Health Hazard Evaluations (HHEs)

(2009) Exposure to hazardous metals during electronics recycling at four UNICOR facilities. (Click to open report)
Introduction: On November 27, 2007, the National Institute for Occupational Safety and Health (NIOSH) received a request for technical assistance from the United States Department of Justice (USDOJ), Office of the Inspector General (OIG), in their health and safety investigation of the Federal Prison Industries, Inc. (UNICOR) electronics recycling program at Bureau of Prisons (BOP) institutions in Elkton, Ohio; Texarkana, Texas; and Atwater, California. We were asked to assess the current medica... (Click to show more) Introduction: On November 27, 2007, the National Institute for Occupational Safety and Health (NIOSH) received a request for technical assistance from the United States Department of Justice (USDOJ), Office of the Inspector General (OIG), in their health and safety investigation of the Federal Prison Industries, Inc. (UNICOR) electronics recycling program at Bureau of Prisons (BOP) institutions in Elkton, Ohio; Texarkana, Texas; and Atwater, California. We were asked to assess the current medical surveillance program for inmates and staff exposed to lead and cadmium during electronics recycling, and to make recommendations for future surveillance. In addition, we were asked to assess past exposures to lead and cadmium, and to investigate the potential for "take-home" exposure. Later we were asked to perform a similar evaluation for the BOP institution in Marianna, Florida. We reviewed medical surveillance records, individual medical records, and industrial hygiene sampling records from each institution. We visited each institution and toured the current and/or former recycling and glass breaking facilities and met with staff and inmates to hear their concerns and present our findings. We also performed industrial hygiene sampling at Elkton and Texarkana. At the time of our site visits, glass breaking was being performed at Elkton and Texarkana, but not at Marianna or Atwater. Letters containing detailed information about our assessment, findings, and recommendations for each facility were sent to the OIG and the warden and union at each facility after each of these evaluations. In August 2009, the OIG forwarded additional data for inmates at Elkton. This report contains a summary of our findings at each institution, a review of the additional biological monitoring for Elkton, and overall conclusions and recommendations. For a copy of the individual letters for each BOP institution, please call 513-841-4382. Facility Evaluations: Federal Correctional Institution Elkton: Electronics recycling at the Federal Correctional Institution (FCI) Elkton appears to have taken place from 1997 until May 2003 without adequate engineering controls, respiratory protection, medical surveillance, or industrial hygiene monitoring. Because of the lack of biological monitoring and industrial hygiene data, we cannot determine the extent of exposure to lead and cadmium that occurred during that time frame, but descriptions of work tasks from staff and inmates indicate that exposures were not well controlled, causing the potential for exposure above occupational exposure limits (OELs) for lead and cadmium. Based upon available sampling results, we determined that the current glass breaking operation (GBO) controls exposure to lead and cadmium to far below occupational exposure limits. The GBO can be further enhanced to limit exposure to those performing glass breaking as well as limiting the migration of lead and cadmium from the GBO into other areas. Results of biological monitoring of staff and inmates since 2003 were unremarkable. While some take-home contamination was documented in inmate cubicles, surface wipe sampling and biological monitoring suggest that take-home contamination did not pose a health threat. In late August 2009, the USDOJ provided biological monitoring data for 10 inmates, 8 of whom were on the roster of inmates performing glass breaking. The results of this monitoring were unremarkable. One inmate glass breaker was tested in early April 2002, prior to the installation of the glass breaking booth in 2003. This inmate is the only individual for whom we have results prior to that time. His blood lead level (BLL) was 5 micrograms per deciliter (microg/dL), and his blood cadmium level (CdB) was 0.7 micrograms per liter. We cannot determine the extent of exposure to lead that occurred in the chip recovery process because of the lack of data. Descriptions of work tasks from staff and a BLL of 5 microg/dL in an inmate 4 months after the process ended indicate that exposure to lead during this process did occur. We found no evidence that actions were taken to prevent exposure to lead at the outset in the chip recovery process and that no medical surveillance was performed until after the process ended. Medical surveillance has not complied with Occupational Safety and Health Administration (OSHA) standards. No medical exams (including physical examinations) were done on inmates, staff received inconsistent examinations and biological monitoring by their personal physicians, biological monitoring for lead was not done at standard intervals, and results were not communicated to the inmates. Inappropriate biological monitoring tests such as urine lead and arsenic testing have been done. Records of medical surveillance were not maintained by the employer for the appropriate length of time. After careful review of existing records and current operations, we conclude that the only persons with current potential for exposure to either lead or cadmium over the OSHA action level are the inmates who perform glass breaking or monthly filter change-out. We believe that medical surveillance can be discontinued for all other inmates and staff. Some former inmates and/or staff may require surveillance under the OSHA Cadmium Standard. Federal Correctional Institution Texarkana: Electronics recycling at FCI Texarkana appears to have been performed from late 2001 until May 2004 without appropriate engineering controls, respiratory protection, medical surveillance, or industrial hygiene monitoring. Because of the sparse biological monitoring and industrial hygiene data, we cannot determine the extent of exposure to lead and cadmium that occurred during that time. Descriptions of work tasks from staff and inmates indicate that exposures were not well controlled, causing a potential for exposure above OELs for lead and cadmium. Based on information provided to us and our industrial hygiene sampling, we believe that the current GBO is a significant improvement with respect to controlling worker exposures to cadmium and lead. Some lead- and cadmium-containing dust is still being carried out of the glass breaking booth. Although this does not represent a serious health hazard, it shows a need to maintain good housekeeping throughout the glass breaking area. Exposures since May 2004 are sufficiently low that the OSHA-mandated medical surveillance has not been required since that time. In addition, the results of medical surveillance conducted since 2003 on inmates and staff were generally unremarkable. It is not possible to quantify past exposures to determine whether they triggered the OSHA lead and/or cadmium standard prior to that time. Inmates are advised of the results of their monitoring and see the physician's assistant; however, records of medical surveillance are not maintained by the employer for the appropriate length of time. Some staff have refused to participate in medical surveillance paid by UNICOR but conducted by their personal physicians. After careful review of existing records and current operations, we conclude that medical surveillance can be discontinued for inmates and staff who work in electronics recycling and GBO. UNICOR may choose to continue to perform the limited biological monitoring currently in place as an additional safeguard against excessive exposure and to provide reassurance to inmates and staff. United States Penitentiary Atwater: Inmates were exposed to cadmium and lead above OELs during glass breaking from 2002-2003. It appears that inmates worked without adequate respiratory protection from April 2002 until July 2002. Exposures seem to have been better controlled with relocation of the GBO to the spray booth; however, one sample taken after the relocation demonstrated significant airborne cadmium exposure. Results of medical surveillance of inmates and staff were unremarkable. The medical surveillance program was not in compliance with the... (Click to show less)
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(2009) Findings from industrial hygiene air sampling, ventilation assessment, and a medical survey at a facility that manufactures flavorings, modified dairy products, and bacterial additives. (Click to open report)
Background: Workers at Chr. Hansen, Inc., in New Berlin, Wisconsin, requested that NIOSH perform a health hazard evaluation to investigate the risk of respiratory and eye problems from exposures to diacetyl, butter flavorings, cheese flavorings, enzymes, colors, bacterial cultures, and cleaning agents. The plant has separate rooms for the production of the following products and product types: 1. Starter distillate, a liquid which contains the flavoring chemical diacetyl, is produced in the star... (Click to show more) Background: Workers at Chr. Hansen, Inc., in New Berlin, Wisconsin, requested that NIOSH perform a health hazard evaluation to investigate the risk of respiratory and eye problems from exposures to diacetyl, butter flavorings, cheese flavorings, enzymes, colors, bacterial cultures, and cleaning agents. The plant has separate rooms for the production of the following products and product types: 1. Starter distillate, a liquid which contains the flavoring chemical diacetyl, is produced in the starter distillate room. 2. CHY-MAXR, a standardized solution of the enzyme chymosin (produced at another plant) is diluted and packaged in the enzymes room; starter distillate is also diluted and packaged in this room. 3. Cheese, dairy, and other flavors and cheese products are produced in the flavors room. 4. Powdered flavors and colors are produced through a spray drying process in the spray dry room. 5. Bacterial blends for use in foods intended for human consumption are produced in the human health room. (Flavorings are not used or produced in this room.) 6. Bacterial blends for use as feed supplements for farm animals are produced in the animal health rooms. (Flavorings are not used or produced in this room.) Exposures related to production of flavorings are of particular concern to NIOSH. Previous NIOSH investigations have identified evidence of a severe disease of the small airways in the lung (bronchiolitis obliterans) among workers exposed to butter flavoring chemicals in microwave popcorn plants and among production workers in flavoring manufacturing plants. Exposures to enzymes and other organic dust are also of concern due to their potential to cause lung disease in some individuals. Workplace exposures to enzymes can cause asthma and other allergic problems. Repeated exposure to organic dusts (materials from living things such as plants, animals, bacteria, or fungi) can cause hypersensitivity pneumonitis, another serious lung disease. Assessment: NIOSH staff visited the plant initially in September 2007 to meet with management and workers, conduct an initial walkthrough of the plant, learn about production processes, and do preliminary air sampling. NIOSH staff returned to the plant in December 2007 to do a detailed ventilation assessment and industrial hygiene air sampling, and to conduct a medical survey which included a questionnaire and lung function testing with spirometry. All current workers in production areas, the QC laboratory, the warehouse, and maintenance were invited to participate in the medical survey. For analyses of the medical survey results by type of potential exposure in the plant, workers were classified as follows: 1. Flavoring workers: Current workers with potential exposure to diacetyl and other flavoring-related chemicals in the starter distillate, enzymes, flavors, or spray dry rooms, the QC laboratory, or in maintenance work. 2. Bacterial products workers: Current workers with potential exposure to bacteria and other organic dusts in the animal health or human health rooms. 3. Warehouse workers. Results: Air sampling showed diacetyl air concentrations in the spray dry, starter distillate, and flavors rooms and in the quality control laboratory that were similar to those measured at some flavoring plants and microwave popcorn plants where some workers have developed severe lung disease likely caused by exposure to diacetyl and possibly other flavoring chemicals. This included both average air concentrations over the work shift and peak air concentrations during specific tasks. The atmospheric pressure in the spray dry and flavors rooms was neutral to positive relative to the warehouse; as a result, movement of air contaminants from those rooms into the warehouse is possible. The Torit local exhaust ventilation unit used during packaging of finished product in the spray dry room allowed some of the captured dust to escape back into the room air. One worker in the flavoring worker group had mild fixed airways obstruction on spirometry testing. Although this finding might be related to flavoring chemical exposures, additional medical tests are required to establish if a particular lung disease is present and the likely cause; information from additional medical evaluation was not available to NIOSH investigators. Among nine current and former workers in flavoring production areas who reported chest symptoms from work exposures, three workers reported chest symptoms from exposure to enzymes; three workers reported chest symptoms from exposure to acids; one worker reported chest symptoms from exposure to diacetyl; and one worker reported chest symptoms from exposure to encapsulated starter distillate. One worker reported eye burning from diacetyl and starter distillate. Air sampling in the animal health large and intermediate packaging rooms showed intermittent peak exposures to dust during ingredient mixing and product packaging activities. For some processes, local exhaust ventilation in these rooms did not adequately control dust exposures. Of ten workers in the animal and human health rooms who participated in the medical survey, five reported post-hire skin problems, four reported chest symptoms from exposures, and three reported work-related eye and nasal symptoms. Two of the four with chest symptoms reported that these occurred with exposure to Biomax and other powders. Spirometry tests in two animal health workers showed restriction, a decreased ability to fully expand the lungs. One of the two workers with restriction also reported weekly episodes of unusual tiredness and fatigue and monthly episodes of fever, chills, or night sweats. These symptoms in an individual with restriction on spirometry can be due to hypersensitivity pneumonitis, a lung disease which occurs in a small percentage of individuals exposed to organic dusts. Additional medical tests are necessary for a physician to establish if an individual has this disease. Conclusions and Recommendations: The levels of diacetyl measured in flavoring production areas at the Chr. Hansen plant may be high enough to put workers at risk of developing severe lung disease. Because flavoring-related lung disease can occur after only several months of exposure and can rapidly progress to severe irreversible disease, uncontrolled exposures should be minimized. Workers in the animal and human health rooms may also be at risk for respiratory symptoms and disease from exposure to organic dust. The Recommendations section of this report contains detailed guidance on what Chr. Hansen mangers should do to decrease exposures in all production rooms, the quality control laboratory, and the warehouse to minimize the potential for workers to develop respiratory and other health effects. The following approaches for prevention are addressed: ventilation improvements, administrative and work practice changes, use of respirators and other personal protective equipment, worker education, and medical monitoring with regularly scheduled spirometry tests. (Click to show less)
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(2009) Report on an investigation of asthma and respiratory symptoms among workers at a soy processing plant. (Click to open report)
On December 12, 2006, the National Institute for Occupational Safety and Health (NIOSH) received a confidential Health Hazard Evaluation (HHE) request from workers at the Solae Company's plant in Memphis, Tennessee. The requesters described respiratory symptoms and diagnoses, including sinus congestion and asthma, which they attributed to the workplace. They noted exposure to soy materials, lime (calcium oxide (CaO)), microbial contaminants such as mold, and insects. NIOSH investigators conducte... (Click to show more) On December 12, 2006, the National Institute for Occupational Safety and Health (NIOSH) received a confidential Health Hazard Evaluation (HHE) request from workers at the Solae Company's plant in Memphis, Tennessee. The requesters described respiratory symptoms and diagnoses, including sinus congestion and asthma, which they attributed to the workplace. They noted exposure to soy materials, lime (calcium oxide (CaO)), microbial contaminants such as mold, and insects. NIOSH investigators conducted telephone interviews with workers, a union representative, treating physicians, and company management and safety officials. On March 6, 2007, NIOSH investigators visited the plant to observe the process, measure concentrations of airborne dust, collect bulk samples of soy materials, and interview workers about their symptoms and exposures. They later conducted an industrial hygiene survey (July 9-13 and July 30-August 3, 2007). NIOSH investigators collected personal and area air samples from different plant areas, sub-areas, and jobs during the survey. They collected: personal (breathing-zone) air samples for inhalable dust and inhalable soy antigen; personal (breathing-zone) and area air measurements for airborne dust of respirable and thoracic size fractions using a real-time sampler; and area air samples for inhalable dust, inhalable soy antigen, total dust, total endotoxin, selected metals, and particle size distributions. They also collected bulk samples of soy materials from different sub-areas of the plant. From July 23-August 2, 2007, NIOSH investigators also conducted a medical survey of current workers at the plant; it consisted of an interviewer-administered questionnaire; lung function testing, including spirometry, bronchodilator, and methacholine challenge testing; and skin and blood allergy testing. Inhalable dust exposures were highest for the autopack operator, unloading switch operator, and sanitation job categories. Some of the samples from these job categories, as well as from starch dumping, exceeded the Occupational Safety and Health Administration (OSHA) permissible exposure limit (PEL) for total dust as particulate not otherwise regulated (PNOR) and the American Conference of Governmental Industrial Hygienists (ACGIH) threshold limit values (TLV) for inhalable dust. The task of starch dumping, which produced the highest dust concentrations measured (21.7 mg/m3), was typically done by workers from several different job categories outside their normal shift work, using respiratory protection. Detectable soy antigen air concentrations were measured in all plant areas and sub-areas; the highest geometric mean inhalable soy antigen area concentration was in the flake processing room (308,000 ng/m3). Job categories with the highest geometric mean soy antigen concentration as measured by personal samples included the unloading switch operator (27,540 ng/m3), curd operator (25,960 ng/m3), and unloading lead (14,360 ng/m3). Currently, there are no occupational exposure standards or guidelines specifically for soybean dusts, though the more general PNOR standard does apply to soybean dusts. The highest endotoxin concentration, 217 EU/m3, was measured in the flake processing room; all other endotoxin concentrations were below 50 EU/m3. Calcium was detected in 5 of 67 total dust air samples; if the calcium in these samples was all present as lime (CaO), the highest corresponding lime concentration in air would have been approximately 0.52 mg/m3, a level well below the existing OSHA standard for lime dust. Of the 281 workers currently employed at the plant by the Solae Company, 147(52%) consented to participate in the medical survey and completed the questionnaire. Participation rates varied by worker classification, ranging from 66 of 94 (70%) production workers to 42 of 114 (37%) non-production workers. NIOSH staff conducted lung function testing for 140 of these workers, skin allergy testing for 132, and blood allergy testing for 135. Participating workers at the Solae plant in Memphis had higher than expected prevalences of physician-diagnosed asthma, sinusitis, and wheeze (a symptom of asthma) compared to the U.S. adult population. The prevalences of current and ever physician-diagnosed asthma for participating males were higher than expected based on a survey of the state of Tennessee, but these differences did not reach statistical significance. Among participants with adult-onset, physician-diagnosed asthma, most were diagnosed after hire at Solae. The incidence rate was five times greater after hire than before hire, consistent with a temporal relationship of occupational exposures preceding asthma diagnosis. Compared to non-production workers, production workers were more likely to report asthma-like symptoms that improve away from work. Work-related asthma-like symptoms were also associated with peak dust concentrations. Compared to workers exposed to lower peak concentrations, participants exposed to higher peak concentrations of dust were more likely to report work-related asthma-like symptoms. Additionally, workers who reported seeing or smelling mold in the workplace were more likely to report work-related sinusitis, nasal allergies, and rash compared to workers not reporting this exposure. Fourteen participants (10%) had airways obstruction on spirometry (six borderline and eight mild or worse severity). Eleven (8%) had spirometry results indicating a restrictive pattern. One had both airways obstruction and restriction. Two had a clinically significant response to bronchodilator and 12, including eight without airways obstruction on spirometry, had evidence of bronchial hyperresponsiveness on methacholine challenge testing. The prevalence of positive immunoglobulin E (IgE) to soy among Solae workers was five times greater than the prevalence among a group of comparison workers who were not occupationally exposed to soy, suggesting that immune recognition of soy among Solae workers resulted from occupational exposures. All asthma outcomes were significantly associated with immune response to soy, as measured by soy-specific IgE levels in the blood but not as measured by the skin prick test for soybean allergy. Concentrations of soy antigen and dust exposure were process-related. Compared to workers exposed to lower peak concentrations, those exposed to higher peak dust concentrations (measured by real-time sampling) were more likely to have spirometry indicating airways obstruction and to report work-related asthma-like symptoms. In addition, level of immunoglobulin G (IgG) to soy was associated with inhalable soy antigen level and work classification. Time-weighted-average inhalable soy antigen and dust concentrations were not associated with asthma outcomes in analyses involving all participants. (Click to show less)
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(2008) Contact dermatitis among machinists at an automotive parts manufacturer. (Click to open report)
NIOSH received a request for an HHE at Dana Corporation in Bristol, Virginia from the United Auto Workers, Local 9023. Employees were concerned that poor indoor environmental quality and exposures to chemicals, nylon powder, and dust from grinding machines were causing rashes, nose bleeds, and respiratory problems, and that SRMF levels from induction heaters were causing cancer. Discussions held with union and management representatives determined that dermatitis was the major concern among empl... (Click to show more) NIOSH received a request for an HHE at Dana Corporation in Bristol, Virginia from the United Auto Workers, Local 9023. Employees were concerned that poor indoor environmental quality and exposures to chemicals, nylon powder, and dust from grinding machines were causing rashes, nose bleeds, and respiratory problems, and that SRMF levels from induction heaters were causing cancer. Discussions held with union and management representatives determined that dermatitis was the major concern among employees. On June 13-15, 2006, NIOSH investigators held an opening meeting with management and union representatives and toured the plant to observe work practices. We measured sub-radiofrequency magnetic field (SRMF) levels near the induction heaters, collected bulk metalworking fluid (MWF) samples, evaluated potential acid gas exposures, assessed Local exhaust ventilation (LEV) at the nylon coating operation and the acid dip tank, interviewed employees privately, and performed medical evaluations of the skin. We found machines using MWFs that were not being cleaned between fluid change-out and machines leaking hydraulic oil into MWF reservoirs. Analysis of bulk MWF samples revealed irritant and sensitizing chemical components. Employees had direct skin contact with MWFs, and their training in the safe use and handling of MWFs was inadequate. Of the 72 employees interviewed, 37 reported a prior or current skin problem that they related to work; 11 employees had a rash that was likely work-related at the time of the evaluation. Exposures to SRMFs and acid gases were below OELs. Aerosol cans of antirust spray were used in areas without LEV, and powder had accumulated on horizontal surfaces near the nylon powder coating operation. We recommend developing a comprehensive MWF maintenance program, repairing machines to avoid oil leakage into MWFs, and avoiding the use of MWFs and biocides with irritating and sensitizing components such as formaldehyde-releasing agents. We recommend that employees report potential work-related health problems to their supervisors. The company should educate employees in the safe use and handling of MWFs, methods to prevent work-related skin disease, and appropriate use of PPE. Ventilation should be improved where antirust spray is used and in the nylon powder coating area when drums are charged. (Click to show less)
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(2008) Exposures at a pottery shop. (Click to open report)
On February 2, 2007, NIOSH received a management request for an HHE at FUNKe Fired Arts, previously known as Annie's Mud Pie Shop, in Cincinnati, Ohio. Although no health symptoms were reported, management was concerned about the potential for employees' long-term exposure to a variety of substances while performing duties at the pottery shop. Exposures of concern included silica from the clay mixing process, elements from mixing dry materials used in the glazes, and VOCs and gases during kiln f... (Click to show more) On February 2, 2007, NIOSH received a management request for an HHE at FUNKe Fired Arts, previously known as Annie's Mud Pie Shop, in Cincinnati, Ohio. Although no health symptoms were reported, management was concerned about the potential for employees' long-term exposure to a variety of substances while performing duties at the pottery shop. Exposures of concern included silica from the clay mixing process, elements from mixing dry materials used in the glazes, and VOCs and gases during kiln firing. Because management requires the use of respirators during clay and glaze mixing, they also requested information on proper respirator use and maintenance. On March 21, 2007, NIOSH investigators held an opening conference and toured the facility to review work processes. On April 11, 12, and May 24, 2007, NIOSH investigators collected eight 8-hour PBZ samples and six area air samples for respirable particulates and silica. Six separate PBZ samples were taken while employees performed specific dust-generating tasks. Wipe sampling for elements was conducted throughout the facility. An ergonomic evaluation of the work processes was performed. During the firing of the kilns, area air samples were taken for elements, NO2, SO2, CO, CO2, and VOCs. CO readings were also taken during forklift activities. None of the PBZ or area air samples exceeded the OSHA PELs or NIOSH RELs for any of the compounds measured, although one employee's exposure for silica was at the NIOSH REL of 0.05 mg/m3. Tasks that created the highest concentrations of respirable silica and particulates included moving bags of raw materials to and from storage and mixing clay. Short-term concentrations of silica were high, reaching 2.0 mg/m3 over 96 minutes of sampling. This exceeded ACGIH's excursion limit of 5 times the TWA TLV. VOCs, NO2, and SO2 concentrations were not detected above the MDC during the kiln-firing process. Although PBZ samples of CO were not taken during the use of the forklift, real-time area CO measurements taken at breathing zone level in the storage room peaked at 204 ppm, exceeding the NIOSH ceiling limit of 200 ppm. Due to the silica content of the clay and the potential for silica exposures to exceed OELs, we recommend using engineering controls to reduce employee exposures. This includes installing LEV in areas where high dust-generating activities take place and improving general building ventilation to allow adequate intake of outdoor air, mixing of indoor air, and dilution of potential airborne contaminants. Engineering controls are the preferred method over respirator use to reduce exposures to workplace contaminants. However, respirators should be used, and a formal respiratory protection program should be implemented until exposures can be reduced below the NIOSH REL and ACGIH excursion limit for silica. We also recommend establishing a health and safety training program for employees on appropriate equipment use and hazards. We further recommend that employees and students practice good hygiene in the workplace. Regular preventive maintenance for the forklift should be performed, eventually transitioning to a low or no emission forklift, and loading dock doors should be kept open while using the forklift to prevent the build-up of CO. (Click to show less)
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