This Health Hazard Evaluation (HHE) report and any recommendations made herein are for the specific facility evaluated and may not be universally 

applicable. Any recommendations made are not to be considered as final statements of NIQSH policy or of any agency or individual involved 

Additional HHE reports are available at http://www cdc govfniosh/hhe/reports 

I-IETA 87-349-20.22 

MARCH 1990 

ROCKCASTLE~A~G 

MOUNT VERNON, KENTUCKY 

I SUMMARY 

NIOSH INVESTIGATORS: 

Teresa Seitz, Cll-I 

Sheny Baron, MD, 

On July 10, 1987, 1he National Ins1i1u1e for OccuJX1tional Safely and Healtll (NIOSH) =ived a request for a 

healtll hazard evaluation from employees at Rockcas1le Manufucturing, Mount Vernon, Kenlllcky, NIOSH was 

asked 10 evalua1e complaints of headaches, burning eyes, nausea, vomiting, minting, and adveroo reproductive efl.ec1s 

among emplqyees attllis fucili1y, which fubricates men's unifonn wrnk p1llts 

On Seplember 8-9, 1987, NIOSH investiga10rs conducted a combined environmenlaI and medical evaluatim 

Personal breaIhing zone and general area air samples for fonmldehyde, organic vapors, and pnticu1ates were 

collec1ed, JX11ches oflhe resin-treated fubria; nsed in garment manufucture were oblained fur deIennina1ion of 

funnaldehyde relea9a, and ooofideulial inlerv:iews were held wilh employees 

I3ecatre a l1Ul1100:ofvenulation and wodc prndioe changes were made fullowing the ini1ia1 siIe visit, afullow-up visiI 

was made on JantJill)' 12-14, 1988, Expooure moni1oring fur funnaldehyde and pnticu1ates was perfonned, and a 

questionnaire was adrninisIered 10 employees 10 obIain infunnation on various syIlljJ1orns, includingm=1oskele1al 

probleIJJS, and, fur women, 1heirreproductive hisImy, The questiOllnaire was sent 10 former employees \\bo 

wciIked anytime after Sep1e!nber 1, 1984, 

Fonnaldehyde air sampJingresults from the ini1ia1 stJl'II'<Yrnnged from 0. 14 ppn110 0.46 JlPl11 in five personal 

brealhing zone (FBZ) air samples, and from 0.32 JlPl1110 0.:70. JlPl11 in 13 area air samples oblained tllfOUghou11he 

plant On the follow-up SUlV~, fonmldehyde exposures were lower, wiIh PBZ conoentrations rnnging OOm DJ9 

ppm 10 0..21 ppm, and from DJ8 ppm 10 0..22 ppm in area air samples oblained in productiondepaI1ments The 

funnaldehyde data a1ro showed less variation between depar1ments andjob classifica1ions. All funnaldehyde results 

were belowthe OSHA and ACGIH evaluation exposure liInits of! ppm, as an S-hourTW A NIOSH, however, 

oonsiders fonnaldehyde a polen1ial carcinogen, and recorrnnends 1hat fonmldehyde exposures be reduced 10 the 

lowest feasible level 

Fonnaldehyde release OOm 8 fubric sanlples ranged fium 163 ITIicrograIll'l of funnaldehyde P:;'1 gmm offubric 

(ugigm)1o 143Dugigm TwosampJestllalwerecuredprim1oanalysisshowedreductionsinfunnaldehyde 

release of425% and 735% .. 

Of the 4 PBZ organic vapor air sanlples oollec1ed on chan::ml1ubes, only 1,1,I-1richloroetllanewas delecled, with 

all values below OJ ppm The current OSHA PEL fm 1,1,I-lriclJloroetllane is 
II lNIRODUcnON 

OnJuly 10, 1987, 1he Nalionallnstitute fur O:cup<!tional Safely and Healfil (NIOSH) received a confidential 

request for a Healfil I-Ia=d Evaluation fium an antllorized employee represen1ative at RDCkcasfie Mlmnfacturing, 

MOtmt Vemon, Kentucky, TIle request concemed cornp1ain1s of headaches, bruning eyes, IJaUS:a, vomiting, 

fuin1ing, and adveIre reproductive ef!ec1s, 

OnSep1ember 8-9, 1987, an initial site visitwas conclncted to evaluate employee exparures to furmaldehyde, 

organic con1aminanls, and particulates, and to investigate adVeITe healfil ef!ec1s reported anIDng file laoof' force. 

PreIiminaIy recommendations regartling local exhanstven11lation, preventive main1erJaJ:Jce, and wode practices were 

made ina letterto Rockcastle dated Sep1ember22, 1987. Becanse annmber ofven1ilationand wolk practice 

changes were made suh3equentto 1his visi1; afullow-up environmental srnvey was conducted on 

JanuaJ)' 12-14, 1988. A healfil ques1iormaire was administered during file follow-up investigation to ob1ain 

infurmalion on wodchis1ory, medical bis1ory, and sympIotns experienced by employee;. An identical qnes1iormaire 

was mailed to furmer Rockcastle Mannfucturing employees, andmrrentemployees who had beenabsent1he day 

file ques1iormaire was administered 

111 BACKGROUND 

Rockcastle Mannfucturing is a rut-!ll:ldsewplant which Dca1es mens unifonn wodc pmI& Atfue time offuis 

evalnalion, fuerewere approximately 190 production employees atfuis fucili1y, fuemajority of which (around 85%) 

operated sewing machines. TIle remaining individuals worlced as press opemlol1l, oven opem1oI1l, UJt!eI1l, 

spreader.;, glue sprayCl1l, bundlCl1l, and maintenance wolker& 

Cellulose-con1aining Des having a 65% polyesteI735% cot1on bleod are nsed 10 Dcate file walk pmI& These 

Des are ob1ained fium a textile finishing rompaoy, where l1leY are impIegna1ed with a 

dime1hloldihydroxyelhyleneurea())MD~resinsys1em Thisresin1reatmeotimpaI1sdurahlepress 

properties, dimensional s1abiIi1y, and ofilerimpor1antproperties 10 cellulosic textiles (eg. coUon, rayon and blends)..' 

The mannfacturing process nsed at fuis plant is considered a poot-cure process, which refers 10 fue Jilctfuat file resin 

is "ctmrl" or chemically oonded 10 l1le fubric aflerl1le gannenthas been fabricated FOIIll'lIdebyde release fium 

lIDc:urn:d DMDHEU resin-trea1ed DC is fi10Ugbt 10 result OOm mace desmption of noncovalenfiy OOoded (or 

"free'~ furrnaIck!hyde, as well as fium l1le hydrolysis of fue furmaIck!hyd<x:ellul= hemiace1aI lxmds.z TIle resin 

furmuIalionhas reportedly changed over file yeaI1l, in an effort 10 reduce fOlIll'lldebyde emission fium l1le trea1ed 

Des. 

TIle manufucturing fuciIily is loca1ed in a wareh~ ofsheetme1al construction, having approximately 12,(XX) square 

feet of open space, Rolls offabric are stored in file DC s10rage area lIDtil needed, genernIly less 11= 90 days OOm 

receipt The DC is tmrOTIed on a 1able in file spreading area, fonning many layers of De PaUem pieces are rut 

fium file 1ayCI1l, using &::isson; mprecut dies, and sorted by 1ype Fabric bundles are fi1ell1aken 10 file glue room 

where file edges are sprayed wifil an aqueous acrylic emulsion, 10 prevent ravelling. This opemtton is perfUlTI1ed in a 

spray b001h, in a room adjacent 10 file sewing area. TIle DC bundles are filen distnbuted 10 fue appropriate 

wmks1ations (areas 14), where filey are rewn and assenlbled inlo pan1s .. Conventional sewing machines are nsed 

along wifil a few automa1ed machines for specialized operations such as belt loops. Afierinspection, file gaI111e1l1s 
Ten bulle ilibric samples were collected for latent fomIDIdehyde mIDIysis, Patches of :fubric of vmying colors 

were obtained fiem the :fubric storage area, alnng witll samples of tlle navy ilibric which was being used dnring 

tlJis stUVey To comrere latent fomIDIdehyde levels on these fubIics, additional fabric smnples were oollec1ed 

befure and mthey were cured Individual :fubric smnples were stored in sealed, polyethylene bag<; until 

analyzed Samples were analyzed fur latent fnnnaldebydeU>ing a metllOd develOjXrl by Bnrlington 

Industries. 4 TIJis oolorimetric method is 1xIsed on tlle American Associatinn ofTex1ile 0Jemists and Colorists' 

(AATCC) sealedjarmetllod, Test Metllod 112-1984, and was originally develOjXrl to assess fonnaldehyde 

release UIlder worst-case storage conditions 5 TIle metllod involves a vapor extraction procedure to measure 

fnnnaldehyde release fiem a weighed patch of ilibric which has been sllspeoded overwater, in a sealedjar, 

andbeated at 50"C fur 20 hOllis, TIle conditions of the test are such tlm betll fire furmaldehyde and 

furmaldel1)'de fiom l1)'dro\ysis are measured 

A bulle sample oftlle aqueous ac1)'lic emulsion used to preventravelling of ilibric edges was analyzed by 

infrared spectroscopy, Waterwas evaporated fiom the sample, leaving a film of the polymer, TIle polymer 

was then dissolved in acetone, and a thin film was cast on a salt plate. An infrared spectrum was then obtained 

ofdlepo1ynJerfilmforlin1heridentificatiOl1oftlJeCOlIlJXlOOJ1s. 

Eight air smnples were oollected furorgpnic vapor analysis U>ing a cl:JaIw1ltube sampling teclmique. Area air 

smnples were obtained in fue glue rocm and in fue oven area Personal breathing zone air samples were 

obtained on individuals worlcing in fueseareas, as wellas byfuepresses. One offue air samples was collected 

in tlJe head5pace of tlle glue oonlainerto identify volatile oompone!lls oftlJis product Representative smnp1es 

were analyzed U>ing a gas chromatograpb equippad witll a mass selective detector (C"'JOMSD) fur peale 

iWltification The remaining samples were analyzEd fur epichlorobydrinand ac1)'lates (oomponents oftlle 

glue1 as well as onntaminanJs ideotified in tlJe GCJMSD analyses, 

Fourpersonal breathing zone (PBZ) and one area air sample were collected fur total particulates (dust and lint) 

U>ing 5-micron (um) pore-size polyvinyl chloride (PVC) filters and calibrated, ba1te!y-opera1lrl sampling 

pumps operating at flowrates of 15 Lpm, Jobs which appeared to have tlle greatest potential for dust 

expooure were selected, including maintenance, tum and ticket, spreading, and cutting. Samples were 

collected and analyzed in accon:lance witll NIOSH Mefuod 0500.' 

To address a conoemregarding heat exposure, temperature andrelative humidity data were collected at 

severallocatiollS wifuin fue plantU>ing a ba1te!y-operated p>ychrometer, 

Follow-yP SurvtQ' 

The follow-up survey was cooducted on Janumy 12-14, 1988., Ten sets ofair samples fur fomIDlde11)'de 

were collected overfue entire worlcshifr, including tl= personal breatllingzone and seven general area air 

smnples, Samples were collected in lllaJ1)' of fue smne areas orjobs as on fue initial survey, for oomparison, 

Side-by-5ide smnples were oollected U>ingfuree differentfonnalde11}'de smnpling teclmiques: tile liquid 

inlpinger metllOd (NIOSH Method 3500), tlle solid sorbent tube metllod (NIOSH Metllod 2502), and a 

passive dilfusion metllOd utilizing Bacharach AitScan* Fnnnaldel1)'de Expoone Monitots The purpcxse fur 

matclling tlle passive mnnitors witll tlle nnpinger and sorbent tube smnples was to observe fue perfonnance of 
There were seveml patterllS of complaints. As previously mentioned, complaints ofhuming ""es were more 

prevalent in 1he early morning, on hot or humid days, and when itrnined Complaints ofbuming ~ were less 

prevalent in fue prereding month, which some worl= atlnbuied to fue =1l increase in use of funs and open 

doors furven1ilation, The worl= who repoI1edrashes believed 1hat 1he absence or presence of rash varied 

wi1h 1he color of fubric in use. 

Eight women interviewed reported adversereproduc1ive effects In additioo, rnnnerous Rockcastle 

employees s1a1ed 1hat 111"" pen:eived a high rate ohniscarriage among co-wOIi<ffi;. AlfilOUgh some 

employees believed file excess ofmiscarriages began about one year afierllle plant opened, l1le majori1y 

believed fue excess occnrred primarily dnring1he prereding two years. Concern was also expressed 1hat fue 

rate ofhir1h defects among children of wOIi<ffi; may also have been eleva1ed 

Follow-yp S!.nvm' 

&wi on 1he pmblerns expn=l during 1he l1OO-raIJdom ini1ial interviews, a questionnaire was designed to 

de1J:lJ.nine fuerate of miscaniages, bir1h defucts, and premature bir1hs, as well as llJeprevalenoe of 

mro.tlookele1al and otlJer healtlJ complaints 1his questionnaire was dislnbu1ed to all employees during a 

fullow-up visit on.J3IlI.Ia!)' 13, 1987. An identical questionnaire, as well as one fullow-up reminderletter, were 

seotto all funner employees who workedany1imeafierSep1ember 1, 1984. 

V, EVALUATIONCRlJERIA 

A Envimnrml1al Evaluation 

As a guide to 1he evaluation of1!Je hazards pooed by work place expa;ures, NIOSH field s1aff employ 

enviJ:orJrooJ1aevaluationai1eriafur1!Jeassessmeotofal11.I!I1be:ofchernicalandpbysicalagents These 

cri1eria are intended to suggest levels ofexpooure to which most worl<erS may be exposed up to 10 hollIS per 

day, 40 hours per week fur a wrnking lifutime wifilout experiencing adverse healtlJ effu:ts, It is, however, 

inljJOI1ant to no1e llJatnotall wOIi<ffi; will be pm1ec1ed fium adverse healtlJ effects if llJeir exposures are 

main1ained below1heoo levels. A small pen:en1age may experienoe adverse healfil effu:ts because of 

individual stJ.<X:ePllbili1y, a pre-exis1ingmedical conditioo, and/or ahypern.:nsi1iviy (allergy). In additioo, some 

hazmdous subs1ances may act in combination widl 01her wrnk place expa;ures, fue general environment; or 

wi1h medications orJXT.lOllal habits oftlJe wrnkerto produce healtlJ effu:ts even iffue OCCUJXI1ional exposures 

are controlled to 1!Je level set by file evaluation cri1eriOll. These combined effu:ts are not often considered by 

fue evaluation cri1eria Also, some SlJOO1anoes are absorbed by direct con1actwitlJ fue skin and mucous 

membranes, and 1hus po1erJ1iaIIy increase 1!Je overall exposure. Final\y, evaluation cri1eria may change over 1he 

years as new infonrntion onllJe toxic effu:ts of an agent 1=1Je available. 

The primary SOlJI1:eS ofenvirorunen1al evaluation cri1eria fur 1!Je work place are: 1) NIOSH Qi1eria 

Documents and Recommended ExpooJre Lin1its (RELs), 2) l1le AnJerican Conference of Govenlmen1al 

Indus1rial Hygienists' (ACGlH) Threshold LimitValues (ILVs), and.3) tile US, DepartmentofI.abor 

(OSHA) Permisstble ExpooJre Limits (PELs). Ofien, tileNIOSH recommendations andACGIH 1L Vs 

are lower tlJan tile corresponding OSHA PELs. The NIOSH REI.s and ACGlli 1L Vs are nsuallY !Jased 
pregnant bampstcrs. J4 No da!a wen,,: found linking fonnIldel\}'de witil temtogenic elfu:ts in humam. There 

was one report in which an increased incidence of mens1rual dron:lers, and of complications of pregnancy and 

deliveI)', were reponed among women worl= exposed to fommldell)1de at a 1exIile fuctrny in tile USSR J5 

The rel= of ti= finding;l has been aiticized, however, due to a lack ofinfurmationreg;mling 1he 

sui1abilily oftlle control group and potential oonfuunding fucIor&J6 

InApril1981, NIOSH ~ed Current Intelligence Bulletin 34, ''Fonnildell)1de: -Evidence of 

Oucinogenicity", DHI-IS (NIOSH) PublicationNo .. 81-11 LJ7 In ti1is bulletin, NIOSHreoommends tim 

fonnildellyde be handled as a potential occupational carcinogen and that appropriate controls be used to 

reduce worl<er exposure to the lowest fuasJble leve16 This recommendation was l::mrl primarily on a study in 

which nasal cancers develOjJErl in rats and mice fullowingrepeated inhalation exposures of awroximately 

15 ppm fonoaldell)1de .. In December, 1987, OSHA published an amended funnaldehyde standard, 

29 CFR 1910J 048. This standard reduoed fue PEL from.3 ppm to 1 ppm, as an 8-hour TWA JB In 

addition, a 15-minuteshorttenn exposure 1irnit (STEL) was setat2 ppm. ACX3IHhas given fonnildehyde 

anA2 designation, indicating fuatACX3IH oonsiders formaldehyde a suspected human carcinogen. The 

ACDIH 1LV forfonnildehyde is 1 ppm as an 8-hourTW Aand2 ppm as a IS-minute STEL J9 ACGIH 

has recently~ a ceiling 1irnit of03 ppm funnlldel\)'de in theirlXltice ofintended cbanges fur 

1989-1990. J9 This value will bereoonsidered fur1he adopted TLVlistafier2 yeaIS. 

C. Particulates 

Airl:xme dust genernted during gpnnentmanuJllcture consists of solid j:eJ1ic1es ofIDbric (lint), whic1l may be 

SllSJX'I1ded in air and inhaled. The CI.IIl1'rl OSHA PEL for total nuisance dust (fmticu1ates not ofuerwise 

regulated) is 15 milligrnm; ofdustj:eIculJic meter of air(rng'rri')20 The ACDIH 1LV fortotalnuisance dust 

is 10 rngjrrr. J9 'Il:ieoo evaluation aiteria were established to minimize rnecbanical irritation of1he eyes, nooe, 

ti:noot and llUlg8. I3ecat.l<e lint j:eJ1ic1es may conlain fu:e or hound funnlldehyde, 1he nuisance dust evaluation 

aiteria may not be appropriate. 

n Adv= ReproductiveOutconies 

Rates ofmiscarriages, stillbiIihs, biIih detects, and premature biIihs were ascertained for current and funner 

WOll1en RockcastIe employees. The rate of miscaniages in tile genernl population is estimated to be from 

10-25% depending upon which ascet1airunent metllOd is used and at what stage fue pregnancies are 

documented." The rate ofbiIih dem is between I and 10"10 depending on whefuerminor defects such as 

la!ge birth rnarl<s are included,2 

VI. RESULTS 

A Environmental 

Resulls from tile GlqX6llre monitoring for fonoaldel\)'de conducted during tile initial survey are shown in Table 

1.. TWA funnaldell)1de levels ranged fro011n1ce(OJ4 ppm) to 0.46 ppm inPBZ air samples, and from 

032 ppm to 0.10 !pm in area air samples obtained in production departmenls. A1tiJOugh tile samples 
product collected on a charcoal tube sample obtained in the headspace of a glue container showed the 

presence of ace1one, isopropyl alcohoL ethyl acetate, t-bu1anol and etll)'l propanoate, witllminor amounls of 

etlJanOl rux! etll)'l bu1anoo1e. Epichloroll)'drin, which is used in the manuJilc1nJe of tlJis product, was not fuund 

in tlle hulk air sample, 

A bulk air sample collected on a charcoal tube obtained nearthe two ctning ovens showed low levels of 

ace1one, isooc1ane, toluene, ruxI perchloroetll)'lene. The remaining organic vapor samples collected as full-shift 

air samples on the 2 oven operators, a s1eanl press operator, and the glue sprayer, showed only 

1,1,I-trichloroetlme (which is present in a solvent ruxI degreasing spray). The concentration of 

1,1,I-trichloroetl1ane in these sanlPles was qui1e low Oess 11m OJ ppm), witll all values fulling well below the 

ctnrent OSHA PEL for 1,1,1,-lrichloroe1hane of350 ppm as an 8-h.ourTW A The NIOSHREL fur 

I,I,I-trichloroetlme is 350 ppm as a 15-minute ceiling level Epichlorohydrin, etl1)'1 acetate, t-bu1anoL 

isopropanoL aoetone, ruxI etll)'l propanoate were not detected on ffi1)' of the PBZ charcoal tube air samples, 

to a limit of de1ection 0[5 ug per sanlPle. This oonesponds wifu levels of epichlorohydrin, etl1)'1 acetate ruxI 

t-bu1anol ofless lImn OJ ppm 

On fue initial smvey (Sep1m1ber, 1987), ambient temperatures rnnged fiom 71 "F to 83°F, wifu 1I1e higl1est 

1emj:Jerntures =nled near the s1eanl presses ruxI ctning ovens, The relative hurniditywifuin the plant ranged 

fiom 48"10 to 68%, wifu the higl1estvalue =nled in the glueroom, which was also the sUeoffue lowest air 

1emperature of71 "F, DIning lIJe Januruy smvey, air temperatures rnnged fiom 71 "F to 82"1', showing liUle 

cliffu:enoe fiom 1I1e initial smvey, Again, 1I1e higl1est1emj:Jerntures were =nled near the presses ruxlthe 

ovens, as expected, TIle relative humidi\ywas considerably lower, rnnging fiom 14% by the presses ruxI 

ovens, to 36% in the sewing rueas 

RMedical 

Of1l1e 191 current employees, 188 responded to lIJe questionnaire, for a response rnre of98% Only 48 of 

the 262 former employees returned 1I1e questionnaire, fur a funner employee response rn1e of only 18%" Of 

the current employees who responded to 1I1e questionnaire, 20 were male (II %) ruxI of fue former 

employees, 3 (6%) were male" /If t, 

,e.,! i 'J .fi.~ . ~. 

RGPJPductive ;it; 

Among 1I1e women respondenls (current ruxI fonner), lIlere were 386 pregnancies, of which 12 were 

=t pregnancies ruxl2 were ectopic pregnancies, These 14 have been exc1nded because 1I1e outcome 

cannot be determined (ectopic pregnancies rue exclnded because 11= is no way to detem1ine ifanomlal 

pregnancy wouId lJaVe oo::urredhad fue egg implan1ed in theu1erus), Additionally, onewon-lan who IJad 

been pregnant 8 times and who had had 6miscaniages was excluded becaure multiple rniscaniages rue more 

likely to be dne to genetic or anatomic = rntlJeI 11= to ex1emal canses, SUcll as occupational exposures, 

TIJis individual lJad 4 of her 6 miscaniages while she was notwodcing ruxI tl= 2 additional miscarriages wIllie 

at Rockcas1le" She was also one of lIle 12 cunentlypregnant et11ployees, 
An eva1uatiem was made of where the individuals wolked who had an adverse ou1come willie worlcing at 

Rockcasl1e. 1here was no diflerence in l1le dis1nbuliem of jobs hetween there who had anoIllJlll preguancy 

while wolking at Rockcas1le and 11= who had an adverse ou1come willie worlcing at Rockcastle (fable 6) 

TIle Ill1e in sewing, 50"/0, wl= moot of the adverse ou1comes oca.nred, was not suhstantially grealerilian l1le 

overnll mle of42%. 

An eva1uatiem was made 10 determine ifl1lere was a concentratiem of adverse reproductive ou1comes during 

any time period. Figure 1 shows a gmph of fue occurrence offuese biI1h defr:c1s, stilIbiI1llS, and prema1ure 

biI1llS by l1le year ofOCCUJrellce. TIlere was a shaJp increase in fuese adverse ou1comes in 1986. 

Mll.'rula;kele1al and O1her Healtll Complain1s 

1lJe resu11s forfile questions CClI1OOllingmlJ.'ruloskele1al comp1ain1s and ol1Jer healfil comp1ain1s were 

1abu1ated for current employees only. Onl1le mll.'rula;kele1ll1 C0111Jllain1s, wolken; were asked 10 Ill1e each 

complaint em a scale ofllo 5 (l=never and 5=oaJ.ways). A pa;itiveresponse was defined as an answer of 4 

or5. The proportions ofpa;itiveresponses were calcuJated and can he fu1.ll1d in Table 7. Moot offue 

comp1ain1s involved file neck, shoulder, OOckand legs as compared 10 1he arms and hands. 

Forfue questions conceminginitation, worlrelS were asked 10 mark tlJe frequency of1heiI symplorns 

(l=neverlo*moot~). Apositiveresponse was asymplom that occurred em moot days. TIleseresul1s 

can he fuund in Table 8. 1lJe moot COl11l11CID symp10rns reportOO included tlJcre =iated with upper 

respimtrny 1mct initation, eye initation, headaches and skin initaticm. 

Vll. DISCUSSION 

Areductiem in funnaldehyde levels inPBZ and area airsamp1es was noted onl1le follow-up survey. This survey 

was ~01Illed afler revernl vernilation changes had been insIi1u1ed, including an increase in 1he atllCJIIDl of dilution 

vernilation and installation oflocal exhaU5I vernilation above fly press and slean1 press tables. Forrrnldebyde 

concentrations in sewing areas I through 4, w!Jere fue majority of1he wrnkfurce is located, averaged 0.68 ppm on 

1he initial survey and 026 ppm em 1he follow-up survey. In addition, 1he exposure mnge was much nanower em l1le 

fullow-up survey, suggestingthat1heventilation changes rmy have improved airciluJJationand mixing within file 

plant It should he noted, howevcr, thatthese funnaldebyde measuremen1s were made at eme point in time and rmy 

notrellect seasonaI variations. Factors winch rmy affect fonnaldel¥le levels include ambient temperature and 

humidi\y, volUllJe of s10red fubric, and changes in resin finishing frnnulations. 

AlfilOUgh 1he funmJdel1)'de levels measured during fins srnvey were all helow fue OSHA PEL andAa:J1H 1L V of 

1 ppm, as an &-hourTW A, effor1s 10 further reduce fonna1dehyde levels should cootinue in an effort 10 achieve fue 

lowest feastble level, as fonnaldebyde is considered a poteotialhurnan carcinogen. A continued reduction in 

funnaldehyde levels will also help minimize comp1ain1s of eye, na;e, and 1lnmt initation, which can he exp!lienced at 

vay low levels. 

As previously noted, resu11s fiurn l1le side-by-side Bachamch Ai=* FonnaIdel1)'de Expa;ure Monilors gave 

somewhat lowerresu11s than file ofiler two established air sampling metllods furfunnaldel¥le. TIlere was some 

difficulty in de1enniningfile actual furrmldehdye an:entmtion obtaiIJed with file I11Oln1ors, due 10 uneven stain 

development These moni1ors nJiIizJ;J 1he principle ofnuc1eation and aystal growtll, wl:terehy furmaldelldye is reac1ed 

witllio file rnoni1or, fommJg a aystal seed filat grows with 1he addition ofa developer solution. TIle difficulty in 
A mnnber ofhealtll complainls were exp=l by employees. Bemuse most ofthe ~ymp1oms occur 10 mm 

people atscme time, furthepwposes of Ollrsurvey a~lp1om was considered present only ifitwasrepor1ed to be 

fitxjllGlt C'almm always" or "always" furmtIDJlookele1lll complaints, aod "on mm days" fortlle otlJef ~1jl1oms).. 

Approximately ooo-tlJird oftlle woIirets repor1ed pain in tlleir shoulders, neck, back, aod leg;. A1tlloogh not fue 

pimaI)' focns of our evaluation, we obrerved awkward pooitiOIlS among tlle worl=. Dc'1ailed ergonomic 

evaluations in otllel: g;nmentmanufacturiog facilities have fOlllld tlJatthere lYJleS of awkward pooitions can result in 

complainls and can lead 10 anumher of medical conditions such as tendonitis, bUISitis, chronic back strain, aod 

varicose veins.24 

Other IJealth complainls frequently reported were ini1lltion of the ~ andnooe, as well as headaches and skin rush. 

Exposures to f01111aldehyde even in low concentrations can lead 10 fuere lypes ofcomplainls. 8 

Vlll RECOMMENDATIONS 

SnJee tlle initial NlOSH investigplion, many ventilationaod workprnc1ice changes were made, scme of which had 

been recomn=ded by the NlOSH investigptors. Further changes have been made since fue second NlOSH visi~ 

includirJgfue installation oflocal exhaust ventilation attlle poilu of steam ger:erationatfue fly press stations .. These 

changes have improved working conditions at this plant The fullawing additional recommendations are offered to 

fi.n1herreduce fue funrnldebyde exp=repotenlial, to minimizepo1erl1ial ergonomic hazards, aod to monitor future 

reproductive outcomes ofRockrastle Manufuc1uring employees. 

1. Rockcas1Ie MarnlC1ctJning should continue 10 WllIkwith tile textile finishing con1JE1Ywhich 5UfPlies fue 

pmt.ane fubrics 10 ensure utilization ofresin systems offering lower f01111aldelJYde release .. Rockcas1Ie should 

also requesttlJalfue finisher supply fumJaldehyde release data onrnudonJ fabric samples as a quaIi1y control 

measure. In addition, fuejJO'lllbility ofnsingpnxure fubrics (which may have lower foona1dehyderelease) 

should be explored 

2. Periodic exp=re monitoring forfumJaldehyde should be perfunned, taking into ronsideration potential 

seasonal variations inf01111aldel1)'Cle levels Expooure monitoring should also be conducted aflerventilation 

clJal1ges are made, whennewresin treatmenls are used, aod following otllerworl(practice changes whicll 

may affirl airbonJe fonnaldehyde levels. 

3. The questionnaire data indicated a 1mge number of complainls oftlle shoulder, neck, back, aod legs. To 

reduce fue potential fordevelopment ofcumula1ive trauma disoo:lers, an ergonomic evaluation should be 

perfOl11Jed atfuis facilily. This isparticuJarly irnplr1an1; in light of planned exp3IlSion aodrenovation activities 

(ms1aIlation ofnew curing ovens, elimination of glue sprnying q:mrtion, increasing fue size oftlle plant etc.) 

4. Since tlJis evaluation fuund a cluster of adverse reproductive outcomes, a surveiJJanoe ~ should be 

established 10 detennine if tlJis trend continues. CIus1em can be due 10 a mIDlber of fuctOIs aod the continued 

surveiJJanoe of pregnancies should dif!Gen!iate an ongoing problem OOm one due 10 otlJeIfac1or.s, includirJg 

chance~ 
15.. Shumilina A V Mens1lual and child-beaJing functiOl1S offemale worlcers OCCUfXl1ionally exJ.XlS"d to the effects 

offonnaldehyde .. Gig TI ProfZabol. 1975,19:18-210 

16.. National Research Council Fonnaldehdye and other aldehydes. National Academy Press, Washington, 

DC. p991, 19810 

17. National Institute furO:cnpatiOllal Safuty andHealU~ NlOSH ClnrentIntelligenceBulletin 

34-fonnaldehyde: evidence of carcinogenicity. (OHl-lS (NlOSl-l publicationllO. 86-122). 

18. O:cnpational Safely and HealUl Administration. Amended Fonnaldehyde Standard. 29 CFR 

1910.1048.. Fed Reg 52 (233), Derember4, 1987. 

19. American Conference of Governmental Irxlu>trial Hygienists. Threshold lilnitvalues and biological expoo..rre 

indices for 1989-1990. ACG1H: Cincinnati, Ohio, 1989 .. 

20. Occupational Safuty and l-lealfu Administration. Air Contaminants -PermissIble Exposure Limits 29 CFR 

1910.1000(amended).. FedReg,Janumy 19,1989. 

210 KlineJ, Steinz, StrobinoB, Susser M, WarlJurtonDSnrveilJance of spontaneous abortions .. Powerin 

environmentall11OllilDring Amer JEpidemioll977; 106: 345-'350 

22. Bengtl<, Epidemiology ofHuman Reproduction. CRC Press: Boca Raton, 1988 .. 

23. BuckGS,GetchellNF .. US.Patent2957746, 1960. 

24. PunnettL,RobinsJM, WegmanDH,~gWM SofttissuedisonlersintheUJ:P"flimh;offunale 

garmentwoIkeffi. ScandJWorlcEnvironl-lealU11985, 11:417425. 
Table 1 

Fonnaldehyde Exposure Data, Rocl«:astle Manuillcturing, Mom! Vemon, KentuclIY 

HETA 87-349, Seplember9, 1987 

Sample De;cription SmnplingTure Sample Volum:: Fonnalrehyclc Concenlrnlion TWA b 

(rninules) (lilcr.;) (ppm)' (ppm) 

Personn} BIl?athing Zone Air Sanmle;c 

ovenopcrnlorlll 516 25 . .0 (.0.29) 

oven opcrntor#2 511 26.7 (.03.0) 

steam press oJ.XT.Ilor 509 276 .038 

glue sptayer 442 19 . .0 (.0.14) 

fly press opcmlDr 471 24.6 .0.46 

AJl.'aAirSarrmlesd 

coof=toom 339 64.4 0.28 

fubric s\or.lgc rum 200 100 . .0 .034 

2m 1.01.0 .0.46 .0.4.0 

boxing def<u1rnen1 197 985 .0.41 

199 995 .0.48 .0.45 

culling table 197 985 .05.0 

198 99 . .0 .0.60 .055 

area 1 -wells 193 %5 .0.60 

198 99 . .0 .0.79 .0.7.0 

rum 2 - poci<ct set 194 97 . .0 .0.60 

199 995 0.77 .0.69 

rum 3 -waist band set 194 97 . .0 .0.60 

198 99 . .0 078 .0.69 

rum4-beltloop 194 97 . .0 .057 

198 99 . .0 0.73 .0.65 

Press mea 190 95 . .0 .0.49 

204 102.0 .0.67 .058 

Press 141 190 95 . .0 .0.47 

2m 101.0 .0.69 .058 

Press 157 190 95.0 .0.48 

193 %5 0.71 .0.60 

outside oven (pant 190 95 . .0 .033 

rockooolingrum) 197 985 .051 .0.42 

gluerocm(stclJ) 186 93..0 .0.32 

fiontofficc (bycopicr) 189 945 .0.13 

outsiclcovcn(pm1trnckcoolingmea) 15 15 . .0 .0.39 

15 15.0 .0.41 

NlOSHRerornrnendedEl<posurelimit(REI.) LO\\1:stFeasibleL=1 

OSHA Pennisslble El<posure limit (pEL) 8-1"TWA L.o 

15·minSTEl 2 . .0 

ACGIHTIut\,holdlimitValu::(llV) 8-hrTWA 1.0 

15-minSTEl 2.0 

, Fonnaldehydc conccnlrnlion ~ cxpr=l in f'1I1S per million (ppm). Vnlucs in parentilCS<S indicaJe fonnalrebydc concenlrnli= bet""cn tile 

limit ofdelcclion (LOD) and limit of quantitation (LOQ). 

b TWA ref"'" to tile tirro-wciglltOO averngc concenlrnlioo over ti" entire s:unpling)"riod 

, Pcn;onnl hreaJhing znne cir s:unples were collected and annlyw:! ru:am1ing to NlOSH MeUlOd 25m (solid SOJbent tube meUJOd). TI" WD 

andLOQ wero4and 12 microgmrns persampl~ respectively 

d Areaairsamples were oollcctcd and annlyw:! accon:ling to NlOSHMetixxl 35OO0mpingermeUJOd). TIJelOD ruxlLOQ were .0.4 and 13 

microgmrns per s:unpl~ respectively 
Table3 

latentFonna1dehyde Levels on Resin-Treated Fabrics 

Fabric 

Demiption 

IJa\oY blue -stored at the plant fur 

less than one IIIOll1h: 

steam pressed only 

steam pressed and cured@ 350 F for 15-min 

IJa\oY blue -stored at the plant for 

>60days: 

steam pressed only 

steam pressed and cured@350Ffor 15-min 

emem1d green -length of stomge unlmown 

not pressed or cured 

bluish black - length of storage on1mown 

not pressed or cured 

brown-length ofstomge on1mown 

not pressed or cured 

royal blue -length of storage on1mowl1 

l10tpressed or cured 

dad<: green -length of storage on1mown 

l10tpressed or cured 

white -length of stomge on1mown 

l10tpressed or cured 

Rockcas1le Manufucturing 

MOllllt Vernon, Kentucky 

HETA87-349 

September 9, 1987 

latent Frnma1dehyde 

uglgpf 

468 

124 (735% reduction) 

280 

161 (42.5% reduction) 

312 

244 

219 

1430 

382 

163 

a latent fonna1dehyde levels are explessed as micmgl1lms offunnaldehyde per gram of fabric (ug'g) 
Fmploymeut Status 

duriogpregnancy 

Rockcastle 

(28 pregnancies) 

Working but Not 

at Rockcastle 

(91 pregnancies) 

NotWorking 

(246 pregnancies) 

Fmploymeut Status 

duringpregnancy 

Rockcastle 

(I9 pregnancies) 

Working butNot 

at Rockcastle 

(71 pregnancies) 

NotWorking 

(206 pregnancies) 

1< 

(A) 

1~0 

...",) il 

.-::,/./ . 

TableS 

Proportions of Adverse Reproductive Outcomes 

Rocl«:astle Mannfucturing 

MOUllt Vernon, Kentucky 

HETA87-349 

JannlUY, 1988 

Gnrent and Fonner Worlrers (365 total pregnancies) 

Binh Defucts* Stillbi!1hs* 

14% 25% 4% 

13% 4% 0 

5% 2% 2% 

Qurent Worlrers Only (2% total pregnancies) 

Miscarriages Bi!1h Defecls* Stillbi!1hs* 

21% 'I 13% 7% 

15% 1{ 3% 0 

5% I) 2% 2% 

* TIlese proportions are based on tile total munber of pregnancies 1hat did not end in a miscarriage 

P.remature* 

13% 

1% 

3% 

Premature* 

-) 

r13% 

2% 

4% ,~ 
Table 7 

Rates of Musculrnkelellll Complainls 

Among Current Rockcastle Employees 

RockcastleManullctnring 

Mount Vemon, Ken1ucky 

HETA87-349 

January, 1988 

Complaint Proportion Who Reported Symptoms 

Shoulder Pain 38"/0 

NeckPain 35% 

LowerBackPain 35% 

UpperBackPain 34% 

Leg Pain 33% 

ForeannPain 19% 

HandNumbness 17% 

ElbowPain 15% 
~. 

Number of Births 

Rockcastie Manufacturing 

HETA 87-349 

7r'------------------------------------------------~ 

6 

5 

4 

3 

2 

1 

~~_ ---1 o 

81 82 83 84 85 86 87 88 

_ Normal Births _ Adverse Outcomes 

Figure 1--Pregnancy outcomes for Rockcastle Manufacturing employees from 1981-1988.