study, Ponomarkov and Tomatis administered styrene in olive oil by stomach
tube to both sexes of one strain of rats and of two strains of mice. There
was a statistically significant increase in lung adenomas and adenocarcinomas
only in female mice of the strain. The authors suggested that their data
provided weak evidence of carcinogenicity of styrene (39). In an NCI
investigation there was an increase in lung adenomas and adenocarcinomas in
male B6C3Fl mice when compared with matched controls, but not in female
mice or in Fischer 344 rats. NCI concluded that the data provided suggestive
but not convincing evidence of the carcinogenicity of styrene (40).
Mortality studies of styrene workers have not shown an excess of cancer
mortality, although there have been suggestions of an excess of leukemia.
Nicholson et. al. studied the mortality experience in one U.S. plant manu-
facturing styrene and polystyrene. The investigators found two cases of
leukemia and one of lymphoma in the study group. After examining 361 death
certificates of other workers employed at least six months, they found five
additional cases of leukemia and four of lymphoma. They anticipated an
excess of leukemia because of previous exposure to benzene of many of these
workers (41). In another U. S. plant, Ott et. al. studied styrene workers
who had been exposed to low levels of styrene for most of their employment
(TWAvLOppm). These styrene workers had lower total mortality and cancer
mortality when compared to the U.S. white male population and to mortality
experience from that company. However, there was a significant excess of
leukemia deaths when compared to the other company employees, although the
excess was not significant when compared to the U.S. population, Most of
the excess was due to lymphatic leukemia. Some workers had been exposed
years previously to high levels of benzene (42). No excess of cancer was

seen in a German plant of employees exposed to styrene. The incidence of


pits (the hulls molds were stationary and positioned below grade level).
However, positioning of these fans was critical and worker movement in the
area caused the fans to be moved and maintaining proper air flow patterns
was difficult. The fans should have had fixed positions (a technique

used in Plant 6). The deck lamination area of this plant also experienced
some stagnant air flow. Otherwise, for a survey conducted in the winter, the
ventilation system engineered for Plant 5 kept exposure averages below 55 ppm
(the single sample collected on the sander is not considered an average).

Plants 3, 4, and 7 each exhibited inadequate control of exposure to
styrene. These surveys were all conducted in the winter, in regions of
the country where little plant leakage (or ability for natural ventilation)
is allowed. These are most likely worst case situations, however, there is
no justification for allowing average exposures at or exceeding 100 ppm.
Evaluation and redesign of present ventilation systems are required.

By looking at exposures by job across all plants a couple of interesting
observations can be made. Firstly, in general, the hull jobs receive the
highest exposures to styrene, followed by the deck, small parts and gel-
coat jobs. In Plants 1 and 6, the exposures are somewhat homogeneous and this
trend is not as obvious. These data seems to support the common sense
notion that exposure to styrene vapor emitted from catalysed resin is pro-
portional to resin consumption. That is, the larger parts require more resin
and these workers receive the higher exposures. The low ranking of the gel-
coat job reflects, in part, the fact that this job is usually performed in
a ventilated spray painting type booth, or is performed on an off-shift
when dilution systems are more adequate. Secondly, the difference in

exposure experienced between chopper and hand lay-up counter parts of hull,

30


A frequency distribution for all jobs, by plant, is shown in Table 5.
Corresponding exposure averages for these jobs are presented for styrene in
Table 6, and for acetone in Table 7, It can be seen from the overall plant
averages that control of styrene exposure was different from plant to plant.
Some were adequate; others were not.

Average exposure to styrene for each job in Plant 1 were kept below
50 ppm (the model development single exposure sample is not considered as
an average). Plant 6 mean exposures were controlled to below 40 ppm in all
but one job. Both of these plants exhibited that exposures in all jobs can
be adequately controlled using dilution ventilation techniques. The im-
portance of the model development should be mentioned. Workers in this
category build the prototypes from a wooden model, or plug. The surface of
the plug is coated with several layers of fiberglass and resin. The exposure
results are of interest in an historical sense, since they most likely depict
the exposures experienced by those first using styrene diluted resins in this
industry. Early resin use was limited to coating wooden boats to make them
more durable. This practice evolved into making the entire boat of FRP using
present techniques. If the coated plug tests satisfactorily a mold is made
from the plug.

Plant 2 exposure means were kept below 45 ppm in all jobs not related
to hull lamination, Stinger installation is a special hull lay-up task.
Stingers are longitudinal support pieces which reinforce the hull bottom.
During this survey a large hull (>50 feet) was being made requiring work in
a stationary upright mold. No attempt was made to move fresh air through
the space during the work and resulted in the high exposures.

Plant 5 experienced similar problems with hull lamination exposures.

Attempts were made, using moveable fans, to move the air through the hull

26


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(udd) obuew (&)AD (add) ueew (dd) ebueq (%) AD (add) ueew (udd) sbuew (%) AD (udd) ueew nN INWId
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79


Within Plant 2 the exposures are relatively homogeneous except
for the hull category whose mean is highly different from the
rest, P=0.0005 or less;

Within Plant 3 the gelcoat mean is different from both the hull
and deck categories, P=0.0132 and 0.0058 respectively;

Within Plant 4 both hull and deck are different from gelcoat
at the P=0.0001 level, and the hull category is also significantly
different from the small parts, P=0.0392;

Within Plant 5 the hull category mean is significantly higher
than all others (at least at P=0.0226) with relative homogeneity
among the other jobs;

Within Plant 7, the gelcoat category mean is significantly lower
than the others (p£-0.001);

Within Plant 7 the only two similarities are between hull and deck,
P=0.2514, and small parts and gelcoat, P=0.7722.

Table 12 presents the P values for comparisons of the chopper and

hand lay-up jobs within the plants that have this job breakdown. No

significant differences exist between the means in Plants 1 and 3 while the

opposite

have the

is true in Plants 2 and 7. In Plants 1 and 7 the lay-up jobs

higher mean exposure and in Plants 2 and 3 the chopper job tends

to be higher (Table 6).

The

in Table

are made:

1.

P-values from the ANOVA comparing plants within job categories are

13. By using Tables 10 and 13 together the following observations

Except within the hull category (P=0.0001) Plants 1 and 2 are
similar;

Plant comparisons 3 vs. 4, 3 vs. 7 and 4 vs. 7 appear homogeneous
across all four major job categories;

Plant comparison 4 vs. 5 and 5 vs. 7 appear to be similar except
in the deck job category.

Tables 14 through 17 display the statistics from the interplant two-

factor ANOVA's performed. As the degrees of freedom were reduced in Tables

15 and 16 there was a slight lessening of the significance of the independent

35


TABLE I

PROPERTIES OF STYRENE

Synonymns

Molecular formula

Formula Weight

Boiling Point (760 mm Hg)
Melting point

Vapor density

Density

Solubility

Flammable (explosive) limits

Flash Point

Fire Point
Autoignition
Critical temperature

temperature

Critical pressure

Vapor pressure

Concentration in saturated air

Conversion factors,
(25 C, 760 mm Hg)

Cinnamene, cinnamol, cinnamenol,
vinyl benzene, phenylethylene,
phenethylene, stryol

C6H SCH=CH2

104,1

145 C (292.4 F)

~30.6 C (-23.1 F)

3.6 (air = 1)

0.9021 g/cu cm (25 C)

0.31 g/100 ml water at 25 Cc;

soluble in ethyl ether, benzene,
heptane, ethanol, acetone

1.5 to 6.7% by volume in air
24-98 F

31 C (887) Tag closed cup
37 C (98F) Tag open cup

OOF

490 C (914 F)

362 C (684 F)

37.8 atm

Temp F ‘Temp C mm Hg
50 10 2.34
68 20 4.50
86 30 8.21
104 40 14.30

5,700 ppm (15 C)

1 ppm = 4.26 mg/cu m
1 mg/cu m= .235 ppm

4a


rrr nr rrr nnnnnnn PLANT=6 ------~
OBS JOB STYRENE ACETONE
336 2 14.40 40.80
337 2 42.10 31.60
338 2 34.20 53.20
339 2 12.80 11540
340 2 18.00 103.00
341 2 6.89 2.75
342 2 48.40 93.70
343 2 1.56 2.00
344 2 23.40 18.20
345 2 12.90 231.00
346 2 18.50 18.80
347 2 29.80 53.50
348 2 15.90 43.30
349 2 23.30 369.00
350 2 43.70 35.30
351 2 23.00 18.90
352 2 3-02 0.54
353 2 18.70 24.30
354 2 12.80 5222
355 4 73.70 110.00
356 4 51.70 96.60
357 4 43.30 60.80
358 4 21.70 66.40
359 4 53.20 33.20
360 4 37.50 19.50
361 4 37.10 49.90
362 4 53.50 8.72
363 4 31.70 28.40
364 4 32.30 24.00
365 4 78.90 33.70
366 4 52.00 9.51
367 4 22.40 9.43
368 4 34.10 36.70
369 4 43.50 24.80
370 4 17.70 9.78
371 4 20.20 12.70
372 4 15.20 10.10
373 4 27240 8.79
374 4 42.00 41.20
375 4 30.30 21.00
376 4 19.50 49.10
377 6 31.70 77.60
378 6 43.40 144.00
379 6 40.30 116.00
380 6 38.40 44.80
381 6 37.10 29.50
382 6 39.00 58.30
383 6 45.90 72.00
384 6 16.40 16.00
385 6 30.20 41.20
386 6 26.00 $1.20
387 6 35.90 25.30

FIBERGLASS REINFORCED PLASTIC BOAT PLANT

APPENDIX A
SURVEY DATA

63

COMBTLY

0.185
0.453
0.395
0.128
0.283
0.692
0.578
0.018
0.252
0.360
0.204
0.252
0.202
0.602
0.472
0.249
0.030
0.211
0.133
0.847
0.614
0.494
0.283
0.565
0.395
0-421
0.544
0.345
0.347
0.823
0.520
0.233
0.378
0.460
0.187
0.215
0.162
0.283
0.461
0.324
0.245
0.395
0.578
0.519
0.429
0.371
0.448
0.531
0. 180
0.343
0.311
0.384

NAME

HULLAN
HULLAM
HOULLAS
HULLAH
HULLAS
RULLAM
HULLAK
HOLLAMS
RULLAA
HULLAN
HULLAM
HULLAM
HULLAM
HULLAS
HULLAS
HULLAS
HULLAM
HULLAN
HULLAB
DECKLAM
DECKLAN
DECKLAB
DECKLAM
DECKLAN
DECKLAN
DECKLAM
DECKLAM
DECKLAMN
DECKLAM
DECKLAK
DECKLAN
DECKLAMN
DECKLAMK
DECKLAM
DECKLAN
DECKLAMN
DECKLAM
DECKLAM
DECKLAM
DECKLAM
DECKLAM
SHPTLAM
SMPTLAN
SUPTLAM
SMPTLAN
SMPTLAMN
SMPTLAM
SMPTLAN
SMPTLAM
SHPTLAM
S&PTLAK
SMPTLAS


CONTROL TECHNOLOGY

There are undesireable acute health effects caused from exposure
to styrene and perhaps some chronic effects as yet unknown. It has been
demonstrated that in the fiberglass reinforced plastic boat industry there
are frequent worker exposures to styrene which are over current standards.
Standards, however, should not be considered as dividing lines between
safety and danger. It is generally more significant that when limits
have been exceeded by a small amount there has been a failure of control
than that one or more individuals have exceeded an agreed exposure.

There are two distinct conditions cf exposure to be considered:

i) in whith the source of exposure is not subject to control;

ii) in which occurrence of the exposure is foreseen and can be limited

by control of the source and by development of satisfactory work
practices.

In the’ FRP boat industry, condition "i" has been the prevailing one for years;
condition "ii" is the one which, if a safe and healthy workplace is the goal,
should be the aim of those in this industry now and in the future.

If a standard approach to control is looked for in this industry it
would be dilution ventilation. In some instances it is shown that this is
a satisfactory method of exposure control. This will always be an important
feature in any control strategy employed for FRP processes, however, in the
general case it will need to be merged with other control features. From
experience gained during the surveys in this study, the following areas are

recommended for future research and development to control styrene exposures

in the FRP industry:

45


DISCUSSION

Industrial hygiene surveys were conducted in seven fiberglass rein-
forced plastic boat fabrication plants. From this standpoint the problem
in this industry is in the control of worker exposure to styrene. The
exposures across all plants were substantially variable, ranging from
two to ‘is3 ppm. Over 20 percent of the personal TWA exposures were over
the 100 ppm eight-hour standard. Most of these predominated in a few plants.

An important trend was identified in the survey results and verified
in the statistical analysis. It was shown that the mean exposures for the
major job categories of hull, deck, small parts and gelcoat, were different
from each other and that the magnitude of these averages followed resin con-
sumption patterns. Styrene exposure is proportional to the amount of cat-
alysed resin used in the job. When the chopper and hand lay-up counterparts
in the hull, deck and small parts categories were compared the results were
mixed. Exposures were not consistently higher for either task, and seemed
to be related to the division of labor between them in the particular plant.

It was demonstrated in the survey results that for some plants dilution
ventilation techniques can adequately control exposure to styrene. It
has also been shown that plants with similar ventilation efficicney (implied
by the overall plant styrene averages) have somewhat homogeneous exposures
within job categories. This information has potential use for purposes of
control. A technique that adequately controls a high exposure taks in one
plant hopefully may be applied with equal effectiveness in a similar plant.
A case in point would be Plants 2 and 5 using the method of fixed fans on the
large hull molds for maintaining dilution air flow as is successfully done
in Plant 6. Application of local exhaust ventilation in Plants 2 and 5

may also work if practical.

43


1o.

11.

12.

REFERENCES

Brighton, C. A., Pritchard, G., and Skinner, G. A., Styrene Polymers:
Technology and Environmental Aspects, Applied Science Publishers LTD,
Essex, England, 1979, pp. 109-136.

Rolston, A. J., "Fiberglass Composite and Fabrication", Chemical
Engineering, pp. 96-110, (Jan. 1980).

Rossavainen, A., "Styrene Use and Occupational Exposure in the Plastics
Industry", Scandanavian Journal of Work, Environment and Health, Vol. 4,
Supplement 2, pp. 7-13 (1978).

Leonardos, G., Kendall, D., and Barnard, N., "Odor Threshold Deter-
minations of 53 Odorant Chemicals", Journal of the Air Pollution Control
Association, Vol. 19, pp. 91-95.

Smith, H. O., and Hochstettler, A. D., "Determination of Odor Thresholds
in Air Using Cl4-Labeled Compounds to Monitor Concentrations",
Environmental Science Technology, Vol. 3, pp. 169-170, (1969).

Brooks, S. M., Anderson, L., Emmett, E., Carson, A., Tsay, J-Y, Elia, V.,
Buncher, R., Karbowsky, R., "The Effects of Protective Equipment on
Styrene Exposure in Workers in the Reinforced Plastics Industry", Archives
of Environmental Health, Vol. 35, No. 5, pp. 287-294, (1980).

“Styrene-Type Monomers", The Dow Chemical Company, Midland, MI.,
13 pp., (1969).

Christensen, H. E., Fairchild, E. J., "Registry of Toxic Effect of
Chemical Substances", HEW (NIOSH) publication no. 76-196. U. Ss.
Department of Health, Education and Welfare, Public Health Service,
Center for Disease Control, National Institute for Occupational Safety
and Health, p. 1107, (1976).

Weast, R. C., "Section C-Organic Compounds", CRC Handbook of Chemistry
and Physics, 54th Ed., CRC Press, Cleveland, 1973-1974).

Patty, F. A., "The aromatic Hydrocarbons", Industrial Hygiene and
Toxicology, 2nd ed., Vol. 2, Interscience Publishers, New York, 1963,
pp. 1229-1231.

"Key Chemical, Styrene," Chemical and Engineering News, Vol. 57,
No. 25, p. 10, (1979).

"Key Polymers, Polyesters," Chemical and Engineering News, Vol. 57,
No. 32, p. 13, (1979).

49


44.

45.

46.

47.

48.

49.

50.

Eile

“Occupational Safety and Health Standards for General Industry",

(29 CFR Part 1910), Table 2-2, U. S. Department of Labor, Occupational
Safety and Health Administration, Commerce Clearing House, Inc.,
Chicago, 1979.

TLV's Threshold for Chemical Substances and Physical Agents in the
Workroom Environment with Intended Changes for 1980, American Conference
Governmental Industrial Hygienists, Cincinnati, 1980.

NIOSH Manual of Analytical Methods, 2nd ed., Vol. 1, DHEW (NIOSH)

Publication No. 77-157-A, Rockville, Md., U. S. Department of Health,
Education and Welfare, Public Health and Service, Center for Disease
Control, National Institute for Occupational Safety and Health, 1977.

SAS User's Guide, 1979 ed. SAS Institute, 1979, pp. 237-264.

Occupational Exposure Sampling Strategy Manual, NIOSH publication

No. 77-173, U.S. Department of Health and Human Services, Public Health
Service, Center for Disease Control, National Institute for Occupational
Safety and Health, U. S. Government Printing Office, Washington, D.C.,
1978.

Schumacher, R. L., Breysse, P. A., Carlyon, W. R., Hibbard, R. P.,
and Kleinman, G. D., "Styrene Exposure in'the Fiberglass Fabrication
Industry in Washington State", American Industrial Hygiene Association
Journal, Vol. 42, pp. 143-149, (Feb. 1981).

Adams, J. M., Personal Communication, June 16, 1961.

Conrad, R. J., Hopkins, B. L., Fitch, H. G., Smith, M. J., Anger, W. K.,
and Dangel, R. F., "A Strategy to Validate Work Practices: An Ap-
plication to the Reinforced Plastics Industry", University of Kansas,
Lawrence, (1980).

53


TABLE 14

Interplant Styrene ANOVA Statistics for the
Hull, Deck, Smallparts and Gelcoat
Job Categoriest+

Source DF Ss F-Value P
Job Category 3 14.8 23.15 0.0001
Plant 6 63.2 49.35 0.0001
Job Category*Plant 18 12.5 3.26 0.0001
DE = Degrees of Freedom

SS = Sum of Squares
TABLE 15
Interplant Styrene ANOVA Statistics for the
Hull and Deck Job Categories +

Source DF ss F-Value P
Job Category 1 2.0 8.56 0.0037
Plant 6 59.2 41.06 0.0001
Job Category * Plant 6 6.1 4.24 0.0004

+ Significance indicated for P<0.05

41


PROCESS DESCRIPTION

The method used in manufacturing FRP boats is called contact molding and
is a zero pressure molding method in which only one side contacts the mold
surface. There are two principal techniques, hand lay-up and spray-up. Materials
used in contact molding are polyester resin, gel coat (pigmented resin), split-
strand glass fiber roving which is used for chopping in the spray-up operation,
chopped-strand mat (made by chopping split-strand glass fibers, mixing with
a binder and pressing into a mat) which is used in hand lay-up, and woven roving
(a heavy cloth made from strand roving in a square weave pattern) whose greatest
use is to provide a structural backbone in the hand lay-up operation.

Hand lay-up: Mat or mat-and-woven roving layers are wetted out with
resin and manually laid-up on the gel coated mold. Resin is applied to the
mold, using a brush on smaller pieces or an airless sprayer system on larger
ones, and mat is laid on top of the resin. The preferred practice uses alternate
layers of mat and woven roving.

Spray-up: A mechanism attached to the sprayer system used for wet out in
hand-lay-up allows for chopping split-strand roving and "throwing" the chopped
fibers onto the mold surface while at the same time spraying polyester resin.
This tool is called a chopper-gun. In this manner a structure can be built up
layer by layer in a mat-like style. Following deposition of fiber and resin,
it is necessary to roll-out the structure (compacting the resin and glass) with
a special rolling wheel. Spray-up is often used in combination with hand lay-
up techniques.

The boat making process begins with polishing the surface of an FRP mold
having the converse shape of the part being made, and the application of a re-

leasing agent (usually a wax) in preparation for the initial layer of gel coat.

13


deck and small parts lamination jobs varies from plant to plant. This
may be indicative of whether the tasks are completely separate between the
two jobs or whether the tasks are shared between the two jobs. In Plants
1 and 7 the choppers took no part in the hand lay-up. In Plant 3, the
chopper participated in the hand lay-up procedure.

There seemed to be no trend to acetone exposures. Extreme exposures
were experienced in a number of jobs. Exposure to acetone results from the
use of this solvent for clean-up purposes. Exposure potential is a function
of the frequency of cleaning tools and other work habits of the individuals.

Because of the percentage (43%) of samples reported in the previous
section as having breakthrough of the acetone, these data will be excluded

from further statistical analysis, the value of which would be doubtful.

Statistical Methods
As the first step in approaching the problem of styrene exposure control
for this industry, certain statistical comparisons are useful. In order to
do the appropriate analysis it was logical to combine the 23 jobs into eight
more manageable job categories. This was logical because:
1. The categories combine jobs whose tasks involve no direct exposure
to styrene and acetone (that is non-resin-use jobs) into a no

exposure category;

2. Those jobs whose tasks involve frequent but not constant direct
exposure into a low exposure category;

3. The remaining jobs are categorized by the part being made, or the
similarity of parts being made, and all involve constant direct
exposure tasks.

There were two reasons for doing this:

1. Not all jobs existed in all plants and many involved small sample
sizes, especially among the low and no exposure groupings;

2. Ease of interplant comparison.

31


APPENDIX A
FIBERGLASS REINFORCED PLASTIC BOAT PLANT
SURVEY DATA

—— SS --- PLANT=5 ~- on ann nanan ne

OBS JOB STYRENE ACETONE COMBTLY NAME

290 10 75.40 92.90 0. 847 AFTDECK

291 10 25.00 49.80 0. 300 AFTDECK

292 ii 52.20 37.60 0.566 FLYBRIDG

293 11 55.40 45.00 0.599 FLYBRIDG

294 11 33.70 46.30 0. 383 PLYBRIDG

295 13 76.20 214.00 0.976 FUELTANK

296 13 37.90 85.60 0.435 FUELTANK

297 13 48.30 48.10 0.531 FUELTANK

298 21 77230 54.00 0.827 SANDER

299 22 21.40 20.50 0.234 PASTEMIX

300 24 4.05 4.09 0.044 AREA

301 24 35.30 80.20 0.433 AREA

302 24 66.00 60.00 0. 666 AREA

303 24 9-90 21.30 0. 120 AREA

304 24 12.80 11.90 0.140 AREA

305 24 20.40 31.170 0.235 AREA

306 24 2.14 2.30 0.023 AREA

307 24 22.10 34.90 0.256 AREA

308 24 12.50 38.00 0. 163 AREA

s— —-~ PLANT=6 - = —— a

OBS JOB STYRENE ACETONE COMBTLV NAME
309 2 60.30 108.00 0.711 HULLAM
310 2 33.60 85.30 0.421 HOLLAM
311 2 49.30 198.00 0.577 HULLANH
312 2 49.50 167.00 0.693 HULLAN
313 2 67.80 89.90 0.768 HULLAM
318 2 51.20 77.80 0.590 HULLAM
315 2 45.60 270.00 0.726 HULLAK
316 2 63.00 113.00 0.743 HULLAA
317 2 9.64 $1.50 0.178 HULLAS
318 2 62.20 183.00 0.805 HULLAM
319 2 32.00 91.30 0.411 HULLAN
320 2 25.10 116.00 0.367 HULLAA
321 2 33.80 74.30 0.412 HULLAM
322 2 75.80 214.00 0.972 HOLLAM
323 2 32. 30 101.00 0.424 HULLAK
324 2 34.60 84.10 0.430 HULLAM
325 2 25.80 49.70 0.308 HULLAM
326 2 27.20 12.70 0.285 HULLAS
327 2 33.60 2.32 0.338 HULLAM
328 2 40.10 21.60 0.423 HULLAM
329 2 57.10 18.30 0.589 HULLAN
330 2 32.80 9.56 0.338 HULLAN
331 2 22.80 38.20 0.266 HULLAM
332 2 34.20 19.00 0.361 HULLAA
333 2 15.40 7.62 0.162 HULLAM
334 2 72.80 113.00 0.841 HULLA
335 2 121.00 288.00 1.500 HULLAM

62




OBS

434
435
436
437
438
439
440
441
442
443
4uy
445
446
G47
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
aya
475
476
477
478
479
480
481
482
483
4B4
485

JOB

WWKOVOINNNVN NN SS SSE SSS EE EE WWWWWWKEWUNNNKHKHNKHNNKKKR Gee eee

STYRENE

72.2
73.9
84.2
106.0
105.0
65.6
105.0
125.0
126.0
120.0
85.9
97.7
103.0
84.9
109.0
127.0
136.0
101.0
54.6
69.2
52.5
68.5
36.0
48.5
51.0
103.0
87.2
113.0
101.0
125.0
107.0
119.0
124.0
85.6
1117.0
130.0
131.0
160.0
128.0
38.8
64.7
87.1
35.2
55.5
60.6
94.5
85.1
76.0
48.9
66.6
46.7
69.6

APPENDIX A
FIBERGLASS REINFORCED PLASTIC BOAT PLANT
SURVEY DATA

------- PLANT=7 -

ACETONE

31.6
44.2
$2.5
41.8
92.6
33.0
81.3
101.0
70.5
88.2
69.3
53.4
70.8
62.5
87.7
36.4
95.2
94.6
53.1
30.6
58.4
69.7
25.8
4t.4
49.8
63.3
52.1
97.45
90.4
123.0
93.7
82.9
89.2
58.0
112.0
98.5
79.9
101.0
79.4
40.7
71.3
122.0
7726
68.6
92.6
187.0
79.6
61.6
48.2
51.2
62.8
38.6

65

COMBTLV

0.754
0.783
0.894
1. 130
0.699
0.689
1.130
1.350
1.330
1.290
0.928
1.030
1.100
0.911
1.180
1.310
1.460
1.100
0.599
0.723
0.583
0.755
0.386
0.526
0.560
1.090
0.924
1.230
1.100
1.370
1.160
1.270
1.230
0.914
1.220
1.400
1.390
1.700
1.360
0.429
0.718
0.993
0.430
0.624
0.699
1.130
0.931
0.822
0.537
0.717
0.530
0.735

NAME

HULLCHOP
HULLCHOP
HULLCHOP
HULLCHOP
HULLCHOP
HULLCHOP
HULLAM
HULLAN
HULLAM
HULLAM
HULLAM
HULLAM
HOLLAM
HULLAN
HULLAM
HULLAM
HULLAM
HULLAM
DECKCHOP
DECKCHOP
DECKCHOP
DECKCHOP
DECKCHOP
DECKCHOP
DECKCHOP
DECKCHOP
DECKCHOP
DECKLAM
DECKLAM
DECKLAN
DECKLAM
DECKLAM
DECKLAM
DECKLAN
DECKLAN
DECKLAM
DECKLAM
DECKLAM
DECKLAM
GELCOAT
GELCOAT
GELCOAT
GELCOAT
GELCOAT
GELCOAT
GELCOAT
GELCOAT
STRILAM
STRILAM
STRILAM
STRILAM
STRILAN


APPENDIX A
FIBERGLASS REINFORCED PLASTIC BOAT PLANT
SURVEY DATA

Tmt ctr tren cre nnnnnnnnnanen— PLANTS6§ ------------- ----------- --- +++

OBS JOB STYRENE ACETONE COMBILY NAME

388 6 27.90 22.60 0. 302 SMPTLAM
389 6 14.00 6.11 0. 7146 SMDPTLAM
390 7 11.80 30.10 0. 148 GELCOAT
391 7 20.40 1222 0.204 GELCOAT
392 7 13.50 13.60 0.148 GELCOAT
393 7 12.20 10.90 0. 133 GELCOAT
394 7 8.82 22.40 0-121 GELCOAT
395 7 7.23 177.00 0.249 GELCOAT
396 7 14.30 5.13 0. 148 GELCOAT
397 7 5.30 10.90 0.000 GELCOAT
398 7 15.20 11.40 0.163 GELCOAT
399 11 75.60 82.40 0.838 FLYBRIDG
400 11 27.40 23.90 0.298 FLYBRIDG
401 11 16.80 47.30 0.215 FLYBRIDG
402 11 50.20 90.00 0.592 FLYBRIDG
403 11 64.70 16.90 0. 664 FLYBRIDG
4O4 V1 10.40 3.89 0. 143 FLYBRIDG
405 11 49.40 21.20 0.515 FLYBRIDG
406 12 19.70 49.90 0.247 HARDTOP
407 12 31.60 34.80 0.351 HARDTOP
408 12 43.50 2.22 0.435 HARDTOP
409 12 33.70 21.90 0.359 HARDTOP
410 13 11.70 26.80 0.144 FUELTANK
411 13 43.20 67.70 0.500 FUELTANK
412 13 21.60 13.40 0.229 FUELTANK
413 13 23.20 496.60 0.279 FUELTANK
414 13 9.27 1.85 0.093 FUELTANK
415 14 62.90 78.00 0.707 SOLELAA
416 14 57.50 124.00 0.699 SOLELAM
417 14 54.80 113.00 0.661 SOLELAN
418 V4 43.60 110.00 0.546 SOLELAM
419 a4 79.70 39.70 0.797 SOLELAS
420 4 29.50 12.50 0.307 SOLELAM
421 14 34.20 18.40 0.360 SOLELAMS
422 to 34.80 11.50 0.360 SOLELAN
423 14 22.80 12.00 0.240 SOLELAN
424 14 25.60 15.00 0.271 SOLELAM
G25 24 11.20 39.80 0.190 AREA

426 24 2.72 0.41 0.272 AREA

427 24 14.90 0.67 0. 149 AREA

428 24 7269 3.45 0.080 AREA

429 24 7.49 5.97 0.081 AREA

430 24 7215 27.80 0. 100 AREA

431 24 9.56 9.17 0.105 AREA

432 24 3.19 0.50 0.319 AREA

433 24 9.78 35.10 0.000 AREA

64


APPENDIX B
(JOB DICTIONARY)

67


TABLE 3

DISTRIBUTION OF STYRENE EXPOSURE BY PLANT

RANGE OF EXPOSURE (PPM)

PLANT 2-50 50-100 100-183 TOTAL
1 34 1g 0 53
2 26 21 20 67
3 13 8 17 38
4 5 39 25 69
5 25 27 10 62
6 94 21 1 116
7 12 24 23 59
ALL 209 159 96* 464

*20.6% over 100 ppm

24


death from cancer was compared to the German population and a control group
within the plant (43).

From the experimental animal investigations and from the epidemiologic
studies, there seems no basis to conclude that styrene is carcinogenic.
(B) Acetone
(i) Irritant effects

Acetone has been reported to produce irritation of the eyes, skin
and upper respiratory tract. Adverse effects on skin include intracellular
edema and disruption of the cells of the keratin layer; this due to the
lipid-solvent properties of acetone. This defatting ability suggests that
liquid acetone may cause dermatitis. Eye nose and throat irritation were
reported in a small group of workers exposed to acetone vapor for eight
hours at an average concentration of 1000 ppm. Another group of subjects
exposed to concentration of 500 and 1000 ppm had eye, nose and throat
irritation (13).
(ii) Effects on the Nervous System

Acetone has been reported to cause narcosis or signs of CNS
depression. Acute intoxication of a ten-year-old boy with acetone resulted
in collapse, stupor and incoherance. Eight workers exposed to acetone at
a concentration greater than 12,000 ppm felt dizzy, lightheaded and reported
weakness of the legs. Another study noted lightheadedness and headache
in workers exposed for eight hours at an average 1000 ppm. CNS disturbances,
such as, dizziness, inebriation, somnolence and headache were reported
among workers in a cellulose acetate fibers production plant. Exposures
ranged from 307 to 918 ppm. The authors attributed these effects to ac-

cumulation of acetone in the body resulting from repeated exposures (13).

1o


Those working in deck and other large parts (flying bridges and aft
decks) lamination also use a great deal of resin. Surface area of these parts
is not as great but is proportional to the hull size. The frame generally
holds these pieces flat or upright and there is no configuration type problem.
Directional fans are used to limit accumulation of vapor.

In small parts lamination, the number of pieces being laid-up will affect
exposure potential. The molds are laid on a table top instead of being mounted
ona frame. There are no configuration problems with these pieces.

Acetone exposure in all instances will depend on the frequency of use as
well as location of dispensing cans.

In the lamination jobs the protective equipment provided included half-
face cartridge respirators and in some plants aprons and gloves. In plants 1,
3, 4, and 6, no formal policy existed governing respirator (or other protective

equipment) use. The other plants had programs with varying enforcement policies.

16


STANDARDS

The Occupational Safety and Health Administration (OSHA) standard for
Styrene is 100 ppm (420 mg/m?) for an eight-hour TWA, 200 ppm (840 mg/m°)
for a ceiling concentration and 600 ppm (2520 mg/m?) for five minutes in any
three-hour time period (44). The American Conference of Governmental Industrial
Hygienists (ACGIH) Threshold Limit Values (tv's) “for styrene are presently
100 ppm (420 mg/m) for an eight-hour TWA and 125 ppm (525 mg/m?) for a
Short Term Exposure Limit (STEL) (The maximum exposure concentration for a
continuous 15-minute period). They propose to change these values to a 50
(215 mg/m?) ppm TLV-TWA and a 100 ppm (425 mg/m?) TLV-STEL in their Notice
of Intended Changes for 1980 (45).

The OSHA Standard for acetone is 1000 ppm (2400 mg/m?) for an eight-hour
TWA (44). NIOSH recommends a 250 ppm (590 mg/m?) exposure limit for up to
a ten-hour work-shift for acetone (13). The present ACGIH TLV-TWA for acetone
is 1000 ppm (2400 mg/m?) for an eight-hour exposure and the present TLV-STEL
is 1250 ppm (3000 g/m) . They propose a change to 750 ppm (1780 mg/m?) for
a TWA and to 1000 ppm (2375 mg/m?) for a STEL in their Notice of Intended

Change for 1980.

12


DISTRIBUTION OF ACETONE EXPOSURE BY PLANT

TABLE 4

RANGE OF EXPOSURE (PPM)

PLANT 0-100 100-200 200-400 TOTAL

1 40 12 1 53

2 56 8 3 67

3 25 12 1 38

4 42 20 7 69

5 55 6 2 62

6 95 16 5 116

7 53 6 0 59
ALL 366 80 18 464

25


HEALTH EFFECTS

(A) Styrene
(i) Irritant Effects

Irritation of the eyes, skin and of the respiratory tract of humans
has occurred due to exposure to styrene. Due to the fat-solvent proper-
ties of styrene, it has caused dermatitis, including rash and chapped skin,
in workers handling the liquid (21, 22). At 100 ppm, human subjects developed
eye, nose and throat irritation within 20 minutes of exposure (16). Workers
in plastics applications exposed to styrene for several years complained of
eye and respiratory tract irritation but were able to tolerate exposure
in excess of 500 ppm for several hours at a time (23). Workers exposed for
almost four years at 45-550 ppm complained of eye, nose and throat irritation,
and about half of them complained of shortness of breath (24). In a factory
where reinforced plastics were made, workers exposed at concentrations greater
than 100 ppm had eye irritation and 30 to 50 percent of them had upper
respiratory tract irritation (21). In another plant, workers exposed to
styrene at 25 to 75 ppm for about one year complained of cough and inflam-
mation of the upper respiratory tract (25).
(ii) Effects on the Nervous System

Experimental exposures of humans and workers exposed to styrene have
demonstrated that styrene causes acute central nervous system (CNS) depression.
At concentrations of 100 ppm or greater, CNS effects have been observed in
human subjects exposed for as little as 30 minutes. Effects such as im-
paired performance of Romberg tests, decreased manual dexterity and coordi-
nation, and increased reaction time were observed. There were also headaches,

fatigue, malaise, difficulty in concentrating, a feeling of intoxication


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77


APPENDIX

A

PIBERGLASS REINFORCED PLASTIC BOAT PLANT

OBS

486
467
488
489
490
4917
492
493
494
495
496
497
498
499
500

24

STYRENE

50.5
26.8
30.1
33-5
29.0
24.1
15.0

0.4
28.0
45.4
57.4
67.0
70.0
62.0
53.8

SUBVEY DAT

—-~-—- PLANT=7 —

ACETONE

43.50
18.40
32.90
55.10
44.10
42.20
21.40

7209
32.20
37. 10
41.20
74.60
32. 80
61.80
33.00

A

66

COMBTLV

0.549
0.286
0.334
0.390
0.334
0.283
0.172
0.011
0. 312
0.491
0.615
0.745
0. 803
0.686
0.571

NAME

STRILAM
FOAMNCHOP
FOAMCHOP
FOAMCHOP
FOAMCHOP
POAMCHOP
MOLDMASK
AREA
AREA
ABEA
AREA
AREA
AREA
AREA
AREA


24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

Bodner, A. H., Butler, G. J., and Okawa, M. T., "Health Hazard
Evaluation/Toxicity Determination Report No. 73-103-128-American
Standard Fiberglass Inc., Stockton, CA", Cincinnati, U. S. Department
of Health, Education and Welfare, Public Health Service, Center for
Disease Control, National Institute for Occupational Safety and Health
10 pp. (1974).

Chmeilewski, J., and Renke, W., “Clinical and Experimental Studies on
the Pathogenesis of Toxic Effects of Styrene-Part II. The Effect of
Styrene on the Respiratory System",

Gamberale, F., and Hullengren, M., "Exposure to Styrene - II, Psy-
chological Functions", Work, Environment and Health, Vol. 11, pp. 86-93,
(1974).

Zielhuis, R. L., Hartogensis, F., Jongh, J., Kalsbeek, J. W. H.,
and VanRees, H., "The Health of Workers Processing Reinforced Poly-
esters", in XIVth International Congress of Occupational Health,
Madrid, Sept. 16-21, 1963, Vol. 3, pp. 1092-97, (1964).

Seppalainen, A. M., Harkonen, H., "“Neurophysiological Findings
among Workers Occupationally Exposed to Styrene", Scandinavian Journal
of Work, Environment and Health, Vol. 3, pp. 140-146, (1976)

Harkonen, H., Lindstrom, K., Seppalainen, A. M., Asp, S., and Hernberg,
S., "Exposure-Response Relationship between Sytrene Exposure and
Central Nervous Functions", Scandinavian Journal of Work Environment
and Health, Vol. 4, pp. 53-59, (1978).

Vainio, H., Paakkonen, R., Ronnholm, K., Raunio, V., and Pelkonen, 0.,
"A Study on the Mutagenic Activity of Styrene and Styrene Oxide",
Scandinavian Journal of Work, Environment and Health, Vol. 2, pp.
147-51, (1976).

Milvy, P., and Garro, A. J., "Mutagenic Activity of Styrene Oxide
(1,2-epoxyethylbenzene), a Presumed Styrene Metabolite" Mutation
Research, Vol. 40, pp. 15-18, (1976).

Stoltz, D. R., Withey, R. J., “Mutagenicity Testing of Styrene and
Styrene Epoxide in Salmonella Typhimurium" Bulletin of Environmental
Contaminants and Toxicology, Vol. 17, pp. 739-42, (1977).

Loprieno, N., Prescuittini, S., Sbrana, I., Stretti, G., Zaccaro,
L., Abbondandoloa, A., Bonatti, S., Fiorio, R., and Mazzaccaro, A.,
"Mutagenicity of Industrial Compounds - VII; Styrene and Styrene
Oxide - II; Point Mutations, Chromosome Aberrations and DNA Repair
Induction Analyses", Scandinavian Journal of Work, Environment and
Health, Vol. 4, Supplement 2, pp. 169-76 (1978).

51


INTRODUCTION

This is a report on an industrial hygiene study undertaken by the
National Institute for Occupational Safety and Health (NIOSH) to document
worker exposure to styrene monomer in fiberglass reinforced plastic (FRP)
boat plants. This study was in conjunction with an epidemiologic study
to determine any chronic health problems related to this exposure. It
was expected that any ill-health effects would be more readily identified
in a group of workers with a history of relatively high exposure to styrene
monomer (the word styrene used throughout this report refers to the monomer) .
The reinforced plastics industry was chosen for study since it offered the
highest potential for worker exposure to styrene due to the type of pro-
cess used and the labor intensive nature of this process. The manufacture
of boats is one of the oldest and most extensive uses of styrene diluted
polyester resins.

Preliminary industrial hygiene and record assessment evaluations were
conducted at fifteen FRP boat manufacturing facilities. ‘Two of these
facilities were identified as appropriate for the mortality study. The
selection criteria were length of operation, completeness of records and
number of employees. Five additional plants were chosen for the industrial
hygiene characterization to obtain a broader data base with which any
health effects found may be compared. Parameters used for selection of
additional plants were production rate, number of employees and environ-

mental controls used.


prevalent in Plants 2, 3, 4, 5, and 7. However, since the last five

surveys were conducted in a two-and-one half month period and no sample
results were available before the surveys had been completed, a correction in

methodology was not possible. There was no styrene breakthrough.

22


APPENDIX A
FIBERGLASS REINFORCED PLASTIC BOAT PLANT
SURVEY DATA

----- ------------- PLANT=2 - - 2 = -----------

OBS JOB STYRENE ACETONE COMBTLV NAME

99 5 46.8 71.1 0.539 SMPTCHOP
100 5 38.6 27.6 0.414 SA&PTCHOP
101 6 30.7 70.8 0.378 SMPTLAM
102 6 25.5 53.0 0.308 SMPTLAS
103 6 27.6 55.3 0.331 SMPTLAM
104 6 39.7 81.1 0.478 SMPTLAM
105 6 36.7 42.9 0.410 SMPTLAM
106 7 29.4 17.3 0.311 GELCOAT
107 7 28.7 20.6 0. 308 GELCOAT
108 8 33.6 45.6 0. 382 STRINST
109 8 45.5 30.2 0.485 STRINST
110 8 156.0 37.4 1.597 STRINST
111 8 160.0 42.0 12642 STRINST
112 8 108.0 23.5 1.108 STRINST
113 8 120.0 34.7 1.235 STRINST
114 8 111.0 23.6 1.134 STRINST
415 8 117.0 33-2 1.203 STRINST
116 16 63.1 31.1 0.622 HODELDEV
117 16 66.6 27.2 0.693 MODELDEV
118 16 88.5 45.2 0.930 MODELDEV
119 16 88.1 45.1 0.926 MODELDEV
120 7 2724 210.0 0.484 OVERLAY
121 17 29.6 105.0 0.411 OVERLAY
122 17 10.4 23.7 0. 132 OVERLAY
123 17 14.5 55.8 0.199 OVERLAY
124 17 43.4 61.8 0.496 OVERLAY
125 17 61.3 28.8 0.642 OVERLAY

aie a --- PLANT=3 ------------- in daataheneeeneaeaeeeteeeeel

OBS JOB STYRENE ACETONE COMBTLY NAME

126 1 136.0 156.00 1.520 HULLCHOP
127 1 123.0 123.00 1.910 HULLCHOP
128 2 119.0 95.00 1.280 HULLAM
129 2 156.0 152.00 1.710 HULLAN
139 2 34.0 13.20 0.353 HULLAS
131 2 142.0 198.00 1.620 HULLAM
132 2 63.4 64.40 0.698 HULLAM
133 2 179.0 117.00 1.910 HULLAM
134 2 150.0 131.00 1.630 HULLAN
135 3 121.0 86. 80 1.300 DECKCHOP
136 3 128.0 112.00 1.390 DECKCHOP
137 4 157.0 114.00 1.620 DECKLAN
138 4 146.0 95. 40 1.560 DECKLAM
139 4 134.0 91.70 1.430 DECKLAM
140 4 114.0 69-40 1.210 DECKLAM
141 4 135.0 112.00 1.460 DECKLAM
142 4 133.0 89.30 1.420 DECKLAM
143 4 53.9 25. 10 0.564 DECKLAN
144 5 58.6 63.00 0.649 SMPTCHOP

58


APPENDIX A
FIBERGLASS REINFORCED PLASTIC BOAT PLANT
SURVEY DATA

-------- wornn---- PLANT=4 -------—-----------------------

OBS JOB STYRENE ACETONE COMBTLV NAME

191 2 108.0 91.7 1.170 HULLAM
192 2 98.9 76.2 12060 HULLAN
193 4 88.2 146.0 1.080 DECKLAN
194 4 73.3 143.0 0.876 DECKLAM
195 4 74.2 94.3 0. 846 DECKLAM
196 4 87.9 105.0 0.984 DECKLAM
197 4 126.0 181.0 1.440 DECKLAM
198 4 88.1 145.0 1.020 DECKLAN
199 4 105.0 121.0 12170 DECKLAN
200 4 111.0 162.0 1.270 DECKLAM
201 4 57.9 105.0 0.684 DECKLAMN
202 4 88.2 170.0 1.050 DECKLAM
203 4 79.4 165.0 0.959 DECKLAN
204 4 73.2 205.0 0.937 DECKLAM
205 4 94.3 187.0 1.090 DSCKLANS
206 4 69.2 125.0 0.813 DECKLAM
207 4 88.5 127.0 1.010 DECKLAM
208 4 92.0 169.0 1.320 DECKLAM
209 4 118.0 135.0 1.320 DECKLAM
210 4 109.0 180.0 1.270 DECKLAN
211 4 100.0 237.0 1.240 DECKLAMN
212 4 105.0 266.0 1.320 DECKLAM
213 4 71.8 102.0 0.820 DECKLAM
214 4 102.0 166.0 1.190 DECKLAM
215 4 158.0 227.0 1.810 DECKLAM
216 4 117.0 161.0 1.330 DECKLAM
217 4 63.8 76.0 0.714 DECKLAM
218 4 132.0 357.0 1. 680 DECKLAM
219 5 66.1 46.1 0.707 SMPTCHOP
220 5 64.2 4a. 0.686 SMPTCHOP
221 7 103.0 81.5 1.110 GELCOAT
222 7 84.0 206.0 1.050 GELCOAT
223 7 58.0 219.0 0.799 GELCOAT
224 7 29.5 16.5 0.311 GELCOAT
225 7 57.7 62.6 0. 640 GELCOAT
226 7 60.9 57.2 0.666 GELCOAT
227 7 51.0 46.2 0.556 GELCOAT
228 7 32.3 38.5 0. 361 GELCOAT
229 7 66.1 49.8 0.711 GELCOAT
230 7 78.9 53.7 0. 843 GELCOAT
231 7 102.0 70.7 1.090 GELCOAT
232 7 45.5 64.2 0.519 GELCOAT
233 16 45.0 86.6 0.537 NODELDEV
234 16 47.3 72.2 0.545 MODELDEV
235 24 60.0 83.6 0.684 AREA
236 24 60.5 66.7 0.672 AREA
237 24 47.4 76.1 0.550 AREA

60


----- naan 2-22 --- nn --- === PLANT=5 ---
OBS JOB STYRENE ACETONE
238 2 77.0 46.00
239 2 84.9 60. 30
240 2 101.0 83.50
241 2 91.0 75.30
242 2 96.6 67.40
243 2 75.0 31.70
204 2 111.0 45.00
245 2 91.3 76.40
246 2 94.1 45.00
247 2 90.6 92.90
248 2 103.0 79.00
249 2 78.1 48.40
250 2 104.0 42.50
251 2 106.0 64.60
252 2 91.0 54.30
253 4 19.6 7.02
254 4 38.0 38.20
255 4 53.6 39.70
256 4 39.7 31.00
257 4 120.0 24.80
258 4 100.0 33.60
259 4 154.0 26.30
260 4 148.0 24.70
261 4 64.8 49.80
262 4 109.0 76.50
263 4 46.2 43.10
264 4 89.0 62.00
265 4 1721 10.70
266 6 41.4 66.40
267 6 4102 140.00
268 6 33.0 62.80
269 6 52.9 112.00
270 6 35.2 75. 80
271 6 77.0 111.00
272 6 24.2 87.00
273 6 49.2 70.00
274 6 39.3 120.00
275 6 35.9 104.00
276 6 45.8 60.00
277 6 54.0 36.10
278 7 42.8 11.70
279 7 41.1 16.20
280 7 18.9 8.18
281 7 61.9 26.20
282 7 57.7 6.90
283 9 40.3 14.90
284 9 72.6 79.10
285 10 45.4 53.10
286 10 98.3 126.00
287 10 66.4 74.50
288 10 67-2 60.20
289 10 25.9 54.20

FIBERGLASS REINFORCED PLASTIC BOAT PLANT

APPENDIX A

SURVEY DATA

61

COMBTLV

0.816
0.909
1.090
0.985
1.030
0.782
1.150
0.989
0.986
0.999
12110
0.829
1.080
1.120
0.964
0.203
0.418
0.576
0.428
1.220
1.030
1.550
1.500
0.698
1.170
0.505
0.952
0.182
0.480
0.522
0.393
0.641
0.428
0.881
0.329
0.562
0.513
0.363
0.518
0.576
0.440
0.427
0.270
0.645
0.583
0.418
0.805
0.507
12170
0.783
0.732
0.313

NAME

HULLAM

HULLAM

HULLAK

HULLAN

HULLAN

HULLAN

HULLAS

HULLAM

HULLAM

HULLAS

AULLAM

HULLAM

HULLAN

HULLAM

HULLAM

DECKLAN
DECKLAM
DECKLAM
DECKLAN
DECKLAM
DECKLAM
DECKLAM
DECKLAN
DECKLAM
DECKLAMN
DECKLAM
DECKLAM
DECKLAN
SMPTLAM
SMPTLAM
SNPTLAM
SMPTLAM
SMPTLAM
SMPTLAM
SMPTLAM
SMPTLAMN
SMPTLAS
SMPTLAN
SMPTLAH
SMPTLAM
GELCOAT
GELCOAT
GELCOAT
GELCOAT
GELCOAT
STRILAM
STRILAM
AFTDECK
AFTDECK
AFTDECK
AFTDECK
AFTDECK


PLANT 5

Plant 5, located in Central North Carolina, produces six lines of power
yachts in the thirty-seven to fifty-three foot class. Production started in
1959 and was around 400 units per year at the time of the survey. There were
fifty laminators in production on two shifts. The ventilation system at Plant 5
consisted of twelve large exhaust ducts, placed at worker level throughout the
lamination area and designed to move 15,000 cubic feet per minute (CFM) of air,
with three tempered make-up air ducts rated at 60,000 CFM. However, at the time
of the survey two of the twelve exhaust ducts were not functioning. Air
velocity indicated that the system may have been in a lower mode of operation.
Production rate and energy conservation factors may have been involved. Another
feature was the placement of circular fans to direct air to the exhaust hoods.
Fans were placed aft of the mold. It should be noted here that the hull molds
were stationed in pits such that the complete structure was below grade level.
In this fashion, the styrene vapor is trapped in the hull until moved toward
the exhaust port via the fan air movement. This probably helps to keep general
area styrene levels lower than they might be otherwise. Unless the fans are
positioned properly, however, the hull lamination workers are exposed to greatly
increased levels. It was noticed that the air movement varied from line to line.
Stationary, properly aimed fans might be a solution to this problem.
PLANT 6

Production at Plant 6 began in 1960 and it presently makes power yachts
ranging from twenty-eight to fifty-eight feet. Seventy laminators worked
three shifts at the time of the survey. This plant is located in Southern
Florida. Production was at four yachts per day. The ventilation system at
Plant 6 consists of exhausted gel coat booths, a number of exhaust fans in
the west end of both lamination buildings, some circulating fans and natural

ventilation provided by the prevailing winds through the buildings. Weather

19


APPENDIX C
(Descriptive Statistics)

70




Abstract ........
Acknowledgements . .. .

Introduction. .... .
Potential Exposures . .
Chemical and Physical Properties
Routes of Exposure...
Health Effects .....
Standards. .......
Process Description . .

Plant Description ...

Description of Survey Methods

Study Results .....
Discussion. ......
Control Technology . . .
References .......

Appendix A - Sampling Results
Appendix B - Job Dictionary

CONTENTS

Appendix C - Descriptive Statistics ...

iii


and a feeling of tension (16, 26). Workers exposed to styrene for = to
twelve years at concentrations frequently greater than 100 ppm for varying
periods of time had increased tendon reflexes and increased reaction times,
headache, fatigue, malaise, tension and dizziness (21, 23, 24, 27). Ab-
normal EEG's have been found in some of the workers exposed for an average
of five years at a level estimated to be above 30 ppm for most workers, but
at or below 30 ppm in the case of a few (28). At concentrations believed
to be greater than 30 ppm as a time-weighted average TWA, abnormal EEG's
were more frequent, and decrements in visuomotor performance were greater
with increasing exposure (29). In workers exposed at an average concentration
of about 80 ppm, there was poorer performance in psychomotor tests (20).
(iii) Mutagenicity

In vitro tests of mutagenicity have indicated that styrene has little
or no mutagenic activity, but that styrene oxide, believed to be an inter-
mediate in the metabolic pathway for styrene, is mutagenic. This had been
found with S typhimurium strains TA 98, 100, 1535, 1537 and 1538 (30, 31, 32).
Mice treated with styrene oxide, but not those treated with styrene, had an
elevated incidence of aberrations in chromosomes from bone marrow cells
removed 24 hours after administration (33). On the other hand, chromosomal
changes were found to be more frequent in styrene-exposed workers than
among controls in two European plants (34, 35, 36, 37).
(iv) Carcinogenicity

The possible carcinogenicity of styrene has been investigated by long
term administration to rodents. One study, which involved vapor exposure
to rats, resulted in an increase in a combined incidence of leukemia and

lymphosarcoma that was not statistically significant (38). In another




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The pigments in gel coat are used for color, since this layer will appear as
the outside surface of the boat, and for resistance to ultraviolet deterioration.
The name gel coat stems from the fact that when the coat reaches a gel state,
the remainder of the laminate is applied.
Methods of contact molding, or lamination, varied between companies.
Plants 2, 5, and 6 used only hand lay-up techniques. That is, the parts were
constructed of alternating layers of chopped strand mat and woven roving, with
each layer being wetted with resin. Plant 4 used spray-up to manufacture some
of the smaller pieces but the process was extensively hand lay-up. Plants 1,
3 and 7 used a combination of hand lay-up and spray-up. These parts were cons-
tructed of alternating layers of chopped fiberglass from a chopper gun and
woven roving. The chopped glass layer is, of course simultaneously mixed with
resin as it is applied. The woven roving layer requires wet-out which is done
using only the spraying mode of the chopper-gun. The chopped layer requires roll-
out to compact the fiberglass and resin. The other layers, whether chopped-
strand mat or woven roving, are usually squeegeed to insure saturation and to
remove excess resin. A reason given, aside from any economic considerations,
for choosing chopped-strand mat over spray-up, was the layer uniformity that this
technique offers, resulting in uniform strength and flexibility of the piece.
Following lamination, structural support is necessary on certain parts.
Plywood and end grain balsa wood are two materials used for this support.
The wood is positioned and then overlayed with fiberglass and resin to secure
it in place. Chopped fiberglass, either from a gun or in mat form is generally
used for this.
The following discussion addresses the factors affecting exposures in

the lamination jobs.

14


Ges iiNicAk REPORT or

Extent of Exposure to
Styrene in the Reinforced
Plastic Boat Making Industry

U.S. DEPARTMENT OF HEALTH AND HUMAN SERVICES
Public Health Service

Centers for Disease Control

National Institute for Occupational Safety and Health


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TABLE 11

+
P-Values for Job Category Comparisons Within Plants

Job Category Plant Plant Plant Plant Plant Plant Plant
Comparison 1 2 3 4 5 6 7
Hull vs. Deck* 0.0528 0.0001 0.6495 0.3499 0.0226 0.0594 0.2514
Hull vs. Small Parts* 0.5288 0.0001 0.4835 0.0392 0.0001 0.9379 0.0009
Hull vs. Gelcoat* 0.1616 0.0005 0.0132 0.0001 0.0008 0.0002 0.0008
Hull vs. Large Parts 0.0012 0.0821

Hull vs. Low Exposure 0.0001 0.0023 0.0001
Hull vs. No Exposure 0.0001 0.0001 0.6980 0.0001
Hull vs. Model Develop 0.7809 0.4409 0.0002

Deck vs. Small Parts* 0.1815 0.1526 0.3154 0.0849 0.0531 0.2237 0.0073
Deck Ys. Gelcoat* 0.9648 0.2179 0.0058 0.0001 0.0803 0.0001 0.0085
Deck Ws. Large Parts 0.2337 0.7564

Deck vs. Low Exposure 0.0203 0.0234 0.0001
Deck vs. No Exposure 0.0001 0.0001 0.6412 0.0001
Deck Vs. Model Develop 0.3294 0.0231 0.0007

Small Parts vs. Gelcoat* 0.3211 0.7153 0.1326 0.6806 0.6825 0.0010 0.7722
Small Parts vs. Large Parts 0.5799 0.1349

Small Parts vs. Low Exp. 0.3287 0.1059 0.0004
Small Parts vs. No Exp. 0.0001 0.0001 0.2429 0.0002
Small Parts vs. Model Dev. 0.6279 0.0016 0.2025

Gelcoat vs. Large Parts 0.4346 0.0001
Gelcoat vs. Low Exposure 0.1815 0.0001
Gelcoat vs. No Exposure 0.0010 0.0026 0.1991 0.0001
Gelcoat vs. Model Develop. 0.3503 0.0096 0.2107

Large Parts vs. Low Exp. 0.0735

Large Parts vs. No Exp. 0.3480

Large Parts vs. Model Dev.

Low Exp. vs. No Exposure 0.0446 0.0702
Low Exp. vs. Model Develop. 0.002

No Exp. Ws. Model. Dev. 0.0031

ALL 0.001 0.001 0.001 0.001 0.002 0.001 0.001

*Indicates Major Job Category Comparisons
+Significance is indicated for p <0.05

37


POTENTIAL EXPOSURES

Exposure to styrene is directly related to the use of thermoset poly-
ester resins. The polyester resin system used in the FRP boat industry is a
mixture of styrene monomer, glycols (propylene glycol or diethylene glycol),
saturated acid (phthalic anhydride or isophthalic anhydride), maleic anhydride
and inhibitors. The handling of resins after manufacture does not involve
exposure to these chemicals other than at trace levels, since they are sub-
stantially converted to polyester (1). The styrene content in the resin is
approximately forty percent (by weight) (1, 2). It is both a reactant and a
diluting solvent. During manual spray-up and lay-up operations, ten to fif-
teen percent of the styrene can evaporate into the work place air (1, 3). The
remainder is consumed in the chemical reaction. The hardening system used
may contain a cobalt salt (cobalt haphthenate) as an initiator and a hydro-
peroxide (methylethylketone peroxide (MEKO) or benzoyl peroxide) as a catalyst
(1, 2). An attempt was made to determine exposure levels to MEKO. The ana-
lytical results were inconclusive, and the significance of exposure to this
substance was not determined. Acetone is the only other compound likely to
be present in large concentrations in the vapor phase. Its copious use as
a solvent for cleaning laminating tools, spraying equipment and workers'
hands warranted documentation of exposure levels. Its high vapor pressure
(226.3 mm Hg @ 25°C) causes it to readily evaporate into ambient air from
open containers. The presence of fiberglass dust was virtually nonexistant

in the laminating areas and therefore was not quantitated.


This report will describe the compounds to which exposure was
quantitated and known health effects associated with exposure, the process
involved in FRP boat fabrication, the plants surveyed, and survey methods
and results. Statistical analyses will be used to determine how the plants
involved compare with respect to control of exposure. A discussion of

control technology applicable to this industry is included.


13.

14.

15.

16.

17.

is.

19.

20.

21.

22.

23.

“criteria for a Recommended Standard", Occupational Exposure to
Keytones, U. S. Department of Health and Human Services, Public Health
Service, Center for Disease Control, NIOSH Publication No. 78-173, U.
S. Government Printing Office, Washington, D.C., (1978).

Perry, R. H., Chilton, C.H., "Physical and Chemical Data", Chemical
Engineers' Handbook, 5th Ed., McGraw Hill, 1976.

Bardodej, Z., "Styrene Metabolism", Ceskoslovenska Hygiene, Vol. 9,
No. 4, pp. 223-36, (1968), (Czech).

Steuart, R. D., Dodd, H. C., Baretta, E. D., and Schaffer, A. W.,
“Human Exposure to Styrene Vapor", Archives of Environmental Health,
Vol. 16, pp. 656-62, (1968).

Riihimaki, V., and Pfaffli, P., "Percutaneous Absorption of Solvent
Vapors in Man", Scandinavian Journal of Work, Environment and Health,
Vol. 4, pp. 73-85, (1978).

Dutkiewicz, T., and Tyras, H., "Skin Absorption of Tolvene, Styrene and
Xylene by Man", British Journal of Industrial Medicine, Vol. 25, p. 243,
(1968).

Gotell, P., Axelson, O., and Lindelof, B., "Field Studies on Human
Styrene Exposure", Vol. 9, pp. 76-83, (1972).

Brooks, S. M., Anderson, L. A., Tsay J-Y, Carson, A., Buncher, C. R.,
Elia, V., Emmett, E. A., "Investigation of Workers Exposed to Styrene
in the Reinforced Plastic Industry -- Health and Psychomotor Status,
Toxicologic and Industrial Hygiene Data and Effects of Protective
Equipment as it Relates to Exposures through Lung and Skin Routes",
University of Cincinnati, College of Medicine, Institute of Environ-
mental Health and Kettering Laboratory Report Prepared for the Society
of Plastics Industries, 330 pp., 1979.

Rosensteel, R. E., and Meyer, C. R., "Health Hazard Evaluation Deter-
mination Report No. 75-150-378-Reinell Boats, Inc., Poplar Bluff,
Mo.", Cincinnati, U. S. Department of Health, Education and Welfare,
Public Health Service, Center for Disease Control, National Institute
for Occupational Safety and Health, 52 pp., (1977).

Golebiowska-Podgorezyk, I., "Clinical and Experimental Studies on the
Pathogenesis of Toxic Effects of Styrene - Part I. Evaluation of the
Role of Styrene in the Occurrence of Occupational Dermatoses",

Gotell, P., Axelson, O., and Lindelof, B., "Field Studies on Human
Styrene Exposure", Work, Environment, Health, Vol. 9, pp. 76-83, (1972).

50


TABLE 8

JOB CATEGORY GROUPINGS

Category Job Category Job
Hull Hullchopper Large Parts Aft Deck Lay-up
Hull Hand Lay-up Fly Bridge Lay-up
Stringer Installation Hardtop Lay-up
Sole Lay-up
Deck Deck Chopper
Deck Hand Lay-up Low Exposure Overlay
Foam & Chop
Small Parts Small Parts Chopper Paste Mixer
Small Parts Hand Lay-up
Stringer Lamination No Exposure Mold Work
Fueltank Paste Mixer
Clean-up
Gelcoat Gelcoat Sander
Mold Masking

Modél
Development

Model Development

33


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DESCRIPTION OF SURVEY METHODS

Charcoal tube sampling is considered a most reliable and effective method
for determining levels of organic chemical vapors and was the method used to
collect all styrene and acetone samples. The sampling train used to collect the
TWA personal and area samples included an MDA Accuhaler® Model 808 sampling
pump connected to a charcoal tube with Tygon tubing. The sampling flow rates
were determined by using 20, 50, and 100 cc/min. limiting orifices. The charcoal
tubes used contained 150 mg of activated coconut shell carbon divided into a
100-mg front section and a 50-mg back-up section separated by a two-mm portion
of urethane foam. The charcoal tube was attached to the collar or lapel in
the worker's breathing zone. The workshift at Plant 1 was divided into three
sampling periods using the 50 cc/min and 100 cc/min flow rates. At Plant 2
the workshift was divided into two sampling periods, again using the 50 cc/min
and 100 cc/min flow rates. During the remaining five surveys, single sample
full shift monitoring at 20 cc/min was used. Sampling times for all surveys
averaged seven and one-half hours per shift.

Analysis of the charcoal tube samples was conducted in accordance with
NIOSH analytical method number P&CAM 127, for organic solvents in air (46).

This is a gas chromatographic method using carbon disulfide as desorbent and

a flame ionization detector. Each sample was analyzed for styrene and acetone.
The lower limits of detection were 0.01 mg/sample for styrene and 0.02 mg/sample
for acetone.

After analysis, it was found that 198 of 464 (42.2%) personal samples
collected had acetone breakthrough (defined as greater than one-third of

the total sample contained in the back-up section charcoal). This condition was

21


TABLE 12

P-Values for Chopper and Hand Lay-up Job Comparisons Within Plants *

PLANT

Job Comparison 1 2 3 7
Hull Chopper Vs. Hull Hand

Lay-Up 0.4246 0.5530 0.0247
Deck Chopper vs. Deck Hand

Lay-up 0.8800 0.0001
Smallparts Chop. vs. Small

Parts Lay-up 0.0007. 0.2723

* Significance is indicated for Ps0.05

38


conditions at this plant location allow for the buildings to be open year round.
The flow through the gel coat booths is reported to be between 130-160 cubic
feet per minute.
PLANT 7

Plant 7, located in Northcentral Minnesota, produces power boats in the
fifteen to twenty-five foot range. This plant opened in 1955 and made fifteen
boats a day using around thirty laminators on one shift at the time of the
survey. During peak periods, production reached seventy-five units per day.
The ventilation system at this plant was comprised of exhaust ventilation
through the five gelcoat booths and four ceiling exhaust fans in the lamination
areas (rated at 30 cubic ft/minute each), with tempered make-up air coming
from ceiling duct work. Due to weather conditions in this region, seasonal
exposures can differ greatly. During warmer months, the use of natural
ventilation increases, augmenting existing controls, leading to lower exposure
potential.

Plants 4, 5, 6, and 7 had medical programs requiring preemployment
physicals. Plant 7 required a follow-up physical every two years. Plants
1, 2, and 3 had no medical program. Every plant had a safety program with
safety equipment being supplied, but not always required. This generally in-
cluded safety glasses, proper respiratcry protection and gloves. Industrial
hygiene monitoring was available to all plants from a variety of sources.
Plants 4, 5, and 6 had industrial hygiene support provided by corporate per-
sonnel. The other plants were monitored, as needed, by state programs or in-
surance carriers. All of the facilities monitored in this study were enclosed
structures and general dilution ventilation was provided with varying degrees

of natural ventilation.

20


APPENDIX A
FIBERGLASS REINFORCED PLASTIC BOAT PLANT
SURVEY DATA

weeen- + 2-3 +--+ +++ === PLANT=1 - -----------—

OBS JOB STYRENE ACETONE COMBTLY WANE

53 16 53-70 14. 40 0.551 MODELDEV
5a 24 8.62 3.09 0.086 AREA
55 24 35.10 3-95 0.355 AREA
56 24 31.70 3.74 0.320 AREA
57 24 25.90 11.70 0.270 AREA
58 24 30.10 10. 40 0.311 AREA

tere manne nnn nn ane = PLANT=2 ---------------------------—---

OBS JOB STYRENE ACETONE COMBTLY NAME

59 2 47.9 90.0 0.569 HULLAM
60 2 4702 60.8 0.533 HULLAM
61 2 50.8 54.2 0.564 HULLAM
62 2 51.8 $2.9 0.571 HULLAS
63 2 100.0 116.0 12116 HULLAM
64 2 94.6 113.0 1.059 HULLAN
65 2 70.6 54.3 0.760 HULLAM
66 2 60.0 79.8 0.680 HULLAM
67 2 59.1 67.5 0.659 HULLAN
68 2 87.7 60.8 0.938 HULLAM
69 2 89.7 73-6 0.971 HULLAM
70 2 117.0 109.0 1.279 HULLAM
71 2 175.0 110.0 1.861 HULLAM
72 2 60.3 18.0 0.621 HULLAM
73 2 56.2 18.0 0.578 HULLAM
74 2 109.0 54.3 1.144 HULLAS
75 2 104.0 53-3 1.093 HULLAM
76 2 183.0 64.2 1.894 HULLAS
77 2 172.0 64.8 1.785 HULLAM
78 2 140.0 66.0 1. 466 HULLAM
79 2 143.0 63.5 12494 HULLAM
80 2 105.0 98.2 1.148 HULLAN
81 2 106.0 102.0 1.162 HULLAM
82 2 61.7 45.4 0.662 HULLAM
83 2 60.6 40.1 0.646 HULLAM
84 2 121.0 78.9 1.289 HULLAM
85 2 121.0 718.7 1.289 HULLAM
86 4 38.2 55.8 0.438 DECKLAN
87 4 40.0 59.0 0.459 DECKLAS
88 4 54.7 86.5 0.633 DECKLAM
89 4 24.3 36.0 0.279 DECKLAM
90 4 50.5 42.4 0.547 DECKLAM
91 4 52.0 55.7 0.576 DECKLAN
92 4 58.3 252.0 0.835 DECKiLAN
93 4 31.4 31.0 0.345 DBCKLAN
94 4 36.7 30.0 0.397 DBCKLAM
95 4 48.7 112.0 0.599 DECKLAM
96 4 48.1 116.0 0.597 DECKLAA
97 4 53.1 212.0 0.743 DECKLAM
98 5 23.7 29.0 0.266 SMPTCHOP

57


ACKNOWLEDGEMENTS

The author wishes to acknowledge the contributions of Dr. Robert L. Harris
and Dr. Gary G. Koch from the University of North Carolina at Chapel Hill,
and the following former and current NIOSH employees who assisted in these
surveys: Mark Boeniger, George A. Carson, Ph.D., Dave Childs,

Richard W. Hartle, Charles S. McCammon, Theodore J. Meinhardt and

Larry Smith. The funding for this work was provided by the Division of
Cancer Cause and Prevention, National Cancer Institute through the
Interagency Agreement on Research on Occupational Carcinogenesis
(Y-01-CP-60605).

vit


(iii) Mutagenisis and Carcinogenisis
No reports that implicated acetone as a mutagen or carcinogen were

found.
(Cc) Summary

Exposure to liquid styrene and liquid acetone can cause dermatitis due
to fat-solvent properties of both liquids. Both vapors have shown to be
irritants to the eyes and upper respiratory tract. Inhalation of styrene
vapor at 50 ppm and higher can cause CNS depression leading to poorer
Psychomotor performance. Exposure to acetone vapor at 310 ppm and greater
can also cause CNS disturbances. It is not unlikely that these acute
effects may be additive at concentrations found in a reinforced plastics
manufacturing plant. Such effects could lead to serious consequences in the
workplace.

Presently available information does not indicate that either styrene

or acetone are carcinogenic.

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73


A strategy for validating work practices in the reinforced plastics
indsutry was applied by Conrad et al from the University of Kansas under a
NIOSH contract (51). In this study the indices of personal exposures de-
creased by up to 74 percent following training for workers with the greatest
exposures, and potentially the most control over their exposures.

The only drawback to work practice guidelines is that they are only
as effective as the training program provided to teach them.

In summary, there is area for improvement in exposure control in most
Plants making reinforced plastic boats. In some cases the use of dilution
ventilation is adequate. In general, however, improvement in present plant
environments will be seen if dilution ventilation is augmented by one of or
a combination of local ventilation, styrene-suppressed resins and work
practices guidelines. Research in these areas can lead to optimal use of

each of these features.

48




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76


JOB CODE

Hullchop - Hull Chopper
Hullam - Hull Lay-up
Deckchop - Deck Chopper
Decklam - Deck Lay-up
Smptchop - Small Parts Chopper
Smptlam - Small Parts Lay~-up
Gelcoat - Gelcoat

Strinst - Stringer Installation
Strilam - Stringer Lamination
Aftdeck - Aft Deck Lay-up
Flybridg - Fly Bridge Lay-up
Hardtop - Hard Top Lay-up
Fueltank - Fueltank Lay-up
Solelam - Sole Lay-up
Moldwork - Moldwork

ModelDev - Model Development
Overlay - Overlay

Foamchop - Foam & Chop
Forklift - Forklift

Cleanup - Clean up

Sander - Sander

Pastemix - Paste Mixer
Moldmask - Mold Masking

Area

55


TABLE 6

GEOMETRIC MEAN STYRENE EXPOSURES BY JOB WITHIN ALL PLANTS

JOB PLANT
1 2 3 4 S) 6 7

Hull Chopper 37.1 129 83.0
Hull Hand Lay-up 48.5 88.2 106 99.3 92.3 27.4 109
Deck Chopper 124 60.5
Deck Hand Lay-up 33.5 43.4 118 92.5 62.4 34.6 117
Small Parts

Chopper 35.0 74.3 65.1
Small Parts

Hand Lay-up 42.6 31.6 117 42.4 31.1
Gelcoat 33.1 29.0 61.4 59.7 41.2 11.2 61.6
Stringer Installation 94.6
Stringer Lamination 54.1 58.6
Aft Deck Lay-up 51.6
Fly Bridge Lay-up 46.0 34.5
Hardtop Lay-up 30.9
Fueltank Lay-up 51.8 18.8
Sole Lay-up 41.2
Moldwork 10.9 33.5
Model Develop. EXE)o7/ 75.6 46.2
Overlay 26.2
Foam & Chop 28.5
Forklift 19.4
Clean-up 30.4
Sander 77.3
Paste Mixer 21.4
Mold Masking 15.0
ALL 37.3 59.8 70.3 85.5 57.8 28.1 73.8

28


10.

ll.

12.

13.

APPENDIX B
Job Dictionary

Hull Chopper - A job whose main task involves the application of a
catalyzed resin, chopped fiberglass mixture to the hull mold using a
chopper gun.

Hull Lay-up - A job whose tasks involve hand manipulation of resin, fiber-
glass and their composite on the hull mold, including squeegeeing and
roll-out.

Deck Chopper - A job whose main task involves the application of a
catalyzed resin, chopper fiberglass mixture to the deck mold using a
chopper-gun.

Deck Lay-up - A job whose main tasks involve hand manipulation of
resin, fiberglass and their composite on the deck mold, including
squeegeeing, and roll-out. .

Smallparts Chopper - A job whose main taks involves the application
of a catalyzed resin, chopper fiberglass mixture to various small
parts molds using a chopper-gun.

Smallparts Lay-up - A job whose tasks involve hand manipulation of
catalyzed resin, fiberglass and their composite on various small
parts molds, including squeeging and roll-out.

Gelcoat - A job whose taks involves the applications of gelcoat, a
pigmented polyester resin, to all molds as a first step in the
fabrication procedure.

Stringer Installation - A job involving the fixing of longitudinal
supports to the bottom of a hull with resin and fiberglass composite.

Stringer Lamination - A job involving the fabrication of hull stringers
from resin and fiberglass composite.

Aft Deck Lay-up - A job involving the hand manipulation of catalyzed
resin, fiberglass and other composite on the aft deck mold, including
squeegeeing and roll-out.

Fly Bridge Lay-Up - A job involving the hand manipulation of catalyzed
resin, fiberglass and their composite on the flying bridge mold, including
squeegeeing and roll-out.

Hardtop Lay-up - A job involving the hand manipulation of catalyzed resin,
fiberglass and their composite on the hardtop mold, including squeegeeing
and roll-out.

Fueltank Lay-up - A job involving the hand manipulation of catalyzed

resin, fiberglass and their composite on the Fueltank Mold, including
squeegeeing and roll-out.

68


TABLE 7

GEOMETRIC MEAN ACETONE EXPOSURES BY JOB WITHIN ALL PLANTS

JOB PLANT.
1 2 3 4 5 6 7
Hull Chopper Soe} 139 45.9
Hull Hand Lay-up 24.3 64.1 86.8 77.9 58.3 41.1 73.2
Deck Chopper 98.6 47.2
Deck Hand Lay-up 69.7 70.7 77.9 153 30.4 25.7 90.6
Small Parts Chopper 38.5 89.1 45.1
Small Parts Hand Lay-up 125 59.1 164 81.8 40.7
Gelcoat 62.5 18.9 50.2 63.9 12.3 13.4 84.5
Stringer Installation 32.9
Stringer Lamination 34.3 50.2
Aft Deck Lay-up 69.1
Fly Bridge Lay-up 42.8 27.4
Hard Top Lay-up 17.0
Fueltank Lay-up 95.9 18.4
Sole Lay-up 34.3
Moldwork 34.3 30.6
Model Development 14.4 36.2 79.0
Overlay 61.1
Foam and Chop 36.2
Forklift 12.2
Clean-up 25.3
Sander 54.0
Paste Mixer 20.5
Mold Masking 21.4
ALL 50.6 54.3 59.3 95.6 47.6 31.0 61.7

29


There were a few plants identified in this study as being homogeneous
with respect to all job category exposures. These same plants exhibited
overall inadequate control of exposure to styrene, which is in line with
plants having similar ventilation efficiencies having similar exposures
among the job categories. While they should individually be evaluated to
identify unique plant specific problems, ventilation system redesign is

most likely necessary for these plants.

44


PLANT DESCRIPTIONS

From June 1978 to March 1979, environmental monitoring was conducted
at seven FRP boat manufacturing facilities. Plants 1 and 2 were the ones
included in the mortality study. Following is a brief description of these
plants:
PLANT 1

Plant 1 produces approximately 400 power boats per year in the seventeen
to twenty-eight foot range. Production began in 1952. The plant is located
in Southwestern Washington and had around thirty-five people working in
lamination during the survey, most of them women. Environmental control
consisted of exhaust ventilation through the gelcoat booth and make up air
from natural sources (open windows and doors). No tempering was provided.
Mobile fans were used for directing air flow.
PLANT 2

Plant 2 manufactured power and sailing boats from twenty-six to forty-two
feet in length at a rate of around 350 per year. They also produced eighteen
to fifty-six foot vessels under contract with the U. S. Navy. The plant was
located in Northwestern Washington. There were approximately fifty laminators
working during the survey. At peak production periods they employed close to
ninety workers in lamination. The ventilation system included exhaust from
the gel coat booth and two large (4 foot diameter) exhaust fans in the lower
wall of the laminating area. A number of mobile fans were used for directing
air flow. Make up air was provided from natural sources. This plant was
destroyed by fire in 1980.
PLANT 3

Plant 3 makes approximately twenty-five different boat models ranging from

fourteen to thirty-four feet. At the time of the survey, production was at

17


less styrene evolution from these than from their general purpose resins.
The mechanism which produces this effect is an additive which migrates
to the surface of the resin after catalyst is added and forms a barrier
preventing the evaporation of styrene (1).

Schumacher et al conducted laboratory and in-plant testing of two
styrene~suppressed resins. In the laboratory tests one resin showed a
reduction of about 30 percent of styrene in the vapor phase. The plant
test showed no difference in employee exposure to styrene using another type
of styrene-suppressed resin {49). Plant 5 has also reported testing of these
types of resins subsequent to the NIOSH survey (50). Some results of this
in plant testing have indicated reductions in styrene exposure of nearly
fifty percent.

As with many innovations there are problems to be solved in regard to
the use of styrene-supressed resins. Primarily there may be differences
in the mechanical properties of finished plastic, such as reduced inter-
laminar adhesion (1,50). Most agree that the development of a satisfactory
resin of this type is a long way off.

Work Practice Guidelines

If properly conceived and implemented work practices can be very
effective in exposure control, it is an opportunity for the workers to
become directly involved. There are always choices to be made when per-
forming job tasks, and education in the right choice at the right time
can have an effect. Examples are things like spraying resin away from
fellow workers and toward ventilation when possible; being certain that sol-
vent containers are closed when appropriate; and minimizing overspray on
to floors and walls. Other advantages to work practices are better house-

keeping and more efficient operations.

47


APPENDIX A
FIBERGLASS REINFORCED PLASTIC BOAT PLANT
SURVEY DATA

-—-a----- PLANT=1 --------- os

OBS JOB STYRENE ACETONE COMBTLY NAME

1 1 34.00 8.22 0.348 HULLCHOP

2 1 40.30 10.60 0.414 HULLCHOP

3 2 50.00 42.18 0.512 HULLAN

4 2 50.90 14.40 0.522 HOLLAN

5 2 61.30 18.10 0.630 HULLAA

6 2 29.80 16.90 0.315 HULLAM

7 2 59.20 12.00 0.604 HULLAA

8 2 67.00 48.00 0.718 HULLAS

9 2 61.00 25.60 0.636 HULLAMN
10 2 65.80 33.20 0.691 HULLAM
11 2 65.30 48.00 0.701 HULLAS
12 2 54.80 17.10 0.565 HULLAS
13 2 47.70 67.80 0. S44 HULLAA
14 2 23.20 29.00 0. 261 HULLAM
15 2 82.70 23.50 0.851 HULLAMN
16 2 65.90 16.40 0.675 HULLAM
17 2 49.00 19.80 0.509 HULLAA
18 2 12.00 45.00 0. 165 HULLAM
19 4 28.70 68.60 0.355 DECKLAM
20 4 30.80 64.20 0. 372 DECKLAN
21 4 53.60 93.40 0.629 DECKLAN
22 4 66.20 102.00 0.763 DECKLAN
23 4 46.50 42.30 0.507 DECKLAM
24 4 46.80 56.80 0. 534 DECKLAM
25 4 44.20 126.00 0.568 DECKLAS
26 4 22.40 77.70 0. 302 DECKLAM
27 4 12.30 43.80 0. 167 DECKLAM
28 4 39.90 76.00 0.474 DECKLAB
29 4 18.00 57.00 0.237 DECKLAMN
30 6 50.20 90.30 0.592 SMNPTLAM
31 6 33.30 107.00 0.437 SAPTLAM
32 6 33.50 114.00 0.449 SMPTLAM
33 6 59.70 62.70 0.659 SMPTLAM
34 6 84.70 133.00 0.979 SMPTLAN
35 6 41.20 120.00 0.532 SMPTLAN
36 6 39.20 199.00 0.590 SMPTLAM
37 6 40.50 132.00 0.537 SMPTLAM
38 6 38.20 174.00 0.556 SMPTLAN
39 6 44.40 108.00 0.552 SNPTLAN
40 6 71230 396.00 1.109 SmPTLAM
44 6 20.10 79.20 0.280 SMPTLAM
42 6 20.20 81.70 0.289 SMPTLAM
u3 6 52.00 164.00 0.683 SMPTLAM
4y 6 58.90 125.00 0.714 SAPTLAK
4S 7 31.50 97.80 0.412 GELCOAT
46 7 44.90 56.90 0.506 GELCOAT
47 7 22.50 55.60 0.280 GELCOAT
48 7 37.80 49.30 0.427 GELCOAT
49 15 7234 16.90 0.090 MOLDWORK
50 a5 8.38 23.50 0.106 MOLDWORK
51 15 19.10 65.40 0. 256 MOLDWORK
52 15 12.20 53.50 0.176 MOLD WORK

56


ABSTRACT

Industrial hygiene surveys were conducted in seven fiberglass rein-
forced plastic boat fabrication plants. This study was designed to
quantitate worker exposure patterns to styrene monomer. Exposure to
acetone was also measured. There were 464 personal air samples collected
in all (results of 96 of these are in excess of the OSHA eight-hour time
weighted average standard of 100 parts per million). Statistical analyses
were conducted to assess the comparability of certain job categories among
the seven plants and within each plant.

Results show that there are differences in exposure among the job
categories which may be indicative of resin use patterns. Also, plants
with similar ventilation efficiency (as indicated by overall plant styrene
levels) showed job category exposure similarities interplant. Dilution
ventilation is indicated as being an adequate control measure in some
plants. Control technology discussion proposes that in conjunction with
general ventilation, the use of local ventilation, styrene-suppressed
resins and work practice guidelines can be effective control methods in

those plants with over-exposure problems.

iii


TABLE 10

JOB CATEGORY DESCRIPTIVE STATISTICS BY PLANT

JOB CATEGORY

Hull
Geo. Mean (ppm)
cv (%)

Deck
Geo. Mean (ppm)
cv (%)

Small Parts
Geo. Mean (ppm)
cv (%)

Gelcoat

Geo. Mean (ppm)
cv (%)

Large Parts
Geo. Mean (ppm)

cv (%)

Low Exposure
Geo. Mean (ppm)

cv (%)

No Exposure
Geo. Mean (ppm)

cv (%)

Model Development
Geo. Mean (ppm)

cv (%)

ALL
Geo. Mean (ppm)
cv (%)

47.1 89.6 111

(11.0) (7.6) (17.7)

33.5 43.4 120

(15.4) (7.6) (10.4)

42.6 32.8 93.4

(10.4) (38.5) (16.9)

33.1 29.0 61.4

(14.8) (1.2) (13.9)

26.2
(27.1)

10.9 30.1

(21.5) (12.3)
53.7 75.6
- (9.0)

37.3 59.8 70.3

PLANT
4

99.3
( 4.6)

92.5
( 4.7)

65.1
(14.6)

59.8
(11.6)

85.5

(7.8) (7.6) (11.4) ( 4.1)

36

92.4 27.4 99.5
( 3-1) (12.0) ( 5.0)

62.3 34.6 88.4
(20.0) ( 9.7) ( 8.9)

45.2 27.0 58.6

(7.5) (11.4) ( 8.6)

41.2 11.3 61.6
(21.1) (13.8) (13.0)

49.8 36:8
(14.5) (11.4)

21.4 28.5
oS (51.5)
77.3 15.0

57.8 28.1 73.8
(6.7) ( 6.4) ( 6.7)


TABLE 9

JOB CATEGORY SAMPLING FREQUENCY DISTRIBUTION BY PLANT

PLANT
1 2 3 4 8 6 7 TOTAL

JOB CATEGORY

Hull 18 35 9 27 al 46 18 168
Deck 11 12 9 26 13 22 21 114
Small Parts 15 8 4 2 17 18 6 70
Gelcoat 4 2 5 12 5 9 8 45
Large Parts 1o 21 31
Low Exposure 6 1 5 12
No Exposure 4 11 1 1 17
Model Development 1 4 2 7
TOTAL 53 67 38 69 62 116 59 464

34


APPENDIX A
FIBERGLASS REINFORCED PLASTIC BOAT PLANT
SURVEY DATA

wee ---------- ==. --- PLANT=3 ----------- —--------------.

OBS JOB STYRENE ACETONE COMBTLV MANE

145 5 94.1 126.00 1.170 SMPTCHOP
146 6 130.0 209.00 1.510 SMPTLAN
147 6 106.0 128.00 1.190 SMPTLAN
148 7 94.5 34. 20 0.979 GELCOAT
149 7 72.6 79.80 0. 806 GELCOAT
150 7 46.2 126.00 0.588 GELCOAT
151 7 60.6 29.50 0.636 GELCOAT
152 7 45.3 31.60 0.485 GELCOAT
153 15 49.0 23.90 0.514 MOLDWORK
154 15 40.0 18.50 0.418 MOLDWORK
155 15 37.1 27.80 0.399 MOLD WORK
156 15 19.2 20.40 0.212 MOLDWORK
157 15 18.2 40.00 0.222 MOLDWORK
158 15 27.4 32.00 0.306 KOLDWORK
159 15 43.6 56.30 0.492 MOLDWORK
160 15 52.6 42.60 0.569 MOLD WORK
161 19 18.8 277 0.286 FORKLIFT
162 19 20.1 15.20 0.216 FORKLIFT
163 20 30.4 25.30 0.329 CLEANUP
164 24 39.3 17.50 0.411 AREA

165 24 25.3 13.80 0.267 AREA

or on nn nn - PLANTH=4 —<. ------- a

OBS JOB STYRENE ACETONE COMBTLY NAME

166 2 80.5 57.7 0.863 HULLAM
167 2 116.0 74.7 1.240 HULLAM
168 2 114.0 79.0 1.220 HULLAN
169 2 99.4 86.9 1.080 HULLAM
170 2 7827 50.4 0.837 HULLAM
171 2 102.0 62.7 1.080 HULLAA
172 2 80.3 71.8 0.875 HULLAM
173 2 96.4 148.0 12110 HULLAN
174 2 71.4 87.3 0.801 HULLAS
175 2 74.8 81.3 0.829 HULLAS
176 2 87.6 98.8 0.975 HULLAM
177 2 146.0 95.7 1.560 HULLAM
178 2 124.0 84.9 1.320 HULLAM
179 2 89.4 63.1 0.957 HOLLAM
180 2 106.0 7528 1.140 HULLAN
181 2 102.0 54.4 1.070 HULLAM
182 2 53-8 81.0 0.619 HULLAK
183 2 93.4 7121 1.000 HULLAS
184 2 153.0 91.6 1.620 HULLAM
185 2 142.0 80.4 12500 HULLAA
186 2 126.0 81.9 1.340 HULLAM
187 2 138.0 87.4 1.470 HULLAM
188 2 85.9 51.0 0.910 HULLAK
189 2 88.7 83.4 0.970 HULLAM
190 2 99.4 90.2 1.080 HULLAN

59


TABLE 2

PROPERTIES OF ACETONE

Synonyms a 2-Propanone, dimethylketal,
dimethyl ketone, beta-ketoacopane,
methyl ketone, pyroacetic ether,
pyroacetic spirit

CH.

Molecular formula C3H60 3
c=0
CH.
Pormula Weight 48.08
Boiling point 56.1 C (133 F)
Melting Point -95.6 C (-140 F)
Density 0.7911 gm/cu m (20 C)
Flammable limits 2.15 to 13% by volume in air
Critical Temperature 188. C (370 F)
Critical pressure 57.1 atm
Vapor pressure 226.3 mm Hg at 25C
Conversion factors 1 ppm - 24.0 mg/cu m
(25c, 760 mm Hg) 1 mg/cu m - 0.417 ppm

4b


i) local ventilation;

ii) styrene suppressed resins;
iii) work practice guidelines.
Local Ventilation

Localized ventilation in general has the advantage of being more
effective in removal of contaminants from the workplace. In operations
where pieces are fabricated at fixed stations local exhaust in the form of
hoods or booths is practical. However, the shapes and sizes of the pieces
needing this type of control (hull molds in particular) have not lended
themselves practically to application. An added factor is the mobile
nature of most processes. The mold is moved from preparation, to gelcoat,
to lay-up and then to a removal station.

There is one source of over-exposure that may be fitted with local
ventilation. That is the stationary hull mold, as used in Plants 2, 5 and 6.
In fact, since the survey was conducted at Plant 5, they have been experi-
menting with a local system for this purpose. The design includes an
exhaust hood over the aft portion with fixed fans at the bow. The effect
is a push-pull system sweeping air from bow to stern, while workers proceed
to laminate counter current to airflow.

The major drawback to local ventilation is the retro-fitting into
existing operations. The unique problems from plant to plant and the
variety of operations and sizes of parts creates the difficulties inherent
in the non-general solution to the problem.

Styrene-suppressed Resins

Recently the introduction of environmental resins, called styrene-

suppressed resins, has been cause for optimism. The manufacturers claim

46


34,

35.

36.

37.

38.

39.

40.

41.

42.

43.

Fleig, I., and Thiess, A., "Mutagenicity Study of Workers Employed

in the Styrene and Polystyrene Processing and Manufacturing Industry",
Scandinavian Journal of Work, Environment and Health » Vol. 4, Supplement
2, pp. 254-58, (1978).

Meretoja, T., Vainio, H., Sorsa, M., and Harkonen, -H., "Occupational
Styrene Exposure and Chromosomal Aberrations", Mutation Research,
Vol. 56, pp. 193-97, (1977).

Meretoja, T., Jarventaus, H., Sorsa, M., and Vainio, H., "Chromosome
Aberrations in Lymphocytes of Workers Exposed. to. Styrene",
Scandinavian Journal of Work, Environment and Health, Vol. 4,
Supplement 2, pp. 259-64, (1978).

Hogstedt, B., Hedner, K., Mark-Vendel, E., Mitelman, F., Schutz, A.,
and Skerfving, S., "Increased Frequency of Chromosome Aberrations in
Workers Exposed to Styrene", Scandinavian Journal of Work, Environment
and Health, Vol. 5, pp. 333-35, (1979).

Jersey, G. C., Balmer, M. F., Quast, J. F., Park, C. N., Schuetz, D. Jey
Beyer, J. E., Olson, K. J., McCollister, S. B., and Rampy, L. W.,

“Two Year Chronic Inhalation Toxicity and Carcinogenicity Study on
Monomeric Styrene in Rats:~ Final Report", MCA No. Sry. 1.1-TOX-INH

(2 yr.), Midland, MI., Dow Chemical USA, 150 Pp-, (Dec. 6, 1978).

Ponomarkov, V., and Tomatis, L., "Effects of Long-Term Oral Administration

of Styrene to Mice and Rats", Scandinavian Journal of Work, Environment.
=e Sourna’ Of Work, Environment
and Health, Supplement 2, pp. 127-35, (1978).

"Bioassay of a Solution of BetasNitrostyrene and Styrene for Possible
Carcinogenicity", CAS No. 102-96-5 and 100-42-5, NIH Publication

No. 79-1726, National Cancer Institute Carcinogenesis Technical

Report Series 170, Bethesda, Md., U. S. Department of Health, Education
and Welfare, Public Health Service, National Institutes of Health
National Cancer Institute, 81 pp., (1979).

Nicholson, W. J., Selikoff, I. J., and Seidman, H., “Mortality
Experience of Styrene-Polystyrene Polymerization Workers - Initial
Findings", Scandinavian Journal of Work, Environment and Health,
Supplement 2, pp. 247-52, (1978).

Ott, M. G., Kolesar, R. C., Scharweber, H. C., Schneider, E. J.,
and Venable, J. R., "A Mortality Survey of Employees Engaged in the
Development or Manufacture of Styrene-Based Products", Submitted
to Journal of Occupational Medicine.

Frentzel-Beyme, R., Thiess, A. M., and Wieland, R., "Survey of
Mortality among Employees Engaged in the Manufacture of Styrene and
Polystyrene at the BASF Ludwigshafen Works", Scandinavian Journal
of Work, Environment and Health, Supplement 2, pp. 231-39, (1978).

52


concentrations for 20 to 30 minutes. However, it was shown that acetone was
absorbed percutaneously when applied to the skin of the subject for 30 minutes
and the subject remained in a chamber for an additional 1.5 hours. This was
demonstrated by levels of acetone found in the blood and urine (13). It
appears that the skin absorption of acetone depends on the extent of exposure.
Ingestion of either styrene or acetone would not contribute significantly

to the body burden in this industry except by accident.


DISCLAIMER

Mention of company names or products do not constitute endorsement by
the National Institute for Occupational Safety and Health.

DHHS (NIOSH) Publication No. 82-110

ii


TABLE 5

JOB FREQUENCY DISTRIBUTION BY PLANT

JOB PLANT,
1 2 3 4 5 6 7 TOTAL

Hull Chopper 2 i) 2 i) (0) (0) 6 1o
Hull Hand Lay-up 16 27 7 27 15 46 12 150
Deck Chopper 0 0 2 oO to) fe) 9 11
Deck Hand Lay-up 11 12 7 26 13 22 12 103
Small Parts

Chopper fe) 3 2 2 fo) (0) 0 7
Small Parts

Hand Lay-up 15 5 2 12 13 0 47
Gelcoat 4 2 5 12 5 9 8 4s
Stringer Installation 0 8 fo) Lo) fe) fo) 0 8
Stringer

Lamination te) oO io) fe) 2 0 6 8
Aft Deck Lay-up (e) (0) {0} 0 7 {0} 0
Fly Bridge Lay-up 0 is} 0 0 3 7 0 1o
Hard Top Lay~-up 0 0 (0) i) 0 4 i) 4
Fueltank Lay-up 0 0 0 Lo) 3 5 0
Sole Lay-up fo) ° ce) (0) 0 10 0 10
Moldwork 4 i) 8 0 Oo oO oO 12
Model Development 1 4 0 2 0 fey fo) 7
Overlay i) 6 {e} to) 0 1) ) 6
Foam and Chop {0} (e} 0 () ie) i) 5 5
Forklift to) oO 2 0 i} oO o) 2
Clean-up io) te) 1 0 0 0 i) ab
Sander i) oO oO i) 1 i} oO 1
Paste Mixer ° 1°) f°) to) 1 to) te) 1
Mold Masking i) Oo 0 io) 0 °o 1 1
Area 5 ie) 2 3 9 9 8 36
TOTAL 58 67 40 72 71 «(125 67 500

27


14, Sole Lay-up - A job involving the hand manipulation of catalyzed resin,
fiberglass and their composite on the sole lay-up mold, including
squeegeeing and roll-out.

15. Moldwork - A job involving preparation of various molds for lamination
by polishing and waxing. May do some repair work.

16. Model Development - A job which involves the hand lay-up of catalyzed
resin and fiberglass over a wooden model.

17. Overlay - A job involving the attachment of various support and structural
pieces to the boat during assembly.

18. Foam and Chop - A job involving the attachment of a false bottom using
chopped fiberglass and resin, drilling holes in this falsebottom, and
pouring a methylene bisphenyl isocyanate (MDI) foam beneath it.

19, Forklift ~ Forklift driver

20. Clean-up - A janitorial job.

21. Sander ~ A job involving the smoothing of edges on finished small parts.

22. Paste Mixer - A job involving the compounding of chopped fiberglass
and catalyzed resin into a paste, used for stringer installation.

23, Mold Masking - The application of masking tape to the waxed hull mold
for detailing the gelcoat.

69


Gel coat is applied in a ventilated booth using an airless sprayer
system, except in the case of stationary molds which are coated in place.
Generally only large hull and deck molds are stationary and at plants using
this system the gel coating was performed on an off-shift so that exposure
was experienced by the gel coater only. Plants 5 and 6 had this arrangement.

In all plants surveyed, the gel coaters were the best protected from exposure.
In addition to booth ventilation, protective clothing was commonplace on the
gel coater. Coverallsy hoods and respirators were almost always worn during
the gel coating operation.

The rest of the jobs are performed in a large area in the plant designated
as the lamination area. Invisible boundaries usually segregate one section
from the other (i.e., the hull lamination from deck lamination), with the entire
environment being controlled by a central dilution ventilation system consisting
of exhaust fans and tempered make-up air. The exception is Plant 6 which used
natural ventilation exclusively. In some instances, the ventilation system
was aided by the use of circular fans which developed directional air flow
patterns. Aside from the effectiveness of the particular ventilation system,
exposure potential is affected by the amount of resin used, the size and con-
figuration of the part, and the protective equipment used.

The hull has the largest surface area over which catalyzed resin is applied
resulting in greater exposure potential for these workers because of styrene
evaporation. Since the hull has a somewhat concave shape its positioning
affects exposure. On the mobile mold frame, the hull is turned on a longitudinal
axis to access both halves for lamination. Laminating on this type mold is some-
what confining; however, if proper air movement is present styrene vapor
does not accumulate. If a stationary hull mold is used, it is always in an
upright position and the worker must perform his job inside this mold. Because
styrene is more dense than air it will accumulate when the mold is in this

position and exposure potential is greater.

15


EXTENT OF EXPOSURE TO STYRENE
IN THE REINFORCED PLASTIC
BOAT MAKING INDUSTRY

Michael S. Crandall

U.S. DEPARTMENT OF HEALTH AND HUMAN SERVICES
Public Health Service
Centers for Disease Control
National Institute for Occupational Safety and Health
Division of Surveillance, Hazard Evaluations and Field Studies
Cincinnati, Ohio 45226

March 1982


TABLE 13

P-Values for Plant Comparisons Within Job Categories*

Plant Small Large Low No Model
Comparison Hull Deck Parts Gelcoat Parts Exposure Exposure Development
lvs. 2 0.0001 0.1494 0.1144 0.6959 0.1220
lvs. 3 0.001 0.001 0.004 0.0219 0.0010

lvs. 4 0.001 0.001 0.1356 0.0114 0.4731
lvs. 5 0.004 0.0006 0.6592 0.4023 0.0010

lvs. 6 0.003 0.8362 0.0009 0.0001

lvs. 7 0.001 0.0001 0.0814 0.0120 0.5060

2 vs. 3 0.2807 0.0001 0.0001 0.0255

2vs. 4 0.4494 0.0001 0.0233 0.0187 0.0219
2 vs. 5 0.8533 0.0361 0.0497 0.2840 0.7158

2 vs. 6 0.0001 0.1429 0.2260 0.0032

2vs. 7 0.4980 0.0001 0.0054 0.0179 0.7880

3vs. 4 0.5856 0.1214 0.2691 0.8976

3 vs. 5 0.4113 0.0006 0.0009 0.1096 0.0474

3 vs. 6 0.0001 0.0001 0.0001 0.0001

3 vs. 7 0.6127 0.0770 0.0577 0.9843 0.1301

4vs.5 0.6710 0.0076 0.1942 0.0771

4vs. 6 0.0001 0.0001 0.0024 0.0001

4vs.7 0.9915 0.7148 0.7305 0.8613

5 vs. 6 0.0001 0.0001 0.0001 0.0001 0.1261

5 vs. 7 0.6888 0.0225 0.1463 0.0740 0.6132 0.0147

6 vs. 7 0.0001 0.0001 0.0001 0.0001

ALL 0.0001 0.0001 0.0001 0.0001 0.1261 0.8671 0.0017 0.0473

* Significance indicated for P<0.05

39


STUDY RESULTS

Descriptive Surey Results

There were 500 air samples collected from the seven plant surveys con-
ducted. Of these 464 were full shift personal TWA samples. These sampling
results are listed by plant and job in Appendix A. For each entry the
styrene and acetone exposure concentrations are given as well as an indicator

of the combined exposure (combined m1 = Cstyrene 4 _Cacetone : when

TL. tyrene TLV acetone

the sum of these fractions exceeds unity the Threshold Limit Value for the
mixture is considered as being exceeded). ‘There were 23 different jobs present
among the plants surveyed. A job dictionary is provided in Appendix B.

Prior to any data analysis the distribution of the data was tested
using the Univariate procedure from the Statistical Analysis System (SAS),
and found to be non-normally distributed (47). Therefore, a log-normal
distribution was assumed as is frequently done in industrial hygiene ap-
plications (48). The SAS Means procedure was then used on the leg-trans-
formed data to generate the descriptive statistics presented for each plant
by job, and for the plants overall. In Appendix C, the geometric mean,
coefficient of variation and exposure ranges for styrene and acetone are
tabulated.

The substantial variability of exposure to styrene in the FRP boat
fabrication industry can be seen in Table 3. Values range from 2 to 183 ppm
among all plants. An important observation is that 96 of these personal
exposures (20.6%) exceeded the 100 ppm, eight-hour TWA standard. Acetone
exposures were also widely variable with exposures in a few instances near
400 ppm (Table 4), which is well below the eight-hour TWA standard of 1000

ppm.

23


The job categories are shown in Table 8 with contributing jobs. Table 9
is a frequency distribution by plant for the job categories.

As was similarly done to the job data, descriptive statistics were
generated for the job categories using the SAS Means procedure on the log~
transformed data. Since the data were imbalanced with respect to the
number of entries for each job category the SAS General Linear Models (GLM)
procedure was used to perform various single-factor and two-factor analyses
of variance (ANOVA). A t-test which compares the means of the independent
variables in the ANOVA is provided by the GLM procedure along with corres-
ponding significance levels (p-values).

Single-factor ANOVA's were conducted to assess. the variation of certain
jobs and all job categories on styrene exposure within each plant, and to
assess the variation of plant on styrene exposure within each job category.
A two-factor ANOVA was then performed to assess the effect of both job cate-
gory and plant, including a term for their interaction, upon the exposure to
styrene. This was conducted using only the job categories present in all
plants; hull, deck, small parts and gelcoat. Due to interaction effects
seen, and noticed relationships, subsequent two factor ANOVA's were run on

subsets of these data.

Statistical Results

Table 10 presents the means and coefficient of variation (CV) for all
eight job categories among all seven plants. Table 11 presents the p-values
for the single-factor ANOVA comparing job categories within the plants. A
p-value < to 0.05 is considered significant. From these two tables the
following observations among the four major job categories are made:

1. Within Plant 1 the greatest difference amont the major job categories
is between hull and deck with borderline significance, P=0.0528;

32




fifteen per day with nearly thirty workers in the lamination areas. Plant 3
is located in East Central Washington and they started production in 1957.
Exhaust ventilation was provided by eleven fans at floor level located on three
sides of the lamination area (six on the south wall, four on the north wall and
one on the east wall). The north and south wall fans were paired and shared
a common plenum with a filtering medium over the entrance. The east wall fan
arrangement was similar. Make-up air was provided from duct work near the
ceiling (w30 feet) running the length of the building (130' x 260'). In
principle the system was not bad, however, poor maintenance of a ventilation
system in FRP operations can destroy the purpose of good design. The filtering
media used was clogged with a hardened resin/fiberglass/dust composite which
limited performance and a few fans were not in operation. Mobile fans were
used for directing air flow. This system was reported to provide five air changes
per hour optimally. Plans were underway for a new system at the time of the
survey.
PLANT 4

Plant 4 is located in Central Texas. It produces small power boats
ranging from fourteen to twenty-five feet and sailing boats from thirteen to
twenty-six feet. Fifty-six employees were working in lamination at the time of
the survey with total production at twenty-five units per day. Forty units per
day was common during peak production periods. The ventilation system here com-
prised exhaust through four gelcoat booths and the painting and grinding booths.
These booths were placed some distance from the general laminating areas, so
that the effectiveness depended on mobile fans moving the contaminants in the
proper direction. Tempered make-up air was supplied from overhead ducts
throughout the production area. This system was reported to provide eleven air

changes per hour optimally.

1s


DEPARTMENT OF HEALTH AND HUMAN SERVICES
PUBLIC HEALTH SERVICE
CENTERS FOR DISEASE CONTROL,
NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH
ROBERT A. TAFT LABORATORIES
4676 COLUMBIA PARKWAY, CINCINNATI, OHIO 45226

OFFICIAL BUSINESS
PENALTY FOR PRIVATE USE. $300

Third Class Mail

POSTAGE AND FEES PAI
U.S. DEPARTMENT OF HI
HHS 396

DHHS (NIOSH) Publication No. 82-110


CHEMICAL AND PHYSICAL PROPERTIES

Styrene (C6H5CH - cH.) is a volatile liquid with an odor threshold re-
ported to be less than one part per million (PPM) (4, 5). It is soluble in
many organic solvents and its solubility in water is about 3.1 mg/ml. Some
properties of styrene are given in Table I (7-10). Monomeric styrene
production peaked at 7.2 billion pounds in 1979 (11). Approximately 500
million pounds of this were used in the production of polyester resins (12).

Acetone (CH3COCH3) is a colorless, highly volatile, flammable liquid
with a burning taste and aromatic odor. It is the simplest but most com-
mercially important ketone. Important properties of acetone are presented in

Table II (13, 14).


APPENDIX A
(SAMPLING RESULTS)

54




variables'on the model. The interaction terms in Table 15 did not lose
significance, possibly, due to the large difference between the hull

and deck means for Plant 2. The same can be said for the difference between
the small parts and gelcoat means for Plants 3 and 6 in their influence on
Table 16 statistics. The ANOVA for Table 17 was run to verify findings
from the previous single factor test indicating a similarity among Plants

3, 4, and 7, with the resulting negation of the interaction effect due

to exclusion of the rest of the plants. This indicates that these Plants

3, 4 and 7 are indeed similar in relative exposure among job categories.

40


TABLE 16

Interplant Styrene ANOVA Statistics for the
Smallparts and Gelcoat Job Categories

Source DF ss F Value PB

Job Category 1 1.2 8.45 0.0045

Plant 6 2349 27.86 0.0001

Job Category * Plant 6 2.7 3.17 0.0068
TABLE 17

Interplant Styrene ANOVA Statistics for Plants 3, 4, and 7

Source DF ss F Value P

Job Category 3 5.17 16192 0.0001
Plant 2 0.76 3.74 0.0263
Job Category * Plant 6 0.42 0.69 0.6613

42


ROUTES OF EXPOSURE

Styrene is readily absorbed by each of the practical routes; namely,
by inhalation, ingestion and skin absorption. Retention rates of from 60 to
75 percent have been reported subsequent to inhalation of styrene (15, 16).
Styrene vapor can also penetrate the skin although less efficiently than the
liquid (17). Liquid styrene is readily absorbed through the intact skin at
rates between 9-15 mg/om?/hr , while the rates for aqueous solutions were
40-80 mg/om?/1, for mean concentrations of 66.5-269 mg/l (18). In a Swedish
study of human styrene exposure in a reinforced plastics fabrication facility,
Gotell, et al, judged the skin absorption to be fairly low (19). Brooks et al
in a more recent (1980) study of reinforced plastics workers found that wearing
gloves/protective clothing with a respiratory protection device did not offer
more protection than the use of respiratory protection alone. Thus, while
there are reports that styrene is readily absorbed through the skin and that
this represents a potential route of exposure, their investigation failed
to demonstrate any significant contribution of percutaneous absorption to
the body burden of styrene among workers in the reinforced plastics industry
(20). Absorbed styrene is excreted mostly in the urine as metabolites, but
some lung excretion occurs (20).

Inhalation absorption of acetone vapor by humans is reported to be directly
proportional to the magnitude of the exposure, and that physical activity
increased the absorption rate. Absorption is related to the minute volume
of air breathed. It was found that acetone can accumulate in the body, which
suggests that long periods of exposure (> 4 hours) are more likely to produce
toxicity. It was demonstrated that acetone concentrations in the blood were

not increased after nude volunteers were exposed to acetone vapor at unspecified