## SECTION 5

## ALUMINUM AND COPPER FOUNDRIES

**5.1 PROFILE**

Nonferrous foundries produce a variety of cast products using alloyed
and unalloyed copper, aluminum and other metals. These foundries may
produce castings of beryllium copper and, to a lesser extent, beryllium
aluminum. Foundries who might use beryllium alloys are classified in the
following industries as defined by NAICS:

-   Aluminum foundries (except die-casting) (NAICS 331524 \[SIC 3365\])

-   Copper foundries (except die-casting) (NAICS 331525 \[SIC 3366\])

    Other foundries perform die-casting of aluminum, copper, and other
    nonferrous alloys:

-   Aluminum die-casting foundries (NAICS 331521 \[SIC 3363\])

-   Nonferrous (except Aluminum) die-casting foundries (NAICS 331522
    \[SIC 3364\])

    Industry representatives suggest, however, that because of its
    metallurgical properties beryllium copper is not likely to be
    die-cast (Mallory, 2001). Table 5-1 shows Census data describing the
    copper and aluminum foundry industries. A limited amount of pure
    beryllium is cast for specialized aerospace applications; however,
    beryllium is usually alloyed with another metal. According to a U.S.
    Department of Energy publication, beryllium is alloyed with copper,
    aluminum, nickel, zinc, and zirconium (DOE, 2002). Beryllium-copper,
    beryllium-aluminum, and beryllium-nickel are cast in the United
    States. Typically, cast beryllium alloy contains 5 percent or less
    of beryllium. ERG found no information about casting of
    beryllium-zinc or beryllium-zirconium alloys in the United States.
    ERG found little information about the types of products produced by
    casting beryllium alloys. It is known, however, that
    beryllium-copper is cast to produce resistance welding electrodes
    and other parts of the welding electrode assembly such as holders
    and shanks; parts for the aerospace industry; and other specialized
    applications.

    ERG found limited information about the number of foundries casting
    beryllium and beryllium alloys. Representatives of neither the
    American Foundry Society nor the Non-Ferrous Founders' Society could
    provide an estimate of the number of foundries casting these metals.
    However, both believe the number is small (Robinson, 2002; NFFS,
    2002). Other industry sources contacted representing companies that
    use beryllium alloys, including a copper and an aluminum foundry, a
    resistance welding electrode manufacturer, and a brass and copper
    rolling mill, also indicated that few foundries cast beryllium and
    beryllium alloys, although they could not estimate the number
    (Barbetti, 2002; Capozzi, 2002; Erickson, 2002; Specialloy, 2002).

  -------------- --------- -------------- ------------- -------------- -------------- -------------- --------------
  **Table 5-1.                                                                                       
  Copper and                                                                                         
  Aluminum                                                                                           
  Foundries,                                                                                         
  2002**                                                                                             

  **NAICS**      **No. of  **No. of       **Total       **Production   **Facilities   **Facilities   **Facilities
                 Firms**   Facilities**   Employees**   Workers**      with \<20      with 20 - 99   with \>99
                                                                       Employees**    Employees**    Employees**

  NAICS 331525,  280       281            7,062         5,831          175 (62%)      92 (33%)       14 (5%)
  Copper                                                                                             
  foundries                                                                                          
  (except                                                                                            
  die-casting)                                                                                       

  NAICS 331524,  508       542            29,108        23,623         310 (57%)      156 (29%)      76 (14%)
  Aluminum                                                                                           
  foundries                                                                                          
  (except                                                                                            
  die-casting)                                                                                       

  NAICS 331521,  255       295            28,264        23,551         109 (37%)      102 (35%)      84 (28%)
  Aluminum                                                                                           
  die-casting                                                                                        
  foundries                                                                                          

  NAICS 3311522, 218       238            14,839        11,875         110 (46%)      84 (35%)       44 (19%)
  Nonferrous                                                                                         
  (except                                                                                            
  aluminum)                                                                                          
  die-casting                                                                                        
  foundries                                                                                          

  Source: U.S.                                                                                       
  Census Bureau,                                                                                     
  2004.                                                                                              
  -------------- --------- -------------- ------------- -------------- -------------- -------------- --------------

Information from OSHA's Integrated Management Information System
indicated that beryllium was detected in 20, or 18.7 percent, of the 107
copper foundries where samples were taken during the period 1979 through
2001 (OSHA, 2003). An extrapolation of this percentage to the population
of copper foundries (281) suggests that about 52 such foundries work
with beryllium-copper alloys. Industry contacts suggest that the number
of foundries casting beryllium alloys has declined in recent years. Of
seven foundries contacted that indicated they have used beryllium
copper, two (28.6 percent) have stopped using the material in recent
years (Dollard, 2002; Enviro, 2001; Johnson, 2002; Specialloy, 2002;
Taylor, 2001; Tricast, 2001; Worldcast, 2001).

Table 5-2 shows Census data describing the number of copper foundries
with shipments in categories that would include beryllium-cooper,
specifically high-copper alloys. The table shows that 25 firms produced
copper and high-copper sand castings, and 25 firms also produced
investment castings out of high-copper alloy alloys. Fewer foundries
produced high-copper mold, centrifugal, and other types of castings.
These categories are not exclusive, however, and firms might be listed
more than once. The number of foundries using high-copper alloys is,
therefore, less than the aggregate shown on the table (89). Assuming the
number of unique foundries represented in Table 5-2 is one-half the
aggregate, the Census data suggest that about 45 copper foundries might
potentially work with beryllium-alloys. This estimate is consistent with
the findings from OSHA's IMIS database, given the recent decline in
beryllium-copper use in the foundry industry.

+---+----------------------------------------------------------+--------+
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+---+----------------------------------------------------------+--------+
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+---+----------------------------------------------------------+--------+
|   | 331250416 Copper and high-copper sand castings (except   | 25     |
|   | bearings and bushings)                                   |        |
+---+----------------------------------------------------------+--------+
|   |                                                          |        |
+---+----------------------------------------------------------+--------+
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+---+----------------------------------------------------------+--------+
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+---+----------------------------------------------------------+--------+
|   | 331250531 Permanent and semipermanent mold castings      | 12     |
+---+----------------------------------------------------------+--------+
|   | 331250536 Centrifugal casings                            | 13     |
+---+----------------------------------------------------------+--------+
|   | 331250541 Investments castings                           | 25     |
+---+----------------------------------------------------------+--------+
|   | 331250546 Other castings                                 | 10     |
+---+----------------------------------------------------------+--------+
|   |                                                          |        |
+---+----------------------------------------------------------+--------+
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+---+----------------------------------------------------------+--------+

ERG found little information to estimate the number of foundries in the
United States that cast beryllium-aluminum alloys. The use of these
alloys is thought to be much less common than the use of beryllium
copper. Further, the representative of an aluminum foundry that uses
beryllium-aluminum master alloys indicated that he believes the trend is
away from the use of beryllium alloys in aluminum foundries (Barbetti,
2002).

As presented in Table 5-3, an estimated 14 foundry companies cast
beryllium-aluminum alloys. Of these foundries, at least 12 are estimated
to use beryllium-aluminum master alloys (Kosto, 2002). The remaining two
foundries cast both pure beryllium and beryllium composite or hybrid
products. These foundries make parts for specialized aerospace
applications (DOD, 2002; Peregrine, 2002). For purposes of this
analysis, ERG divided these establishments between the two aluminum
foundry industries

Table 5-3 summarizes these estimates of the numbers of beryllium alloy
foundries. Employee estimates are based on the average employments sizes
for the respective industries. ERG, thus, estimates a total of 97
foundry establishments with 4,547 employees, of which 3,694 are employed
in production occupations.

  ---------------------------- -------------------- ------------- ----------------
  **Table 5-3. Foundries                                          
  Casting Beryllium and                                           
  Beryllium Alloys**                                              

  **Industry**                 **Establishments**   **Total       **Production
                                                    Employees**   Employees**

  NAICS 331521, Aluminum       7                    671           559
  die-casting foundries                                           

  NAICS 3311522, Nonferrous    38                   2,369         1,896
  (except aluminum)                                               
  die-casting foundries                                           

  NAICS 331524, Aluminum       7                    376           305
  foundries (except                                               
  die-casting)                                                    

  NAICS 331525, Copper         45                   1,131         934
  foundries (except                                               
  die-casting)                                                    

  **Total**                    97                   4,547         3,694

  Source: ERG estimates; see                                      
  text.                                                           
  ---------------------------- -------------------- ------------- ----------------

ERG also used information from the 2002 Economic Census to estimate the
numbers of beryllium-alloy foundries that perform sand casting. Based on
Census data, ERG estimated that 25 copper foundries in NAICS 331525
might perform sand casting of copper-beryllium alloys (US Census Bureau,
2004). The remaining establishments in this industry are assumed to
perform other types of casting operations (e.g., permanent mold,
investment, or lost wax casting).

**5.1.1 Affected Job Categories**

[]{.mark}

The metal casting industry is extremely diverse, employing many
different casting processes for a wide variety of applications. The
following sections address, by job category, foundry processes typically
associated with worker exposure to beryllium, worker exposure levels,
baseline working conditions, additional controls available, and
preliminary conclusions regarding the extent of exposure reduction
possible.

[]{.mark}

The production of castings using beryllium alloys includes the following
basic processes: 1) preparing a mold into which the molten metal is
poured; 2) melting and pouring the molten metal; and 3) cleaning the
cooled metal casting to remove molding and extraneous metal (NIOSH,
1985). The primary job categories with potential for beryllium exposure
in foundries are as follows:

-   Molder (including sand mold-maker and permanent mold
    maintenance)\[see note below\]

-   Material handler

-   Furnace operator (also melt operator)

-   Pouring operator

-   Shakeout operator (only in foundries using sand molds or cores)

-   Abrasive blasting (shotblast) operator

-   Finishing/grinding operator

-   Maintenance operator (including furnace and ladle maintenance)

-   Housekeeping worker

Note: In this analysis, the term *sand* is used generically to refer to
any granular media used in "green sand casting" or other sand-casting
process. As an alternative to silica, sand may consist of zircon,
olivine, granular ceramic media, or other materials.

The volume, size, and type of castings produced vary widely from one
foundry to another, ranging from a few large specialized castings to
thousands of small castings per shift. Depending on the size of the
foundry, each task may be performed by a separate operator or one
operator may be responsible for several tasks. In high production
foundries, workers are likely to be responsible for a single task (e.g.,
molder, pouring operator, furnace operator) whereas in small, or highly
automated shops a single worker may be assigned to several operations,
such as combined responsibilities for furnace operation and pouring
(NIOSH, 1978).

[]{.mark}

In addition to the categories listed above, other operations may occur
in foundries, including the following: pattern making, core making,
welding, arc-air gouging, X-ray inspection of castings, and buffing.
Welding (and air-arc gouging) is the subject of a specific section of
this analysis and is not further addressed here. ERG assumes that the
other operations are not associated with significant direct beryllium
exposure and therefore they are not discussed in detail in this report.
Table 5-4 presents a summary of the major activities of foundry workers
potentially exposed to beryllium foundries.

[]{.mark}

+----------------------+-----------------------------------------------+
| **Table 5-4. Job     |                                               |
| Categories and Major |                                               |
| Activities of        |                                               |
| Workers Potentially  |                                               |
| Exposed to Beryllium |                                               |
| in Foundries**       |                                               |
|                      |                                               |
| []{.mark}            |                                               |
+======================+===============================================+
| **Job Category**     | **Major Activities**                          |
+----------------------+-----------------------------------------------+
| Molder (mold         | In foundries with re-usable molds, maintains  |
| maintenance, mold    | molds, removes metal deposits, cleans molds.  |
| formation, sand      | In sand casting foundries, monitors sand      |
| systems operation)   | systems and molding machine operation. May    |
|                      | apply mold parting/coating/release compound.  |
+----------------------+-----------------------------------------------+
| Material Handler     | May operate a front-end loader, forklift,     |
| (forlklift operator, | crane, or other material moving equipment to  |
| crane operator)      | transport metal, castings, or other           |
|                      | materials. Assists other workers with manual  |
|                      | handling activities (such as furnace          |
|                      | charging).                                    |
+----------------------+-----------------------------------------------+
| Furnace Operator     | Controls and monitors furnaces used to        |
| (Melt Operator)      | produce molten metal. Loads metal into        |
|                      | furnaces and skims dross from molten metal.   |
+----------------------+-----------------------------------------------+
| Pouring Operator     | Transfers molten metal into ladle or holding  |
| (Ladle Operator,     | furnace, and then into molds, typically via   |
| casting operator)    | equipment supported by a cart, crane, or rail |
|                      | configuration.                                |
+----------------------+-----------------------------------------------+
| Shakeout Operator    | In foundries using sand molds or cores,       |
|                      | oversees operation of shakeout and knockout   |
|                      | equipment to separate castings from molds.    |
|                      | Contact with equipment and castings depends   |
|                      | on the degree of automation.                  |
+----------------------+-----------------------------------------------+
| Abrasive Blasting    | Typically operates shotblasting cabinet; if   |
| Operator (includes   | very large casting, may blast on open floor   |
| Wheelabrator         | or use compressed air to clean castings.      |
| Operator, Rotoblast  |                                               |
| Operator)            |                                               |
+----------------------+-----------------------------------------------+
| Grinding/Finishing   | Uses portable or bench tools such as          |
| Operator (includes   | chippers, grinders, and polishers to remove   |
| Saw Operator,        | defects and adhered molding material from     |
| Sanding Operator)    | castings.                                     |
+----------------------+-----------------------------------------------+
| Maintenance Operator | Repairs and maintains foundry and furnace     |
|                      | equipment. May perform repair and maintenance |
|                      | of refractory lining on furnace, ladle, and   |
|                      | tundish. Activities may include dry sweeping, |
|                      | vacuuming, shoveling. Chips metal splatter    |
|                      | from floors and equipment.                    |
+----------------------+-----------------------------------------------+
| Housekeeping Worker  | Activities may include dry sweeping,          |
|                      | vacuuming, shoveling, and wiping. Chips metal |
|                      | splatter from floors and equipment.           |
+----------------------+-----------------------------------------------+

[]{.mark}

To derive estimates of the detailed distribution by occupation, ERG used
the 2002 Occupational Employment Survey to estimate the percentages of
foundry employees in each of these job classifications (BLS, 2003). The
percentages were then adjusted to account for occupations specific to
sand casting foundries (shakeout operator) and to ensure a minimum
number of employees per establishment (at least one) in each job
classification. The resultant percentages were then applied to the
employment totals to estimate the numbers of employees by job category
in the affected establishments. These estimates are shown in Table 5-4.

**5.2 PROCESS DESCRIPTIONS**

**Molder**: Molders prepare, clean, and maintain permanent and
non-permanent molds. Permanent (reusable) molds, or dies, require little
daily preparation other than assembly and cleaning (brushing, sweeping,
scraping, minor grinding, and applying mold release agents). If the
previous casting left beryllium residue (usually in the form of oxides)
on the molds, molders may be exposed to beryllium as they remove this
material. When molds will be reused immediately, workers perform these
tasks in the pouring area (in foundries with a small workforce, molder
tasks may be performed by the pouring operator). Molds can also be
transported to other areas for maintenance.

+----------------------------+--------------------+--------------------+
| **Table 5-5. Distribution  |                    |                    |
| of Beryllium Alloy Foundry |                    |                    |
| Employment by Affected Job |                    |                    |
| Category**                 |                    |                    |
+============================+====================+====================+
| **Job Category**           | **Percentage of    | **Number of        |
|                            | Employment**       | Employees**        |
+----------------------------+--------------------+--------------------+
| Molder                     | 13.8%              | 627                |
+----------------------------+--------------------+--------------------+
| Material handler           | 2.1%               | 95                 |
+----------------------------+--------------------+--------------------+
| Furnace operator           | 2.6%               | 118                |
+----------------------------+--------------------+--------------------+
| Pouring operator           | 4.2%               | 191                |
+----------------------------+--------------------+--------------------+
| Shakeout operator          | 1.5%               | 68                 |
+----------------------------+--------------------+--------------------+
| Abrasive blasting operator | 2.4%               | 109                |
+----------------------------+--------------------+--------------------+
| Grinding/sawyer            | 7.2%               | 327                |
+----------------------------+--------------------+--------------------+
| Maintenance operator       | 2.2%               | 100                |
+----------------------------+--------------------+--------------------+
| Housekeeping workers       | 3.3%               | 150                |
+----------------------------+--------------------+--------------------+
| Total -- affected job      | 39.4%              | 1,787              |
| categories                 |                    |                    |
+----------------------------+--------------------+--------------------+
| Other, non-affected        | 60.6%              | 2,760              |
| occupations                |                    |                    |
+----------------------------+--------------------+--------------------+
| []{.mark}                  |                    |                    |
+----------------------------+--------------------+--------------------+
| **Total**                  | 100.0%             | 4,547              |
+----------------------------+--------------------+--------------------+
| []{.mark}                  |                    |                    |
|                            |                    |                    |
| Sources: BLS, 2003; US     |                    |                    |
| Census Bureau, 2004; ERG   |                    |                    |
| estimates. See text.       |                    |                    |
+----------------------------+--------------------+--------------------+

In facilities that use non-permanent molds (e.g., sand casting
foundries), molders typically prepare molds by shaping granular media
(sand or similar substances) media and a binder into shapes that will
form molten metal, but will disintegrate to the original granular
structure when casting is complete. Sand casting methods do little to
minimize oxide formation and sand castings may be covered with beryllium
oxide (Corbett, 2004). As a result, reclaimed molding sand may become
contaminated with oxide dislodged from the casting during shakeout
activities. This process creates a source of beryllium exposure for
workers handling the sand and preparing molds in foundries that cast
beryllium alloys.

These sand molders usually work in an area of the foundry that is
functionally separate from other foundry activities; however, air
monitoring of lead and cadmium in copper and bronze sand casting
foundries indicates that molders can experience secondary metal fume and
dust exposures when poorly balanced ventilation systems allow
contaminated air to flow from melting and pouring spaces to the molding
area (CCMA, 2000). Results from OSHA's IMIS system indicate that molders
can also be exposed to beryllium (OSHA, 2003).

Note: ERG finds that the available information (with results exclusively
from OSHA's IMIS) is inadequate to differentiate workers handling
reusable molds and those working with expendable or sand molds. This is
an area where additional process and exposure information would help
determine whether workers performing these tasks should be divided into
two separate job categories.

**Material Handler (heavy equipment operator, crane operator, forklift
operator):** Material handlers transport materials and castings between
workstations. For these workers, the primary sources of beryllium
exposure include ineffectively controlled processes associated with
other job categories that the material handler must pass by or work
near, spilled and settled dusts that can be disturbed by the transport
equipment they operate (such as forklifts), dust released directly from
loads being transported by the material handler (e.g., fuming ladles,
open barrels of excess metal trimmed from casting), and beryllium fume
and dust that cause cross contamination in areas frequented by material
handlers. Forklift operators who charge furnaces and move dross/scrap
receptacles can experience beryllium dust exposure from these sources.
Forklift and crane operators who move new castings may encounter
beryllium oxide dust from these items or be exposed to fume as they pass
near active melting and pouring operations. As has been shown in other
studies, forklift drivers' exposure often related to areas they enter
where other workers' activities generate elevated airborne
concentrations of contaminant (ERG, 2003a).

**Furnace Operator (melt operator, furnace assistant):** Furnace
operators charge furnaces with new and/or reused metal (foundry scrap
returns), supervise the melting process, sparge molten metal in the
furnace (i.e., bubble gas through molten metal to promote mixing), skim
dross (use a scoop/wand to remove oxides and other contaminants that
form a scum at the surface of the molten metal). The tasks associated
with managing dross are reportedly among the activities that generate
the highest beryllium exposure levels in foundries (Corbett, 2004).

Furnace operators spend the majority of their time melting metal. The
more automated this process, the less physically involved the operator
will be with the furnace. Furnace operators frequently spend a
substantial amount of their shift in an office or control booth,
monitoring the melting process remotely and through periodic checks.
Certain tasks must be performed for each melt. Furnace charges (raw
materials in the form of ingot or foundry returns) must be prepared
(weighed) to create the desired mix, pre-heated, and placed in the
furnace (more than one charge may be required per melt). Heating the
charge usually occurs in a large specialized bucket placed in a separate
furnace. In addition to dust that might be released during the transfer
process, pre heating can cause air currents that disturb
beryllium-containing dust, particularly on foundry scrap returned to the
furnace for melting (the previous melting/casting cycle may have caused
beryllium oxides to form). Transfer of the charge to the furnace may be
manual or automated, depending on the size of the furnace and level of
foundry automation. Furnace operators often transfer the raw materials
(brought by a material handler to the furnace area) from a transport
container to the special bucket used for preheating the charge or making
additions to the furnace.

Once the raw material is in the furnace the operator initiates the
melting process, which involves several repetitive steps centered around
the furnace. Induction furnaces, typically cylindrical without a
refractory lid (open top), have been growing in popularity for a number
of years and now are the most common type of equipment controlled by
furnace operators. The furnace typically includes a small platform at
the top for the operator. Some foundry designs also include a separate
observation/control platform removed from the furnace or an enclosed
control room.

Regardless of the furnace type or foundry design, most of the melting
steps are similar. In one step, the furnace operator monitors the extent
to which impurities in the metal and oxygen (from air at the molten
metal surface) create dross (a "scum" on top of the molten metal).
Furnace operators must remove this dross at regular intervals to improve
the purity of the molten metal and prevent the newly forming oxides from
becoming incorporated into the melt when it is stirred.

To skim the dross, the furnace operator typically uses a scoop on a long
handle and reaches into the furnace to scoop the impurities from the
surface. After emptying the scoop into a receptacle, typically a bucket,
the operator repeats the process as many times as necessary. As was
previously noted, beryllium has an affinity for oxygen and oxides that
form on the surface of metal can have a higher beryllium content than
the base metal. Extra beryllium may be added to the mix to compensate
for beryllium lost as oxide and to ensure the final casting contains the
correct percentage. Furnace operators experience beryllium exposure when
they reach into the furnace (fumes rising off molten metal), when they
bring dross off the surface and move the scoop outside the furnace, and
when they knock the dross from the scoop into the receptacle. Additional
exposure may occur when the operator handles the dross receptacle to
transport it or empty it into a larger storage container. In addition to
the beryllium hazard, this work is physically demanding and hot.

Other activities associated with the melting process include sparging
the molten metal to stir it (adding gas-generating substance on a wand
or using an automated process, collecting samples for analysis (again
reaching into the furnace), and cleaning the melt deck. Operators also
visually check the melt frequently to determine whether other actions
are required. Eventually the metal is properly formulated, melted,
drossed, and sparged -- at this point the furnace operator adjusts the
furnace for tapping, that is transferring molten metal out of the
furnace for pouring. For example, in a typical operation, the furnace
will be tipped to pour metal into a tundish (gravity-feeds molds) or a
ladle (a container used to transport molten metal to another area where
it will be poured). This point marks the beginning of activities in the
Pouring Operator job category.

In smaller or more automated foundries, same individual will often
perform a number of jobs, for example furnace operators can control both
the furnace and the pouring operations (ERG, 2003b). These jobs are
separate in larger foundries, therefore exposures and controls relating
to pouring activities are addressed under the Pouring Operator job
category. Additionally, some furnace operators also maintain furnace
refractory linings, which can be contaminated with beryllium/oxide from
contact with molten metal that impregnates the semi-porous refractory
surface. This task, often performed by maintenance staff, is addressed
under the job category of Maintenance Workers (furnace maintenance).

Furnace operators frequently receive help from designated furnace
operation assistants and employees who normally work in other job
categories, but are appointed as helpers during the melt process (ERG,
2003b). During their time in working in the furnace area ERG has
considered these assistants and helpers to be performing work associated
with the furnace operator job category.

**Pouring Operator**: Pouring operators supervise the transfer of molten
metal from furnace (and any intermediary ladles) into molds. Depending
on the type of casting performed by the foundry, these workers oversee a
wider range of common or molding equipment. Examples include sand molds,
permanent molds such as dies, vacuum molding equipment (sucks molten
metal into mold), centrifugal (spins molten metal to force it out into a
mold or to coat the inside of a spinning cylinder -- such as for
manufacturing pipes), and water-chilled molds that quickly cool casting
surfaces (AFS, 2000). Depending on mold type, foundry staffing, and
casting size, some or all duties may be shared by the furnace operator,
the pouring operator, the molder, and/or the shakeout operator. One
worker may perform all these jobs (ERG, 2003b).

Beryllium fumes can enter pouring operators' breathing zones as the fume
rises off molten metal in open ladles, tundishs, and molds. AFS in its
*Foundry Ventilation Manual* (1985) notes, "Normally, copper and its
alloying agents due to greater toxicity have lower allowable exposure
levels (threshold limit values or permissible exposure levels) than
ferrous metals and their alloying agents." Additionally,
"...copper-based alloys have a lower vapor pressure than ferrous metals.
In the molten sate, they produce more metallic fume. Since the main
reservoir for the molten metal is the ladle(s), the majority of
emissions from these pouring operations emanates from that source than
the mold itself. Once copper-based alloys have solidified, the emission
of air contaminants drops to a very low level."

Fume escaping into the work area contribute to background exposure
levels in the pouring area and any other areas where air currents
transport the fume. Other sources of beryllium exposure in the pouring
area include any beryllium metal or oxide residue left on the molds (see
Molder job category) and refurbishing of the tundish and ladles (see the
Maintenance Operator job category). Adjacent operations can also
influence employee exposure in the pouring area. For practical reasons,
the pouring area is nearly always located adjacent to the furnace area,
with minimal barriers between the two spaces. Beryllium fume and dust
released from the furnace area can be a substantial source of exposure
for pouring operators. As an example, in Case History Foundry A, CCMA
(2000) describes a foundry in which make-up air was introduced behind
the furnaces. "The induced air supply swept any fugitive fume emissions
from the melting and ladle filling operations and moved them toward
shakeout, pouring, and molding, in that order.... The pouring lines were
also stagnant to a large extent, because the fans doing the general
ventilation were high overhead with no potential for creating air
movement near the factory floor."

Exhaust ventilation systems are available for numerous types of
equipment used in the pouring area; however, this equipment is not
consistently installed in foundries. Additionally, some ventilation
systems require special work practices and may be used improperly, which
decreases their effectiveness.

**Shakeout Operator*:*** Shakeout operators separate molds from
castings. If sand molds or sand cores are used in the casting process,
shakeout operators use vibrating equipment to dislodge granular media
("sand"). This process is generally termed "shakeout." Under some
casting conditions, beryllium oxide can form on the casting surface. In
these cases, sand can be contaminated with residual beryllium oxide from
contact with the cast metal surface.

Shakeout operators monitor equipment that separates castings from mold
materials by mechanically vibrating or tumbling the casting, The
castings, along with large lumps of molding sand and excess metal,
remain on top, while fine materials (primarily molding sand) feed
through grates. Sand separated during shakeout is transported away on a
portion of the sand transport system and is frequently reused (overseen
by another group of workers, molders). Shakeout operators may observe
automated equipment or might perform manual operations, primarily
loading and unloading the vibrating equipment. Additionally, depending
on the size of the cast metal, a material handler (e.g., crane operator)
may work in the shakeout area, hoisting the flask and then dumping it on
a vibrating table. During this operation, a second operator may be
responsible for rehooking the cast metal piece onto the crane for
transfer to the finishing area (NIOSH, 1978). Shakeouts vary from a
method of manually turning over the mold to systems that are fully
automated (AFS, 1985).

[]{.mark}

A NIOSH study described a manual shakeout operation at a copper-base
casting operation. At this facility, an oscillating shakeout was
mobilized on a set of tracks for shakeout at the end of any of the five
mold conveyor lines. Three workers operated the shakeout, two to dump
the molds from the pouring conveyor and simultaneously to retrieve the
bottom board, and the other worker to hook the casting off the conveyor
(NIOSH, 1978). Workers may also use sledgehammers and compressed air to
move excess sand from castings (NIOSH HETA 92-0090-2296, 1993). These
high-energy processes release substantial dust. If the molding materials
are contaminated with beryllium, beryllium dust might be released
(Corbett, 2004).

[]{.mark}

Shakeout operator's duties frequently overlap with those of pouring
operators and material handlers. For some casting methods (e.g.,
extruded casting processes), the shakeout operator job category may be
completely eliminated.

**Abrasive blasting operator:** Abrasive blasting operators clean
casting to remove residual molding material (sand, investment) and
surface oxides, and to prepare the metal surface for additional
treatment (e.g., painting). To blast the casting, theses workers use
abrasive media, usually steel shot or steel grit. Abrasive blasting
operators typically operate automated blasting machines (e.g.,
Wheelabrator) or related equipment such as tumbling media mills that
perform a similar function in cleaning castings. Large castings are
abrasively blasted in booths, although castings too large to fit in a
booth are typically blasted in an open area. Both surface oxide and
metal alloy dust can be released (chipped) from surface of casting
during surface preparation, which is typically performed using steel
grit or steel shot as the abrasive blasting media. Some abrasives can
themselves be a source of additional beryllium exposure (due to
beryllium content of abrasive media) (see Section 11 -- Abrasive
Blasting).

**Grinding/Finishing Operator:** Grinding/finishing operators perform
any required steps needed to finish castings (except cleaning steps
performed by shakeout operators and abrasive blasting operators). They
can use saws to removes gates, sprues and risers or trim the casting to
specification. These workers also perform grinding to remove minor
casting surface defects. They finish castings by polishing, sanding or
grinding pieces to customer specifications. Grinding/finishing operators
can use abrasive cut-off saws, stationary or hand-held grinding
equipment, sanding equipment, and machine tools (precision machining
activities grouped with this category). All of these items remove metal
from the casting and create beryllium metal dust. Some grinding and
sanding is performed to remove beryllium-containing oxide that forms on
the product during the casting process. This work can be performed using
wet methods in aluminum and copper foundries (ERG, 2003b).

**Maintenance Operators:** Maintenance operators repair equipment
throughout the facility. From the perspective of beryllium exposure,
important maintenance functions of this job category are the maintenance
of refractory linings on furnaces, ladles, and tundishes, and changing
ventilation system bags or filters.

Maintenance operators encounter beryllium when they chip and scrape
refractory ceramic linings that have been in contact with beryllium
alloys. Although new refractory ceramic material (usually a cementitious
mineral product) does not contain appreciable beryllium, molten metal
and metal oxides coat (and in some cases impregnate) the semi-porous
refractory surface upon use (Corbett, 2004). As noted previously, oxides
of beryllium can contain an appreciably higher beryllium content than
the original alloy. The oxide that accumulates on furnace, ladle, and
tundish walls can have a beryllium content that is several percent
higher than the original beryllium alloy held in that receptacle.
Because refractory ceramic linings are fragile (damaged by the heating
and cooling cycles to which they are subjected), maintenance operators
in some foundries must repair cracks and thin spots on a daily basis.
Furnace maintenance workers use manual (hammer and chisel, or scraping
tools) or power equipment (pneumatic chipping tools) to chip away
damaged/cracked refractory lining prior to patching (Refractory Services
Provider A, 2003b; ERG, 2003a). In some foundries, furnace operators and
pouring operators also perform this task. At the ERG Site Visit 7
foundry, tundish maintenance was performed immediately after the metal
was poured, while the metal on the tundish was still hot. Debris were
removed from one or more square feet of surface area and placed in a
ventilated receiving container. The furnace operator than patched and
painted the tundish with a coating similar to mold-release agent.
Throughout the entire process, the operator moved in and out of the area
of influence of the pouring area exhaust ventilation (Corbett, 2005a;
Corbett, 2005b).

**Housekeeping workers:** Sources of exposure during housekeeping
include beryllium-containing dust disturbed during housekeeping
(handling contaminated equipment, dry sweeping, dry wiping, moving dusty
items, and chipping splattered metal).

**5.3 EXPOSURE PROFILE**

*Sources of exposure information*: For aluminum and copper foundries,
ERG examined the affected job categories, including mold maker, material
handler, furnace operator, pouring operator, shakeout operator, abrasive
blasting operator, grinding/finishing operator, maintenance operator and
housekeeping worker.

Limited information is available regarding worker exposure to beryllium
in copper and aluminum foundries. The available sources of exposure
information include:

-   Reports containing individual exposure results

-   Information from analogous industries (from various sources
    summarized in the relevant section of this analysis)

-   OSHA's Integrated Management Information System (IMIS)

*Individual exposure results*: The three sources of individually
reported exposure results include:

-   A 2003 ERG site visit conducted in a copper-beryllium casting
    facility (ERG, 2003). This small foundry used direct chill casting
    methods to cast 2 percent beryllium alloy. A total of four PZB
    beryllium samples were obtained for three workers over two days.
    Because the workers were permitted to end the shift when they melted
    and poured one batch of ally, the sampling periods were all less
    than 5 hours. Investigators obtained hand and surface wipe samples
    at this facility. The ERG investigators also obtained three personal
    particle number samples.

-   A site visit (Case History D) conducted in 1999 at a
    ferrous/non-ferrous centrifugal casting foundry by the California
    Cast Metals Associations (CCMA, 2000). The case history offers a
    brief description of the pouring area and several days worth of PBZ
    air sampling results (beryllium, arsenic, cadmium, chromium, lead,
    nickel and selenium) for various job categories. Most samples were
    at least 7 hours in duration. One beryllium result that exceeded
    OSHA's current PEL for beryllium, while all other results were well
    below the respective PELs for the metals evaluated (many of these
    results were also below the limits of detection.

-   A much earlier NIOSH Health Hazard Evaluation, conducted in 1975, at
    a facility that handled beryllium alloys of aluminum and copper in
    several capacities, including foundry melting and casting operations
    (NIOSH, 1976). For this analysis, ERG extracted the results for
    foundry-related operations, which indicate that beryllium was
    present in variable concentrations in many areas of the facility. In
    addition to air monitoring, NIOSH conducted a review of randomly
    selected employee medical records, which indicated that one employee
    experienced beryllium dermatosis, one employee had acute beryllium
    pneumonitis, and nine employees had chronic beryllium disease.

> Table 5A-1 in Appendix 5A includes the individual results (full- and
> partial-shift) obtained from these sources for the job categories of
> interest. The full-shift results are summarized here in Tables 5-6 and
> 5-7.

+-----+----------------+----------+-----------------+-------+--------+
| *   |                |          |                 |       |        |
| *Ta |                |          |                 |       |        |
| ble |                |          |                 |       |        |
| 5   |                |          |                 |       |        |
| -6. |                |          |                 |       |        |
| S   |                |          |                 |       |        |
| umm |                |          |                 |       |        |
| ary |                |          |                 |       |        |
| of  |                |          |                 |       |        |
| I   |                |          |                 |       |        |
| ndi |                |          |                 |       |        |
| vid |                |          |                 |       |        |
| ual |                |          |                 |       |        |
| F   |                |          |                 |       |        |
| ull |                |          |                 |       |        |
| -Sh |                |          |                 |       |        |
| ift |                |          |                 |       |        |
| PBZ |                |          |                 |       |        |
| Ber |                |          |                 |       |        |
| yll |                |          |                 |       |        |
| ium |                |          |                 |       |        |
| Ex  |                |          |                 |       |        |
| pos |                |          |                 |       |        |
| ure |                |          |                 |       |        |
| Lev |                |          |                 |       |        |
| els |                |          |                 |       |        |
| By  |                |          |                 |       |        |
| Job |                |          |                 |       |        |
| Ca  |                |          |                 |       |        |
| teg |                |          |                 |       |        |
| ory |                |          |                 |       |        |
| for |                |          |                 |       |        |
| W   |                |          |                 |       |        |
| ork |                |          |                 |       |        |
| ers |                |          |                 |       |        |
| in  |                |          |                 |       |        |
| Cop |                |          |                 |       |        |
| per |                |          |                 |       |        |
| and |                |          |                 |       |        |
| Al  |                |          |                 |       |        |
| umi |                |          |                 |       |        |
| num |                |          |                 |       |        |
| Fou |                |          |                 |       |        |
| ndr |                |          |                 |       |        |
| ies |                |          |                 |       |        |
| (   |                |          |                 |       |        |
| SIC |                |          |                 |       |        |
| 33  |                |          |                 |       |        |
| 64, |                |          |                 |       |        |
| 33  |                |          |                 |       |        |
| 65, |                |          |                 |       |        |
| and |                |          |                 |       |        |
| 3   |                |          |                 |       |        |
| 366 |                |          |                 |       |        |
| )** |                |          |                 |       |        |
+=====+================+==========+=================+=======+========+
|     | **Job          | **Number | **Range**       | **M   | **Me   |
|     | Categories**   | of       |                 | ean** | dian** |
|     |                | Positive | **(μg/m^3^)**   |       |        |
|     |                | R        |                 | **(   | *      |
|     |                | esults** |                 | μg/m^ | *(μg/m |
|     |                |          |                 | 3^)** | ^3^)** |
+-----+----------------+----------+-----------------+-------+--------+
|     | Molder         | \--      | \--             | \--   | \--    |
+-----+----------------+----------+-----------------+-------+--------+
|     | Material       | 1        | 0.93            | 0.93  | 0.93   |
|     | handler        |          |                 |       |        |
|     | (              |          |                 |       |        |
|     | crane/forklift |          |                 |       |        |
|     | operator)      |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
|     | Furnace        | 5        | 0.2 to 19.76    | 4.3   | 0.69   |
|     | operator       |          |                 |       |        |
|     | (melt/heating  |          |                 |       |        |
|     | operator and   |          |                 |       |        |
|     | assistants)    |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
|     | Pouring        | 3        | 0.2 to 2.2      | 0.87  | 0.2    |
|     | operator       |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
|     | Shakeout       | \--      | \--             | \--   | \--    |
|     | operator       |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
|     | Abrasive       | \--      | \--             | \--   | \--    |
|     | blasting       |          |                 |       |        |
|     | operator       |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
|     | Gr             | 4        | 0.2 to 0.69     | 0.3   | 0.2    |
|     | inder/sawyer/s |          |                 |       |        |
|     | ander/finisher |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
|     | Maintenance    | \--      | \--             | \--   | \--    |
|     | operator       |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
|     | Housekeeping   | \--      | \--             | \--   | \-\--  |
|     | workers        |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
| O   |                |          |                 |       |        |
| nly |                |          |                 |       |        |
| q   |                |          |                 |       |        |
| uan |                |          |                 |       |        |
| tif |                |          |                 |       |        |
| ied |                |          |                 |       |        |
| r   |                |          |                 |       |        |
| esu |                |          |                 |       |        |
| lts |                |          |                 |       |        |
| are |                |          |                 |       |        |
| co  |                |          |                 |       |        |
| nsi |                |          |                 |       |        |
| der |                |          |                 |       |        |
| ed. |                |          |                 |       |        |
| R   |                |          |                 |       |        |
| esu |                |          |                 |       |        |
| lts |                |          |                 |       |        |
| be  |                |          |                 |       |        |
| low |                |          |                 |       |        |
| the |                |          |                 |       |        |
| li  |                |          |                 |       |        |
| mit |                |          |                 |       |        |
| of  |                |          |                 |       |        |
| det |                |          |                 |       |        |
| ect |                |          |                 |       |        |
| ion |                |          |                 |       |        |
| are |                |          |                 |       |        |
| co  |                |          |                 |       |        |
| nse |                |          |                 |       |        |
| rva |                |          |                 |       |        |
| tiv |                |          |                 |       |        |
| ely |                |          |                 |       |        |
| set |                |          |                 |       |        |
| at  |                |          |                 |       |        |
| the |                |          |                 |       |        |
| li  |                |          |                 |       |        |
| mit |                |          |                 |       |        |
| of  |                |          |                 |       |        |
| d   |                |          |                 |       |        |
| ete |                |          |                 |       |        |
| cti |                |          |                 |       |        |
| on, |                |          |                 |       |        |
| w   |                |          |                 |       |        |
| hen |                |          |                 |       |        |
| t   |                |          |                 |       |        |
| hat |                |          |                 |       |        |
| va  |                |          |                 |       |        |
| lue |                |          |                 |       |        |
| is  |                |          |                 |       |        |
| a   |                |          |                 |       |        |
| vai |                |          |                 |       |        |
| lab |                |          |                 |       |        |
| le. |                |          |                 |       |        |
|     |                |          |                 |       |        |
| S   |                |          |                 |       |        |
| our |                |          |                 |       |        |
| ce: |                |          |                 |       |        |
| NIO |                |          |                 |       |        |
| SH, |                |          |                 |       |        |
| 19  |                |          |                 |       |        |
| 76; |                |          |                 |       |        |
| C   |                |          |                 |       |        |
| CMA |                |          |                 |       |        |
| 20  |                |          |                 |       |        |
| 00; |                |          |                 |       |        |
| Ap  |                |          |                 |       |        |
| pen |                |          |                 |       |        |
| dix |                |          |                 |       |        |
| 5   |                |          |                 |       |        |
| -A; |                |          |                 |       |        |
| and |                |          |                 |       |        |
| a   |                |          |                 |       |        |
| sso |                |          |                 |       |        |
| cia |                |          |                 |       |        |
| ted |                |          |                 |       |        |
| not |                |          |                 |       |        |
| es. |                |          |                 |       |        |
| See |                |          |                 |       |        |
| the |                |          |                 |       |        |
| in  |                |          |                 |       |        |
| dus |                |          |                 |       |        |
| try |                |          |                 |       |        |
| p   |                |          |                 |       |        |
| rof |                |          |                 |       |        |
| ile |                |          |                 |       |        |
| and |                |          |                 |       |        |
| p   |                |          |                 |       |        |
| roc |                |          |                 |       |        |
| ess |                |          |                 |       |        |
| de  |                |          |                 |       |        |
| scr |                |          |                 |       |        |
| ipt |                |          |                 |       |        |
| ion |                |          |                 |       |        |
| for |                |          |                 |       |        |
| a   |                |          |                 |       |        |
| ddi |                |          |                 |       |        |
| tio |                |          |                 |       |        |
| nal |                |          |                 |       |        |
| inf |                |          |                 |       |        |
| orm |                |          |                 |       |        |
| ati |                |          |                 |       |        |
| on. |                |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+

+----------------------+-----+-----+-----+-------+----+-----+------+
| **Table 5-7.         |     |     |     |       |    |     |      |
| Distribution of      |     |     |     |       |    |     |      |
| Individual PBZ Total |     |     |     |       |    |     |      |
| Beryllium Exposure   |     |     |     |       |    |     |      |
| Readings for         |     |     |     |       |    |     |      |
| Aluminum and Copper  |     |     |     |       |    |     |      |
| Foundries (SIC 3364, |     |     |     |       |    |     |      |
| 3365, and 3366)**    |     |     |     |       |    |     |      |
+======================+=====+=====+=====+=======+====+=====+======+
| **Job Categories**   | **  |     |     |       |    |     | *    |
|                      | Num |     |     |       |    |     | *Tot |
|                      | ber |     |     |       |    |     | al** |
|                      | of  |     |     |       |    |     |      |
|                      | R   |     |     |       |    |     |      |
|                      | esu |     |     |       |    |     |      |
|                      | lts |     |     |       |    |     |      |
|                      | in  |     |     |       |    |     |      |
|                      | Ra  |     |     |       |    |     |      |
|                      | nge |     |     |       |    |     |      |
|                      | (µ  |     |     |       |    |     |      |
|                      | g/m |     |     |       |    |     |      |
|                      | ^3^ |     |     |       |    |     |      |
|                      | )** |     |     |       |    |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+
|                      | ≤   | \>  | \>  | \>    | \> | \>  |      |
|                      | 0.1 | 0.1 | 0.2 | 0.5   | 1  | 2.0 |      |
|                      |     | to  | to  | to ≤  | .0 |     |      |
|                      |     | ≤   | ≤   | 1.0   | to |     |      |
|                      |     | 0.2 | 0.5 |       | ≤  |     |      |
|                      |     |     |     |       | 2  |     |      |
|                      |     |     |     |       | .0 |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Molder               | *   | *   | *   | **    | *  | *   | **\  |
|                      | *\- | *\- | *\- | \--** | *\ | *\- | --** |
|                      | -** | -** | -** |       | -- | -** |      |
|                      |     |     |     |       | ** |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Material handler     | **  | **  | **  | **1** | *  | **  | *    |
| (crane/forklift      | 0** | 0** | 0** |       | *0 | 0** | *1** |
| operator)            |     |     |     | **(10 | ** |     |      |
|                      | **  | **  | **  | 0%)** |    | **  | **   |
|                      | (0% | (0% | (0% |       | ** | (0% | (100 |
|                      | )** | )** | )** |       | (0 | )** | %)** |
|                      |     |     |     |       | %) |     |      |
|                      |     |     |     |       | ** |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Furnace operator     | **  | **  | **  | **2** | *  | **  | *    |
| (melt/heating        | 0** | 2** | 0** |       | *0 | 1** | *5** |
| operator and         |     |     |     | **(4  | ** |     |      |
| assistants)          | **  | **( | **  | 0%)** |    | **( | **   |
|                      | (0% | 40% | (0% |       | ** | 20% | (100 |
|                      | )** | )** | )** |       | (0 | )** | %)** |
|                      |     |     |     |       | %) |     |      |
|                      |     |     |     |       | ** |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Pouring operator     | **  | **  | **  | **0** | *  | **  | *    |
|                      | 0** | 2** | 0** |       | *0 | 1** | *3** |
|                      |     |     |     | **(   | ** |     |      |
|                      | **  | **( | **  | 0%)** |    | **( | **   |
|                      | (0% | 66% | (0% |       | ** | 33% | (100 |
|                      | )** | )** | )** |       | (0 | )** | %)** |
|                      |     |     |     |       | %) |     |      |
|                      |     |     |     |       | ** |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Shakeout operator    | *   | *   | *   | **    | *  | *   | **\  |
|                      | *\- | *\- | *\- | \--** | *\ | *\- | --** |
|                      | -** | -** | -** |       | -- | -** |      |
|                      |     |     |     |       | ** |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Abrasive blasting    | *   | *   | *   | **    | *  | *   | **\  |
| operator             | *\- | *\- | *\- | \--** | *\ | *\- | --** |
|                      | -** | -** | -** |       | -- | -** |      |
|                      |     |     |     |       | ** |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Grinder/sa           | **  | **  | **  | **1** | *  | **  | *    |
| wyer/sander/finisher | 3** | 0** | 0** |       | *0 | 0** | *4** |
|                      |     |     |     | **(2  | ** |     |      |
|                      | **( | **  | **  | 5%)** |    | **  | **   |
|                      | 75% | (0% | (0% |       | ** | (0% | (100 |
|                      | )** | )** | )** |       | (0 | )** | %)** |
|                      |     |     |     |       | %) |     |      |
|                      |     |     |     |       | ** |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Maintenance operator | *   | *   | *   | \--   | *  | *   | \--  |
|                      | *\- | *\- | *\- |       | *\ | *\- |      |
|                      | -** | -** | -** |       | -- | -** |      |
|                      |     |     |     |       | ** |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Housekeeping worker  | *   | *   | *   | \--   | *  | *   | \--  |
|                      | *\- | *\- | *\- |       | *\ | *\- |      |
|                      | -** | -** | -** |       | -- | -** |      |
|                      |     |     |     |       | ** |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+
| **All Foundries**    | **  | **  | **  | **4** | *  | **  | **   |
|                      | 3** | 4** | 0** |       | *0 | 2** | 13** |
|                      |     |     |     | **(3  | ** |     |      |
|                      | **( | **( | **  | 1%)** |    | **( | **   |
|                      | 23% | 31% | (0% |       | ** | 15% | (100 |
|                      | )** | )** | )** |       | (0 | )** | %)** |
|                      |     |     |     |       | %) |     |      |
|                      |     |     |     |       | ** |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Sources: NIOSH,      |     |     |     |       |    |     |      |
| 1976; CCMA, 2000.    |     |     |     |       |    |     |      |
| Data not available   |     |     |     |       |    |     |      |
| for all job          |     |     |     |       |    |     |      |
| categories.          |     |     |     |       |    |     |      |
|                      |     |     |     |       |    |     |      |
| Percentages may not  |     |     |     |       |    |     |      |
| add up to 100 due to |     |     |     |       |    |     |      |
| rounding.            |     |     |     |       |    |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+

*Analogous industries*: Further information is available for a related
industry, secondary smelting, which includes similar melting and casting
operations (see Section 6 -- Secondary Smelting, Refining and Alloying).
Additionally, a beryllium producer operates foundry facilities and
information is available for this company's alloy furnace operations
(See Section 3 -- Beryllium Production). Results for applicable job
categories are summarized here in Tables 5-8 and 5-9.

+--------+---------------+----------+----------------+-------+-------+
| *      |               |          |                |       |       |
| *Table |               |          |                |       |       |
| 5-8.   |               |          |                |       |       |
| S      |               |          |                |       |       |
| ummary |               |          |                |       |       |
| of     |               |          |                |       |       |
| Indi   |               |          |                |       |       |
| vidual |               |          |                |       |       |
| Full   |               |          |                |       |       |
| -Shift |               |          |                |       |       |
| PBZ    |               |          |                |       |       |
| Ber    |               |          |                |       |       |
| yllium |               |          |                |       |       |
| Ex     |               |          |                |       |       |
| posure |               |          |                |       |       |
| Levels |               |          |                |       |       |
| By Job |               |          |                |       |       |
| Ca     |               |          |                |       |       |
| tegory |               |          |                |       |       |
| for**  |               |          |                |       |       |
|        |               |          |                |       |       |
| **W    |               |          |                |       |       |
| orkers |               |          |                |       |       |
| Perf   |               |          |                |       |       |
| orming |               |          |                |       |       |
| Ana    |               |          |                |       |       |
| logous |               |          |                |       |       |
| Acti   |               |          |                |       |       |
| vities |               |          |                |       |       |
| in     |               |          |                |       |       |
| Other  |               |          |                |       |       |
| Indust |               |          |                |       |       |
| ries** |               |          |                |       |       |
+========+===============+==========+================+=======+=======+
| **Indu | **Job         | **Number | **Range**      | **M   | **Med |
| stry** | Description** | of       |                | ean** | ian** |
|        |               | Positive | **(μg/m^3^)**  |       |       |
|        |               | R        |                | **(   | **(   |
|        |               | esults** |                | μg/m^ | μg/m^ |
|        |               |          |                | 3^)** | 3^)** |
+--------+---------------+----------+----------------+-------+-------+
| Sm     | Material      | 25       | 0.005 to 0.21  | 0.063 | 0.005 |
| elting | Handling      |          |                |       |       |
|        | Worker        |          |                |       |       |
| (code) |               |          |                |       |       |
+--------+---------------+----------+----------------+-------+-------+
| Ber    | Furnace       | 97       | 0.06 to 48.07  | 1.46  | 0.50  |
| yllium | Operations    |          |                |       |       |
| Prod   |               |          |                |       |       |
| uction | -- Alloy,     |          |                |       |       |
|        | Induction     |          |                |       |       |
|        | furnaces      |          |                |       |       |
+--------+---------------+----------+----------------+-------+-------+
| Ber    | Furnace       | 38       | 0.15 to 9.37   | 1.95  | 0.95  |
| yllium | Operations    |          |                |       |       |
| Prod   |               |          |                |       |       |
| uction | -- Alloy, Arc |          |                |       |       |
|        | furnaces      |          |                |       |       |
+--------+---------------+----------+----------------+-------+-------+
| Sm     | Furnace       | 41       | 0.004 to 1.7   | 0.39  | 0.25  |
| elting | Operator      |          |                |       |       |
|        | (melting)     |          |                |       |       |
| (code) |               |          |                |       |       |
+--------+---------------+----------+----------------+-------+-------+
| Sm     | Furnace       | 48       | 0.004 to 1.5   | 0.29  | 0.21  |
| elting | Helper        |          |                |       |       |
|        | (melting)     |          |                |       |       |
| (code) |               |          |                |       |       |
+--------+---------------+----------+----------------+-------+-------+
| Sm     | Casting       | 14       | 0.23 to 0.6    | 0.52  | 0.52  |
| elting | Operator      |          |                |       |       |
|        |               |          |                |       |       |
| (code) |               |          |                |       |       |
+--------+---------------+----------+----------------+-------+-------+
| Sm     | Casting       | 8        | 0.5 to 0.59    | 0.53  | 0.52  |
| elting | Helper        |          |                |       |       |
|        |               |          |                |       |       |
| (code) |               |          |                |       |       |
+--------+---------------+----------+----------------+-------+-------+
| Sm     | Maintenance   | 12       | 0.006 to 0.3   | 0.11  | 0.10  |
| elting | worker        |          |                |       |       |
|        | (furnaces)    |          |                |       |       |
| (code) |               |          |                |       |       |
+--------+---------------+----------+----------------+-------+-------+
| Sm     | Housekeeping  | 13       | 0.19 to 1.1    | 0.40  | 0.3   |
| elting | workers       |          |                |       |       |
| (code) |               |          |                |       |       |
+--------+---------------+----------+----------------+-------+-------+
| So     |               |          |                |       |       |
| urces: |               |          |                |       |       |
| S      |               |          |                |       |       |
| ection |               |          |                |       |       |
| 3 --   |               |          |                |       |       |
| Ber    |               |          |                |       |       |
| yllium |               |          |                |       |       |
| Produ  |               |          |                |       |       |
| ction; |               |          |                |       |       |
| S      |               |          |                |       |       |
| ection |               |          |                |       |       |
| 6 --   |               |          |                |       |       |
| Sme    |               |          |                |       |       |
| lting, |               |          |                |       |       |
| Ref    |               |          |                |       |       |
| ining, |               |          |                |       |       |
| and    |               |          |                |       |       |
| Al     |               |          |                |       |       |
| loying |               |          |                |       |       |
+--------+---------------+----------+----------------+-------+-------+

+----------------------+-----+-----+-----+-------+----+-----+------+
| **Table 5-9.         |     |     |     |       |    |     |      |
| Distribution of      |     |     |     |       |    |     |      |
| Individual PBZ Total |     |     |     |       |    |     |      |
| Beryllium Exposure   |     |     |     |       |    |     |      |
| Readings in          |     |     |     |       |    |     |      |
| Analogous            |     |     |     |       |    |     |      |
| Industries**         |     |     |     |       |    |     |      |
+======================+=====+=====+=====+=======+====+=====+======+
| **Industry/Job       | **  |     |     |       |    |     | *    |
| Categories**         | Num |     |     |       |    |     | *Tot |
|                      | ber |     |     |       |    |     | al** |
|                      | of  |     |     |       |    |     |      |
|                      | R   |     |     |       |    |     |      |
|                      | esu |     |     |       |    |     |      |
|                      | lts |     |     |       |    |     |      |
|                      | in  |     |     |       |    |     |      |
|                      | Ra  |     |     |       |    |     |      |
|                      | nge |     |     |       |    |     |      |
|                      | (µ  |     |     |       |    |     |      |
|                      | g/m |     |     |       |    |     |      |
|                      | ^3^ |     |     |       |    |     |      |
|                      | )** |     |     |       |    |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+
|                      | ≤   | \>  | \>  | \>    | \> | \>  |      |
|                      | 0.1 | 0.1 | 0.2 | 0.5   | 1  | 2.0 |      |
|                      |     | to  | to  | to ≤  | .0 |     |      |
|                      |     | ≤   | ≤   | 1.0   | to |     |      |
|                      |     | 0.2 | 0.5 |       | ≤  |     |      |
|                      |     |     |     |       | 2  |     |      |
|                      |     |     |     |       | .0 |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Smelting/            | 18  | 0   | 7   | 0     | 0  | 0   | **   |
|                      |     |     |     |       |    |     | 25** |
| Material Handling    | (7  | (   | (2  | (0%)  | (0 | (   |      |
| Worker               | 2%) | 0%) | 8%) |       | %) | 0%) | **   |
|                      |     |     |     |       |    |     | (100 |
|                      |     |     |     |       |    |     | %)** |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Beryllium            | 5   | 12  | 32  | 26    | 13 | 9   | **   |
| production/          |     |     |     |       |    |     | 97** |
|                      | (   | (1  | (3  | (27%) | (  | (   |      |
| -- Alloy, Induction  | 5%) | 2%) | 3%) |       | 14 | 9%) | **   |
| furnaces (used for   |     |     |     |       | %) |     | (100 |
| 0.1% to 2 %          |     |     |     |       |    |     | %)** |
| beryllium alloys)    |     |     |     |       |    |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Beryllium            | 0   | 1   | 6   | 14    | 7  | 10  | **   |
| production/          |     |     |     |       |    |     | 38** |
|                      | (   | (   | (1  | (37%) | (  | (2  |      |
| -- Alloy, Arc        | 0%) | 3%) | 6%) |       | 18 | 6%) | **   |
| furnaces (used for   |     |     |     |       | %) |     | (100 |
| beryllium "master"   |     |     |     |       |    |     | %)** |
| alloys containing 4% |     |     |     |       |    |     |      |
| beryllium)           |     |     |     |       |    |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Smelting/            | 9   | 3   | 15  | 12    | 2  | 0   | **   |
|                      |     |     |     |       |    |     | 41** |
| Furnace Operator     | (2  | (   | (3  | (29%) | (5 | (   |      |
| (melting)            | 2%) | 7%) | 7%) |       | %) | 0%) | **   |
|                      |     |     |     |       |    |     | (100 |
|                      |     |     |     |       |    |     | %)** |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Smelting/            | 15  | 0   | 20  | 11    | 2  | 0   | **   |
|                      |     |     |     |       |    |     | 48** |
| Furnace Helper       | (3  | (   | (4  | (23%) | (4 | (   |      |
| (melting)            | 1%) | 0%) | 2%) |       | %) | 0%) | **   |
|                      |     |     |     |       |    |     | (100 |
|                      |     |     |     |       |    |     | %)** |
+----------------------+-----+-----+-----+-------+----+-----+------+
| # Smelting/          | 0   | 0   | 4   | 10    | 0  | 0   | **   |
|                      |     |     |     |       |    |     | 14** |
| # Casting Operator   | (   | (   | (2  | (71%) | (0 | (   |      |
|                      | 0%) | 0%) | 9%) |       | %) | 0%) | **   |
|                      |     |     |     |       |    |     | (100 |
|                      |     |     |     |       |    |     | %)** |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Smelting/            | 0   | 0   | 3   | 5     | 0  | 0   | *    |
|                      |     |     |     |       |    |     | *8** |
| Casting Helper       | (   | (   | (3  | (62%) | (0 | (   |      |
|                      | 0%) | 0%) | 8%) |       | %) | 0%) | **   |
|                      |     |     |     |       |    |     | (100 |
|                      |     |     |     |       |    |     | %)** |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Smelting/            | 6   | 2   | 4   | 0     | 0  | 0   | **   |
|                      |     |     |     |       |    |     | 12** |
| Maintenance operator | (5  | (1  | (3  | (0%)  | (0 | (   |      |
| (furnace             | 0%) | 7%) | 3%) |       | %) | 0%) | **   |
| maintenance)         |     |     |     |       |    |     | (100 |
|                      |     |     |     |       |    |     | %)** |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Smelting/            | 0   | 5   | 5   | 2     | 1  | 0   | **   |
|                      |     |     |     |       |    |     | 13** |
| Housekeeping worker  | (   | (3  | (3  | (15%) | (8 | (   |      |
|                      | 0%) | 8%) | 8%) |       | %) | 0%) | **   |
|                      |     |     |     |       |    |     | (100 |
|                      |     |     |     |       |    |     | %)** |
+----------------------+-----+-----+-----+-------+----+-----+------+
| Sources: Section 3   |     |     |     |       |    |     |      |
| -- Beryllium         |     |     |     |       |    |     |      |
| Production; Section  |     |     |     |       |    |     |      |
| 6 -- Smelting,       |     |     |     |       |    |     |      |
| Refining, and        |     |     |     |       |    |     |      |
| Alloying             |     |     |     |       |    |     |      |
|                      |     |     |     |       |    |     |      |
| Percentages may not  |     |     |     |       |    |     |      |
| add up to 100 due to |     |     |     |       |    |     |      |
| rounding.            |     |     |     |       |    |     |      |
+----------------------+-----+-----+-----+-------+----+-----+------+

*IMIS:* OSHA's Integrated Management Information System (IMIS) entries
for the years 1979 to 2003 also contain beryllium personal air sampling
results associated with aluminum and copper foundries (SIC 3363, 3364,
3365, and 3366). These results are summarized by SIC in Tables 5-10 and
5-11. The subsequent Tables 5-12 and 5-13 contain the means, medians and
distribution of positive-value results (beryllium detected in the
sample) associated with relevant job categories in SIC 3364, 3365, and
3366. Information was inadequate to classify the three positive results
from SIC 3363 into applicable job categories.

As is typical of results in IMIS, information is not available regarding
worker activities, the engineering controls in place, personal
protective equipment worn during sampling, non-detectable sample
concentrations, and sample duration. This source of results was not
designed to capture that level of detail.

+---+-------+------------+---------+---------------+-----+----+----+
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+---+-------+------------+---------+---------------+-----+----+----+
| * | **To  | # SIC D    | **Total | **Job         | **R | *  | *  |
| * | tal** | escription | Sam     | D             | ang | *M | *M |
| S |       |            | ples/** | escriptions** | e^b | ea | ed |
| I | **Num |            |         |               | ^** | n^ | ia |
| C | ber** |            | *       |               |     | b^ | n^ |
| * |       |            | *Number |               | *   | ** | b^ |
| * | *     |            | Samples |               | *(μ |    | ** |
|   | *of** |            | with    |               | g/m | *  |    |
| * |       |            | P       |               | ^3^ | *( | *  |
| * | **E   |            | ositive |               | )** | μg | *( |
| C | stabl |            | Resul   |               |     | /m | μg |
| o | ishme |            | ts^a^** |               |     | ^3 | /m |
| d | nts** |            |         |               |     | ^) | ^3 |
| e |       |            |         |               |     | ** | ^) |
| * |       |            |         |               |     |    | ** |
| * |       |            |         |               |     |    |    |
+---+-------+------------+---------+---------------+-----+----+----+
| 3 | Not   | Aluminum   | 3/18    | Laborer       | 0   | 0. | 0  |
| 3 | deter | D          |         |               | .17 | 19 | .2 |
| 6 | mined | ie-Casting | (2%)    |               | to  |    |    |
| 3 |       | Foundries  |         |               | 0.2 |    |    |
+---+-------+------------+---------+---------------+-----+----+----+
| 3 | Not   | N          | 17/63   | Furnace       | 0   | 1. | 0. |
| 3 | deter | on-Ferrous |         | operator,     | .01 | 54 | 05 |
| 6 | mined | Die        | (10%)   | Grinder       | to  |    |    |
| 4 |       | Casting    |         | operator,     | 13  |    |    |
|   |       | Foundries  |         | "spinner      |     |    |    |
|   |       | (except    |         | operator"     |     |    |    |
|   |       | aluminum)  |         |               |     |    |    |
+---+-------+------------+---------+---------------+-----+----+----+
| 3 | Not   | Aluminum   | 68/179  | Furnace       | 0   | 1. | 0  |
| 3 | deter | Foundries  |         | operator,     | .03 | 22 | .5 |
| 6 | mined |            | (40%)   | Pouring       | to  |    |    |
| 5 |       |            |         | operator      | 8.8 |    |    |
|   |       |            |         | Gr            |     |    |    |
|   |       |            |         | inder/sanding |     |    |    |
|   |       |            |         | machine       |     |    |    |
|   |       |            |         | operator,     |     |    |    |
|   |       |            |         | Welder, Mold  |     |    |    |
|   |       |            |         | maker         |     |    |    |
+---+-------+------------+---------+---------------+-----+----+----+
| 3 | Not   | Copper     | 81/821  | Furnace       | 0.  | 0. | 0  |
| 3 | deter | Foundries  |         | operator,     | 016 | 63 | .1 |
| 6 | mined |            | (48%)   | Pouring       | to  |    |    |
| 6 |       |            |         | operator,     | 6.1 |    |    |
|   |       |            |         | Shakeout      |     |    |    |
|   |       |            |         | operator,     |     |    |    |
|   |       |            |         | Gr            |     |    |    |
|   |       |            |         | inder/sanding |     |    |    |
|   |       |            |         | machine       |     |    |    |
|   |       |            |         | operator,     |     |    |    |
|   |       |            |         | Abrasive      |     |    |    |
|   |       |            |         | blasting      |     |    |    |
|   |       |            |         | operator,     |     |    |    |
|   |       |            |         | Welder, Mold  |     |    |    |
|   |       |            |         | maker         |     |    |    |
+---+-------+------------+---------+---------------+-----+----+----+
| * |       | All        | **16    |               | *   | *  | *  |
| * |       | Aluminum   | 9/821** |               | *0. | *N | *N |
| T |       | and Copper |         |               | 016 | /A | /A |
| o |       | Foundries  |         |               | to  | ** | ** |
| t |       |            |         |               | 1   |    |    |
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+---+-------+------------+---------+---------------+-----+----+----+
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| I |       |            |         |               |     |    |    |
| C |       |            |         |               |     |    |    |
| 3 |       |            |         |               |     |    |    |
| 8 |       |            |         |               |     |    |    |
| 4 |       |            |         |               |     |    |    |
| 3 |       |            |         |               |     |    |    |
| - |       |            |         |               |     |    |    |
| - |       |            |         |               |     |    |    |
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| a |       |            |         |               |     |    |    |
| l |       |            |         |               |     |    |    |
| E |       |            |         |               |     |    |    |
| q |       |            |         |               |     |    |    |
| u |       |            |         |               |     |    |    |
| i |       |            |         |               |     |    |    |
| p |       |            |         |               |     |    |    |
| m |       |            |         |               |     |    |    |
| e |       |            |         |               |     |    |    |
| n |       |            |         |               |     |    |    |
| t |       |            |         |               |     |    |    |
| a |       |            |         |               |     |    |    |
| n |       |            |         |               |     |    |    |
| d |       |            |         |               |     |    |    |
| S |       |            |         |               |     |    |    |
| u |       |            |         |               |     |    |    |
| p |       |            |         |               |     |    |    |
| p |       |            |         |               |     |    |    |
| l |       |            |         |               |     |    |    |
| i |       |            |         |               |     |    |    |
| e |       |            |         |               |     |    |    |
| s |       |            |         |               |     |    |    |
| . |       |            |         |               |     |    |    |
+---+-------+------------+---------+---------------+-----+----+----+

+----------------------+-----+-----+-----+-----+-----+-----+------+
| **Table 5-11.        |     |     |     |     |     |     |      |
| Distribution of      |     |     |     |     |     |     |      |
| Personal Total       |     |     |     |     |     |     |      |
| Beryllium Exposure   |     |     |     |     |     |     |      |
| Readings in IMIS**   |     |     |     |     |     |     |      |
|                      |     |     |     |     |     |     |      |
| **for Aluminum and   |     |     |     |     |     |     |      |
| Copper Foundries     |     |     |     |     |     |     |      |
| (SICs 3363, 3364,    |     |     |     |     |     |     |      |
| 3365, and 3366)**    |     |     |     |     |     |     |      |
+======================+=====+=====+=====+=====+=====+=====+======+
| **SIC**              | **  |     |     |     |     |     | *    |
|                      | Num |     |     |     |     |     | *Tot |
| **Description**      | ber |     |     |     |     |     | al** |
|                      | of  |     |     |     |     |     |      |
|                      | Po  |     |     |     |     |     |      |
|                      | sit |     |     |     |     |     |      |
|                      | ive |     |     |     |     |     |      |
|                      | R   |     |     |     |     |     |      |
|                      | esu |     |     |     |     |     |      |
|                      | lts |     |     |     |     |     |      |
|                      | in  |     |     |     |     |     |      |
|                      | Ra  |     |     |     |     |     |      |
|                      | nge |     |     |     |     |     |      |
|                      | (µ  |     |     |     |     |     |      |
|                      | g/m |     |     |     |     |     |      |
|                      | ^3^ |     |     |     |     |     |      |
|                      | )** |     |     |     |     |     |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+
|                      | **≤ | *   | *   | *   | *   | *   |      |
|                      | 0.  | *\> | *\> | *\> | *\> | *\> |      |
|                      | 1** | 0.1 | 0.2 | 0.5 | 1.0 | 2.  |      |
|                      |     | to  | to  | to  | to  | 0** |      |
|                      |     | ≤   | ≤   | ≤   | ≤   |     |      |
|                      |     | 0.  | 0.  | 1.  | 2.  |     |      |
|                      |     | 2** | 5** | 0** | 0** |     |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| 3363                 | 0   | 3   | 0   | 0   | 0   | 0   | *    |
|                      |     |     |     |     |     |     | *3** |
| Aluminum Die-Casting | (   | (10 | (   | (   | (   | (   |      |
| Foundries            | 0%) | 0%) | 0%) | 0%) | 0%) | 0%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| 3364                 | 13  | 0   | 0   | 0   | 2   | 2   | **   |
|                      |     |     |     |     |     |     | 17** |
| Non-Ferrous Die      | (7  | (   | (   | (   | (1  | (1  |      |
| Casting Foundries    | 6%) | 0%) | 0%) | 0%) | 2%) | 2%) | **   |
| (except aluminum)    |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| 3365                 | 14  | 11  | 9   | 11  | 10  | 13  | **   |
|                      |     |     |     |     |     |     | 68** |
| Aluminum Foundries   | (2  | (1  | (1  | (1  | (1  | (1  |      |
|                      | 1%) | 6%) | 3%) | 6%) | 5%) | 9%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| 3366                 | 40  | 13  | 10  | 7   | 2   | 9   | **   |
|                      |     |     |     |     |     |     | 81** |
| Copper Foundries     | (4  | (1  | (1  | (   | (   | (1  |      |
|                      | 9%) | 6%) | 2%) | 9%) | 2%) | 1%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| **Combined Aluminum  | **6 | **2 | **1 | **1 | **1 | **2 | **1  |
| and Copper           | 7** | 7** | 9** | 8** | 4** | 4** | 69** |
| Foundries**          |     |     |     |     |     |     |      |
|                      | **( | **( | **( | **( | **  | **( | **   |
|                      | 40% | 16% | 11% | 11% | (8% | 14% | (100 |
|                      | )** | )** | )** | )** | )** | )** | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Source: OSHA IMIS    |     |     |     |     |     |     |      |
| Database 1979 to     |     |     |     |     |     |     |      |
| July 2003.           |     |     |     |     |     |     |      |
|                      |     |     |     |     |     |     |      |
| Percentages may not  |     |     |     |     |     |     |      |
| add up to 100 due to |     |     |     |     |     |     |      |
| rounding.            |     |     |     |     |     |     |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+

+-----+----------------+----------+-----------------+-------+--------+
| *   |                |          |                 |       |        |
| *Ta |                |          |                 |       |        |
| ble |                |          |                 |       |        |
| 5-  |                |          |                 |       |        |
| 12. |                |          |                 |       |        |
| Pe  |                |          |                 |       |        |
| rso |                |          |                 |       |        |
| nal |                |          |                 |       |        |
| To  |                |          |                 |       |        |
| tal |                |          |                 |       |        |
| Ber |                |          |                 |       |        |
| yll |                |          |                 |       |        |
| ium |                |          |                 |       |        |
| Ex  |                |          |                 |       |        |
| pos |                |          |                 |       |        |
| ure |                |          |                 |       |        |
| Re  |                |          |                 |       |        |
| adi |                |          |                 |       |        |
| ngs |                |          |                 |       |        |
| in  |                |          |                 |       |        |
| I   |                |          |                 |       |        |
| MIS |                |          |                 |       |        |
| For |                |          |                 |       |        |
| W   |                |          |                 |       |        |
| ork |                |          |                 |       |        |
| ers |                |          |                 |       |        |
| In  |                |          |                 |       |        |
| Sp  |                |          |                 |       |        |
| eci |                |          |                 |       |        |
| fic |                |          |                 |       |        |
| Job |                |          |                 |       |        |
| C   |                |          |                 |       |        |
| ate |                |          |                 |       |        |
| gor |                |          |                 |       |        |
| ies |                |          |                 |       |        |
| In  |                |          |                 |       |        |
| Al  |                |          |                 |       |        |
| umi |                |          |                 |       |        |
| num |                |          |                 |       |        |
| And |                |          |                 |       |        |
| Cop |                |          |                 |       |        |
| per |                |          |                 |       |        |
| Fou |                |          |                 |       |        |
| ndr |                |          |                 |       |        |
| ies |                |          |                 |       |        |
| (S  |                |          |                 |       |        |
| ICs |                |          |                 |       |        |
| 33  |                |          |                 |       |        |
| 64, |                |          |                 |       |        |
| 33  |                |          |                 |       |        |
| 65, |                |          |                 |       |        |
| and |                |          |                 |       |        |
| 3   |                |          |                 |       |        |
| 366 |                |          |                 |       |        |
| )** |                |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
|     | Job Categories | **Number | **Range**       | **M   | **Me   |
|     |                | of       |                 | ean** | dian** |
|     |                | positive | **(μg/m^3^)**   |       |        |
|     |                | r        |                 | **(   | *      |
|     |                | esults** |                 | μg/m^ | *(μg/m |
|     |                |          |                 | 3^)** | ^3^)** |
+-----+----------------+----------+-----------------+-------+--------+
|     | Molder         | 10       | 0.018 to 1.7    | 0.75  | 0.85   |
+-----+----------------+----------+-----------------+-------+--------+
|     | Material       | 0        | N/A             | N/A   | N/A    |
|     | handler        |          |                 |       |        |
|     | (              |          |                 |       |        |
|     | crane/forklift |          |                 |       |        |
|     | operator)      |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
|     | Furnace        | 27       | 0.01 to 13.0    | 2.01  | 0.17   |
|     | operator       |          |                 |       |        |
|     | (melt/heating  |          |                 |       |        |
|     | operator and   |          |                 |       |        |
|     | assistants)    |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
|     | Pouring        | 32       | 0.016 to 5.0    | 0.623 | 0.1    |
|     | operator       |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
|     | Shakeout       | 6        | 0.05 to 0.5     | 0.22  | 0.11   |
|     | operator       |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
|     | Abrasive       | 3        | 0.02 to 0.101   | 0.074 | 0.101  |
|     | blasting       |          |                 |       |        |
|     | operator       |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
|     | Gr             | 29       | 0.02 to 1.1     | 0.3   | 0.1    |
|     | inder/sawyer/s |          |                 |       |        |
|     | ander/finisher |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
|     | Maintenance    | 0        | N/A             | N/A   | N/A    |
|     | operator       |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
|     | Housekeeping   | 0        | N/A             | N/A   | N/A    |
|     | worker         |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
| **T |                | 107      | **0.01 to 13**  | **    | *      |
| ota |                |          |                 | N/A** | *N/A** |
| l** |                |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+
| S   |                |          |                 |       |        |
| our |                |          |                 |       |        |
| ce: |                |          |                 |       |        |
| O   |                |          |                 |       |        |
| SHA |                |          |                 |       |        |
| I   |                |          |                 |       |        |
| MIS |                |          |                 |       |        |
| Da  |                |          |                 |       |        |
| tab |                |          |                 |       |        |
| ase |                |          |                 |       |        |
| 1   |                |          |                 |       |        |
| 979 |                |          |                 |       |        |
| to  |                |          |                 |       |        |
| J   |                |          |                 |       |        |
| uly |                |          |                 |       |        |
| 20  |                |          |                 |       |        |
| 03. |                |          |                 |       |        |
|     |                |          |                 |       |        |
| N/A |                |          |                 |       |        |
| me  |                |          |                 |       |        |
| ans |                |          |                 |       |        |
| "   |                |          |                 |       |        |
| not |                |          |                 |       |        |
| ap  |                |          |                 |       |        |
| pli |                |          |                 |       |        |
| cab |                |          |                 |       |        |
| le" |                |          |                 |       |        |
+-----+----------------+----------+-----------------+-------+--------+

+----------------------+-----+-----+-----+-----+-----+-----+------+
| **Table 5-13.        |     |     |     |     |     |     |      |
| Distribution of      |     |     |     |     |     |     |      |
| Positive-Value PBZ   |     |     |     |     |     |     |      |
| Total Beryllium      |     |     |     |     |     |     |      |
| Exposure Readings in |     |     |     |     |     |     |      |
| IMIS for Workers in  |     |     |     |     |     |     |      |
| Specific job         |     |     |     |     |     |     |      |
| Categories in        |     |     |     |     |     |     |      |
| Aluminum and Copper  |     |     |     |     |     |     |      |
| Foundries (SIC       |     |     |     |     |     |     |      |
| Groups 3364, 3365,   |     |     |     |     |     |     |      |
| and 3366)**          |     |     |     |     |     |     |      |
+======================+=====+=====+=====+=====+=====+=====+======+
| **Job Categories**   | **  |     |     |     |     |     | *    |
|                      | Num |     |     |     |     |     | *Tot |
|                      | ber |     |     |     |     |     | al** |
|                      | of  |     |     |     |     |     |      |
|                      | R   |     |     |     |     |     |      |
|                      | esu |     |     |     |     |     |      |
|                      | lts |     |     |     |     |     |      |
|                      | in  |     |     |     |     |     |      |
|                      | Ra  |     |     |     |     |     |      |
|                      | nge |     |     |     |     |     |      |
|                      | (µ  |     |     |     |     |     |      |
|                      | g/m |     |     |     |     |     |      |
|                      | ^3^ |     |     |     |     |     |      |
|                      | )** |     |     |     |     |     |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+
|                      | **≤ | *   | *   | *   | *   | *   |      |
|                      | 0.  | *\> | *\> | *\> | *\> | *\> |      |
|                      | 1** | 0.1 | 0.2 | 0.5 | 1.0 | 2.  |      |
|                      |     | to  | to  | to  | to  | 0** |      |
|                      |     | ≤   | ≤   | ≤   | ≤   |     |      |
|                      |     | 0.  | 0.  | 1.  | 2.  |     |      |
|                      |     | 2** | 5** | 0** | 0** |     |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Molder               | 1   | 1   | 1   | 5   | 2   | 0   | **   |
|                      |     |     |     |     |     |     | 10** |
|                      | (1  | (1  | (1  | (5  | (2  | (   |      |
|                      | 0%) | 0%) | 0%) | 0%) | 0%) | 0%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Material handler     | \-- | \-- | \-- | \-- | \-- | \-- | **\  |
| (crane/forklift      |     |     |     |     |     |     | --** |
| operator)            |     |     |     |     |     |     |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Furnace operator     | 11  | 4   | 0   | 1   | 1   | 10  | **   |
| (melt/heating        |     |     |     |     |     |     | 27** |
| operator and         | (4  | (1  | (   | (   | (   | (3  |      |
| assistants)          | 1%) | 5%) | 0%) | 4%) | 4%) | 7%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Pouring operator     | 18  | 4   | 2   | 3   | 1   | 4   | **   |
|                      |     |     |     |     |     |     | 32** |
|                      | (5  | (1  | (   | (   | (   | (1  |      |
|                      | 6%) | 3%) | 6%) | 9%) | 3%) | 3%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Shakeout operator    | 3   | 1   | 2   | 0   | 0   | 0   | *    |
|                      |     |     |     |     |     |     | *6** |
|                      | (5  | (1  | (3  | (   | (   | (   |      |
|                      | 0%) | 7%) | 3%) | 0%) | 0%) | 0%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Abrasive blasting    | 1   | 2   | 0   | 0   | 0   | 0   | *    |
| operator             |     |     |     |     |     |     | *3** |
|                      | (3  | (6  | (   | (   | (   | (   |      |
|                      | 3%) | 7%) | 0%) | 0%) | 0%) | 0%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Grinder/sa           | 15  | 1   | 9   | 1   | 3   | 0   | **   |
| wyer/sander/finisher |     |     |     |     |     |     | 29** |
|                      | (5  | (   | (3  | (   | (1  | (   |      |
|                      | 2%) | 3%) | 1%) | 3%) | 0%) | 0%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Maintenance operator | *   | *   | *   | \-- | *   | *   | \--  |
|                      | *\- | *\- | *\- |     | *\- | *\- |      |
|                      | -** | -** | -** |     | -** | -** |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Housekeeping worker  | *   | *   | *   | *   | *   | *   | **\  |
|                      | *\- | *\- | *\- | *\- | *\- | *\- | --** |
|                      | -** | -** | -** | -** | -** | -** |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| **All Job            | **4 | **1 | **1 | **1 | **  | **1 | **1  |
| Categories**         | 9** | 3** | 4** | 0** | 7** | 4** | 07** |
|                      |     |     |     |     |     |     |      |
|                      | **( | **( | **( | **  | **  | **( | **   |
|                      | 46% | 12% | 13% | (9% | (7% | 13% | (100 |
|                      | )** | )** | )** | )** | )** | )** | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Source: OSHA IMIS    |     |     |     |     |     |     |      |
| Database 1979 to     |     |     |     |     |     |     |      |
| July 2003. See the   |     |     |     |     |     |     |      |
| industry profile and |     |     |     |     |     |     |      |
| process description  |     |     |     |     |     |     |      |
| for additional       |     |     |     |     |     |     |      |
| information.         |     |     |     |     |     |     |      |
|                      |     |     |     |     |     |     |      |
| Only positive        |     |     |     |     |     |     |      |
| results are          |     |     |     |     |     |     |      |
| considered.          |     |     |     |     |     |     |      |
|                      |     |     |     |     |     |     |      |
| Percentages may not  |     |     |     |     |     |     |      |
| add up to 100 due to |     |     |     |     |     |     |      |
| rounding.            |     |     |     |     |     |     |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+

*Dental alloys:* ERG was not able to identify exposure information for
workers engaged in producing non-precious metal dental alloys (e.g.,
nickel-beryllium dental alloys). No beryllium exposure results for SIC
3843 (Dental Equipment and Supplies) were entered into the IMIS database
between the years 1979 and 2003. However, an OSHA inspection report
offers insight into a dental equipment manufacturer's dental alloy
production facility (a captive foundry), which at the time of OSHA's
visit operated as a typical non-ferrous sand casting foundry (OSHA
Inspection Report Number range CHAPTER122252281). Furthermore, as with
most facilities that melt beryllium alloys, foundries that cast
nickel-based alloys generally do so as a portion of their business,
which usually includes a variety of other metal alloys (e.g., copper,
aluminum, bronze). Thus, ERG considers the information available for
aluminum and copper foundries to be generally relevant to the dental
alloy production industry, taking into account the possible difference
in foundry facility size. Captive foundries associated with
establishments dedicated to producing materials for the dental industry
might be smaller than the average industrial foundry. The process of
casting dental alloys to form dental appliances (e.g., bridges and
crowns) is covered under Section 10 - Dental Laboratories.

*Influence of beryllium oxide formation:* Due to beryllium affinity for
oxygen, oxide on molten metal can contain substantially higher
percentage of beryllium -- by several fold - than the alloy it forms on,
based on industry experience with bulk air sampling and ventilation
filter dust percentages that are higher in beryllium content than the
alloys handled in the area (Corbett, 2004).

1.  **Air Samples**

This exposure profile for copper and aluminum foundries describes worker
exposure levels in each of the affected job categories. For each job
category, ERG reviewed the available exposure information and selected
the set of results that appears to best represent foundry industry
workers. In some cases ERG combined individually reported results with
IMIS results for the same job category to produce a more robust profile
of the category. In other cases, only IMIS results are available and ERG
has relied on that data set. For two job categories, maintenance
operators and housekeeping workers, ERG was not able to identify
exposure information specific to the foundry industry. For these two
groups, ERG has relied on results from the analogous smelting industry,
which uses some of the same processes as are encountered in foundries.
Tables 5-14 and 5-15 summarize the exposure profile for each job
category and for the industry as a whole.

+--------+-------------------+---------+---------------+------+------+
| *      |                   |         |               |      |      |
| *Table |                   |         |               |      |      |
| 5-14.  |                   |         |               |      |      |
| Ex     |                   |         |               |      |      |
| posure |                   |         |               |      |      |
| P      |                   |         |               |      |      |
| rofile |                   |         |               |      |      |
| By Job |                   |         |               |      |      |
| Ca     |                   |         |               |      |      |
| tegory |                   |         |               |      |      |
| For    |                   |         |               |      |      |
| W      |                   |         |               |      |      |
| orkers |                   |         |               |      |      |
| In     |                   |         |               |      |      |
| Al     |                   |         |               |      |      |
| uminum |                   |         |               |      |      |
| And    |                   |         |               |      |      |
| Copper |                   |         |               |      |      |
| Found  |                   |         |               |      |      |
| ries** |                   |         |               |      |      |
|        |                   |         |               |      |      |
| ###    |                   |         |               |      |      |
+========+===================+=========+===============+======+======+
| **So   | Job Categories    | *       | **Range**     | **Me | **   |
| urce** |                   | *Number |               | an** | Medi |
|        |                   | of      | **(μg/m^3^)** |      | an** |
|        |                   | Sa      |               | *    |      |
|        |                   | mples** |               | *(μg | *    |
|        |                   |         |               | /m^3 | *(μg |
|        |                   |         |               | ^)** | /m^3 |
|        |                   |         |               |      | ^)** |
+--------+-------------------+---------+---------------+------+------+
| IMIS   | Molder            | 10      | 0.018 to 1.7  | 0.75 | 0.85 |
+--------+-------------------+---------+---------------+------+------+
| Indi   | Material handler  | 2       | 0.93 to 2.38  | 1.66 | 1.66 |
| vidual | (crane/forklift   |         |               |      |      |
| r      | operator)         |         |               |      |      |
| esults |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| IMI    | Furnace operator  | 38      | 0.01 to 25.06 | 3.28 | 0.73 |
| S+Indi | (melt/heating     |         |               |      |      |
| vidual | operator and      |         |               |      |      |
| r      | assistants)       |         |               |      |      |
| esults |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| IMI    | Pouring operator  | 35      | 0.016 to 5.0  | 0.64 | 0.1  |
| S+Indi |                   |         |               |      |      |
| vidual |                   |         |               |      |      |
| r      |                   |         |               |      |      |
| esults |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| IMIS   | Shakeout operator | 6       | 0.05 to 0.5   | 0.22 | 0.11 |
+--------+-------------------+---------+---------------+------+------+
| IMI    | Abrasive blasting | 4       | 0.02 to 0.7   | 0    | 0    |
| S+Indi | operator          |         |               | .231 | .101 |
| vidual |                   |         |               |      |      |
| r      |                   |         |               |      |      |
| esults |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| IMI    | Grinder/sawye     | 34      | 0.02 to 15.56 | 0.75 | 0.2  |
| S+Indi | r/sander/finisher |         |               |      |      |
| vidual |                   |         |               |      |      |
| r      |                   |         |               |      |      |
| esults |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| Ana    | Maintenance       | 12      | 0.006 to 0.3  | 0.11 | 0.10 |
| logous | (furnace          |         |               |      |      |
| in     | maintenance)      |         |               |      |      |
| dustry |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| Ana    | Housekeeping      | 13      | 0.19 to 1.1   | 0.40 | 0.3  |
| logous | workers           |         |               |      |      |
| in     |                   |         |               |      |      |
| dustry |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
|        | **All Job         | 154     | **0.006 to    | **N  | **N  |
|        | Categories**      |         | 25.06**       | /A** | /A** |
+--------+-------------------+---------+---------------+------+------+
| S      |                   |         |               |      |      |
| ource: |                   |         |               |      |      |
| See    |                   |         |               |      |      |
| Tables |                   |         |               |      |      |
| 5-6    |                   |         |               |      |      |
| t      |                   |         |               |      |      |
| hrough |                   |         |               |      |      |
| 5-13.  |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+

+----------------------+-----+-----+-----+-----+-----+-----+------+
| **Table 5-15.        |     |     |     |     |     |     |      |
| Exposure Profile.    |     |     |     |     |     |     |      |
| Distribution by Job  |     |     |     |     |     |     |      |
| Category for         |     |     |     |     |     |     |      |
| Workers**            |     |     |     |     |     |     |      |
|                      |     |     |     |     |     |     |      |
| **in Aluminum and    |     |     |     |     |     |     |      |
| Copper Foundries**   |     |     |     |     |     |     |      |
+======================+=====+=====+=====+=====+=====+=====+======+
| **Job Categories**   | **  |     |     |     |     |     | *    |
|                      | Num |     |     |     |     |     | *Tot |
|                      | ber |     |     |     |     |     | al** |
|                      | of  |     |     |     |     |     |      |
|                      | R   |     |     |     |     |     |      |
|                      | esu |     |     |     |     |     |      |
|                      | lts |     |     |     |     |     |      |
|                      | in  |     |     |     |     |     |      |
|                      | Ra  |     |     |     |     |     |      |
|                      | nge |     |     |     |     |     |      |
|                      | (µ  |     |     |     |     |     |      |
|                      | g/m |     |     |     |     |     |      |
|                      | ^3^ |     |     |     |     |     |      |
|                      | )** |     |     |     |     |     |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+
|                      | **≤ | *   | *   | *   | *   | *   |      |
|                      | 0.  | *\> | *\> | *\> | *\> | *\> |      |
|                      | 1** | 0.1 | 0.2 | 0.5 | 1.0 | 2.  |      |
|                      |     | to  | to  | to  | to  | 0** |      |
|                      |     | ≤   | ≤   | ≤   | ≤   |     |      |
|                      |     | 0.  | 0.  | 1.  | 2.  |     |      |
|                      |     | 2** | 5** | 0** | 0** |     |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Molder               | 1   | 1   | 1   | 5   | 2   | 0   | **   |
|                      |     |     |     |     |     |     | 10** |
|                      | (1  | (1  | (1  | (5  | (2  | (   |      |
|                      | 0%) | 0%) | 0%) | 0%) | 0%) | 0%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Material handler     | 0   | 0   | 0   | 1   | 0   | 1   | *    |
| (crane/forklift      |     |     |     |     |     |     | *2** |
| operator)            | (   | (   | (   | (5  | (   | (5  |      |
|                      | 0%) | 0%) | 0%) | 0%) | 0%) | 0%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Furnace operator     | 11  | 7   | 0   | 3   | 2   | 15  | **   |
| (melt/heating        |     |     |     |     |     |     | 38** |
| operator and         | (2  | (1  | (   | (   | (   | (3  |      |
| assistants)          | 9%) | 8%) | 0%) | 8%) | 5%) | 9%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Pouring operator     | 18  | 6   | 2   | 3   | 1   | 5   | **   |
|                      |     |     |     |     |     |     | 35** |
|                      | (5  | (1  | (   | (   | (   | (1  |      |
|                      | 1%) | 7%) | 6%) | 9%) | 3%) | 4%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Shakeout operator    | 3   | 1   | 2   | 0   | 0   | 0   | *    |
|                      |     |     |     |     |     |     | *6** |
|                      | (5  | (1  | (3  | (   | (   | (   |      |
|                      | 0%) | 7%) | 3%) | 0%) | 0%) | 0%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Abrasive blasting    | 1   | 2   | 0   | 1   | 0   | 0   | *    |
| operator             |     |     |     |     |     |     | *4** |
|                      | (2  | (5  | (   | (2  | (   | (   |      |
|                      | 5%) | 0%) | 0%) | 5%) | 0%) | 0%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Grinder/sa           | 15  | 4   | 9   | 2   | 3   | 1   | **   |
| wyer/sander/finisher |     |     |     |     |     |     | 34** |
|                      | (4  | (1  | (2  | (   | (   | (   |      |
|                      | 4%) | 2%) | 6%) | 6%) | 9%) | 3%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Maintenance operator | 6   | 2   | 4   | 0   | 0   | 0   | **   |
| (furnace             |     |     |     |     |     |     | 12** |
| maintenance)         | (5  | (1  | (3  | (   | (   | (   |      |
|                      | 0%) | 7%) | 3%) | 0%) | 0%) | 0%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Housekeeping worker  | 0   | 5   | 5   | 2   | 1   | 0   | **   |
|                      |     |     |     |     |     |     | 13** |
|                      | (   | (3  | (3  | (1  | (   | (   |      |
|                      | 0%) | 8%) | 8%) | 5%) | 8%) | 0%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| **All Job            | **5 | **2 | **2 | **1 | **  | **2 | **1  |
| Categories**         | 5** | 8** | 3** | 7** | 9** | 2** | 54** |
|                      |     |     |     |     |     |     |      |
|                      | **( | **( | **( | **( | **  | **( | **   |
|                      | 36% | 18% | 15% | 11% | (6% | 14% | (100 |
|                      | )** | )** | )** | )** | )** | )** | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Source: See Tables   |     |     |     |     |     |     |      |
| 5-6 to 5-14 and the  |     |     |     |     |     |     |      |
| industry profile and |     |     |     |     |     |     |      |
| process description  |     |     |     |     |     |     |      |
| for additional       |     |     |     |     |     |     |      |
| information.         |     |     |     |     |     |     |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+

2.  **Exposure profile**

**Molder:** The OSHA IMIS database contains 10 PZB beryllium results for
molders in aluminum and copper foundries. Because these are the only
quantified results available, ERG has used this group for the exposure
profile despite the limited documentation available for individual
results contained in IMIS. These results, summarized in Tables 5-14 and
5-15, range from 0.018 μg/m^3^ to 1.7 μg/m^3^. The median value for
these results is 0.8 μg/m^3^ (mean 0.7 μg/m^3^). Fifty percent, or half
(5) of the 10 results fall between 0.5 μg/m^3^ and 1.0 μg/m^3^. Two
results (20 percent) lie between 1.0 and 2.0 μg/m^3^. The remaining
three results are 0.5 μg/m^3^ or less and include one value less than
0.1 μg/m^3^ and one value between 0.1 and 0.2 μg/m^3^. As with all data
obtained from IMIS, no additional information is available regarding the
sampling or working conditions associated with these results.
Additionally, because these values may include some less-than-full-shift
results, they may overestimate the workers' true average daily exposure
level.

An additional molder result (below the limit of detection) was obtained
when NIOSH visited a beryllium ally (copper and aluminum) casting
facility in 1975. The limit of detection, however, was not stated in the
source documentation and this result could not be included in the
exposure profile. Local exhaust ventilation was reportedly available at
all operations where dust and fume were generated. At the same facility,
NIOSH obtained several full-shift results between 0.5 μg/m^3^ and 1.0
μg/m^3^ for workers in other job categories (furnace operators, crane
operator, and a finish grinder) and short-term results as high as 25.06
μg/m^3^, indicating that beryllium was present in the facility and
exposure was wide-spread (NIOSH, 1976).

**Material Handler:** Results for material handlers in beryllium alloy
casting foundries are very limited. NIOSH reported a single full-shift
PZB result of 0.93 μg/m^3^ for a crane operator at the previously
described beryllium alloy (copper and aluminum) casting facility (NIOSH,
1976). A more recent less-than-full-shift (252-minute) result of 2.38
μg/m^3^ was obtained by ERG for a forklift operator at a facility
casting copper-beryllium (ERG, 2003). The short duration of the sample
was due to an abbreviated work shift (typical at that facility) and
represents the employee's total exposure for the day, resulting in an
8-hour TWA of 1.25 μg/m^3^. However, a worker performing equivalent
activities for a full 8-hour shift would likely have experienced a
full-shift exposure similar to the short-term result of 2.38 μg/m^3^. In
this small foundry the material handler operated an open cab forklift to
deliver raw materials to the furnace (loaded into the furnace by hand),
moved tundish (pour lines) into position in the pouring area, and
removed large castings from direct chill casting molds. The same worker
also used a low-speed saw (wet process) for a brief period (less than 20
minutes) to cut castings to customer specifications.
Less-than-full-shift results for other workers in this foundry ranged
from 1.92 to 14.04 μg/m^3^.

In the absence of other results, ERG has relied upon these two values
for the material handler exposure profile (see tables 5-14 and 5-15).
ERG notes that this is an area where additional information would
increase the reliability of the profile.

Air sampling results for hexavalent chromium (chromium VI) also suggest
that material handler exposure results for metal fumes can be similar to
or exceed those of other foundry workers. Consultants to OSHA obtained
full shift chromium VI results (presented as 8-hour TWAs) of 0.52 and
1.0 μg/m^3^ for crane operators at an iron and steel foundry. A
less-than-full-shift result (269 minutes) of 1.7 μg/m^3^ was also
reported for a crane operator at this facility (OSHA H054A). The crane
operators worked in an unventilated, open cab attached to the crane
bridge and were "routinely exposed to fumes from the furnace and pouring
operations." For comparison, it is interesting to note that 8-hour TWA
chromium results for the floor-level workers at these operations
(including furnace and pouring operators) were consistently lower (in
the range of 0.2 μg/m^3^).

**Furnace Operator:** Workers in the furnace operator job category have
the highest potential and most consistently elevated beryllium exposure
of any job category in foundries. The elevated exposure is primarily
related to handling of beryllium-containing dross, work practices that
place the furnace operator's breathing zone in the path of fumes rising
off the furnace, and inadequate design/maintenance of ventilation
systems.

This exposure profile for furnace operators is based on 38 combined
results obtained from OSHA IMIS and several sources that report
individual beryllium results for foundry workers (OSHA, 2003; ERG,
2003b; NIOSH 1976; CCMA, 2000). This combination incorporates
information from the widest possible group of foundries and foundry
types. It is important to note that, because sample durations are not
available for IMIS PBZ results and these values might be associated with
a wide range of sample durations, ERG has also included in the exposure
profile all available individually reported results for furnace
operators, regardless of sample duration, including six less-than-full
shift results (265 minutes to 350 minutes). As IMIS results may not have
been adjusted as 8-hour TWAs, nor have the individually reported results
been adjusted. Instead, ERG asserts that the exposure level reported for
the duration sampled represents the exposure that would have been
reported had the sampling period continued for a full 8 hours. For the
interested reader, ERG calculated the 8-hour TWAs for these six results
(see Table 5A-1 in Appendix 5A) and determined that their use in the
exposure profile (in place of the value for the period sample) would not
have a notable impact on the profile. While the upper range and median
would be somewhat lower (yet still above the current PEL), the median
and distribution of the results would be unchanged. Each calculated
8-hour TWA result remained in the same exposure range as its original
value.

As indicated in Tables 5-14 and 5-15 the 38 results range from 0.01
μg/m^3^ to 25.06 μg/m^3^, with a median of 0.73 μg/m^3^ (mean 3.28
μg/m^3^). More than one-third of the 38 results (15 values, or 39
percent) are above the current PEL of 2.0 μg/m^3^ and over half the
results (52 percent) exceed 0.5 μg/m^3^. Nearly another one-third (29
percent, or 11 of 38 readings) are 0.1 μg/m^3^ or less, while 47 percent
are 0.2 μg/m^3^ or less. The apparent bimodal distribution, with more
than 85 percent of the results either below 0.2 and greater than 2.0
suggest dramatic differences in either the work practices, the
engineering controls, or both. Among the few results for which work
condition information is available, ERG notes a trend toward higher
exposure levels in cases where ventilation systems were deemed
inadequate or poorly designed for worker protection. The following
discussion describes these results in greater detail.

Tables 5-16, 5-17, and 5A-1 summarize and present the five full-shift
PBZ beryllium results that ERG identified for furnace operators. These
results range from 0.2 μg/m^3^ to 19.76 μg/m^3^, with a median of 0.69
μg/m^3^ (mean 4.3 μg/m^3^). These represent the highest range and mean
exposure value among the job categories in this industry. The median is
the third highest (behind molders and material handlers). The
distribution of these five results includes two exposure levels (40
percent) less than 0.2 μg/m^3^ (in this case also the limit of
detection), two results (40 percent) that fall between 0.5 μg/m^3^ and
1.0 μg/m^3^, and the highest result, a single value (20 percent) that
lies well above 2.0 μg/m^3^. These results were obtained in the
centrifugal casting foundry and the beryllium alloy foundry evaluated by
NIOSH, both of which have been mentioned previously (CCMA, 2000; NIOSH,
1976).

The two lowest of the individually reported full-shift furnace operator
results, both less than the limit of detection of 0.2 μg/m^3^, were
obtained at the ferrous/non-ferrous centrifugal casting foundry. (A
third less-than-full-shift result at the same level was also reported.)
This facility manufactured cylindrical castings of various diameters,
which ranged in length from 6 inches to 120 inches (10 feet). The
presence of beryllium in this facility (Case History Foundry D) was
confirmed by a result of 2.2 μg/m^3^ for a worker in the pouring
operator job category. These furnace operators ("melters") tended
induction furnaces fitted with close-fitting furnace-mounted exhaust
hoods. Additional local exhaust ventilation was present in the adjacent
pouring area, where fumes were collected by mobile ladle hoods and
"suction at the pour spout of the centrifugal caster" (CCMA, 200).

The three highest individually reported full-shift results available for
this job category (0.69 μg/m^3^, 0.79 μg/m^3^, and 19.76 μg/m^3^) were
obtained in 1975 at a beryllium alloy tool and parts manufacturing
facility that cast copper and aluminum in the foundry portion of their
operations. At the time, the facility employed 447 personnel, 350 of
whom were production workers. Other industrial operations, including
alloy recovery from dross, occurred elsewhere in the facility. NIOSH
noted "Local exhaust ventilation is supplied at all operations where
dust and fumes re generated." However, "where engineering controls
existed, they were inadequate, considering the toxicity of the
contaminant"(NIOSH, 1976).

Several additional results were reported for this job category.
Specifically, five less-than-full-shift results between 0.2 μg/m^3^ (the
limit of detection) and 25.06 μg/m^3^ are available for furnace
operators (and their helpers) casting copper and aluminum alloys of
beryllium. These values represent the actual exposure level for the
period sampled (all between 250 to 350 minutes). A sixth result of 14.08
μg/m^3^ was obtained using the same sample filter over two abbreviated
shifts (about 265 minutes each) for a total sample time of 532 minutes
(investigators used this strategy to ensure an adequate sample volume to
achieve a quantifiable result -- a step that proved to be unnecessary).
This result represents the composite TWA for the two shifts.

Three of these less-than-full-shift results, 1.92 μg/m^3^, 4.18 μg/m^3^,
and the 14.08 μg/m^3^ value, are known to have encompassed the workers'
total exposure for the day(s) (ERG, 2003b). ERG calculated 8-hour TWA
readings of 1.07 μg/m^3^, 2.31 μg/m^3^, and 7.80 μg/m^3^ for these
values.[^1] These results are particularly interesting because they
demonstrate that foundry workers continue to experience the level of
exposure reported by NIOSH in the 1970's.

These three less-than-full-shift results, even when reported as 8-hour
TWAs, all exceed the median for furnace operators and two of the results
exceed the current PEL for beryllium (2.0 μg/m^3^). The results for a
furnace operator (one sample over 2 days) and an assistant (two samples
over two days) were obtained in 2003 at a copper-beryllium casting
foundry. These exposure levels are associated with an overhead canopy
hood located over the furnace, under which the furnace operator stood
while checking the furnace and skimming the dross "so that the furnace
operator is standing in the exhaust stream of contaminants from the
furnace" (ERG, 2003b). Neither the hood nor the associated ductwork was
designed to maximize employee protection. The furnace operator
positioned the dross receptacle (a bucket) under a second smaller hood
(Corbett, 2005b).

At the facility visited by ERG, the foundry area and adjacent offices
were separated by doors, which were usually open. Foundry employees
spent some of the shift sitting in the office while waiting for the
melt, taking no special precautions when entering the office from the
plant area. A dark film of graphite mold release covered many surfaces,
influencing the appearance of the facility and indicating the
possibility of widespread cross contamination. There was, however, a
central vacuum system available for cleaning the furnace area. ERG
believes that this descriptive information is illustrative, although the
individual results from this study are not necessarily representative of
exposure levels in all foundries due to the abbreviated work shift.
These workers conducted one melt and pour over a period of about 4
hours, then were allowed to consider the shift complete and leave the
facility for the day (ERG, 2003b, Corbett, 2005a).

Other summary results for furnace operators suggest similar exposure
trends. OSHA's IMIS database contains 27 PBZ results for furnace
operators in aluminum and copper foundries. The applicable results in
OSHA's IMIS database (summarized in Tables 5-10 and 5-11) range from
0.01 μg/m^3^ to 13.0 μg/m^3^ and are described by a median of 0.17
μg/m^3^ and a mean of 2.01 μg/m^3^ (OSHA, 2003). The range, mean and
median for IMIS results are all somewhat lower than group of individual
results, but present a similar trend of exposure values spread across a
wide range and frequently exceeding the current PEL. For example, eleven
of the 27 IMIS results (41 percent) are 0.1 μg/m^3^ or less and 56
percent are 0.2 μg/m^3^ or less, while 10 of the 27 results (37 percent)
exceeds 2.0 μg/m^3^.

The full-shift PBZ results from furnace operations obtained at a
beryllium production facility (summarized in Section 3 -- Beryllium
Production) and reproduced here in Table 5-16 also support the trend
described by the exposure profile for furnace operators. The beryllium
producer reported 97 results for beryllium alloy operations involving
induction furnaces, which range from 0.06 μg/m^3^ to 48.07 μg/m^3^
(median 0.5 μg/m^3^, mean 1.46 μg/m^3^). At the same company, alloy
melting using another type of furnace follow the same general trend; the
38 results for workers involved with arc furnace operations ranged from
0.15 μg/m^3^ to 9.37 μg/m^3^ (median 0.95 μg/m^3^, mean 1.95 μg/m^3^)
(see Section 3 -- Beryllium Production).

Tables 5-16 and 5-17 compare the summarized results and distribution of
the furnace operator exposure profile with results from the supporting
data sets and other sources (e.g., beryllium production industry and
smelting industry). The tables show a clear pattern of wide exposure
ranges characterized by results that are frequently well above the
current PEL of 2.0 μg/m^3^ and medians that often fall between 0.5
μg/m^3^ and 1.0 μg/m^3^.

+--------+-------------------+---------+---------------+------+------+
| *      |                   |         |               |      |      |
| *Table |                   |         |               |      |      |
| 5-16.  |                   |         |               |      |      |
| Comp   |                   |         |               |      |      |
| arison |                   |         |               |      |      |
| of     |                   |         |               |      |      |
| F      |                   |         |               |      |      |
| urnace |                   |         |               |      |      |
| Op     |                   |         |               |      |      |
| erator |                   |         |               |      |      |
| PBZ    |                   |         |               |      |      |
| Ber    |                   |         |               |      |      |
| yllium |                   |         |               |      |      |
| R      |                   |         |               |      |      |
| esults |                   |         |               |      |      |
| from   |                   |         |               |      |      |
| V      |                   |         |               |      |      |
| arious |                   |         |               |      |      |
| Sou    |                   |         |               |      |      |
| rces** |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| **So   | Job Category or   | *       | **Range^c^**  | **M  | *    |
| urce** | Title             | *Number |               | ean* | *Med |
|        |                   | of      | **(μg/m^3^)** | *^c^ | ian* |
|        |                   | Sa      |               |      | *^c^ |
|        |                   | mples** |               | *    |      |
|        |                   |         |               | *(μg | *    |
|        |                   |         |               | /m^3 | *(μg |
|        |                   |         |               | ^)** | /m^3 |
|        |                   |         |               |      | ^)** |
+--------+-------------------+---------+---------------+------+------+
| Ex     | Furnace operator  | 38      | 0.01 to 25.06 | 3.28 | 0.73 |
| posure |                   |         |               |      |      |
| p      |                   |         |               |      |      |
| rofile |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| Indi   | Furnace operator  | 5       | 0.2 to 19.76  | 4.3  | 0.69 |
| vidual |                   |         |               |      |      |
| full   |                   |         |               |      |      |
| -shift |                   |         |               |      |      |
| r      |                   |         |               |      |      |
| esults |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| IMIS   | Furnace operator  | 27      | 0.01 to 13.0  | 2.01 | 0.17 |
+--------+-------------------+---------+---------------+------+------+
| S      | Furnace           | 97      | 0.06 to 48.07 | 1.46 | 0.50 |
| ection | Operations        |         |               |      |      |
| 3      |                   |         |               |      |      |
|        | -- Alloy,         |         |               |      |      |
| Ber    | Induction         |         |               |      |      |
| yllium | furnaces          |         |               |      |      |
| prod   |                   |         |               |      |      |
| uction | (0.1% to 2 %      |         |               |      |      |
|        | beryllium alloys) |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| S      | Furnace           | 38      | 0.15 to 9.37  | 1.95 | 0.95 |
| ection | Operations        |         |               |      |      |
| 3      |                   |         |               |      |      |
|        | -- Alloy, Arc     |         |               |      |      |
| Ber    | furnaces          |         |               |      |      |
| yllium |                   |         |               |      |      |
| prod   | (4% beryllium     |         |               |      |      |
| uction | alloy)            |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| S      | Furnace Operator  | 41      | 0.004 to 1.7  | 0.39 | 0.25 |
| ection | (melting)         |         |               |      |      |
| 6      |                   |         |               |      |      |
|        |                   |         |               |      |      |
| Sm     |                   |         |               |      |      |
| elting |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| S      | Furnace Helper    | 48      | 0.004 to 1.5  | 0.29 | 0.21 |
| ection | (melting)         |         |               |      |      |
| 6      |                   |         |               |      |      |
|        |                   |         |               |      |      |
| Sm     |                   |         |               |      |      |
| elting |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| S      |                   |         |               |      |      |
| ource: |                   |         |               |      |      |
| See    |                   |         |               |      |      |
| Tables |                   |         |               |      |      |
| 5-6 to |                   |         |               |      |      |
| 5-15   |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+

+----------------------+-----+-----+-----+-----+-----+-----+------+
| **Table 5-17.        |     |     |     |     |     |     |      |
| Comparison of        |     |     |     |     |     |     |      |
| Distribution of      |     |     |     |     |     |     |      |
| Furnace Operator PBZ |     |     |     |     |     |     |      |
| Beryllium Results    |     |     |     |     |     |     |      |
| from Various         |     |     |     |     |     |     |      |
| Sources**            |     |     |     |     |     |     |      |
+======================+=====+=====+=====+=====+=====+=====+======+
| **Source**           | **  |     |     |     |     |     | *    |
|                      | Num |     |     |     |     |     | *Tot |
|                      | ber |     |     |     |     |     | al** |
|                      | of  |     |     |     |     |     |      |
|                      | R   |     |     |     |     |     |      |
|                      | esu |     |     |     |     |     |      |
|                      | lts |     |     |     |     |     |      |
|                      | in  |     |     |     |     |     |      |
|                      | Ra  |     |     |     |     |     |      |
|                      | nge |     |     |     |     |     |      |
|                      | (µ  |     |     |     |     |     |      |
|                      | g/m |     |     |     |     |     |      |
|                      | ^3^ |     |     |     |     |     |      |
|                      | )** |     |     |     |     |     |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+
|                      | **≤ | *   | *   | *   | *   | *   |      |
|                      | 0.  | *\> | *\> | *\> | *\> | *\> |      |
|                      | 1** | 0.1 | 0.2 | 0.5 | 1.0 | 2.  |      |
|                      |     | to  | to  | to  | to  | 0** |      |
|                      |     | ≤   | ≤   | ≤   | ≤   |     |      |
|                      |     | 0.  | 0.  | 1.  | 2.  |     |      |
|                      |     | 2** | 5** | 0** | 0** |     |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Exposure profile     | 11  | 7   | 0   | 3   | 2   | 15  | **   |
|                      |     |     |     |     |     |     | 38** |
|                      | (2  | (1  | (   | (   | (   | (3  |      |
|                      | 9%) | 8%) | 0%) | 8%) | 5%) | 9%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Individual           | 0   | 2   | 0   | 2   | 0   | 1   | *    |
| full-shift results   |     |     |     |     |     |     | *5** |
|                      | (   | (4  | (   | (4  | (   | (2  |      |
|                      | 0%) | 0%) | 0%) | 0%) | 0%) | 0%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| IMIS                 | 11  | 4   | 0   | 1   | 1   | 10  | **   |
|                      |     |     |     |     |     |     | 27** |
|                      | (4  | (1  | (   | (   | (   | (3  |      |
|                      | 1%) | 5%) | 0%) | 4%) | 4%) | 7%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Brush Wellman        | 5   | 12  | 32  | 26  | 13  | 9   | **   |
|                      |     |     |     |     |     |     | 97** |
| -- Alloy, Induction  | (   | (1  | (3  | (2  | (1  | (   |      |
| furnaces (used for   | 5%) | 2%) | 3%) | 7%) | 4%) | 9%) | **   |
| 0.1% to 2 %          |     |     |     |     |     |     | (100 |
| beryllium alloys)    |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Brush Wellman        | 0   | 1   | 6   | 14  | 7   | 10  | **   |
|                      |     |     |     |     |     |     | 38** |
| -- Alloy, Arc        | (   | (   | (1  | (3  | (1  | (2  |      |
| furnaces (used for   | 0%) | 3%) | 6%) | 7%) | 8%) | 6%) | **   |
| beryllium "master"   |     |     |     |     |     |     | (100 |
| alloys containing 4% |     |     |     |     |     |     | %)** |
| beryllium)           |     |     |     |     |     |     |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Smelting/            | 9   | 3   | 15  | 12  | 2   | 0   | **   |
|                      |     |     |     |     |     |     | 41** |
| Furnace Operator     | (2  | (   | (3  | (2  | (   | (   |      |
| (melting)            | 2%) | 7%) | 7%) | 9%) | 5%) | 0%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Smelting/            | 15  | 0   | 20  | 11  | 2   | 0   | **   |
|                      |     |     |     |     |     |     | 48** |
| Furnace Helper       | (3  | (   | (4  | (2  | (   | (   |      |
| (melting)            | 1%) | 0%) | 2%) | 3%) | 4%) | 0%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Source: See Tables   |     |     |     |     |     |     |      |
| 5-6 to 5-15 and the  |     |     |     |     |     |     |      |
| industry profile and |     |     |     |     |     |     |      |
| process description  |     |     |     |     |     |     |      |
| for additional       |     |     |     |     |     |     |      |
| information.         |     |     |     |     |     |     |      |
|                      |     |     |     |     |     |     |      |
| Only positive        |     |     |     |     |     |     |      |
| results are          |     |     |     |     |     |     |      |
| considered.          |     |     |     |     |     |     |      |
|                      |     |     |     |     |     |     |      |
| Percentages may not  |     |     |     |     |     |     |      |
| add up to 100 due to |     |     |     |     |     |     |      |
| rounding.            |     |     |     |     |     |     |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+

**Pouring operator:** The exposure profile for pouring operators is
based on combined results obtained from OSHA's IMIS and a California
Cast Metals Association case study that reports individual beryllium
results for foundry workers in the pouring area (OSHA, 2003; CCMA,
2000).

As indicated in Tables 5-14 and 5-15 the 35 pouring operator results
range from 0.016 μg/m^3^ to 5.0 μg/m^3^, with a median of 0.1 μg/m^3^
(mean 0.64 μg/m^3^). Most beryllium results for pouring operators (68
percent, or 24 of 35 values) are less than or equal to 0.2 μg/m^3^. In
fact, 18 values, or more than half (51 percent) of the 35 results are
less than 0.1 μg/m^3^. Of the 11 results exceeding 0.2 μg/m^3^, five (14
percent) also exceed the current PEL of 2.0 μg/m^3^.

ERG identified three individual full-shift PBZ beryllium exposure
results for pouring operators. These are summarized in Tables 5-6 and
5-7. The results, which include two values less than the limit of
detection (0.2 μg/m^3^) and a single value of 2.2 μg/m^3^, were all
obtained on the same date at the centrifugal casting foundry mentioned
previously as Case History Foundry D (CCMA, 2000). These results are
associated with pouring/casting-area workers performing various tasks,
including pouring metal. The worker designation of the pouring "casting"
operator with the highest exposure (2.2 μg/m^3^) suggests this worker
was primarily involved in the actual casting process; however, no
further details are available. The pouring area was fitted with
engineering controls such as mobile ladle exhaust hoods, fixed exhaust
at the centrifugal mold pour spout, and a tight-fitting furnace-mounted
exhaust hood on the adjacent furnace. Elevated crystalline silica
results associated with a worker brushing silica mold release agent out
the centrifugal castings subsequently prompted the foundry to improve
ventilation at the mold access point (CCMA, 2000). Although the pouring
operator result of 2.2 μg/m^3^ exceeds OSHA's current PEL for beryllium,
other metal exposure levels (arsenic, cadmium, chromium, lead, nickel,
and selenium) at this facility were substantially lower than in other
foundries presented as case studies by this source (CCMA, 2000).

The OSHA IMIS database also includes beryllium results for pouring
operators working in aluminum and copper foundries.[^2] The 32 results
range from 0.016 μg/m^3^ to 5.0 μg/m^3^, with a median of 0.1 μg/m^3^
and a mean of 0.623 μg/m^3^. As the median indicates, the majority of
pouring operator results in IMIS (56 percent, or 18 of 32 results) are
less than 0.1 μg/m^3^. Tables 5-18 and 5-19 summarize these results and
show that the remainder of the values are distributed widely across the
ranges of interest, with four results (13 percent) exceeded the current
PEL of 2.0 μg/m^3^, and 8 results (25 percent) exceeding 0.5 μg/m^3^.
Although the values for pouring operators included in IMIS range more
widely than do the limited number of available individually reported
results, the mean and median values for IMIS results are both somewhat
lower than for the individually reported results.

Tables 5-18 and 5-19 also show that workers performing similar
activities (casting and casting helper) in the smelting industry are
associated with a tighter range of exposure levels. Readings for
fourteen castors and eight castor's helpers working in the smelting
industry were well within the range experienced by foundry pouring
operators and the means are remarkably similar, although the medians are
higher in the smelting industry.

+--------+-------------------+---------+---------------+------+------+
| *      |                   |         |               |      |      |
| *Table |                   |         |               |      |      |
| 5-18.  |                   |         |               |      |      |
| Comp   |                   |         |               |      |      |
| arison |                   |         |               |      |      |
| of     |                   |         |               |      |      |
| P      |                   |         |               |      |      |
| ouring |                   |         |               |      |      |
| Op     |                   |         |               |      |      |
| erator |                   |         |               |      |      |
| PBZ    |                   |         |               |      |      |
| Ber    |                   |         |               |      |      |
| yllium |                   |         |               |      |      |
| R      |                   |         |               |      |      |
| esults |                   |         |               |      |      |
| from   |                   |         |               |      |      |
| V      |                   |         |               |      |      |
| arious |                   |         |               |      |      |
| Sou    |                   |         |               |      |      |
| rces** |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| **So   | Job Category or   | *       | **Range^c^**  | **M  | *    |
| urce** | Title             | *Number |               | ean* | *Med |
|        |                   | of      | **(μg/m^3^)** | *^c^ | ian* |
|        |                   | Sa      |               |      | *^c^ |
|        |                   | mples** |               | *    |      |
|        |                   |         |               | *(μg | *    |
|        |                   |         |               | /m^3 | *(μg |
|        |                   |         |               | ^)** | /m^3 |
|        |                   |         |               |      | ^)** |
+--------+-------------------+---------+---------------+------+------+
| Ex     | Pouring operator  | 35      | 0.016 to 5.0  | 0.64 | 0.1  |
| posure |                   |         |               |      |      |
| p      |                   |         |               |      |      |
| rofile |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| Indi   | Pouring operator  | 3       | 0.2 to 2.2    | 0.87 | 0.2  |
| vidual |                   |         |               |      |      |
| full   |                   |         |               |      |      |
| -shift |                   |         |               |      |      |
| r      |                   |         |               |      |      |
| esults |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| IMIS   | Pouring operator  | 32      | 0.016 to 5.0  | 0    | 0.1  |
|        |                   |         |               | .623 |      |
+--------+-------------------+---------+---------------+------+------+
| Sm     | Casting operator  | 14      | 0.23 to 0.6   | 0.52 | 0.52 |
| elting |                   |         |               |      |      |
|        |                   |         |               |      |      |
| S      |                   |         |               |      |      |
| ection |                   |         |               |      |      |
| 6      |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| Sm     | Casting helper    | 8       | 0.5 to 0.59   | 0.53 | 0.52 |
| elting |                   |         |               |      |      |
|        |                   |         |               |      |      |
| S      |                   |         |               |      |      |
| ection |                   |         |               |      |      |
| 6      |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+
| S      |                   |         |               |      |      |
| ource: |                   |         |               |      |      |
| See    |                   |         |               |      |      |
| Tables |                   |         |               |      |      |
| 5-6 to |                   |         |               |      |      |
| 5-15.  |                   |         |               |      |      |
+--------+-------------------+---------+---------------+------+------+

+----------------------+-----+-----+-----+-----+-----+-----+------+
| **Table 5-19.        |     |     |     |     |     |     |      |
| Comparison of        |     |     |     |     |     |     |      |
| Distribution of      |     |     |     |     |     |     |      |
| Pouring Operator PBZ |     |     |     |     |     |     |      |
| Beryllium Results    |     |     |     |     |     |     |      |
| from Various         |     |     |     |     |     |     |      |
| Sources**            |     |     |     |     |     |     |      |
+======================+=====+=====+=====+=====+=====+=====+======+
| **Source/Job         | **  |     |     |     |     |     | *    |
| Category**           | Num |     |     |     |     |     | *Tot |
|                      | ber |     |     |     |     |     | al** |
|                      | of  |     |     |     |     |     |      |
|                      | R   |     |     |     |     |     |      |
|                      | esu |     |     |     |     |     |      |
|                      | lts |     |     |     |     |     |      |
|                      | in  |     |     |     |     |     |      |
|                      | Ra  |     |     |     |     |     |      |
|                      | nge |     |     |     |     |     |      |
|                      | (µ  |     |     |     |     |     |      |
|                      | g/m |     |     |     |     |     |      |
|                      | ^3^ |     |     |     |     |     |      |
|                      | )** |     |     |     |     |     |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+
|                      | **≤ | *   | *   | *   | *   | *   |      |
|                      | 0.  | *\> | *\> | *\> | *\> | *\> |      |
|                      | 1** | 0.1 | 0.2 | 0.5 | 1.0 | 2.  |      |
|                      |     | to  | to  | to  | to  | 0** |      |
|                      |     | ≤   | ≤   | ≤   | ≤   |     |      |
|                      |     | 0.  | 0.  | 1.  | 2.  |     |      |
|                      |     | 2** | 5** | 0** | 0** |     |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Exposure profile     | 18  | 6   | 2   | 3   | 1   | 5   | **   |
|                      |     |     |     |     |     |     | 35** |
|                      | (5  | (1  | (   | (   | (   | (1  |      |
|                      | 1%) | 7%) | 6%) | 9%) | 3%) | 4%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Individual           | 0   | 2   | 0   | 2   | 0   | 1   | *    |
| full-shift results   |     |     |     |     |     |     | *3** |
|                      | (   | (6  | (   | (4  | (   | (3  |      |
|                      | 0%) | 6%) | 0%) | 0%) | 0%) | 3%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| IMIS/Pouring         | 18  | 4   | 2   | 3   | 1   | 4   | **   |
| operator             |     |     |     |     |     |     | 32** |
|                      | (5  | (1  | (   | (   | (   | (1  |      |
|                      | 6%) | 3%) | 6%) | 9%) | 3%) | 3%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| # Smelting/          | 0   | 0   | 4   | 10  | 0   | 0   | **   |
|                      |     |     |     |     |     |     | 14** |
| # Casting Operator   | (   | (   | (2  | (7  | (   | (   |      |
|                      | 0%) | 0%) | 9%) | 1%) | 0%) | 0%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Smelting/            | 0   | 0   | 3   | 5   | 0   | 0   | *    |
|                      |     |     |     |     |     |     | *8** |
| Casting Helper       | (   | (   | (3  | (6  | (   | (   |      |
|                      | 0%) | 0%) | 8%) | 2%) | 0%) | 0%) | **   |
|                      |     |     |     |     |     |     | (100 |
|                      |     |     |     |     |     |     | %)** |
+----------------------+-----+-----+-----+-----+-----+-----+------+
| Source: See Tables   |     |     |     |     |     |     |      |
| 5-6 to 5-15 and the  |     |     |     |     |     |     |      |
| industry profile and |     |     |     |     |     |     |      |
| process description  |     |     |     |     |     |     |      |
| for additional       |     |     |     |     |     |     |      |
| information.         |     |     |     |     |     |     |      |
|                      |     |     |     |     |     |     |      |
| Only positive        |     |     |     |     |     |     |      |
| results are          |     |     |     |     |     |     |      |
| considered.          |     |     |     |     |     |     |      |
|                      |     |     |     |     |     |     |      |
| Percentages may not  |     |     |     |     |     |     |      |
| add up to 100 due to |     |     |     |     |     |     |      |
| rounding.            |     |     |     |     |     |     |      |
+----------------------+-----+-----+-----+-----+-----+-----+------+

No results specifically for pouring tasks area available from the
beryllium-copper foundry visited by ERG (2003b). There, the pouring
activities were performed during the last hour of the shift and
investigators judged that furnace operations (such as dross skimming)
made the largest contribution to beryllium exposure results. In the
casting area, canopy hoods collected air from casting stations and from
conveyers that carried castings out of the pouring area. These
ventilation systems were connected to a primary dust collection bag
house, with secondary HEPA filtration (Corbett, 2005b).

##### Shakeout Operator: ERG based the exposure profile for shakeout operators on six results contained in OSHA's IMIS system. Because ERG was unable to identify other results for this job category, ERG has used the IMIS group for the exposure profile despite the limited documentation available for individual results contained in IMIS. As presented in Tables 5-14 and 5-15, the results used for the exposure profile range from 0.05 μg/m^3^ to 0.5 μg/m^3^ and are represented by a median of 0.11 μg/m^3^ (mean 0.22 μg/m^3^). Three of the results (50 percent) are 0.1 μg/m^3^ or less, one reading (17 percent) falls between 0.1 μg/m^3^ and 0.2 μg/m^3^, while the remaining two results (33 percent) are 0.5 μg/m^3^ or less. No further details are available regarding the activities and conditions associated with these samples. ERG suggests that additional information on exposure levels and working conditions for this job category would increase the reliability of this exposure profile.

**Abrasive Blasting Operator:** ERG based the exposure profile for
abrasive blasting operators on three results contained in OSHA's IMIS
system, plus a single value from CCMA's Case History D (OSHA, 2003;
CCMA, 2000). The value from CCMA is from a short-duration PBZ sample
(112 minutes); however, to be consistent with results from IMIS, and for
the reasons described under furnace operators, ERG has used the result
in the exposure profile without converting it to an 8-hour TWA. The
source documentation does not indicate whether or not the sampling
period encompassed the abrasive blasting operator's total beryllium
exposure for the shift. Because abrasive blasting operators in foundries
typically spend the majority of their shift at this task, ERG believes
that the result of less than the limit of detection (0.7 μg/m^3^) could
also reasonably represent an exposure level that a full-time abrasive
blasting operator might experience. To check the impact this decision
had on the analysis, ERG calculated the 8-hour TWA (0.16 μg/m^3^) and
found that use of this lower value would reduce the upper range and
median for the abrasive blasting operator job category, but would not
impact the median (0.16 μg/m^3^ would remain the highest of the results
that ERG identified for this job category). By using the result reported
for the period sampled, ERG estimates that the exposure profile is more
likely to overestimate than underestimate the extent to which abrasive
blasting operators are exposed to beryllium levels exceeding 0.5
μg/m^3^. A larger group of full-shift samples would confirm or disprove
this hypothesis. The other values, from IMIS, include the minimum value
of 0.02 μg/m^3^ and two results of 0.101 μg/m^3^. IMIS reports neither
the sample durations associated with these results, nor whether they
represent 8-hour TWA values.

The single short-term result, from the centrifugal casting facility
previously described in this analysis, is the only value for which
additional information is available. The worker used a "blast booth" in
a foundry where exposure levels for several metals were all well below
the respective PELs and usually below the limits of detection.

**Grinding/Finishing Operator:** As presented in Tables 5-14 and 5-15,
the 34 PBZ exposure results for grinding/finishing operators range from
0.2 to 0.69 μg/m^3^, with a median of 0.2 μg/m^3^ (mean 0.3 μg/m^3^).
The results range from 0.02 μg/m^3^ to 15.56 μg/m^3^, with a median of
0.2 μg/m^3^ and mean of 0.75 μg/m^3^. Nearly half of the total (15 of
the 34 results, or 44 percent) are 0.1 μg/m^3^ or less. An additional 4
results (12 percent) fall between 0.1 μg/m^3^ and 0.2 μg/m^3^, and
another 9 (26 percent) exceed 0.2 μg/m^3^ but are less than 0.5 μg/m^3^.
Overall, 28 results (82 percent) are 0.5 μg/m^3^ or less. Just one
result exceeds the current PEL of 2.0 μg/m^3^.

Twenty-nine of these 34 results are contained in OSHA's IMIS, while the
remaining exposure values were reported individually by CCMA and NIOSH
(OSHA, 2003; CCMA, 2000; NIOSH 1976). These individually reported values
include the results of four full-shift samples and one
less-than-full-shift (321-minute) sample. As with previous foundry job
categories, in the absence of additional information, ERG considers the
partial-shift result to represent the exposure level that a worker
full-time grinding operator could experience during a complete shift.
ERG calculated the 8-hour TWA for this result (10.41 μg/m^3^) and
determined that it's use would only impact the upper range (still 5
times greater than the current PEL) and, to a lesser extent the mean.
The median and exposure profile would not be impacted.

Although this job category encompasses workers performing a variety of
finishing tasks, all involve abrasive action on castings. Among the
available data, ERG observes no trends indicating that any task
contributes to exposure more than others and this grouping is justified.
For example, investigators implicate cut-off saws and abrasive cutters
as a primary source of non-fume metal dust in foundries (CCMA, 2000).
However, among the results available to ERG, the exposure levels of
workers using abrasive cut-off saws appear at the bottom, (0.03
μg/m^3^), middle (0.18 μg/m^3^), and top (15.56 μg/m^3^) of the range
for this job category. Workers sanding castings may be found near the
bottom (0.1 μg/m^3^) and near the top (1.1 μg/m^3^) of the range.
Finishing operators using grinding equipment appear throughout the
range.

Three of the individually reported results, all less than the limit of
detection (0.2 μg/m^3^ in this case) were obtained by CCMA in 1999 at a
centrifugal casting foundry (Case History D) that handled both ferrous
and non-ferrous metals. The three workers included two machinists and a
grinder/"snagger." Although these results were below the limit of
detection, on the same date a measurable level of beryllium was found in
the breathing zone of a worker in another job category, indicating
beryllium was present in the foundry (CCMA, 2000).

Two other results (0.69 μg/m^3^ and the less-than-full-shift value of
15.56 μg/m^3^) were obtained by NIOSH for workers using a finish grinder
and a cut-off/swing grinder (respectively) to finish beryllium alloy
castings (NIOSH, 1976). These were among the highest exposure levels
reported at the facility (the result from one furnace operator was
higher). A third full-shift result below the limit of detection (not
provided) was reported at this site for a grinding/finishing operator
using a "saw cutter" (because the result can not be quantified, it is
not included in the exposure profile). Although NIOSH noted that exhaust
ventilation was used wherever dust and fume were generated, the
investigators deemed the ventilation systems inadequate.

**Maintenance Operators:** ERG was not able to identify any beryllium
exposure results for maintenance operators in aluminum or copper
foundries. PZB beryllium results for maintenance operators are
available, however, for maintenance workers involved with furnace
maintenance activities in the smelting industry. Smelting facilities
perform some of the same operations found in foundries, such as melting
and casting of beryllium-containing alloys using equipment similar to
that used in foundries. Section 6 of this analysis, dealing with
Smelting, Refining, and Alloying describes the job category of "furnace
maintenance worker," which is related to the foundry maintenance
operator job category. In the absence of maintenance operator results
obtained in foundries, ERG has selected the results for smelting
industry furnace maintenance operators as a reasonable alternative.
While these results might underestimate the actual exposure of foundry
maintenance operators (in general, most beryllium air sampling results
reported for smelting facilities are somewhat lower than the results
measured in foundries), ERG believes that the smelting furnace
maintenance operator job category provides a useful surrogate for
foundry maintenance operators. Briefly, as presented in Tables 5-14 and
5-15, the 12 results for furnace maintenance operators in the smelting
and metal recycling industry ranged from 0.006 μg/m^3^ to 0.3 μg/m^3^,
with a median value of 0.10 μg/m^3^ (mean 0.11 μg/m^3^). Half (6) of the
results are less the 0.1 μg/m^3^, while 17 percent (2) results are
greater than 0.1 μg/m^3^ but less than 0.2 μg/m^3^, and the remaining 33
percent (4) of the results exceed 0.2 μg/m^3^ but are less than or equal
to 0.5 μg/m^3^.

See Section 6 for a more complete discussion of the exposure profile for
this job category.

**Housekeeping workers:** ERG was not able to identify beryllium
exposure results for housekeeping workers in aluminum or copper
foundries. PZB beryllium results for housekeeping workers are available,
however, for workers involved in housekeeping activities in the smelting
industry. As was noted previously, smelting facilities perform some of
the same beryllium alloy operations found in foundries. Section 6 of
this analysis, dealing with Smelting, Refining, and Alloying describes
the job category of "housekeeping worker," which is related to the
foundry housekeeping worker job category. In the absence of maintenance
operator results obtained in foundries, ERG has selected the results for
smelting industry housekeeping workers as a reasonable alternative. As
with other job categories, the smelter results might underestimate the
actual exposure of foundry housekeeping workers. Nevertheless, ERG
believes that the smelting housekeeping worker job category provides a
useful surrogate for foundry housekeeping workers. A brief review of the
housekeeping worker results from Section 6, also presented in Table 5-8,
indicates that 13 results for this job category from the smelting and
metal recycling industry ranged from 0.19 μg/m^3^ to 1.1 μg/m^3^, with a
median value of 0.3 μg/m^3^ (mean 0.40 μg/m^3^). All 13 of the results
exceed 0.1 μg/m^3^, although 38 percent (5) of these results are 0.2
μg/m^3^ or lower and 77 percent (10) of the results are 0.5 μg/m^3^ or
less. Fifteen percent of the results (2) are fall between 0.5 μg/m^3^
and 1.0 μg/m^3^, while a single final value (8 percent) exceeds 1.0 but
is less than 0.2 μg/m^3^.

Please see Section 6 for a more complete discussion of the exposure
profile for this job category.

In a draft study of silica exposures, Number range CHAPTERERG determined
that the exposures for housekeeping workers are closely related to the
general exposure levels in the foundry, and to the specific area where
they spend the most time. Where exposures are elevated, the cases
presented in the exposure profile suggest that adjacent operations are
the primary source of exposure for housekeeping workers, although their
own work will likely contribute to their exposure when dry sand is
involved (ERG, 2003a).

> **5.3.2 Wipe Samples**
>
> **5.3.2.1 Hand Samples**

Hand wipes were obtained by asking study participants to wipe their
hands before the end of their shift or during the shift, at least two
hours after their last hand washing. Participants were instructed to
lift a fresh wet-wipe from its opened container and to thoroughly wipe
both hands (including the front and back, up to the wrists, and each
finger), removing as much dirt as possible. The wipe was then placed in
a labeled screw-top glass vial for analysis. The hand wiping exercise
was supervised and timed for 30 seconds by the investigators to ensure
consistency from subject to subject. A tracing of both hands of each
participant was taken to estimate the total surface area of the
participants' hands. The concentration of beryllium on the workers'
hands is reported in micrograms of beryllium per 100 square centimeters
(μg/100 cm^2^) (ERG, 2003b).

Table 5-20 presents results of hand wipe samples obtained by ERG in a
beryllium copper casting facility (Site Visit 7). The results range from
0.47 to 25.2 μg/100 cm^2^, with five of the 6 readings (83 percent)
exceeding 2.0 μg/100 cm^2^. These results are markedly higher than those
obtained in other types of facilities visited by ERG. For example, hand
wipe samples at a smelting and recycling facility ranged from \<0.006 to
1.21 μg/100 cm^2^. At that facility, just one out of the 28 results
exceeded 0.55 μg/100 cm^2^ (ERG, 2004b-Site visit 2).

  ------------------- ----------------- ------------- --------------- ----------- -----------
  Table 5-20. Wipe                                                                
  Samples Obtained                                                                
  from Hands                                                                      
  (combined results                                                               
  from both hands)                                                                

  **Activity**        **Be              **skin        **surface       **date**    **job**
                      Concentration**   condition**   area(cm^2^)**               

  **(hour previous to **(μg/100                                                    
  wipe)**             cm^2^)**                                                    

  preparing mold for  2.98              good          649             9/16/2003   furnace
  pour                                                                            helper

  casting charging    2.52              good          649             9/17/2003   furnace
                                                                                  helper

  rubbing, skimming,  5.37              fair          625             9/16/2003   furnace
  sparge set-u                                                                    operator

  casting, charging   25.20             fair          625             9/17/2003   furnace
                                                                                  operator

  setting up sparging 0.47              fair          648             9/16/2003   forklift op

  Table 5-20. Wipe                                                                
  Samples Obtained                                                                
  from Hands                                                                      
  (combined results                                                               
  from both hands)                                                                

  **Activity**        **Be              **skin        **surface       **date**    **job**
                      Concentration**   condition**   area(cm^2^)**               

  **(hour previous to **(μg/100                                                    
  wipe)**             cm^2^)**                                                    

  Casting             1.96              good          648             9/17/2003   forklift op

  Source: ERG (2003b)                                                             
  ------------------- ----------------- ------------- --------------- ----------- -----------

2.  **Surface Wipe Samples**

Surface contamination sampling was done using a plastic template
containing a 100 cm^2^ square opening (10 cm on a side) and wet-wipes.
Investigators donned a clean pair of disposable gloves, placed the
template on the surface to be sampled, and marked the corners with a
moistened wipe. The template was removed and the perimeter outlined with
the same moistened wipe. The inside of the square was then wiped
according to NIOSH Method 9100 and the wipe placed in a screw-top glass
vial for analysis. The template was cleaned in preparation for the next
wipe sample and the gloves were discarded (ERG, 2003b).

Surface wipe samples can be used to locate areas of contamination and to
evaluate the effectiveness of cleaning practices and procedures. Table
5-21 presents beryllium surface contamination data collected during ERG
site visit to a beryllium-copper foundry (ERG, 2003b). Note that these
data represent readings obtained during production shifts and do not
necessarily represent the levels that can be achieved after cleaning.
These data do indicate that surfaces in both the foundry and office
areas are contaminated with beryllium and that surface contamination
within the workplace can be highly variable. Surfaces in foundry areas
might become contaminated with beryllium through direct contact with
beryllium-contaminated castings or materials (e.g., substances such as
dust from granular casting media or graphite mold release used in
contact with molten alloy) or through workers via hand, clothing, and
shoe contamination. Once a worker contaminates his or her hands (or
gloves), shoes, or clothing with beryllium, everything that worker
touches or comes into contact with might in turn become contaminated
with some level of beryllium (i.e., cross-contamination).

Not surprisingly, some of the highest contamination occurred on surfaces
in the production area near major sources of beryllium dust (the top of
the carbon drum and the top of the furnace control box in the furnace
area). These surfaces are unless included in a rigorous housekeeping
program, these surfaces are unlikely to be cleaned regularly. Other
areas of notable contamination include porous or difficult-to-clean
surfaces where workers from the foundry area frequently place their
hands (the chair arm rest and the office telephone keypad, which was
notably contaminated compared to the office desk top). The highest
concentration of beryllium was found on a conduit on the office wall,
another surface that would be difficult to clean. These results point to
an incomplete housekeeping program that allows substantial levels of
contaminant to spread and accumulate throughout the production areas,
hygienic areas, and office.

**As with hand wipe samples, the surface wipe results from the
beryllium-copper casting facility are notably higher than the surface
contamination levels reported for other types of facilities visited by
ERG. The median surface contamination result was 1.1 μg/100 cm^2^ at the
smelting facility that ERG visited. Although results reported in the
smelter "melt shop" were substantially higher (up to 680 μg/100 cm^2^),
only 1 (8 percent) of the 13 foundry production area surface results was
less than the median level of 14 μg/100 cm^2^ reported for the melting
areas in the smelting facility (ERG, 2004b-Site visit 2).**

+--------+-------------------+----------------+----------+------------+
| #      |                   |                |          |            |
| #####  |                   |                |          |            |
|        |                   |                |          |            |
| ###    |                   |                |          |            |
| ### Ta |                   |                |          |            |
| ble 5- |                   |                |          |            |
| 21. Re |                   |                |          |            |
| sults  |                   |                |          |            |
| of Sur |                   |                |          |            |
| face S |                   |                |          |            |
| amples |                   |                |          |            |
|        |                   |                |          |            |
| ##     |                   |                |          |            |
| ####   |                   |                |          |            |
+========+===================+================+==========+============+
| **SA   | **AREA**          | **TOTAL Be     | *        | **Be CONC  |
| MPLE** |                   | (μg)**         | *SURFACE | (μg/100    |
|        |                   |                | AREA     | cm^2^)**   |
|        |                   |                | (        |            |
|        |                   |                | cm^2^)** |            |
+--------+-------------------+----------------+----------+------------+
| 1      | secretary's desk  | 2.00           | 100      | 2.00       |
+--------+-------------------+----------------+----------+------------+
| 2      | secretary's chair | 13.45          | 100      | 13.45      |
|        | mat               |                |          |            |
+--------+-------------------+----------------+----------+------------+
| 3      | secretary's       | 3.58           | 100      | 3.58       |
|        | filing cabinet    |                |          |            |
+--------+-------------------+----------------+----------+------------+
| 4      | top of radio      | 69.22          | 100      | 69.22      |
+--------+-------------------+----------------+----------+------------+
| 5      | forklift steering | 3.78           | 100      | 3.78       |
|        | wheel             |                |          |            |
+--------+-------------------+----------------+----------+------------+
| 6      | top of carbon     | 265.00         | 100      | 265.00     |
|        | drum              |                |          |            |
+--------+-------------------+----------------+----------+------------+
| 7      | chair arm rest    | 270.00         | 100      | 270.00     |
+--------+-------------------+----------------+----------+------------+
| 8      | #1 furnace hood   | 110.00         | 100      | 110.00     |
|        | canopy            |                |          |            |
+--------+-------------------+----------------+----------+------------+
| 9      | top of drum lid   | 530.00         | 100      | 530.00     |
+--------+-------------------+----------------+----------+------------+
| 10     | #1 furnace top of | 565.00         | 100      | 565.00     |
|        | tilt control      |                |          |            |
+--------+-------------------+----------------+----------+------------+
| 11     | top of clothes    | 12.70          | 100      | 12.70      |
|        | washer            |                |          |            |
+--------+-------------------+----------------+----------+------------+
| 12     | restroom door     | 20.54          | 100      | 20.54      |
|        | handle            |                |          |            |
+--------+-------------------+----------------+----------+------------+
| 13     | dresser top in    | 10.93          | 100      | 10.93      |
|        | rest room         |                |          |            |
+--------+-------------------+----------------+----------+------------+
| 14     | counter top in    | 4.35           | 100      | 4.35       |
|        | rest room         |                |          |            |
+--------+-------------------+----------------+----------+------------+
| 15     | forklift seat     | 1.93           | 100      | 1.93       |
+--------+-------------------+----------------+----------+------------+
| 16     | forklift rear top | 212.10         | 100      | 212.10     |
+--------+-------------------+----------------+----------+------------+
| 17     | floor in front of | 56.68          | 100      | 56.68      |
|        | casting pit       |                |          |            |
+--------+-------------------+----------------+----------+------------+
| 18     | dross ventilation | 176.50         | 100      | 176.50     |
|        | hood furnace #3   |                |          |            |
+--------+-------------------+----------------+----------+------------+
| 19     | top of hack saw   | 355.00         | 100      | 355.00     |
|        | arm               |                |          |            |
+--------+-------------------+----------------+----------+------------+
| 21     | office desk       | 35.38          | 100      | 35.38      |
|        | telephone keypad  |                |          |            |
+--------+-------------------+----------------+----------+------------+
| 22     | conduit on wall   | 850            | 100      | 850        |
|        | in office         |                |          |            |
+--------+-------------------+----------------+----------+------------+
| 23     | top of compressed | 18.96          | 100      | 18.96      |
|        | gas cylinder on   |                |          |            |
|        | loading dock      |                |          |            |
+--------+-------------------+----------------+----------+------------+
| 24     | top of vise       | 259.5          | 100      | 259.5      |
+--------+-------------------+----------------+----------+------------+
| 25     | storage rack rail | 201            | 100      | 201        |
+--------+-------------------+----------------+----------+------------+
| 26     | restroom floor    | 30.74          | 100      | 30.74      |
+--------+-------------------+----------------+----------+------------+
| S      |                   |                |          |            |
| ource: |                   |                |          |            |
| ERG    |                   |                |          |            |
| (      |                   |                |          |            |
| 2003b) |                   |                |          |            |
|        |                   |                |          |            |
| ^\*^ND |                   |                |          |            |
| --     |                   |                |          |            |
| less   |                   |                |          |            |
| than   |                   |                |          |            |
| 0.04  |                   |                |          |            |
| μg     |                   |                |          |            |
+--------+-------------------+----------------+----------+------------+

**5.4 TECHNOLOGICAL FEASIBILITY**

**5.4.1 Baseline and Additional Controls by Job Category**

Foundry workers have historically encountered numerous contaminants in
their workplaces. Metals, such as beryllium, present a serious challenge
because dust from fume, dross, and other sources are difficult to
control using traditional methods. Other hazards, such as crystalline
silica ("silica") are also prevalent in foundries, particularly those
that use sand casting methods. For crystalline silica, OSHA has
conducted an analysis of exposure levels and control methods similar to
this analysis for beryllium. There are many similarities, including the
elevated exposure levels reported for in foundries for both contaminants
relative to the levels in other industries. Most of the affected job
categories can experience exposure to both beryllium and silica. Some of
the same controls methods available for one of these contaminants will
also help control the other. However, because the sources of beryllium
and silica exposure are different, several job categories require
different controls to limit the beryllium or silica exposures of foundry
workers. For example, furnace operators exposure to silica tends to be
modest unless they handle silica-contaminated charge metal (e.g.,
foundry return scrap) or repair furnace linings. In a facility that
casts beryllium alloy, however, these same furnace operators can have
notable exposure to beryllium. In addition to being present as a
contaminant on charge metal, substantial amounts of beryllium fumes or
dust can be released during every process involving the molten metal.
For these reasons, the control methods appropriate for beryllium
exposure reduction overlap with, but are not identical to the controls
used for silica. Because OSHA's levels of interest for beryllium (0.1
μg/m^3^ to 2 μg/m^3^) are approximately 10 to 1,000 times lower than the
silica levels OSHA considered (25 μg/m^3^ to 100 μg/m^3^), more
substantial control measures are required to manage the beryllium
exposure levels of workers in some job categories.

***Molder ---Baseline conditions/controls:*** Baseline conditions for
molders in sand-casting foundries typically include use of reclaimed
sand (NIOSH, 1985). Molders perform dry brushing and sweeping of molds
and work surfaces and occasionally use pneumatic grinders or compressed
air for cleaning. Ventilation is usually available for sand reclamation
and sand handling equipment, although the systems may be poorly designed
or ineffectively maintained (ERG, 2003a). General ventilation is
typically available in the mold-preparation and pouring areas. Even in
foundries that have installed substantial local exhaust ventilation, the
plant-wide ventilation is not sufficiently balanced to prevent
contaminants from migrating between areas of the foundry (CCMA, 2000).

Molders who handle and maintain reusable molds usually perform basic
cleaning and conditioning (dry sweeping, applying surface preparations)
in the pouring area where the mold is used (CCMA, 2000; Corbett, 2005b).
These workers sometimes transport the molds to a special work area for
additional care such as grinding and refurbishing (associated with
median exposure levels of 0.05 μg/m^3^) (see Section 3-Beryllium
Production). However, based on the exposure levels reported for this job
category (median 0.85 μg/m^3^), ERG judges that molders do not typically
use a dedicated, ventilated work area and more frequently work on molds
where ever is most convenient (probably the pouring line), using
ventilation available at that location. This ventilation would typically
not be specifically intended for the purpose of mold maintenance.

All the results for molders identified by ERG are from OSHA's IMIS
system, which includes no process or control information. Therefore, ERG
is unable to determine the exposure level associated with baseline
conditions. Nor is ERG able to confirm that molders in sand casting
foundries and facilities using permanent molds are similarly exposed.
Additional information regarding the process, work conditions/controls,
and exposure levels of both types of molders would allow ERG to define
this group more precisely, or divide it into two job categories if more
appropriate. In the interim, and in the absence of other information,
ERG suggests that the median exposure level for molders (0.85 μg/m^3^)
serves as an adequate surrogate for the baseline exposure level. If more
specific or efficient controls were commonly in use, ERG estimates that
exposure levels for this job category would be closer to the median
exposure for pouring operators (0.1 μg/m^3^) or grinding/finishing
operators (0.2 μg/m^3^) -- who either work nearby or frequently perform
generally similar tasks.

***Molder ---Additional Controls:*** The estimated baseline exposure
level for this job category is 0.85 μg/m^3^. Additional controls will be
required to reduce the exposure of most molders to levels of 0.5 μg/m^3^
or less.

Casting processes with reusable molds (e.g., die casting) can be
relatively clean, with a minimum amount of oxide produced (Corbett,
2004). Oxide formation is particularly low with direct chill (DC)
casting methods currently in use by some foundries, which use a (water)
cooling jacket surrounding the mold to reduce the casting surface
temperature rapidly (within seconds), before oxide can form (Corbett,
2004; ERG, 2003). Even so, oxide deposits can develop on molds and
molders require local exhaust ventilation to minimize exposures during
cleaning.

Anecdotal evidence describes a beryllium exposure result well in excess
of the current PEL (2.0 μg/m^3^) obtained for a foundry worker who used
a pneumatic grinder to remove a beryllium oxide deposit from a mold
without local exhaust ventilation (Corbett, 2004). In contrast, a
beryllium producer reports that the majority (71 percent) of results
were 0.1 μg/m^3^ or less (median 0.05 μg/m^3^) for workers who
reconditioned molds and dies using the following controls (see Section 3
-- Beryllium Production) (Corbett, 2005b)[^3]:

-   HEPA vacuuming molds before handling;

-   wet wiping molds before handling;

-   transporting molds to special work zone away from the pouring area;
    and

-   using dedicate workbenches with operator-positioned exhaust trunk
    for grinding on molds with hand-held grinder/polisher.

The specific benefit of HEPA vacuuming and wet wiping molds before
handling them is not known. However, a report of lead abatement methods
suggests that using wet scraping methods and a HEPA vacuum can reduce
airborne exposure levels during lead abatement activities by 75%
compared to dry scraping and sweeping (reducing lead exposure levels to
25 μg/m^3^ from 100 μg/m^3^) (Sussell, 1999). Although the processes are
not precisely equivalent, ERG hypothesizes the use of HEPA vacuum and
wet-cleaning methods accounts for a similar percentage of molders
beryllium exposure levels. Thus, workers who do not HEPA vacuum and wet
wipe the molds might have exposure level that are 4-times higher (the
inverse of a 75 percent reduction) than workers who do pre-clean molds
in this manner. This suggests that the majority of molders who do use
special workbenches and exhaust trunks, but *do not* use HEPA vacuum and
wet-cleaning methods could experience median exposure levels in the
range of 0.4 μg/m^3^, which is 4-times higher than the 0.1 μg/m^3^ level
experience by most beryllium production workers who also employ exhaust
trunks at special workbenches and *do* use such methods to pre-clean
molds.

This scenario just presented demonstrates that most molders exposures
could potentially be reduced from the estimated current baseline (0.85
μg/m^3^), to a level of 0.5 μg/m^3^ or less, through the use of
dedicated workbenches and operator-positioned exhaust trunks for mold
maintenance work. Furthermore, by also pre-cleaning the molds using HEPA
vacuums and wet-cleaning methods, the exposure levels of most molders
could be reduced to a level of 0.1 μg/m^3^ or less, as has been reported
for 71 percent of the mold maintenance workers who use this method.

These same molders could achieve additional reductions in beryllium
exposure by improving exhaust ventilation at the dedicated workbenches.
For example, use of downdraft tables in addition to exhaust trunks would
increase the consistency of the dust control over the benefit provided
by operator-positioned trunks alone. Studies have demonstrated that
exposures can be reduced by improving local exhaust ventilation and
reducing dependence on workers to correctly position exhaust systems.
Additionally, Haung et al. (2004) demonstrated that a flanged exhaust
duct over a work table provided simulated vapor capture levels by 28
percent, while an improved "wake-controlled" hood design reduced
exposure levels by 52 percent. This hood design is open-sided to
accommodate large workpieces and is intended to minimize the effects of
cross drafts.

Local exhaust ventilation can also be installed at the mold position to
help control beryllium released during mold cleaning. Specifically,
local exhaust ventilation is used by some foundries to control other
hazards associated with mold release agents. CCMA reported on a
centrifugal casting foundry (Case History Foundry D) that was
implementing improved local exhaust ventilation the at the centrifugal
mold cleaning position when it was discovered that the crystalline
silica mold release agent contributed to workers' silica exposures
(CCMA, 2000).

If a sand-casting facility finds that reclaimed granular media
previously used to cast beryllium alloy is an ongoing source of
beryllium dust, the facility has several options for eliminating this
exposure of molding operator exposure. First, the foundry can avoid
reclaiming granular media used to cast beryllium alloy. Disposing of
media rather than reusing it will virtually eliminate the media as a
source of possible exposure. \[Note: In some regions low levels of
naturally occurring beryllium contamination may occur in certain
granular media -- however, the percent beryllium content are fractional.
ERG estimates that molder exposure from this source would be
substantially lower than occurs during abrasive blasting with the
equivalent media. This has been shown to be the case for other air
contaminants, such as crystalline silica, which generates exposure
levels during silica sand blasting that are routinely thousands of times
greater than the maximum values reported for molders using silica
sand.\]

As a second option, some foundries where granular media is a source of
beryllium exposure for molders might be able to switch to other non-sand
casting methods that both eliminate the granular media and reduce
surface oxide formation. While this control method would be suitable for
some types of castings (e.g., simple shapes), non-sand casting methods
will not be appropriate for some alloys and more complex casting shapes.

The beryllium exposure levels of molders who spend time in the pouring
area will be decreased to the extent that pouring operator exposures are
reduced. Until such a time as exposures during the pouring operation can
be completely controlled, molders should avoid working in the pouring
area when fumes or beryllium dust could be present --during pouring,
initial phases of casting cooling, and tundish refurbishing (see the job
category for furnace maintenance workers).

Molders are also exposed to airborne metals when poorly balanced
ventilation systems allow contaminated air from other parts of the
foundry to enter the molding area. Lead and cadmium evaluations
demonstrate how metal fumes (including beryllium fume) may be spread
through a facility to the molding area. For example, air monitoring
conducted by the foundry industry showed that molders in sand casting
foundries are exposed to metals, such as lead and cadmium, in foundries
that cast copper-based alloys containing these elements (CCMA, 2000).
Results for molders obtained between 1994 and 1999 in two copper alloy
and bronze foundries (Case Histories A and B) indicated personal
breathing zone (PBZ) lead ranging from 20 to 90 percent of the
permissible exposure limit (PEL) for lead of 50 μg/m^3^ (CCMA, 2000).

Industry consultants conducted a detailed ventilation assessment in one
of these foundries (Case History A), revealing that :

> *The ventilation in this foundry was predominantly exhaust-driven.
> Because of the negative pressure created by the local hoods and
> several roof ventilators, air was induced into the casting department
> through openings behind the furnaces. The induced supply air swept any
> fugitive fume emissions from the melting and ladle filling operations
> and moved them toward shakeout, pouring, and molding, in that order.
> This cross-contamination pattern probably explains why the shakeout
> operators and molders were exposed as they were. The molders were
> downstream of both the furnace and the pouring operations in a very
> stagnant part of the facility* (CCMA, 2000).

At this foundry (Case History A), where the majority of castings
contained 81 percent copper and approximately 8 percent lead, the lead
exposure of furnace tenders and pouring operators were 2 to 10 times
higher than the levels associated with molders (or 1 to 5 times the OSHA
PEL for lead). The cadmium exposure levels for pouring operators and
furnace tenders rarely approached the cadmium PEL of 5 μg/m^3^, but were
approximately 10 (or more) times the cadmium results associated with
molders (two results of 0.22 μg/m^3^ and 0.37 μg/m^3^) (CCMA, 2000).
This example demonstrates the effect that improper balance in foundry
ventilation can have on the metal exposure levels of molders. However,
due to differences in an alloy's metal content, melting points, and
oxide generation rate, it is not possible to infer that airborne
beryllium levels would be at the same concentration as are measured for
cadmium (or any other metal).

To combat cross contamination caused by improper balance in facility
ventilation, CCMA advocates an integrated "whole foundry" approach to
ventilation system design, testing, monitoring, and maintenance. The
CCMA system maximizes local capture of fume at the points where it is
generated and balances all (local and general) air exhaust and supply
systems in each work area to minimize cross contamination. Initial and
routine system testing and air monitoring point to areas where
improvements or maintenance are needed. One of the system's authors goes
on to note that "Cross-contamination can be virtually eliminated by
establishing zones of balanced ventilation" (Scholz and Liellom, 2000).
Elimination of cross-contamination will also virtually eliminate (to
levels less than μg/m^3^) airborne contamination from other foundry
areas as a source of beryllium exposure for workers in the molding area.

***Molder---Conclusion**:* Over 80 percent of all molders currently
achieve beryllium exposure levels less than 1.0 μg/m^3^. The vast
majority of these, who work in mold making areas remote from the furnace
and pouring departments, are likely to achieve levels of 0.1 μg/m^3^
when other job categories are controlled to a similar level and by
avoiding reclamation (reuse) of beryllium-contaminated granular casting
media. Alternatively, in addition to avoiding reclamation of granular
casting media, sand-casting foundries can balance facility ventilation
systems to eliminate cross-contamination of the molding area from other
foundry spaces.

Furthermore, ERG estimates that the exposure level of most molders who
clean and maintain permanent molds (assumed to include the 20 percent of
molders currently exposed to levels between 1 and 2.2 μg/m^3^) might be
reduced to levels of 0.1 μg/m^3^ or less by consistently using HEPA
vacuums, wet-cleaning methods, and local exhaust ventilation (flexible
trunks) at dedicated workbenches when maintaining with the molds.
Seventy one percent of mold maintenance workers using this method
achieved exposure levels of 0.1 μg/m^3^ or less. The addition of
downdraft or other booth-based ventilation would likely increase the
percentage of molders who achieve this level.

***Material handler---Baseline conditions/controls:*** Material handlers
typically operate open cab cranes and forklifts (ERG, 2003; OSHA H054A).
Poor housekeeping on the material handling equipment and in the facility
contribute to their exposure, as do inefficient process ventilation and
poorly balanced general facility ventilation systems that allow airborne
contaminants to spread throughout the facility (CCMA, 2000; ERG, 2003;
OSHA H054A).

Material handlers also assist with manual work in foundry departments
where process ventilation exists to some extent, but is not specific to
the operation performed by the material handler. For example, material
handlers (and other workers) who deliver charge to the furnace operator
can manually load charge into buckets (ERG, 2003b). This work would be
conducted in the vicinity of the furnace hood (or even a charge bucket
heating hood), but with no ventilation specifically applied to the
charge transfer operation (see furnace operator job category).

A material handler who operated a crane from an open cab in a beryllium
alloy casting facility experienced a full shift exposure of 0.93
μg/m^3^. While ERG does not have additional information that would
confirm the validity of this value as the baseline level for the job
category, ERG judges this result to better represent the exposure of
material handlers in relation to work with their own equipment than does
the other available value (for a forklift operator who spent
considerable time assisting with other tasks and used a cutting saw
during the shift).

***Material handler---Additional Controls:*** The beryllium exposure
levels of material handlers will decrease substantially when control
measures are implemented to reduce the exposures of workers in other job
categories. Airborne beryllium emitted from processes or present at
elevated background levels contribute to the total beryllium exposure of
material handlers who work in or pass through those spaces. Until such
measures are introduced, material handlers should minimize entry at peak
periods of exposure in areas where exposure is difficult to control,
such as the furnace area during dross skimming.

*Housekeeping:* Plant-wide diligent housekeeping and migration control
efforts will also help decrease material handler exposures. In
particular, vehicular traffic can re-entrain/resuspend settled dust in
foundries and contribute to airborne contaminant concentrations (CCMA,
2000). Settled dust and spilled debris can be disturbed by passing
vehicles, including forklifts, trucks, and in-plant tractors and rail
transport equipment. In a separate analysis of a different contaminant,
ERG identified numerous instances in several industries where poor
housekeeping contributed to the crystalline silica exposure of material
handlers driving on dusty surfaces (2003a). Because both substances are
components of dust in contaminated areas, ERG judges that the effect of
poor housekeeping has a similar effect on the beryllium exposure of
material handlers. A combination of controlling other job categories to
a similar level and increasing housekeeping to eliminate settled dust
should reduce material handler exposures to levels well below the ranges
of interest.

*Process enclosures:* Until other job categories are controlled to a
similar level, material handlers typically will not be able to avoid
*all* work near dust or fume emitting processes (e.g., delivering and
loading charge into the furnace or assisting with casting and de-molding
operations). In facilities where material handlers must work near
process that have not yet been fully controlled, enclosures and modified
work practices can help decrease material handler exposures. For
example, until a close-fitting ventilation hood can be installed on the
furnace, a physical barrier around the furnace to reduce spread of fumes
might help minimize the beryllium exposure of material handlers
delivering raw materials to the furnace area during melting.

*Operator enclosures:* Operator cabs on equipment such as forklifts and
cranes can help reduce the beryllium exposure level of material
handlers. A 1996 NIOSH report of a lead smelting facility demonstrated
an 80 percent reduction in lead concentrations inside the cab compared
to outside the cab on a front-end loader (NIOSH, 1996). During raw
material storage operations the protective value of the cab was even
greater, providing 95 percent reduction. NIOSH obtained these values at
a time when visible dust was noted in the cab and another data
collection effort indicated that the dust in the cabs contained lead.
Exposure reduction levels would likely have been lower if cabs had been
cleaned and NIOSH recommended cabs receive a thorough cleaning (using
wet methods) after each shift.

More recent studies have demonstrated that even greater reductions are
possible when the cab is properly sealed, fitted with air conditioning
and pressurizing equipment, and consistently maintained. Haney (2000)
showed that enclosing cabs on heavy equipment in an agricultural setting
can reduce the operator's exposure to respirable dust by 90 to 95
percent (inside the cab compared to outside the cab). In another study
evaluating exposure controls for pesticides, aerosol monitoring was
performed on a factory-installed cab (original equipment) and a retrofit
cab (aftermarket addition to a tractor that was not originally
enclosed). The authors compared air inside and outside the cab and
concluded that both cabs provided *at least* a factor of 5 reduction (80
percent reduction) for 0.3 micrometer (μm) particles (Hall et al.,
2002). Actual measurements of particles less than 1 μm showed protective
factors of 43 and 16 for the two cabs, indicating that exposure
reductions in the range of 94 percent to 97 percent are possible for
these fine particles. Greater protection factors were reported for
larger particles (greater than 3 μm). The authors also noted that the
evaluation method used in this study "can be applied to various cabs
used in different industries including agriculture, construction, and
manufacturing."

In another recent report on cab enclosures, Cecala et al (2005) measured
an average cab efficiency of 93 percent for respirable dust (measured
inside and outside the cab) during active operating conditions at an
earth-drilling site. The operator opened and closed the door several
times, which contributed to the dust inside the cab.

Effective operator enclosures are fully sealed (around doors and windows
and utility gaps as for electrical wiring). These cabs are pressurized
to provide fresh, filtered air to the operator. In hot environments,
cooling the air encourages workers to keep windows and doors closed
consistently. Providing heating and cooling at the ceiling, rather than
floor level, minimizes disturbance of dust from the operator's boots.
Enclosed cabs are currently in use at some foundries: NIOSH describes a
gray iron foundry where crane operators worked in enclosed, pressurized
cabs. In this example, 230 cubic feet per minute (CFM) of makeup air was
provided to an 80 cubic foot (ft^3^) cab (NIOSH, 2000 - Case 07).
Although the cab operator experienced crystalline silica exposure (for
reasons that are not clear), this NIOSH report offers just one of
several example of how cabs can be modified. Cecala et al (2005) also
made modifications to an earth drill that included adding a
pressurization system that provided 70 CFM filtered make-up air (outside
air) to the 45-ft3 cab. The system raised the cab pressurization from
0.005 inches of water to 0.1 inches of water and also provided "about 1½
filtered air changes to the enclosed cab every minute" through a
near-respiratory quality electrostatic filter with a rating of 97
percent efficiency for test particles of 0.3 μm. An electrostatic filter
was selected because it provided less resistance (restriction per unit
area of filter) than a traditional mechanical filter. Cecala further
improved the cab by disconnecting the original floor-level heater and
installing a ceiling-level combination A/C and heater unit after the
investigators found that the floor-level heater greatly increased dust
concentrations inside the cab, perhaps by disturbing dust on the floor
and the operator's boots. It was this cab that achieved the previously
mentioned 93 percent average reduction in respirable dust (when operated
without the original floor-level heater) (Cecala et al., 2005). In this
case, the modifications cost approximately \$3,200 plus an additional 40
man-hours to change equipment and seal/inspect the cab.

To calculate the benefit such a cab would offer foundry material
handlers, ERG calculated that a 90 percent reduction (rounding down from
the exposure reductions reported by most authors) in the 0.93 μg/m^3^
value offered as the baseline exposure level for this job category would
result in an exposure level of 0.093 μg/m^3^ (or less than 0.1 μg/m^3^).

*Automation*: Many manual processes with which material handlers assist
other foundry departments can be automated. For example, the material
handler at ERG Site 7 assists other workers in loading the furnace
charge manually (ERG, 2003b). This process is performed automatically
using a fully-enclosed conveyer at (Case History) Foundry E (CCMA,
2000). Such a system would all but eliminate the involvement of the
material handler in the process.

*Work practices:* Modified work practices can have an impact on material
handler exposure. For example, raw material/charge deliveries might be
timed so that material handlers or overhead crane operators approached
the furnace between periods of degassing, sparging, and dross skimming,
thus avoiding those periods when airborne contaminant levels in that
area are highest. Forklift operators who deliver large castings to
shakeout areas should move out of the area before vibratory equipment is
activated. Material handlers should not linger in areas where exposure
is incompletely controlled.

##### *Material handler---Conclusion:* The extremely limited available information suggests that the current baseline full-shift beryllium exposure levels for material handlers could be 0.93 μg/m^3^. ERG estimates that most material handlers will achieve exposure levels of 0.1 μg/m^3^ or less when exposure levels of other job categories are reduced to an equivalent level and at the same time by improving housekeeping to minimize the presence of settled dust in the facility and in the cab of any material handling equipment. 

Where exposure levels continue to exceed this level (including in
facilities where other job categories continue to exceed 0.1 μg/m^3^),
ERG estimates that material handlers can still achieve this level
through consistent use of fully enclosed, sealed, pressurized, and air
conditioned operator cabs for most. Such cabs routinely provide the
operator with better than 90 percent reduction in dust exposure levels
(Cecala et al., 2005; Hall et al, 2002; Haney, 2000). A 90 percent
reduction to the baseline exposure result of 0.93 μg/m^3^ would bring
the beryllium exposure level of material handlers down to 0.093 μg/m^3^.

***Furnace operator---Baseline conditions/controls:*** Furnace operators
typically work with exhaust ventilation at the furnace; however, the
ventilation system is likely to have been designed to capture heat and
control foundry emissions under environmental initiatives. These systems
are not necessarily in optimal working condition or of a suitable design
to minimize worker exposure, but may have been improved from the
original intend of capturing heat. Where furnace ventilation systems
were described for non-ferrous foundries by NIOSH, ERG, and CCMA, few of
the systems were fully effective (designs did not incorporate adequate
features for worker protection) (NIOSH, 1976; ERG, 2003b; CCMA 2000).
Most foundries make a minimal effort, if any, to control exposure from
collected dross and/or charge preparation activities (Beryllium Alloy
Casting Facility A, 2005). Housekeeping is typically not adequate to
manage the quantity of dust and debris generated. Although some
facilities have central vacuum systems in the furnace area, surface wipe
samples indicate that these are not used with adequate frequency or
efficiency to eliminate accumulations of beryllium-containing dust (ERG,
2003b). Therefore, ERG considers baseline controls to include some form
of local exhaust ventilation (such as a slotted plenum), which provides
somewhat improved worker protection over traditional canopy hoods. Other
baseline controls include an industrial vacuum system, which is used
inconsistently as part of a modest housekeeping program. Furnace
operators also typically use some form of dross collection receptacle,
but without dedicated exhaust ventilation. Nor is exhaust ventilation
typically available for furnace charge preparation or charge bucket
heating activities.

The modest number of individually reported exposure results available to
ERG include several that might represent baseline conditions (ERG,
2003b; NIOSH, 1976). Most of these, however, are several times higher
than the median level, suggesting that the situation was atypical of
foundries in general (for example operators could have performed
additional activities such as furnace relining, addressed here in the
maintenance operator job category, or these results might be associated
with an increased reliance on poorly performing canopy hoods, as at ERG
Site 7).

In the absence of additional well-documented exposure results, ERG
judges that the lowest of the results obtained by NIOSH best represents
the baseline exposure level for furnace operators. Thus, the preliminary
baseline exposure level is 0.69 μg/m^3^. This judgment is based on the
assertion by NIOSH that all dust and fume producing activities were
ventilated at this facility, but that "where engineering controls
existed, they were inadequate, considering the toxicity of the
contaminant" (NIOSH, 1976). Other, higher results were also obtained at
this facility, but again, they exceed the levels experienced by most
furnace operators to the extent that they cannot be considered to
represent the baseline.

ERG acknowledges that many years have passed since NIOSH obtained the
designated baseline air sample. ERG notes that this baseline level is
preliminary until such time as additional, more recent information
becomes available.

ERG also acknowledges that few results for furnace operators are in the
range of the estimated baseline level. However, the little information
associated with the lower results (0.2 μg/m^3^ or less) suggests this
level can be achieved through use of furnace mounted hoods and use of
efficient controls for metal fume and dust throughout the facility, as
was the case in Case History D (CCMA, 2000). Yet other information from
other foundries described in the same reference, and from ERG's Site 7,
suggest this type of control is not widely used and cannot be considered
as a baseline condition (CCMA, 2000; ERG, 2003b). Furthermore, the
numerous results above the baseline level appear to represent a range of
conditions and include large variations in exposure level even within
the same facility, including in the foundry where the provisory baseline
level was obtained. ERG argues that this baseline result is better
associated with the upper half of the bimodal distribution of furnace
operator results. ERG selected the lowest level in that range to
acknowledge that half the available furnace operator results fall below
this interim baseline level.

***Furnace operator---Additional Controls:*** The preliminary baseline
beryllium exposure level for furnace operators is 0.69 μg/m^3^. Furnace
operators will require additional controls to achieve beryllium results
of 0.5 μg/m^3^ or the lower levels of interest. Additionally, it is
important to note that a substantial number of furnace operators (39
percent) experience exposure levels well in excess of the current
beryllium PEL of 2.0 μg/m^3^. Although the available information is
inadequate to confirm the reasons for these elevated exposure levels,
ERG finds that some of the highest results are associated with furnace
operators who performed extensive dross skimming and other furnace
tending activities under a canopy exhaust that pulled fume and dust from
dross skimming through the workers' breathing zone. Additionally, the
operator with highest exposures also conducted pouring tasks -- which
can contribute elevated peak exposures.

Particular challenges associated with reducing the exposure levels of
furnace operators include the high temperatures in and around furnaces
(which render impractical many traditional materials and designs for
engineering controls or automation), the frequent need for furnace
operators to work at the furnace edge, and handling dross and dross
receptacles (Corbett, 2005a).

To reduce most furnace operator exposures to levels of 0.5 μg/m^3^ or
less, furnace operators will need to implement several control measures:

-   Installing local exhaust ventilation on the dross receptacle;

-   Improving local exhaust ventilation on furnaces;

-   Installing operator's booths pressurized with filtered air; and

-   HEPA vacuuming or otherwise cleaning clothing when exiting the
    furnace area.

Dross receptacles must be fitted with exhaust ventilation. A beryllium
producer designed and installed a *ventilated dross collection* tray
that holds several scoops of dross removed from the furnace. When the
tray is full, the operator activates a control that withdraws the dross
tray into a ventilated enclosure and dumps the tray contents into a
barrel (also under exhaust ventilation). The tray is then extended from
the upper enclosure, ready to be refilled (Corbett, 2005a).

Foundries will also need to improve local exhaust ventilation on
furnaces to improve fume and dust capture and to reduce the influence of
cross drafts (CCMA, 2000). A foundry casting copper-based alloy, Case
History Foundry C, used a horseshoe-shaped slotted hood at the top of
the furnace (CCMA, 2000). This design allows ready access to the molten
metal for treatment and dross skimming. An auxiliary ventilation system
would be required to ensure skimmed dross and the associated scoop
constantly would be held under exhaust ventilation as they passed
between the furnace mouth, the dross receptacle, and the scoop storage
area. Although no metal air sampling results are available for this
system, studies of other equipment have demonstrated the effectiveness
of circular or semicircular slots at the mouths of process containers
such as bag dumping receptacles (bins and totes), ball mills, and mixing
vats. Iwasaki and Ojima (1997) provide details for designing a circular
hood which, when compared to the uncontrolled situation, reduced chromic
oxide dust by 96 percent in the vicinity of mixing vessel mouths. The
measurements were made while the chromic oxide was being introduced into
the vessel, when the falling dust caused turbulence in the vessel and
displaced air through the vessel opening. ACGIH (2001) offers several
designs for circular slot ventilation systems. The beryllium production
industry also uses slotted ventilation hoods around induction furnace
openings

Furthermore, furnace operators must be provided with *control booths
equipped* with air conditioning and high efficiency particulate air
(HEPA) filters (99.97 percent effective against particles of 0.3
micrometers size). The same principles described for operator cabs (in
the material handler job category) will be effective for furnace
operator booths. As a final control method necessary for most furnace
operators to achieve levels of 0.5 μg/m^3^ or less, workers exiting the
melting and casting area must also *clean their clothing* (e.g., with a
HEPA vacuum or a HEPA-filtered air shower). This step reduces the extent
to which clothing continue to contribute to worker exposure as they move
to other, possibly cleaner areas. Additionally, the step will reduce the
spread of beryllium to other facility areas.

The effectiveness of this combination of controls (improved ventilation
at the furnace, ventilated dross collection receptacles, operator's
control booth, and cleaning clothing after spending time in the furnace
area) are demonstrated by results achieved by a beryllium production
facility for induction furnace alloy casting operations (working with
0.1 percent to 2 percent beryllium in alloy). Using these controls, the
median exposure level of furnace operators involved in beryllium
production is 0.5 μg/m^3^.

Other controls will be required to help furnace operators achieve the
lower exposure levels of interest.

*Furnace-mounted exhaust hoods*: Ventilation exhaust hoods located at
any distance above the furnace are subject to air disturbances and cross
currents that render them less effective. These furnaces hoods also make
it possible for workers to lean over the furnace, placing their
breathing zone between the source of fume and the exhaust hood.

Several alternative hood designs are readily available, although some
require modifications to, or even replacement of the furnace. A
centrifugal casting foundry (Case History Foundry D), which casts both
ferrous and non-ferrous alloys, uses furnace-mounted exhaust hoods. This
type of hood eliminates the influence of cross drafts and also prevents
operators from working between the fume source and the exhaust hood.
Both of the full-shift beryllium furnace operator exposure results
associated with this control were less than the limit of detection (in
this case 0.2 μg/m^3^). ACGIH (2001) offers a design for an enclosing
induction furnace melting hood (VS-55-07). Foundries that do not perform
extensive dross removal might also achieve this level, but ERG
anticipates that this type of hood would present a challenge to
facilities casting high-purity beryllium alloys.

Dross must be removed from the metal to produce quality castings (Air
Products, 2005). A fully enclosing hood would hamper the process. For
example, the reduced access to the furnace top means workers would not
be able to remove dross without displacing the hood. To minimize this
problem, foundries would need to design the hoods with trap doors to
access the melt. Even so, ERG understands that purity specifications for
certain castings will require more rigorous dross removal and greater
access to the furnace interior. In these facilities it will be necessary
to remove the enclosing exhaust hood and replace it with an auxiliary
ventilation system, which will capture fume and dust while providing
access to the furnace. At the same time, to better capture fume and dust
from dross as the dross is transferred out of the furnace, foundries
will need to incorporate a ventilation system extension or mobile arm
that covers the entire path of the dross scoop from the furnace to the
ventilated receptacle. ERG is not aware of a commercial source for such
a ventilation system; however experts agree that to fully control fumes
from toxic metals it is necessary to keep the entire process under local
exhaust ventilation (CCMA, 2000; Corbett, 2005a). Because retrofit
foundry ventilation systems are often custom designed, the lack of a
commercial source is a less compelling concern than it might otherwise
be. Recent advances in computer modeling offer advanced methods for
designing exhaust ventilation and for predicting the benefits of various
configurations (NIOSH, 2002--EPHB 233-133c; Huang et al., 2004; Heinonen
et al., 1996).

*Preventive maintenance* on the furnace and ventilation system is a
critical component of worker protection. A continuous maintenance
program, including frequent inspections, is necessary. NIOSH visited a
foundry (Case History 11) that found it was important to check the
furnace cover seal seat after each charging to ensure it was in good
condition. On a daily basis the facility also monitored dust collector
differential pressure and motor amperage, augers and fans, and hoppers
(for overfilling). Ventilation system drive components, pneumatic
systems, and hoods were checked once per week, as were bag house
filtration units. The fan impellers were cleaned monthly (NIOSH, 1978).
A program of routine air monitoring would also help identify problems
with exposure controls so they could be investigated and corrected
(CCMA, 2000).

*Enhanced work practices*, consistently applied, might further reduce
furnace operator exposure levels. For example, current exposure levels
at with beryllium production furnace operations are associated with
problems such as overfilling the specially designed dross tray (adding
more scoops than the tray will hold), thus preventing the tray from
retracting properly (Corbett, 2005a).

An additional work practice challenge involves overfilling the dross
collection barrel (in the ventilated enclosure) before changing the
barrel. Employees of the beryllium production industry reportedly find
it difficult to predict when the barrel is full. These problems could be
eliminated by enforcing strict policies on work practices such as dross
tray filling and barrel filling. A level indicator (mechanical or
optical) to help workers determine barrel fullness could be installed to
aid the process. As indicated in Section 3 - Beryllium Production, work
practice enhancements might achieve an average exposure reduction of 32
percent. A 32 percent reduction in the 0.5 μg/m^3^ exposure level would
result in a median exposure level for furnace operators of 0.34 μg/m^3^,
but this control alone would not necessarily reduce exposures to the
next level of interest (0.2 μg/m^3^ or less).

To meet this next lowest level of interest, it might be necessary to
eliminate manual dross skimming and dross barrel changing by automating
these processes. Dross barrel changing could be automated using existing
materials handling technology. For example, remote controlled
manipulators could allow a worker in a control booth to seal the barrel
and clean the barrel exterior before removing the dross barrel from the
ventilated enclosure.

Automating the dross skimming process presents a greater challenge and
the feasibility of this technology needs to be investigated. However,
two induction furnace manufacturers contacted by ERG suggest that
mechanical dross skimming is possible. This process has been developed
only to a limited extent and is not widely marketed because furnace
manufacturers have not received customer requests for this feature.
Customers may be reluctant to embrace such technology because furnace
dross skimming is a "sensitive" task, requiring the correct amount of
hand pressure during the rubbing and scraping. If not performed
correctly, molten metal could become superheated and/or the refractory
lining could be damaged (resulting in furnace explosion). Given the
potential safety issues, furnace manufacturers suggest that employers
might be reluctant to automate the dross removal process (Pillar
Induction Company, 2004). However, at least one manufacturer does offer
equipment to partially automate the dross skimming task. The substantial
expense associated with automation is offset where the foundry can use
the same piece of equipment for several furnaces of similar size (ABB
USA, 2004). By completely eliminating both manual dross barrel changing
and manual dross skimming as a source of furnace operator exposure, ERG
estimates that furnace operators could achieve exposure levels of 0.2 or
less μg/m^3^. ERG was not able to obtain exposure information for this
combination of processes because these methods are not currently in use.

Another option for reducing (but not eliminating) manual dross skimming
involves prevention of dross formation. Dross is formed by impurities in
the metal with which the furnace is charged and by oxygen (in air)
contacting the hot metal surface. Increasing the cleanliness of the
molten metal helps minimize dross formation. Another means of reducing
dross/oxide formation is using vacuum environment or an inert gas at the
melt surface. Inert gas prevents beryllium metal in the molten alloy
from contacting oxygen in air and forming oxide. Manufacturers who heat
treat beryllium alloys as part of the annealing process often do so in
an inert atmosphere to minimize oxide production on the surface of the
alloy (Corbett, 2004). Inert atmospheres include an evacuated chamber
(oxygen sucked out, creating a vacuum), or alternatively, a chamber or
blanket of an inert gas, such as argon or nitrogen, which displaces air
at the molten metal surface. The oxygen level can be reduced from the
usual 21 percent in air to 1 percent in the inert gas) (Beryllium
Casting Facility A, 2005; Air Products, 2005).

Several foundry operations have attempted to use an inert gas layer at
the surface of the molten metal. The advantages of this technology are
great; by reducing dross production by 50 percent (or more for metals
that are strongly attracted to oxygen) foundries can reduce the amount
of time workers spend removing dross (Beryllium Casting Facility A,
2005; Air Products, 2005). Use of the oxygen-displacing blankets also
results in a more pure metal for casting (Corbett, 2005a; Beryllium
Casting Facility A, 2005; Air Products, 2005).

The NGK Company (Japan) reports success with this method (Corbett,
2004). That company, however, did not respond to an inquiry. Other
attempts at inert gas layering have had mixed success and not resulted
in a marked decrease in employee exposure levels. In principle this
method could reduce beryllium exposure levels for the furnace operator
and others who work in the area (e.g., material handlers, maintenance
workers -- including those repairing refractory linings that become
contaminated with dross residue). In practice, facilities that use this
method may need to spend time modifying the ventilation system and
balancing exhaust rate/exhaust point to maximize heat removal while
minimizing disruption of the inert gas layer (Corbett, 2004). Even with
oxygen displacement technologies, fumes continue to be generated at a
rate dependent on the physical properties of the metal and the
temperature (Air Products, 2005).

Industrial gas supply companies offer services that assist foundries in
achieving the optimal equipment configuration for excluding oxygen while
conserving inert gas supplies (Air Products, 2005). At this time,
however, these services do not evaluate employee exposure as one
criteria for a satisfactory design.

Furnace charge loading and charge bucket heating can contribute to
furnace operator exposures to metal dusts, including those that contain
beryllium (CCMA, 2000). Furnace operators will need to conduct both
processes under local exhaust ventilation. Although not widely used,
such systems have been in use for many years. In 1978 NIOSH described a
gray iron foundry (Case History 9) that used a 10,000 CFM exhaust system
to provide local exhaust ventilation first at the point where the charge
bucket was filled, then at the charge pre-heater hood. Dampers were used
to divert the entire air flow to the first hood used in this sequential
process, then to the second hood (NIOSH, 1978). Much of the process was
automated at this foundry, however the principles of ventilating the
bucket loading and heating steps hold for all methods. In ERG's
professional judgment a downdraft table or back-draft plenum hood at the
charge bucket filling station could substantially reduce furnace
operator exposure levels. Charge bucket pre-heaters, fitted with exhaust
ventilation in the form of caps covering the bucket mouths and each
connected to an exhaust duct, are pictured in a review of Case History
Foundry G - iron and aluminum casting foundry (CCMA, 2000). As mentioned
previously in the discussion of material handlers, CCMA also describes a
gray iron foundry (Case History Foundry E) that used an enclosed charge
feed conveyer to transfer the charge to the furnace. In figure VS-50-21,
ACGIH (2001) recommends an airflow rate of 250 CFM per square foot of
open area on the hood when covered conveyers carry toxic materials (such
as beryllium).

***Furnace operator---Conclusion:*** ERG estimates that most furnace
operators can achieve exposure levels of 0.5 μg/m^3^ or less by
installing local exhaust ventilation on the dross receptacle; improving
local exhaust ventilation on furnaces; installing operator's booths
pressurized with filtered air; and HEPA vacuuming or otherwise cleaning
clothing when exiting the furnace area. Nearly half of the furnace
operator results presented in the exposure profile are already below
this value. Additionally, alloy induction furnace operators employed by
a beryllium producer achieved used this combination of controls to
achieve a median of 0.5 μg/m^3^ (see Section 3 -- Beryllium Production).

In foundries where alloy purity is less critical, furnace operators can
further reduce their exposure level, to levels of 0.2 μg/m^3^ or less by
using fully enclosing furnace hoods and all but eliminating manual dross
skimming. Many furnace operators have already achieve this level,
possibly by this method, as did two furnace operators at Case History
Foundry D (CCMA, 2000). To the extent that nearly all furnace operators
are able to eliminate dross skimming and dross barrel handling, ERG
estimates that the exposure level of nearly all furnace operators would
be reduced to 0.2 μg/m^3^ or less. Until that time, many furnace
operators (possibly the 39 percent with exposure levels exceeding the
current PEL) would require respiratory protection to reach this level.

Although a number of additional controls are available to furnace
operators, and each could reduce one source of beryllium exposure by
some percent, ERG judges that even when all methods are combined, it may
not be possible for most furnace operators to achieve levels of 0.1 or
less μg/m^3^, unless, as above, dross skimming and barrel changing are
eliminated as part of the control method.

***Pouring operator---Baseline Conditions/Controls**:* The median
exposure level for pouring operators is 0.1 μg/m^3^. This median level
suggests that baseline controls for pouring operators include mobile
ladle hoods and some form of ventilation on pouring lines. However, the
systems might not be maintained in optimal condition.

There is some evidence to support this assertion. Due to the greater
toxicity of the alloy components in these foundries, pouring area
ventilation in non-ferrous casting facilities is typically designed to
provide better exposure control than the pouring area ventilation
systems in other foundries. For example, four of the non-ferrous casting
foundries (Case History Foundries A through D) for which CCMA described
pouring facilities and the ERG site visit foundry all contained some
form of local exhaust ventilation in the pouring area (CCMA, 2000; ERG
2003; Corbett, 2005b). Although two of these systems were described as
"state of the art," none functioned optimally due to problems with work
practices, inadequate exhaust rates, cross-currents and lack of makeup
air, or system design.

There is inadequate information to definitively state the baseline
exposure level for pouring operators. Control information is available
for just three results, all from one facility. The baseline controls
were in place at this facility (Case History Foundry D) (CMA, 2000).
However, all three of the results exceed the median value of 0.1 μg/m^3^
presented in the exposure profile (although two of the results are below
the limit of detection of 0.2 μg/m^3^, it is not possible to say they
are less than 0.1 μg/m^3^). This situation suggests that either the
exposure profile does not represent an accurate profile of this job
category, or the three results do not accurately represent the typical
conditions. Additional, well-documented exposure information for pouring
operators would allow ERG to better judge which is the case. Until such
information is available, ERG estimates that the baseline exposure level
is equal to the median level, 0.1 μg/m^3^. Furthermore, ERG judges this
to be a reasonable preliminary estimate. More results are at this level
(or near it 0.1 μg/m^3^ to 0.11 μg/m^3^) than any other single exposure
level in the exposure profile. Additionally, it is entirely possible
that the two values from Case History Foundry D that are below the limit
of detection (0.2 μg/m^3^) are also in fact in the range of 0.1 μg/m^3^.

***Pouring operator---Additional Controls***: As presented in Tables
5-14 and 5-15, the estimated baseline beryllium exposure level for
pouring operators is 0.1 μg/m^3^. The baseline controls include a fairly
advanced group of control methods, however, there is always room for
improvement.

Foundry experts agree that local exhaust ventilation is the primary
control measure for pouring operations involving toxic metals, such as
beryllium (and lead). "Properly engineered source exhaust, whereby air
contaminants are drawn away from the breathing zone, is the only really
effective means of air contaminant control. General ventilation, in the
form of powered roof ventilation, is used by foundries, which pour and
cool molds in open floor areas. This type of ventilation is, at best,
effective only in minimizing the excursion of fume, smoke, and gases to
other workplace areas. For those employees involved in the actual
pouring, general ventilation methods offer little breathing zone
protection" (AFS, 1985). "Experience of nonferrous foundries alloying
with lead indicates that control to a 50 lead μg/m^3^ exposure level
warrants that the casting process be ventilated the entire time that the
metal is in the molten state. The molten metal cycle includes melting,
furnace drossing, tapping into ladles, ladle drossing, hot metal
transport, mold pouring, and pigging. Ladle preheaters should be added
to the list of casting processes to be ventilated, because of the fume
produced by the flames contacting the residual metal in the ladle"
(CCMA, 2000).

A number of ventilation system designs for pouring operator tasks are
available in the AFS *Foundry Ventilation Manual*, the American
Conference of Governmental Industrial Hygienists (ACGIH) Industrial
Ventilation -- A Manual of Recommended Practice, and a report by CCMA
(AFS, 1985, ACGIH, 2001; CCMA, 2000). These documents describe special
mobile ventilation hoods that pouring operators can attach to ladles.
The hoods connect to flexible ducts extending from overhead trunks
(ACGIH, 2001). When the ladle is transported by crane, the duct moves
with the crane. Other similar designs are available for ladles pushed on
wheeled carts or on tracks. When appropriately designed, ventilated, and
fitted to the ladle, these hoods continuously exhaust the ladle as it
carries metal from the furnace to the molds. With their enclosing
design, these hoods have the potential to collect virtually all fume
(and other contaminants) rising from molten metal in the ladle.

The act of filling the ladle during furnace tapping can disrupt
ladle-mounted ventilation if a portion of the hood must be displaced to
allow workers to pour metal into the ladle. To maximize fume control
during furnace tapping, CCMA (2000) advocates the use of close-capture
hoods on both the furnace and on the ladle. "During tapping into the
ladles, both hoods draw at the fume, from either side of the ladle.
Ladle hoods are usually built with a hinged section over the front of
the ladle that can be swung away during tapping without disconnecting
the ventilation suction" (CCMA, 2000). Most ladle hood designs specify
that a source of make-up air should be provided near the furnace tapping
position. Not only will make-up air cool and provide fresh air to the
worker, but the air will also help balance the direction of air
currents, maximizing the ventilation effectiveness while the ladle hood
is open.

Ladle hoods in some foundries require access ports that allow the
pouring operator to treat the molten metal using methods similar to
those used by furnace operators (e.g., skimming dross and inoculating
the metal with additives). As a related work practice, pouring operators
can perform these tasks while the ladle is still under the influence of
both the ladle and the furnace ventilation systems.

Several examples offer insight into metal fume exposure levels when
circumstances prevent these controls from working as intended. For
example, CCMA (2000) describes Case History Foundry A, a brass (8 to 9
percent lead) sand-casting foundry with "state-of-the-art" local exhaust
controls in the pouring area. The system consisted of:

-   a canopy hood over the ladle preheating station (a photograph shows
    a hood approximately twice the diameter of the ladle, positioned
    about one ladle diameter above the ladle)

-   ventilation at the furnace tapping station

-   a mobile ladle hood (a photo shows a gap of a few inches between the
    hood and the ladle)

-   a slotted duct above the molds to exhaust fumes after pouring
    (photograph shows that the slotted duct runs down the centerline of
    a row of molds, with slots on the side of the duct at about the same
    spacing as the molds are spaced on their conveyer)

Nevertheless, the lead exposure levels for pouring operators were, on
average, the highest in the facility. The CCMA report notes that fumes
at this facility appeared to be well controlled throughout the pouring
process, except while workers manually moved and positioned the
hoist-supported ladle. One noted problem was the speed at which the
ladle moved. "Fume could be seen trailing behind the ladle during fast
movement, exposing the operator who was behind the moving ladle." The
CCMA investigator suggested that the airflow rates be evaluated to be
sure that individual hoods in the ventilation system were drawing air at
the intended rate (CCMA, 2000). Additionally, the investigator noted
that poor ventilation balance in the foundry and the strength and
location of other exhaust hoods in the pouring area also may have
contributed to pouring operator exposures. Supply air from behind the
furnace was drawn past the furnace and into the pouring area, sweeping
with it any fugitive emissions from the furnace. Under these conditions,
eight full-shift PBZ lead exposure levels for pouring operators,
obtained on 8 different occasions between 1994 and 1999, were routinely
two to four times the PEL for lead (50 μg/m^3^). On three of these
occasions, cadmium was also evaluated. The three full-shift PBZ cadmium
results for pouring operators were also among the highest of the 16
cadmium results reported for all job categories at that foundry. The
cadmium readings ranged from 2.7 μg/m^3^ to 4.4 μg/m^3^, which
approaches the PEL for cadmium of 5 μg/m^3^. Together the lead and
cadmium results indicate that the combined problems were adequate to
overcome this "state-of-the-art" exhaust system and resulted in
significant metal exposures for pouring operators.

Lead results for pouring operators were also elevated at a second
foundry casting copper-based alloy (5 percent lead). The second foundry
(Case History Foundry B) was also described as having a
"state-of-the-art" ventilation system in the fume producing areas,
including hoods on the furnace, pouring ladles, and ladle pre-heater. In
this case, the investigator believed that "draw on the hoods was weak"
and that an "inadequate exhaust rate may have been responsible for these
high readings" (CCMA, 2000). ERG believes that the findings at these two
foundries suggest that, had beryllium been present, beryllium exposures
might also have been significant.

In the absence of more definitive results, ERG also believes that those
pouring operator beryllium results that exceed the baseline exposure
level (0.1 μg/m^3^) are likely to be associated with either a
ventilation system that is not state-of-the-art, or one that could be so
designated -- but is not operated in an efficient manner. The decreased
in efficiency might either be due to inadequate exhaust rates as seen in
the previous two examples from CCMA (2000), and/or due to work practices
that contribute to exposure, as was also evident in the first
example).[^4]

Thus ERG proposes that foundries where pouring operators frequently
experience exposure levels exceeding 0.1 μg/m^3^ can reduce exposures to
that level by the baseline ventilation systems in the pouring area and
ensuring that exhaust rates are adequate to capture contaminants
released by pouring area processes. This assumes that exposure levels
associated with other job categories in the foundry are similarly
controlled and that the foundry ventilation system is balanced to
minimize cross-contamination if a release occurs in another area.

Pouring operators currently working with the baseline controls can
reduce their exposure levels by augmenting the controls with ventilated
ladle heaters, as recommended by CCMA (2000). Increased attention to
work practices, such as avoiding the path of any fumes that do escape,
and to ventilation system maintenance, will also help reduce the
exposure level of this group. As noted elsewhere in this analysis,
improvements in either work practices or engineering controls can reduce
exposure levels by 20 to 50 percent *each*. Using a ladle heater
(instead of a torch that applies heat inconsistently and can overheat
residual alloy, causing it to fume) will further decrease exposure
levels by an undetermined amount. By improving both work practices (fume
avoidance) and engineering controls (routine maintenance and testing of
ventilation systems), ERG estimates that a larger group of pouring
operators (well over the current 51 percent) will achieve exposure
levels of 0.1 μg/m^3^ or less. Applying the cumulative exposure
reduction of at least 50 percent to the results of those of pouring
operators (17 percent) with current exposure levels of 0.2 μg/m^3^ or
less, ERG estimates that nearly 70 percent of pouring operators (51
percent plus 17 percent) would be able to achieve results of 0.1 μg/m^3^
or less.

***Pouring operator---Conclusion:*** Based on the exposure profile, more
than half (51 percent) of pouring operators already achieve exposure
results of 0.1 μg/m^3^ or less. ERG's preliminary estimate suggests that
most (nearly 71 percent) of pouring operators would be able to reach
this level by improving work practices and engineering controls.

Access to additional information regarding the beryllium exposure
levels, work practices, and controls associated with beryllium alloy
casting foundries would allow ERG to confirm or revise this preliminary
estimate.

***Shakeout operator---Baseline conditions/controls**:* Little
information is available to describe the working conditions of shakeout
operators in foundries that cast beryllium alloys. The foundry that ERG
visited (Site Visit 7) did not use a shakeout process. Rather, the
casting extruded from the direct-chill mold passed directly to the
finishing area on a conveyer fitted with exhaust ventilation.

Some beryllium alloy casting facilities, however, do use sand-casting
methods or sand cores that require a shakeout process (Corbette, 2004).
According to the *AFS Foundry Ventilation Manual* (AFS, 1985), the
shakeout operation is typically one of the dirtiest operations in
foundries. The source of exposure is dust released as hot, dry sand
molds are agitated, broken, and separated from castings. Shakeout
conditions vary dramatically; however, an analysis of crystalline silica
exposure in other types of foundries (e.g., ferrous sand-casting
foundries SIC 3321, NAICS 331511), the majority of facilities have
installed LEV in the shakeout area (ERG, 2003a). Thus, ERG concludes
that the baseline condition involves shakeout work performed by an
operator positioning castings on enclosed or ventilated equipment that
is used to separate sand from castings. However, the report also
suggests that enclosure and ventilation are not uniformly effective as
used.

The available exposure information for this job category (from IMIS)
does not allow ERG to link any beryllium results with specific controls.
Of the six exposure results available, three are equal to 0.05 μg/m^3^.
In the absence of other information, ERG judges these results to offer
the best representation of the baseline exposure level available at this
time.

***Shakeout operator---Additional Controls:*** The industry profile
suggests that the beryllium exposure level of half the operators is 0.05
μg/m^3^, while the remaining shakeout operators experience exposure
levels that are all 0.5 μg/m^3^ or less (median 0.11 μg/m^3^).

In some foundries the beryllium exposure level of shakeout operators
could be nearly eliminated by switching to non-sand casting methods,
particularly methods that reduce surface beryllium oxide formation (die
casting, direct chill casting, and rapid temperature controlled cooling
methods for castings) (AFS, 2000). Use of foam or other expendable
material for cores (rather than sand) is increasingly popular. When sand
is used, it should be collected under ventilated conditions for
disposal. Foundries should avoid re-using contaminated sand.

A draft analysis of crystalline silica in foundries showed that there
are several opportunities to reduce the dust exposure of shakeout
operators by installing or upgrading ventilation (ERG, 2003a). Number
range CHAPTERFoundries that currently use enclosed equipment to separate
sand from castings can reduce shakeout operator exposures by improving
the enclosures, fixing leaks, and ensuring ventilation provides at least
200 fpm air velocity across all openings (AFS, 1985; ACGIH, 2001).
Additionally, to minimize exposure of shakeout operators to beryllium
released from other processes, foundries should ensure that local
exhaust ventilation systems are coordinated with general ventilation to
prevent flow of contaminated air from/between the furnace, pouring and
shakeout areas. For the lowest PEL options, consider automating and
fully enclose the shakeout (except for very large castings).

The following discussion notes the methods available for reducing
shakeout operator exposures to dust containing crystalline silica. ERG
believes that dusts containing beryllium will be controlled to an
equivalent extent by these methods.

Shakeout enclosures are available as standard equipment or may be
constructed by the foundry. The ACGIH ventilation manual (ACGIH (2001))
provides four ventilation designs for open and enclosed styles of
shakeout equipment. As an option on all their machines, a shakeout
equipment manufacturer offers standard covers specifically to help
control dust. This company sells shakeout equipment to handle molds from
0 to 40 tons; however the benefits of enclosure have not been quantified
for any size mold (Kinergy, 2000). Although data is not available to
quantify the benefit for reducing beryllium exposure levels, OSHA did
quantify the benefit of a flexible foundry-made shakeout enclosure for
reducing crystalline silica results. A "pickoff" worker who removed
castings from a vibrating conveyor in the shakeout area had full-shift
TWA respirable quartz exposure levels of 95 µg/m³ in 1997 and 126 µg/m³
in 1998; following the installation of a flexible fireproof curtain
adjacent to the mold dump area to direct the dust to the ceiling-mounted
exhaust ducts, as well as installation of equipment to remove more sand
from the casting prior to its arrival at the pickoff area, the worker's
respirable quartz exposure was reduced to 74 µg/m³ (an average of 33
percent) in 1999 (OSHA SEP Inspection Report 300530029). When
contaminated sand is the source of beryllium exposure, a corresponding
reduction in beryllium levels might also be assumed for this control
method.

NIOSH also supports the use of ventilated enclosures. NIOSH recommended
that the shaker table be enclosed on three sides and ventilated, and
that molds be dropped onto the semi-enclosed shaker table rather than
directly onto the floor (NIOSH HETA 92-0044-2265,1992).

Rotary sand/casting separators or rotary media drums are an alternative
to vibrating shakeout equipment for many small to medium size casting
applications (South Cast Equipment, 2000; Didion, 2003). For example
sand casting systems (particularly flaskless casting systems) often
include a rotary media drum to separate sand and clean the casting as
the next step after pouring and cooling. This equipment tumbles the
casting along with metal shapes or "media" (for example, 1- to 2-inch
stars) that remove and separate sand from both castings and scrap. Only
sand in small internal spaces of the casting is not completely removed.
Although the effectiveness of this equipment for reducing worker
exposure has not been quantified, the double concentric barrel design
(an inner perforated barrel rotating within an outer ventilated barrel)
is reportedly "significantly less dusty than a vibratory shakeout"
(South Cast Equipment, 2000). At the same time, according to one
manufacturer, castings are cleaner and require less shot blasting time
and less labor during subsequent phases of casting production (Didion,
2003).

"Four-in-one" shotblast machines are another alternative to the
vibratory shakeout process for small and medium size castings (O'Brien,
2000). This enclosed, ventilated equipment serves multiple functions
including separating casting from sand, blasting off sticking sand, and
sifting sand for reuse. Again, the effectiveness of this equipment has
not been quantified; however, NIOSH noted the benefits of this enclosed,
ventilated design (O'Brien, 2000). Multiple automated processes in one
continuous enclosure may reduce the chance of worker exposure during
manual handling or from dust escaping at transfer points.

Enclosing the process is preferable to enclosing the operator because
dust emissions from shakeout operations have been implicated in
cross-contamination dust exposure of other foundry workers (ERG, 2003a).
However, enclosing the operator has proven effective in specific
circumstances. For example, NIOSH evaluated a foundry that had enclosed
an entire shakeout and finishing line in an isolation room (NIOSH
ECTB-233-107c, 2000).

Small jobbing foundries or foundries producing very large castings may
employ floor shakeout operators who perform manual operations as they
upset molds or retrieve castings. According to the AFS foundry
ventilation manual (AFS, 1985), this type of floor shakeout operation is
most difficult to control. The manual notes that PBZ protection may be
required in such cases, but adds, "Exposure is usually short and can be
further reduced by transporting the castings and sand to a ventilated
station." However, the principles of enclosure and ventilation apply
even to large objects and some exposure reduction is possible. ERG
proposes that it is also feasible to use portable enclosures and
ventilation systems, as well as ventilated tools and, under some
circumstances, operator cabs during separation of molds and sand from
large castings.

Certain ventilation system designs will be more practical for large
castings than others; however, effectiveness of any system will be
reduced if used improperly. NIOSH evaluated several scenarios for
reducing exposure during shakeout activities involving large castings.
In 1998 NIOSH visited a gray iron foundry producing large castings
(bathtubs) and reported full-shift or near-full shift (342 to 465
minutes) silica sampling results obtained on two dates under differing
conditions (NIOSH EPHB 233-133c, 2002). At this facility, the shakeout
stations were fitted with side panels (that provided fresh air to the
worker) and exhaust hoods that formed a partial canopy above; the area
directly above the process was left open to allow overhead cranes to
move the large castings in and out of the area. This ventilation system
had been renovated and overhauled in two previous (but unsuccessful)
attempts to reduce worker silica exposure levels. In an attempt to
control worker exposures, the foundry was considering a third major
modification to the system.

NIOSH noted several possible problems with both the existing and
proposed systems. First, the hoods were located too far from the
contaminant source (the casting) to be classified as receiving hoods for
the shakeout process. Additionally, the workers typically did not
activate the hood exhaust fans and used man-cooling fans only. On the
first sampling day, the silica results for shakeout operators were 140
µg/m³, 290 µg/m³, 320 µg/m³, and 400 µg/m³ under typical working
conditions, which included the cooling fans blowing on the workers and
exhaust fans turned off. Shakeout operator exposure levels were reduced
30 to 50 percent on the following day, when the cooling fans were turned
off and the exhaust fans turned on (as designed). Under these improved
conditions NIOSH obtained generally lower results of 80 µg/m³, 200
µg/m³, 210 µg/m³, and 260 µg/m³ during the periods sampled (NIOSH EPHB
233-133c, 2002).^2^[^5] Although still well above the current PEL for
crystalline silica, these result show that workers can achieve some
reduction in exposure levels by modifying work practices to use existing
ventilation systems as intended, even when the system is not fully
effective. Until poorly performing systems can be improved or replaced,
shakeout operators should continue to use the ventilation system that
are in place. Fans used for worker comfort can disturb airflow patterns
associated with exhaust ventilation systems intended to remove
contaminated air.

Next, as part of the same study, NIOSH used computer modeling to test 18
different combinations of ventilation system modifications that might be
used to improve dust control at the shakeout stations. The model
predicted how well each design would reduce the concentration of
airborne respirable dust and also considered energy usage factors. The
simulation design results suggested the following points regarding the
situation at this foundry:

-   Side barriers and fresh air supplied from the side were effective
    for limiting the spread of dust and for providing clean air to the
    workers.

-   The addition of floor exhaust (suction) near the shakeout table
    would be effective for capturing dust.

-   The existing overhead exhaust ducts acted as a ceiling that helped
    provide direction to and improve the effectiveness of the \[fresh
    air\] supply jet.

-   The overhead exhaust at this foundry did not offer a clear benefit
    to worker exposure.

Furthermore, the results suggested several ventilation system designs,
based on the points noted above, that might reduce respirable
particulates (including silica) by a substantial amount. The computer
model predicted the five best designs might reduce exposure by 98
percent or more compared to no ventilation. The model also predicted
that these designs would offer a reduction of 86 percent compared to the
existing ineffective ventilation system if that system were operated at
twice the actual air exhaust rate (NIOSH EPHB 233-133c, 2002).^2^[^6] As
an added benefit, this computer model also helped engineers evaluate the
best performing proposed designs to determine which offered beneficial
exposure reduction for the least amount of air exhausted. Recognizing
that the prediction of 98 percent reduction might not be achieved under
real-world conditions, ERG concludes that large reductions are possible
with appropriately designed ventilation systems, but that more realistic
values might include a reduction of 90 percent compared to no
ventilation (or 75 percent reduction compared to the existing
ineffective overhead ventilation system). Finally, this NIOSH report
shows that even relatively modern, or recently renovated exhaust
ventilation systems do not necessarily perform effectively; however,
opportunities for substantial improvement are available to facilities
that consider a full range of realistic design options.

Wet methods, such as wetting sand as it is removed from the casting
might also be beneficial for controlling shakeout operator exposures to
silica. A gray iron foundry visited by NIOSH used a water spray for dust
control where a vibratory conveyer exited an enclosed shakeout area
(NIOSH ECTB 233-107c). At this facility, NIOSH noted that the water
spray was spluttering, not noticeably misty, and offered marginal
coverage of the dust source, indicating that the spray was not
performing optimally. Together, the inefficient water spray and slot
ventilation (presumably working as intended), was associated with
results of 22 µg/m³ to 104 µg/m³ for workers in various job categories
(shakeout operator, knockout operator, finishing operator) who performed
tasks in the area. A well-maintained water spray would likely have
improved the dust control in this area. Directional water mist sprays
offer effective silica dust control during operations in other
industries. For example, NIOSH found that a fine water mist spray
reduced the respirable dust exposures of impact drill (jackhammer)
operators by 70 to 90 percent during construction work, compared to 50
to 60 percent reduction when jackhammers were fitted with LEV (Echt et
al. 2003; NIOSH EPHB 282-11a, 2003). Although one is mobile and one is a
stationary activity, impact drilling on concrete and foundry shakeout
operations are both high-energy activities that generate substantial
quantities of respirable silica dust.

Several cases demonstrate the value of enclosed and ventilated shakeout
equipment, particularly when combined with other dust control measures.
An enclosed dust collection system (not further described) was
associated with full-shift PBZ readings for shakeout operators of less
than or equal to 13 (2 readings), 30, and 41 µg/m³. These readings were
obtained at a foundry that had made a systematic effort to identify and
abate all sources of dust emission with the establishment of a "Sand
Leak Team" consisting of an engineer, maintenance and production
supervisors, and employees (ERG# MI-1483). Another foundry enclosed the
shakeout conveyer and exhausted the enclosure at a rate of 8,000 cfm
(for a 10-foot segment) as part of a comprehensive effort to reduce
exposure throughout the facility. With the enclosure in place results of
13 and µg/m³ and 37 µg/m³ were obtained for workers in the shakeout area
(OSHA SEP Inspection Report 303207518).

A combination of controls substantially reduced shakeout operator
exposure levels at a foundry evaluated by OSHA and described earlier in
the section on molders. At this facility, shakeout operators dumped
molds onto a shaker conveyer, operated a rotary media drum that removed
additional sand from the casting, and then hung the castings on an
overhead conveyer. Initially, this process was associated with an
operator exposure level that was 380 percent of the current PEL
(measured as respirable dust containing crystalline silica). The
employer then "designed and built an enclosure that ran the length of
the shakeout conveyer from the mold dump position to the \[media
tumbler\]" and also increased exhaust ventilation to the area. Once
these changes were in place and the facility had been vacuumed and power
washed, shakeout operator exposure levels decreased to 20 percent of the
current PEL (Irwin, 2003). ERG estimates shakeout operator crystalline
silica exposure levels were reduced from approximately 300 µg/m³ to less
than 40 µg/m³ when the facility implemented these controls.^2^[^7]

***Shakeout operator---Conclusion:*** Based on the limited exposure
profile, half (50 percent) of shakeout operators already achieve
exposure levels of 0.1µg/m³ or less. ERG judges that another 25 percent
of shakeout operators, those currently exposed to levels of 0.2 µg/m³,
could reach the lower value by improving the function and maintenance of
existing shakeout ventilation systems. A foundry visited by NIOSH found
that by simply reducing crosscurrents cause by man-cooling fans and
using a foundry ventilation system as designed allowed shakeout
operators to reduce exposure levels by 50 percent. Computer models
predicted that a substantial additional reduction (over 75 percent)
could be achieved by renovating the existing shakeout area ventilation
system (NIOSH EPHB 233-133c, 2002). A 50 percent or greater reduction in
exposure levels of 0.2 µg/m³ would reduce operator exposures to
0.1µg/m³.

***Abrasive blasting operator---Baseline conditions/controls:***
Abrasive blasting operators in foundries typically use enclosed and
ventilated blasting units that are partially or fully automated. As
noted earlier, large castings are blasted in a booth or in the open.
ERG's analysis of crystalline silica in foundries suggested that
blasting machines are typically poorly maintained, incompletely sealed,
and associated with inefficient ventilation systems (ERG, 2003a). This
assertion is also supported by an 8-hour TWA chromium VI result of 1.5
μg/m^3^ (based on a 387-minute sample) for the operator of a tumbling
mill at an iron and steel foundry where the equipment jammed and worker
climbed into the mill to correct the problem. (Tumbling mills serve a
similar metal cleaning function as abrasive blasting machines). This
exposure level was elevated above the normal level (estimated by the
investigator to be approximately1.0 μg/m^3^ of chromium (OSHA
HO54A).[^8]

The four beryllium exposure results available for abrasive blasting
operators in aluminum and copper foundries include two results of 0.101,
plus a result that is higher and another that is lower. Thus, among the
very limited available results, the exposure level of 0.101 is the most
prevalent. No supporting information is available regarding the work
conditions associated with any of these exposure results. Until
additional information becomes available, for the purposes of this
analysis ERG judges that 0.101 μg/m^3^ is the most likely baseline
exposure value and is associated with the baseline controls.

***Abrasive blasting operator---Additional Controls:*** The preliminary
baseline beryllium exposure levels for abrasive blasting operators in
aluminum and copper foundries is 0.101 μg/m^3^. As was previously
described under the discussion on molders, cross contamination between
foundry areas can contribute to workers' exposure levels. ERG notes that
when the exposures of workers in other job categories are reduced to a
similar level, abrasive blasting operator exposure levels are likely to
decrease by the very small increment (one-one hundredth of a μg/m^3^)
needed for most abrasive blasting operators (75 percent) to achieve
exposure results of 0.1 or less.

Although they do not appear to be necessary in most foundries, a number
of additional control methods are available for abrasive blasting
operators.

*Improve existing blasting machines:* A primary control for abrasive
blasting operators involves repairing or improving the blasting machines
to seal leaks, augmenting ventilation systems to achieve 500 fpm air
flow through all openings as recommended for blasting cabinets by ACGIH
or as recommended by the machine manufacturer (ACGIH, 2001; Pangborn,
2003). Blasting machine manufacturers offer programs to rebuild and
retrofit these machines and also provide long-term service contracts
(Pangborn, 2003). New abrasive blasting machines are readily available
from a variety of commercial sources. Even a minor improvement in
blasting machine function, such as servicing the fan motor and adjusting
belt tension, would be likely add enough benefit to reduce the exposure
level of abrasive blasting operators currently at the baseline level
(0.101 μg/m^3^) to a level of 0.1 μg/m^3^ or less.

*Sealed blasting machines*: To minimize beryllium exposure to levels,
foundries might wish to select airtight, batch-style blasting machines,
with a door that seals closed. The modest leakage that might occur from
continuous blasting machines (parts constantly conveyed in and out of
the machine though openings in the machine) might prevent abrasive
blasting operators from achieving the lowest levels, while a
well-functioning, completely sealed blasting machine could be expected
to reduce exposures to minimum levels. An important feature of a fully
enclosed blasting machine (or blast cabinet) is an interlock that
prevents the blasting machine door from being opened until the
ventilation system has had a chance to exhaust the unit. To achieve
these lowest exposure levels, ERG judges that it will also be necessary
to control dust release during transport of castings to and away from
blasting machines. To this end, conveyers, containers and other
equipment used to transport castings to the blasting machines should be
enclosed and any openings exhausted with local exhaust ventilation.
After blasting with abrasive, castings and the interior of blasting unit
should be wiped to remove dust from surfaces (similar techniques are
used to minimize dust from machining operations; see Sections 3 --
Beryllium Production and Section 7 -- Precision Turned Products).
Additionally, ERG believes that unless blast media can be thoroughly
cleaned, the media should be completely replaced periodically to
minimize increasing levels of beryllium contamination of the media.
Although ERG has not been able to quantify the benefit of this control
for abrasive blasting operators working on beryllium alloys, higher
concentrations of a contaminant in bulk samples typically result in
higher exposure concentrations if dust from the bulk sample become
airborne.

*Isolating booths*: A control option for manual abrasive blasting of
small and large castings involves booths that separate the worker from
the casting. For small castings, a well enclosed, ventilated
glove-box-style blasting cabinet would serve the purpose. For large
castings, available options include linking glove boxes (suitable for
long castings). For example, one manufacturer produces ventilated
cabinets with internal working compartment dimensions 60 inches wide by
48 inches deep by 36 inches high, which has reportedly been used for
abrasive blasting of granite tombstones (Pauli, 2001a; Pauli, 2001b).
This size box is interlocked, to prevent operation unless the unit is
sealed, and ventilated at 840 cfm. In addition, the boxes are fitted
with a dust collector (filter efficiency 99.9 percent for 0.3 micron
particles available on some models) and a completely enclosed,
ventilated media reclamation system. A larger ventilation system is
required when two or more of these cabinets are linked together to
provide a larger internal workspace (Pauli, 2001b).

Castings that are larger in more than one dimension would require the
roomier, but less effective alternative. Abrasive blast booths that
include an incompletely sealed partition to separate the operator from
the blasting activity (for example roll-up doors with an access slot and
window) will provide an additional level of protection, if negative
pressure is maintained in the blasting enclosure. This type of equipment
is commercially available and was used by two granite working facilities
in which NIOSH conducted control technology assessments (Ruemelin, 2000;
NIOSH, 1999-Case 06; NIOSH, 2000-Case 31). NIOSH, however, reported
mixed results in these booths' ability to control crystalline silica
exposures. Air pressure and turbulence introduced during blasting may
limit the reliability of this control option.

*Wet abrasive blasting:* Wet abrasive blasting or water-jetting methods
(adding water to the blasting solution or blasting with high pressure
water) offers an additional control option for both small and large
non-ferrous castings. Use of wet methods can significantly reduce
airborne dust during surface cleaning (SSPC, 2001). A report prepared
for the U.S. Army National Guard (presenting U.S. Naval Yard Study
results) compares various wet and dry abrasive blasting methods and the
frequency with which heavy metal PELs were exceeded (Industrial Hygiene
West, 2000). Air sampling suggested workers had a 33 percent to 44
percent risk of exceeding the PELs for lead (50 μg/m^3^) or cadmium (5
μg/m^3^) when using dry blasting methods (open abrasive blasting and
blasting inside a blasting enclosure). In contrast, limited sample
results for workers using low volume water slurry blasting (steel shot
with water added) and high pressure water jetting (without abrasive
added) indicated the risk of exceeding the lead or cadmium PEL was
between 0 percent and 3 percent.[^9]

Although wet methods can reduce dust levels substantially,
contaminant-bearing mist or water can generated during the processes can
contribute to worker exposure levels if these sources are not
subsequently controlled. Exposures to heavy metals can occur if
dust-laden water from the blasting process is allowed to dry and the
dust becomes re-suspended in air. Combining exhaust ventilation appears
to be particularly important for controlling air contaminants at the
beryllium levels under consideration. The same report just described
includes an example that demonstrates the importance of controlling mist
and dust during wet blasting methods. In this case, a consultant
conducted air sampling for the Army National Guard while a worker used
hydroblasting (abrasive media in water) to remove lead paint from a
vehicle trailer. A short-term (115 minutes) PBZ air sample resulted in a
lead exposure level of 120 μg/m^3^, nearly 2.5 times the PEL for lead.
Study results indicate "paint removal was performed inside a building
that had no ventilation system to evacuate the air mist" (Industrial
Hygiene West, 2000).

*Reduce beryllium oxide on castings*: Reducing beryllium oxide formation
on casting surfaces is an additional option for reducing the beryllium
exposure of abrasive blasting operators. Because any oxide on the
casting will be removed during blasting, and because beryllium oxide
often has a greater beryllium content than the base metal, reducing
oxide formation might have a notable effect on blasting operator
exposure. Casting methods that minimize oxide formation include methods
that minimize the contact of air (oxygen) with the hot metal surface,
such as permanent mold or die-casting. Particularly effective are
methods that cool the casting rapidly to reduce surface temperatures to
a level at which oxide does not form as quickly (e.g., direct chill
casting). One casting facility visited by NIOSH (a secondary smelter
that also cast copper anodes for an electrolysis process) sprayed and
submerged red-hot castings in water to cool them as quickly as possible
(NIOSH, 1984). The benefit of reducing surface oxide as a method for
reducing abrasive blasting operator exposure levels has not been
quantified for beryllium; however, reducing the amount of
contaminant-bearing coatings is a common exposure control method in
other industries. For example, workers use chemical strippers to remove
lead or cadmium paints from metal that will subsequently be worked
(welded, or sanded/blasted to improve the anchor pattern for future
paint). In the case of beryllium alloy castings, the base metal would
continue to be a source of exposure for blasting operators.

***Abrasive blasting operator---Conclusions:*** As discussed previously,
the preliminary baseline exposure level for abrasive blasting operators
is 0.101 μg/m^3^. Based on the potential for background levels of
beryllium to decrease slightly when the exposure levels of other job
categories are controlled, ERG estimates that this change will be
adequate to reduce the exposure of most abrasive blasting operators (75
percent) by the one-one hundredth of a μg/m^3^ needed for this group to
achieve exposure levels of 0.1 μg/m^3^or less.

***Grinding/finishing operator---Baseline conditions/controls:***
Grinding, sanding, cutting and polishing of aluminum and copper castings
is most frequently performed as a wet process. Wet methods were used
with the saw at ERG Site 7, a copper beryllium casting facility (ERG,
2003b). Housekeeping in and around the grinding/finish workstation,
however, is not always thorough or performed consistently.

As with other job categories, little information is available to
describe controls associated with the exposure results ERG (2003b) was
able to obtain for this job category. The saw at ERG Site 7, for which
the best documentation is available, was used briefly by a material
handler who worked in all areas of the foundry over the abbreviated
shift. No grinding/finishing operator results are available from this
site (no worker was dedicated to this task at that small foundry).
Supporting information is available for several job categories at Case
History Foundry D; however, the narrative does not describe the working
conditions of the grinding/finishing operators (two machinists and a
grinder/snagger) (CCMA, 2000). Nevertheless, these three results
represent ERG's best estimate of the baseline conditions for
grinding/finishing operators.

The case history reports the presence of well-considered exposure
controls in other foundry areas. This suggests that controls such as wet
methods are likely used for the facility's non-ferrous finishing
activities. The three full-shift beryllium results for
grinding/finishing operators at Case History Foundry D are all less than
the limit of detection (0.2 μg/m^3^). As noted in the exposure profile,
this value also happens to represent the median result (0.2 μg/m^3^) for
grinding/finishing operators. Until additional information becomes
available on the exposure level associated with baseline conditions, ERG
has adopted 0.2 μg/m^3^ as the baseline exposure level for
grinding/finishing operators.

***Grinding/finishing operator---Additional Controls:*** The baseline
exposure level for grinding/finishing operators is 0.2 μg/m^3^. These
operators will require additional controls to achieve the lower level of
interest. Some of the available methods for reducing the beryllium
exposure of grinding/finishing operators are specific to foundries
(e.g., decreasing casting defects). Other methods are work practice and
engineering controls related to the equipment and processes, which are
generally similar to the equipment and processes described for
machinists (including those operating cutting equipment and hand-held
grinding tools) in Section 7 -- Precision Turned Products. The following
discussion covers the control methods unique to foundries. For a
detailed discussion of equipment- and process-based controls, please
refer to Section 7.

The grinding/finishing operators in foundries typically work on the
castings produced by other workers in the same facility. This gives
foundries an added opportunity to reduce the exposure of their own
grinding/finishing operators by producing the cleanest possible
castings. To do this they can reduce the amount of oxide on the surface
of castings and also reduce the quantity of casting defects that require
grinding and/or finishing.

*Reduce surface oxide*: Some casting methods reduce formation of surface
oxide by preventing the molten metal from contacting oxygen in air.
These casting methods include die-casting and other reusable solid molds
into which metal is poured. The solid metal walls of the mold stay in
contact with the molten metal and exclude air. Methods that cool the
metal quickly, (e.g., direct chill casting) reportedly offer an added
benefit. These rapid cooling methods reduce the molten metal surface to
a temperature less than the level where oxides form readily (Corbett,
2004). Direct chill casting, involving a chilled water jacket
circulating around the mold, is the method used by ERG Site 7, a
beryllium-copper casting facility (ERG, 2003b). The castings at this
site were described as "very clean" (Corbett, 2005a). Other casting
facilities use water baths on molds and water spray on hot castings for
the same purpose -- to rapidly cool the casting surface and minimize
opportunity for oxides to form. A smelting facility visited by NIOSH
used this technique to cool cast anodes (NIOSH, 1984).

*Reduce casting defects:* Sand inclusions, surface imperfections, and
other defects incorporated into casting surfaces are chipped or ground
out by grinding/finishing operators. According to a report appearing in
Modern Casting magazine, nine different process-related problems can
leave sand tightly adhered to the casting surface (burn-in) and eleven
process problems may result in sand embedded as projections into the
casting (sand inclusions) (Spada, 2000). Causes range from low (or high)
mold moisture or the wrong sand mixture to equipment problems. Once
identified, each cause may be eliminated by modifying and improving
process quality control (Spada, 2000). Use of refractory mold and core
coatings may also minimize burn-in (Coelho and Bharati, 1999). Another
option is substitution of one granular media for another that reduces
the incident of burn-in. For example, five gray and ductile iron
foundries testing a ceramic alternative to silica sand for casting and
each reported reduction of burn-in/burn-on during green sand, core,
shell, and lost foam casting applications (Carbo, 2000). Of these, one
foundry (Number 6) reported an estimated 90 percent reduction in burn-in
when it switched to the alternate ceramic media for cores.

*Pre-cleaning castings*: Most castings may be pre-cleaned using
enclosed, automated, and ventilated processes, such as vibrating
abrasive media, rotary media drums, or enclosed shot blasting (Huston,
1981; South Cast Equipment, 2000; Pangborn, 2000). Pre-cleaning is
typically performed after shakeout, but in some cases these pre-cleaning
methods can replace the shakeout process entirely (South Cast Equipment,
2000). Pre-cleaning produces cleaner castings and thus reduces labor
associated with grinding and other finishing tasks (Huston, 1981;
Didion, 2000b). This means that grinding/finishing operators would need
to spend less time working on beryllium alloy castings and therefore
reduce the overall beryllium exposure associated with these tasks.

[]{.mark}

Other control methods for grinding/finishing operators are based on the
tools or work practices. See Section 7 -- Precision-turned Products for
a discussion of these methods.

***Grinding/finishing operator---Conclusion:*** \[To be added\]

***Maintenance operators---Baseline conditions/controls:*** Based on
information from the ERG, NIOSH, and CCMA reports, ERG believes that
maintenance operators most typically work with general ventilation only,
unless work is performed on equipment that is exhausted. When working on
ventilated equipment, such as furnaces, the process exhaust ventilation
system might offer some degree of exposure control for the maintenance
operator, but is unlikely to be designed to provide optimal control of
maintenance activities. As an example, furnace ventilation hoods are
designed to capture fumes released from the top of the furnace, rather
than from the furnace interior where a maintenance operator might chip
and patch the refractory lining.

***Maintenance operators---Additional Controls:*** The baseline
beryllium exposure level for maintenance operators is inferred to be
0.10 μg/m^3^ -- (same as FURNACE MAINTENANCE, SMELTING). []{.mark}

[]{.mark}

Please see the discussion of furnace maintenance operators in Section 6-
Smelting, Refining, and Alloying.

*Work practices:* Careful pre-cleaning of equipment before maintenance
activities can reduce maintenance operator exposure levels. The
following example describes procedures in a pharmaceutical firm, another
industry that handles highly toxic dusts. A health and safety
representative from this pharmaceutical manufacturer described
pre-cleaning requirements and noted that the company requires equipment
operators to be familiar with specific equipment cleaning and
decontamination procedures before the operator is certified to use that
piece of equipment. When maintenance or repair is required, the
equipment is cleaned (typically by the equipment operator or a
housekeeping assistant) to the required specifications before the
maintenance operator or service person is permitted to approach the
equipment (Pharmaceutical Manufacturer A, 2004).

The pharmaceutical manufacturer's cleaning procedure typically begins by
shutting down the equipment (to prevent the release of additional
particulate matter). The worker then uses a HEPA vacuum on all surfaces
to remove any loose dust. This is followed by a wet wiping step, to
remove lightly adhered particles. During and after this cleaning, the
local work area ventilation system is operated to capture any particles
disturbed during the cleaning. This company sometimes requires surface
wipe tests to confirm the level of cleanliness before the equipment can
be moved. While product protection is the original basis for this level
of cleaning, company health and safety staff indicate that these steps
effectively control the exposure levels of workers who subsequently
perform maintenance or otherwise handle the equipment. Specifically,
these methods reduce exposures to a level for which respiratory
protection is not required for workers maintaining equipment that
produces pharmaceutical substances with allowable occupational exposure
limits in the "micron range" (this facility reportedly does not
manufacture substances with occupational exposure limits lower than the
approximate range of OSHA's current PEL for beryllium of 2 μg/m^3^)
(Pharmaceutical Manufacturer A, 2004).

[]{.mark}

To make the vigorous cleaning process easier, and to encourage
meaningful visual cleanliness inspections, the pharmaceutical
manufacturer places a priority on acquiring equipment made of stainless
steel using "clean in place" designs. That is, equipment designed to be
cleaned in it's operating location by the qualified worker, rather than
using a design that would have to be transported to an equipment shower
room, or shipped to the manufacturer for cleaning (Pharmaceutical
Manufacturer A, 2004).

[]{.mark}

Maintenance operators can also reduce their exposure levels by using
administrative controls such as scheduling routine maintenance to avoid
times when incompletely controlled process is being conducted in the
area.

[]{.mark}

Work practices such as limiting the number or location of operators
working in a furnace at one time, could reduce maintenance operator
exposures during chipping activities. During an evaluation of respirable
crystalline silica, OSHA obtained a notably higher result for a worker
reportedly using a jackhammer in the "lower part of a \[furnace\]" than
was reported for the second operator who also used a jackhammer during
the same evaluation (OSHA SEP Inspection Report 116201997). Sweeney and
Gilgrist (1998) also reported a higher respirable silica exposure level
for an operator working in a lower position within a 1,100-pound holding
furnace for molten aluminum: "Of the two workers involved in performing
this project, the higher exposure occurred to employee 1, who did less
of the jackhammering but more of the grabbing and tossing of the pieces
and chunks of old refractory material. This apparently was because his
head was down closer to the jackhammer's point of operation and dust
generated than the head of operator 2, who was standing up and operated
the jackhammer. However, both employees were overexposed to the
respirable dust containing crystalline silica."

[]{.mark}

*Local exhaust ventilation:* For most maintenance operators, the primary
control might include portable local exhaust ventilation systems or
stationary systems that can be adapted to benefit the maintenance
operator. As was previously noted, maintenance operators work positions
may limit the benefit of process ventilation systems on the equipment
they service. For example, tundish repair can occur on the pouring line
floor near exhaust ventilation intended for the hot molds. A slotted
hood or duct trunk at the pouring station might provide some exposure
control when the tundish is between the worker and the hood; however the
control is not typically constant. As work progresses around the
tundish, however, eventually the worker's back will be to the
ventilation hood and contaminated air from the tundish cleaning might be
pulled past the worker's breathing zone.

[]{.mark}

A company that provides refractory overhaul services developed a method
for installing temporary LEV in a gas-fired furnace. This method is used
for complete lining removals, but is also applicable to smaller
(patching jobs). The method involves company-built exhaust fans fitted
with air filters (three filters of increasing efficiency in series)
(Refractory Services Provider A, 2003a). The fans create an air flow
pattern in the furnace that pulls fresh air from outside the furnace
past the worker's face and removed dusty air from near the chipping
point. Workers stretch plastic sheeting as necessary to ensure the fresh
air enters the furnace only from the most advantageous point (for the
purpose of providing clean air to the worker), while they set one or
more fan/filter boxes into the opposite and lower end of the furnace to
exhaust contaminated air. Existing openings, such as access hatches and
gas vents, are used as needed to maintain favorable circulation
(Refractory Services Provider A, 2003b). The position of sheeting and
boxes might need to be moved as the work progresses to other sections of
the furnace. Although the fan/filter boxes are specially built for this
purpose, they are made of materials readily available at hardware stores
and cost relatively little to produce (approximately 30 dollars per box,
plus the cost of the fan) (Refractory Services Provider A, 2003b).

[]{.mark}

Providing exhaust ventilation throughout a process, from start to
finish, will help maximize control of metal dust and fume (CCMA, 2000).
ERG believes this principle holds true regardless of whether the dust
and fume are cadmium, lead, or beryllium. Maintenance operators who
repair refractory linings benefit from enclosed, exhausted receptacles
to hold debris generated during the repair process.
Beryllium-contaminated waste (such as spent refractory materials)
generated during maintenance activities should be transferred under
local exhaust ventilation from the furnace or tundish to the receptacle.

Ve*ntilated chipping tools*: The benefits of tool mounted systems for
controlling beryllium has been demonstrated for the control of hazardous
dusts (such as crystalline silica) in other industries, including the
construction and the ready-mix concrete industries. The chipping of
refractory materials is similar to chipping concrete, another
silica-containing material. To evaluate chipping equipment, NIOSH tested
two tool-mounted LEV shrouds for hand-held pneumatic chipping equipment
(impact drills): one custom built, the other a commercially available
model. Comparing multiple short-term samples, NIOSH found that the
shrouds reduced PBZ respirable dust by 48 to 60 percent (NIOSH,
2003-EPHB 282-11a). In a separate evaluation, NIOSH showed that this
type of LEV system controls dust equally well for larger and smaller
chipping equipment. NIOSH collected short-term PBZ samples while workers
used 25 or 30 pound jack hammers to chip concrete from inside concrete
mixer truck drums. During 90 to 120 minute periods of active chipping,
mean respirable silica levels decreased 69 percent (from 970 to 300
µg/m³) when the workers used a tool-mounted LEV shroud in these enclosed
spaces (NIOSH, 2001-EPHB 247-19). In this study, a combination of LEV
and general exhaust ventilation provided additional dust control,
resulting in a 78 percent decrease in respirable silica readings.
Respirable dust levels decreased by a slightly smaller amount (54
percent) due to a lower percentage of silica in samples associated with
shroud use.

*Wet methods:* Recent studies have also shown that wet dust control
methods are effective for controlling respirable dust released during
chipping. NIOSH (2003-EPHB 282-11a) investigated a water spray dust
control used by construction workers breaking concrete with 60 and
90-pound jack hammers. A spray nozzle was fitted to the body of the
chipping tool and a fine mist directed at the breaking point. Using both
a direct reading instrument and a high-flow cyclone and filter media,
NIOSH collected 10-minute readings with and without the spray activated.
Compared to uncontrolled pavement breaking, PBZ respirable dust
concentrations were between 72 and 90 percent lower when the water spray
was used. The flow rate of 350 milliliters (12 ounces) per minute
reportedly dried quickly, without adding a substantial amount of water
to the work site (NIOSH, 2003-EPHB 282-11a). Sam and Williams (2000)
also reported that a water spray nozzle mounted on a hand-held pneumatic
chipper decreased respirable dust approximately 70 percent in the
worker's breathing zone. Tool-mounted water spray devices can be
manufactured using materials obtained from a hardware store and include
a garden spray nozzle, tubing, clamps, and a control valve (Sam and
Williams, 2000).

[]{.mark}

Water spray is also useful for controlling dust associated with cleanup.
After chipping, Refractory Services Provider A (2003b) uses a garden
mister to moisten refractory debris in the bottom of the furnace. This
step helps control dust as the waste is removed from the furnace.
Wetting the furnace lining requires an extra step to dry the refractory
material before the furnace is brought to working temperature. However,
despite this complication, wet methods remain the best option for
controlling respirable dusts from high-energy activities such a
pneumatic chipping and should be considered when toxic materials are
involved.

[]{.mark}

*Reducing dross and oxide production:* Any success in reducing dross
formation at the surface of the molten metal (as discussed for the
furnace operator job category) is also likely to reduce deposition of
dross onto furnace walls. However, because of the limited experience
with these controls and problematic results in applications, the benefit
of this control has not been quantified. Even if a method such as inert
gas layering were to be successfully implemented at the furnace, some
oxide is likely to occur at the ladle and tundish (although the quantity
might be limited because metal poured from the furnace would be
cleaner).

***Maintenance operators---Conclusion:*** \[To be added -- same as for
smelters\]

***Housekeeping worker -- Baseline conditions/controls:*** In a draft
analysis of crystalline silica in foundries, ERG concludes that
housekeeping workers most frequently perform manual cleaning tasks.
Additionally, the exposure level of housekeeping workers appears closely
related to the general exposure levels in the foundry, and to the
specific area where they spend the most time. Where exposures are
elevated, the cases presented in the exposure profile suggest that
adjacent operations are the primary source of exposure for housekeeping
workers, although their own work will likely contribute to their
exposure when dry sand is involved. Limited information suggests that
central vacuum systems may be available, particularly in the furnace
area (ERG 2003b).

\[Add housekeeping worker from smelters\]

[]{.mark}

***Housekeeping worker---Additional controls:*** In the absence of
specific information on foundry housekeeping workers, and as shown in
Table 5-8, the median exposure level for housekeeping workers in an
analogous industry (smelting) is 0.3 µg/m^3^. Table 5-9 indicates that
100 percent of the exposure levels for these workers are greater than
the lowest proposed PEL option of 0.1 µg/m^3^. Approximately 62 percent
of the exposure levels are greater than 0.2 µg/m^3^, and eight percent
of the exposure levels exceed 1 µg/m^3^. Additional controls will be
required to reduce operator exposures. With one exception, the same
controls outlined for the housekeeping worker job category in Section 6
-- Smelters, Refining, and Alloying -- will also apply to foundry
housekeeping workers. The exception involves eliminating the use of
beryllium-containing scrap or limiting its use to scrap containing a low
percentage of beryllium. ERG believes that foundries casting beryllium
alloys will not be able to reduce the beryllium content of their raw
materials unless the foundry is able to implement a method for reducing
dross/oxide formation, which decreases the amount of beryllium available
for the finished alloy. Successful implementation of a dross-reduction
method, such as inert gas layering, could reduce the background and
furnace area beryllium exposure levels of housekeeping workers.

[]{.mark}

***Housekeeping Worker---Conclusion:*** \[To be added -- same as
smelters\]

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Didion. 2003. Testimonials. Didion International, Inc., St. Peters, MO.
Internet web site:
\<[[http://www.didion.com/company_news.htm\>.]{.underline}](../%3Chttp://www.didion.com/company_news.htm%3E.)
Accessed October 25.

DOD. 2002. Castable Beryllium-Aluminum Alloys: Starmet Corporation
(Concord, MA). U.S. Department of Defense, Ballistic Missile Defense Web
site.
[[http://www.bdmtechnology.net/techsearch.asp?articleid=403]{.underline}](http://www.bdmtechnology.net/)
Accessed January 16, 2002.

DOE. 2002. Chronic Beryllium Disease Prevention Program. U.S. Department
of Energy Web site.
[[http://tis.eh.doe.gov/be/index.html-ssi]{.underline}](http://tis.eh.doe.gov/be/index.html-ssi)

Dollard. 2002. Telephone conversation between Richard Dollard, Miller
Centrifugal Casting Co. and John L. Bennett, Consultant to ERG, Inc.,
February 15, 2002.

Echt, A., K.Sieber, E. Jones, D. Schill, D. Lefkowtz, J.Sugar, and K.
Hoffner. 2003. Control of respirable dust and crystalline silica from
breaking concrete with a jackhammer; in Case Studies column (D. Tharr,
Column Editor). Applied Occupational and Environmental Hygiene
18(7):491-495. July.

Enviro. 2001. Telephone conversation between representative, Enviro
Voraxial Technology, Inc. and ERG, Inc., November 2001.

ERG. 2003a. Technological Feasibility Study of Regulatory Alternatives
for a Proposed Crystalline Silica Standard. September, 2003. Draft
Report. Submitted to OSHA. September. Number range CHAPTER

ERG. 2003b. Site visit report: Beryllium Site 7. Eastern Research Group.
Lexington, MA.

ERG. 2004a. Draft report. Beryllium Production. Eastern Research Group.
Lexington, MA. September 30.

ERG. 2004b. Site vist to a precious and base metals recovery facility
(ERG site 2). January 13-13, 2003. Eastern Research Group, Inc.,
Lexington, MA. April 23.

ERG# MI-1483. Michigan Department of Public Health. Case File.

Industrial Hygiene West. 2000. Evaluation of occupational hazards using
high pressure water jetting. Prepared by Industrial Hygiene West for the
U.S. Army National Guard. September.

Hall, R.M., W.A. Heitbrink, and L.D. Reed. 2002. Evaluation of a tractor
cab using real-time aerosol counting instrumentation. Applied
Occupational and Environmental Health 17(1):47-54.

Haney, R. 2000. Presentation at Triagency Workshop -- Measurement and
Control of Silica. At National Institute for Occupational Safety and
Health, Morgantown, WV. June 28.

Heinonen et al. 1996. Local ventilation for powder handling --
combination of local supply and exhaust air. American Industrial Hygiene
Association Journal, 57:356-364. April.

Huang, et al. 2004. Development and characterization of a
wake-controlled exterior hood. Journal of Occupational and Environmental
Hygiene, 1:769-778. December.

Huston, R.N. 1981. Abstract number 820130: Cast Cleaning Methods -
Vibratory Finishing. From Cleaning Room Technology, Proceedings of
AFS/CMI Conference, Rosemont, IL. P 89- 102. Internet web site for Cast
Metals Institute \<http://www.castmetals.com\>. Accessed December 21,
2000.

Number range CHAPTERIrwin. 2003. Overexposure to Crystalline Silica in a
Foundry Operation, OSHA Compliance Issues column, R.E. Fairfax, Column
Editor. Applied Occupational and Environmental Hygiene 18(1):18-21.
January.

Iwasaki and Ojima. 1997. Design of a circular slot hood for a local
exhaust system and its application to a mixing process for fine
particles and organic solvents. Industrial Health, 35:135-142.

Johnson. 2002. Telephone conversation between Buck Johnson, Ceramet and
John L. Bennett, Consultant to ERG, Inc., February 18, 2002.

Kinergy Corporation. 2000. Personal Communication. Phone call between
representative of Kinergy Corporation, Louisville, KY, and Whitney Long,
Eastern Research Group, Inc. November 30.

Kosto. 2002. Telephone conversation between Tim Kosto, Millward Alloys,
Inc. and John L. Bennett, consultant to ERG, Inc., February 6 and 13,
2002.

Mallory. 2001. Telephone conversation between James Mallory, Executive
Director Non-Ferrous Founders' Society and Chester Fenton of ERG.
November 30, 2001.

NFFS. 2002. Telephone conversation between representative of the
Non-Ferrous Founders' Society and John L. Bennett, consultant to ERG,
Inc., February 12, 2002.

NIOSH. 1976. Health Hazard Evaluation Determination Report No.
75-87-280, Kawecki Berylco Industries, Inc., Reading, PA (Document
number PB89-161251). National Institute for Occupational Safety and
Health, Cincinnati, OH. April.

NIOSH. 1978. An Evaluation of Occupational Health Hazard Control
Technology for the Foundry Industry (DHEW/NIOSH Publication 79-114).
NTIS publication number PB297560. National Institute for Occupational
Safety and Health, Cincinnati, OH. October

NIOSH. 1984. Health hazard evaluation report (HETA) 82-024-1428,
Chemetco, Incorporated, Alton, IL. Cincinnati, OH: National Institute
for Occupational Safety and Health. March.

Number range CHAPTER

NIOSH. 1985. Recommendations for Control of Occupational Safety and
Health Hazards: Foundries. DHHS (NIOSH) Publication No. 85-116.
Cincinnati, OH: National Institute for Occupational Safety and Health.
September.

NIOSH. 1999-case 06. Control technology and exposure assessment for
occupational exposure to crystalline silica, Case 06 -- Monument
manufacture (ECTB 233-106c). Cincinnati, OH: National Institute for
Occupational Safety and Health. August 5.

NIOSH. 2000. Control technology and exposure assessment for occupational
exposure to crystalline silica, Case 07 -- A gray iron foundry operation
(ECTB 233-107c). Cincinnati, OH: National Institute for Occupational
Safety and Health. April.

NIOSH. 2000-Case 31. Control technology and exposure assessment for
occupational exposure to crystalline silica, Case 031 -- A granite shed.
(ECTB 233-131). Cincinnati, OH: National Institute for Occupational
Safety and Health. August.

NIOSH HETA 92-0044-2265. 1992. Health Hazard Evaluation Report. General
Castings Company, Liberty Road Facility, Delaware, OH. HETA
92-0044-2265. Cincinnati, OH: National Institute for Occupational Safety
and Health. October.

NIOSH ECTB 233-113c. 2000. Control Technology and Exposure Assessment
for Occupational Exposure to Crystalline Silica: Case 13 - A Steel
Foundry Operation. File Number ECTB 233-113c. Cincinnati, OH: National
Institute for Occupational Safety and Health. March.

Number range CHAPTERNIOSH. 2001. Control Technology for Ready-mix Truck
Drum Cleaning (EPBH 247-19). U.S. Department of Health and Human
Services, Public Health Service, Centers for Disease Control and
Prevention, National Institute for Occupational Safety and Health,
Division of Physical Sciences and Engineering, Cincinnati, OH. May 31.

NIOSH. 2002- EPHB 233-133c. Control Technology and Exposure Assessment
for Occupational Exposure to Crystalline Silica: Case 33 -- a gray iron
foundry with computational fluid dynamics used to analyze an existing
control and model proposed modifications (EPHB 233-133c). U.S.
Department of Health and Human Services, Public Health Service, Centers
for Disease Control and Prevention, National Institute for Occupational
Safety and Health, Division of Physical Sciences and Engineering,
Cincinnati, OH. January.

NIOSH. 2003-EPHB 282-11a. In-depth survey report: Control of respirable
dust and crystalline silica from breaking concrete with a jackhammer -
at Bishop Sanzari Companies, North Bergen, NJ (EPHB 282-11a). U.S.
Department of Health and Human Services, Public Health Service, Centers
for Disease Control and Prevention, National Institute for Occupational
Safety and Health, Division of Physical Sciences and Engineering,
Cincinnati, OH. February.

O'Brien, Dennis. 2000. Personal Communication. Phone call between Dennis
O'Brien of National Institute of Occupational Safety and Health and ERG.
October 27.

OSHA, 2003. Integrated Management Information System (IMIS) for date
range 1979 to July 2003. Occupational Safety and Health Administration.
Obtained August 24, 2003.

OSHA H054A. Beryllium Docket Exhibit 35-45-27. Site visit report --
Company F (Iron and Steel Foundry). January 30, 1997.

OSHA Inspection Report 116201997. OSHA Special Emphasis Program (SEP)
Inspection Report 116201997.

OSHA Inspection Report Number range CHAPTER122252281. OSHA Special
Emphasis Program (SEP) Inspection Report 122252281.

Number range CHAPTER

OSHA SEP Inspection Report 300530029. OSHA Special Emphasis Program
(SEP) Inspection Report 300530029.

OSHA SEP Inspection Report 303207518. OSHA Special Emphasis Program
(SEP) Inspection Report 303207518.

Pangborn. 2000. Pangborn Corporation. Internet web site.
\<http://www.pangborn.com/products1b.html\>. Accessed December 27.

Number range CHAPTERPangborn. 2003. Pangborn Corporation. Internet web
site. \<http://www.pangborn.com/products2.html\>. Accessed November 9.

Pauli. 2001a. Product information for RAM 31 Dry Stripping Cabinet.
Pauli Systems, Fairfield, California.

Pauli. 2001b. Personal communication between representatives of Pauli
Systems, Fairfield, California and ERG. At SSPC2001 -- Industrial
protective coatings conference and exhibit. Atlanta GA. November 13.

Peregrine. 2002. Peregrine Falcon Corp. Web site.
[[http://www.peregrinecorp.com.]{.underline}](http://www.peregrinecorp.com/)
Accessed January 16, 2002.

Pharmaceutical Manufacturer A. 2004. Personal communication between
representative of Pharmaceutical Manufacturer A and ERG. December 2.

Pillar Induction Company. 2004. Personal communication between Pillar
Induction

Company and ERG. December 13.

Number range CHAPTERRefractory Services Provider A. 2003a. Personal
communication between Refractory Services Provider A and ERG. October 6.

Refractory Services Provider A. 2003b. Personal communication between
Refractory Services Provider A and ERG. October 7.

Robinson. 2002. Telephone conversation between Steve Robinson, Technical
Specialist,

American Foundry Society and ERG, February 11.

Ruemelin. 2000. Personal communication between representative of
Ruemelin Mfg. Co., Inc, Milwaukee, WI and ERG. September 25.

Sam, K. and D. Williams. 2000. Control measures for reducing employee
exposure to concentrations of total and respirable silica in the
ready-mixed concrete industry during truck drum cleaning. American
Industrial Hygiene Conference & Exposition, Orlando, Florida. May 24.

Scholz, R.C and J.C. Liello. 2000. A foundry ventilation approach whose
time has come. Submitted to: American Foundrymen's Society for
presentation at 2000 Casting Congress. RMT, Inc., Brookfield, WI.

Spada, A.T (Ed.). 2000. Identifying Molding Problems - A *Modern
Casting* Staff Report. Modern Casting. Volume 90, Number 9. (September).

South Cast Equipment. 2000. Personal Communication. Phone call between
Ron Brown of South Cast Equipment (distributor of Didion rotary drums)
and Whitney Long, Eastern Research Group, Inc. (October 27).

Specialloy. 2002. Telephone conversation between representative,
Specialloy, Inc. and John L. Bennett, Consultant to ERG, Inc., February
12, 2002.

SSPC. 2001. Introduction to water-jetting systems and surface
preparation quality assurance (Manual for SSPC Workshop P-W-1).
Presented at SSPC2001 -- The Industrial Protective Coatings Conference
and Exhibit. November 11, Atlanta, GA.

Sweeney, J. and D. Gilgrist. 1998. Exposures to respirable silica during
relining of furnaces for molten metals. In OSHA Compliance Issues column
(R. Fairfax, Editor). Appl. Occup. Environ. Hyg. 13(7):508-510. July.

Taylor. 2001. Telephone conversation between representative, Taylor
Precision Casting Division of American Industrial Casting, Inc. and ERG,
Inc., November 2001.

Tricast. 2001. Telephone conversation between representative, Tricast
Corp. and ERG, Inc., November 2001.

U.S. Census Bureau. 2004. 2002 Economic Census.

Worldcast. 2001. Telephone conversation between representative,
Worldcast Networks, Inc. and ERG, Inc., November 2001.

**Appendix 5A**

**Individual PBZ Beryllium Exposure Levels By Job Category for Workers
in Copper and Aluminum Foundries**

+---+---+--------+------------------+------+-------+----+----+-----+
| * |   |        |                  |      |       |    |    |     |
| * |   |        |                  |      |       |    |    |     |
| T |   |        |                  |      |       |    |    |     |
| a |   |        |                  |      |       |    |    |     |
| b |   |        |                  |      |       |    |    |     |
| l |   |        |                  |      |       |    |    |     |
| e |   |        |                  |      |       |    |    |     |
| 5 |   |        |                  |      |       |    |    |     |
| A |   |        |                  |      |       |    |    |     |
| - |   |        |                  |      |       |    |    |     |
| 1 |   |        |                  |      |       |    |    |     |
| . |   |        |                  |      |       |    |    |     |
| I |   |        |                  |      |       |    |    |     |
| n |   |        |                  |      |       |    |    |     |
| d |   |        |                  |      |       |    |    |     |
| i |   |        |                  |      |       |    |    |     |
| v |   |        |                  |      |       |    |    |     |
| i |   |        |                  |      |       |    |    |     |
| d |   |        |                  |      |       |    |    |     |
| u |   |        |                  |      |       |    |    |     |
| a |   |        |                  |      |       |    |    |     |
| l |   |        |                  |      |       |    |    |     |
| P |   |        |                  |      |       |    |    |     |
| B |   |        |                  |      |       |    |    |     |
| Z |   |        |                  |      |       |    |    |     |
| B |   |        |                  |      |       |    |    |     |
| e |   |        |                  |      |       |    |    |     |
| r |   |        |                  |      |       |    |    |     |
| y |   |        |                  |      |       |    |    |     |
| l |   |        |                  |      |       |    |    |     |
| l |   |        |                  |      |       |    |    |     |
| i |   |        |                  |      |       |    |    |     |
| u |   |        |                  |      |       |    |    |     |
| m |   |        |                  |      |       |    |    |     |
| E |   |        |                  |      |       |    |    |     |
| x |   |        |                  |      |       |    |    |     |
| p |   |        |                  |      |       |    |    |     |
| o |   |        |                  |      |       |    |    |     |
| s |   |        |                  |      |       |    |    |     |
| u |   |        |                  |      |       |    |    |     |
| r |   |        |                  |      |       |    |    |     |
| e |   |        |                  |      |       |    |    |     |
| L |   |        |                  |      |       |    |    |     |
| e |   |        |                  |      |       |    |    |     |
| v |   |        |                  |      |       |    |    |     |
| e |   |        |                  |      |       |    |    |     |
| l |   |        |                  |      |       |    |    |     |
| s |   |        |                  |      |       |    |    |     |
| B |   |        |                  |      |       |    |    |     |
| y |   |        |                  |      |       |    |    |     |
| J |   |        |                  |      |       |    |    |     |
| o |   |        |                  |      |       |    |    |     |
| b |   |        |                  |      |       |    |    |     |
| C |   |        |                  |      |       |    |    |     |
| a |   |        |                  |      |       |    |    |     |
| t |   |        |                  |      |       |    |    |     |
| e |   |        |                  |      |       |    |    |     |
| g |   |        |                  |      |       |    |    |     |
| o |   |        |                  |      |       |    |    |     |
| r |   |        |                  |      |       |    |    |     |
| y |   |        |                  |      |       |    |    |     |
| f |   |        |                  |      |       |    |    |     |
| o |   |        |                  |      |       |    |    |     |
| r |   |        |                  |      |       |    |    |     |
| W |   |        |                  |      |       |    |    |     |
| o |   |        |                  |      |       |    |    |     |
| r |   |        |                  |      |       |    |    |     |
| k |   |        |                  |      |       |    |    |     |
| e |   |        |                  |      |       |    |    |     |
| r |   |        |                  |      |       |    |    |     |
| s |   |        |                  |      |       |    |    |     |
| i |   |        |                  |      |       |    |    |     |
| n |   |        |                  |      |       |    |    |     |
| * |   |        |                  |      |       |    |    |     |
| * |   |        |                  |      |       |    |    |     |
|   |   |        |                  |      |       |    |    |     |
| * |   |        |                  |      |       |    |    |     |
| * |   |        |                  |      |       |    |    |     |
| C |   |        |                  |      |       |    |    |     |
| o |   |        |                  |      |       |    |    |     |
| p |   |        |                  |      |       |    |    |     |
| p |   |        |                  |      |       |    |    |     |
| e |   |        |                  |      |       |    |    |     |
| r |   |        |                  |      |       |    |    |     |
| a |   |        |                  |      |       |    |    |     |
| n |   |        |                  |      |       |    |    |     |
| d |   |        |                  |      |       |    |    |     |
| A |   |        |                  |      |       |    |    |     |
| l |   |        |                  |      |       |    |    |     |
| u |   |        |                  |      |       |    |    |     |
| m |   |        |                  |      |       |    |    |     |
| i |   |        |                  |      |       |    |    |     |
| n |   |        |                  |      |       |    |    |     |
| u |   |        |                  |      |       |    |    |     |
| m |   |        |                  |      |       |    |    |     |
| F |   |        |                  |      |       |    |    |     |
| o |   |        |                  |      |       |    |    |     |
| u |   |        |                  |      |       |    |    |     |
| n |   |        |                  |      |       |    |    |     |
| d |   |        |                  |      |       |    |    |     |
| r |   |        |                  |      |       |    |    |     |
| i |   |        |                  |      |       |    |    |     |
| e |   |        |                  |      |       |    |    |     |
| s |   |        |                  |      |       |    |    |     |
| ( |   |        |                  |      |       |    |    |     |
| S |   |        |                  |      |       |    |    |     |
| I |   |        |                  |      |       |    |    |     |
| C |   |        |                  |      |       |    |    |     |
| 3 |   |        |                  |      |       |    |    |     |
| 3 |   |        |                  |      |       |    |    |     |
| 6 |   |        |                  |      |       |    |    |     |
| 4 |   |        |                  |      |       |    |    |     |
| , |   |        |                  |      |       |    |    |     |
| 3 |   |        |                  |      |       |    |    |     |
| 3 |   |        |                  |      |       |    |    |     |
| 6 |   |        |                  |      |       |    |    |     |
| 5 |   |        |                  |      |       |    |    |     |
| , |   |        |                  |      |       |    |    |     |
| a |   |        |                  |      |       |    |    |     |
| n |   |        |                  |      |       |    |    |     |
| d |   |        |                  |      |       |    |    |     |
| 3 |   |        |                  |      |       |    |    |     |
| 3 |   |        |                  |      |       |    |    |     |
| 6 |   |        |                  |      |       |    |    |     |
| 6 |   |        |                  |      |       |    |    |     |
| ) |   |        |                  |      |       |    |    |     |
| * |   |        |                  |      |       |    |    |     |
| * |   |        |                  |      |       |    |    |     |
+===+===+========+==================+======+=======+====+====+=====+
| * | * | Job    | Task             | **Fu |       | *  |    |     |
| * | * | Ca     | Desc             | ll-s |       | *L |    |     |
| S | S | tegory | ription/Comments | hift |       | es |    |     |
| o | a |        |                  | R    |       | s- |    |     |
| u | m | Job    |                  | esul |       | th |    |     |
| r | p | title  |                  | ts** |       | an |    |     |
| c | l |        |                  |      |       | Fu |    |     |
| e | e |        |                  |      |       | ll |    |     |
| * | * |        |                  |      |       | -s |    |     |
| * | * |        |                  |      |       | hi |    |     |
|   |   |        |                  |      |       | ft |    |     |
|   | * |        |                  |      |       | R  |    |     |
|   | * |        |                  |      |       | es |    |     |
|   | Y |        |                  |      |       | ul |    |     |
|   | e |        |                  |      |       | ts |    |     |
|   | a |        |                  |      |       | ** |    |     |
|   | r |        |                  |      |       |    |    |     |
|   | * |        |                  |      |       |    |    |     |
|   | * |        |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
|   |   |        |                  | **Sa | **Con | ** | *  |     |
|   |   |        |                  | mple | centr | Sa | *C |     |
|   |   |        |                  | Du   | ation | mp | on |     |
|   |   |        |                  | rati | (     | le | ce |     |
|   |   |        |                  | on** | μg/m^ | Du | nt |     |
|   |   |        |                  |      | 3^)** | ra | ra |     |
|   |   |        |                  | *    |       | ti | ti |     |
|   |   |        |                  | *(Mi |       | on | on |     |
|   |   |        |                  | nute |       | ** | (  |     |
|   |   |        |                  | s)** |       |    | μg |     |
|   |   |        |                  |      |       | *  | /m |     |
|   |   |        |                  |      |       | *( | ^3 |     |
|   |   |        |                  |      |       | Mi | ^) |     |
|   |   |        |                  |      |       | nu | ** |     |
|   |   |        |                  |      |       | te |    |     |
|   |   |        |                  |      |       | s) |    |     |
|   |   |        |                  |      |       | ** |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
|   |   |        |                  |      |       |    | ** | **  |
|   |   |        |                  |      |       |    | Sa | 8-h |
|   |   |        |                  |      |       |    | mp | our |
|   |   |        |                  |      |       |    | le | TW  |
|   |   |        |                  |      |       |    | pe | A** |
|   |   |        |                  |      |       |    | ri |     |
|   |   |        |                  |      |       |    | od |     |
|   |   |        |                  |      |       |    | ** |     |
+---+---+--------+------------------+------+-------+----+----+-----+
|   |   | Molder |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| N | 1 | Molder | Beryllium alloy  | 382  | ND    | \  | \  | \-- |
| I | 9 |        | casting. Local   |      |       | -- | -- |     |
| O | 7 |        | exhaust          |      |       |    |    |     |
| S | 5 |        | ventilation      |      |       |    |    |     |
| H |   |        | reportedly       |      |       |    |    |     |
| , |   |        | available for    |      |       |    |    |     |
| 1 |   |        | all operations   |      |       |    |    |     |
| 9 |   |        | where dust and   |      |       |    |    |     |
| 7 |   |        | fume generated   |      |       |    |    |     |
| 6 |   |        |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
|   |   | Ma     |                  |      |       |    |    |     |
|   |   | terial |                  |      |       |    |    |     |
|   |   | h      |                  |      |       |    |    |     |
|   |   | andler |                  |      |       |    |    |     |
|   |   | (cr    |                  |      |       |    |    |     |
|   |   | ane/fo |                  |      |       |    |    |     |
|   |   | rklift |                  |      |       |    |    |     |
|   |   | ope    |                  |      |       |    |    |     |
|   |   | rator) |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| E | 2 | Fo     | Copper-beryllium | \--  | \--   | 2  | 2. | 1   |
| R | 0 | rklift | direct-chill     |      |       | 52 | 38 | .25 |
| G | 0 | op     | casting          |      |       |    |    |     |
| , | 3 | erator | facility.        |      |       |    |    |     |
| 2 |   |        | Open-cab         |      |       |    |    |     |
| 0 |   |        | forklift, moved  |      |       |    |    |     |
| 0 |   |        | raw materials    |      |       |    |    |     |
| 3 |   |        | and castings in  |      |       |    |    |     |
|   |   |        | the furnace and  |      |       |    |    |     |
|   |   |        | pouring areas,   |      |       |    |    |     |
|   |   |        | removes large    |      |       |    |    |     |
|   |   |        | castings from    |      |       |    |    |     |
|   |   |        | molds, also      |      |       |    |    |     |
|   |   |        | performed some   |      |       |    |    |     |
|   |   |        | cutting with a   |      |       |    |    |     |
|   |   |        | saw.             |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| N | 1 | Crane  | Beryllium alloy  | 424  | 0.93  | \  | \  | \-- |
| I | 9 | op     | casting. Local   |      |       | -- | -- |     |
| O | 7 | erator | exhaust          |      |       |    |    |     |
| S | 5 |        | ventilation      |      |       |    |    |     |
| H |   |        | reportedly       |      |       |    |    |     |
| , |   |        | available for    |      |       |    |    |     |
| 1 |   |        | all operations   |      |       |    |    |     |
| 9 |   |        | where dust and   |      |       |    |    |     |
| 7 |   |        | fume generated   |      |       |    |    |     |
| 6 |   |        |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
|   |   | F      |                  |      |       |    |    |     |
|   |   | urnace |                  |      |       |    |    |     |
|   |   | op     |                  |      |       |    |    |     |
|   |   | erator |                  |      |       |    |    |     |
|   |   | (      |                  |      |       |    |    |     |
|   |   | melt/h |                  |      |       |    |    |     |
|   |   | eating |                  |      |       |    |    |     |
|   |   | op     |                  |      |       |    |    |     |
|   |   | erator |                  |      |       |    |    |     |
|   |   | and    |                  |      |       |    |    |     |
|   |   | assis  |                  |      |       |    |    |     |
|   |   | tants) |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| E | 2 | F      | Copper-beryllium | \--  | \--   | 2  | 4. | 2   |
| R | 0 | urnace | direct-chill     |      |       | 65 | 18 | .31 |
| G | 0 | helper | casting          |      |       |    |    |     |
| , | 3 | (day   | facility.        |      |       |    |    |     |
| 2 |   | 1)     | Assists furnace  |      |       |    |    |     |
| 0 |   |        | operator except  |      |       |    |    |     |
| 0 |   |        | during pouring.  |      |       |    |    |     |
| 3 |   |        |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| E | 2 | F      | Copper-beryllium | \--  | \--   | 2  | 1. | 1   |
| R | 0 | urnace | direct-chill     |      |       | 67 | 92 | .07 |
| G | 0 | helper | casting          |      |       |    |    |     |
| , | 3 | (day   | facility.        |      |       |    |    |     |
| 2 |   | 2)     | Assists furnace  |      |       |    |    |     |
| 0 |   |        | operator except  |      |       |    |    |     |
| 0 |   |        | during pouring.  |      |       |    |    |     |
| 3 |   |        |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| E | 2 | F      | Copper-beryllium | \--  | \--   | 5  | 1  | 7.8 |
| R | 0 | urnace | direct-chill     |      |       | 32 | 4. | 0\* |
| G | 0 | op     | casting          |      |       | \* | 08 |     |
| , | 3 | erator | facility.        |      |       |    | \* |     |
| 2 |   | (days  | Oversees melt    |      |       |    |    |     |
| 0 |   | 1 and  | and pour. Works  |      |       |    |    |     |
| 0 |   | 2)     | in office,       |      |       |    |    |     |
| 3 |   |        | leaving          |      |       |    |    |     |
|   |   |        | occasionally to  |      |       |    |    |     |
|   |   |        | check on melt or |      |       |    |    |     |
|   |   |        | take samples,    |      |       |    |    |     |
|   |   |        | skims dross by   |      |       |    |    |     |
|   |   |        | hand, sparges    |      |       |    |    |     |
|   |   |        | melt, controls   |      |       |    |    |     |
|   |   |        | pour to mold or  |      |       |    |    |     |
|   |   |        | tundish from a   |      |       |    |    |     |
|   |   |        | platform.        |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| C | 1 | Melter | Ferrous and      | 452  | \<    | \  | \  |     |
| C | 9 |        | non-ferrous      |      | 0.    | -- | -- |     |
| M | 9 |        | centrifugal      |      | 2\*\* |    |    |     |
| A | 9 |        | casting.         |      |       |    |    |     |
| , |   |        | Airborne metals  |      |       |    |    |     |
| 2 |   |        | relatively well  |      |       |    |    |     |
| 0 |   |        | controlled       |      |       |    |    |     |
| 0 |   |        | throughout this  |      |       |    |    |     |
| 0 |   |        | facility.        |      |       |    |    |     |
|   |   |        | Furnace-mounted  |      |       |    |    |     |
|   |   |        | and mobile ladle |      |       |    |    |     |
|   |   |        | exhaust hoods.   |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| C | 1 | Melter | Ferrous and      | 415  | \<    | \  | \  | \-- |
| C | 9 |        | non-ferrous      |      | 0.2   | -- | -- |     |
| M | 9 |        | centrifugal      |      |       |    |    |     |
| A | 9 |        | casting.         |      |       |    |    |     |
| , |   |        | Airborne metals  |      |       |    |    |     |
| 2 |   |        | relatively well  |      |       |    |    |     |
| 0 |   |        | controlled       |      |       |    |    |     |
| 0 |   |        | throughout this  |      |       |    |    |     |
| 0 |   |        | facility.        |      |       |    |    |     |
|   |   |        | Furnace-mounted  |      |       |    |    |     |
|   |   |        | and mobile ladle |      |       |    |    |     |
|   |   |        | exhaust hoods.   |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| C | 1 | Melter | Ferrous and      | \--  | \--   | 3  | \< | \<0 |
| C | 9 |        | non-ferrous      |      |       | 50 | 0  | .14 |
| M | 9 |        | centrifugal      |      |       |    | .2 |     |
| A | 8 |        | casting.         |      |       |    |    |     |
| , |   |        | Airborne metals  |      |       |    |    |     |
| 2 |   |        | relatively well  |      |       |    |    |     |
| 0 |   |        | controlled       |      |       |    |    |     |
| 0 |   |        | throughout this  |      |       |    |    |     |
| 0 |   |        | facility.        |      |       |    |    |     |
|   |   |        | Furnace-mounted  |      |       |    |    |     |
|   |   |        | and mobile ladle |      |       |    |    |     |
|   |   |        | exhaust hoods.   |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| N | 1 | F      | Beryllium alloy  | 391  | 19.76 | \  | \  | \-- |
| I | 9 | urnace | casting. Local   |      |       | -- | -- |     |
| O | 7 | op     | exhaust          |      |       |    |    |     |
| S | 5 | erator | ventilation      |      |       |    |    |     |
| H |   |        | reportedly       |      |       |    |    |     |
| , |   |        | available for    |      |       |    |    |     |
| 1 |   |        | all operations   |      |       |    |    |     |
| 9 |   |        | where dust and   |      |       |    |    |     |
| 7 |   |        | fume generated,  |      |       |    |    |     |
| 6 |   |        | wore respirator  |      |       |    |    |     |
|   |   |        | for portion of   |      |       |    |    |     |
|   |   |        | shift            |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| N | 1 | F      | Beryllium alloy  | 425  | 0.69  | \  | \  | \-- |
| I | 9 | urnace | casting. Local   |      |       | -- | -- |     |
| O | 7 | op     | exhaust          |      |       |    |    |     |
| S | 5 | erator | ventilation      |      |       |    |    |     |
| H |   |        | reportedly       |      |       |    |    |     |
| , |   |        | available for    |      |       |    |    |     |
| 1 |   |        | all operations   |      |       |    |    |     |
| 9 |   |        | where dust and   |      |       |    |    |     |
| 7 |   |        | fume generated   |      |       |    |    |     |
| 6 |   |        |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| N | 1 | He     | Beryllium alloy  | 427  | ND    | \  | \  | \-- |
| I | 9 | ater-w | casting. Local   |      |       | -- | -- |     |
| O | 7 | eigher | exhaust          |      |       |    |    |     |
| S | 5 | (Remel | ventilation      |      |       |    |    |     |
| H |   | t/melt | reportedly       |      |       |    |    |     |
| , |   | and    | available for    |      |       |    |    |     |
| 1 |   | cast   | all operations   |      |       |    |    |     |
| 9 |   | area)  | where dust and   |      |       |    |    |     |
| 7 |   |        | fume generated   |      |       |    |    |     |
| 6 |   |        |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| N | 1 | F      | Beryllium alloy  | 417  | 0.79  | \  | \  | \-- |
| I | 9 | urnace | casting. Local   |      |       | -- | -- |     |
| O | 7 | helper | exhaust          |      |       |    |    |     |
| S | 5 |        | ventilation      |      |       |    |    |     |
| H |   |        | reportedly       |      |       |    |    |     |
| , |   |        | available for    |      |       |    |    |     |
| 1 |   |        | all operations   |      |       |    |    |     |
| 9 |   |        | where dust and   |      |       |    |    |     |
| 7 |   |        | fume generated   |      |       |    |    |     |
| 6 |   |        |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| N | 1 | F      | Be               | \--  | \--   | 3  | 2  | 15  |
| I | 9 | oundry | ryllium-aluminum |      |       | 06 | 5. | .98 |
| O | 7 | op     | heating and      |      |       |    | 06 |     |
| S | 5 | erator | button casting.  |      |       |    |    |     |
| H |   |        | Local exhaust    |      |       |    |    |     |
| , |   |        | ventilation      |      |       |    |    |     |
| 1 |   |        | reportedly       |      |       |    |    |     |
| 9 |   |        | available for    |      |       |    |    |     |
| 7 |   |        | all operations   |      |       |    |    |     |
| 6 |   |        | where dust and   |      |       |    |    |     |
|   |   |        | fume generated   |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| N | 1 | F      | Be               | \--  | \--   | 3  | 3. | 2   |
| I | 9 | oundry | ryllium-aluminum |      |       | 09 | 33 | .14 |
| O | 7 | op     | heating and      |      |       |    |    |     |
| S | 5 | erator | button casting.  |      |       |    |    |     |
| H |   | Helper | Local exhaust    |      |       |    |    |     |
| , |   |        | ventilation      |      |       |    |    |     |
| 1 |   |        | reportedly       |      |       |    |    |     |
| 9 |   |        | available for    |      |       |    |    |     |
| 7 |   |        | all operations   |      |       |    |    |     |
| 6 |   |        | where dust and   |      |       |    |    |     |
|   |   |        | fume generated   |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
|   |   | P      |                  |      |       |    |    |     |
|   |   | ouring |                  |      |       |    |    |     |
|   |   | op     |                  |      |       |    |    |     |
|   |   | erator |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| C | 1 | Mold   | Ferrous and      | 415  | \<    | \  | \  | \-- |
| C | 9 | sp     | non-ferrous      |      | 0.2   | -- | -- |     |
| M | 9 | rayer/ | centrifugal      |      |       |    |    |     |
| A | 9 | pourer | casting.         |      |       |    |    |     |
| , |   |        | Airborne metals  |      |       |    |    |     |
| 2 |   |        | relatively well  |      |       |    |    |     |
| 0 |   |        | controlled       |      |       |    |    |     |
| 0 |   |        | throughout this  |      |       |    |    |     |
| 0 |   |        | facility.        |      |       |    |    |     |
|   |   |        | Exhaust hoods    |      |       |    |    |     |
|   |   |        | mounted on       |      |       |    |    |     |
|   |   |        | furnace, mobile  |      |       |    |    |     |
|   |   |        | ladle, and       |      |       |    |    |     |
|   |   |        | centrifugal      |      |       |    |    |     |
|   |   |        | caster pour      |      |       |    |    |     |
|   |   |        | spout.           |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| C | 1 | Plate  | Ferrous and      | 402  | \<    | \  | \  | \-- |
| C | 9 | spryer | non-ferrous      |      | 0.2   | -- | -- |     |
| M | 9 | (c     | centrifugal      |      |       |    |    |     |
| A | 9 | asting | casting.         |      |       |    |    |     |
| , |   | area)  | Airborne metals  |      |       |    |    |     |
| 2 |   |        | relatively well  |      |       |    |    |     |
| 0 |   |        | controlled       |      |       |    |    |     |
| 0 |   |        | throughout this  |      |       |    |    |     |
| 0 |   |        | facility.        |      |       |    |    |     |
|   |   |        | Exhaust hoods    |      |       |    |    |     |
|   |   |        | mounted on       |      |       |    |    |     |
|   |   |        | furnace, mobile  |      |       |    |    |     |
|   |   |        | ladle, and       |      |       |    |    |     |
|   |   |        | centrifugal      |      |       |    |    |     |
|   |   |        | caster pour      |      |       |    |    |     |
|   |   |        | spout.           |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| C | 1 | C      | Ferrous and      | 440  | 2.2   | \  | \  | \-- |
| C | 9 | asting | non-ferrous      |      |       | -- | -- |     |
| M | 9 |        | centrifugal      |      |       |    |    |     |
| A | 8 |        | casting.         |      |       |    |    |     |
| , |   |        | Airborne metals  |      |       |    |    |     |
| 2 |   |        | relatively well  |      |       |    |    |     |
| 0 |   |        | controlled       |      |       |    |    |     |
| 0 |   |        | throughout this  |      |       |    |    |     |
| 0 |   |        | facility.        |      |       |    |    |     |
|   |   |        | Exhaust hoods    |      |       |    |    |     |
|   |   |        | mounted on       |      |       |    |    |     |
|   |   |        | furnace, mobile  |      |       |    |    |     |
|   |   |        | ladle, and       |      |       |    |    |     |
|   |   |        | centrifugal      |      |       |    |    |     |
|   |   |        | caster pour      |      |       |    |    |     |
|   |   |        | spout.           |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
|   |   | Sh     | \<No results     |      |       |    |    |     |
|   |   | akeout | available\>      |      |       |    |    |     |
|   |   | op     |                  |      |       |    |    |     |
|   |   | erator |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
|   |   | Ab     |                  |      |       |    |    |     |
|   |   | rasive |                  |      |       |    |    |     |
|   |   | bl     |                  |      |       |    |    |     |
|   |   | asting |                  |      |       |    |    |     |
|   |   | op     |                  |      |       |    |    |     |
|   |   | erator |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| C | 1 | Blast  | Ferrous and      | \--  | \--   | 1  | \< | \<0 |
| C | 9 | booth  | non-ferrous      |      |       | 12 | 0  | .16 |
| M | 9 |        | centrifugal      |      |       |    | .7 |     |
| A | 9 |        | casting.         |      |       |    |    |     |
| , |   |        | Airborne metals  |      |       |    |    |     |
| 2 |   |        | relatively well  |      |       |    |    |     |
| 0 |   |        | controlled       |      |       |    |    |     |
| 0 |   |        | throughout this  |      |       |    |    |     |
| 0 |   |        | facility.        |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
|   |   | Grinde |                  |      |       |    |    |     |
|   |   | r/sawy |                  |      |       |    |    |     |
|   |   | er/san |                  |      |       |    |    |     |
|   |   | der/fi |                  |      |       |    |    |     |
|   |   | nisher |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| C | 1 | Mac    | Ferrous and      | 410  | \<    | \  | \  | \-- |
| C | 9 | hinist | non-ferrous      |      | 0.2   | -- | -- |     |
| M | 9 |        | centrifugal      |      |       |    |    |     |
| A | 9 |        | casting.         |      |       |    |    |     |
| , |   |        | Airborne metals  |      |       |    |    |     |
| 2 |   |        | relatively well  |      |       |    |    |     |
| 0 |   |        | controlled       |      |       |    |    |     |
| 0 |   |        | throughout this  |      |       |    |    |     |
| 0 |   |        | facility.        |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| C | 1 | Mac    | Ferrous and      | 415  | \<    | \  | \  | \-- |
| C | 9 | hinist | non-ferrous      |      | 0.2   | -- | -- |     |
| M | 9 |        | centrifugal      |      |       |    |    |     |
| A | 9 |        | casting.         |      |       |    |    |     |
| , |   |        | Airborne metals  |      |       |    |    |     |
| 2 |   |        | relatively well  |      |       |    |    |     |
| 0 |   |        | controlled       |      |       |    |    |     |
| 0 |   |        | throughout this  |      |       |    |    |     |
| 0 |   |        | facility.        |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| C | 1 | Gri    | Ferrous and      | 398  | \<    | \  | \  | \-- |
| C | 9 | nder/s | non-ferrous      |      | 0.2   | -- | -- |     |
| M | 9 | nagger | centrifugal      |      |       |    |    |     |
| A | 9 |        | casting.         |      |       |    |    |     |
| , |   |        | Airborne metals  |      |       |    |    |     |
| 2 |   |        | relatively well  |      |       |    |    |     |
| 0 |   |        | controlled       |      |       |    |    |     |
| 0 |   |        | throughout this  |      |       |    |    |     |
| 0 |   |        | facility.        |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| N | 1 | Finish | Local exhaust    | 384  | 0.69  | \  | \  | \-- |
| I | 9 | g      | ventilation      |      |       | -- | -- |     |
| O | 7 | rinder | reportedly       |      |       |    |    |     |
| S | 5 |        | available for    |      |       |    |    |     |
| H |   |        | all operations   |      |       |    |    |     |
| , |   |        | where dust and   |      |       |    |    |     |
| 1 |   |        | fume generated,  |      |       |    |    |     |
| 9 |   |        | wore respirator  |      |       |    |    |     |
| 7 |   |        |                  |      |       |    |    |     |
| 6 |   |        |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| N | 1 | Saw    | Local exhaust    | 422  | ND    | \  | \  | \-- |
| I | 9 | cutter | ventilation      |      |       | -- | -- |     |
| O | 7 |        | reportedly       |      |       |    |    |     |
| S | 5 |        | available for    |      |       |    |    |     |
| H |   |        | all operations   |      |       |    |    |     |
| , |   |        | where dust and   |      |       |    |    |     |
| 1 |   |        | fume generated   |      |       |    |    |     |
| 9 |   |        |                  |      |       |    |    |     |
| 7 |   |        |                  |      |       |    |    |     |
| 6 |   |        |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| N | 1 | Cu     | Local exhaust    | \--  | \--   | 3  | 1  | 10  |
| I | 9 | t-off, | ventilation      |      |       | 21 | 5. | .41 |
| O | 7 | swing  | reportedly       |      |       |    | 56 |     |
| S | 5 | g      | available for    |      |       |    |    |     |
| H |   | rinder | all operations   |      |       |    |    |     |
| , |   |        | where dust and   |      |       |    |    |     |
| 1 |   |        | fume generated,  |      |       |    |    |     |
| 9 |   |        | wore respirator  |      |       |    |    |     |
| 7 |   |        |                  |      |       |    |    |     |
| 6 |   |        |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
|   |   | Mainte |                  |      |       |    |    |     |
|   |   | nance/ |                  |      |       |    |    |     |
|   |   | Housek |                  |      |       |    |    |     |
|   |   | eeping |                  |      |       |    |    |     |
|   |   | w      |                  |      |       |    |    |     |
|   |   | orkers |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| N | 1 | F      | Local exhaust    | 426  | ND    | \  | \  | \-- |
| I | 9 | urnace | ventilation      |      |       | -- | -- |     |
| O | 7 | rep    | reportedly       |      |       |    |    |     |
| S | 5 | airman | available for    |      |       |    |    |     |
| H |   |        | all operations   |      |       |    |    |     |
| , |   |        | where dust and   |      |       |    |    |     |
| 1 |   |        | fume generated,  |      |       |    |    |     |
| 9 |   |        | wore respirator. |      |       |    |    |     |
| 7 |   |        |                  |      |       |    |    |     |
| 6 |   |        |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+
| P |   |        |                  |      |       |    |    |     |
| Z |   |        |                  |      |       |    |    |     |
| B |   |        |                  |      |       |    |    |     |
| m |   |        |                  |      |       |    |    |     |
| e |   |        |                  |      |       |    |    |     |
| a |   |        |                  |      |       |    |    |     |
| n |   |        |                  |      |       |    |    |     |
| s |   |        |                  |      |       |    |    |     |
| P |   |        |                  |      |       |    |    |     |
| e |   |        |                  |      |       |    |    |     |
| r |   |        |                  |      |       |    |    |     |
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| l |   |        |                  |      |       |    |    |     |
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| a |   |        |                  |      |       |    |    |     |
| t |   |        |                  |      |       |    |    |     |
| h |   |        |                  |      |       |    |    |     |
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| n |   |        |                  |      |       |    |    |     |
| g |   |        |                  |      |       |    |    |     |
| Z |   |        |                  |      |       |    |    |     |
| o |   |        |                  |      |       |    |    |     |
| n |   |        |                  |      |       |    |    |     |
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| N |   |        |                  |      |       |    |    |     |
| D |   |        |                  |      |       |    |    |     |
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| \ |   |        |                  |      |       |    |    |     |
| * |   |        |                  |      |       |    |    |     |
| T |   |        |                  |      |       |    |    |     |
| W |   |        |                  |      |       |    |    |     |
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| c |   |        |                  |      |       |    |    |     |
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| m |   |        |                  |      |       |    |    |     |
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| d |   |        |                  |      |       |    |    |     |
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| t |   |        |                  |      |       |    |    |     |
| e |   |        |                  |      |       |    |    |     |
| c |   |        |                  |      |       |    |    |     |
| t |   |        |                  |      |       |    |    |     |
| i |   |        |                  |      |       |    |    |     |
| o |   |        |                  |      |       |    |    |     |
| n |   |        |                  |      |       |    |    |     |
| . |   |        |                  |      |       |    |    |     |
+---+---+--------+------------------+------+-------+----+----+-----+

**Appendix 5B**

**Beryllium Deposited Submicrometer Particle Concentration Results and
Discussion for ERG Site 7**

**Beryllium Deposited Submicrometer Particle Concentration Results and
Discussion for ERG Site 7**

Particle size, surface area, number of particles, solubility, and the
chemical form of beryllium involved may all be relevant to the
development of disease. It has also been suggested that beryllium can
enter through either intact skin or breaks in the skin to initiate
sensitization. Recent studies have shown that particles less than 1
micrometer (μm) in diameter can penetrate intact skin that has been
flexed. Therefore, ERG investigators evaluated the presence of these
small particles, the deposited submicrometer particle concentration
(DSP). The Be DSP represents the airborne concentration of beryllium
particles that are of a size that would deposit in the lung and is
reported as particles per cubic centimeter of air (p/cc).

Table 5B-1 contains the three personal breathing zone (PBZ) total
beryllium and beryllium deposited submicrometer particle (Be DSP) number
concentrations for the furnace operator and helper at ERG Site 7 -- a
beryllium alloy casting facility (ERB, 2003b). These readings represent
the workers' entire exposure for the shift, although in this case the
shifts were abbreviated - less than 5 hours.

The highest Be DSP (furnace operator) was associated with the highest
total beryllium exposure result, the highest average DPS number (all DPS
particles), and the highest percent beryllium. It is possible that the
additional fume exposure experienced by the furnace operator during
pouring could be responsible for these elevated levels. Beryllium (a
strong reducing agent) is known to form fume and surface oxides more
aggressively than most other metals commonly found in these alloys
(Beryllium Casting Facility A, 2005). The furnace operator's increased
contact with beryllium fume (a fine particle) might have increased both
the average number of fine particles and the beryllium content in this
worker's breathing zone. The dust exposure of the furnace helper likely
represents some fume from the furnace and the general dust (including
carbon particles) described throughout the foundry.

The furnace assistant experienced the lowest Be DSP number reported at
this site (1.1 p/cc) on the second sampling day, when the percent
beryllium in this worker's breathing zone was the lowest (0.06 percent
on day 1, compared to 0.36 percent beryllium on day 2). The DPS fine
particle count for the furnace assistant was actually somewhat higher on
that second day than on the first day (indicating that the worker was
exposed to more fine particles on day 2); however, the lower percent
beryllium on day 2 is responsible for the decrease in Be DPS.

+-------+--------------------------------------+----------+-----------+
| Table |                                      |          |           |
| B-1.  |                                      |          |           |
| PBZ   |                                      |          |           |
| Total |                                      |          |           |
| Bery  |                                      |          |           |
| llium |                                      |          |           |
| and   |                                      |          |           |
| Bery  |                                      |          |           |
| llium |                                      |          |           |
| Depo  |                                      |          |           |
| sited |                                      |          |           |
| Sub   |                                      |          |           |
| micro |                                      |          |           |
| meter |                                      |          |           |
| Par   |                                      |          |           |
| ticle |                                      |          |           |
| N     |                                      |          |           |
| umber |                                      |          |           |
| (Be   |                                      |          |           |
| DSP)  |                                      |          |           |
| Rea   |                                      |          |           |
| dings |                                      |          |           |
| of a  |                                      |          |           |
| Fu    |                                      |          |           |
| rnace |                                      |          |           |
| Ope   |                                      |          |           |
| rator |                                      |          |           |
| and   |                                      |          |           |
| Assi  |                                      |          |           |
| stant |                                      |          |           |
| in a  |                                      |          |           |
| Bery  |                                      |          |           |
| llium |                                      |          |           |
| Alloy |                                      |          |           |
| Ca    |                                      |          |           |
| sting |                                      |          |           |
| Fac   |                                      |          |           |
| ility |                                      |          |           |
+=======+======================================+==========+===========+
| **    | #######                              | **Total  | **        |
| Facil |                                      | Ber      | Average** |
| ity** | ####### Description                  | yllium** |           |
|       |                                      |          | **Be      |
|       |                                      | *        | DSP**     |
|       |                                      | *Concent |           |
|       |                                      | ration** | **Concen  |
|       |                                      |          | tration** |
|       |                                      | **(μg    |           |
|       |                                      | /m^3^)** | *         |
|       |                                      |          | *(p/cc)** |
+-------+--------------------------------------+----------+-----------+
| ERG   | *Furnace Helper:* Assisted and       | 4.18     | 4.7       |
| Site  | worked along side the furnace        |          |           |
| 7     | operator except during the pouring   |          |           |
|       | process (furnace helper did not      |          |           |
|       | participate in the pour). Day 1,     |          |           |
|       | 265-minute sample. (0.39% beryllium) |          |           |
+-------+--------------------------------------+----------+-----------+
| ERG   | *Furnace Helper:* Assisted and       | 1.92     | 1.1       |
| Site  | worked along side the furnace        |          |           |
| 7     | operator except during the pouring   |          |           |
|       | process (furnace helper did not      |          |           |
|       | participate in the pour). Day 2,     |          |           |
|       | 267-minute sample. (0.06% beryllium) |          |           |
+-------+--------------------------------------+----------+-----------+
| ERG   | *Furnace Operator:* Controlled       | 14.08    | 65.1      |
| Site  | melting and furnace operations from  |          |           |
| 7     | platform at furnace, worked in       |          |           |
|       | office. Also collected samples,      |          |           |
|       | sparged, and skimmed dross from      |          |           |
|       | molten metal. Furnace was fitted     |          |           |
|       | with canopy hood. LEV also present   |          |           |
|       | on dross receptacle and pouring      |          |           |
|       | conveyer. 532-minute sample obtained |          |           |
|       | using the same sampling filters and  |          |           |
|       | equipment during abbreviated shifts  |          |           |
|       | (of approximately 266 minutes each)  |          |           |
|       | on two consecutive days. (1.57%      |          |           |
|       | beryllium)                           |          |           |
+-------+--------------------------------------+----------+-----------+
| ^\*^  |                                      |          |           |
| Be    |                                      |          |           |
| DSP   |                                      |          |           |
| n     |                                      |          |           |
| umber |                                      |          |           |
| re    |                                      |          |           |
| ading |                                      |          |           |
| not   |                                      |          |           |
| deter |                                      |          |           |
| mined |                                      |          |           |
| due   |                                      |          |           |
| to    |                                      |          |           |
| sam   |                                      |          |           |
| pling |                                      |          |           |
| equi  |                                      |          |           |
| pment |                                      |          |           |
| ma    |                                      |          |           |
| lfunc |                                      |          |           |
| tion. |                                      |          |           |
|       |                                      |          |           |
| PBZ:  |                                      |          |           |
| per   |                                      |          |           |
| sonal |                                      |          |           |
| brea  |                                      |          |           |
| thing |                                      |          |           |
| zone. |                                      |          |           |
|       |                                      |          |           |
| LEV:  |                                      |          |           |
| local |                                      |          |           |
| ex    |                                      |          |           |
| haust |                                      |          |           |
| ve    |                                      |          |           |
| ntila |                                      |          |           |
| tion. |                                      |          |           |
|       |                                      |          |           |
| Sou   |                                      |          |           |
| rces: |                                      |          |           |
| ERG,  |                                      |          |           |
| 2003b |                                      |          |           |
+-------+--------------------------------------+----------+-----------+

[^1]: For the result obtained over two shifts, ERG calculated the 8-hour
    TWA by assuming that the exposure contribution and sample times were
    the same on each day (one half of 532 minutes, or about 266 minutes
    each day). Based on results for other furnace workers those days,
    the sample time assumption is probably accurate to within a few
    minutes; however, the actual exposure levels might have been
    different on the two days. Although further analysis is not possible
    with the available information, the results suggest that the actual
    exposure of the furnace operator likely exceeded the current PEL of
    2.0 μg/m^3^ each day.

[^2]: ERG searched for results associated with aluminum and copper
    foundries and the term "pour" in the job description.

[^3]: The percentage of beryllium in the beryllium producer's castings
    can be substantially higher (5 percent or more) than is typical of
    aluminum and copper foundries (2 percent or less, and often below
    0.5 percent)

[^4]: It is interesting to note that Case History Foundry D, where the
    three best-documented exposure profile results were obtained, was
    not described as having a state-of-the-art ventilation system in the
    pouring area (although several elements of a good system were in
    place and reported employee exposures to other metals were generally
    below the limits of detection) (CCMA, 2000). The metals cast at this
    foundry are described only as "ferrous and non-ferrous." Results for
    arsenic, beryllium, cadmium, chromium, lead, nickel, and selenium
    are reported.

[^5]: ^6^ ^26^These sample results are not included in the exposure
    profile.

[^6]: ^7^ ^27^NIOSH notes that this type of modeling (computational
    fluid dynamics) is best used to help experienced engineers "identify
    quantitative factors that point the way to an optimal design, and
    that historical ventilation design experience \[should\] be used to
    bring the design to its final form." The model is not intended to
    predict actual exposure levels.

[^7]: ^8^ ^28^ This estimate is based on the initial (2.93 mg/m³) and
    post abatement (0.55 mg/m³) respirable dust results (Irwin, 2003).
    The respective OSHA-calculated PELs (0.7 mg/m³ and 2.04 mg/m³) and
    the equation PEL = 10/(2 + % silica in the sample), from 29 CFR
    1910.1000 Table Z3, were used to determine the percentage of silica
    in the respirable dust samples. For each results, ERG multiplied the
    fraction of silica by the respirable dust result to obtain the
    corresponding respirable silica result.

[^8]: Note that this example is offered only as an indication of the
    extent to which the relative exposure levels can be affected when
    equipment is poorly maintained. Chromium air sampling results cannot
    be directly equated to the results that might have been obtained for
    beryllium had this scenario occurred at a beryllium alloy foundry.

[^9]: The total number of results reported for each method and
    contaminant (cadmium \[Cd\] or lead \[Pb\]) are as follows: *Open
    abrasive blasting* (Cd -- 21 results; Pb -- 12 results),
    *Containment with recycled metal media* (Cd -- 207 results; Pb --338
    results), *Low volume water slurry blasting* (Cd -- 22 results; Pb
    -- 38 results), *High pressure water jetting* (Cd -- 25 results; Pb
    -- 25 results). Neither individual results nor information on the
    metals content of the material (coatings) being removed are
    available.