Author: Englund, John, G Title: Total Dust Exposure to Company XYZ's Employees While Deburring

Extruded Aluminum The accompanying research report is submitted to the University of Wisconsin-Stout, Graduate School in partial

completion of the requirements for the

Graduate Degree/ Major: MS Risk Control

Research Adviser: Elbert Sorrell, Ed.D.

Submission TermN ear: Fall, 2011

Number of Pages: 44

Style Manual Used: American Psychological Association, 6th edition

[gl I understand that this research report must be officially approved by the Graduate School and that an electronic copy of the approved version will be made available through the University Library website [gl I attest that the research report is my original work (that any copyrightable materials have been used with the permission of the originai authors), and as such, it is automatically protected by the laws, rules, and regulations of the U.S. Copyright Office.

STUDENT'S NAME: John Englund

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This section to be completed by the Graduate School This final research report has been approved by the Graduate School.

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Englund, John G. Total Dust Exposure to Company XYZ’s Employees While Deburring

Extruded Aluminum

Abstract

The purpose of this study was to determine, by conducting air quality monitoring, if and

to what extent Company XYZ’s employees were being exposed to total dust in the deburring

area while deburring extruded aluminum. In addition, the scope of this research paper focuses

on different controls to reduce the exposure to total dust and a follow up air quality monitoring to

determine if implemented controls did in fact decrease the employee’s exposure to total dust.

Through the literature, air quality monitoring, and follow up air quality monitoring all the

goals of the study were achieved. The literature consisted of topics relating to different sampling

techniques, the respiratory system, respiratory protection, and different occupational respiratory

illnesses. This along with the initial air quality monitoring it appears employees deburring

extruded aluminum have the potential of being over exposed to total dust during a normal days

work shift.

As a result, recommendations will be suggested and implemented at Company XYZ and

a follow up air quality monitoring will be conducted to verify the efficiency of the implemented

controls.

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Acknowledgments

I would like to sincerely thank the many professors who have helped me along the way

during my time at the University of Wisconsin-Stout from my undergraduate degree to my

graduate degree. I would like to thank Mary Volk, Dr. Bryan Beamer, Dr. Eugene Ruenger, Lyle

Koerner, and especially Dr. Brian Finder and Dr. Elbert Sorrell for their help, support, and

guidance throughout my graduate studies. I could not have achieved this accomplishment

without all of them.

I would like to thank my Occupational Health and Safety mentor and role model Matt

McCoy for his encouragement, confidence in my abilities, and taking a chance on me when no

one else would.

I would like to thank my mother, father, two brothers, mother-in-law, father-in-law,

sisters-in-law, and brothers-in-law for their continued love, help, and support throughout this

project. I could not have completed this without the love and support of my wonderful wife Jill

and children; John IV and Juliet who are my inspiration to achieve greatness.

Finally, a special thanks to the safety director and company where I completed

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Table of Contents

…………………………………………………………………………………………………Page

Abstract……………………………………………………………………………………………2

Chapter I: Introduction……………………………………………………………………………6

Statement of the Problem…………………………………………………………….……7

Purpose of the Study………………………………………………………………………7

Goals of the Study…………………………………………………………………………8

Background and Significance……………………………………………………………..8

Limitations of the Study…………………………………………………………...………8

Assumptions of the Study…………………………………………………………………9

Definition of Terms……………………………………………………………………..…9

Chapter II: Literature Review……………………………………………………………………11

Background………………………………………………………………………………11

Sampling Techniques…………………………………………………………………….13

Respiratory Protection Analysis…………………………………………………………15

Anatomy of the Respiratory System……………………………………………………..18

Occupational Respiratory Illnesses………………………………………………………21

Summary…………………………………………………………………………………22

Chapter III: Methodology……………………………………………………………………..…23

Subject Selection and Description……………………………………………………….23

Instrumentation…………………………………………………………………………..24

Data Collection Procedures………………………………………………………………24

Data Analysis…………………………………………………………………………….25

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Limitations……………………………………………………………………………….26

Chapter IV: Results………………………………………………………………………………28

Initial Sampling………………………………………………………………………….28

Figure 1: Initial Air Quality Monitoring Results………………………………………..31

Follow up Sampling…………………………………………………………………….32

Figure 2: Follow up Air Quality Monitoring Results…………………………………...34

Discussion………………………………………………………………………………35

Chapter V: Summary, Conclusions, and Recommendations…..………………………………...36

Methods…………………………………………………………………………………..36

Conclusions………………………………………………………………………………37

Recommendations………………………………………………………………………..38

Engineering Controls…………………………………………………………………….38

Administrative Controls………………………………………………………………….38

Areas of Further Improvement…………………………………………………………...39

References………………………………………………………………………………………..40

Appendix A: NIOSH: Particulates Not Otherwise Regulated, Total 0500….…………………...42

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Chapter I: Introduction

Company XYZ is an aluminum extrusion company that is capable of creating an endless

variety of aluminum products through the extrusion process. Since there are so many

possibilities, Company XYZ has created a standard catalog of products and can also produce

custom extrusions. Clients often come to Company XYZ with an idea about a product they wish

to have completed, which usually include the shape and a die print. Company XYZ has many

years of experience in aluminum extrusions and often applies their expertise to assist their clients

through the design and development process including helping their clients understand the

possibilities and limitations of aluminum extrusion.

As soon as an agreement is made between Company XYZ and their client, Company

XYZ will begin the process of extruding a sample for their client to inspect and approve. In

order to extrude a sample for a client, Company XYZ will determine which size press will be

used for the product depending on several variables. Company XYZ has three different sized

presses in their factory; a seven inch press, an eight inch press, and a nine inch press. Sometimes

Company XYZ already has a die the client would like to use and sometime the client will have

their own design. If the latter is the case, a die maker will create a die; this die is the property of

the client but will be stored at Company XYZ’s die warehouse; to create the extruded product.

Company XYZ will extrude a sample of the product and send it to the client to view and

approve.

Once the client approves the sample, Company XYZ will extrude the aluminum for the

client to the amount they want to order for the size of their project. The aluminum product can

be cut a couple of different ways once extruded. The first way to be cut is called the lineal cut

process. This is where the aluminum is cut into longer lengths and is cut at the press. This

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process usually results in a smoother cut, but will not be possible if the client wants a product

under a certain size.

For orders where smaller sized products of aluminum are required by the client the

aluminum is extruded in longer lengths at the press and taken to be cut in the resaw area. The

resaw area is where these long pieces of extruded aluminum are cut into smaller portions to the

size specified by the client. The cuts that are made in the resaw area are not as smooth as the

lineal cut process and most often times results in burrs that are attached to the ends of the

aluminum pieces where the cuts have been made. These pieces of extruded aluminum are then

taken to the deburring area to have the burrs removed.

The deburring process consists of employees manually debur the pieces of aluminum

using powered hand grinding wheels. While deburring the aluminum products, the burrs are

grinded down into very small particles which can become airborne. The grinding wheels also

become wore down and produces airborne particles as well.

Statement of the Problem

The current process of deburring aluminum products has the potential of placing

Company XYZ’s employees at risk of being overexposed to total dust resulting in various

respirable risk factors.

Purpose of the Study

The purpose of the study was to determine, by conducting air quality monitoring, if and

to what extent Company XYZ’s employees were being exposed to total dust in the deburring

area. The paper also focuses on various ways to reduce the exposure to Company XYZ’s

employees and make relevant recommendations to be implemented at Company XYZ. A follow-

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up air quality monitoring test was conducted to determine the effectiveness of the implemented

recommendations in the deburring area.

Goals of the Study

1. Conduct air quality monitoring for total dust in the deburring area of Company XYZ

2. Determine if and to what extent the workers in the deburring area of Company XYZ are

being exposed to total dust

3. Decrease employee’s exposure to total dust by implementing applicable controls

4. Conduct a follow-up air quality test to determine the effectiveness of implemented

controls

Background and Significance

Company XYZ is an aluminum extrusion company that extrudes approximately 8.5

million pounds of product per year. After the aluminum is extruded into a specific shape the

ends are checked for burrs where they were originally cut. Of the 8.5 million pounds of

aluminum product, approximately 1 million pounds are sent to the deburring area per year.

Typically, the ends of the shorter cut pieces have burrs which need to be removed through the

deburring process. Employees working in the deburring area, where approximately 1 million

pounds of extruded aluminum is deburred per year have the potential to be overexposed to total

dust as a result of the process.

Limitations of the Study

The limitations of this research are:

Company XYZ is only going to be purchasing four air quality tests, so if there is a

problem (i.e. blowout, pump stops working, etc...) with one or more of the tests

there will be less data to analyze

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Company XYZ’s employee will be deburring as part of their regular job

Assumptions of the Study

Deburring is a constant process that must be run throughout the hours of operation,

which are 24 hours a day, five days per week, Monday through Friday

The employees working in the deburring area are consistently working in the

deburring area throughout their weekly shifts

There is a constant exposure to total dust because this is a constant process

Approximately 1 million pounds of extruded aluminum is deburred per year, this

amounts to approximately 83,333 pounds per month, or 3,788 pounds per day, or

on average 158 pounds per hour

Definitions of terms

Billet. May be solid or hollow in form, commonly cylindrical, used as the final length of

material charged into the extrusion press cylinder. It is usually a cast product, but may be a

wrought product or sintered from powder compact (The Aluminum Extrusion Council, 2008)

Burrs. A thin ridge of roughness left by a cutting operation such as slitting, trimming,

shearing, blanking, or sawing (The Aluminum Extrusion Council, 2008)

Deburr/Deburring. Removing burrs, sharp edges, or fins from metal parts by filing,

grinding, or tumbling (The Aluminum Extrusion Council, 2008)

Die/Dies. In extrusion a tool with an opening through which heated aluminum is forced

by pressure, taking on that cross-sectional shape (The Aluminum Extrusion Council, 2008)

Extrusion. The method of extruding wherein the die and ram are at opposite ends of the

billet and the product and ram travel in the same direction (The Aluminum Extrusion Council,

2008)

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Powered Air-Purifying Respirator (PAPR). An air-purifying respirator that uses a blower

to force ambient air through air-purifying elements to the inlet covering (OSHA 29 CFR

1910.134(b))

Self-Contained Breathing Apparatus (SCBA). An atmosphere-supplying respirator for

which the breathing air source is designed to be carried to the user (OSHA 29 CRF 1910.134(b))

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Chapter II: Literature Review

The purpose of the study was to determine, by conducting air quality monitoring, if and

to what extent Company XYZ’s employees were being exposed to total dust in the deburring

area. This section of the paper will help to introduce and explain the multiple processes of

aluminum extrusion and will focus on the deburring process and how this has the potential to

create a respirable hazardous environment to Company XYZ’s employees. Reducing the total

dust from the deburring process that a potential employee from Company XYZ is being exposed

to should lead to a decreased likelihood of an employee developing a respirable disease.

Background

Aluminum is the third most abundant element on earth, after oxygen and silicon

(Gammon, 1999). Aluminum is a chemically reactive metal, but is much less reactive than other

alkali and alkaline metals. It does not react at an appreciable rate with water at room

temperature; however, it does react readily with oxygen. The aluminum on the surface of the

metal does react with oxygen; however, the aluminum oxide that forms creates an adherent coat

which acts to protect the underlying metal from further reaction. Aluminum reacts less quickly

than other metals in a moist environment, and it does not normally corrode or rust, which makes

it very versatile in many different applications (Gammon, 1999).

Aluminum is a very versatile metal (and the most abundant metallic element on the earth)

and according to The Aluminum Extrusion Council is used for extrusion for a few different

reasons. Aluminum is extremely light in weight for its strength. Its high reflectivity, high

thermal conductivity, nontoxicity, and corrosive resistance make it a very attractive metal for the

extrusion process (The Aluminum Extrusion Council, 2008).

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According to The Aluminum Extrusion Council; “Aluminum extrusion is a versatile

metal-forming process that allows real design freedom with built-in near-net-shape ability and

unique properties that are unsurpassed by competing materials” (The Aluminum Extrusion

Council, 2008). The design phase is the first step in the aluminum extrusion process. After the

design is complete the physical extrusion process can start (The Aluminum Extrusion Council,

2008). The process starts with a billet, which is a cylindrical raw piece of aluminum. The billet

is heated in order soften it and is then pressed through a precisely formed opening called a die

using a ram. The die is what gives the piece of aluminum its shape.

A simple way to think about this process is like squeezing ointment out of a tube. If the

opening to the tube is round then the ointment will come out cylindrical, but if the opening is flat

then the ointment will come out like a sheet (Penn Aluminum International LLC, 2005).

After the aluminum is pressed out of the die it is cut and cooled with air and water. If the

extrusion needs to be longer, billets can be welded together before being placed in the press to

create one larger piece of aluminum (Manufacturing Industry News, 2011). The extrusion is

then ready to be deburred and then heat treated one last time before it is ready to ship.

During the deburring process the small burrs that are left on the product from the raw cuts

are removed by various ways to smooth out the product. One of the more common processes of

deburring would be to grid the burrs off with a grinding wheel. This process produces very small

particles (or particle matter, PM) from the extruded aluminum as well as from the grinding wheel

itself that are mixed with the ambient air to create dust or dust clouds.

Dust contains particulate matter suspended in the air (Stacey, 1993). The process by

which dust forms may vary from condensation or mechanical means such as breakdown to

smaller particles, in Company XYZ’s case deburring cut aluminum. Dust clouds that are

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generated consist of a wide range of particle sizes which could be within the breathable area of

and inhaled by an employee. It is fairly rare for a dust cloud to be pure in terms of chemical

composition; most often industrial dusts contain a number of components which have various

synergistic or differing toxicological effects (Stacey, 1993). The size typical particles found in

the general and occupational environment range from 0.01 to 1000 µm in diameter; however,

only the lower size particulate matter (less than 200 µm) is relevant to various types of lung

disease (Stacey, 1993). The Occupational Safety and Health Administration (OSHA) has a set

permissible exposure limit (PEL) to total dust which is 15 mg/m3.

For a particulate to have a direct health impact on an employee it must be deposited on

either the skin or inhaled into the respiratory system. Outside of particulate matter being

deposited in a region of the respiratory tract, the second most important toxicological factor for

particulates is their chemical make-up and the manner in which they are present in the body

(Stacey, 1993).

Absorption of metal particulates in the work place can have many different effects on the

body (Stacey, 1993). This process has the potential of placing worker in a hazardous

environment if the concentrations of contaminants in the air are over the acceptable limits. In

order to determine the concentration of the contaminants air quality sampling must be conducted.

Sampling Techniques

The 1991 American Conference of Governmental Industrial Hygienists (ACGIH)

Threshold Limit Value list contains approximately 126 specific dusts on which there is available

information sufficient to be able to set an industrial exposure limit. This number constitutes only

a small amount of the types of dust that are found in an industrial situation and partly indicates

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the difficulties experienced in obtaining specific data on substances which have a complex

chemical composition and variable biological effects on exposed workers (Stacey, 1993).

Particles have a specific mass in comparison to the air in which they are mixed and are

subject to physical forces such as gravitation, inertia, and diffusion. Thus, they are removed

quickly from the air and can easily be captured and measured through different air monitoring

sampling processes such as filtration (Stacey, 1993). If particles are inhaled they can be

deposited in the respiratory tract.

Air sampling for particle matter is a fundamental activity used in the industrial hygiene

field, and a large majority of occupational exposure limits are based on the results of some type

of air sampling. The most commonly measured value for occupational exposure purposes is the

eight-hour time-weighted average (TWA) (Plog, 2002). The most typically used industrial

hygiene air sampling is to collect particle matter on a filter that is placed in the worker’s

“breathing zone” (which is around 9 inches within the nose and mouth of the worker) (Plog,

2002). Air is pulled through the filter by a pump that is set at a certain flow rate (typically in

liters per minute), and this pump is attached to the worker for the work shift to be exposed to the

same condition the worker would be exposed to over a typical eight hour work shift.

In this case a personal monitoring device is used to sample the air. According to Plog;

“personal monitoring is the measurement of a particular employee’s exposure to airborne

contaminants and, in theory, reflect actual exposure to the employee” (Plog, 2002, p. 498). Plog

raises a good point that even in testing the breathable air the employee is exposed to it might not

result in the total exposure because some particle matter can be absorbed through the skin or

mucus membranes in addition to be inhaled (Plog, 2002).

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Personal air sampling relies on a battery operated pump that the employee would wear

(typically on their belt with a hose connected to the filter clipped to the employee’s lapel) for a

given amount of time throughout the sampling (Plog, 2002). There are benefits and drawbacks

to having an employee wear a battery operated device for sampling. This gives the employee the

benefit to be able to work anywhere and not have to be close to an electrical outlet for the pump

to be plugged into, and they can be easy to move around if clipped on a belt. A few drawbacks

would include having a hose connecting the pump to the filter over the worker’s shoulder might

get in the way of conducting work, and a battery might die throughout the work shift and if the

worker does not notice when this happened the test would be invalid.

Air sampling is used to evaluate employee exposure and to assist in the design or

evaluation of control measures to be implemented if the sampling confirms an exposure is too

high (Plog, 2002). One way to help reduce the exposure to particle matter hazards is to use

personal protective equipment (PPE), such as respirators, because the best prevention for

contaminants entering the body and causing respiratory illnesses is avoidance of the inhaled

substances that cause lung diseases (The Ohio State University Medical Center, 2011).

Respiratory Protection Analysis

The Occupational Safety and Health Administration 29 Code of Federal Regulations

1910: General Industry Regulations have an entire subpart dedicated to personal protective

equipment, or PPE. The regulation 1910.132(a) under general requirements for PPE (Subpart I)

and states “Protective equipment, including personal protective equipment for the eyes, face,

head, and extremities, protective clothing, respiratory devices, and protective shields and

barriers, shall be provided, used, and maintained in a sanitary and reliable condition wherever it

is necessary by reason of hazards of processes or environment, chemical hazards, radiological

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hazards, or mechanical irritants encountered in a manner capable of causing injury or impairment

in the function of any part of the body through absorption, inhalation, or physical contact.”

Absorption, according to Stacey, is the passage of chemical molecules across the membranes of

the cells that separate internal and external aspects of the body (Stacey, 1993). In other words a

company must provide applicable and suitable PPE for the purpose intended, implement the use,

and maintain personal protective equipment for an employee if there is the potential for an

employee to be working in a hazardous environment at the company.

There are many different kinds of personal protective equipment that will protect any

area of the body where injury could result from absorption, inhalation, or physical contact.

There are also different levels of protective equipment that will protect from different chemicals

and contaminants. Respirators are protective devices that protect the user’s nose, mouth, or the

entire face and/or head from inhalation contaminants and hazardous atmospheres (Chaff, 2006).

There are two main types of respirators to ensure the breathable air an employee will be

exposed to is clean and clear of contaminants. One type is an air-purifying respirator (APRs)

and the other is a supplied-air respirator (SARs) (Chaff, 2006). One approach (air-purifying

respirator) is to filter the air before a worker inhales it, as the approach with an N95 (a respirator

where ambient air is filtered through the respirator by the wearer’s effort) and a powered air-

purifying respirator (PAPR). The other approach (supplied-air respirator) supplies air that is

compressed in a tank and is the correct mixture of oxygen and inert gases that is free of

contaminants, such as a self-contained breathing apparatus (SCBA) (Brauer, 2006). So for

example, an N95 respirator will provide a different level of protection that a powered air-

purifying respirator or a self-contained breathing apparatus.

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When selecting a respirator to use, Chaff suggests thinking about these eight questions to

help make a logical decision about what kind of respirator is needed:

1. “What is the nature of the hazard (e.g. chemical properties, concentration in the

air, warning properties)?

2. Is the airborne contaminant a gas, a vapor, or a particulate (e.g. fume, mist, or

dust)?

3. Are the airborne concentrations below or above the exposure limit, or are they at

or above concentrations considered to be immediately dangerous to life or health?

4. What are the health effects of the airborne contaminants (e.g. carcinogenic,

potentially lethal, irritating to eyes, or absorbed through the skin)?

5. What activities will the employee be performing while wearing the respirator (e.g.

strenuous work)?

6. How long will the employee need to wear the respirator?

7. Does the selected respirator fit the employee properly?

8. Where is the nearest safe area that has respirable air?” (Chaff, 2006, p. 201-202)

Plog also writes about selecting the proper type of respiratory protection and some

determining factors to consider:

“Identification of the substance or substances for which respiratory protection is

necessary and the activities of the workers

Determination of the hazards of each substance and its significant physical and

chemical properties, particularly the presence or absence of oil particles

Determination of the maximum levels of air contamination expected, probability

of oxygen deficiency, and the condition of exposure

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Determination of the period of time for which respiratory protection must be worn

Determination of the capabilities, physical characteristics, and limitations

essential to the safe use of the respiratory protective device

Identification of facilities needed for maintenance

Determination of the location of the hazardous work area in relation to the nearest

area with respirable-quality air

Occupational exposure limit substance

Respirator assigned protection factors” (Plog, 2002, p. 601)

Most of the factors or questions that both authors have highlighted are very similar,

which reinforces the importance of understanding all of the factors involved with respiratory

protection before selection and use of a respirator. Plog goes on in more detail about the proper

selection of respirators and how an assessment should be conducted. Plog states the following

must be included in the assessment “The nature of the hazardous operation or process, the type

of respiratory hazard, the location of the hazardous area in relation to the nearest respirable air

source, the time period that respirators must be worn, and the worker’s activities” (Plog, 2002, p.

688-689).

According to Stacey, the lungs and the respiratory system appear to be the main organs

of toxicity following occupational exposure (Stacey, 1993); therefore, respiratory protection is

worn by the user in order to protect the worker’s respiratory system.

Anatomy of the Respiratory System

According to Plog, “the term respiration refers to the tissue enzyme oxidation processes

that use oxygen and produce carbon dioxide. The following are subdivisions of the overall

process:

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Breathing – movement of chest/lung complex to ventilate the alveoli

External respiration – exchange of gas (oxygen and carbon dioxide) between lung

(alveolar) air and blood

Internal respiration – exchange of gas between tissue blood and tissue cells

Intracellular respiration – ultimate utilization of oxygen by the cells with the

coincident release of carbon dioxide.” (Plog, 2002, p. 41)

The major function of the human respiratory system is to bring oxygen into the blood so

the blood can supply oxygen to the rest of the body (The Franklin Institute, 2011). The

respiratory system consists of many different and unique organs that include the nose, the

pharynx, the larynx, the trachea, the bronchi, and the lungs (Plog, 2002). These organs are split

up into the upper respiratory tract and the lower respiratory tract. The upper respiratory tract

includes the nose, nasal cavity, larynx, and the trachea; while the lower respiratory tract includes

the bronchi and the lungs (University of Maryland Medical Center, 2008).

Respiration begins with the nose and mouth (The Franklin Institute, 2011). The nose

consists of an internal and an external portion (Plog, 2002). The external portion is the portion

that protrudes from the face and varies from person to person. The internal portion of the nose is

part of the skull between the top of the mouth and the forehead called the nasal cavities. The

nasal cavities open to the outside through the nostrils, just inside the nostrils are vestibules in

each of the cavities. The vestibule is lined with skin and hair that serve to trap dust particles that

are inhaled through the nose. When air is inhaled through the nose it is warmed and moistened

in the nasal passage and in the process some particles are removed by impaction on the nasal

hairs and other particles are separated out through the different bends in the air path (Plog, 2002).

20

Once air passes through the nasal cavity it moves to the pharynx (the throat). According

to Plog, “the pharynx, or throat, is a tublar passageway attached to the base of the skull and

extending downward behind the nasal cavity, the mouth, and the larynx to continue as the

esophagus.” (Plog, 2002, p. 37). At the bottom of the throat there are two separate passageways

that are called the esophagus, which carries food and liquids to the stomach, and the trachea,

which carries air and other gases to the lungs (Plog, 2002). The pharynx connects the nasal

passage and the larynx, which helps to inhale air through the mouth and into the lungs.

When inhaling, air moves from the pharynx to the larynx. The larynx is also referred to

as the voice box. This serves as the passageway between the pharynx and the trachea. The

larynx acts like a valve that closes to prevents solids and liquids from entering the lower

respiratory tract and opens when air is flowing through. The larynx is the organ of voice, and

when air is forced past the vocal cords, vibrating them, sounds are produced (Plog, 2002).

Air then travels into the trachea (also known as the windpipe) from the larynx. The

trachea extends from the larynx through the neck and into the chest cavity, which is then divided

into two tubes, the right and the left bronchi (Plog, 2002). The left and the right bronchi then

enter the left and the right lung respectively (each bronchus enters a separate lung). The lungs

are essentially a pair of cone-shaped organs made up of spongy, pinkish-gray tissue; they also

take up most of the space in the chest (The Ohio State University Medical Center, 2011).

The two lungs are actually not the exact same is shape and size. The right lung is slightly

larger than the left lung and is divided into three different lobes, where the left lung is divided

into only two lobes (The Ohio State University Medical Center, 2011).

21

Like the skin, the lung epithelium come into contact with the outside world, however,

there are many differences between what the skin is exposed to and what the lungs are exposed

to (Stacey, 1993).

All of these organs are integral parts of the respiratory system and can all be affected by

different respiratory hazards found in the workplace. Different respiratory hazards can target the

upper respiratory tract, the lower respiratory tract, or the entire respiratory system and

occupational respiratory illnesses could potentially develop from this type of exposure.

Occupational Respiratory Illnesses

According to The Ohio State University Medical Center, “repeated and long-term

exposures to certain irritants on the job can lead to an array of lung diseases that may have

lasting effects, even after exposure ceases. Certain occupations, because of the nature of their

location, work, and environment, are more at risk for occupational lung diseases than others”

(The Ohio State University Medical Center, 2011).

Some occupational respiratory illnesses that Furlow lists in an article in the Radiologic

Technology Journal are: “Ardystil syndrome, asbestosis, aluminum pneumoconiosis, bauxite

fibrosis, berylliosis (chronic beryllium disease), black lung (coal workers’ pneumoconiosis),

calcicosis, flavor workers’ lung, hard metal (tungsten carbide alloy) pneumoconiosis,

hypersensitivity pneumonitis (eg, flock workers’ or bird fanciers’ lung), occupational asthma,

sarcoidosisa, siderosis, silicosis, silicosiderosis, talcosis, and talcosilicosis” (Furlow, 2011).

Some of these would not pertain to Company XYZ’s employees because of the different particles

and elements associated with the diseases; however, there are a few that could be possible for an

employee at Company XYZ to develop in the deburring area.

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In an article written by Dr. Karen E Bridgman, she mentions some factors that contribute

to lung diseases:

“Environmental pollutants, for example hydrocarbons from smoke

Heavy metals – cadmium causes fibrosis of the lungs, mercury accumulates in the

lungs, and long term excessive intake of nickel can result in degeneration of the lungs

Dietary deficiencies such as essential fatty acids, Vitamin A, lechithin etc, adversely

affect the health of lung tissue, mucous and lung function

Inflammation and/or allergies cause systemic membrane inflammation

Infection from external and internal sources

Excess oxidation

Ozone is a potential respiratory irritant known to induce lung injury in humans”

(Bridgman, 2011)

Summary

After reviewing the literature Company XYZ’s employees have the potential of being

over exposed to total dust during the deburring process after aluminum has been extruded and

developing occupational respiratory illnesses. The employees at Company XYZ’s concern

would be developing respiratory illnesses from inhaling airborne particulate matter produced

during this process. An air quality test to measure total dust during the deburring process needs

to be conducted using NIOSH analytical method 0500. The potential exposure needs to be

assessed and recommendations need to be provided if the results of the air sampling conclude

workers are being over exposed to total dust.

23

Chapter III: Methodology

The purpose of the study was to determine, by conducting air quality monitoring, if and

to what extent Company XYZ’s employees were being exposed to total dust in the deburring

area. In addition, the scope of this research paper will focus on different ways to improve the

current process and make applicable recommendations. The main goals that were identified to

be accomplished throughout the study were:

1. Conduct air quality monitoring for total dust in the deburring area of Company XYZ

2. Determine if and to what extent the workers in the deburring area of Company XYZ are

being exposed to total dust

3. Decrease employee’s exposure to total dust by implementing applicable

recommendations/controls

4. Conduct a follow-up air quality test to determine the effectiveness of implemented

controls

This chapter will provide an explanation of methods used in the study. Included in this

chapter is subject description, instrumentation, data collection procedures, data analysis, and

limitations of the study.

Subject Selection and Description

Subjects were selected based on their day-to-day job duties and responsibilities, which is

located in the deburring area of Company XYZ. A typical work week for one of these

employees consists of approximately eight hours per day for five days per week. The deburring

area is an area of Company XYZ that was identified by the Safety Director to have a potential

hazardous environment to the workers in the area. The testing method used to determine the

exposure to total dust the employees were exposed to in the deburring area was the acceptable

24

NIOSH 0500 testing protocol. The NIOSH 0500 testing protocol is applicable to determine

nonspecific total dust concentration to which a worker is exposed.

Instrumentation

The testing method that was used to determine the exposure of total dust was the NIOSH

0500 testing procedure. The instruments involved in this testing protocol are as follows:

A personal sampling pump that will sample 1 to 2 liters per minute and will be clipped

to the employee’s belt during sampling

A 2 to 5 µm pore size membrane or equivalent hydrophobic filter and supporting pad

in a 37mm cassette filter holder

A flexible connecting tube to connect the personal sampling pump to the cassette

Rotameter (a device used to measure the flow rate of the air being pulled through the

cassette) to calibrate the pump before and after use

All of the equipment was rented through an accredited laboratory that also analyzed the

filters upon completion of the air sampling.

Data Collection Procedures

All of the equipment was connected according to the manufacturer’s recommendation

included with the personal sampling pump. The order of connection was; the cassette (with the

filter already installed) was connected to the flexible connecting tube (the webbed side of the

cassette connected to the tube to ensure the correct air flow direction) then to the flexible

connecting tube was connected to the intact airflow port of the personal sampling pump. This

pump battery was charged for twenty four hours before the testing was conducted to ensure the

pump would work throughout the eight-hour work shift. The author also confirmed the air flow

rate of the personal sampling pump using the rotameter before the sampling began.

25

The personal sampling pump was connected to the employee’s belt and the tube was

placed around the back of the employee with the sampling cassette clipped to the lapel of the

shirt so that it was in the breathing area of the employee (within 10 inches of the mouth and nose

of the employee). The pump was placed on the employee for approximately eight hours during

the work shift and then collected after the work shift. The rotameter was connected to the

personal sampling pump after the work shift and monitoring was concluded and removed from

the employee in order to collect the flow rate of the pump after the sampling. The pump was

post calibrated because it would be possible that the flow rate of the pump changed depending

upon the amount of particulate matter that was collected on the filter throughout the sampling

timeframe. Once the post calibration was conducted the cassette was plugged from both ends to

ensure no more particulate matter would come in or fall out of the cassette and filter.

This process was followed once during the first test (on one employee) and then three

times after the controls were implemented at Company XYZ on three other employees who were

working in the deburring area that day.

A field blank was also used and weighed to be compared to the collected sample in each

of the testing sessions.

Data Analysis

The sampling cassettes were collected and sent, along with the air volume in liters (which

was calculated using the amount of time the pump was sampling along with the flow rate of the

personal sampling pump pre- and post-sampling) to the accredited laboratory which then

followed the NIOSH 0500 protocol to determine the total dust the employee was exposed to

during the eight hour work shift. The steps the accredited laboratory followed according to the

NIOSH 0500 protocol are:

26

1. “Wipe dust from the external surface of the filter cassette with a moist paper towel to

minimize contamination

2. Remove the top and bottom plugs from the filter cassette and equilibrate for at least 2

hour in the balance room

3. Remove the cassette band, pry open the cassette, and remove the filter gently to avoid

loss of dust

4. Zero the microbalance before all weighings. Use the same microbalance for weighing

filters before and after sample collection. Maintain and calibrate the balance with

National Institute of Standards and Technology Class S-1.1 or ASTM Class 1 weights

5. Weigh each filter, including field blanks. Record the post-sampling weight, (mg). Record

anything remarkable about a filter (e.g., overload, leakage, wet, torn, etc.)” (Clere and

Hearl, NIOSH Manual of Analytical Methods (NMAM), 1994)

This data was then sent back to the author to analyze further and repot out to the

Company XYZ’s Safety Director.

Limitations of the Study

Key limitations of the study’s methodology include:

Company XYZ is only going to be purchasing four air quality tests, so if there is a

problem (i.e. blowout, pump stops working, etc...) with one or more of the tests there will

be less data to analyze

The flow rate could potentially change throughout the day depending on the amount of

particulate matter that is collected on the filter

27

The employee in the deburring area will not be under constant surveillance by the author

so there is a potential the employee could, as part of their regular job duties, move in a

way that would crimp the tube or somehow change the flow rate of the pump

28

Chapter IV: Results

The purpose of the study was to determine, by conducting air quality monitoring, if and

to what extent Company XYZ’s employees were being exposed to total dust in the deburring

area. In addition, this research paper will focus on different ways to improve the current process

and make applicable recommendations. The main goals or objectives that were identified to be

accomplished throughout the study were:

1. Conduct air quality monitoring for total dust in the deburring area of Company XYZ

2. Determine if and to what extent the workers in the deburring area of Company XYZ are

being exposed to total dust

3. Decrease employee’s exposure to total dust by implementing applicable

recommendations/controls

4. Conduct a follow-up air quality test to determine the effectiveness of implemented

controls

This chapter will provide the results of the initial air quality monitoring that was

conducted on one employee, interpretations and calculations of this test; as well as the results

from the follow-up air quality monitoring conducted on three employees after recommended

controls were implemented by Company XYZ in the deburring area. This chapter will also

contain the test results from the accredited laboratory with confidential information edited out as

figures.

Initial Sampling

In order to achieve the first goal or objective an air quality monitoring test was conducted

on one employee in the deburring area of Company XYZ. This was conducted to identify if

there was a potential for employees being over exposed to total dust.

29

The sampling pump was calibrated to an initial air flow of 2.0 liters per minute using a

rotameter. The sampling pump was attached to the employee at Company XYZ in the deburring

area per the manufacturer’s recommendations and turned on to sample until the pump was turned

off and removed from the employee. The sampling pump was placed on the employee for 390

minutes, or 6.5 hours. After the sampling pump was removed from the employee the pump was

connected to the same rotameter once again and was shown to have the same air flow rate of 2.0

liters per minute as before the sampling started. The filter was sent to the accredited laboratory

and was weighted to have 26.5 milligrams of particulate matter on the filter that was collected

from the air quality monitoring.

In order to achieve the second goal of the study calculation of the resulting air quality

monitoring test data had to be interpreted and converted to milligrams per cubic meter. In order

to determine if the employee was over exposed to total dust the resulting data must be compared

to the Minnesota OSHA permissible exposure limit, or MNOSHA PEL, which is in milligrams

per cubic meters. By multiplying the flow rate in liters by the time in minutes it will yield the

total number of liters of air that was pulled through the filter by the sampling pump.

390 minutes * 2.0 L/minute = 780 L

Once the total volume of air that passed through the filter is figured out the total liters of

air needs to be converted to cubic meters which is a factor of one thousand, so 780 liters equals

0.780 cubic meters in volume. With the amount of cubic meters know this number can now put

into a calculation with the total weight of the particulate matter on the filter, which was 26.5

milligrams.

26.5 mg / 0.780 m3 = 33.97 or 34 mg/m3

30

This calculation results in showing that the employee was exposed to 34 mg/m3 of total

dust during the 390 minute, or 6.5 hours of working while conducting deburring of aluminum at

Company XYZ. Figure 1 below is the report from the accredited laboratory with some

information edited out.

The results from the initial air quality sampling indicated employees had the potential to

be over exposed to total dust in the deburring area. Therefore, in order to achieve the third goal

of the study some controls that were recommended (which will be discussed in further details in

Chapter V: Summary, Conclusions, and Recommendations) were implemented and follow up air

quality sampling was performed to determine if and to what extent the implemented controls

helped to decrease the employee’s exposure to total dust.

31

Figure 1 – Initial Air Quality Monitoring Results

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32

Follow up Sampling

In order to achieve the fourth goal of the study the same steps and procedures were used

during a follow up air quality sampling the only difference being that the follow up consisted of

three individual employees wearing air sampling pumps instead of only one employee and

applicable recommended controls were implemented.

The first of the three employees wore a sampling pump for 489 minutes (8.15 hours), the

second employee wore a sampling pump for 495 minutes (8.25 hours), and the third employee

wore a sampling pump for 490 minutes (8.17 hours).

All pumps were calibrated using the rotameter to have a flow rate of 2.0 liters per minute,

however, the rotameter used during this calibration had a conversion formula of y = 1.05x –

0.190, where x = the rotameter reading when connected to the sampling pump and y = the

adjusted flow rate based on the rotameter calibration in the laboratory. This meant that the 2.0

number that was read from the rotameter had to be plugged into the equation as x, and y was the

number used in the calculations. Also, the pre-calibration of the sampling pump on employee 3

was 2.0, however, the post-calibration on the sampling pump was 2.10, which meant that the two

numbers had to be averaged and used in the equation as the flow rate (2.05). Thus resulting in

the following equations:

Sampling pump 1 – y = 1.05(2.0) – 0.190 = 1.91 liters per minute

Sampling pump 2 – y = 1.05(2.0) – 0.190 = 1.91 liters per minute

Sampling pump 3 – y = 1.05(2.05) – 0.190 = 1.96 liters per minute

The calculations for total volume of air pulled through the sampling pumps (and filters)

are listed out below:

Employee 1 – 489 minutes * 1.91 L/minute = 934 L

33

Employee 2 – 495 minutes * 1.91 L/minute = 945.5 L

Employee 3 – 490 minutes * 1.96 L/minute = 960.4 L

Next the total volume of each of the employees was converted to cubic meters, which

would be; Employee 1 = 0.934m3, Employee 2 = 0.9445m3, and Employee 3 = 0.9604 m3.

The accredited laboratory weighted the filters to be 0.913 mg, 1.83 mg, and 0.295 mg

respectively. So using those numbers the total milligrams per cubic meter can be calculated.

Employee 1 = 0.913 mg / 0.934 m3 = 0.98 mg/m3

Employee 2 = 1.83 mg / 0.9445 m3 = 1.9 mg/m3

Employee 3 = 0.295 mg / 0.9604 m3 = 0.31 mg/m3

Figure 2 below is the report from the accredited laboratory with some information edited

out.

34

Figure 2 – Follow up Air Quality Monitoring Results

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35

Discussion

According to the results of the air quality sampling and the literature review employees

deburring the extruded aluminum in the deburring area of Company XYZ are potentially being

overexposed to total dust during a normal work shift. This could potentially lead to various

occupational respiratory illnesses and skin contact hazards. The literature review supports the

implementation of controls, such as respiratory protection, etc…, to decrease the potential

exposure to total dust. Implementing controls could potentially result in decreased employee

exposure to the present hazards.

36

Chapter V: Summary, Conclusions, and Recommendations

The current process of deburring extruded aluminum in the deburring area of Company

has the potential of placing Company XYZ’s employees at risk of being over exposed to total

dust and possibly developing various occupational respiratory illnesses. Therefore, the purpose

of the study was to determine if and to what extent Company XYZ’s employees were being

exposed to total dust in the deburring area. In addition to the purpose of the study, the author

will make applicable recommendation to decrease this potential exposure to Company XYZ’s

employees. The main goals or objectives of this study that were identified to be accomplished

were:

1. Conduct air quality monitoring for total dust in the deburring area of Company XYZ

2. Determine if and to what extent the workers in the deburring area of Company XYZ are

being exposed to total dust

3. Decrease employee’s exposure to total dust by implementing applicable

recommendations/controls

4. Conduct a follow-up air quality test to determine the effectiveness of implemented

controls

This chapter will provide conclusions from the study and both engineering and

administrative controls that will be recommended to Company XYZ to decrease employee

exposure to total dust. This chapter will also contain ideas for areas of further research on this

topic.

Methods

This paper focused on identifying if there was a potential for employees deburring

extruded aluminum in the deburring area of Company XYZ to be over exposed to total dust and

37

if so to what extent. These goals were achieved by conducting a literature review on various

respiratory topics (air sampling techniques, respiratory protection analysis, anatomy of the

respiratory system, and occupational respiratory illnesses) and conducting an air quality

sampling test on an employee performing this job at Company XYZ.

It was also a goal of this study to decrease employee’s exposure to total dust in the

deburring area by implementing various engineering and administrative controls or

recommendations and then verify the potential for exposure decreased by conducting a follow up

air quality sampling test. This was achieved by discussing applicable recommendations with the

Safety Director of Company XYZ and implementing a few of these recommendations, then

conducting a follow up air quality sampling test.

Conclusions

Based on the initial air quality sampling results of 34 mg/m3 it is shown that employees

deburring extruded aluminum in the deburring area are being exposed to over twice the

permissible exposure limit (PEL) set by the Occupational Health and Safety

Administration (OSHA), which is 15 mg/m3.

Based on the initial air quality sampling as well as the literature review it is concluded

that the process of deburring extruded aluminum in the deburring area of Company XYZ

has the potential of over exposing employees in this area to total dust, which could enter

the respiratory system and potentially result in occupational respiratory illnesses.

Based on the follow up air quality sampling results (0.98 mg/m3, 1.9 mg/m3, and

0.31mg/m3) after applicable recommendations were implemented, it is concluded the

controls implemented did decrease the employee’s exposure to total dust in the deburing

area of Company XYZ.

38

Recommendations

The following sections consist of engineering and administrative controls the author

recommends will help Company XYZ control the potential of their employees from being over

exposed to total dust while deburring extruded aluminum in the deburring area.

Engineering Controls

Consider changing the grinding wheel used in the hand-held grinder used to deburr the

extruded aluminum. Changing the grinding wheel could potentially lead to less

particulate matter in the air in the breathing area of the employee.

Install a hood system over the deburing area that has an air ventilation intake right beside

the hand grinder. This would potentially prevent particulate matter from mixing with the

air and creating a dust cloud in the breathable area of the employee.

Install a more fine saw blade to reduce the amount of burr on the cut aluminum. This

could potentially reduce the burrs on the aluminum as this will create a finer cut resulting

in less need for detail work, such as deburring.

Administrative Controls

Rotate employees in and out of the deburring area more often. Do not have an employee

work in the deburring area for more than a couple of hours at a time, and not for an entire

eight hour shift. This will decrease the time the employee is exposed to total dust.

Implement a respiratory protection program to require employees in the deburring area to

wear applicable respirators in order to decrease the exposure to particulate matter in the

deburring area. This will filter out certain particulate matter and will potentially decrease

employee exposure.

39

Areas of Further Improvement

Through this study the author has identified that there is a potential of placing employees

at risk of being over exposed to total dust while deburring extruded aluminum in the deburring

area of Company XYZ. In Chapter IV: Results, it was shown that Company XYZ has decreased

this exposure to total dust well below the OSHA permissible exposure limit (PEL) by

implementing some of the controls recommended by the author. As a result of implementing

these controls Company XYZ has practically eliminated the exposure to total dust in the

deburring area, therefore, there is no need for further areas of improvement as it relates to this

topic at Company XYZ.

40

References

The Aluminum Extruders Council (AEC). (2011). Retrieved October 13, 2011, from

http://www.aec.org/techinfo/expro.html.

American Psychological Association. (2001). Publication Manual of the American

Psychological Association (Fifth Edition). Washington, DC: American Psychological

Association.

Braner, Roger L. (2006). Safety and Health for Engineers. Hoboken, New Jersey: John Wiley

and Son, Inc.

Bridgman, Karen E., (March 2011). A Systemic Approach to Respiratory Health [Electronic

version]. Journal of the Australian Traditional-Medicine Society, 17(1), 9-16.

Chaff, Linda F. (2006). Total Health and Safety for Health Care Facilities. Chicago, IL: Health

Forum, Inc.

Ebbing, Darrell D. and Gammon, Steven D. (1999). General Chemistry: 5th

Edition. Boston,

MA: Houghton Mifflin Company.

The Franklin Institute. (2011). Retrieved October 15, 2011, from

http://www.fi.edu/learn/heart/systems/respiration.html.

Furlow, Bryant, (July/August 2011). Occupational Lung Diseases [Electronic version].

Radiologic Technology, 82(6), 543-565.

Krieger, Gary R. (1995). Accident Prevention Manual for Business & Industry. Itasca, IL:

National Safety Council.

Manufacturing Industry News. (2011). Retrieved October 13, 2011, from

http://manufacturing.hubspot.com/bid/26793/The-Aluminum-Extrusion-Manufacturing-

Process.

41

Occupational Safety and Health Administration, U.S Department of Labor. (2011). Personal

Protective Equipment: Respiratory Protection: 1910.134(b). Retrieved from

http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_

id=12716.

The Ohio State University Medical Center. (2011). Retrieved October 15, 2011, from

http://medicalcenter.osu.edu/patientcare/healthcare_services/lung_diseases/about/anatom

y/Pages/index.aspx.

Penn Aluminum International LLC. (2005). Retrieved October 13, 2011, from

http://www.pennaluminum.com/extproc.asp.

Plog, Barbara A. (2002). Fundamentals of Industrial Hygiene: 5th

Edition. Itasca, IL: National

Safety Council.

Stacey, Neill H. (1993). Occupational Toxicology. Bristal, PA: Taylor and Francis, Inc.

University of Maryland Medical Center. (January 18, 2008). Retrieved November 11, 2011, from

http://www.umm.edu/respiratory/anatomy.htm.

42

SAMPLER: FILTER (tared 37-mm, 5-µm PVC filter)

FLOW RATE: 1 to 2 L/min

VOL-MIN: 7 L @ 15 mg/m -MAX: 133 L @ 15 mg/m

SHIPMENT: routine

SAMPLE STABILITY: indefinitely

BLANKS: 2 to 10 field blanks per set

BULK

SAMPLE: none required

ACCURACY

RANGE STUDIED: 8 to 28 mg/m

BIAS: 0.01%

OVERALL PRECISION ( ) : 0.056 [1]

ACCURACY: ±11.04%

TECHNIQUE: GRAVIMETRIC (FILTER WEIGHT)

ANALYTE: airborne particulate material

BALANCE: 0.001 mg sensitivity; use same balance before and after sample collection

CALIBRATION: National Institute of Standards and Technology Class S-1.1 weights or ASTM Class 1 weights

RANGE: 0.1 to 2 mg per sample

ESTIMATED LOD: 0.03 mg per sample

PRECISION ( ): 0.026 [2]

OVERALL PRECISION ( ) : 0.056 [1]

Appendix A: NIOSH: Particulates Not Otherwise Regulated, Total 0500

METHOD: 0500, Issue 2 EVALUATION: FULL Issue 1: 15 February 1984 Issue 2: 15 August 1994

OSHA: 15 mg/m3 PROPERTIES: contains no asbestos and quartz less than 1% NIOSH: no REL ACGIH: 10 mg/m3, total dust less than 1% quartz

SYNONYMS: nuisance dusts; particulates not otherwise classified

SAMPLING MEASUREMENT

APPLICABILITY: The working range is 1 to 20 mg/m3 for a 100-L air sample. This method is nonspecific and determines the total dust concentration to which a worker is exposed. It may be applied, e.g., to gravimetric determination of fibrous glass [3] in addition to the other ACGIH particulates not otherwise regulated [4].

INTERFERENCES: Organic and volatile particulate matter may be removed by dry ashing [3].

OTHER METHODS: This method is similar to the criteria document method for fibrous glass [3] and Method 5000 for carbon black. This method replaces Method S349 [5]. Impingers and direct-reading instruments may be used to collect total dust samples, but these have limitations for personal sampling.

43

EQUIPMENT:

1. Sampler: 37-mm PVC, 2- to 5-µm pore size membrane or equivalent hydrophobic filter and supporting pad in 37-mm cassette filter holder.

2. Personal sampling pump, 1 to 2 L/min, with flexible connecting tubing. 3. Microbalance, capable of weighing to 0.001 mg. 4. Static neutralizer: e.g., Po-210; replace nine months after the production date. 5. Forceps (preferably nylon). 6. Environmental chamber or room for balance (e.g., 20 °C ± 1 °C and 50% ± 5% RH).

SPECIAL PRECAUTIONS: None.

PREPARATION OF FILTERS BEFORE SAMPLING:

1. Equilibrate the filters in an environmentally controlled weighing area or chamber for at least 2 h. NOTE: An environmentally controlled chamber is desirable, but not required.

2. Number the backup pads with a ballpoint pen and place them, numbered side down, in filter cassette bottom sections.

3. Weigh the filters in an environmentally controlled area or chamber. Record the filter tare weight, (mg). a. Zero the balance before each weighing. b. Handle the filter with forceps. Pass the filter over an antistatic radiation source. Repeat this step

if filter does not release easily from the forceps or if filter attracts balance pan. Static electricity can cause erroneous weight readings.

4. Assemble the filter in the filter cassettes and close firmly so that leakage around the filter will not occur. Place a plug in each opening of the filter cassette. Place a cellulose shrink band around the filter cassette, allow to dry and mark with the same number as the backup pad.

SAMPLING:

5. Calibrate each personal sampling pump with a representative sampler in line. 6. Sample at 1 to 2 L/min for a total sample volume of 7 to 133 L. Do not exceed a total filter loading of

approximately 2 mg total dust. Take two to four replicate samples for each batch of field samples for quality assurance on the sampling procedure.

SAMPLE PREPARATION:

7. Wipe dust from the external surface of the filter cassette with a moist paper towel to minimize contamination. Discard the paper towel.

8. Remove the top and bottom plugs from the filter cassette. Equilibrate for at least 2 h in the balance room.

9. Remove the cassette band, pry open the cassette, and remove the filter gently to avoid loss of dust. NOTE: If the filter adheres to the underside of the cassette top, very gently lift away by using the dull side of a scalpel blade. This must be done carefully or the filter will tear.

CALIBRATION AND QUALITY CONTROL:

10. Zero the microbalance before all weighings. Use the same microbalance for weighing filters before and after sample collection. Maintain and calibrate the balance with National Institute o f Standards and Technology Class S-1.1 or ASTM Class 1 weights.

11. The set of replicate samples should be exposed to the same dust environment, either in a laboratory dust chamber [7] or in the field [8]. The quality control samples must be taken with

44

the same equipment, procedures, and personnel used in the routine field samples. The relative standard deviation calculated from these replicates should be recorded on control charts and action taken when the precision is out of control [7].

MEASUREMENT:

12. Weigh each filter, including field blanks. Record the post-sampling weight , (mg). Record anything remarkable about a filter (e.g., overload, leakage, wet, torn, etc.)

CALCULATIONS:

13. Calculate the concentration of total particulate, (mg/m3), in the air volume sampled, (L):

mg/m3

where: W1 = tare weight of the filter before sampling (mg), W2 = post-sampling weight of sampling-containing filter (mg) B1 = mean tare weight of blank filter (mg) B2 = mean post-sampling weight of blank filter (mg) EVALUATION OF METHOD:

Lab testing with blank filters and generated atmospheres of carbon black was done at 8 to 28 mg/m3 [2,6]. Precision and accuracy data are given on page 0500-1.

REFERENCES:

[1] NIOSH Manual of Analytical Methods, 3rd ed., NMAM 5000, DHHS (NIOSH) Publication No. 84-100 (1984).

[2] Unpublished data from Non-textile Cotton Study, NIOSH/DRDS/EIB. [3] NIOSH Criteria for a Recommended Standard ... Occupational Exposure to Fibrous Glass, U.S.

Department of Health, Education, and Welfare, Publ. (NIOSH) 77-152, 119–142 (1977). [4] 1993-1994 Threshold Limit Values and Biological Exposure Indices, Appendix D, ACGIH, Cincinnati,

OH (1993). [5] NIOSH Manual of Analytical Methods, 2nd ed., V. 3, S349, U.S. Department of Health, Education, and

Welfare, Publ. (NIOSH) 77-157-C (1977). [6] Documentation of the NIOSH Validation Tests, S262 and S349, U.S. Department of Health,

Education, and Welfare, Publ. (NIOSH) 77-185 (1977). [7] Bowman, J.D., D.L. Bartley, G.M. Breuer, L.J. Doemeny, and D.J. Murdock. Accuracy Criteria

Recommended for the Certification of Gravimetric Coal Mine Dust Personal Samplers. NTIS Pub. No. PB 85-222446 (1984).

[8] Breslin, J.A., S.J. Page, and R.A. Jankowski. Precision of Personal Sampling of Respirable Dust in Coal Mines, U.S. Bureau of Mines Report of Investigations #8740 (1983).

METHOD REVISED BY: Jerry Clere and Frank Hearl, P.E., NIOSH/DRDS