Health Hazard Evaluations (HHEs)

(2000) Newark Fire Department, Newark, New Jersey. (Click to open report)
On December 22, 1998, the National Institute for Occupational Safety and Health (NIOSH) received a request for a health hazard evaluation (HHE) from the International Association of Fire Fighters (IAFF) on behalf of fire fighters from the Newark Fire Department (NFD) to assess the incident response procedures followed during a fire in a refuse waste-to-energy facility (American Ref-fuel) on December 17, 1998, in Newark, New Jersey. The IAFF indicated that several of the fire fighters responding ... (Click to show more) On December 22, 1998, the National Institute for Occupational Safety and Health (NIOSH) received a request for a health hazard evaluation (HHE) from the International Association of Fire Fighters (IAFF) on behalf of fire fighters from the Newark Fire Department (NFD) to assess the incident response procedures followed during a fire in a refuse waste-to-energy facility (American Ref-fuel) on December 17, 1998, in Newark, New Jersey. The IAFF indicated that several of the fire fighters responding to the incident were subsequently hospitalized due to smoke and chlorine gas inhalation. NIOSH investigators conducted a site visit to the NFD on April 12-13, 1999, and again on June 24, 1999. NIOSH personnel conducted private interviews with several NFD fire fighters who responded to the incident and reviewed several incident-related records provided by the NFD, including the department's standard operating procedures (SOPs) and medical records. Self-administered questionnaires were distributed to fire fighters who were not present on the days of the NIOSH investigation. In addition to the medical interviews and questionnaires, medical records were reviewed from five hospitals where the fire fighters received medical care, and from the occupational medicine provider for the NFD. NIOSH investigators also visited American Ref-fuel. On December 17, 1998, the NFD received a report of a fire in the refuse pit of American Ref-fuel. The fire was declared a hazardous materials incident as information became known that the fire had involved chlorine bleach cleaner which, according to the product's material safety data sheet, would liberate chlorine and phosgene as decomposition products. Fire fighters used the plant's showering facilities for decontamination purposes before all of the 37 responding fire fighters were sent to area hospitals for evaluation. The medical survey showed that most fire fighters at the scene experienced some degree of acute upper respiratory tract irritation, and many experienced lower respiratory tract irritation as well. Fifteen had persistent symptoms at 24 hours, and 13 had symptoms at the time of the NIOSH investigation. Based on the combustion of chlorine-containing cleaner, the fire fighters' exposures probably consisted primarily of irritant gases, such as chlorine and nitrogen trichloride. Medical records revealed that the treating physicians were aware that the fire fighters were exposed to chemicals at a fire and were concerned about the inhalation of toxic fumes and smoke. However, neither fire fighters nor treating physicians knew what specific toxins were present. The symptoms of the fire fighters were consistent in the different hospitals, however the diagnostic tests performed differed. The university based hospital performed the most diagnostic tests on the fire fighters. The other hospitals performed fewer tests, but this did not appear to result in a greater rate of adverse health outcomes. The elements leading to fire fighter exposures at the waste-to-energy plant on December 17, 1998, are complex and multi-factorial in nature. Clearly, fire fighters did encounter exposures to irritant gasses at the scene. The NFD approached the incident in fire mode, when in fact, a hazardous materials (HAZMAT) response approach would have been more appropriate. Most fire fighters suffered irritant symptoms that were the result of exposures to irritant gases at American Ref-fuel. For those fire fighters who had recovered at the time of the NIOSH investigation or did not develop symptoms, it is unlikely that this exposure will result in further health problems. Those who developed more significant respiratory symptoms were being evaluated by health care providers. Several recommendations are offered for improving fire fighter health and safety, including recommendations for better integration of fire fighter medical surveillance information with acute care occupational medicine providers, better personal protective equipment (PPE) usage, and filling gaps in HAZMAT coverage. (Click to show less)
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(2000) Spectro Coating Corporation, Leominster, MA. (Click to open report)
The Spectro Coating Corporation applies flock to backing materials in one plant in Leominster, Massachusetts. The management requested a health hazard evaluation (HHE) to get a better understanding of the respiratory hazards in the plant. At the time of the request, an extensive HHE at another company's flocking facility in Rhode Island (NIOSH 1998) had uncovered a cluster of cases of a new occupational lung disease (flock workers' lung) [Kern et al. 1998]. In addition, one worker at Spectro Coa... (Click to show more) The Spectro Coating Corporation applies flock to backing materials in one plant in Leominster, Massachusetts. The management requested a health hazard evaluation (HHE) to get a better understanding of the respiratory hazards in the plant. At the time of the request, an extensive HHE at another company's flocking facility in Rhode Island (NIOSH 1998) had uncovered a cluster of cases of a new occupational lung disease (flock workers' lung) [Kern et al. 1998]. In addition, one worker at Spectro Coating had a diagnosis of the same illness. In November 1998, NIOSH conducted an investigation at the Spectro Coating plant consisting of a symptom and work history questionnaire and personal and area sampling, primarily for respirable dust (small enough to reach the deepest areas of the lungs) and fiber counts. Approximately 87% of the workers participated in the survey. The results and conclusions of the survey are as follows: The same types of particles identified at the Rhode Island plant were also present in air samples collected at Spectro Coating. Even though the dust concentrations were lower compared to those in the Rhode Island plant, blow-down exposures at Spectro Coating were associated with respiratory symptoms in workers. Blow-down cleaning with compressed air and flock-loading resulted in the highest dust concentrations measured in this workplace. Blow-down exposures were associated with an excess of fever/aches and cough/phlegm. Decreasing exposures should lead to decreased symptoms and complaints. Gravimetric respirable dust measurement appears to be a suitable method for characterizing concentrations in this setting. Smoking alone and in interaction with the exposures from compressed air cleaning was associated with symptoms. Respirator use was sporadic, and many workers had not been fit-tested. The following are specific recommendations for this workplace: Reduce dust exposures with engineering controls. Until engineering controls are in place, limit the use of blow-downs and use personal respiratory protection to control dust exposures. Expend the annual medical examination to include a means for identifying workers with frequent fever, aches, cough, phlegm, wheezing, or other respiratory symptoms. Workers with any of these symptoms should receive a medical evaluation and an opportunity to reduce dust exposures by placement out of high exposure jobs. Periodically inform workers about work-related disease observed among flock workers and how to reduce or control their risk of disease. Implement a no-smoking policy at the plant (NIOSH 1991). If allowed at all, smoking at the plant should be restricted to designated, seperately-ventilated smoking areas. Workers should be encouraged to stop smoking altogether through an employer-sponsored smoking cessation program and education campaign. NIOSH investigators determined that a health hazard exists from occupational exposure to flock-associated dust This risk is characterized by the occurrence of physician-diagnosed interstitial lung disease in at least one worker, and by the results of a respiratory symptom survey that suggest an association of respiratory and systemic symptoms with conducting compressed air cleaning (blow-downs). The hazard is related to dust exposure and is found to be the greatest in the flocking room. Reduction of worker exposure to airborne dust is recommended to protect the health of the workers at this plant. (Click to show less)
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(2000) Thyssen-Dover Elevator, Middleton, Tennessee. (Click to open report)
On March 14, 2000, the National Institute for Occupational Safety and Health (NIOSH) received a joint management/union request for a health hazard evaluation (HHE) at the Thyssen-Dover Elevator facility in Middleton, Tennessee. The request asked NIOSH to determine if workplace exposures are related to health problems that some employees have experienced. Specific areas of concern identified in the request included both traditional welding and laser metal cutting processes. Reported symptoms were... (Click to show more) On March 14, 2000, the National Institute for Occupational Safety and Health (NIOSH) received a joint management/union request for a health hazard evaluation (HHE) at the Thyssen-Dover Elevator facility in Middleton, Tennessee. The request asked NIOSH to determine if workplace exposures are related to health problems that some employees have experienced. Specific areas of concern identified in the request included both traditional welding and laser metal cutting processes. Reported symptoms were muscle weakness, tingling fingers, weight loss, and diverticulitis. On May 1-3, 2000, NIOSH researchers conducted a site visit at the Thyssen-Dover Elevator facility. During the site visit, integrated personal air sampling was conducted to evaluate employee exposure to welding fume during the first and second work shifts in Departments 544, 543, 591, 597, and at the Bystronic laser. Instantaneous air samples were collected for carbon monoxide (CO), oxides of nitrogen (NOx), and ozone (O3) at various locations in the manufacturing area. Bulk samples for asbestos analysis were obtained from ceiling insulation and the Department 544 oven. Company accident and illness records were reviewed. Confidential interviews were conducted with 24 first and second shift employees. The laser cutting operation was reviewed. The personal air sampling results showed that employees in Department 544 were exposed to total welding fume, above the American Conference of Governmental Industrial Hygienists (ACGIH) threshold limit value (TLV) of 5 milligrams per cubic meter (mg/m 3 ). Full shift time-weighted average (TWA) exposures for the two employees in this department were 5.44 mg/m3 and 6.10 mg/m3 . NIOSH recommends controlling welding fume to the lowest feasible concentration and meeting the exposure limit for each welding fume constituent. Element-specific analyses of the welding fume components showed that manganese exposure for the two Department 544 workers exceeded the ACGIH TLV of 0.2 mg/m3 on the day of the monitoring. TWA concentrations measured were 0.23 mg/m3 and 0.31 mg/m3 . The NIOSH recommended exposure limit (REL) for manganese fume is 1.0 mg/m3 . One sample from a Department 544 welder found exposure to lead in excess of the 30 micrograms per cubic meter Action Level established by the Occupational Safety and Health Administration. No other samples indicated the presence of lead above the limit of quantification. The source of the lead was not determined. In general, air contaminant concentrations were lower during the second (evening) work shift. General dilution ventilation is the primary ventilation control at this facility. Carbon monoxide concentrations of 8-12 parts per million (ppm) were measured at various locations of the manufacturing area during the first shift. The NIOSH REL for CO is 35 ppm and the ACGIH TLV for CO is 25 ppm. The primary source of the CO is likely the propane-powered lift trucks. Low concentrations of NOx were measured at some welding stations and ozone was not detected in any of the samples. No asbestos was found in any of the bulk samples. A limited review of the laser cutting operation indicated that protective shielding to prevent eye exposure to beam radiation may not be adequate. Worker complaints were grouped into three general categories; gastro-intestinal symptoms, neurological symptoms, and chronic sinusitis. Symptoms that were reported appeared to be associated with the work (i.e., symptoms appeared after reporting for work and improved or resolved after the employee left work). However, no work exposures could be found that would be the primary cause of chronic sinusitis or gastrointestinal symptoms. Welders complained of neurologic symptoms that were suggestive of manganese poisoning. Manganese exposure levels measured during this site visit would not be expected to result in manganese poisoning, but higher past exposure levels, or chronic exposure to elevated manganese levels, may account for the symptoms described by welders at this plant. Industrial hygiene monitoring found Department 544 worker exposure to total welding fume and manganese in excess of established criteria. One sample from this department showed lead exposure in excess of regulatory criteria. Because the facility is an open manufacturing environment, incorporates numerous processes, and relies on general dilution ventilation as the primary control, the worker exposure profile in the manufacturing area is complex. Contaminant concentrations were generally lower on the second shift. Shielding to prevent eye exposure to beam radiation on a high power laser cutter may have been altered. Workers reported gastro-intestinal symptoms, neurological symptoms, and chronic sinusitis. The temporal pattern for the gastrointestinal and chronic sinusitis was consistent with a workplace exposure, however, no workplace exposures were found that would explain these symptoms. Manganese levels measured at this site would not be expected to result in the neurologic symptoms observed and/or reported, however, higher past exposures or chronic exposures over time may account for these symptoms. Recommendations to provide respiratory protection as an interim measure, improve ventilation, conduct additional monitoring, utilize welding shields, review and modify the laser cutter, and reduce carbon monoxide emissions are in the Recommendations section of this report. (Click to show less)
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(1999) Astoria Metal Corporation, Hunters Point Naval Shipyard, San Francisco, California. (Click to open report)
On May 7, 1997, the (NIOSH) received a request for a health hazard evaluation (HHE) at Astoria Metal Corporation (AMC) located at Hunters Point Naval Shipyard in San Francisco, California. The request, which was submitted jointly by AMC management and the International Brotherhood of Boilermakers, raised concerns about repetitive motion injuries and metal exposures during welding, torch cutting, grinding, and abrasive blasting operations. Due to an ongoing OSHA investigation, NIOSH did not condu... (Click to show more) On May 7, 1997, the (NIOSH) received a request for a health hazard evaluation (HHE) at Astoria Metal Corporation (AMC) located at Hunters Point Naval Shipyard in San Francisco, California. The request, which was submitted jointly by AMC management and the International Brotherhood of Boilermakers, raised concerns about repetitive motion injuries and metal exposures during welding, torch cutting, grinding, and abrasive blasting operations. Due to an ongoing OSHA investigation, NIOSH did not conduct a site visit until April 1998. On April 1, 1998, NIOSH researchers conducted an industrial hygiene and ergonomic evaluation on ships being repaired or dismantled on Dry Dock #4, to identify specific work areas and job tasks and to devise an air sampling and ergonomic evaluation plan. On April 2 and 3, 1998, personal breathing zone (PBZ) air samples and bulk paint chip samples were collected for metals analysis. NIOSH investigators also reviewed the lead and respiratory protection programs, and the OSHA 200 Log and Summary of Occupational Illnesses and Injuries. An ergonomic evaluation was conducted on selected employees performing welding tasks on Dry Dock #4, and on three office workers performing administrative duties that involved the use of personal computers. PBZ air samples were collected from AMC workers performing job tasks involving welding, grinding, and torch cutting. In the process area, three workers were monitored while torch cutting (with oxygen and propane) large metal structures (gimbal assembly) removed from the superstructure of the Glomar Explorer. In the dry dock, five workers were monitored while retrofitting and repairing two barges; two workers were underneath the barges and three were inside the barge tanks. Work activities included stick and metal inert gas (MIG) welding of new materials onto the barge. Also in the dry dock, two workers onboard the U.S.S. Ashtabula were monitored while torch cutting and removing non-ferrous materials such as brass, copper, and aluminum from the engine room. PBZ air sample results (8-hr, time -weighted averages (TWAs)) are separated into four work areas: the U.S.S. Ashtabula, the process area, inside the barge tank, and under the barge. On the U.S.S. Ashtabula, all four PBZ air sample lead concentrations exceeded the NIOSH recommended exposure limit (REL), OSHA permissible exposure limit (PEL), and the ACGIH threshold limit value (TLV) of 50 micrograms per cubic meter (ug/m3), with lead concentrations ranging from 253 to 435 ug/m3. Cadmium concentrations ranged from 10 to 61 ug/m3: all four PBZ air sample concentrations exceeded the PEL of 5 ug/m3 and TLV of 10 ug/m3. NIOSH considers cadmium to be a potential occupational carcinogen, and recommends that exposures be reduced to the lowest feasible levels. The highest lead and cadmium concentrations were collected from the worker torch cutting and removing non-ferrous materials. Nickel concentrations ranged from 14 to 55 ug/m3, with three of four PBZ air sample concentrations exceeding the REL of 15 ug/m3. Copper concentrations ranged from 168 to 362 ug/m3, with all four PBZ air sample concentrations exceeding the REL and the PEL of 100 ug/m3. The highest nickel and copper concentrations were collected from the firewatcher. In the process area, lead concentrations ranged from 41 to 399 ug/m3; four of five PBZ air sample concentrations exceeded the REL, PEL, and TLV of 50 ug/m3. Cadmium concentrations ranged from less than concentrations ranged from 1 to 43 ug/m3; three of five PBZ air samples exceeded the REL of 15 ug/m3. Copper concentrations range from 6 to 63 ug/m3; all five PBZ air sample concentrations were below the REL and the PEL. In the barge tank, lead concentrations ranged from 79 to 356 ug/m3; all five PBZ air sample concentrations exceeded the REL, PEL, and TLV. Nickel concentrations ranged from less than 0.6 to 3 ug/m3; all PBZ air sample concentrations were below relevant evaluation criteria. Manganese concentrations ranged from 82 to 873 ug/m3; four of five PBZ air sample concentrations exceeded the TLV of 200 ug/m3. Copper concentrations ranged from 11 to 19 ug/m3; all five PBZ air sample concentrations were below relevant evaluation criteria. Under the barge, lead concentrations ranged from less than 0.6 ug/m3 to 2.5 ug/m3; all four PBZ air sample concentrations were below relevant evaluation criteria. All nickel concentrations were below the minimum detectable concentrations (MDC) of concentrations ranged from 46 to 75 ug/m3; all PBZ air sample concentrations were below relevant evaluation criteria. Copper concentrations ranged from 2 to 5 ug/m3 and were below all relevant evaluation criteria. Workers performing tasks that involved welding, grinding, or torch cutting wore NIOSH-approved half-face, air-purifying respirators equipped with organic vapor and high efficiency particulate air (HEPA) filters. NIOSH has given these respirators an assigned protection factor (APF) of 10. Therefore, the maximum use concentration (MUC) for these respirators for lead is 500 ug/m3 as an 8-hr TWA (OSHA PEL of 50 ug/m3 x APF of 10 = 500 ug/m3). The MUC for cadmium is 50 ug/m3 as an 8-hr TWA. Based on this information, if the respirators are properly fitted to the workers and used in conjunction with a comprehensive respiratory protection program, personal exposures to lead, nickel, copper, and manganese would be expected to be below the occupational exposure limit. However, two of four PBZ air sample concentrations collected from workers on the ship exceeded the MUC of 50 ug/m3 for cadmium for these respirators. (Click to show less)
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(1999) Forest Park Police Department, Forest Park, Ohio. (Click to open report)
On June 30, 1997, the National Institute for Occupational Safety and Health (NIOSH) received a Health Hazard Evaluation (HHE) request from an employer representative of the Forest Park Police Department (FPPD). The requester was concerned for potential exposure to lead among range users. NIOSH investigators originally assigned to this HHE request conducted a walk-through evaluation on July 14, 1997, and a more thorough industrial hygiene evaluation on July 29, 1997. In November 1998, this HHE wa... (Click to show more) On June 30, 1997, the National Institute for Occupational Safety and Health (NIOSH) received a Health Hazard Evaluation (HHE) request from an employer representative of the Forest Park Police Department (FPPD). The requester was concerned for potential exposure to lead among range users. NIOSH investigators originally assigned to this HHE request conducted a walk-through evaluation on July 14, 1997, and a more thorough industrial hygiene evaluation on July 29, 1997. In November 1998, this HHE was reassigned because of personnel changes within NIOSH. Subsequently, a walk-through survey of the police firing range was conducted by the new hygienist on November 4, 1998, and further evaluations were conducted on December 10th and 21st, 1998. (Click to show less)
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