotalparticulatesincludesalldustandotheraerosolsintheair(such asweldingfumes)inadditiontotheMWFs.Theextractablefractionrepresentstheportionofthesamplethat wasMWFs. b ND=notdetected(belowtheminimumdetectableconcentration).


Appendix A: tABles (Continued)

TableA2:AirsamplingResultsforAcids(March6-7,2007)

Sample Concentrationmg/m3

Department Job Title Time Sulfuric (Minutes) HCl NitricAcid Acid

Extractor Laborer

HotDip Laborer Operator Operator

Laboratory LabTech LabTech

PBZAirSamples 440 NDa 0.025 ND 356 0.054 Trace

Pumpfailed 308 0.29 Traceb Trace 497 ND 0.025 Trace 460 ND Trace Trace 431 ND 0.032 Trace

GalvanizingLine

Operator Operator Operator Operator Operator Operator Operator Operator

498 625 620 607 523 640 649 456

ND ND ND ND ND ND ND ND

0.054 0.052 0.032 Trace Trace ND

Trace Trace

Trace Trace Trace Trace Trace Trace Trace Trace

Maintenance Maintenance 426

Pump failed ND ND ND

Maintenance 420 ND 0.038 Trace Maintenance 441 ND 0.028 ND

Maintenance Maintenance 405 ND Trace ND Maintenance 445 ND Trace Trace

AreaAirsamples HotDip HClEnclosure 15 ND ND ND HotDip HClEnclosure 21 3.1 ND ND NIOSHREL-TWA 5 1 NIOSHREL-C 7 NIOSHSTEL 10 OSHAPEL-TWA 1 OSHAPEL-C 7 5 MDCc 0.068 0.0075 0.015 MQCd 0.23 0.024 0.20 a ND=notdetected(belowtheMDC).b Trace=resultwasbetweentheMDCandMQC.c MDC=Minimumdetectableconcentrationcalculatedbydividingthemethodlimitofdetectionbythehighestsamplevolumecollected(0.133m3).d MQC=Minimumquantifiableconcentrationcalculatedbydividingthemethodlimitofquantificationbythe highestsamplevolumecollected(0.133m3).



TableA3:PBZAirsamplingResultsforCr(VI)onPVCFilters(March6-7,2007)

Department JobTitle SampleTime Concentrationµg/m3

(Minutes)

Welding MillOperator Welding MillOperator Welding MillOperator

500 Tracea

500 Trace 505

Welding MillOperator Welding EndFinisher

0.026 562 Trace 429

Welding EndFinisher Welding EndWelder Welding EndWelder NIOSHREL-TWA OSHAPEL-TWA OSHAAL MDCb

MQCc

0.040 556 0.026 615 Trace 558 Trace

1 5

2.5 0.0066 0.023

a Trace=SampleresultwasbetweentheMDCandMQC. b MDC=Minimumdetectableconcentrationcalculatedbydividingthemethodlimitof detectionbythehighestsamplevolumecollected(1.2m3). c MQC=Minimumquantifiableconcentrationcalculatedbydividingthemethodlimitof quantificationbythehighestsamplevolumecollected(1.2m3).



TableA4:PBZAirsamplingResultsforCr(VI)onQuartzFilters(March6-7,2007)

Department JobTitle SampleTime (Minutes) Concentrationmg/m3

HotDip Extractor 438 Tracea

HotDip HotDip

Extractor Extractor

415 474

0.047 NDb

HotDip Operator 509 0.071 HotDip Operator 496 0.039 HotDip Laborer 435 0.051 HotDip Laborer 443 Trace Maintenance Maintenance 468 ND Maintenance Maintenance 476 ND Galvanizing Operator 607 ND Galvanizing Operator 646 Trace Galvanizing Operator 636 Trace Galvanizing Operator 616 Trace Galvanizing SprayMachineOperator 498 Trace Galvanizing SprayMachineOperator 639 Trace NIOSHREL-TWA 1 OSHAPEL-TWA 5 OSHAAL 2.5 MDCc 0.0077 MQCd 0.038 a Trace=SampleresultwasbetweentheMDCandMQC. b ND=notdetected(belowtheMDC). c MDC=Minimumdetectableconcentrationcalculatedbydividingthemethodlimitofdetectionbythe highestsamplevolumecollected(1.3m3). d MQC=Minimumquantifiableconcentrationcalculatedbydividingthemethodlimitofquantificationbythe highestsamplevolumecollected(1.3m3).



TableA5:AirSamplingResultsforElementsfromWeldingFumes(March6-7,2007)

Sample Type

Department JobTitle Sample

Time (minutes) Cu Fe

Concentrationµg/m3

Mn Sr Ti Zn

Welding MillOperator MillOperator

500 505

4.8 NDa

11 63

0.65 0.45

0.016 0.012

0.059 0.038

23 15

Utility 428 5.8 380 5.2 0.071 0.44 27 Utility 489 ND 140 1.2 0.078 0.13 19 EndWelder 559 0.37 180 0.88 0.040 0.24 17 EndWelder 611 0.82 220 1.2 0.030 0.15 21 EndWelder 474 0.28 67 1.2 0.013 0.088 7.7

PBZb WeldingExtras 562 0.22 87 0.48 0.011 0.048 11 WeldingExtras 557 0.87 10 0.64 0.013 0.091 27

Threading Packaging Operator 391 ND 19 0.16 ND 0.027 250

Inspector 398 ND 56 9.3 0.022 0.51 160 Packaging Operator 441 0.47 19 1.1 ND 0.048 130

HotDip Laborer 415 ND 23 0.34 0.020 0.093 580

GAc Welding MillLine4 MillLine5

502 229

0.42 220 1.4 0.022 Pumpfailed

0.059 17

Threading NIOSHREL-TWA

Remetalizer 455 ND 1000

23 5000

0.53 1000

0.78 0.099 LFCd

1450 5000

OSHAPEL-TWA 1000 10000 15000e 5000 OSHAPEL-Ceiling ACGIHTLV

5000 200 0.50f

a ND=notdetected(belowtheminimumdetectableconcentrationsforcopperandstrontiumof0.16and0.0082µg/m3

respectively).bPBZ=personalbreathingzoneairsample.c GA=generalareaairsample.d LFC=Lowestfeasibleconcentration.e TheOELindicatedisfortitaniumdioxide.Thelaboratoryresultswerereportedastitanium.f TheOELindicatedisforstrontiumchromate.Thelaboratoryresultswerereportedasstrontium.Comments:(1)Cu=copper;Fe=iron;Mn=manganese;Sr=strontium;Ti=titanium;Zn=zinc.(2)Thefollowingelementswerenotdetectedinanyoftheairsamples:beryllium,lead,lithium,selenium,tellurium,thalium;tin,yttrium,andzirconium.(3)Thefollowingelementsweredetected,butatconcentrationswhichwere100times(ormore)belowtheirrespectiveOELs:cadmium,chromium,cobalt,magnesium,molybdenum,silver,andvanadium.(4)Oneareasamplecollectedbymill4contained0.6µgofnickel,whichis25timeslessthantheNIOSHRELof15µg/m3.



TableA6:PersonalNoiseDosimetryResults(March6-7,2007)

Department JobTitle SampleTime (minutes)

OSHAAL Dose dBA

OSHAPEL Dose dBA

NIOSHREL Dose dBA

Galvanizing Bundler 627 113.3% 90.9 97.3% 89.8 961.5% 94.8 Galvanizing Bundler 632 90.8% 89.3 73.7% 87.8 620.0% 92.9 HotDip HotDipExtractor 416 217.3% 95.6 191.9% 94.7 5961.1% 102.7 HotDip HotDipExtractor 474 160.2% 93.4 131.9% 92.0 2536.4% 99.0 HotDip HotDipOperator 432 205.6% 95.2 176.5% 94.1 4215.7% 101.2 HotDip HotDipLaborer 265 90.8% 89.3 45.4% 84.3 649.3% 93.1 HotDip HotDipLoader 611 66.9% 87.1 51.4% 85.2 356.2% 90.5 HotDip HotDipLoader 662 123.1% 91.5 116.5% 91.1 837.1% 94.2 Maintenance Maintenance 477 54.3% 85.6 39.0% 83.2 399.8% 91.0 Maintenance Maintenance 475 19.8% 78.3 8.5% 72.2 93.3% 84.7 Maintenance Maintenance 476 95.9% 89.7 79.0% 88.3 1491.1% 96.7 Maintenance Maintenance 464 28.7% 81.0 13.4% 75.5 109.7% 85.4 Shipping MaterialHandler 496 61.6% 86.5 33.4% 82.1 282.7% 89.5 Shipping MaterialHandler 628 72.7% 87.7 46.7% 84.5 565.3% 92.5 Shipping MaterialHandler 408 77.9% 88.2 49.3% 84.9 448.7% 91.5 Shipping MaterialHandler 448 55.1% 85.7 30.8% 81.5 214.3% 88.3 Shipping MaterialHandler 453 60.7% 86.4 39.0% 83.2 356.2% 90.5 Shipping MaterialHandler 448 63.3% 86.7 43.5% 84.0 303.0% 89.8 Threading PackagingOperator 400 73.7% 87.8 39.5% 83.3 876.7% 94.4 Threading PackagingOperator 448 48.0% 84.7 23.7% 79.6 170.1% 87.3 Threading SawOperator 357 104.2% 90.3 77.9% 88.2 552.4% 92.4 Threading SawOperator 383 77.9% 88.2 57.4% 86.0 418.7% 91.2 Threading ThreaderOperator 401 87.1% 89.0 60.7% 86.4 356.2% 90.5 Threading ThreaderOperator 446 72.7% 87.7 59.9% 86.3 373.0% 90.7 Threading ThreadingInspector 398 58.2% 86.1 38.4% 83.1 303.0% 89.8 Welding Bander 430 84.7% 88.8 69.7% 87.4 620.0% 92.9 Welding Bander 465 83.5% 88.7 67.8% 87.2 578.5% 92.6 Welding Bander 431 211.4% 95.4 197.2% 94.9 1635.5% 97.1 Welding Bander 490 113.3% 90.9 92.0% 89.4 745.8% 93.7 Welding EndFinisher 163 41.2% 83.6 16.7% 77.1 148.1% 86.7 Welding EndFinisher 469 155.8% 93.2 141.4% 92.5 1712.8% 97.3 Welding EndFinisher 382 52.1% 85.3 33.0% 82.0 276.3% 89.4 Welding MillOperator 654 69.7% 87.4 39.0% 83.2 317.3% 90.0 Welding MillOperator 561 44.8% 84.2 16.3% 76.9 155.1% 86.9 Welding Utility 429 15.0% 76.3 59.9% 86.3 46.7% 81.7 NoiseExposureLimits 50% 85 100% 90 100% 85


Appendix B: metHods

AirsamplesforMWFs,metals,andCr(VI)werecollectedusingSKCAirCheck®2000airsampling pumpswithasamplingtrainconsistingofTygon®tubingconnectedtotheinletportofthepumpandthe samplemedia.Foracids,lowflowSKCPocketPumps®wereused.Eachpumpwascalibratedbeforeand afteruse.Thesamplingmediawasattachedtotheemployee’slapelwithinthebreathingzone(breathing zoneisdefinedasanareainfrontoftheshoulderswitharadiusof6to9inches).Thespecificanalytical methods,flowrates,andsamplemediausedarediscussedbelow.

Metalworking Fluid Air Samples

NIOSHinvestigatorscollected21PBZairsamplesforMWFsusing37-mmclosed-facedthree-piece cassettescontainingatared2-µmpore-sizePTFEfilterandthesupportingpadandasamplingrateof1.6 Lpm.Thesamplingtrainconsistedofacassette,aBGIthoraciccyclone,andTygontubingconnectingthe samplingassemblytoapersonalpump.Thesampleswereanalyzedbygravimetricanalysisforthethoracic fractionofMWFparticulatesperNIOSHMethod5524[NIOSH2006].

Hexavalent Chromium

NIOSHinvestigatorscollected23full-shiftPBZairsamplesforCr(VI)on37-mmdiameter,5.0-µmpore sizePVCorquartzfiltersataflowrateof2Lpm.Wheretherewasapotentialforthepresenceofacid mist,quartzfilterswereusedtopreventreductionoftheCr(VI)totrivalentchromium[Ashleyetal. 2003].ThesampleswereanalyzedforCr(VI)byionchromatographywithpost-columnderivatizationand ultravioletdetectionperNIOSHMethod7605[NIOSH2006].

Acids

NIOSHinvestigatorscollected21full-shiftPBZand2short-term(15-minutes)GAairsamplesforacid mistsonsilicageltubesataflowrateof0.2Lpm.Thesampleswereanalyzedforhydrochloricacid,nitric acid,andsulfuricacidusingionchromatographyperNIOSHMethod7903[NIOSH2006].

Metals/Elements

NIOSHinvestigatorscollected12PBZand4GAfull-shiftairsampleson37-mmdiametercassetteswith 0.8-µmporesizemixedcelluloseesterfiltersataflowrateof2.0Lpm.Thesampleswereanalyzedusing inductivelycoupledargonplasma-atomicemissionspectroscopyperNMAMMethod7300[NIOSH2006].

Noise

NIOSHinvestigatorscollected35full-shift,personalnoiseexposuremeasurementswhileworkers performedtypicaldailyactivities.QuestTechnologies(Oconomowoc,Wisconsin)NoisePro®series


Appendix B: metHods (Continued)

dosimeterswereusedtomeasurepersonalnoiseexposure.Thenoisedosimeterswereattachedtothe wearer’sbeltorpocket,andasmallremotemicrophonewasfastenedtothewearer’sshirtatapoint midwaybetweentheearandtheoutsideoftheshoulder.Asmallwindscreenprovidedbythedosimeter manufacturerwasplacedoverthemicrophoneduringmeasurementstoreduceoreliminateartifactnoise generatedbyanobjectbumpingagainstthemicrophoneorwindblowingacrossthemicrophone.The dosimeterswereremoveduponcompletionoftheworkshift.

Real-timenoisemeasurementswerecollectedatseveralworkstationsorpiecesofequipmentusingaQuest TechnologiesSoundPro®ModelSE/DLsoundlevelmeter.Theinstrumentwasequippedwitha0.5-inch free-fieldType2electretmicrophone.Themicrophonehasafrequencyresponserange(±2dB)from20 Hertzto17kilohertz.

Noisemeasurementdatacollectedusingdosimetersandsoundlevelmetersweredownloadedtoa personalcomputerforinterpretationwithQuestSuite®ProfessionalIIforWindows®computersoftware. Allnoisemonitoringequipmentwerecalibratedbeforeandafteruseaccordingtothemanufacturer’s instructions.

References

AshleyK,HoweAM,DemangeM,NygrenO[2003].Samplingandanalysisconsiderationsforthe determinationofCr(VI)inworkplaceair.JEnvironMonit5(5):707–716.

BergerEH,RoysterLH,RoysterJD,DriscollDP,LayneM,eds.[2003].Thenoisemanual.5threv.ed. Fairfax,VA:AmericanIndustrialHygieneAssociation.

NIOSH[2006].NIOSHmanualofanalyticalmethods(NMAM®).4thed.SchlechtPC,O’ConnorPF, eds.Cincinnati,OH:U.S.DepartmentofHealthandHumanServices,PublicHealthService,Centersfor DiseaseControlandPrevention,NationalInstituteforOccupationalSafetyandHealth,DHHS(NIOSH) Publication94–113(August,1994);1stSupplementPublication96–135,2ndSupplementPublication 98–119;3rdSupplement2003–154.[http://www.cdc.gov/niosh/nmam/].


Appendix C: oCCupAtionAl exposuRe limits And HeAltH effeCts

Inevaluatingthehazardsposedbyworkplaceexposures,NIOSHinvestigatorsusebothmandatory(legally enforceable)andrecommendedOELsforchemical,physical,andbiologicalagentsasaguideformaking recommendations.OELshavebeendevelopedbyFederalagenciesandsafetyandhealthorganizations topreventtheoccurrenceofadversehealtheffectsfromworkplaceexposures.Generally,OELssuggest levelsofexposuretowhichmostworkersmaybeexposedupto10hoursperday,40hoursperweekfor aworkinglifetimewithoutexperiencingadversehealtheffects.However,notallworkerswillbeprotected fromadversehealtheffectseveniftheirexposuresaremaintainedbelowtheselevels.Asmallpercentage mayexperienceadversehealtheffectsbecauseofindividualsusceptibility,apre-existingmedicalcondition, and/orahypersensitivity(allergy).Inaddition,somehazardoussubstancesmayactincombinationwith otherworkplaceexposures,thegeneralenvironment,orwithmedicationsorpersonalhabitsoftheworker toproducehealtheffectseveniftheoccupationalexposuresarecontrolledatthelevelsetbytheexposure limit.Also,somesubstancescanbeabsorbedbydirectcontactwiththeskinandmucousmembranesin additiontobeinginhaled,whichcontributestotheindividual’soverallexposure.

MostOELsareexpressedasaTWAexposure.ATWAreferstotheaverageexposureduringanormal 8-to10-hourworkday.SomechemicalsubstancesandphysicalagentshaverecommendedSTELorceiling valueswheretherearehealtheffectsfromexposuresovertheshort-term.Unlessotherwisenoted,the STELisa15-minuteTWAexposurethatshouldnotbeexceededatanytimeduringaworkday,andthe ceilinglimitisanexposurethatshouldnotbeexceededatanytime. IntheU.S.,OELshavebeenestablishedbyFederalagencies,professionalorganizations,stateand localgovernments,andotherentities.SomeOELsarelegallyenforceablelimits,whileothersare recommendations.TheU.S.DepartmentofLaborOSHAPELs(29CFR1910[generalindustry];29 CFR1926[constructionindustry];and29CFR1917[maritimeindustry])arelegallimitsenforceablein workplacescoveredundertheOccupationalSafetyandHealthAct.NIOSHRELsarerecommendations basedonacriticalreviewofthescientificandtechnicalinformationavailableonagivenhazardandthe adequacyofmethodstoidentifyandcontrolthehazard.NIOSHRELscanbefoundintheNIOSH Pocket Guide to Chemical Hazards[NIOSH2005].NIOSHalsorecommendsdifferenttypesofriskmanagement practices(e.g.,engineeringcontrols,safeworkpractices,workereducation/training,personalprotective equipment,andexposureandmedicalmonitoring)tominimizetheriskofexposureandadversehealth effectsfromthesehazards.OtherOELsthatarecommonlyusedandcitedintheU.S.includetheTLVs recommendedbyACGIH,aprofessionalorganization,andtheWEELsrecommendedbytheAmerican IndustrialHygieneAssociation,anotherprofessionalorganization.ACGIHTLVsareconsideredvoluntary exposureguidelinesforusebyindustrialhygienistsandotherstrainedinthisdiscipline“toassistinthe controlofhealthhazards”[ACGIH2007].WEELshavebeenestablishedforsomechemicals“whenno otherlegalorauthoritativelimitsexist”[AIHA2007].

EmployersshouldunderstandthatnotallhazardouschemicalshavespecificOSHAPELs,andforsome agentsthelegallyenforceableandrecommendedlimitsmaynotreflectcurrenthealth-basedinformation. However,anemployerisstillrequiredbyOSHAtoprotectitsemployeesfromhazardsevenintheabsence ofaspecificOSHAPEL.OSHArequiresanemployertofurnishemployeesaplaceofemploymentfree fromrecognizedhazardsthatcauseorarelikelytocausedeathorseriousphysicalharm[Occupational


Appendix C: oCCupAtionAl exposuRe limits And HeAltH effeCts (Continued)

SafetyandHealthActof1970,PublicLaw91–596,sec.5(a)(1)].Thus,NIOSHinvestigatorsencourage employerstouseotherOELswhenmakingriskassessmentandriskmanagementdecisionstobestprotect thehealthoftheiremployees.NIOSHinvestigatorsalsoencouragetheuseofthetraditionalhierarchy ofcontrolsapproachtoeliminateorminimizeidentifiedworkplacehazards.Thisincludes,inorderof preference,theuseof:(1)substitutionoreliminationofthehazardousagent,(2)engineeringcontrols(e.g., localexhaustventilation,processenclosure,dilutionventilation),(3)administrativecontrols(e.g.,limiting timeofexposure,employeetraining,workpracticechanges,medicalsurveillance),and(4)personal protectiveequipment(e.g.,respiratoryprotection,gloves,eyeprotection,hearingprotection).

Metalworking Fluids

Metalremovalprocessesgenerateagreatdealofheat.MWFsareusedduringgrinding,cutting,or boringofmetalpartstocoolandlubricatethecuttingtoolsandthemetalparts.TheMWFalsoprovides corrosionprotectionforthemachinedparts,preventssmoking,andincreasesthelifeofthecuttingtools. MWFshelpremovechipsandfinemetalandabrasiveparticlesfromthecuttingzone.TheMWFmay containamixtureofsubstancesincludingbiocides,corrosioninhibitors,metalfines,trampoils,bacteria, andotherbiologicalcontaminants[NIOSH1998b].

ExposuretoMWFcanresultfrominhalationoftheMWFaerosols,orfromskincontactwiththefluids duetosettlingofaerosols,contactwithpartsandequipment,andsplashing.MWFmaycauseemployees toexperiencerespiratoryproblemsiftheairborneconcentrationisabovetheNIOSHRELs;some employeesmayexperiencehealtheffectsatconcentrationsbelowtheselimits[NIOSH1998b].Inhalation ofMWFmistoraerosolsmaycauseirritationofthethroat,nose,andlungsresultinginsymptomssuch assorethroat,eyeirritation,runnynose,nosebleeds,cough,wheezing,increasedphlegmproduction,and shortnessofbreath.ExposuretoMWFhasalsobeenassociatedwithasthma,andsmokingmayworsenthe respiratoryeffectsofMWFaerosols.Addingexcessiveamountsofbiocidestocuttingfluidsmaycauseskin and/orrespiratoryirritation.

Syntheticandsemi-syntheticMWFsaredilutedwithwater.Hencetheycanbeabreedinggroundfor bacteriaifaninadequateamountofbiocideisadded.HightemperatureandpH,andthepresenceof metalscanfavorbacterialgrowth.Levelsofmicrobialcontaminationareanindicationofthecleanliness ordegreeofmaintenanceoftheMWF.However,addingtoomuchbiocidemayresultinbiocide-resistant strainsofbacteria.InhalationofMWFaerosolscontainingbacteriamayresultinrespiratoryproblems. WorkerswithbrokenskinmaydevelopskininfectionsiftheyhavecontactwithMWFcontaminatedwith bacteria.WhencontaminatedMWFisreplaced,someofthebacteriamayremainandproliferatewithin ashortperiodifthesystemisnotadequatelycleaned.Atthistimethereisinsufficienthealthdatato recommendaspecificlimitforbacterialorfungalcontaminationinMWFs.

NIOSHrecommendslimitingexposurestoMWFaerosolsto0.4mg/m3ofairforthethoracicparticulate massor0.5mg/m3forthetotalparticulatemass,asaTWAconcentrationforupto10hoursperday duringa40-hourworkweek.TheRELisintendedtopreventorgreatlyreducerespiratorydisorders



associatedwithMWFexposure.Thesamplingmethodusedforthisevaluationallowstheextractionof MWFfromtotalthoracicparticulates.NIOSHconsideredproposinganRELbasedontheextractable fractionofMWF;however,thereiscurrentlyinsufficientscientificevidencethatextractableMWFis superiortothoracicparticulateaerosolsasapredictorofadversehealtheffectsfromMWF[NIOSH 1998b].Someworkershavedevelopedwork-relatedasthma,Hypersensitivitypneumonitis,orother adverserespiratoryeffectswhenexposedtoMWFsatconcentrationsbelowtheNIOSHREL.Limiting exposuretoMWFaerosolsisalsoprudentbecausecertainMWFexposureshavebeenassociatedwith variouscancers.Inaddition,limitingdermal(skin)exposureiscriticaltopreventingallergicandirritant disordersrelatedtoMWFexposure.Inmostmetalworkingoperations,itistechnologicallyfeasibleto limitMWFaerosolexposuresto0.4mg/m3orless[NIOSH1998b].NIOSHalsorecommendsmedical monitoringforemployeesexposedtoMWF[NIOSH1998b].Medicalmonitoringisneededfortheearly identificationofworkerswhodevelopsymptomsofMWF-relatedconditionssuchashypersensitivity pneumonitis,asthma,anddermatitis.AllworkersexposedtoMWFaerosolconcentrationsabovea designatedlevel(e.g.,halftheREL)shouldbeincluded.NIOSHpublication98-102Criteriafora RecommendedStandard,OccupationalExposuretoMetalworkingFluids,providesguidelinesfor administeringamedicalmonitoringprogram[NIOSH1998b].

Inorganic Acids

Acidsareprimaryirritantsoftheskinandmucousmembranes.Inhalationofacidmistgenerallycauses immediatesymptomsduetohighsolubilityinmucousmembranes[LaDou1990].HCl,nitricacid,and sulfuricacidhavegoodwarningpropertiesduetotheirirritatingeffectsandlowodorthresholds.Ina workernotificationnoticetosteelworkersNIOSHreportedthatexposuretoacidmistmayincrease theriskoflarynxandlungcancer[NIOSH1991].Aswithotherchemicalshealtheffectsdependonthe concentrationoftheacid,airborneconcentration,workprocess,existingcontrols,anduseofPPE.

HClisirritatingtotheeyes,mucousmembranes,andskin[ATSDR2002].Themajoreffectsofacute exposureareusuallylimitedtotheupperrespiratorytractandaresufficientlyseveretoencourageprompt withdrawalfromacontaminatedatmosphere.Severalstudiessuggestthisprotectiveresponseisso strongthathumanshaverarelybeensubmittedtodamagingconcentrations[Grant1986;Stevensetal.]. InhalationexposureofmalevolunteerstoHClatconcentrationsbetween50and100ppmforonehour werereportedasbarelytolerable,and10ppmwasthemaximalconcentrationacceptableforprolonged exposure[HendersonandHaggard1943].Acuteexposurescausingsignificanttraumaareusuallylimited topeoplewhoarepreventedfromescaping;insuchcases,laryngealspasmorpulmonaryedemamay occur.Highconcentrationsofthegascauseeyeirritationandmaycauseprolongedorpermanentvisual impairment.Exposureoftheskintoahighconcentrationofthegasortoaconcentratedsolutionofthe acidwillcauseburns;repeatedorprolongedexposuretodilutesolutionsmaycausedermatitis.Erosion oftheexposedteethmayoccurfromrepeatedorprolongedexposure[NIOSH1981;Proctoretal.1996]. BoththeOSHAPELandtheNIOSHRELforHClare7mg/m3fora15-minuteceilingexposure[CFR 2006a;NIOSH1988,2005].



Nitricacidisacolorless,yellow,orredfumingliquidwithasuffocatingodor[NIOSH2005].Nitricacid isacorrosiveliquidthatseverelyirritatestheskinandeyesuponcontact.Nitricacidmistcanirritatethe nose,throat,andlungsandcausedentalerosion.Lungirritationcausescoughingand/orshortnessof breath,andexposuretohighconcentrationscancausepulmonaryedema(abuild-upoffluidinthelungs). Ingestionofnitricacidwillresultinseverethroatandstomachdestruction.NIOSHandOSHAhaveset TWAexposurelimitsfornitricacidat5mg/m3[NIOSH2005].NIOSHandACGIHalsohavesetSTELs at10mg/m3forthissubstance[NIOSH2005,ACGIH2007].

Sulfuricacidisasevereirritanttotheeyes,mucousmembranes,andskin.Concentratedsulfuric acidisacorrosive,whichcancausesevereburnsoncontactandeventuallyresultintissuescarring. Sulfuricacidmistscancauseeye,nose,andthroatirritation;respiratoryirritation(suchascoughand bronchoconstriction);anddentalerosion.Theextentofrespiratoryirritationdependsonfactorssuchas airconcentration,particlesize,temperature,andhumidity[NIOSH1974].Anumberofepidemiologic studieshaveindicatedthatexposuretosulfuricacidmistandotheracidmistsareassociatedwithcancer. Afterreviewofthesestudies,theInternationalAgencyforResearchonCancerdeterminedthatthere issufficientevidencethatoccupationalexposuretostronginorganicacidmistscontainingsulfuricacid iscarcinogenic[Ahlborgetal.1981;Soskolneetal.1984;1992].NIOSHandOSHAhaveestablished evaluationcriteriaforsulfuricacidat1mg/m3asaTWAtopreventdentalerosionandtheirritanteffects ofexposure[NIOSH1992,2005].

Hexavalent Chromium

Cr(VI)compoundsincludeleadchromateandzincchromatepigments,chromicacid,andsoluble compoundssuchasthoseusedinchromiumplating.SomeCr(VI)compoundsaresevereirritantsof therespiratorytractandskin,andsome(includingchromates)havebeenfoundtocauselungcancer inexposedworkers[HathwayandProctor2004].Allergicdermatitisisoneofthemostcommoneffects ofchromiumtoxicityamongexposedworkers.Cr(VI)iscorrosiveandcauseschroniculcerationand perforationofthenasalseptum[IARC1997].Cr(VI)readilypenetratescellmembranesandonceinside thecellitisreducedtoCr(III).OnceinsideacellCr(III)hasthecapacitytocauseDNAdamage.NIOSH hasidentifiedCr(VI)asapotentialoccupationalcarcinogen.TheNIOSHRELforanupto10-hour TWAexposuretoairborneCr(VI)is1.0µg/m3[NIOSH2005].Ingeneralindustry,Cr(VI) is regulated by OSHA standard CFR 1910.1026. TheOSHAPELforCr(VI)is5µg/m3,andtheALis2.5µg/ m3calculatedasan8-hourTWA.ExceedingtheALtriggerscertainrequirementssuchasperiodicsampling andmedicalsurveillance[CFR2006b].NIOSH considers all Cr(VI) compounds (including chromic acid) to be potential occupational carcinogens.

Noise

Noise-inducedlossofhearingisanirreversible,sensorineuralconditionthatprogresseswithexposure. Althoughhearingabilitydeclineswithage(presbycusis)inallpopulations,exposuretonoiseproduces hearinglossgreaterthanthatresultingfromthenaturalagingprocess.Thisnoise-inducedlossiscaused



bydamagetonervecellsoftheinnerear(cochlea)and,unlikesomeconductivehearingdisorders,cannot betreatedmedically[Bergeretal.2003].Whilelossofhearingmayresultfromasingleexposuretoa verybriefimpulsenoiseorexplosion,suchtraumaticlossesarerare.Inmostcases,noise-inducedhearing lossisinsidious.Typically,itbeginstodevelopat4000or6000Hz(thehearingrangeis20Hzto20000 Hz)andspreadstolowerandhigherfrequencies.Often,materialimpairmenthasoccurredbeforethe conditionisclearlyrecognized.Suchimpairmentisusuallysevereenoughtopermanentlyaffectaperson’s abilitytohearandunderstandspeechundereverydayconditions.Althoughtheprimaryfrequenciesof humanspeechrangefrom200Hzto2000Hz,researchhasshownthattheconsonantsounds,which enablepeopletodistinguishwordssuchas“fish”from“fist,”havestillhigherfrequencycomponents [Suter1978].

ThedBAisthepreferredunitformeasuringsoundlevelstoassessworkernoiseexposures.ThedBAscale isweightedtoapproximatethesensoryresponseofthehumaneartosoundfrequenciesnearthethreshold ofhearing.Thedecibelunitisdimensionless,andrepresentsthelogarithmicrelationshipofthemeasured soundpressureleveltoanarbitraryreferencesoundpressure(20micropascals,thenormalthreshold ofhumanhearingatafrequencyof1000Hz).Decibelunitsareusedbecauseoftheverylargerangeof soundpressurelevelsaudibletothehumanear.BecausethedBAscaleislogarithmic,increasesof3dBA, 10dBA,and20dBArepresentadoubling,tenfoldincrease,andhundredfoldincreaseofsoundenergy, respectively.Noiseexposuresexpressedindecibelscannotbeaveragedbytakingthesimplearithmetic mean.

TheOSHAstandardforoccupationalexposuretonoise(29CFR1910.95)[CFR2003]specifiesa maximumPELof90dBAforadurationof8hoursperday.Theregulation,incalculatingthePEL,uses a5dBtime/intensitytradingrelationship,orexchangerate.Thismeansthatapersonmaybeexposedto noiselevelsof95dBAfornomorethan4hours,to100dBAfor2hours,etc.Conversely,upto16hours exposureto85dBAisallowedbythisexchangerate.Thedurationandsoundlevelintensitiescanbe combinedinordertocalculateaworker’sdailynoisedoseaccordingtotheformula:

Dose=100X(C1/T1+C2/T2+...+Cn/Tn),

whereCnindicatesthetotaltimeofexposureataspecificnoiselevelandTnindicatesthereference durationforthatlevelasgiveninTableG-16aoftheOSHAnoiseregulation.Duringany24-hourperiod, aworkerisallowedupto100%ofthedailynoisedose.Dosesgreaterthan100%areinexcessofthe OSHAPEL.

TheOSHAregulationhasanadditionalALof85dBA;anemployershalladministeracontinuing, effectivehearingconservationprogramwhenthe8-hourTWAvalueexceedstheAL.Theprogrammust includemonitoring,employeenotification,observation,audiometrictesting,hearingprotectors,training, andrecordkeeping.Alloftheserequirementsareincludedin29CFR1910.95,paragraphs(c)through (o).Finally,theOSHAnoisestandardstatesthatwhenworkersareexposedtonoiselevelsinexcessofthe OSHAPELof90dBA,feasibleengineeringoradministrativecontrolsshallbeimplementedtoreducethe workers’exposurelevels.



NIOSH[NIOSH1998c]andACGIH[ACGIH2007]recommendanexposurecriteriaof85dBAasa TWAfor8hours,whichis5dBlessthantheOSHAstandard.Thecriteriaalsouseamoreconservative 3dBtime/intensitytradingrelationshipincalculatingexposurelimits.The3-dBexchangerateusedby NIOSHassumesthatequalamountsofsoundenergywillproduceequalamountsofhearingimpairment regardlessofhowthesoundenergyisdistributedintime[Driscoll2000].UsingNIOSHcriteria,aworker canbeexposedto85dBAfor8hours,buttonomorethan88dBAfor4hoursor91dBAfor2hours. Twelve-hourexposureshavetobe83dBAorlessaccordingtotheNIOSHREL.

Audiometricevaluationsofworkersareconductedinquietlocations,preferablyinasound-attenuating chamber,bypresentingpuretonesofvaryingfrequenciesatthresholdlevels(i.e.,thelevelofasound thatthepersoncanjustbarelyhear).AudiogramsaredisplayedandstoredastablesorchartsoftheHL atspecifiedtestfrequencies[ANSI1996].ZerodBHLrepresentsthehearinglevelofanaverage,young individualwithnormalhearing.InOSHA-mandatedhearingconservationprograms,thresholdsmust bemeasuredforpure-tonesignalsatthetestfrequenciesof500,1000,2000,3000,4000,and6000Hz. Individualemployee’sannualaudiogramsarecomparedtotheirownbaselineaudiogramtodetermine theamountofSTSthatmighthaveoccurredbetweenthetwotests.Specifically,OSHAstatesthatan STShasoccurrediftheaveragethresholdvaluesat2000,3000,and4000Hzhaveincreasedby10dBor moreineitherearwhencomparingtheannualaudiogramtothebaselineaudiogram[CFR2003].The NIOSH-recommendedthresholdshiftcriterionisa15-dBshiftatanyfrequencyineitherearfrom500– 6000Hzmeasuredtwiceinsuccession[NIOSH1998a].Practically,thecriterionismetbyimmediately retestinganemployeewhoexhibitsa15-dBshiftfrombaselineonanannualtest.Ifthe15-dBshift persistsonthesecondtest,aconfirmatoryfollow-uptestshouldbegivenwithin30daysoftheinitial annualexamination.Bothofthesethresholdshiftcriteriarequireatleasttwoaudiometrictests.Incases whereonlyoneaudiogramisavailable,acriterionhasbeenproposedforsingle-frequencyimpairment determinations[Eaglesetal.1968].Itemploysalowerfence(theamountofhearinglossnecessarybefore ahearinghandicapissaidtoexist)of25dBHL.Withthiscriterion,anypersonwhohasahearinglevelof 26dBHLorgreateratanysinglefrequencyisclassifiedashavingsomedegreeofhearingloss.Thedegree oflosscanrangefrommild(26–40dBHL)toprofound(>90dBHL).

Theaudiogramprofileisaplotofthehearingtestfrequencies(x-axis)versusthehearingthresholdlevels (y-axis).Formanyworkers,theaudiogramprofiletendstoslopedownwardtowardthehighfrequencies withanimprovementattheaudiogram’shighestfrequencies,forminga“notch”[Suter2002].Anotch inanindividualwithnormalhearingmayindicatetheearlyonsetofhearingloss.Althoughnouniversal criteriondefineswhatconstitutesa“notch,”severalmathematicalmodelsthatattempttoidentifynotches arepresentedinthescientificliterature[Dobie2002;Niskaretal.2001;Cooper1976].Therelative strengthsandweaknessesofthesemodelshavealsobeenreviewed[Rabinowitz2003].Forthisevaluation, anotchisdefinedasthefrequencywherethehearinglevelisprecededbyanimprovementofatleast 10dBandfollowedbyanimprovementofatleast5dB.Thenotchfromoccupationalnoisecanoccur between3000and6000Hz,dependingonthefrequencyspectrumofthenoise,andtheanatomyof theindividual’sear[ACOM1989;Osguthorpe2001].Itisgenerallyacceptedthatanotchat4000Hz indicatesoccupationalhearingloss[Princeetal.1997].Ontheotherhand,someresearchershaveargued



thatthenotchat6000Hzmaynotbeagoodmarkerforoccupationalhearinglossbecauseitiswidely seeninyoungadultsandotherswithlittledocumentedoccupationalnoiseexposure[McBride2001].An individualmayhavenotchesatdifferentfrequenciesinoneorbothears[Suter2002].

Confined Spaces

Confinedspacespresentanumberofpotentialoccupationalhazardsfortheworkerswhomustenter orworkwithinoraroundtheselocations.Thepotentialhazardsassociatedwithconfinedspacescanbe groupedintothreegeneralcategories:hazardousatmospheres,safetyhazards,andexposuretophysical agents.Hazardousatmospheresincludeoxygendeficient,explosive/flammable,toxic,andirritating atmospheres.Safetyhazardsmayincludemechanicaltrauma,electrocution,slipsandfalls,engulfment inmaterials,interferencewithcommunication,contactwithsharpedges,andotherhazardsrelatedto enteringorexitingthespace.Physicalagentstowhichworkersmaybeexposedwhileinconfinedspaces includethermalconditions(hotorcold),noise,vibration,andradioactivematerials.

AconfinedspaceisdefinedbyNIOSHas“anareawhichbydesignhaslimitedopeningsforentryand exit,unfavorablenaturalventilationwhichcouldcontain(orproduce)dangerousaircontaminants,and whichisnotintendedforcontinuousemployeeoccupancy”[NIOSH1987,2007].TheNIOSHcriteria forworkinginconfinedspacesfurtherclassifyconfinedspacesbasedupontheatmosphericcharacteristics suchasoxygenlevel,flammability,andtoxicity.Ifanyofthehazardspresentanimmediatelydangerous tolifeorhealthsituation,theconfinedspaceisdesignatedClassA.AClassBconfinedspacehasthe potentialforcausinginjuryand/orillness,whileinaClassCspacethehazardpotentialwouldnotrequire anyspecialmodificationoftheworkprocedure[NIOSH1979].

TheFatalityAssessmentandControlEvaluationprojectconductedbyNIOSHdiscoveredthreerecurring confinedspaceprograminadequacies:lackofrecognitionofconfinedspacehazards,lackoftesting andevaluationoftheconfinedspacepriortoentry(andcontinuedmonitoringduringoccupancy),and unplannedandinappropriaterescueprocedures[NIOSH1986].Addressingeachofthesedeficiencies couldcontributetothepreventionofconfinedspacefatalities.

TheOSHAconfinedspaceruleisaversatile“performanceorientated”standardthatallowssome latitudeforemployerstointerpretandapplytheconfinedspaceprogramrequirementsspecifictotheir establishments,providingthefundamentalprecautionarymeasuresareimplementedtopreventconfined spaceinjuriesanddeaths.OnJanuary14,1993,OSHApromulgatedafinalruletitledPermit-Required ConfinedSpaces,whichoutlinestheminimumrequirementsforemployerstoensurethesafetyofworkers duringconfinespaceentry[CFR1993].ThedefinitionofaconfinedspacedeterminedbyOSHAisany spacethatislargeenoughandconfiguredtoallowanemployeetoenterandperformwork;haslimited orrestrictedmeansofaccessintoandegressfromwithin;andisnotdesignedforcontinuousemployee occupancy.

OSHAfurtherdistinguishesconfinedspacesbasedonthepotentialofthespacetoposehazardous exposureconditionsandclassifiesthesespacesasnon-permitversuspermit-requiredconfinedspaces.An



OSHApermit-requiredconfinedspacemustmeettheabovedefinitionandhavethepotentialtoproduce atleastoneofthefollowinghazardousconditions:

● ahazardousatmosphere.

● amaterialthatcouldengulfanentrant.

● aninternalconfigurationsuchthatanentrantcouldbetrappedorasphyxiated.

● anyotherrecognizedserioussafetyorhealthhazard.

Welding Fumes/Metals

Theeffectofweldingfumesonanindividual’shealthcanvarydependingonthelengthandintensity oftheexposureandthespecificmetalsinvolved.Ofparticularconcernareweldingprocessesinvolving stainlesssteel,cadmiumorlead-coatedsteel,andmetalssuchasnickel,chrome,zinc,andcopper.Fumes fromthesemetalsareconsiderablymoretoxicthanthoseencounteredwhenweldingironormildsteel. Epidemiologicalstudiesandcasereportsofworkersexposedtoweldingemissionshaveshownanexcessive incidenceofacuteandchronicrespiratorydiseases[NIOSH1988].Theseillnessesincludemetalfume fever,pneumonitis,pulmonaryedema,andexcessiveincidenceoflungcanceramongwelders.

Thecontentofweldingfumesdependsonthebasemetalbeingwelded,theweldingprocessand parameters(suchasvoltageandamperage),thecompositionoftheconsumableweldingelectrodeorwire, theshieldinggas,andanysurfacecoatingsorcontaminantsonthebasemetal.Thefluxcoating(orcore) oftheelectrode/wiremaycontainupto30organicandinorganiccompounds.Ingeneral,weldingfume constituentsmayincludeminerals,suchassilicaandfluorides,andmetals,suchasarsenic,beryllium, cadmium,chromium,cobalt,nickel,copper,iron,lead,magnesium,manganese,molybdenum,tin, vanadium,andzinc[WeldingInstitute1976;NIOSH1988;Rekus1990].NoPELfortotalweldingfumes hasbeenestablishedbyOSHA;however,PELshavebeensetforindividualweldingfumeconstituents (e.g.,iron,manganese)[CFR2006a].NIOSHhasconcludedthatitisnotpossibletoestablishanexposure limitfortotalweldingemissionsbecausethecompositionofweldingfumesandgasesvariesgreatly,and theweldingconstituentsmayinteracttoproduceadversehealtheffects.Therefore,NIOSHrecommends controllingtotalweldingfumetothelowestfeasibleconcentrationandmeetingtheexposurelimitfor eachweldingfumeconstituent[NIOSH2005].Inadditiontoweldingfumes,manyotherpotentialhealth hazardsexistforwelders.WeldingoperationscanproducegaseousemissionssuchasCO,ozone,nitrogen dioxide,andphosgene(formedfromchlorinatedsolventdecomposition)[WeldingInstitute1976;NIOSH 1988;Rekus1990].Welderscanalsobeexposedtohazardouslevelsofultravioletradiationfromthe weldingarcifweldingscreensorotherprecautionsarenotused.

Zinc

ExposuretozincconcernedmanyworkersatRepublicConduit.Zincoxidemayexistasafumeordust, andatRepublicConduititisfoundasafumeatthehotdiptankandasadustinthethreadingarea, remetalizing,baghouse,andvicinityoftheseareas.Inhalationofzincoxidefumemaycauseaninfluenza-



likeillnesscalledmetalfumefever[HathawayandProctor2004;NIOSH1981].Symptomsmayinclude irritationofthethroat,tightnessofthechest,andadrycough.Severalhoursafterexposuresymptomsmay includechills,fatigue,headache,lowbackpain,musclecramps,nausea,andvomiting.Thesesymptoms arenotproducedwhenzincoxidepowderisinhaled.Theyonlyoccurfromexposuretorecentlygenerated fumesbecauseparticlestendtoflocculate(bunchtogether)aftergeneration,forminglargerparticlesthat aretrappedbytheupperrespiratorytractandwillnotreachthelungs.Zincoxidedustisconsidereda nuisancedustthathaslittleornoeffectonthelungs[HathawayandProctor2004].NIOSHhasanREL-TWAof5mg/m3forzincoxidedustandfumes.NIOSHalsohasaceilingRELlimitof15mg/m3for zincoxidedustandanREL-STELof10mg/m3forzincoxidefumes[NIOSH2005].OSHAhasaPEL-TWAof5mg/m3forzincoxidefumes,15mg/m3forzincoxideastotaldust,and5mg/m3forzincoxide respirabledust.

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Appendix d: Confined spACe entRy pRogRAm

Weofferthefollowingrecommendationstoreducerisksassociatedwithconfinedspaceentryatyourfacility[CFR1993]:

1. DevelopachecklistforeachconfinedspacethattheEntrySupervisorcanusetocomplywith entryrequirements.29CFR1910.146AppendixCprovidesexamplesofpermitrequiredconfined spacesandentryprocedures.Theseexamplesmaybeusedinconductinganassessmentofyour confinedspaces.ThemethodologyusedtowritetheJSAsyouprovidedusmayalsobeused whenassessingyourconfinedspaces.Includesafetyprecautionsforweldingoruseofhazardous chemicalsinconfinedspaces.

2. Labelandsecureconfinedspacestopreventunauthorizedentry.

3. Theentrypermitshouldspecifythesequencefortestingaircontaminanthazards(e.g.itis criticallyimportantthatoxygenlevelbemeasuredfirst).Theentrypermitshouldalsoprovide spacetodocumentinitialandperiodicairmonitoringresults.

4. Ifblowersareusedtoventilateaconfinedspacetheattendantshouldensurethatcontaminants suchasexhaustfromaforkliftarenotintroducedintotheconfinedspace.

5. Theentrypermitshouldspecifytheemergencycontactinformationandshouldalsodocument thatthePleasureRidgeParkFireDepartmenthasbeencontactedbeforeactualpermitspaceentry occurs.

6. Theentrypermitshouldspecifythephysicalhazardsinthespace,themethodsforcontrolling physicalhazards,anddocumentthatphysicalhazardshaveactuallybeencontrolled.

7. Theentrypermitshouldspecifytheventilationrate(i.e.,minimumnumberofairchangesper hour),whenventilationofthespaceisrequired.

8. YourwritteninstructionsforconfinedspaceentrystateunderSpecificProcedures,“Aminimum oftwotrainedemployeesmustbewithinlineofsiteandverbalcommunicationofoneanother outsideoftheconfinedspace”.Theattendantsshouldhavevisualorverbalcommunicationwith workersenteringtheconfinedspace.

9. PlanandcoordinateapracticerescuewiththePleasureRidgeParkfiredepartmenttoensurethat timelyrescuecanbeachievedintheeventofanactualemergencyinaconfinedspace.

10. Afterrevisionsaremade,werecommendthatyourwrittenproceduresbereviewedbyaqualified safetyprofessionalsuchasaCIH,CSP,orregisteredsafetyengineer.Youcanalsocontactyour state’sOSHAConsultationOfficeforassistanceinevaluatingyourhealthandsafetyprograms. TheOSHAConsultationOfficeservicesarefreeandtheywillnotdiscloseyourname,company name,orviolationstotheircomplianceoffice,howevertheywillexpectyoutocorrectany violationsofOSHAstandardsfound.

11. Employeecomplaintsabouttheeffectivenessoftheconfinedspaceprogramaregroundsfor reviewingtheprogram.


Appendix d: Confined spACe entRy pRogRAm (Continued)

Reference

CFR[1993].29CFR1910.146,permitrequiredconfinedspaces.CodeofFederalRegulations. Washington,DC:U.S.GovernmentPrintingOffice.


informing affected employees, we encourage that e

ACknowledgements And

AvAilABility of RepoRt TheHazardEvaluationandTechnicalAssistanceBranch(HETAB) oftheNationalInstituteforOccupationalSafetyandHealth (NIOSH)conductsfieldinvestigationsofpossiblehealthhazards intheworkplace.Theseinvestigationsareconductedunderthe authorityofSection20(a)(6)oftheOccupationalSafetyand Health(OSHA)Actof1970,29U.S.C.669(a)(6)whichauthorizes theSecretaryofHealthandHumanServices,followingawritten requestfromanyemployersorauthorizedrepresentativeof employees,todeterminewhetheranysubstancenormallyfound intheplaceofemploymenthaspotentiallytoxiceffectsinsuch concentrationsasusedorfound.

HETABalsoprovides,uponrequest,technicalandconsultative assistancetofederal,state,andlocalagencies;labor;industry;and othergroupsorindividualstocontroloccupationalhealthhazards andtopreventrelatedtraumaanddisease.Mentionofcompany namesorproductsdoesnotconstituteendorsementbyNIOSH.

ThisreportwaspreparedbyManuelRodriguez,ChristineA.West, andScottE.BrueckofHETAB,DivisionofSurveillance,Hazard EvaluationsandFieldStudies(DSHEFS).Industrialhygienefield assistancewasprovidedbySrinivasDurgamandLyndaEwers. AnalyticalsupportwasprovidedbyBureauVeritasNorthAmerica. DesktoppublishingwasperformedbyRobinSmith.Editorial assistancewasprovidedbyEllenGalloway.Healthcommunication assistancewasprovidedbyStefanieEvans.

Copiesofthisreporthavebeensenttoemployeeandmanagement representativesatRepublicConduitandtheKentuckyState OSHAOffice.Thisreportisnotcopyrightedandmaybefreely reproduced.Thereportmaybeviewedandprintedfromthe followinginternetaddress:http://www.cdc.gov/niosh/hhe.Copies maybepurchasedfromtheNationalTechnicalInformation Service(NTIS)at5825PortRoyalRoad,Springfield,Virginia 22161.


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manufacturing,RepublicConduit,Louisville,Kentucky.Cincinnati,OH:U.S. DepartmentofHealthandHumanServices,PublicHealthService,Centersfor DiseaseControlandPrevention,NationalInstituteforOccupationalSafetyand Health,NIOSHHETANo.2006-0332-3058.

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