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SEC Petition Evaluation Report

Petition SEC-00223 

Report Rev #: 1 Report Submittal Date: June 3, 2015 

Subject Expert(s): Karin Jessen, Ed Scalsky

Site Expert(s): N/A

Petition Administrative Summary

Petition Under Evaluation

Petition # Petition 

Type

Petition

Receipt Date

Qualification 

Date

DOE/AWE Facility Name

SEC-00223 83.13 November 19, 2014 February 2, 2015 The Carborundum Company (Buffalo 

Avenue, Niagara Falls NY)

Petitioner-Requested Class Definition 

All employees who worked in any area of the Carborundum Company facility on Buffalo Avenue, Niagara Falls, 

NY from January 1, 1943 through December 31, 1976.

Class Evaluated by NIOSH

All employees who worked in any area of the Carborundum Company facility on Buffalo Avenue, Niagara Falls, 

NY from January 1, 1943 through December 31, 1976.

NIOSH-Proposed Class(es) to be Added to the SEC

None

Related Petition Summary Information 

SEC Petition Tracking #(s) Petition Type DOE/AWE Facility Name Petition Status

N/A N/A N/A N/A

Related Evaluation Report Information 

Report Title DOE/AWE Facility Name

N/A N/A

ORAU Lead Technical Evaluator: Karin Jessen ORAU Peer Review Completed By: Daniel Stempfley

Peer Review Completed By: [Signature on File] 6/3/2015

Tom Tomes Date

SEC Petition Evaluation Reviewed By: [Signature on File] 6/3/2015 

James W. Neton Date

SEC Evaluation Approved By: [Signature on File] 6/3/2015 

Stuart L. Hinnefeld Date
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Evaluation Report Summary: SEC-00223, Carborundum Company

This evaluation report by the National Institute for Occupational Safety and Health (NIOSH)

addresses a class of employees proposed for addition to the Special Exposure Cohort (SEC) per the 

Energy Employees Occupational Illness Compensation Program Act of 2000, as amended, 42 U.S.C. 

§ 7384 et seq. (EEOICPA) and 42 C.F.R. pt. 83, Procedures for Designating Classes of Employees as 

Members of the Special Exposure Cohort under the Energy Employees Occupational Illness 

Compensation Program Act of 2000. 

Petitioner-Requested Class Definition

Petition SEC-00223 was received on November 19, 2014, and qualified on February 2, 2015. The 

petitioner requested that NIOSH consider the following class: All employees who worked in any area 

of the Carborundum Company facility on Buffalo Avenue, Niagara Falls, NY from January, 1, 1943 

through December 31, 1976. 

Class Evaluated by NIOSH

Based on its preliminary research, NIOSH accepted the petitioner-requested class. NIOSH evaluated 

the following class: All employees who worked in any area of the Carborundum Company facility on 

Buffalo Avenue, Niagara Falls, NY from January, 1, 1943 through December 31, 1976.

NOTE: In the DOE’s Office of Environment, Health, Safety and Security facility description for the 

Carborundum Company, there are two operational periods (1943-1944 and 1959-1967) and two 

residual periods (1945-1958 and 1968-1992). Because there are no identified dose reconstruction 

infeasibilities for the site, NIOSH has limited its evaluation to the petitioner’s requested class period 

from 1943 through 1976. 

NIOSH-Proposed Class(es) to be Added to the SEC 

Based on its full research of the class under evaluation, NIOSH has obtained sufficient information on 

material types, material quantities, and some processing methods. Based on its analysis of these 

available resources, NIOSH found no part of the class under evaluation for which it cannot estimate 

radiation doses with sufficient accuracy.

Feasibility of Dose Reconstruction

Per EEOICPA and 42 C.F.R. § 83.13(c)(1), NIOSH has established that it has access to sufficient 

information to: (1) estimate the maximum radiation dose, for every type of cancer for which radiation 

doses are reconstructed, that could have been incurred in plausible circumstances by any member of 

the class; or (2) estimate radiation doses of members of the class more precisely than an estimate of 

maximum dose. Information from available resources is sufficient to document or estimate the 

maximum internal and external potential exposure to members of the evaluated class under plausible 

circumstances during the specified period. 
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Health Endangerment Determination

Per EEOICPA and 42 C.F.R. § 83.13(c)(3), a health endangerment determination is not required 

because NIOSH has determined that it has sufficient information to estimate dose for the members of 

the evaluated class.
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Table of Contents

1.0 Purpose and Scope .......................................................................................................................... 9

2.0 Introduction .................................................................................................................................... 9

3.0 SEC-00223 Carborundum Company Class Definitions ............................................................... 10

3.1 Petitioner-Requested Class Definition and Basis ................................................................ 10

3.2 Class Evaluated by NIOSH ................................................................................................. 11

3.3 NIOSH-Proposed Class(es) to be Added to the SEC .......................................................... 12

4.0 Data Sources Reviewed by NIOSH to Evaluate the Class ........................................................... 12

4.1 Site Profile Technical Basis Documents (TBDs) ................................................................ 13

4.2 ORAU Technical Information Bulletins (OTIBs) and Procedures ..................................... 13

4.3 Facility Employees and Experts .......................................................................................... 14

4.4 Previous Dose Reconstructions ........................................................................................... 15

4.5 NIOSH Site Research Database .......................................................................................... 15

4.6 Other Technical Sources ...................................................................................................... 16

4.7 Documentation and/or Affidavits Provided by Petitioners ................................................. 16

5.0 Radiological Operations Relevant to the Class Evaluated by NIOSH ......................................... 16

5.1 Carborundum Company Plant and Process Descriptions .................................................... 17

5.1.1 First Operational Period (1943-1944) Process Descriptions ................................... 21

5.1.2 First Residual Period (1945-1958) .......................................................................... 22

5.1.3 Second Operational Period (1959-1967) Process Descriptions ............................... 23

5.1.4 Second Residual Period (1968-1976) ...................................................................... 35

5.2 Radiological Exposure Sources from Carborundum Company Operations ........................ 36

5.2.1 Internal Radiological Exposure Sources from Carborundum Co. Operations ........ 40

5.2.1.1 First Operational Period (1943-1944) ...................................................... 40

5.2.1.2 First Residual Period (1945-1958) ........................................................... 40

5.2.1.3 Second Operational Period (1959-1967) .................................................. 40

5.2.1.4 Second Residual Period (1968-1976) ....................................................... 41

5.2.2 External Radiological Exposure Sources from Carborundum Co. Operations ....... 41

5.2.2.1 First Operational Period (1943-1944) ...................................................... 43

5.2.2.2 First Residual Period (1945-1958) ........................................................... 43

5.2.2.3 Second Operational Period (1959-1967) .................................................. 43

5.2.2.4 Second Residual Period (1968-1976) ....................................................... 46

6.0 Summary of Available Monitoring Data for the Class Evaluated by NIOSH ............................. 46

6.1 Available Carborundum Company Internal Monitoring Data ............................................. 46

6.2 Available Carborundum Company External Monitoring Data ........................................... 48

7.0 Feasibility of Dose Reconstruction for the Class Evaluated by NIOSH ...................................... 48

7.1 Pedigree of Carborundum Company Data .......................................................................... 49

7.1.1 Internal Monitoring Data Pedigree Review ............................................................. 49

7.1.2 External Monitoring Data Pedigree Review ............................................................ 49
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7.2 Evaluation of Bounding Internal Radiation Doses at Carborundum Company .................. 50

7.2.1 Evaluation of Bounding Process-Related Internal Doses ........................................ 50

7.2.2 Methods for Bounding Internal Dose at Carborundum Company .......................... 53

7.2.2.1 Methods for Bounding Operational Period Internal Dose ........................ 53

7.2.2.2 Methods for Bounding Residual Period Internal Dose ............................. 54

7.2.3 Internal Dose Reconstruction Feasibility Conclusion ............................................. 54

7.3 Evaluation of Bounding External Radiation Doses at Carborundum Company ................. 55

7.3.1 Evaluation of Bounding Process-Related External Doses ....................................... 55

7.3.2 Carborundum Company Occupational X-Ray Examinations ................................. 56

7.3.3 Methods for Bounding External Dose at Carborundum Company ......................... 57

7.3.3.1 Methods for Bounding Operational Period External Dose ....................... 57

7.3.3.2 Methods for Bounding Residual Period External Doses .......................... 60

7.3.4 External Dose Reconstruction Feasibility Conclusion ............................................ 60

7.4 Evaluation of Petition Basis for SEC-00223 ....................................................................... 61

7.5 Summary of Feasibility Findings for Petition SEC-00223 .................................................. 63

8.0 Evaluation of Health Endangerment for Petition SEC-00223 ...................................................... 64

9.0 Class Conclusion for Petition SEC-00223 ................................................................................... 65

10.0 References .................................................................................................................................... 67

Attachment 1: Data Capture Synopsis ................................................................................................... 73
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Tables 

Table 4-1: No. of Carborundum Company Claims Submitted Under the Dose Reconstruction Rule .. 15

Table 5-1: Carborundum Radiological Work During the First Operational Period .............................. 22

Table 5-2: Carborundum Radiological Contract Work During the Second Operational Period ........... 26

Table 5-3: Isotopic Analysis of PuO2 .................................................................................................... 37

Table 5-4: Summary of Carborundum Exposure Sources Over the Contract Timelines ...................... 38

Table 5-5: Principal Radiation Emissions from Natural Uranium and Short-lived Decay Products .... 42

Table 5-6: Carborundum Radioactive Material Inventory in 1962 ....................................................... 45

Table 6-1: Carborundum Uranium Air Dust Samples ........................................................................... 47

Table 6-2: Carborundum Plutonium Air Dust Samples ........................................................................ 48

Table 7-1: Summary of Feasibility Findings for SEC-00223 ............................................................... 64

Figures 

Figure 5-1: The Carborundum Company Site at Niagara Falls, NY ..................................................... 18

Figure 5-2: Carborundum Facility for Investigating Refractory Materials ........................................... 20
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SEC Petition Evaluation Report for SEC-00223

ATTRIBUTION AND ANNOTATION: This is a single-author document. All conclusions drawn from 

the data presented in this evaluation were made by the ORAU Team Lead Technical Evaluator: Karin 

Jessen, Oak Ridge Associated Universities. The rationales for all conclusions in this document are 

explained in the associated text.

1.0 Purpose and Scope

This report evaluates the feasibility of reconstructing doses for all employees who worked in any area 

of the Carborundum Company facility on Buffalo Avenue, Niagara Falls, NY from January 1, 1943 

through December 31, 1976. It provides information and analyses germane to considering a petition 

for adding a class of employees to the congressionally-created SEC. 

This report does not make any determinations concerning the feasibility of dose reconstruction that 

necessarily apply to any individual energy employee who might require a dose reconstruction from 

NIOSH. This report also does not contain the final determination as to whether the proposed class 

will be added to the SEC (see Section 2.0). 

This evaluation was conducted in accordance with the requirements of EEOICPA, 42 C.F.R. pt. 83, 

and the guidance contained in the Division of Compensation Analysis and Support’s (DCAS) Internal 

Procedures for the Evaluation of Special Exposure Cohort Petitions, DCAS-PR-004.1

2.0 Introduction 

Both EEOICPA and 42 C.F.R. pt. 83 require NIOSH to evaluate qualified petitions requesting that the 

Department of Health and Human Services (HHS) add a class of employees to the SEC. The 

evaluation is intended to provide a fair, science-based determination of whether it is feasible to 

estimate with sufficient accuracy the radiation doses of the class of employees through NIOSH dose 

reconstructions.2 

42 C.F.R. § 83.13(c)(1) states: Radiation doses can be estimated with sufficient accuracy if NIOSH 

has established that it has access to sufficient information to estimate the maximum radiation dose, 

for every type of cancer for which radiation doses are reconstructed, that could have been incurred in 

plausible circumstances by any member of the class, or if NIOSH has established that it has access to 

sufficient information to estimate the radiation doses of members of the class more precisely than an 

estimate of the maximum radiation dose.

 

 

1 DCAS was formerly known as the Office of Compensation Analysis and Support (OCAS).

2 NIOSH dose reconstructions under EEOICPA are performed using the methods promulgated under 42 C.F.R. pt. 82 and 

the detailed implementation guidelines available at http://www.cdc.gov/niosh/ocas.
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Under 42 C.F.R. § 83.13(c)(3), if it is not feasible to estimate with sufficient accuracy radiation doses 

for members of the class, then NIOSH must determine that there is a reasonable likelihood that such 

radiation doses may have endangered the health of members of the class. The regulation requires 

NIOSH to assume that any duration of unprotected exposure may have endangered the health of 

members of a class when it has been established that the class may have been exposed to radiation 

during a discrete incident likely to have involved levels of exposure similarly high to those occurring 

during nuclear criticality incidents. If the occurrence of such an exceptionally high-level exposure has 

not been established, then NIOSH is required to specify that health was endangered for those workers 

who were employed for at least 250 aggregated work days within the parameters established for the 

class or in combination with work days within the parameters established for one or more other SEC 

classes. 

NIOSH is required to document its evaluation in a report, and to do so, relies upon both its own dose 

reconstruction expertise as well as technical support from its contractor, Oak Ridge Associated 

Universities (ORAU). Once completed, NIOSH provides the report to both the petitioner(s) and the 

Advisory Board on Radiation and Worker Health (Board). The Board will consider the NIOSH 

evaluation report, together with the petition, petitioner(s) comments, and other information the Board 

considers appropriate, in order to make recommendations to the Secretary of HHS on whether or not 

to add one or more classes of employees to the SEC. Once NIOSH has received and considered the 

advice of the Board, the Director of NIOSH will propose a decision on behalf of HHS. The Secretary 

of HHS will make the final decision, taking into account the NIOSH evaluation, the advice of the 

Board, and the proposed decision issued by NIOSH. As part of this decision process, petitioners may 

seek a review of certain types of final decisions issued by the Secretary of HHS.

3

 

3.0 SEC-00223 Carborundum Company Class Definitions 

The following subsections address the evolution of the class definition for SEC-00223, Carborundum 

Company (Buffalo Avenue). When a petition is submitted, the requested class definition is reviewed

as submitted. Based on its review of the available site information and data, NIOSH will make a 

determination whether to qualify for full evaluation all, some, or no part of the petitioner-requested

class. If some portion of the petitioner-requested class is qualified, NIOSH will specify that class 

along with a justification for any modification of the petitioner’s class. After a full evaluation of the 

qualified class, NIOSH will determine whether to propose a class for addition to the SEC and will 

specify that proposed class definition. 

3.1 Petitioner-Requested Class Definition and Basis

Petition SEC-00223 was received on November 19, 2014, and qualified on February 2, 2015. The 

petitioner requested that NIOSH consider the following class: All employees who worked in any area 

of the Carborundum Company facility on Buffalo Avenue, Niagara Falls, NY from January 1, 1943 

through December 31, 1976. 

 

3 See 42 C.F.R. pt. 83 for a full description of the procedures summarized here. Additional internal procedures are 

available at http://www.cdc.gov/niosh/ocas.
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The petitioner provided information and affidavit statements in support of the petitioner’s belief that 

accurate dose reconstruction over time is impossible for the Carborundum Company, Buffalo Ave., 

workers in question. NIOSH deemed the following information and affidavit statements sufficient to 

qualify SEC-00223 for evaluation: 

Petition Basis: Radiation exposures and radiation doses potentially incurred by members of the 

proposed class were not monitored either through personal monitoring or through area monitoring. 

Petitioner Statement: To the best of my knowledge the plant was not monitored for radiation 

during the time of employment as the attached papers state my dad was exposed to various forms 

of radiation throughout the plant during the years he worked there.

Based on its Carborundum Company documentation reviews and research relating to the SEC 

petition, NIOSH determined that it had limited monitoring data or process information for 

Carborundum workers during the petitioner-requested time period. Specifically, NIOSH determined 

that air sampling, radiological surveys, and dosimetry data records are not complete for all 

radionuclides during the petitioner-defined periods. NIOSH concluded that there is sufficient 

documentation to support, for at least part of the requested time period, the petition basis that internal 

and external radiation exposures and radiation doses were not adequately monitored at the 

Carborundum Company, either through personal monitoring or area monitoring. The information and 

statements provided by the petitioner qualified the petition for further consideration by NIOSH, the 

Board, and HHS. The details of the petition basis are addressed in Section 7.4. 

3.2 Class Evaluated by NIOSH

Based on its preliminary research, NIOSH accepted the petitioner-requested class. Therefore, NIOSH 

defined the following class for further evaluation: All employees who worked in any area of the 

Carborundum Company facility on Buffalo Avenue, Niagara Falls, NY from January, 1, 1943 through 

December 31, 1976. 

NOTE: The DOE’s Office of Environment, Health, Safety and Security maintains a Facility List 

Database that provides summaries of EEOICPA-covered facilities. As shown below, the facility 

description for the Carborundum Company specifies two operational periods and two residual periods. 

Because there are no identified dose reconstruction infeasibilities for the site, NIOSH has limited its 

evaluation to the petitioner’s requested class period from 1943 through 1976. 

1 - Carborundum Company

State: New York Location: Niagara Falls 

Time Period: AWE 1943-1944; 1959-1967; Residual Radiation: 1945-1958; 1968-1992 

Facility Type: Atomic Weapons Employer 

Facility Description: In 1943 and 1944 the Carborundum Company at its Globar Plant and 

Buffalo Avenue locations was engaged in various phases of Manhattan Engineer District (MED) 

programs to determine suitable methods for engineering and shaping uranium rods. This work 

also involved the forming, coating, and canning of uranium rods for the MED pile. From 1959 

through 1967, the company used powder fabrication techniques to manufacture uranium, 
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plutonium, and carbide pellets for an AEC research program. The Hanford facility supplied 

Carborundum with materials during that period. 

Carborundum also performed work during the 1950s that is not covered under EEOICPA, 

including fabricating nuclear fuel elements for commercial purposes and producing zirconium, 

hafnium, and titanium for AEC’s special reactor materials program. 

During the period of residual contamination, as designated by the National Institute for 

Occupational Safety and Health and as noted in the dates above, employees of subsequent owners 

and operators of this facility are also covered under EEOICPA. 

(https://ehss.energy.gov/Search/Facility/ViewByName.aspx)

3.3 NIOSH-Proposed Class(es) to be Added to the SEC

Based on its research, NIOSH has obtained information on material types, material quantities, and 

processing methods that allow dose reconstruction to be performed with sufficient accuracy for the 

evaluated period at the Carborundum Company facility on Buffalo Avenue, Niagara Falls, NY based 

on guidance in Battelle-TBD-6000, ORAUT-OTIB-0070, internal/external/medical X-ray dose 

reconstruction methodologies discussed herein, and the currently-available process and area 

monitoring data for the Carborundum Company facility. Based on its analysis of these available 

resources, NIOSH found no part of the class under evaluation for which it cannot estimate radiation 

doses with sufficient accuracy. 

4.0 Data Sources Reviewed by NIOSH to Evaluate the Class

As is standard practice, NIOSH completed an extensive database and Internet search for information 

regarding the Carborundum Company, Buffalo Ave, Niagara Falls, NY. The database search included 

the DOE Legacy Management Considered Sites database, the DOE Office of Scientific and Technical 

Information (OSTI) database, the Energy Citations database, and the Hanford Declassified Document 

Retrieval System. In addition to general Internet searches, the NIOSH Internet search included OSTI 

OpenNet Advanced searches, OSTI Information Bridge Fielded searches, Nuclear Regulatory 

Commission (NRC) Agency-wide Documents Access and Management (ADAMS) web searches, the 

DOE Office of Human Radiation Experiments website, and the DOE-National Nuclear Security 

Administration-Nevada Site Office-search. Attachment 1 contains a summary of Carborundum 

Company documents. The summary specifically identifies data capture details and general 

descriptions of the documents retrieved. 

In addition to the database and Internet searches listed above, NIOSH identified and reviewed 

numerous data sources to determine information relevant to determining the feasibility of dose 

reconstruction for the class of employees under evaluation. This included determining the availability 

of information on personal monitoring, area monitoring, industrial processes, and radiation source 

materials. The following subsections summarize the data sources identified and reviewed by NIOSH. 
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4.1 Site Profile Technical Basis Documents (TBDs) 

A Site Profile provides specific information concerning the documentation of historical practices at 

the specified site. Dose reconstructors can use the Site Profile to evaluate internal and external 

dosimetry data for monitored and unmonitored workers, and to supplement, or substitute for, 

individual monitoring data. A Site Profile consists of an Introduction and five Technical Basis 

Documents (TBDs) that provide process history information, information on personal and area 

monitoring, radiation source descriptions, and references to primary documents relevant to the 

radiological operations at the site. The Site Profile for a small site may consist of a single document. 

A Site Profile for the Carborundum Company does not exist. As part of NIOSH’s evaluation detailed 

herein, it examined the following TBD for insights into Carborundum Company operations or related 

topics/operations at other sites: 

• Battelle-TBD-6000, Technical Basis Document: Site Profiles for Atomic Weapons Employers That 

Worked Uranium Metals, Rev 1, Battelle Memorial Institute; June 17, 2011; SRDB Ref ID: 

101251 

4.2 ORAU Technical Information Bulletins (OTIBs) and Procedures 

An ORAU Technical Information Bulletin (OTIB) is a general working document that provides 

guidance for preparing dose reconstructions at particular sites or categories of sites. An ORAU 

Procedure provides specific requirements and guidance regarding EEOICPA project-level activities, 

including preparation of dose reconstructions at particular sites or categories of sites. NIOSH 

reviewed the following OTIBs as part of its evaluation:

• OTIB: Dose Reconstruction from Occupational Medical X-Ray Procedures, ORAUT-OTIB-0006, 

Rev. 04; Oak Ridge Associated Universities; June 20, 2011; SRDB Ref ID: 98147

• OTIB: Technical Information Bulletin: Dose Reconstruction during Residual Radioactivity 

Periods at Atomic Weapons Employer Facilities, ORAUT-OTIB-0070, Rev 01, Oak Ridge 

Associated Universities Team, March 5, 2012, SRDB Reference ID 108851.

• OTIB: Guidance on Assigning Occupational X-ray Dose Under EEOICPA for X-rays 

Administered Off Site, ORAUT-OTIB-0079, Rev. 00; Oak Ridge Associated Universities; January 

3, 2011; SRDB Ref ID: 89563
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4.3 Facility Employees and Experts

To obtain additional information, NIOSH interviewed six former Carborundum employees. NIOSH 

attempted to conduct interviews for the first operational period (1943-1944), but were not able to 

locate former workers from that period. As a result, there are no interviews that cover Carborundum 

site workers or operations during the 1943-1944 operational period. The six former Carborundum 

employees interviewed worked at Carborundum after the 1950s. 

• Personal Communication, 2015a, Personal Communication with former Carborundum Company 

[job title redacted]; Telephone Interview by ORAU Team; February 13, 2015; SRDB Ref ID: 

142192

• Personal Communication, 2015b, Personal Communication with former Carborundum Company 

[job title redacted]; Telephone Interview by ORAU Team; February 13, 2015; SRDB Ref ID: 

142173

• Personal Communication, 2015c, Personal Communication with former Carborundum Company 

[job title redacted]; Telephone Interview by ORAU Team; February 16, 2015; SRDB Ref ID: 

142172

• Personal Communication, 2015d, Personal Communication with former Carborundum Company 

[job title redacted]; Telephone Interview by ORAU Team; February 16, 2015; SRDB Ref ID: 

142193

• Personal Communication, 2015e, Personal Communication with former Carborundum Company 

[job title redacted]; Telephone Interview by ORAU Team; February 17, 2015; SRDB Ref ID: 

142174

• Personal Communication, 2015f, Personal Communication with former Carborundum Company 

[job title redacted]; Telephone Interview by ORAU Team; February 23, 2015; SRDB Ref ID: 

142194

• Personal Communication, 2015g, Personal Communication with former Carborundum Company 

[job title redacted]; Telephone Interview by ORAU Team; April 27, 2015; SRDB Ref ID: 144379
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4.4 Previous Dose Reconstructions

NIOSH reviewed its NIOSH DCAS Claims Tracking System (referred to as NOCTS) to locate

EEOICPA-related dose reconstructions that might provide information relevant to the petition 

evaluation. Table 4-1 summarizes the results of this review. (NOCTS data available as of March 16, 

2015)

Table 4-1: No. of Carborundum Company Claims Submitted Under the Dose Reconstruction Rule

Description Totals

Total number of claims submitted for dose reconstruction 120

Total number of claims submitted for energy employees who worked during the period under 

evaluation (January 1, 1943 through December 31, 1976). 106

Number of dose reconstructions completed for energy employees who worked during the period

under evaluation (i.e., the number of such claims completed by NIOSH and submitted to the 

Department of Labor for final approval). 90

Number of claims for which internal dosimetry records were obtained for the identified years in the 

evaluated class definition 0

Number of claims for which external dosimetry records were obtained for the identified years in the 

evaluated class definition 0

NIOSH reviewed each claim to determine whether internal and/or external personal monitoring 

records could be obtained for the employee. As noted in Table 4-1, NIOSH has not received external 

or internal monitoring data from the Carborundum Company for any claimants.

4.5 NIOSH Site Research Database

NIOSH also examined its Site Research Database (SRDB) to locate documents supporting the 

assessment of the evaluated class. Two hundred twenty documents in this database were identified as 

pertaining to the Carborundum Company. These documents were evaluated for their relevance to this 

petition. The documents include historical background on program descriptions (e.g., air dust 

monitoring, radiological controls, program information, medical monitoring, process materials, and 

process descriptions).
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4.6 Other Technical Sources

• DCAS-IG-003, Radiation Exposures Covered for Dose Reconstructions under Part B of the 

Energy Employees Occupational Illness Compensation Program Act, Rev 01, NIOSH, Division 

of Compensation Analysis and Support; October 5, 2010; SRDB Ref ID: 88929

• DCAS-TIB-0010, Technical Information Bulletin: Best Estimate External Dose Reconstruction 

for Glovebox Workers, Rev 04, NIOSH, Division of Compensation Analysis and Support; 

November 28, 2011; SRDB Ref ID: 104815

4.7 Documentation and/or Affidavits Provided by Petitioners

In qualifying and evaluating the petition, NIOSH reviewed the following documents submitted by the 

petitioners:

• SEC Petition Form B, received November 19, 2014; DSA Ref ID: 120430 (Petition, 2014)

• Affidavit from one of two survivors asserting that the plant was not monitored for radiation during 

the deceased worker’s time of employment. The survivor states the deceased was exposed to 

various forms of radiation throughout the plant during the years worked there; received November 

19, 2014; DSA Ref ID: 120430 (Affidavit, 2014)

• Attachment to Form B: Two pages from the deceased worker’s dose reconstruction; received 

November 19, 2014; DSA Ref ID: 120430, PDF pp. 7-8 (Attachment, 2014)

5.0 Radiological Operations Relevant to the Class Evaluated by 

NIOSH

The Carborundum Company site on Buffalo Avenue has two operational periods and two residual 

periods. These periods will be addressed in chronological order, as listed below:

• First Operational Period: 1943-1944

• First Residual Period: 1945-1958

• Second Operational Period: 1959-1967

• Second Residual Period: 1968-1992

NOTE: The evaluation and feasibility conclusions in this report only extend to 1976 based on the 

petitioner’s requested class of 1943-1976 and the results of the feasibility findings in this 

report.

The following subsections summarize both radiological operations at the Carborundum Company 

from January 1, 1943 to December 31, 1976 and the information available to NIOSH to characterize 

particular processes and radioactive source materials. Although the DOE’s Facility Description 

(provided in Section 3.2) indicates a variety of uranium activities from 1943-1944, references 

available to NIOSH indicate that Carborundum performed limited experimental work on uranium 
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metal in 1943, as described in Section 5.1.1. NIOSH has identified source term quantities for this 

work, but has discovered no radiological monitoring data for the first operational period (1943-1944). 

The work in the second operational period involved the synthesis and study of carbide fuel 

compounds. NIOSH has limited radiological monitoring information on the activities that were 

performed at the Carborundum Company site on Buffalo Ave. during this operational period (1959-

1967). The information included within this evaluation report is intended only to be a summary of 

the available information for the Carborundum Company facility on Buffalo Avenue, Niagara Falls, 

NY from January 1, 1943 through December 31, 1976, consistent with the direction for the EEOICPA 

process and the requested class defined in the SEC petition associated with this evaluation report.

5.1 Carborundum Company Plant and Process Descriptions

The Carborundum Company was located at 1920 Buffalo Avenue (address on file from 1921-2001) in 

Niagara Falls, NY. The company was founded on Sept. 21, 1891 following the discovery of crystal

stones that chemical analysis revealed to be silicon carbide. Because the silicon carbide powder was 

considered an excellent abrasive material, the company became known as the electro-chemical and 

electro-metallurgical center of the world. The abrasive products appeared on grinding wheels, 

sharpening stones, and sandpaper. The Carborundum Company developed newer and softer 

man-made abrasives and before long it was a national and international enterprise (Carborundum 

History, 1991).

No documentation has been found regarding the exact physical size of the facility or the exact number 

of buildings for any period at the site. From interviews, it is estimated that approximately 30-50 

buildings were on site at Buffalo Avenue (Personal Communication, 2015f; Personal Communication, 

2015c) by the second operational period; one interviewee suggested that, at that time, the site 

encompassed about 200 acres (Personal Communication, 2015a). In 1953, new modern quarters for 

the Research and Development Division were completed; these quarters occupied over 60,000 square 

feet in Building 1. This facility included complete laboratory and mechanical equipment; a battery of 

experimental, high-temperature electric furnaces; high-temperature and electronic microscopes; an 

analytical X-ray installation; sonic graders; a research machine shop; an extensive technical library;

and one of the most comprehensive patent reference departments in the country (Carborundum 

History, 1991).
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Source: Romance of Carborundum, 1960s, PDF p. 12

Figure 5-1: The Carborundum Company Site at Niagara Falls, NY

Records show that the Carborundum Company employed approximately 6,000-7,000 employees 

during the mid-to-late 1940s. Limited documentation has been found regarding the number of 

employees in later years up to the point in 1983 when the plant was closed and the remaining 

employees at the site lost their jobs (Kostoff, 2008).

The Carborundum Company, at its Buffalo Avenue plant, was involved with the Manhattan Engineer 

District (MED) programs in 1943, and was involved with centerless-grinding testing using grinding 

wheels and different abrasives. NIOSH presumes this work could have been performed at the Buffalo 

Avenue location, although no information on the location is currently available. Carborundum was 

also involved in various phases of fuel development work during the 1959-1967 time period. The 

processes involved during these two operational periods varied considerably. The following sections 

discuss the available information on Carborundum Company’s operations during these two periods. 

The Globar Plant is also listed in the covered facility definition for Carborundum. During the 1920s, 

the Wireless Resistor Company of America, based in Milwaukee, pioneered the use of silicon carbide 

in an electric heating element called "Globar." In 1927, Carborundum purchased that company, by 

then called the Globar Corporation, and moved its production to Niagara Falls. A new facility was 

constructed on Hyde Park Boulevard and the transfer was complete in August 1928 (Carborundum 

Company, 2015, PDF p. 3; Carborundum History, 1991, PDF p. 44; Globar, 2009). The Globar plant 

is not part of this SEC petition because it is not located at the Buffalo Avenue site. Therefore, it will 

not be discussed further in this evaluation report. 
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DuPont, on behalf of the U.S. Government, subcontracted different companies to perform various 

types of work turning uranium billets into finished slugs for use in the Clinton and Hanford piles. In 

May 1943, DuPont had unfinished slugs delivered to Carborundum to determine the type of abrasive 

wheel and optimum speeds appropriate for production grinding; this experimental grinding was 

performed in June 1943.

Throughout the late 1940s and 1950s, between the first and second covered operational periods, 

Carborundum became a very successful company in the field of industrial technology and grew more 

sophisticated and complex, attracting many talented research scientists to Niagara Falls. In 1953, the 

company completed modern new quarters for its Research and Development Division, which 

developed new products such as Fiberfrax, a ceramic-fiber high-temperature insulation.

In 1959, under Contract No. AT (40-1)-2558, Carborundum did work for the U.S. Atomic Energy 

Commission (AEC) as part of the AEC Fuel Cycle Development Program. The objective of this work 

was to develop refractory uranium materials possessing sufficient advantage over uranium dioxide to 

warrant their use as reactor fuels. The initial contract covered the period from May 1959 through 

December, 1960 (Refractory Uranium, 1959-60, PDF p. 7). The contract was modified and extended 

to continue this work. Memos dated September 19, 1962 and November 2, 1962 discuss inventory 

and instructions for disposal of the government-owned Source and Special Nuclear Materials with 

regards to the close-out of this contract (Contract Closeout, 1962, PDF p. 2).

In 1960, the Carborundum Company completed a Central Laboratory facility upgrade for 

investigating the synthesis and fabrication of refractory materials containing plutonium in such forms 

as carbides, silicides, oxides, and nitrides, which was an addition to Carborundum’s uranium contract 

work. These materials are toxic and some are very sensitive to oxygen and moisture, especially in a 

finely-divided form. To be able to work with these materials, a leak-tight glove-box system was 

required. In addition, a decision to fabricate mainly by sintering at atmospheric pressure, rather than 

in a vacuum, required the glove box to have a carefully-controlled inert atmosphere. The facility was 

also protected by alarms and safety devices that were in continuous operation. The facility operated 

on a one-shift, five-day week basis (Refractory Plutonium, 1962). This facility was located in the 

Central Laboratory; it was 15 feet wide, 48 feet long and 8.5 feet high with enameled steel-paneled 

walls and ceiling and vinyl floor covering (See Figure 5-2). This area had a change room (11 by 15 

feet) and a work space (15 by 37 feet). A helium purification and recirculation system serviced the 

building and occupied a 12 by 24 foot space in an adjacent room (Refractory Plutonium, 1962, PDF p. 

3). The Central Laboratory (aka as the Central Facility) refers to the fourth floor of Building 1.

Of the glove boxes indicated in Figure 5-2, #1, #2, and #6 operated with an air atmosphere, and #3, 

#4, and #5 operated with high-purity helium atmosphere. The glove boxes averaged 3 feet high, 3.5 

feet wide, and 5 feet long. They were constructed of welded aluminum plate with full side safetyplate glass windows. The air and helium glove box systems were connected by a vacuum lock located 

between #2 and #3, while the remaining boxes (with the exception of #6) were connected by twolayered flexible plastic tubing. Materials could be moved into or out of the box system by the 

pouching technique (which may also be referred to as bag outs), or directly through the O-ring-sealed 

sliding door of #1 box, which was maintained at a low level of contamination (Refractory Plutonium, 

1962).
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Source: Refractory Plutonium, 1962, PDF p. 3

Figure 5-2: Carborundum Facility for Investigating Refractory Materials

During the second operational period, the Carborundum Company was a subcontractor to United 

Nuclear Corporation (UNC), formerly known as Nuclear Development Corporation of America 

(NDA), from 1959-1965 under various contracts. UNC performed conceptual design, fuel evaluation, 

and fuel irradiation. Carborundum Company fabricated the fuel. Both companies operated 

plutonium-handling facilities (Carbide Fuel, May1963). 

From Feb. 1, 1964 through Oct. 30, 1965, the Carborundum Company was subcontracted to UNC to

study uranium-plutonium monoxides. This work was sponsored jointly by the U.S. Atomic Energy 

Commission and the Joint U.S.-Euratom Research and Development Program (Monoxides, 1966).

The Carborundum Company performed work with the AEC under contract No. AT (30-1)-3713. The 

contract years were from May 23, 1966 through February 28, 1967. The work studied the preparation 

of mixed-carbide fuel using co-precipitation and the synthesis of (UPu)C (Final Report, 1967).

During the mid-1960s and into the late 1970s, upon completion of Carborundum’s AEC-related work 

in its second covered operational period, the company refocused on its core ceramic technology, 

moving beyond the capital goods market into the steel, paper, plastics, pollution control, and china 

industries. In the mid-1970s, the Carborundum Company began the development of pressureless 

sintered alpha silicon carbide, which marked its entry into the world of structural ceramics. At the 

same time, Carborundum fought off a hostile takeover attempt by Eaton Corp, only to be purchased 
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by Kennecott Copper Corporation. Through the 1980s, Carborundum’s name was changed twice 

before returning to the Carborundum name in 1988. During this time, the company was reorganized 

into three operating companies. Silicon carbide continued to be one of the company’s core minerals 

with the development of Hexoloy alpha silicon carbide products. The company resumed its traditional 

investment focus in research, development, and capital expansion; the company moved into 

development of materials for the growing semiconductor industry. A significant change occurred in 

1983 when the Buffalo Ave plant was closed and 650 people lost their jobs. In 1987, British 

Petroleum acquired Standard Oil and its Carborundum subsidiary. During this time, the company 

developed aluminum nitride substrates and ceramic packages for the semiconductor industry and 

continued developing new uses for its Fiberfrax technology while maintaining global leadership in 

sales of its Globar heating elements. By 1990, St. Gobain purchased the Carborundum abrasives unit

(Carborundum Company, 2015; Carborundum Timeline, 2006). 

A response memo dated June 23, 1993 provides follow-up information to a March 8, 1993 memo 

regarding potentially-contaminated sites from ORNL Region 1. The response memo states that the 

Carborundum Company Research Center, Buffalo Ave., was surveyed at the time of closure and that 

additional information was required to remove this site from the list (Sites, 1993). Subsequent 

information for the nuclear material license number at Carborundum indicates the site was cleared 

from the ORNL list in 1993 (ORNL, 1999).

5.1.1 First Operational Period (1943-1944) Process Descriptions

The 1943 Carborundum experimental grinding operation performed for DuPont was for the purpose of 

determining the type of abrasive wheel to use and the optimum speeds to maintain during a production 

grinding job. The project report (Clinton, 1945) has a list of project correspondence that indicates 

there was a letter issued May 17, 1943, granting approval to send one uranium rod to Carborundum 

for centerless grinding experiments. Details in the text of the report and shipping records do not 

indicate that a rod was sent, but indicates that ten Clinton-sized unfinished slugs were shipped in May 

1943 to Carborundum for experimental grinding to determine the type of abrasive wheel to use and 

the optimum speeds to maintain during a production grinding job. Shipping and receiving and 

accountability records for that project show Carborundum taking receipt of 30 pounds of slugs from 

Herring-Hall-Marvin Safe Company (HHM Safe Co. - one of the DuPont subcontractors) on June 1, 

1943. Based on the most common size of Clinton slugs provided in the report (finish size: 1.1” 

diameter by 4” long), 30 pounds of unfinished slugs would be nominally equivalent to ten slugs 

(Clinton, 1943, PDF p. 14; Clinton, 1945, PDF pp. 89, 103, 233, 273).

The shipping and receiving records indicate that Carborundum actually returned 33 pounds of slugs to 

HHM Safe Co. on Sept. 27, 1943, which is three pounds more than received in June. The three-pound 

discrepancy was noted in accountability records, and presumably could be from differences in 

measured weights, or possibly contaminated residues added to the return shipment (both the project 

report text and shipping records indicate that sweepings, machine turnings, and residues from various 

subcontractors had to be recovered and returned, although there is no such detailed information for the 

limited machining work done by Carborundum). Table 5-1 presents the information associated with 

the slug-grinding operation (Accountability, 1944; Clinton, 1943; Clinton, 1944; Clinton, 1945, PDF 

p. 273).
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Table 5-1: Carborundum Radiological Work During the First Operational Period

Type of Work Radionuclides Amounts Report Type

(SRDB Ref ID)

Project No.

Grinding to determine the 

appropriate type of abrasive 

wheel and optimum speed 

for production grinding 

(June 1943).

Uranium

(U was physically 

on site from June 

1943-Sept. 1943.)

Ten unfinished 

slugs totaling 30 

pounds

Metal Fabrication Program

Dummy Slug Program and 

Unbounded Slug Program

(33190, PDF p. 103)

Clinton Engineer 

Works

Project 1553

In a letter to DuPont on July 2, 1943, Carborundum reported on centerless grinding tests using a 

specific grinding wheel and various set-ups and abrasives. Although some chatter still existed after a 

particular test, various dressing speeds were tried. By using a 26” per minute traverse of the diamond, 

seven pieces were ground without chatter. Two other pieces were used at a slower traverse speed. 

The letter also states that there was one smaller piece. Carborundum returned ten pieces per DuPont 

instructions. This document only reported on the results obtained and did not include the actual 

set-up, radiological exposure potential, or airborne potential (Centerless Grinding, 1943, PDF p. 5).

5.1.2 First Residual Period (1945-1958)

During World War II (the first operational period at the site), the Carborundum Company was 

involved with centerless-grinding testing using grinding wheels and different abrasives. (Centerless 

Grinding, 1943). The residual radioactive materials that remained from covered radiological 

operations occurring during the first operational period are all that must be accounted for in the first 

residual period. The subsequent operations that occurred between the first and second operational 

periods at the Buffalo Avenue facility are discussed in the following paragraphs.

After the war, Carborundum embarked on an ambitious commercial expansion plan. Improvement of 

traditional product lines was part of this expansion. The company upgraded and expanded facilities in 

order to make the company more competitive in the postwar era. The Niagara Falls facilities were 

modernized and new facilities were built or purchased in other areas across the United States and 

Canada.

Carborundum was involved with many projects during the first residual period, many not specifically 

located at the Buffalo Ave. plant. Carborundum began development of its Fiberfrax ceramic fiber 

and, in 1952, began to market its first commercial applications (Carborundum Company, 2015). In 

the 1952-1953 time-frame, Carborundum began experiments to commercially produce a grade of 

boron carbide suitable for the fabrication of Boral (Site Inspection, 1990). This work was 

non-radiological. In October 1954, a new line of tool room wheels known as the V-40 line made a 

debut. The development of the V-40 wheels at the Bonded Abrasives Division was based on input 

and suggestions gathered in the field from grinding machine operators. (Carborundum History, 1991, 

PDF p. 73). 

Beginning in 1955, Carborundum was involved with the production of silicon carbide for structural 

materials for the Aircraft Nuclear Propulsion Department of General Electric Company. The GE 

contract went from September 28, 1955 to September 27, 1956. Carborundum proposed and was 
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granted an extension to September 28, 1957 (Silicon Carbide, 1956). A second extension was given 

into 1958 (Silicon Carbide, 1957). A second periodic report was issued in May 1956 (Silicon 

Carbide, 1958). This contract was identified as commercial work and therefore, is not included in the 

covered period evaluation.

NIOSH interviewed several former Carborundum employees who worked during the first residual

period. One former employee stated he worked in different departments in the Diamond Wheel 

Department and also worked on a lathe. He made diamond insets to cut different kinds of metals 

(Personal Communication, 2015b). The other former employee stated he was involved with the 

synthesis of ceramic materials, borides, carbides, nitrides, and silicides. He handled enriched 

Boron-10 and processed over 2000 pounds that was converted to boron carbide, which was not 

radioactive. He also stated he made thorium oxide and thorium carbide in the early stages of his work 

(~1955) (Personal Communication, 2015d).

5.1.3 Second Operational Period (1959-1967) Process Descriptions

During the second operational period, the Carborundum Company worked as a prime or subcontractor 

on many contracts for the AEC, including United Nuclear Corporation (formerly Nuclear 

Development Corporation of America). Table 5-2 lists the contracts within this operational period 

with brief descriptions of the work. Some of these contracts are discussed in more detail in the 

subsequent text. There were seven contracts that covered the work during this second operational 

period (1959-1967). 

Synthesis and Fabrication of Uranium Refractory Compounds:

• Contract AT-(40-1)-2558 covered uranium work from May 1959 through December 1960. The 

purpose of this work was to develop methods to synthesize the materials UN, UC, and U3Si2. 

Many batches of UC were made with batch sizes ranging from about 30 grams to 6 pounds. This 

work was part of the AEC Fuel Development Program (Refractory Uranium, 1959-60, PDF p. 13). 

This was the beginning of the uranium contract work and covered AEC work for the second 

operational period.

Synthesis and Study of Uranium/Plutonium Carbide Pellets:

• Contract AT-(30-1)-2303 was part of the Carbide Fuel Development Program initiated in May 

1959. Design and construction of a facility for carbide fabrication at the Carborundum Company 

was completed in 1960. The equipment was tested by work with UC prior to the start-up of 

operations with plutonium in March 1961 (first shipment of Pu received in June 1960). Seven 

batches of PuC were made by mixing PuO2 and carbon, then furnacing at differing temperatures 

and hold times (Carbide Fuel, 1961, PDF p. 14).

• Contract AT-(30-1)-2899 covered work from May 15, 1959 through October 15, 1965. As part of 

the Carbide Fuel Development Program, this work was concerned with the technology of UC-PuC 

fuels. The major goals were to produce (UPu)C and obtain data on its irradiation behavior for 

long burn-ups and at high-power generation rates. Four hundred grams of (U0.95Pu0.5)C0 98 powder 

was synthesized for fabrication (Final Report, 1965).
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Synthesis and Study of Uranium/Plutonium Monoxides:

• Contract AT-(30-1)-3305 covered work from February 1, 1964 through October 30, 1965. 

Carborundum was the subcontractor to United Nuclear Corporation and conducted fabrication 

studies of uranium and plutonium monoxides in helium. Mixtures of UO2-PuO2 were used to 

synthesize U-Pu monoxide compositions (Monoxides, 1966, PDF pp. 5-6).

• Contract AT(30-1)-3713 was associated with the AEC Fuel Cycle Development and studied the 

preparation of mixed carbide fuel using co-precipitation and the synthesis of (UPu)C. This 

contract covered the period May 23, 1966 through February 28, 1967 (Mixed Carbide Fuel, 1966; 

Final Report, 1967). The end date of this contract corresponds to the end of the AEC contract 

work and second operational period at Carborundum.

Out-of-Pile Properties of Mixed Uranium Plutonium Carbides:

• Contract AT-(30-1)-3118 covered the time period from February 6, 1962 through December 6, 

1963 and was closely coordinated with the AEC-sponsored Carbide Fuel Development Program. 

Carborundum was a subcontractor to United Nuclear Corporation whereby UNC performed the 

property determinations and Carborundum prepared the fuel samples. Four 100-gram synthesis 

batches were prepared from UO2, PuO2, (UPu)C. Also, a total of 550 grams of UO2, PuO2, and 

carbon powder was synthesized in 70-100-g batches (Out-of-Pile Progress, 1963, PDF pp. 17, 22)

• Contract AT-(30-1)-3254 was closely coordinated with the Carbide Fuel Development Program. 

The goal under this contract was to determine the out-of-pile properties of (UPu)C which have the 

most significant effect on the operational characteristics of the fuel. The powder fabrication 

initiated under AT (30-1)-2889 continued with this contract (Out-of-Pile Final, 1963, PDF pp. 10, 

14).

During this second operational period, a great deal of research was conducted at the Buffalo Avenue 

facility. This research began in May 1959 with uranium work. In 1960, a facility was completed for 

the synthesis and fabrication of UC-PuC fuels. As noted by the contracts information, the first 

plutonium shipment was received in June 1960 and plutonium work began in March 1961. 

Carborundum was contracted to mix uranium and plutonium fuels as part of their work on the Carbide 

Fuel Development program in support of UNC. While different mixtures were possible, the most 

common carbide mixture included 95% uranium and 5% plutonium. All work with radioactive 

material was done in the Central Research Laboratory, which was specifically constructed to support 

this work. The classified work with plutonium was conducted on the fourth floor in a secure room 

that required an escort for entry (Personal Communication, 2015c). 

Several former employees were interviewed to discuss the work that they performed at Buffalo 

Avenue. Some of the work consisted of mixing uranium and plutonium oxides together in relatively 

small amounts (mg to gm) to make pellets. The results of each experiment were recorded in log books 

and the pellets were sent for spectroanalysis to determine the specific compounds that resulted 

(Personal Communication, 2015a). Much of the work with the uranium and plutonium mixtures was 

performed in glove boxes. One interviewee stated that he worked with small amounts because of a 

limitation imposed by the site based on the limitations of the available equipment. It was stated that
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there were glove boxes, small tube furnaces, and a large high-frequency furnace that were used to 

make uranium carbide (Personal Communication, 2015d). In addition, there was classified work that 

employed a special room requiring an escort for entry. One interviewee noted that the plutonium for 

the classified project was restricted to 200 mgs at any one time. The interviewee who discussed this 

operation was not aware how many experiments were performed using 200 mgs of plutonium

(Personal Communication, 2015c).
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Table 5-2: Carborundum Radiological Contract Work During the Second Operational Period

Contract No. Years Reported Type of Work Radionuclides

(SRDB Ref ID)

Amounts

(SRDB Ref ID)

Comments

(SRDB Ref ID)

Report Type

(SRDB Ref ID)

AT-(40-1)-2558

5/59-12/60

Synthesis and fabrication of 

refractory U compounds: 

Three phases: (1) 

development of methods for 

synthesis of compounds; (2) 

fabrication of synthesized 

materials; and (3) 

determination of properties, 

such as thermal conductivity, 

thermal expansion, hightemperature strength.

Purpose: To develop 

methods to synthesize the 

materials UN, UC, and 

U3Si2. Purpose was to 

develop methods of 

fabrication and to study 

various properties of the 

compounds for use as reactor 

fuel.

UO2, U3O8, UN 

(powder), U3Si2

Request for 10 

pounds of U 

shot

(46756)

Many batches” 

of UC were 

made; batch 

sizes ranged 

from about 30 g 

to 6 lb. 

(140519)

1500 gm batch 

of UN

1200 gms of 

UN was made 

(140489)

3 lb lot of UC 

was prepared 

by the carbon 

reduction of 

UO2 

100 gms of U 

metal shot was 

acid treated 

(140492)

Part of the AEC Fuel 

Development Program

The goal was to develop 

refractory uranium materials 

possessing a sufficient 

advantage over UO2. 

Initial contract period was 

5/13/59 through 11/1/60. No 

work done during May/June 

for facility improvements.

Carborundum had to replace a 

glove box that was being used 

for some of the uranium work 

on this contract.

(140489)

Summary Report

(140519)

4th Quarterly 

Report

(140516)

5th quarterly report

(140518)

Monthly report

(140489)

Report 8

(140492)

Report 10

(140496)

Report 11

(140498)

3/1/61-5/31/61

Synthesis and fabrication of 

refractory U compounds.

Sintering of U monocarbide. 

Depleted UO2; 

Thermax 

Thermatomic 

Carbon

453.6 g of UO2; 

60.5 g of 

carbon for each 

synthesis 

experiment.

Purpose of work: develop 

refractory U materials 

possessing sufficient 

advantages over UO2 to 

warrant their use as reactor 

fuels. The UC was a powder. 

Depleted UO2 from ORNL; 

Thermax Thermatomic 

Carbon from R.T. Vanderbilt 

Co.

Two modifications were 

made to this contract to go 

beyond 12/60.

First Quarterly 

Report

(45329)
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Table 5-2: Carborundum Radiological Contract Work During the Second Operational Period

Contract No. Years Reported Type of Work Radionuclides

(SRDB Ref ID)

Amounts

(SRDB Ref ID)

Comments

(SRDB Ref ID)

Report Type

(SRDB Ref ID)

6/6/60

Fabrication of plutonium 

carbide pellets using some of 

the following methods:

ball milling, chemical 

analyses, crushing, cold 

pressing, sintering, grinding 

pellets.

PuO2, UO2 3 kg of Pu over 

3 years; the first 

and only 

shipment in 

1960 will be 

500 g of Pu 

from Hanford.

Carbide Fuel Development.

Report states that if there is 

any external radiation 

exposure it will be to the 

hands. All Pu compounds 

will be handled on a 

containment basis. Maximum 

amount of contained Pu will 

Feasibility Report

(19739)

not exceed 600 g. No more 

than 200 g of Pu shall be in 

AT(30-1)-2303

process.

2/1/61-4/30/61

Fuel Fabrication and 

Evaluation: Explore various 

methods of fuel preparation 

and fabrication into 

cylindrical pellets, beginning 

with powders. Evaluate 

pellet density measurements.

Pu, Pu+U-235, 

PuC-UC, UO2

Synthesis of 

PuC from PuO2. 

Seven batches 

of PuC were 

made by mixing 

PuO2 and 

carbon then 

furnacing at 

differing 

The Pu facility started 

operations in March 1961. 

Prior to 1961, the equipment 

was tested by work with UC.

Six reports are listed in 

covering 10/15/59 to 2/28/61 

(61981); these reports are 

currently unavailable.

Progress Report

(61981)

temperatures 

and hold times. 

AT(30-1)-3118 2/6/61-12/6/63

Out-of-pile properties of 

mixed U-Pu carbides. Goal is 

to determine the properties

of (UPu)C.

Pu, U

Materials 

produced. 80% 

UC-20% PuC 

solid solutions

Four 100 gm 

synthesis 

batches were 

prepared from 

UO2, PuO2, 

(UPu)C. A

total of 550 gm 

of UO2, PuO2

Prepared fuel samples. This 

program was closely 

coordinated with the Carbide 

Fuel Development program 

(AT30-1)-2899.

Final Report

(65005)

and carbon 

powder was 

synthesized in 

70-100- gm 

batches
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Table 5-2: Carborundum Radiological Contract Work During the Second Operational Period

Contract No. Years Reported Type of Work Radionuclides

(SRDB Ref ID)

Amounts

(SRDB Ref ID)

Comments

(SRDB Ref ID)

Report Type

(SRDB Ref ID)

5/1959-

10/15/65** 

UNC* provided conceptual 

design, fuel evaluation, and 

fuel irradiation. The 

Carborundum Company 

performed fuel fabrication.

UC, PuC

All work 

investigated 

mixed carbides 

at 20 w/o PuC, 

except property 

measurements 

which were 

made at 5 w/o 

PuC fuel.

400 g of (U0.95 

Pu.0.5)C0.98 

powder was 

synthesized for 

fabrication (70 

pellets were 

fabricated).

The Carbide Fuel 

Development Program was 

concerned with the 

technology of the entire UCPuC fuel cycle. The major 

goals were to produce 

(UPu)C and obtain data on its 

irradiation behavior for long 

burn-ups and at high-power 

generation rates. Other areas 

of the fuel cycle were 

explored to discover possible 

problems.

Final Report 

(53617)

Six reports were 

published under 

this contract, 

Phases I-VI

AT(30-1)-2899

Program initiated in May 

1959; continued for 4.5 years.

9/15/61-12/31/61

Explore methods for 

preparation of fuel from 

powders and its fabrication 

into cylindrical pellets, 

evaluate pellets by density 

measurement, chemical 

analysis, X-ray diffraction, 

hardness.

UC-PuC

powder was 

synthesized 

from oxides 

and carbons

Produce 

(U0.8Pu0.2)C0.95

NOTE: Comment in report 

says Pu facilities continued 

satisfactory operation at zero 

contamination levels

NOTE: Pu is lost during 

synthesis or sintering and a 

small amount of Pu being lost 

during annealing.

(61996)

1/1/62-3/31/62

AEC fuel-cycle development 

program concerned with 

entire UC-PuC fuel cycle. 

Fuel fabrication done by 

Carborundum.

Pu, U

UC-PuC pellets 

Sintering 

experiments 

with 

(U0.8Pu0.2)C0.95 

Carbide Fuel Development, 

part of AEC Fuel Cycle 

Development Program.

Fuel made of UC and PuC 

Progress Report

(61995)

had a potential of reducing 

fuel-cycle cost of existing 

fast-breeder reactors.
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Table 5-2: Carborundum Radiological Contract Work During the Second Operational Period

Contract No. Years Reported Type of Work Radionuclides

(SRDB Ref ID)

Amounts

(SRDB Ref ID)

Comments

(SRDB Ref ID)

Report Type

(SRDB Ref ID)

AT(30-1)-2899

(cont.)

4/1/62-6/30/62

Fabrication of the UC-PuC 

irradiation tests

UC, PuC, UCPuC pelletsAll powder 

required for the 

NU was 

synthesized 

Reaction to the 

760 gm batch 

of PuO2-UO2-C 

yielded ~580 g 

of single phase 

(U0.2Pu0.2)C0.95

solid solution

There are 10 previous reports 

listed in this progress report.

Progress Report

(61990)

Performing conceptual 

design, fuel evaluation and 

fuel irradiation. 

Powder 

containing 

normal U, EU, 

Pu

760 gm batch 

of PuO2-UO2-C 

yielded ~580 g 

of 

(U0.8Pu0.2)C0.95, 

200 g of 

Carbide Fuel Development, 

this project is sponsored by 

the USAEC Division of 

Reactor Development.

Goal was to produce UC-PuC 

Phase IV Report

(65097)

9/15/61-9/30/62

(U0.8Pu0.2)C0.95 

powder were 

produced in 40 

gm lots

Each specimen 

contained 16 

fuel pellets.

to obtain data on irradiation 

behavior for long burn-ups 

and at high-power generation 

rates.

Goal was to develop method 

for preparation of high 

density pellets for irradiation 

studies Experiments were run 

with both normal and 

enriched U.

11 previous reports listed
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Table 5-2: Carborundum Radiological Contract Work During the Second Operational Period

Contract No. Years Reported Type of Work Radionuclides

(SRDB Ref ID)

Amounts

(SRDB Ref ID)

Comments

(SRDB Ref ID)

Report Type

(SRDB Ref ID)

AT(30-1)-2899

(cont.) 10/1/62-3/31/63

Produce (UPu)C and obtain 

data on its irradiation 

behavior for long burn-ups 

and at high-power generation 

rates.

(UPu)C Synthesis of 

about 400 g of 

(U0.95Pu0.05)C0.98

50 gm reaction mixes of 

PuO2, UO2 were blended and 

cold pressed. There were 8 

synthesis experiments.

Progress Report

(65092)

12 NDA and 

UNC* progress 

reports listed prior 

to this report from 

10/15/59-3/31/63

AT(30-1)-3254 2/6/62-10/31/62

Out-of-pile properties of 

mixed U-Pu carbides. 

Carborundum prepared the 

fuel samples. Powder 

fabrication initiated under 

AT(30-1)-2889 is being 

continued.

(UPu)C

80% UC-20% 

PuC

Sintering 

experiments 

with 

(U0.8Pu0.2)C0.95

This program was closely 

coordinated with the Carbide 

Fuel Development program. 

The studies were a 

continuation of work 

performed under AT(30-1)-

2899

Progress Report

(64284)

8 previous reports listed

Study of U-Pu Monoxides. 

U-Pu monoxide 

compositions were 

synthesized by carbon and U 

reduction methods.

U, Pu

Depleted UO2, 

PuO2, UHx, 

UC, UN

Started with 

UO2-PuO2

mixtures to 

synthesize UPu monoxide 

Two synthesis routes: (1) 

reduction of mixed PuO2 and 

UO2 with carbon; (2) 

reduction of mixed dioxides 

with U metal: carried out in 

Final Summary 

Report

(65007)

2/1/64-10/30/65 type materials helium and vacuum at temps 

from 1450-19000

C.

AT(30-1)-3305 Previous progress in reports:

UNC*: 5096, 5102, 5117, 

5132, 5138, covering years:

2/1/64-9/30/65

7/1/65-9/30/65

Study of U-Pu monoxides Materials 

containing as 

high as 85 w/o 

of a (UPu)(OC) 

composition

Synthesis of 

(U0.8Pu02)C

Related reports: AT(30-

1)3254, 2/6/62-10/31/62 (see 

above)

Quarterly Progress 

Report

(65010)
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Table 5-2: Carborundum Radiological Contract Work During the Second Operational Period

Contract No. Years Reported Type of Work Radionuclides

(SRDB Ref ID)

Amounts

(SRDB Ref ID)

Comments

(SRDB Ref ID)

Report Type

(SRDB Ref ID)

AT(30-1)-3713

9/1/66-11/30/66

Part of the AEC Fuel Cycle 

Development Program

Studies of the preparation of 

mixed carbide fuel utilizing 

co-precipitation; synthesis of 

(UPu)C.

X-ray analysis used.

U as UO2; Pu

 

Concentration 

of the U or 

U,Pu in the 

nitrate solutions 

was ~0.15 g/ml

(U0.8Pu0.2)C Object is to extend the 

technology to the preparation 

of (UPu)C fuels 

Uranyl nitrate and Pu nitrate 

solutions were mixed to yield 

4/1 ratio of U to Pu. 

Quarterly Progress 

Report No. 2

(53582)

11/23/66-2/28/67

Part of the AEC Fuel Cycle 

Development Program

Study of synthesis (UPu)C 

compounds utilizing the coprecipitation of the carbon 

and metal-bearing materials 

from a common solvent.

(UPu)C Started with 

(U0.8Pu0.2)C 

Object is to extend the 

technology to the preparation 

of (UPu)C fuels 

Final Report

May 23, 1966-

February 28, 1967

(143094)

*United Nuclear Corporation (UNC), Development Division, was formerly Nuclear Development Corporation of America (NDA). The subcontractor is the Carborundum 

Company. UNC performed the conceptual design, fuel evaluation, fuel irradiation, and irradiated fuel examination. Carborundum fabricated the fuel. Both companies 

operated plutonium-handling facilities.

**X-ray diffraction analyses were not made on this program due to the carbide oxidizing on the planchet.
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An abstract published in Reactor Technology on liquid metal fast breeder reactors discusses the 

Carbide Fuel Development Phase 1 Report for the period from May 15 to September 15, 1959 

(Reactor Technology, 1960s, PDF p. 85). The abstract references contract AT(30-1)-2303 between 

the Nuclear Development Corporation of America (NDA) and the Carborundum Company. 

Subsequently, the Carbide Fuel Development project was the subject of a letter dated March 30, 1960,

to the Nuclear Safety Board from the Radiation Branch, Environmental Sciences Division, Health and 

Safety Laboratory. This letter discusses the proposal for the Carborundum Company to manufacture 

ceramic pellets containing PuC mixed with UC (normal enrichment) at their Central Research 

Laboratories in Niagara Falls, New York. Over a period of three years, a total of approximately three

kilograms of plutonium were to be fabricated into pellets. The first shipment of plutonium from 

Hanford (the only shipment during 1960) was to consist of 500 grams (Feasibility Report, 1960).

The following processes were to be involved in the fabrication of PuC pellets (operational details 

unspecified):

1. Weighing the PuO2 Powder as received from the supplier

2. Chemical analysis

3. Addition of UO2 and carbon

4. Ball milling

5. Heating to form the monocarbides

6. Crushing

7. Chemical and X-ray analysis

8. Ball milling

9. Cold pressing into pellets

10. Sintering into dense form

11. Grinding pellets

12. Inspection and shipment

The results of the Carbide Fuel Development project are documented in many reports, as indicated in 

the listings in the Foreword section of each progress report (Carbide Fuel, 1961, PDF p. 6).

Handling standards for plutonium were established in a planning document, which consisted of the 

following requirements:

1. All plutonium handling would be done in a glove box.

2. Any waste or scrap generated in the glove box would be removed using the “pouch” method.

3. The maximum amount of contained plutonium in storage shall not exceed 600 grams at any one 

time.

4. No single container could contain more than 200 grams of plutonium.

5. No more than 200 grams of plutonium or uranium/plutonium mix could be in-process at any one 

time.

6. No more than 100 grams of plutonium could be used in any single batch in process, with a 

maximum of two simultaneous batches in operation at any given time.
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Each phase of the operation of fuel fabrication and testing was performed in an inert helium 

atmosphere.

The minimum critical mass for a water-reflected solution containing Pu-239 was identified as 510 

grams, and the recommended safe mass was listed as 250 grams. Considering this information, the 

Carborundum Company pellet process was recommended for approval because the maximum of 200 

grams of plutonium that would be stored per container or be in process at any one time (Feasibility 

Report, 1960).

Carborundum was involved as a prime contractor or a subcontractor in several phases of the AEC’s

Fuels Cycle Development Program. One aspect of this work is described in the Summary Report, 

Synthesis and Fabrication of Refractory Uranium Compounds, dated February 1961 (Refractory 

Uranium, 1959-60). The report covers the period from May 1959 through December 1960.

The object of the investigation was the development of refractory uranium materials possessing 

sufficient advantage over uranium dioxide to warrant their use as reactor fuels (Refractory Uranium, 

1959-60). To this end, the various properties of these materials had to be examined. The materials 

chosen for examination consisted of uranium monocarbide (UC), uranium mononitride, and the 

silicide U3Si2 - all of which have higher densities than UO2 (Refractory Uranium, 1959-60).

The work program was divided into three phases: (1) the development of methods for synthesis of the 

compounds; (2) fabrication of the synthesized materials into bodies suitable for testing; and (3)

the determination of properties of the materials such as thermal conductivity, thermal expansion, and 

high-temperature strength (Refractory Uranium, 1959-60, PDF p. 10).

The majority of the work was conducted on small samples of various solutions of the uranium. For 

example, the chemical analysis included a representative batch of 1500 grams of UC was prepared 

from a non-pelletized mix of uranium, combined carbon, uncombined carbon, nitrogen, iron, and 

oxygen. It appears that, at various stages of the experimentation, it was necessary to use different 

furnaces or enclosures. The types of furnaces and enclosures that were available included: 

atmosphere induction furnaces, muffle furnaces, a vacuum induction furnace, nitriding furnaces, a 

quench furnace, a hot-pressing furnace, a thermal conductivity furnace, a high-temperature modulusof-rupture apparatus, a high-temperature furnace, and glove boxes (Refractory Uranium, 1959-60).

Another aspect of the work involved synthesis experiments with UC. Three approaches were 

considered for the preparation of UC: 

1. Reduction of an oxide (UO2 or U308) by carbon: For this experiment, carbon was heated with both 

UO2 and U3O8 to produce UC. The reaction mixture was usually prepared for furnacing as 

follows: the oxide and carbon were mixed by dry ball-milling for 24 hours in a rubber-lined mill 

with stainless steel balls and then pressed into pellets measuring 5/8 inches by 5/8 inches. This 

was done at 15,000 - 20,000 pounds per square inch using about 2 percent of water as a temporary 

binder (Refractory Uranium, 1959-60, PDF p. 11). It is unknown how many experiments were run 

or how much uranium was used for each experiment. However, many batches of UC were made 

by heating stoichiometric mixtures of UO2 and carbon in the vacuum induction furnace at 1750-

1800°C. The size of the batches varied from about 30 grams to 6 pounds (Refractory Uranium, 
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1959-60, PDF p. 13). The resulting mixtures underwent an X-ray analysis to determine the 

characteristics of the resulting compounds.

2. Reaction of ammonium diuranate and carbon: The experiment was based on the assumption that 

ammonium diuranate would decompose to U308 under the reaction conditions and the carbon 

would then react with the U308 to form uranium carbide (uranium monocarbide). The pellets were 

heated in a ceramic tube furnace in an argon atmosphere. A temperature of about 700°C was 

reached in approximately 20 minutes and the maximum temperature of 1700°C in about 3 to 4 

hours. The pellets were held at 1700°C for one hour and then allowed to cool in argon to room 

temperature (Refractory Uranium, 1959-60, PDF p. 14).

3. Reaction of Uranium and Carbon: This method of preparation was used exclusively in connection 

with a simultaneous synthesis and fabrication process described above for fabrication of uranium 

carbide (uranium monocarbide) (Refractory Uranium, 1959-60, PDF p. 14).

These experiments and others were all part of the Carbide Fuel Development Program, which was 

concerned with the technology of the entire UC-PuC fuel cycle. The major goal of the program was 

to produce (UPu)C and to obtain data on its irradiation behavior for long burn-ups and at high-power

generation rates. The program was initiated in May 1959 and, as originally outlined, covered a period 

of about 4-1/2 years (Carbide Fuel, May1963, PDF p. 18).

Many of the overall experiments consisted of the following: synthesizing compounds and fabricating 

them into pellets; determining the coefficients of expansion; measuring melting points and vapor 

pressures; checking compatibility with other elements at various high temperatures; and performing 

irradiation tests (X-ray diffraction). These procedures involved handling of the radioactive material in 

one form or another in order to mix the chemicals and make transfers between the many enclosures 

for individual tests; this handling provided potential opportunities for exposure.

The exact quantities used in each experiment are not known. However, NIOSH does have 

information from a September 19, 1962 contract closeout notification in which Carborundum notified 

the Nuclear Regulatory Commission (NRC) of the radioactive material quantities on-hand and 

requested disposal instruction prior to the closeout of contract AT(40-1)-2558 (Contract Closeout, 

1962). Section 5.2.2.3 lists the radioactive material that Carborundum had at that time. However, one 

of the steps in the fuel fabrication and evaluation was the preparation of powder for synthesizing the 

uranium, plutonium, and carbide mixture as well as the fabrication of test specimens. This process 

used a total of about 400 grams of a powdered mixture of uranium, plutonium, and carbide (Carbide 

Fuel, May1963, PDF p. 12).

This program was to evaluate the out-of-pile properties of mixed uranium-plutonium carbides at the 

5% Pu level. A total of about 400 g of (U0.95 Pu0.5) C0.98 powder was synthesized for the fabrication of 

test specimens.

Fifty-gram reaction mixes of PuO2, UO2, and carbon were blended and cold-pressed without a binder 

at about 5000 psi (pieces about 0.2 in. in diameter), and then heated in helium to 1625°C with a hold 

time of 5-1/2 hours. The reaction end-point was determined by monitoring the exhaust gas drawn 

from the heated furnace for CO. The results of analyses for total carbon and X-ray diffraction, as 

determined on the pulverized reaction products, showed the percent total carbon to be 4.94, 4.88, 4.74, 
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4.66, 4.78, 4.76, 4.73, and 4.79 respectively for the eight experiments (400 total grams split into 50 

gram portions). 

It was also stated that normal uranium was used in this synthesis. The carbide powders resulting from 

the eight synthesis experiments were combined and subsequently ball-milled for 24 hours in a rubberlined mill using stainless steel balls and then sent for X-ray diffraction (Carbide Fuel, May1963, PDF 

p. 12).

X-Ray Diffraction

The ceramic pellets containing PuC-UC were manufactured by Carborundum as a subcontractor to 

United Nuclear Corporation, Inc. The fuels were evaluated by various means, including X-ray 

diffraction analysis (XRD) (Breslin, 1960). The X-ray powder diffraction method is used very 

extensively for compound or phase identification (Gundaker, 1971). Carborundum used this method

to analyze the fuel as part of the fuel fabrication process. 

In XRD, a very small beam of low-energy monochromatic X-rays irradiated a sample of matter –

mixed-oxide fuel (PuC-UC) in the case of Carborundum. The X-rays are scattered by the individual 

atoms in the sample. In crystalline samples, the atoms are arranged in a lattice pattern. The scattered 

X-rays from the sample will interfere with each other, causing scattered X-rays to be emitted only in 

some directions and not others. This causes a diffraction pattern that can be recorded and analyzed, 

providing specific information about the atomic structure of the sample. 

5.1.4 Second Residual Period (1968-19764)

All covered AEC work at the Carborundum Company was completed in 1967, which marks the end of 

the second operational period and beginning of the second residual period. The residual radioactive 

materials that remained from covered operations occurring during the second (and first) operational 

period(s) are all that must be accounted for in the second residual period. The operations that 

occurred between the second operational period and the end of the evaluated (covered) period at the 

Buffalo Avenue facility are of no radiological consequence; these interim operations are discussed in 

the following paragraphs.

There was some information on the non-radiological work that continued at the Carborundum 

Company during the second residual period, which included the following:

• In 1968, Carborundum manufactured some boron carbide powder for GE Atomic Power. Some of 

this material was tested for composition and density by ORNL in 1969, but the Carborundum 

work was not radiological (Fabrication, 1970).

• In 1968, Carborundum did some studies for Westinghouse Astronuclear Laboratory (WANL) on 

niobium carbide, but the work was not radiological (Niobium, 1969).

 4 As previously discussed, the second residual period as defined by DOE ends in 1992; however, based on the feasibility 

findings presented in this evaluation report, the assessment of the second residual period is limited to the petitionerrequested class time-frame, which extends only through 1976.
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• In 1972, Carborundum produced some un-irradiated cylindrical pellets of boron carbide for testing 

as part of the EBR II program (EBR II, 1972). 

NIOSH interviewed several former Carborundum employees who worked during the second residual 

period. One former employee stated that he worked in the mid-1970s and made bullet-proof vests and 

armor for PT boats. The base product was carbon. The material was put into ovens to make the 

plating for the armor. Sometimes the plating would be cracked. If the plating could be fixed, it would 

need grinding and smoothing; this created a lot of dust. Masks were not used during this process and 

there was no ventilation (Personal Communication, 2015b). The plates for the armor vests were made 

for the Vietnam War and this work was done in Building 14. This building had a firing range to test 

the armor plating (Personal Communication, 2015f). 

Although the Carborundum Company is mentioned by name in numerous documents because of their 

grinding wheels, NIOSH did not find any information on any other potentially-covered radiological 

operations after 1967. 

 

There are Carborundum Company annual reports available to NIOSH for 1971, 1972, and 1973 that 

discuss overall sales and expenditures; however, these reports do not discuss any further ongoing 

AEC-related processes (Annual Report, 1971; Annual Report, 1972; Annual Report, 1973).

5.2 Radiological Exposure Sources from Carborundum Company Operations

The following subsections provide an overview of the internal and external exposure sources for the 

Carborundum Company class under evaluation. Carborundum performed a great deal of research and 

development with mixtures of uranium oxide and plutonium oxide to develop fuel pellets, synthesize 

chemicals, and fabricate fuels.

The radionuclide-specific source terms that may be applicable to operational and residual radioactivity 

periods at Carborundum are uranium and plutonium. The following subsections describe the 

radioactive materials applicable to the time-period discussions within this section of this report. 

In December 1960, a paper, Status of Carbide Fuel Development at the Carborundum Company, was 

presented at the third AEC Uranium Carbide meeting at Oak Ridge. This paper described the work 

done since the previous meeting, the future work that was planned, and some of the changes that were 

to be made in the uranium carbide–plutonium carbide fuel development program. Plutonium carbide 

was to be synthesized from plutonium oxide (PuO2) that was prepared by Dow Chemical by the 

oxidation of plutonium metal. The oxide contained approximately 240 ppm of impurities. Table 5-3 

shows the isotopic analysis of the PuO2 (Carbide Fuel, 1960, PDF p. 8). 
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Table 5-3: Isotopic Analysis of PuO2

Isotope Percent

Pu-238 0.00

Pu-239 93.50

Pu-240 5.90

Pu-241 0.60

Pu-242 0.00

As indicated in the October 15, 1965 document, Carbide Fuel Development Final Report (Final 

Report, 1965, PDF p. 48), Carborundum used PuO2 from Dow Chemical in the study of the 

preparation of (UPu)C powder. The impurities in this powder was stated as <400 ppm; these 

impurities would contain traces of Pu-240 and Pu-241. 

In addition, the 1966 Final Summary Report of the Study of Uranium-Plutonium Monoxides

(Monoxides, 1966), indicated that the goal of the study was to find a uranium-plutonium 

monoxide-type fuel for water-cooled thermal reactors that would have a heat-generation capability 

better than, and water-corrosion resistance equivalent to, Pu02 and (UPu)02. 

Plutonium enrichment was employed in this study in anticipation of the day when sufficient 

plutonium would be available to reduce reliance on uranium isotope enrichment facilities. Although 

early core loadings would use Pu-239, subsequent ones could use increasing amounts of Pu-240 to 

increase the reactivity burn-up limit of the reactor. Total plutonium concentrations of up to 10% 

would be introduced into the uranium fuel (Monoxides, 1966, PDF p. 14). In addition to Pu-239, 

Pu-240 and Pu-241 could also be sources of exposure. 

Natural uranium refers to uranium consisting of approximately 99.3% U-238, 0.7% U-235, and a very 

small amount of U-234, by weight. In terms of radioactivity, natural uranium contains approximately 

equal percentages of U-238 (48.6%) and U-234 (49.2%). These radionuclides emit alpha particles 

with primary emission energies of 4.20 MeV and 4.15 MeV (U-238), and 4.77 MeV and 4.72 MeV 

(U-234) (Rad Handbook, 1970). The radioactivity contribution from U-235 is much smaller 

(approximately 2.2%) relative to U-238 or U-234. U-235 emits alpha particles with energies of 4.40 

MeV and 4.37 MeV. Plutonium provides a source of alpha activity. Pu-239 emits alphas with 

primary emission energies of 5.11 MeV (11%) and 5.16 MeV (88%). Pu-240 emits alphas with 

primary emission energies of 5.12 MeV (24%) and 5.17 MeV (76%). Pu-241 emits alphas with 

primary emission energies of 4.85 MeV (0.0003%) and 4.90 MeV (0.0019%). (Rad Handbook, 1970). 

Many of the contracts involving Carborundum overlapped for various periods of time and 

involved different process materials. Table 5-4 presents Carborundum contracts in parallel 

timelines; the corresponding process materials represent the respective source terms for the 

periods. 
SEC-00223 06-03-15 Carborundum Company 

Page 38 of 79 

Table 5-4: Summary of Carborundum Exposure Sources Over the Contract Timelines

Contract/Type of Work

(SRDB Ref ID)

Years

1943 1944 1945-

1954

1955-

1958

1959 1960* 1961 1962 1963 1964 1965 1966 1967

Clinton Engineer Works 

Project 1553:

Metal Fabrication 

U --- --- --- --- --- --- --- --- --- --- --- ---

Program, Dummy Slug 

Program and Unbounded 

Slug Program 

(machining, grinding, 

grooving).

(33190)

AT-(40-1)-2558: 

Synthesis and Fabrication 

of Refractory U 

Compounds.

(140519)

(45329)

--- --- --- --- UO2, 

U3O8, 

UN 

powder, 

U3Si2

UO2, 

U3O8, 

UN 

powder, 

U3Si2

Depleted 

UO2; 

--- --- --- --- --- ---

AT(30-1)-2899: Carbide 

Fuel Development 

Program: Fuel 

Fabrication.

(53617) 

--- --- --- --- UC UC, Pu UC, PuC

Powder 

containing 

normal U, 

Eu, Pu

UC, PuC

Pellets

Powder 

containing 

normal U, 

Eu, Pu

UC, PuC UC, PuC

Mixed 

carbides

UC, 

PuC

Mixed 

carbides

--- ---

AT(30-1)-2303: Carbide 

Fuel Development

(61981)

(53617) 

--- --- --- --- --- UC, 

UO2,

Pu

--- --- --- --- --- --- ---

AT(30-1)-3118;

closely coordinated with 

AT(30-1)-2899

(65005)

--- --- --- --- --- --- U-Pu 

carbides

--- --- --- --- --- ---

AT(30-1)-3254; closely 

related to AT(30-1)-1. 

Studies were a 

continuation of AT(30-

1)-2889.

(64284)

--- --- --- --- --- --- --- (UPu)C

80% UC20% PuC

--- --- --- --- ---
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Table 5-4: Summary of Carborundum Exposure Sources Over the Contract Timelines

Contract/Type of Work

(SRDB Ref ID)

Years

1943 1944 1945-

1954

1955-

1958

1959 1960* 1961 1962 1963 1964 1965 1966 1967

AT(30-1)-3305: Study of 

U-Pu Monoxides; UNC 

Project-2321

(65007)

--- --- --- --- --- --- --- --- --- U, Pu

Depleted 

UO2, 

PuO2, 

UHx, 

UC, UN

U, Pu

Deplete

d UO2, 

PuO2, 

UHx, 

UC, UN

--- ---

AT (30-1)-3713; 

Associated with the AEC 

Fuel Cycle Development 

Program: Studies of the 

preparation of mixed 

carbide fuel utilizing coprecipitation; synthesis of 

(UPu)C.

(53582)

--- --- --- --- --- --- --- --- --- --- --- UO2; Pu

(UPu)C

UO2; Pu

(UPu)C

Three hyphens (---) mean there was no corresponding contract activity during this period.

* The sources of Pu in 1960 were limited to a shipment received in late 1960; processing did not begin until March 1961. 
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Page 40 of 79 

5.2.1 Internal Radiological Exposure Sources from Carborundum Co. Operations

The primary potential source of internally-deposited radioactivity resulting from Carborundum 

Company operations was inhalation and ingestion of natural, depleted, and enriched uranium and 

plutonium. Uranium was present at the site as a powder. In addition, plutonium-239 was present 

during the second operational period.

5.2.1.1 First Operational Period (1943-1944) 

As indicated previously, Carborundum was involved with centerless-grinding testing using grinding 

wheels and different abrasives. This effort also included performing work on uranium slugs. The 

quantity of material identified in the first operational period is approximately 30 lbs of uranium (10 

slugs) that were shipped between Carborundum and HHM Safe Company (Clinton, 1943, PDF pp. 9, 

14). It was also noted that one rod was authorized to be sent to Carborundum on May 17, 1943 for 

centerless grinding experiments (Clinton, 1945, PDF p. 273). Based on the shipping records and 

description of work performed during the first operational period, NIOSH has concluded that 

Carborundum received 10 slugs. The slugs were received on June 1, 1943; the grinding work was 

done that month and results were reported on July 2, 1943. Return shipment of the slugs was not 

made until September 27, 1943. DuPont reported that there was no health supervision required 

because of the limited work performed (T-metal, 1944, PDF p. 13). Although the work was limited, 

centerless grinding of uranium has been known to produce significant levels of airborne radioactivity, 

creating an inhalation and ingestion hazard.

5.2.1.2 First Residual Period (1945-1958) 

Only the residual materials that were considered a primary source during the first operational period 

need to be considered during the first residual period. Therefore, only natural uranium is considered 

to be a source that must be accounted for during the residual period from 1945-1958. 

5.2.1.3 Second Operational Period (1959-1967) 

Work at Carborundum during the second operational period (1959-1967) consisted of research and 

development. During this period, Carborundum worked with uranium and plutonium powders and 

chemicals to synthesize fuel pellets, and to develop refractory uranium materials possessing sufficient 

advantage over uranium dioxide to warrant their use as reactor fuels. Carborundum fabricated test 

samples of these materials and performed a variety of tests to verify their economic viability and their 

ability to replace uranium dioxide fuels. Although much of the experimentation and testing was 

conducted in enclosures, there was a potential for internal exposure (inhalation or ingestion) during 

the handling of uranium and plutonium powders and chemicals. 
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At its Central Research Laboratories in Niagara Falls, the Carborundum Company manufactured 

ceramic pellets that contained PuC mixed with UC (normal enrichment). During a three-year period, 

approximately three kilograms of plutonium were fabricated into pellets. The first plutonium 

shipment came from Hanford in 1960 and was 500 grams (Feasibility Report, 1960). The plutonium 

source term for this period is assumed to be the 10-year-aged 12% plutonium mix that has been used 

to bound the doses (see Section 7.2.2.1) 

According to an interviewee, the plutonium work he did was classified and he was the only one in the 

room making pellets with a mixture of uranium and plutonium (Personal Communication, 2015c). 

NIOSH has not identified the specific procedures employed for this individual’s work but it is 

assumed to be the same or similar chemical analysis discussed previously for making fuel pellets. 

Consequently, there would have been some potential for internal exposures to chemicals and powders. 

At the time Carborundum closed out contract AT(40-1)-2558 for source and special nuclear material, 

it had in its possession various amounts of depleted and 10% enriched uranium powder (Contract 

Closeout, 1962). These forms of uranium were used in the preparation of UC pellets and varioussized pieces were used for testing physical properties in connection with the Carbide Development 

Program (Carbide Fuel, 1960). 

5.2.1.4 Second Residual Period (1968-19765

) 

As is the case with the first residual period, only the residual materials considered a primary source 

during the second operational period (and any carryover from the first operational period) need to be 

considered during the second residual period. Therefore, uranium and plutonium are considered to be 

sources that must be accounted for during the second residual period from 1968-1976, as evaluated in 

this report. 

5.2.2 External Radiological Exposure Sources from Carborundum Co. Operations

Based on information and documentation available to NIOSH, as discussed in this evaluation report, 

the potential for external radiation doses from uranium, uranium decay products, and plutonium 

existed at the Carborundum Company. The following subsections discuss the external exposure 

sources for the Carborundum Company workers evaluated in this report. The external sources result 

in photon and beta radiations represented in Table 5-5, as well as some potential neutron exposures. 

 

5 As previously discussed, the second residual period as defined by DOE ends in 1992; however, based on the feasibility 

findings presented in this evaluation report, the assessment of the second residual period is limited to the petitionerrequested class time frame, which extends only through 1976.
 

 

 

SEC-00223 06-03-15 Carborundum Company 

Table 5-5: Principal Radiation Emissions from Natural Uranium and Short-lived Decay Products 

Radionuclide Half-life Beta Energy (MeV Max) Photon (x or γ) Energy (MeV) 

U-238 4.468 x 109 years None x: 0.013 (8.8%) 

Th-234 24.1 days 0.096 (25%) x: 0.013 (9.6%) 

0.189 (73%) γ: 0.063 (3.8%) 

γ: 0.093 (5.4%) 

Pa-234m 1.17 minutes 2.28 (98.6%) γ: 0.765 (0.2%) 

~1.4 (1.4%) γ: 01.001 (0.6%) 

U-235 7.038 x 108 years None x: 0.013 (31%) 

x: 0.090-0.105 (9.3%) 

γ: 0.144 (10.5%) 

γ: 0.163 (4.7%) 

γ: 0.186 (54%) 

γ: 0.205 (4.7%) 

Th-231 25.5 hours 0.206 (15%) x: 0.013 (71%) 

0.288 (49%) γ: 0.026 (14.7%) 

0.305 (35%) γ: 0.084 (6.4%) 

U-234 244,500 years None x: 0.013 (10.5%) 

γ: 0.053 (0.2%) 

Source: Battelle-TBD-6000, PDF p. 20. The above table shows the principal radiation emissions from natural 

uranium and its short-lived decay products that are of concern for external radiation (not including bremsstrahlung). 

Photon 

Carborundum conducted work with natural, depleted, and enriched uranium as well as plutonium. 

External exposures to photon radiation would have resulted from the immediate daughter 

radionuclides in the uranium decay chain. The uranium progeny that result in the most significant 

photon exposures include Th-234 and Pa-234m (Rad Handbook, 1970). Note that these isotopes have 

relatively-short half-lives and can be assumed to be in equilibrium with the parent U-238. Because of 

their short half-lives, the exposure potential from these isotopes would travel with the parent and will 

not be considered separately. Plutonium itself is not a major contributor to photon dose. However, 

Pu-239 decays by alpha emission to U-235, whose short-lived daughters do contribute to total photon 

exposure. Table 5-5 shows the primary isotopes, principal emissions, and photon energies associated 

with natural uranium and short-lived decay products. 

Beta 

Radiation fields from uranium are frequently dominated by contributions from daughter-product 

radionuclides. For example, nearly the entire beta radiation field from DU comes from the daughter 

radionuclide Pa-234m, and to a lesser extent, from Th-234. 

Table 5-5 shows the principal beta emitters and their energies for uranium. Because Pu-239 decays 

directly to U-235, the beta-emitters present in this decay chain are already accounted for in Table 5-5. 

As indicated, there are a significant number of high-energy beta radiations that represent a shallow 

dose exposure concern for site workers. Workers who handled the uranium would have received 

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shallow dose exposures. The primary exposure areas would have been the hands and forearms, the 

neck and face, and other areas of the body that might not have been covered.

Neutron

The source of neutrons would result from the work with uranium and plutonium that was conducted in 

the glove boxes during the second operational period. Neutron doses for Carborundum were 

calculated using the MCNPX software. Dose rates were calculated at 30 centimeters and one meter 

from the face of the glove box. Based on the nature of the work and the forms of the materials being 

handled during operations at Carborundum, neutrons are only considered to be a potential external 

exposure source during the second operational period. 

5.2.2.1 First Operational Period (1943-1944)

As indicated previously, Carborundum was involved with centerless-grinding testing using grinding 

wheels and different abrasives. This work was performed on 10 uranium slugs that were shipped 

between Carborundum and HHM Safe Co. (Clinton, 1943, PDF pp. 9, 14). Therefore, Carborundum’s 

experimental grinding of T-metal (uranium) in June 1943 included an external uranium exposure 

hazard (T-metal, 1944, PDF p. 13).

5.2.2.2 First Residual Period (1945-1958)

Based on the removal of the exposure sources from the site during the first residual period, the 

external doses and potential for external exposures are considerably lower than that of the associated 

operational period. There is further discussion and analysis of the external exposures during the first 

residual period in Section 7 of this report.

5.2.2.3 Second Operational Period (1959-1967)

The second operational period included quantities of both uranium and plutonium that contributed to 

the on-site source term. Between 1959 and 1967, Carborundum had seven contracts for a variety of 

experimental procedures. The contracts included work with both uranium and plutonium.

The experimental procedures during the second operational period included different research and 

development methods, such as: synthesis and fabrication of refractory uranium compounds; 

fabrication of plutonium pellets; fuel fabrication; evaluation of mixed uranium-plutonium carbide 

fuels; and fuel irradiation. Shipping and receipt records, contract descriptions, and licensing 

information provide an indication of the quantities of radioactive material that was on the 

Carborundum site. Quantities included three kg of Pu over a three-year period, 1500 grams of UN, 

three pounds of UC, and various batches of different U-Pu alloy carbides. Table 5-2 lists known 

quantities.

Although most of the experimental work was conducted in glove boxes, they were potential sources of 

exposure for the workers. The work involved the investigation of methods for synthesizing the 

compounds, fabrication of the materials for testing, and determining the properties of these materials. 

Another major effort was the carbide fuel development program, which involved fabrication and 
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testing uranium and plutonium fuel pellets and studying out-of-pile properties of mixed U/Pu 

carbides. This work also included performing conceptual design, fuel evaluation, and irradiation.

While many of the procedures mentioned above do not provide the amounts of radioactive material 

used, several other experiments do provide that information. Please note that the dates indicated in the 

parentheses in the bullets below are approximate dates that are based on progress/summary reports.

• During the synthesis of uranium monocarbide a representative batch of UC consisted of 1500 

grams (1959-1960) (Refractory Uranium, 1959-60, PDF p. 11).

• In another experiment designed to determine the effect of the thermal history of the UC powder 

(time and temperature used in the synthesis) on its subsequent sinterability, each experiment used 

453.6 grams of UO2 (Refractory Uranium, 1961, PDF p. 7). The number of experiments 

conducted has not been stated (1961). 

• During the synthesis of thermal conductivity specimens a total of 550 grams of UO2, PuO2 and 

carbon powder was synthesized in 70 -100 gram batches (1961-1963) (Out-of-Pile Final, 1963, 

PDF p. 22). 

• One of the steps in the evaluation of the out-of-pile properties of mixed uranium-plutonium

carbides at the 5% PuC level was the preparation of the powder. In this procedure, about 400 

grams of (U0.95 Pu0.05)C0.98 powder was synthesized for the fabrication of test specimens (1959-1965)

(Final Report, 1965, PDF p. 77; Carbide Fuel, May1963, PDF p. 12).

• Other experiments during the fuel development program consisted of the fuel synthesis for the 

fabrication of UC-PuC irradiation testing. In one experiment, the natural uranium powder 

required for the natural uranium irradiation specimens was synthesized. Reaction of the 760-gram 

batch of PuO2-UO2-C yielded approximately 580 grams of an essentially single-phase 

(U0.8Pu0,2)C0.95 solid solution. In its synthesis, the reaction batch was divided into 16 lots of about 

50 grams each (1962-1963) (Carbide Fuel, 1962, PDF p. 11; Carbide Fuel, Mar1963, PDF p. 19).

Other material that was available at Carborundum was contained in their letter to the NRC. On 

September 19, 1962, Carborundum notified the Nuclear Regulatory Commission (NRC) of the 

closeout of contract AT(40-1)-2558 and to obtain their instructions for the disposal of the radioactive 

material they possessed (Contract Closeout, 1962). Table 5-6 lists the radioactive material that 

Carborundum had at that time.
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Table 5-6: Carborundum Radioactive Material Inventory in 1962

Material Category and Uranium Type Amount

Contract: Normal Uranium

As metallic uranium in powder form, as received 9,260 grams of U

As uranium monocarbide in powder form, as received 44 grams of UC

As uranium nitride in powder form, as received 27 grams of UN

As chemical residues 14 grams of U

Contract: Depleted Uranium

As uranium dioxide in powder form, as received 13,379 grams of U

As U3O8 in powder form contains carbon as an impurity 3,170 grams of U

Contract: 10% Enriched Uranium

As metallic uranium in powder form, as received 54 grams of U

As uranium dioxide in powder form, as received 829 grams of U

As U3O8 in powder form contains carbon as an impurity 609 grams of U

As UC, on wipers, used containers and crucibles (questionable recovery) 72 grams of U

License: Depleted Uranium as Metallic Turnings 340 grams of U

Depleted Uranium Monocarbide as shot 47 grams of U

X-Ray Diffraction Machines

An additional external exposure source that must be accounted for during the second operational 

period is from the X-ray Diffraction Machines in use to analyze the UC-PuC materials being 

produced. The greatest hazard from XRD machines is from external exposure from the primary beam. 

This can occur most commonly during alignment procedures, where the target must be aligned with 

the output port, the sample with the primary beam, and the detector or film holder with the reflected 

beam (Lubenau, 1969). If the X-ray beam is inadvertently turned on during alignment, the operator’s 

fingers or hands may be inadvertently exposed to the primary beam. Historically, these types of 

accidents are the primary hazard from XRD machines (Thomas, 1971, PDF p. 145). No evidence of 

these types of radiation accidents has been found at Carborundum. 

The scattered radiation is also of low energy and occurs in small, directional beams. Any leakage of 

radiation from the device through small cracks in shielding or other components would also tend to be 

of low energy, and in small, directional beams. Operators usually sit safely nearby the device during 

normal operation. Operators are not usually monitored for radiation exposure, because of the small 

likelihood of the very small beams interacting with the small dosimeter device (Blatz, 1971, PDF p. 

76). 
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5.2.2.4 Second Residual Period (1968-19766)

As in the case of the first residual period, based on the removal of the exposure sources from the site 

during the second residual period, the external doses and potential for external exposures are 

considerably lower than that of the associated operational period. There is further discussion and 

analysis of the external exposures during the second residual period in Section 7 of this report.

6.0 Summary of Available Monitoring Data for the Class Evaluated 

by NIOSH

The following subsections provide an overview of the state of the available internal and external 

monitoring data for the Carborundum Company class under evaluation.

6.1 Available Carborundum Company Internal Monitoring Data

NIOSH has not found any radiological surveys conducted during the two operational periods at the 

Carborundum Company, nor has NIOSH found any bioassay data for any Carborundum personnel 

during the period under evaluation (January 1, 1943 through December 31, 1976).

NIOSH has obtained limited air dust monitoring results for the second operational period under 

evaluation (Sample Results, 1947-1961, PDF pp. 172-176). A total of nine readable uranium air dust 

samples were taken in November 1959 (with one control sample) and in April 1961 (see Table 6-1). 

Sixteen plutonium air dust samples were taken in April and June 1961 (with one control sample) (see 

Table 6-2).

Uranium:

• On November 9, 1959, a series of six general area dust samples were taken. One sample had a 

positive result of 6 dpm/m3.

• On April 5, 1961, a second series of three general area samples was collected, all with positive 

results. The highest result was 21 dpm/m3

.

NIOSH has not found any documentation to support why these samples were taken on these dates or if 

people were present in the room.

 6

As previously discussed, the second residual period as defined by DOE ends in 1992; however, based on the feasibility 

findings presented in this evaluation report, the assessment of the second residual period is limited to the petitionerrequested class time frame, which extends only through 1976.
SEC-00223 06-03-15 Carborundum Company 

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Table 6-1: Carborundum Uranium Air Dust Samples

Sample Location and No. Sample Date Sample Result (dpm/m3) 

GA -Rm 17 NW- uranium 

canning area Sample #11 April 5, 1961 21

GA- Rm 17 - C work aisle 

Sample # 12 April 5, 1961 5.2

GA- (unreadable) area 

Sample # 13 April 5, 1961 10

Not Readable April 19, 1961 Not Readable

GA Hood Room Nov. 9, 1959 ---

GA Hood Room Nov. 9, 1959 ---

GA Furnace Room Nov. 9, 1959 ---

GA Furnace Room Nov. 9, 1959 6

GA Source Room Nov. 9, 1959 ---

GA Source Room Nov. 9, 1959 ---

Control Nov. 9, 1959 ---

Three hyphens (---) indicate that no result was given for the specified sample.

Plutonium: 

• On April 5, 1961, a series of eight air dust general area and breathing zone samples was taken. All 

samples on this date had positive results with the highest result of 22 dpm/sample. 

• On June 7, 1961, a second series of eight air dust general area and breathing zone (not including 

the control) samples was collected. Four of the samples (three breathing zone samples and one 

general area sample) had positive results. The highest result was 0.76 dpm/sample. 

NIOSH has not found any documentation to support why these samples were taken on these dates. 
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Table 6-2: Carborundum Plutonium Air Dust Samples

Sample Location Sample Date Sample Result

(α dpm/sample)

Sample 1C-GA- 4 ft high at Box #6 unreadable April 5, 1961 0.6

Sample 1F Sample description not specified April 5, 1961 0.2

Sample 2C BZ (GA) Between Boxes 2 and 3 April 5, 1961 22.0

Sample 2F Sample description not specified April 5, 1961 0.1

Sample 3C GA- 4 ft high at Box #6 unreadable April 5, 1961 0.8

Sample 3F Sample description not specified April 5, 1961 0.2

Sample 4C BZ (GA) Between Boxes 2 and 3 April 5, 1961 2.2

Sample 4F Sample description not specified April 5, 1961 0.1

BZ Box #2 cyclone-operator performing (text not readable) June 7, 1961 0.57

BZ Box #2 adjacent to 3034-0 (Location/sample 3034-0 is 

near Box # 2) June 7, 1961 0.00

GA Adjacent to Schmidt Sampler June 7, 1961 0.76

BZ Box #5 Operator observing vacuum furnace operation June 7, 1961 0.76

BZ (GA) Box #3 cyclone June 7, 1961 0.38

BZ (GA) Box # 2 Adjacent to 3034-4 (Location/sample 3034-

4 is near Box # 2) June 7, 1961 0.00

GA Same as 3034-2 (location/sample 3034-2 unknown) June 7, 1961 0.00

BZ Same as 3034-3 (location/sample 3034-3 unknown) June 7, 1961 0.00

Control June 7, 1961 0.00

6.2 Available Carborundum Company External Monitoring Data

NIOSH has not identified Carborundum Company or DOE documentation that would show that the 

operational areas or the workers were monitored for external radiation, either during the two AWE 

operational periods or the two residual radiation periods. 

7.0 Feasibility of Dose Reconstruction for the Class Evaluated by 

NIOSH

The feasibility determination for the class of employees under evaluation in this report is governed by 

both EEOICPA and 42 C.F.R. § 83.13(c)(1). Under that Act and rule, NIOSH must establish whether 

or not it has access to sufficient information either to estimate the maximum radiation dose for every 

type of cancer for which radiation doses are reconstructed that could have been incurred under 

plausible circumstances by any member of the class, or to estimate the radiation doses to members of 

the class more precisely than a maximum dose estimate. If NIOSH has access to sufficient 

information for either case, NIOSH would then determine that it would be feasible to conduct dose 

reconstructions. 

In determining feasibility, NIOSH begins by evaluating whether current or completed NIOSH dose 

reconstructions demonstrate the feasibility of estimating with sufficient accuracy the potential 

radiation exposures of the class. If the conclusion is one of infeasibility, NIOSH systematically 

evaluates the sufficiency of different types of monitoring data, process and source or source term data, 
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which together or individually might assure that NIOSH can estimate either the maximum doses that 

members of the class might have incurred, or more precise quantities that reflect the variability of 

exposures experienced by groups or individual members of the class as summarized in Section 7.4. 

This approach is discussed in DCAS’s SEC Petition Evaluation Internal Procedures which are

available at http://www.cdc.gov/niosh/ocas. The next four major subsections of this Evaluation 

Report examine:

• The sufficiency and reliability of the available data. (Section 7.1)

• The feasibility of reconstructing internal radiation doses. (Section 7.2)

• The feasibility of reconstructing external radiation doses. (Section 7.3)

• The bases for petition SEC-00223 as submitted by the petitioner. (Section 7.4)

7.1 Pedigree of Carborundum Company Data

This subsection answers questions that need to be asked before performing a feasibility evaluation. 

Data Pedigree addresses the background, history, and origin of the data. It requires looking at site 

methodologies that may have changed over time; primary versus secondary data sources and whether 

they match; and whether data are internally consistent. All these issues form the bedrock of the 

researcher’s confidence and later conclusions about the data’s quality, credibility, reliability, 

representativeness, and sufficiency for determining the feasibility of dose reconstruction. The 

feasibility evaluation presupposes that data pedigree issues have been settled.

7.1.1 Internal Monitoring Data Pedigree Review

NIOSH has not identified any urinalysis, whole-body counts, or lung counts for either the two 

operational periods or the two residual periods. Therefore, an internal monitoring data sufficiency and 

pedigree evaluation is not possible for these types of data. 

However, NIOSH has identified uranium and plutonium air sample data during the second operational 

period (1959-1967) that are original reports and are, therefore, primary data sources. The reports are 

mostly legible and use appropriate reporting units. NIOSH believes these data to be sufficient to 

assess a bounding internal exposure scenario. Considering this information, no additional pedigree 

review was performed for these data.

7.1.2 External Monitoring Data Pedigree Review

NIOSH has not located any external monitoring data for the Carborundum Company for the two 

operational periods and two residual periods under evaluation. Therefore, a complete external data 

sufficiency and pedigree evaluation is not possible for the period from January 1, 1943 through 

December 31, 1976.
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7.2 Evaluation of Bounding Internal Radiation Doses at Carborundum 

Company

The principal source of internal radiation doses for members of the class under evaluation was the 

potential inhalation and ingestion of natural, depleted, and enriched uranium, and plutonium. For the 

Manhattan Project and the AEC, natural uranium was used during the early years. Some low-enriched 

uranium began to be used in reactor fuels (Battelle-TBD-6000, PDF p. 14) and some AWE sites, 

including Carborundum, did use some enriched uranium. NIOSH has not found any information 

regarding the use of enriched uranium at Carborundum other than the contract information listed in 

Table 5-2 of this report, which appears to be a limited-scope operation performed under contract 

AT (30-1)-2899. During the first operational period (1943), the uranium was in the metallic form. 

For the second operational period, the form included metals and oxides as well as forms of plutonium. 

The grinding and processing operations performed at Carborundum could have caused some of the 

uranium (or plutonium in the second period) to go airborne, resulting in personnel internal exposures 

from inhalation or ingestion of airborne radioactive materials. A former Carborundum employee who

worked at the facility during the second operational period stated that the uranium that came into the 

facility had to be ground to a small powder (Personal Communication, 2015d). In addition, based on 

the closeout of contract AT(40-1)-2558 (Contract Closeout, 1962), during the second operational 

period the uranium was received in powder form, as indicated in Table 5-6 above. There was also a 

potential for personnel exposure due to re-suspension of contamination during the operational and 

residual radioactivity periods. The following subsections address the ability to bound internal doses, 

methods for bounding doses, and the feasibility of internal dose reconstruction.

7.2.1 Evaluation of Bounding Process-Related Internal Doses

The Carborundum bioassay program may have been different for selected personnel. One individual 

stated he had urine samples every 3-6 months while the plutonium workers were sampled more often

(Personal Communication, 2015d). The individual who worked with plutonium stated he provided

both urine and blood samples every 2-3 weeks (Personal Communication, 2015c). However, NIOSH 

has not found any urine sample data or radiological surveys, with the exception of the air dust samples 

in November 1959 and April and June 1961, for any of the covered periods evaluated in this report.

NIOSH has identified uranium and plutonium dust sample results, as listed in Tables 6-1 and 6-2 and 

discussed below. As previously discussed in this report, Carborundum did experimental work on 

types of abrasive wheels and the speed with which the grinding was done to optimize the grinding 

process. Carborundum did not do centerless grinding on a production schedule. However, because the 

same type of work was performed on a production scale and schedule at other facilities, it was 

determined that the airborne activity identified at those companies and the guidance in Battelle-TBD6000 could be used to support bounding Carborundum internal doses.

The following subsections summarize the extent and limitations of information available for 

reconstructing the process-related internal doses of members of the class under evaluation.
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First Operational Period (1943–1944)

NIOSH has not identified any bioassay data for Carborundum employees or airborne data for the first 

operational period (1943-1944). Internal doses from uranium intakes during the first operational 

period are estimated using the data from the pre-1951 “Machining” operation in Tables 7.8 and 7.9 of 

the Technical Basis Document: Site Profiles for Atomic Weapons Employers That Worked Uranium 

Metals (Battelle-TBD-6000). 

The work performed at Carborundum was done for the purpose of experimentally determining the 

appropriate type of abrasive wheel and the optimum speeds to maintain. Carborundum was not the 

site where the actual final uranium production grinding operation was performed. The information

from this operational period at Carborundum (as discussed in Section 5) denotes that the scale of this 

uranium operation was very limited (30 pounds of slugs) and conducted in June 1943. The 30 pounds 

consisted of ten slugs that were shipped from HHM Safe Co. to Carborundum in May 1943 and 

returned to HHM Safe Co. in September 1943. Based on its review of the available data as well as the 

methodology identified for bounding dose, NIOSH concludes that the Battelle-TBD-6000 

methodology is based on large-scale and large-quantity operations, and therefore, serves to support 

bounding internal exposures for Carborundum’s first operational period.

First Residual Dose Period (1945–1958)

NIOSH has not identified any monitoring data or post-operational survey data that would support 

assessing personnel doses to residual radioactivity during the first residual period (1945-1958). Doses 

from residual uranium are determined using the adjustments found in the Technical Information 

Bulletin: Dose Reconstruction during Residual Radioactivity Periods at Atomic Weapons Employer 

Facilities (ORAUT-OTIB-0070). This approach is deemed sufficient to bound the residual period 

exposures because the approach is based on the radiological source term from the first operational 

period. As discussed, the operations during the first operational period were limited in scope of 

radiological work and involved a very limited radiological source term.

Second Operational Period (1959–1967)

NIOSH has identified air sample results for uranium and plutonium for the second operational period, 

as discussed below and shown in Tables 6-1 and 6-2. Because the operations were of an experimental 

nature and the sample data are limited in scope, a statistical analysis was performed on both the 

uranium and plutonium sample results to determine their respective doses. However, two former 

employees stated that the work was done in glove boxes. The first individual (SRDB ID: 142192) 

was a lab technician who worked with small amounts (mg to gm quantities) of uranium oxides and 

plutonium oxides. He indicated he worked in glove boxes that were used to contain acid fumes. The 

second individual (SRDB ID: 142193) was a lab technician, and later, an engineer who worked with 

depleted uranium synthesizing uranium carbide. He stated they had glove boxes and small tube 

furnaces. He also indicated they had a susceptor furnace about 12 inches in diameter that heated up the 

unit. He stated they could only make small quantities of the enriched-uranium-carbide reaction because it 

needed to go to a high temperature range. This was not in a glove box, but in a room under negative 

pressure. Finally, it was indicated that very few workers were involved in this operation; the interviewee 

stated he was the only one in the area during his shift because of security clearance requirements (Personal

Communication, 2015c).
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• Uranium: Doses are assigned based on dust sampling data found for November 1959 and April 

1961 (Sample Results, 1947-1961). On November 9, 1959, a series of six general area dust 

samples were taken. A second series of three samples, all with positive results, was collected on 

April 5, 1961. One other sample was taken; the sample date is unknown, but it was received on 

April 19; it is not legible. Uranium doses are assigned as 100% U-234 for the purposes of 

individual uranium dose evaluation.

• Plutonium: On April 5, 1961, a series of eight dust samples was taken. Two were identified as 

general area samples, two were identified as breathing zone samples, and four were either without 

description or the description was illegible. All samples on this date had positive results. On June 

7, 1961, a second series of eight samples was collected. Six of the samples were identified as 

breathing zone samples, while two were identified as general area samples. Four of the samples 

had positive results. Plutonium intakes are assessed based on dust sampling data found for April 

1961 and June 1961 (Sample Results, 1947-1961) and assigned as 12% 10-year aged plutonium.

Second Residual Dose Period (1968–19767

)

As was the case for the first residual period, NIOSH has not identified any monitoring data or 

post-operational survey data that would support assessing personnel doses to residual radioactivity 

during the second residual period. However, doses from residual uranium and plutonium are 

determined using the adjustments found in the Technical Information Bulletin: Dose Reconstruction 

during Residual Radioactivity Periods at Atomic Weapons Employer Facilities (ORAUT-OTIB0070). This approach is again deemed sufficient to bound the residual period exposures because the 

approach is based on the radiological source term from the associated second operational period, as 

well as any carryover from the first operational period. As discussed, the operations during the first 

and second operational periods were limited in scope and source term, including a limited number of 

personnel assigned to specific AEC-related work areas.

• Uranium: Doses from residual uranium are determined using the adjustments found in the 

Technical Information Bulletin: Dose Reconstruction during Residual Radioactivity Periods at 

Atomic Weapons Employer Facilities (ORAUT-OTIB-0070). Bounding uranium doses are 

assigned as 100% U-234.

• Plutonium: Intakes are assigned in the same manner as uranium intakes, using the adjustment 

factors for the residual period, as reflected in ORAUT-OTIB-0070. Bounding plutonium intakes 

are assigned as 12% 10-year aged plutonium.

 7 As previously discussed, the second residual period as defined by DOE ends in 1992; however, based on the feasibility 

findings presented in this evaluation report, the assessment of the second residual period is limited to the petitionerrequested class time frame, which extends only through 1976.
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7.2.2 Methods for Bounding Internal Dose at Carborundum Company

7.2.2.1 Methods for Bounding Operational Period Internal Dose

First Operational Period (1943–1944)

For the first operational period, there are no bioassay data for Carborundum employees. Internal 

doses from uranium intakes during the first operational period are estimated using the data from the 

pre-1951 “Machining” operation in Tables 7.8 and 7.9 in the TBD, Site Profiles for Atomic Weapons 

Employers That Worked Uranium Metals (Battelle-TBD-6000). Because of the chemical and physical 

forms of uranium used at the site, only Type M or S solubility was evaluated.

Second Operational Period (1959–1967)

It is not possible to accurately separate which worker worked with only uranium or only plutonium. 

In addition, the carbide mixture is a combination of uranium and plutonium. Therefore, in order to be 

claimant-favorable for the second operational period and its associated residual period, both uranium 

and plutonium should be concurrently assigned.

• Uranium: For the second operational period (1959-1967), uranium doses are assigned based on 

dust sample data found for November 1959 and April 1961 (Sample Results, 1947-1961). On 

November 9, 1959, a series of six general area dust samples were taken. A second series of three 

samples was collected on April 5, 1961. A statistical analysis of these samples results in a GM of 

1.666 dpm/m3

, a GSD of 2.5111, and a 95th percentile of 7.578 dpm/m3. Considering the controls 

on the operations (i.e., use of glove boxes, ventilation, and information from interviewees 

denoting the very radiologically-clean nature of the work).

The general area air concentrations are suitable for radiological production support personnel and, 

after adjustment, for supervisors and other worker categories. Therefore, these values will be 

doubled (or scaled-up from the values used for support personnel), consistent with DR methods 

and approaches using similar data, to estimate exposures for operators. Uranium doses are 

assigned as 100% U-234.

• Plutonium: Plutonium doses are assigned based on dust sampling data found for April 1961 and 

June 1961 (Sample Results, 1947-1961). On April 5, 1961, a series of eight dust samples was 

taken. Four were identified as general area samples, two of which were also identified as 

breathing zone samples, and four were either without description or the description was illegible. 

On June 7, 1961, a second series of eight samples and one control sample was collected. Six of 

the samples were identified as breathing zone samples; two were identified as breathing zone and 

general area samples. Two samples were identified as general area samples. A statistical analysis 

of these samples results in a GM of 0.022 dpm/m3, a GSD of 7.244, and a 95th percentile of 0.578 

dpm/m3

. Considering the controls on the operations (i.e., use of glove boxes, ventilation, and 

information from interviewees denoting the very radiologically-clean nature of the work).

Similar to the uranium approach, the general area and breathing zone air concentrations are 

suitable for radiological production support personnel and, after adjustment, for supervisors and 

other worker categories. Therefore, to include all workers and to be favorable to the claimants, 
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these values will be doubled (or scaled-up from the values used for support personnel), consistent 

with DR methods and approaches using similar data, to estimate exposures for operators. 

Plutonium intakes are assigned as 12% 10-year aged plutonium.

7.2.2.2 Methods for Bounding Residual Period Internal Dose

First Residual Dose Period (1945–1958)

For the first residual period, doses from residual uranium resulting from the first operational period 

are depleted over the residual period using the adjustments found in the Technical Information 

Bulletin, Dose Reconstruction During Residual Radioactivity Periods at Atomic Weapons Employer 

Facilities (ORAUT-OTIB-0070). Inhalation and ingestion uranium doses were calculated for 

production areas and non-production areas. Uranium doses are assigned as 100% U-234. 

Second Residual Dose Period (1968–19768)

• Uranium: For the second residual period, doses from residual uranium resulting from the second 

operational period are depleted over the residual period using the adjustments found in the 

Technical Information Bulletin, Dose Reconstruction During Residual Radioactivity Periods at 

Atomic Weapons Employer Facilities (ORAUT-OTIB-0070). As during the first residual period, 

inhalation and ingestion intake values have been calculated for production areas and 

non-production areas. Uranium doses are assigned as 100% uranium-234.

• Plutonium: For the second residual period, doses from residual plutonium resulting from the 

second operational period are depleted over the residual period using the adjustments found in the 

Technical Information Bulletin, Dose Reconstruction During Residual Radioactivity Periods at 

Atomic Weapons Employer Facilities (ORAUT-OTIB-0070). As during the first residual period, 

inhalation and ingestion intake values have been calculated for production areas and 

non-production areas. Plutonium intakes are assigned as 12% 10-year-aged plutonium.

7.2.3 Internal Dose Reconstruction Feasibility Conclusion

NIOSH has concluded that it is feasible to reconstruct internal doses at the Carborundum Company, 

Buffalo Avenue facilities in Niagara Falls, New York, using the following approaches:

• First Operational Period (1943-1944): Use the information in the Technical Basis Document: Site 

Profiles for Atomic Weapons Employers That Worked Uranium Metals (Battelle-TBD-6000).

• First Residual Period (1945-1958): The intakes for the first residual period will be extended 

through 1992, as the operations in the first operational period occurred in a separate location from 

the second operational period. Use the adjustments found in the Technical Information Bulletin: 

Dose Reconstruction During Residual Radioactivity Periods at Atomic Weapons Employer 

Facilities (ORAUT-OTIB-0070).

 8 As previously discussed, the second residual period as defined by DOE ends in 1992; however, based on the feasibility 

findings presented in this evaluation report, the assessment of the second residual period is limited to the petitionerrequested class time frame, which extends only through 1976.
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• Second Operational Period (1959-1967): Use the uranium and plutonium air sample data 

identified for 1959 and 1961.

• Second Residual Period (1968-19769): Using the ORAUT-OTIB-0070 methodology, during the 

second residual period, the more claimant-favorable exposure between the first residual period that 

extends into the second residual period (i.e., intakes derived from the first operational period but 

extended into the second residual period) and the second residual period itself (i.e., intakes derived 

from the second operational period) will be assigned.

NIOSH may choose to employ a more refined approach when reconstructing individual doses based 

on information obtained during the evaluation of individual claims. The NIOSH example dose 

reconstruction methodologies, to be provided separately from this evaluation report, will demonstrate 

the applicable bounding approaches for reconstructing doses for the applicable residual and 

operational periods at Carborundum.

7.3 Evaluation of Bounding External Radiation Doses at Carborundum 

Company

The principal source of external radiation doses for members of the evaluated class was photon and 

beta (electron) radiation associated with research and development of uranium and plutonium carbide 

materials, and the development of fuel for AEC operational activities, including depleted and enriched 

uranium. The X-ray powder diffraction method was used extensively for compound or phase

identification (Gundaker, 1971); Carborundum used this method to analyze the fuel as part of the fuel 

fabrication process.

The following subsections address the ability to bound external doses, methods for bounding doses, 

and the feasibility of external dose reconstruction.

7.3.1 Evaluation of Bounding Process-Related External Doses

NIOSH has not identified any external monitoring records or personal dosimetry data associated with 

the uranium or plutonium processing that occurred, nor has NIOSH been able to identify any radiation 

surveys or area monitoring data for the period from January 1, 1943 through December 31, 1976.

Shipping and receipt records, contract descriptions, and licensing information provide an indication of 

the quantities of radioactive material that was on the Carborundum site during the periods under 

evaluation. These quantities are discussed in preceding sections of this evaluation report and, in the 

absence of more definitive data, can be used to support bounding the external dose from exposure to 

these materials. 

Based on the machining (grinding) work performed at Carborundum, slug production was selected 

from the processes found in Battelle-TBD-6000 to evaluate and bound Carborundum doses. 

 9 As previously discussed, the second residual period as defined by DOE ends in 1992; however, based on the feasibility 

findings presented in this evaluation report, the assessment of the second residual period is limited to the petitionerrequested class time frame, which extends only through 1976.
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Individual external doses are assigned based on the specific work performed, using the categories 

described below:

• Operators: Individuals who operated process equipment and/or routinely handled radiological 

materials.

• General Labor/Radiological Work Support Personnel: Individuals who were in close contact with 

the radiological materials product for a portion of the working day. This category would include 

maintenance workers, laboratory workers, and health physics monitors.

• Supervisor/Non-Radiological Work Production Personnel: Individuals who routinely worked in 

the production areas and periodically may have been in the vicinity of processing. This includes 

supervisory staff, engineers, and individuals who were not in contact with the radiological 

materials but who worked routinely in the production areas.

• Clerk/Other: Individuals who worked in the environment outside the production areas where 

radiological work was being performed. This includes office workers and non-radiological 

production workers that are clearly documented to be in a physically different location than the 

radiological work (e.g., a different building).

The following subsections summarize the extent and limitations of information available for 

reconstructing the process-related external doses of members of the class under evaluation.

7.3.2 Carborundum Company Occupational X-Ray Examinations

NIOSH has not found any evidence of active medical supervision at the Carborundum Company. 

NIOSH did find evidence that medical supervision was not necessary for the first operational period 

(T-metal, 1944, PDF p. 13). NIOSH has not found any data relevant to medical X-rays at 

Carborundum for the second operational period. Medical X-rays are not required to be considered 

during residual radiation periods. Per ORAUT-OTIB-0006 and ORAUT-OTIB-0079, in the absence 

of information to the contrary, NIOSH assumes that medical X-ray examinations were performed on 

site during the second operational period.

• First Operational Period (1943-1944): In a letter dated October 11, 1944 from the E.I. du Pont 

Engineering Department to the Medical Director discussing the companies that performed work on 

T metal, it is stated that Carborundum performed experimental grinding of T metal in June 1943. 

It further states that there was very limited exposure with no medical supervision necessary 

(T-metal, 1944, PDF p. 13). Therefore, NIOSH will not assess medical X-rays for the first 

operational period.

• Second Operational Period (1959-1967): NIOSH has not identified information that indicates 

medical X-ray examinations were NOT performed at the Carborundum Company. Therefore, 

NIOSH will assume that pre-employment, annual, and termination PA radiographic chest X-ray 

screenings were performed for workers during the second operational period. NIOSH will bound 

doses using the methodology defined in ORAUT-OTIB-0006.
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7.3.3 Methods for Bounding External Dose at Carborundum Company

There is an established protocol for assessing external exposure when performing dose

reconstructions:

• Photon Dose

• Beta Dose

• Neutron Dose

• Other (XRD)

• Medical X-ray Dose (as applicable per Section 7.3.2)

However, NIOSH has determined that, for Carborundum, it is more appropriate to discuss bounding 

external doses for identified operational and residual time periods that encompass the rationale for the 

stated radiation types. Although no external monitoring data are available to NIOSH for the 

Carborundum Company, the tables and discussions in Battelle-TBD-6000 and ORAUT-OTIB-0006, 

as well as the calculated doses for plutonium, can be used to bound the various operational period 

external doses at Carborundum. The following sections provide the details for bounding the external 

doses for Carborundum operational and residual periods.

7.3.3.1 Methods for Bounding Operational Period External Dose

The following subsections discuss the methods for bounding the external doses to Carborundum 

workers according to the operational time periods. 

External doses for uranium exposures during the operational periods are assessed using the exposure, 

R, dose equivalent organ DCF (dose conversion factor). All penetrating doses are assigned as 30–250 

keV photons. Shallow doses are assigned as >15 keV electrons (Battelle-TBD-6000).

External doses for plutonium exposures during the operational periods are assessed using the deep, 

Hp(10), dose equivalent organ DCF (dose conversion factor). Photon/neutron energy distributions 

associated with plutonium will be based on the dose calculations from the MCNPX software using the 

restrictions for plutonium within the Carborundum glove box complex. Shallow doses are assigned as 

<30 keV photons (Battelle-TBD-6000).

First Operational Period (1943-1944)

In the absence of personnel-specific external dosimetry records during the first operational period, 

external dose from uranium will be estimated using the data found in the TBD, Site Profiles for 

Atomic Weapons Employers That Worked Uranium Metals (Battelle-TBD-6000). These estimates are

bounding because the work at Carborundum was of an experimental nature and not performed on a 

production schedule. Specifically, the section of Tables 7.8 and 7.9 pertaining to pre-1951 dose rate 

for “Machining” should be used. These doses are limited to the time the slugs were on site (June 1, 

1943 to September 27, 1943).
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As indicated in Section 5.2.2 of this report, based on the nature of the work and the forms of the 

materials being handled during operations at Carborundum, neutrons are not evaluated for the first 

operational period; they are only considered to be a potential external exposure source during the 

second operational period. 

As previously discussed, because no medical monitoring was required for Carborundum, no 

Occupational Medical X-ray dose will be assigned for the first operational period at the site.

Second Operational Period (1959-1967)

Uranium photons

In the absence of personnel-specific external dosimetry records during the second operational period, 

external dose from uranium during this period will be estimated using the data found in the TBD, Site 

Profiles for Atomic Weapons Employers That Worked Uranium Metals (Battelle-TBD-6000); 

specifically, the section of Tables 7.8 and 7.9 pertaining to “1956 on” for “Machining.” 

External doses from uranium exposure during this period are corrected using the deep dose equivalent 

organ DCF (dose conversion factor) and are assigned as a lognormal distribution with a GSD 

(geometric standard deviation) of 5.0. All penetrating doses are assigned as 30–250 keV photons, 

whereas all shallow doses are assigned as >15 keV electrons (Battelle-TBD-6000).

Plutonium photons

In addition to the external doses from uranium described above, photon doses from plutonium are 

assigned to all Operators and General Laborers during the second operational period (1959–1967) 

unless definitive information is provided for an energy employee that indicates the individual was not 

involved with the plutonium-processing operation. A dose calculation (using the MCNPX software) 

was performed, based on the restrictions for plutonium use within the glove box complex at 

Carborundum. The site plutonium operating limits were 100 grams per batch with a maximum of two 

simultaneous batches per operation. 

Dose rates were calculated at 30 centimeters and one meter from the face of the glove box. The 

30-centimeter dose will be assigned to Operators. It is assumed that support workers would have 

spent the majority of their time at the one-meter distance. Uncorrected photon dose from plutonium to 

General Laborers, Supervisors, and others workers was calculated to be less than 1 millirem/year 

(<0.001 rem/year).

External photon doses from plutonium exposure during this period are corrected using the deep dose 

equivalent organ DCF and assigned in IREP as a lognormal distribution with a GSD of 5. Photon 

energy distributions associated with plutonium will be based on the dose calculations from the 

MCNPX software using the restrictions for plutonium within the Carborundum glove box complex. 

All photon doses are assigned as acute.
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Neutrons

The source of neutrons would result from the work with uranium and plutonium that was conducted in 

the glove boxes. Neutron doses for Carborundum were calculated using the MCNPX software. 

Neutron dose rates were calculated at 30 centimeters and one meter from the face of the glove box. 

The 30-centimeter dose will be assigned to Operators. It was assumed that support workers would 

have spent the majority of their time at the one-meter distance. Neutron energy distributions 

associated with plutonium will be based on the dose calculations from the MCNPX software using the 

restrictions for plutonium within the Carborundum glove box complex. They are multiplied by the 

deep dose equivalent organ DCF and assigned in IREP as a lognormal distribution with a GSD of 5. 

All neutron doses are assigned as chronic.

X-Ray Diffraction

NIOSH has not identified any information that discusses the X-ray diffraction units nor have any 

radiation surveys been found. However, NIOSH has previously approved a method for estimating 

dose from diffracted X-ray beams (NIOSH, 2007, PDF p. 17). The method was applied as a bounding 

approach in cases where class members indicated that they operated an X-ray diffraction unit with 

makeshift shielding over the diffraction chamber (or similar discussions). The method was sitespecific, based on detailed accounts of the equipment and technical factors; however, the same level 

of detail has not been found for Carborundum.

Lubenau provides measurements of scatter from a survey of XRD units in the state of Pennsylvania in 

1966 (Lubenau, 1969). Scatter measurements for three XRD units with copper targets are provided, 

ranging from 0.5-2.0 mR/hour at the table (i.e., bench top) edge. These measurements are reported as 

maximum scatter values from the respective machines during operation. The highest scatter 

measurement of 2.0 mR/hour can be used as the starting point for dose assessment for Carborundum 

since technical details (kV, mA, etc.) have not been found. The following assumptions can be used to 

determine doses due to the X-ray diffraction units:

XRD Assumptions:

1. The worker (operator) is seated at bench top, which supports the XRD machine, for 20 

hours/week.

2. Only the upper, anterior portion of the body is exposed in this AP geometry (about 25% of total 

body surface area).

3. The worker (operator) is exposed to only the scattered, diffracted beam, not the primary beam. 

Accidents involving the primary beam would have to be assessed separately on a case-by-case 

basis.

4. The diffracted beam from the copper target contains characteristic X-rays from copper, with a Kα

energy of 8.1 keV.

5. The fraction of time that tissue is exposed to the diffracted beam is proportional to the ratio of the 

diffracted beam size (area) to the area potentially exposed (front upper torso).
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Medical X-ray Dose 

NIOSH has not found any evidence of active medical supervision at the Carborundum Company. Per 

ORAUT-OTIB-0006 and ORAUT-OTIB-0079, in the absence of information to the contrary, NIOSH 

assumes that medical X-ray examinations were performed on site during the second operational period 

(1959-1967) and can be bound using these documents. 

7.3.3.2 Methods for Bounding Residual Period External Doses 

There are two residual contamination periods (1945–1958 and 1968-1992). However, the second 

residual period has been evaluated to 1976, the end of the time period requested by the petitioner. 

Medical X-rays are not required to be considered during residual radiation periods. 

First Residual Period (1945–1958) 

External doses during the residual contamination periods were estimated using the Exposure-to-Dose 

Coefficients in EPA-FGR-12 and the estimated surface and air contamination levels at Carborundum. 

External doses for the non-operational areas are assumed to be 10% of the operational areas, per 

guidance found in the TBD, Site Profiles for Atomic Weapons Employers That Worked Uranium 

Metals (Battelle-TBD-6000). For the residual periods, all data were assigned as a constant 

distribution, and all doses were determined to be less than 0.001 rem/year. 

Second Residual Period (1968-1976) 

As is the case with the first residual period, external doses during the residual contamination periods 

were estimated using the Exposure-to-Dose Coefficients in EPA-FGR-12 and the estimated surface 

and air contamination levels at Carborundum. External doses for the non-operational areas are 

assumed to be 10% of the operational areas, per guidance found in the TBD, Site Profiles for Atomic 

Weapons Employers That Worked Uranium Metals (Battelle-TBD-6000). For the residual periods, all 

data were assigned as a constant distribution, and all doses were determined to be less than 0.001 

rem/year.

Because plutonium operations covered under the Energy Employees Occupational Illness Compensation Program Act stopped at the end of the second operational period, the potential neutron and 

photon dose rates from residual contamination were determined to be less than 0.001 rem/year. 

Therefore, no external doses from plutonium are assigned during the second residual period. 

7.3.4 External Dose Reconstruction Feasibility Conclusion 

NIOSH has concluded that it is feasible to reconstruct external doses at the Carborundum Company, 

Buffalo Avenue facilities in Niagara Falls, New York, using the following approaches:

• First Operational Period (1943-1944): External doses for uranium exposures during the 

operational periods are assessed using the exposure, R, dose equivalent organ DCF (dose 

conversion factor). All penetrating doses are assigned as 30–250 keV photons. Shallow doses are 

assigned as >15 keV electrons. External dose from uranium during the operational period will be 
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estimated using the data found in TBD: Site Profiles for Atomic Weapons Employers That Worked 

Uranium Metals (Battelle-TBD-6000).

• First Residual Period (1945-1958): External doses during the residual contamination periods were 

estimated using the Exposure-to-Dose Coefficients in EPA-FGR-12 and the estimated surface and 

air contamination levels at Carborundum. External doses for the non-operational areas are 

assumed to be 10% of the operational areas, per guidance found in the TBD, Site Profiles for 

Atomic Weapons Employers That Worked Uranium Metals (Battelle-TBD-6000). For the residual 

periods, all data were assigned as a constant distribution, and all doses were determined to be less 

than 0.001 rem/year.

• Second Operational Period (1959-1967): External dose from uranium during the operational 

period will be estimated using the data found in TBD: Site Profiles for Atomic Weapons 

Employers That Worked Uranium Metals (Battelle-TBD-6000). External photon doses from 

plutonium exposure during this period are corrected using the deep dose equivalent organ DCF 

and assigned in IREP as a lognormal distribution with a GSD of 5. Photon/neutron energy 

distributions associated with plutonium will be based on dose calculations from the MCNPX 

software using the restrictions for plutonium within the Carborundum glove box complex. All 

photon doses are assigned as acute. They are multiplied by the deep dose equivalent organ DCF 

and assigned in IREP as a lognormal distribution with a GSD of 5. All neutron doses are assigned 

as chronic. Medical X-ray dose will be reconstructed using the methodology defined in ORAUTOTIB-0006; XRD dose will be reconstructed using the previously-discussed methodology for 

estimating dose from diffracted X-ray beams (NIOSH, 2007, PDF p. 17).

• Second Residual Period (1968-1976): External doses during the residual contamination periods 

were estimated using the Exposure-to-Dose Coefficients in EPA-FGR-12 and the estimated 

surface and air contamination levels at Carborundum. External doses for the non-operational areas 

are assumed to be 10% of the operational areas, per guidance found in TBD, Site Profiles for 

Atomic Weapons Employers That Worked Uranium Metals (Battelle-TBD-6000). For the residual 

periods, all data were assigned as a constant distribution, and all doses were determined to be less 

than 0.001 rem/year.

NIOSH may choose to employ a more refined approach when reconstructing individual doses based 

on information obtained during the evaluation of individual claims. The NIOSH example dose 

reconstruction methodologies, to be provided separately from this evaluation report, will demonstrate 

the applicable bounding approaches for reconstructing doses for the applicable residual and 

operational periods at Carborundum.

7.4 Evaluation of Petition Basis for SEC-00223

The following assertion was made on behalf of petition SEC-00223 for the Carborundum Company:

SEC-00223: To the best of my knowledge the plant was not monitored for radiation during the time of 

employment as the attached papers state my dad was exposed to various forms of radiation 

throughout the plant during the years he worked there.
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As indicated in Section 6.2, NIOSH has not found any personal or area monitoring data for the 

Carborundum Company for the period under evaluation. However, NIOSH will use the methodology 

defined in this evaluation report to reconstruct personnel dose in the absence of personnel or area 

monitoring data for Carborundum.

SEC-00223: Determine the location and scope of the Globar Plant.

The Globar Plant, initially located in Milwaukee, pioneered the use of silicon carbide in an electric 

heating element call “Globar.” In 1927, Carborundum purchased that company, by then called Globar 

Corporation, and moved its production to Niagara Falls. The Globar plant is not part of this SEC 

petition because it is not located at the Buffalo Ave site (Carborundum Company, 2015).

SEC-00223: There appears to be no monitoring data.

No monitoring data were found for the Carborundum Company. Six former employees were 

interviewed. Three former employees indicated they wore radiation badges (Personal 

Communication, 2015a; Personal Communication, 2015c; Personal Communication, 2015d). One 

former employee stated he gave a urine sample every 2-3 weeks and went to the doctor to get a white 

blood cell count (Personal Communication, 2015c). Another former employee stated he gave urine 

samples about every 3-6 months (Personal Communication, 2015d). Two former employees stated 

that all notes were kept in log books, but the notes have been destroyed (Personal Communication, 

2015c; Personal Communication, 2015d). However, NIOSH will use the methodology defined in this 

evaluation report to reconstruct personnel dose in the absence of personnel or area monitoring data for 

Carborundum.

SEC-00223: Lack of Specific detail in the SRDB documents.

NIOSH was able to locate an additional ninety-two documents during its data capture efforts. Many 

of these documents provided relevant information on Carborundum.

SEC-00223: Carborundum Contracts

With the additional data capture, NIOSH has been able to review the work Carborundum was 

responsible for as a subcontractor under different contracts during the two operational and two 

residual periods. This has been addressed throughout the evaluation report.

SEC-00223: Medical X-rays

During its research, NIOSH learned that medical X-rays were not necessary during the first 

operational period. NIOSH has not found any data relevant to medical X-rays at Carborundum for the 

second operational period. Reconstruction of medical X-ray dose is not applicable to the residual 

radioactivity periods at Carborundum.
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SEC-00223: Sources of material from ORNL

NIOSH learned that ORNL provided small amounts of radioactive material to Carborundum. ORNL 

provided depleted UO2 which was ball-milled for 24 hours in a rubber-lined ball mill with stainless 

steel balls to an average particle size of less than one micron (Refractory Uranium, 1961).

SEC-00223: Sources of Plutonium from Hanford

NIOSH learned that Hanford provided plutonium to Carborundum over a three-year period totaling 

approximately three kilograms, which was fabricated into pellets. The first and only shipment in 1960 

consisted of 500 grams (Breslin, 1960).

SEC-00223: X-Ray Diffraction

Carborundum used XRD extensively for compound or phase identification to analyze fuel as part of 

the fuel fabrication process. Due to the scattering of the X-rays, this method causes a diffraction 

pattern that can be recorded and analyzed, providing specific information about the atomic structure of 

the samples. NIOSH has previously approved a method for estimating dose from diffracted X-ray

beams. This method could be applied to Carborundum using certain assumptions (see Section 

7.3.3.1). 

7.5 Summary of Feasibility Findings for Petition SEC-00223

This report evaluates the feasibility for completing dose reconstructions for employees at the 

Carborundum Company from January 1, 1943 through December 31, 1976. NIOSH found that the 

available monitoring records, process descriptions, and source term data available are sufficient to 

complete dose reconstructions for the evaluated class of employees in conjunction with Battelle-TBD6000 and the dose reconstruction methodology.

Table 7-1 summarizes the results of the feasibility findings at the Carborundum Company for each 

exposure source during the time periods 1943-1944 and 1959-1967 (operational periods) and 

1945-1958 and 1968-197610 (residual periods).

 10 As previously discussed, the second residual period as defined by DOE ends in 1992; however, based on the feasibility 

findings presented in this evaluation report, the assessment of the second residual period is limited to the petitionerrequested class time frame, which extends only through 1976.
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Table 7-1: Summary of Feasibility Findings for SEC-00223

1943-1944 and 1959-1967 (operational periods); 

1945-1958 and 1968-1976 (residual periods)

Source of Exposure

Operational Periods

Jan. 1, 1943 through Dec. 31, 1944

Jan. 1, 1959 through Dec. 31, 1967

Residual Periods

Jan. 1, 1945 through Dec. 31, 1958

Jan. 1, 1968 through Dec. 31, 1976

Reconstruction 

Feasible

Reconstruction 

Not Feasible

Reconstruction 

Feasible

Reconstruction

Not Feasible

Internal1 X X

 - Uranium X X

 - Plutonium X X

External X X

 - Gamma X X

 - Beta X X

 - Neutron N/A (1943-1944)

X (1959-1967)

N/A (1943-1944) N/A N/A

 - X-ray Diffraction N/A (1943-1944)

X (1959-1967)

N/A (1943-1944) N/A N/A

 - Occupational Medical X-ray N/A (1943-1944)

X (1959-1967)

N/A (1943-1944) N/A N/A

1 Internal includes an evaluation airborne dust data.

As of March 16, 2015, a total of 106 claims have been submitted to NIOSH for individuals who 

worked at the Carborundum Company during the period under evaluation in this report. Dose 

reconstructions have been completed for 90 individuals (~85%).

8.0 Evaluation of Health Endangerment for Petition SEC-00223

The health endangerment determination for the class of employees covered by this evaluation report is 

governed by both EEOICPA and 42 C.F.R. § 83.13(c)(3). Under these requirements, if it is not 

feasible to estimate with sufficient accuracy radiation doses for members of the class, NIOSH must 

also determine that there is a reasonable likelihood that such radiation doses may have endangered the 

health of members of the class. Section 83.13 requires NIOSH to assume that any duration of 

unprotected exposure may have endangered the health of members of a class when it has been 

established that the class may have been exposed to radiation during a discrete incident likely to have 

involved levels of exposure similarly high to those occurring during nuclear criticality incidents. If 

the occurrence of such an exceptionally high-level exposure has not been established, then NIOSH is 

required to specify that health was endangered for those workers who were employed for a number of 

work days aggregating at least 250 work days within the parameters established for the class or in 

combination with work days within the parameters established for one or more other classes of 

employees in the SEC. 

NIOSH has sufficient information on the types and quantities of material processed at the 

Carborundum Company as well as sufficient air monitoring data to bound internal and external 
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exposures. NIOSH’s evaluation determined that it is feasible to estimate radiation dose for members 

of the NIOSH-evaluated class with sufficient accuracy based on the sum of information available from 

available resources. Therefore, a health endangerment determination is not required. 

9.0 Class Conclusion for Petition SEC-00223

Based on its full research of the class under evaluation, NIOSH found no part of said class for which it 

cannot estimate radiation doses with sufficient accuracy. This class includes all employees who 

worked in any area of the Carborundum Company facility on Buffalo Avenue, Niagara Falls, NY 

from January 1, 1943 through December 31, 1976.

NIOSH has carefully reviewed all material sent in by the petitioner, including the specific assertions 

stated in the petition, and has responded herein (see Section 7.4). NIOSH has also reviewed available 

technical resources and many other references, including the Site Research Database (SRDB), for 

information relevant to SEC-00223. In addition, NIOSH reviewed its NOCTS dose reconstruction 

database to identify EEOICPA-related dose reconstructions that might provide information relevant to 

the petition evaluation.

These actions are based on existing, approved NIOSH processes used in dose reconstruction for 

claims under EEOICPA. NIOSH’s guiding principle in conducting these dose reconstructions is to 

ensure that the assumptions used are fair, consistent, and well-grounded in the best available science. 

Simultaneously, uncertainties in the science and data must be handled to the advantage, rather than to 

the detriment, of the petitioners. When adequate personal dose monitoring information is not 

available, or is very limited, NIOSH may use the highest reasonably possible radiation dose, based on 

reliable science, documented experience, and relevant data to determine the feasibility of 

reconstructing the dose of an SEC petition class. NIOSH contends that it has complied with these 

standards of performance in determining the feasibility or infeasibility of reconstructing dose for the 

class under evaluation.
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10.0 References

42 C.F.R. pt. 81, Guidelines for Determining the Probability of Causation Under the Energy 

Employees Occupational Illness Compensation Program Act of 2000; Final Rule, Federal 

Register/Vol. 67, No. 85/Thursday, p. 22,296; May 2, 2002; SRDB Ref ID: 19391

42 C.F.R. pt. 82, Methods for Radiation Dose Reconstruction Under the Energy Employees 

Occupational Illness Compensation Program Act of 2000; Final Rule; May 2, 2002; SRDB Ref ID: 

19392

42 C.F.R. pt. 83, Procedures for Designating Classes of Employees as Members of the Special 

Exposure Cohort Under the Energy Employees Occupational Illness Compensation Program Act of 

2000; Final Rule; May 28, 2004; SRDB Ref ID: 22001

42 U.S.C. §§ 7384-7385 [EEOICPA], Energy Employees Occupational Illness Compensation 

Program Act of 2000, as amended

Accountability, 1944, Carborundum Company, Niagara Falls, Monthly Accountability Report for 

March 1944, The Carborundum Company; March 1944; SRDB Ref ID: 121034

Affidavit, 2014, Affidavit from one of two survivors accompanying SEC Form B Petition; received 

November 19, 2014; DSA Ref ID: 120430

Annual Report, 1971, The Carborundum Company 1971 Annual Report, The Carborundum Company; 

1971; SRDB Ref ID: 141425

Annual Report, 1972, The Carborundum Company 1972 Annual Report, The Carborundum Company; 

1972; SRDB Ref ID: 141426

Annual Report, 1973, The Carborundum Company 1973 Annual Report, The Carborundum Company; 

1973; SRDB Ref ID: 141427

Attachment, 2014, Attachment to SEC Form B Petition; received November 19, 2014; DSA Ref ID: 

120430, PDF pp. 7-8

Battelle-TBD-6000, Technical Basis Document: Site Profiles for Atomic Weapons Employers That 

Worked Uranium Metals, Rev 1, Battelle Memorial Institute; June 17, 2011; SRDB Ref ID: 101251

Blatz, 1971, Public Health Experience in X-ray Diffraction, H. Blatz; U.S. Department of Health 

Education and Welfare; 1971; SRDB Ref ID: 32635, PDF p. 76

Breslin, 1960, Carborundum Company Feasibility Report for Fabrication of Plutonium Carbide 

Pellets, A. Breslin; Carborundum Company; June 6, 1960; SRDB Ref ID: 19739, PDF p. 5

Carbide Fuel, 1960, Status of Carbide Fuel Development at the Carborundum Company, K. Taylor; 

The Carborundum Company; November 21, 1960; SRDB Ref ID: 46759
SEC-00223 06-03-15 Carborundum Company

68 of 79

Carbide Fuel, 1961, Carbide Fuel Development Progress Report: Period of February 1, 1961 to April 

30, 1961; NDA 2162-3; A. Strasser (Nuclear Development Corporation of America) and K. Taylor

(Carborundum Company); Nuclear Development Corporation of America (prime contractor); June 1, 

1961; SRDB Ref ID: 61981

Carbide Fuel, 1962, Carbide Fuel Development Progress Report: Period of April 1, 1962 to June 30, 

1962; UNC-5030; A. Strasser (United Nuclear) and K. Taylor (The Carborundum Company); United 

Nuclear Corporation (prime contractor); August 10, 1962; SRDB Ref ID: 61990

Carbide Fuel, Mar1963, Carbide Fuel Development Phase IV Report: Period of September 15, 1961 

to September 30, 1962; UNC-5055; A. Strasser (United Nuclear) and K. Taylor, et al (The 

Carborundum Company); United Nuclear Corporation (prime contractor); March 31, 1963; SRDB Ref 

ID: 65097

Carbide Fuel, May1963, Carbide Fuel Development Progress Report: Period of October 1, 1962 to 

March 31, 1963; UNC-5056; A. Strasser, et al (United Nuclear) and K. Taylor, et al (The 

Carborundum Company); United Nuclear Corporation (prime contractor); May 1, 1963; SRDB Ref 

ID: 65092

Carborundum History, 1991, The Carborundum Company: The First 100 Years – 1891-1991, The 

Carborundum Company; September 21, 1991; SRDB Ref ID: 73136

Carborundum Company, 2015, 2015, Carborundum Company – Company Profile, Information, 

Business Description, History, Background Information on Carborundum Company; ReferenceFor 

Business.com; accessed January 20, 2015; SRDB Ref ID: 140566

Carborundum Timeline, 2006, Headline No. 3: Carborundum Timeline, Niagara Gazette; July 24, 

2006; SRDB Ref ID: 140563

Centerless Grinding, 1943, Centerless Grinding, letter from Carborundum Company to E. I. Du Pont 

de Nemours & Company; July 2, 1943; SRDB Ref ID: 126763

Clinton, 1943, Clinton Engineer Works Monthly Accountability Reports for 1943, Clinton Engineering 

Works; various dates in 1943; SRDB Ref ID: 120588

Clinton, 1944, Clinton Engineer Works Monthly Accountability Reports for 1944, Clinton Engineering 

Works; various dates in 1944; SRDB Ref ID: 120591

Clinton, 1945, The Metal Fabrication Program for the Clinton Engineer Works and the Hanford 

Engineer Works, Including the Dummy Slug Program and the Unbonded Slug Program – Project 

1553, E. I. DuPont du Nemours and Company, Inc.; August 1945; SRDB Ref ID: 33190

Contract Closeout, 1962, Closeout of Contract AT(40-1)-2558: Source and Special Nuclear Materials, 

The Carborundum Company; September 19, 1962; SRDB Ref ID: 46754 
SEC-00223 06-03-15 Carborundum Company

69 of 79

DCAS-IG-003, Radiation Exposures Covered for Dose Reconstructions under Part B of the Energy 

Employees Occupational Illness Compensation Program Act, Rev 1, NIOSH, Division of 

Compensation Analysis and Support; October 5, 2010; SRDB Ref ID: 88929

DCAS-PR-004, Internal Procedures for the Evaluation of Special Exposure Cohort Petitions, Rev. 1, 

National Institute for Occupational Safety and Health (NIOSH); Cincinnati, Ohio; April 15, 2011; 

SRDB Ref ID: 94768

DCAS-TIB-0010, Technical Information Bulletin: Best Estimate External Dose Reconstruction for 

Glovebox Workers, Rev 3, NIOSH, Division of Compensation Analysis and Support; June 18, 2010; 

SRDB Ref ID: 85226

EBR II, 1972, Investigations of Materials Compatibility Relevant to the EBR II System, Argonne 

National Laboratory, July 1972; http://www.osti.gov/scitech/servlets/purl/4577680; SRDB Ref ID: 

142151

EPA-FGR-12, Federal Guidance Report No. 12, External Exposure to Radionuclides in Air, Water, 

and Soil, K. Eckerman, et al; September 1993; SRDB Ref ID: 11997

Fabrication, 1970, Fabrication of Non-Fuel Core Components for SEFOR, (SEFOR=Southwest 

Experimental Fast Oxide Reactor); General Electric; February 1970; 

http://www.osti.gov/scitech/servlets/purl/4094888; SRDB Ref ID: 142149

Feasibility Report, 1960, Carborundum Company Feasibility Report for Fabrication of Plutonium 

Carbide Pellets, memo from H. V. Werner (Nuclear Safety Board) to E. Katine (Health and Safety 

Laboratory); March 30, 1960; SRDB Ref ID: 19739

Final Report, 1965, Carbide Fuel Development: Final Report, Period of May 15, 1959 to October 15, 

1965, A. Strasser and D. Stahl; Carborundum Company (subcontractor to United Nuclear 

Corporation); October 15, 1965; SRDB Ref ID: 53617

Final Report, 1967, Studies of the Preparation of Mixed Carbide Fuel Utilizing Co-precipitation, Final 

Report to the USAEC for the Period May 23, 1966 through February 28, 1967, NYO-3713-3, C. H. 

McMurty; April 15, 1967; SRDB Ref ID: 143094 (Sensitive Document – Export Controlled 

Information) 

Globar, 2009, Globar Superfund Site, New York State Department of Environmental Conservation; 

Fact Sheet – September 2009; SRDB Ref ID: In public domain: 

http://www.dec.ny.gov/chemical/57903.html. 

Gundaker, 1971, Radiation Safety in X-Ray Diffraction and Spectroscopy, E. Gundaker; U.S. 

Department of Health Education and Welfare; 1971; SRDB Ref ID: 32635, PDF p. 28

Irradiation, 1959, Irradiation Tests, letter from D. Cope (Reactor Division) to K. Taylor 

(Carborundum Company); December 7, 1959; SRDB Ref ID: 47808, PDF pp. 23-24
SEC-00223 06-03-15 Carborundum Company

70 of 79

Kostoff, 2008, Local History: Franchot Tone’s Industrialist Father Widely Admired, article on the life 

of Frank J. Tone; Kostoff; Niagara Falls Reporter; February 26, 2008; SRDB Ref ID: 141626

Lubenau, 1969, Analytical X-ray Hazards: A Continuing Problem, J. Lubenau; Health Physics 

16:739-746, December 1969; SRDB Ref ID: 14296

Met Lab, 1946, Air Sample Results for Metallurgical Laboratory – 1946, Metallurgical Laboratory; 

various dates in 1946; SRDB Ref ID: 16801

Mixed Carbide Fuel, 1966, Studies of the Preparation of Mixed Carbide Fuel Utilizing Coprecipitation, C. H. McMurtry, et al; Carborundum Company; 1966; SRDB Ref ID: 53582

Monoxides, 1966, Study of Uranium-Plutonium Monoxides, Final Summary Report, UNC-5144; R. 

Forbes, et al (United Nuclear) and J. Anderson, et al (The Carborundum Company); United Nuclear 

Corporation (prime contractor); January 31, 1966; SRDB Ref ID: 65007

Niobium, 1969, Effects of Composition and Processing on the Properties of Niobium CarbideGraphite Composite Material, Westinghouse Astronuclear Laboratory; November 

1969; http://www.osti.gov/scitech/servlets/purl/4204111; SRDB Ref ID: 142150

NIOSH, 2007, Addendum to SEC-00059 Sandia National Laboratory-Livermore Evaluation Report, 

National Institute of Occupational Safety and Health; September 10, 2007; DSA Ref ID: 103695, PDF 

p. 17

ORAUT-OTIB-0006, Dose Reconstruction from Occupational Medical X-Ray Procedures, Rev. 04; 

Oak Ridge Associated Universities; June 20, 2011; SRDB Ref ID: 98147

ORAUT-OTIB-0070, Technical Information Bulletin: Dose Reconstruction during Residual 

Radioactivity Periods at Atomic Weapons Employer Facilities, Rev 01, Oak Ridge Associated 

Universities Team, March 5, 2012, SRDB Reference ID 108851.

ORAUT-OTIB-0079, Guidance on Assigning Occupational X-ray Dose Under EEOICPA for X-rays 

Administered Off Site, Rev. 00; Oak Ridge Associated Universities; January 3, 2011; SRDB Ref ID: 

89563

ORNL, 1999, Potentially Contaminated Sites from ORNL Region I, Oak Ridge National Laboratory; 

printed in 1999; SRDB Ref ID: 40810

Out-of-Pile Progress, 1963, Out-of-Pile Properties of Mixed Uranium-Plutonium Carbides: Progress 

Report, Period of February 6, 1962 to October 31, 1962, A. Strasser, et al; United Nuclear and 

Carborundum Company; September 18, 1963; SRDB Ref ID: 64284

Out-of-Pile Final, 1963, Out-of-Pile Properties of Mixed Uranium-Plutonium Carbides: Final Report,

D. Stahl, et al; United Nuclear and Carborundum Company; December 6, 1963; SRDB Ref ID: 65005

Personal Communication, 2015a, Personal Communication with former Carborundum Company [job 

title redacted]; Telephone Interview by ORAU Team; February 13, 2015; SRDB Ref ID: 142192
SEC-00223 06-03-15 Carborundum Company

71 of 79

Personal Communication, 2015b, Personal Communication with former Carborundum Company [job 

title redacted]; Telephone Interview by ORAU Team; February 13, 2015; SRDB Ref ID: 142173 

Personal Communication, 2015c, Personal Communication with former Carborundum Company [job 

title redacted]; Telephone Interview by ORAU Team; February 16, 2015; SRDB Ref ID: 142172

Personal Communication, 2015d, Personal Communication with former Carborundum Company [job 

title redacted]; Telephone Interview by ORAU Team; February 16, 2015; SRDB Ref ID: 142193

Personal Communication, 2015e, Personal Communication with former Carborundum Company [job 

title redacted]; Telephone Interview by ORAU Team; February 17, 2015; SRDB Ref ID: 142174

Personal Communication, 2015f, Personal Communication with former Carborundum Company [job 

title redacted]; Telephone Interview by ORAU Team; February 23, 2015; SRDB Ref ID: 142194

Personal Communication, 2015g, Personal Communication with former Carborundum Company [job 

title redacted]; Telephone Interview by ORAU Team; April 27, 2015; SRDB Ref ID: 144379

Petition, 2014, SEC Petition Form B; received November 19, 2014; National Institute for 

Occupational Safety and Health; DSA Ref ID: 120430

Rad Handbook, 1970, Radiological Health Handbook, PHS-PUBL-2016; U.S. Public Health Service; 

Revised Edition, January 1970; SRDB Ref ID: 75017

Reactor Technology, 1960s, Liquid Metal Fast Breeder Reactors: 1948-1961, TID-3333, Part I; U.S. 

Atomic Energy Commission, Division of Reactor Development and Technology; 1960s; SRDB Ref 

ID: 142107

Refractory Plutonium, 1962, Research Facility for the Synthesis and Fabrication of Refractory 

Plutonium Materials, F. A. Saulino, et al; The Carborundum Company, Research and Development 

Division; November 1962; SRDB Ref ID: 56948

Refractory Uranium, 1959-60, Synthesis and Fabrication of Refractory Uranium Compounds, K. M. 

Taylor, et al; The Carborundum Company, Research and Development Division; February 1961; 

SRDB Ref ID: 140519

Refractory Uranium, 1961, Synthesis and Fabrication of Refractory Uranium Compounds, K. M. 

Taylor, et al; The Carborundum Company, Research and Development Division; June 29, 1961; 

SRDB Ref ID: 45329

Requirements, 1959, SS Materials Requirements for Fuel Cycle Development, author unknown, but 

initialed “ALB”; date unknown; SRDB Ref ID: 47808, PDF p. 18

Romance of Carborundum, 1960s, The Romance of Carborundum, brochure about The Carborundum 

Company plus many historical documents, including catalogs and marketing collateral; The 

Carborundum Company; various dates in 1960s; SRDB Ref ID: 141423
SEC-00223 06-03-15 Carborundum Company 

72 of 79 

Sample Results, 1947-1961, Radiological Sample Result of Different Types, U.S. Atomic Energy 

Commission, Health and Safety Laboratory; 1947 through 1961; SRDB Ref ID: 11452 

Silicon Carbide, 1956, Proposal to General Electric Company, Cincinnati, Ohio on Extension and 

Expansion of Research on Dense Silicon Carbide Materials by The Carborundum Company, The 

Carborundum Company; August 2, 1956; SRDB Ref ID: 93471 

Silicon Carbide, 1957, Proposal on Extension of Research on Dense Silicon Carbide, The 

Carborundum Company; August 28, 1957; SRDB Ref ID: 93472 

Silicon Carbide, 1958, Dense Silicon Carbide for Use as a Structural and a Fuek Element Material in 

Air-Cooled Reactors, Second Periodic Report: January 1, 1958 to April 30, 1958; The Carborundum 

Company; May 23, 1958; SRDB Ref ID: 93474 

Site Inspection, 1990, Site Inspection Report for the Niagara Falls Storage Site, Lewiston, New York; 

author unknown; date 1990 or early 1990s; SRDB Ref ID: 61056 

Sites, 1993, Potentially Contaminated Sites from ORNL Region I, memo from Carrol A. Armstrong; 

June 23, 1993; SRDB Ref ID: 42260 

SS Materials, 1959, SS Materials for Use Under Fuel Cycle Development, memo from H. Roth 

(Research and Development Division) to C. Keller (Production Division); June 18, 1959; SRDB Ref 

ID: 47808, PDF p. 15 

Status, 1959, Status of Materials for Use Under Fuel Cycle Development Program, letter from D. 

Cope (Reactor Division) to J. Ruch (Feed Materials Division); July 23, 1959; SRDB Ref ID: 47808, 

PDF p. 22 

Thomas, 1971, Radiation Safety: Objectives and Considerations, J. W. Thomas; U.S. Department of 

Health Education and Welfare; 1971; SRDB Ref ID: 32635, PDF p. 145 

T-metal, 1944, T-metal Fabrication, memo by Dr. G. H. Gehrmann; E.I. du Pont de Nemours & 

Company; October 11, 1944; SRDB Ref ID: 21831 

Transfer, 1959, Transfer of SS Material to: The Carborundum Company, Niagara Falls, N.Y. and 

Union Carbide Metals Company, Niagara Falls, N.Y., memo from M. Eisenbud (NYOO) to S. Sapirie 

(OROO); June 16, 1959; SRDB Ref ID: 47808, PDF p. 13 
SEC-00223 06-03-15 Carborundum Company 

Page 73 of 79 

Attachment 1: Data Capture Synopsis

Table A1-1: Data Capture Synopsis for Carborundum Company

Data Capture Information General Description of Documents Captured Date 

Completed

Uploaded 

to SRDB

Primary Site/Company Name: Carborundum Company

AWE 1943-1944; 1959-1967; Residual Radiation 1945-

1958; 1968-1992 

Alternate Site Names: NA

Physical Size of the Site: No documentation has been found 

regarding the physical size of the facility or the number of 

buildings on site. From interviews, it is estimated that 

approximately 30-50 buildings were on site; one 

interviewee suggested that the site encompassed about 200 

acres. The Research and Development Building (also 

known as Building 1 and the Nuclear Building) was the 

only building that had radioactive materials. This building 

had four stories that occupied over 60,000 square feet. 

Population of the Site: Records show that the Carborundum 

Company employed approximately 6,000-7,000 employees 

during the 1940s. No other documentation has been found 

regarding the number of employees in later years.

Note: The Buffalo Avenue plant closed in 1983, at which 

time over 650 employees lost their jobs.

Existing successors have been contacted with no relevant data identified 

to date.

The following companies have been in the succession of some part of 

the Carborundum Company: 

- Kennecott Copper Corp (mid 1970's) located in London and dissolved

- Standard Oil of Ohio (1981)

- Norton (~1983)

- British Petroleum (1987 - bought SOHIO)

- St. Gobain (1995)

- Unifrax (1996)

- Washington Mills Electric Minerals (Not successor, used part of site)

03/23/2015 0

State Contacted: NY State Dept. of Environmental 

Conservation

Contract AT(40-1)-2558 source and special nuclear materials 

documents and status of carbide fuel development at the Carborundum 

Company.

04/06/2015 5

Battelle Memorial Institute - King Avenue Hazards subcommittee concerning SP-3. 09/20/2011 1

British Petroleum (BP) No relevant documents identified. 09/29/2008 0

Cincinnati Public Library Monoxide type compounds of uranium and plutonium and research 

facility information for the synthesis and fabrication of refractory 

plutonium materials.

01/16/2009 2

Department of Labor / Paragon Waste disposal in Niagara Falls area and DOD analysis of the NY 

interim report on toxic substances.

12/30/2008 6
SEC-00223 06-03-15 Carborundum Company 

74 of 79 

Table A1-1: Data Capture Synopsis for Carborundum Company

Data Capture Information General Description of Documents Captured Date 

Completed

Uploaded 

to SRDB

DOE Germantown Carborundum Company feasibility report for fabrication of plutonium 

carbide pellets.

11/21/2005 1

DOE Legacy Management - Grand Junction Office Contract between the Carborundum Metals Company, Inc. and the 

Atomic Energy Commission, dense silicon carbide quarterly report, 

material accountability, inspection report with release survey, orange 

oxide shipments, Parkersburg site operations chronology, processing of 

thorium ore, source material license, and an elimination 

recommendation and listed references.

08/30/2011 27

DOE Legacy Management - Morgantown No relevant documents identified. 03/16/2015 0

DOE Oak Ridge Operations Office Radiological survey of Guterl Specialty Steel. 11/18/2003 1

DOE Oak Ridge Operations, Records Holding Task Group Monthly accountability reports and a security survey. 03/06/2015 7

DOE Office of Scientific and Technical Information 

(OSTI)

Studies of the preparation of mixed carbide fuel using co-precipitation. 11/06/2008 1

Environmental Measurements Laboratory (EML) / HASL Site visits, annual report, thorium 

symposium V on aerosols. 

sampling and storage, and the 03/08/2005 1

Federal Records Center (FRC) - Kansas City Historical documents compiled for FUSRAP related review. 07/14/2008 1

Hanford Irradiation processing monthly report, DOE investigation, and a 

material balance report. OPEN - Hanford Data Request 109 requesting 

key word searches.

OPEN 5

Interlibrary Loan Synthesis and fabrication of refractory plutonium 

story of the Carborundum Company.

materials and the 02/04/2015 2

Internet - Defense Technical Information Center (DTIC) No relevant documents identified. 03/18/2015 0

Internet - DOE Comprehensive Epidemiologic Data 

Resource (CEDR)

No relevant documents identified. 03/18/2015 0

Internet - DOE Environmental Management Linking Legacies Chapter 3: Wastes. 10/28/2007 1

Internet - DOE Hanford Declassified Document Retrieval 

System (DDRS)

Centerless grinding and a Hanford operations monthly report. 06/27/2013 3

Internet - DOE Legacy Management Considered Sites No relevant documents identified. 01/20/2015 0

Internet -

(NNSA) -

DOE National Nuclear Security 

Nevada Site Office

Administration No relevant documents identified. 03/18/2015 0

Internet - DOE OpenNet Manhattan District History Book and an H-Division progress report. 01/19/2015 2

Internet - DOE OSTI Energy Citations Out-of-pile properties of mixed uranium-plutonium carbides progress 

reports, and a study of uranium-plutonium monoxides final summary 

report.

05/12/2009 12
SEC-00223 06-03-15 Carborundum Company 

75 of 79 

Table A1-1: Data Capture Synopsis for Carborundum Company

Data Capture Information General Description of Documents Captured Date 

Completed

Uploaded 

to SRDB

Internet - DOE OSTI Information Bridge The metal fabrication program, Hanford operation monthly report, 

quarterly report on synthesis and fabrication of refractory uranium 

compounds, Chemical Processing Department monthly reports, Carbide 

Fuel Development final report, and residual radioactivity in the vicinity 

of formerly utilized med/aec sites.

11/17/2011 10

Internet - DOE OSTI SciTech Connect Synthesis and fabrication of refractory uranium compounds, monthly 

progress reports 1960, steam-cooled power reactor evaluation, 

fabrication of non-fuel core components for SEFOR, effects of 

composition and processing on the properties of niobium carbide - 

graphite composite material, and investigations of materials 

compatibility relevant to the EBR-II system.

03/25/2015 12

Internet -

(EECAP)

Energy Employees Claimant Assistance Project No relevant documents identified. 04/07/2015 0

Internet - Google British scientists visit to Carborundum plant, assessment of failure 

mechanisms for GFR vented fuel pins using hexoloy cladding, company 

profile, business description, site history and background, film 

implementation of a neutron detector, Carborundum timeline, magnetic 

trapping of ultracold neutrons, mapping waste - setting the stage to 

clean-up Niagara, molten-salt reactor program semiannual progress 

report, neutron radiography (nrad), poisoned workers and poisoned 

places, the bomb that fell on Niagara, and uranium monocarbide and 

method of preparation.

03/13/2015 51

Internet - Health Physics Journal No relevant documents identified. 03/18/2015 0

Internet -

Health 

Journal of Occupational and Environmental No relevant documents identified. 03/18/2015 0

Internet - National Academies Press (NAP) No relevant documents identified. 01/20/2015 0

Internet - National Environmental Publications Information 

System (NEPIS)

No relevant documents identified. 01/20/2015 0

Internet - NIOSH Report on residual beryllium and radioactive contamination. 08/31/2011 3

Internet - NRC Agencywide Document 

Management (ADAMS) 

Access and Loose material licenses reviewed by the regions or transferred to an 

agreement state, staff evaluation of sites identified in the USA Today 

article, legal information, spent fuel pool scoping study, and monitoring 

degradation of phenolic resin-based neutron absorbers in spent nuclear 

fuel pools.

01/20/2015 11

Internet - USACE/FUSRAP No relevant documents identified. 01/20/2015 0
SEC-00223 06-03-15 Carborundum Company 

76 of 79 

Table A1-1: Data Capture Synopsis for Carborundum Company

Data Capture Information General Description of Documents Captured Date 

Completed

Uploaded 

to SRDB

Internet - Washington State University (U.S. Transuranium 

and Uranium Registries)

No relevant documents identified. 01/20/2015 0

National Archives and Records Administration (NARA) -

Atlanta

Subcontractors that 

reports 1958-1963.

worked on uranium fabrication, and contracts and 03/17/2015 3

National Archives and Records Administration (NARA) -

Kansas City

Niagara Falls area radiological 

Love Canal contamination.

measurements and information related to 08/14/2008 3

New York Environmental Protection Agency Office No relevant documents identified. 03/16/2015 0

New York State Archives Shipment and disposition of contaminated sludge at LOOW. 03/19/2012 1

National Institute of Occupational Safety and Health 

(NIOSH)

Annual report to Congress and Carborundum history. 08/27/2014 5

Niagara County Historian Office No relevant documents identified. 01/23/2015 0

Niagara Falls Fire Department No relevant documents identified. 02/02/2015 0

NRC Public Document Room No relevant documents identified. 02/20/2015 0

Oak Ridge National Laboratory (ORNL) Source and special nuclear material accountability report. 03/19/2014 5

ORAU Team Documented communication with former employees and estimate of 

maximum plausible dose at AWE's.

03/31/2015 8

S. Cohen & Associates (SC&A) Activities and discussion related to the Hematite Plant area. 04/07/2011 1

Savannah River Site Dosimetry visitor cards. 08/26/2008 1

St. Gobain (NY) No relevant documents identified. 10/28/2008 0

Unifrax No relevant documents identified. 06/18/2008 0

University of Buffalo Carborundum Company annual report, projected proposal to examine 

adsorptive materials, zirconium - hafnium - titanium joint feasibility 

study, presentation of New York society of security analysis, metal 

progress, refractory fibrous materials, and the Romance of 

Carborundum.

03/26/2015 18

University of Utah (Kennecott Collection) No relevant documents identified. 08/07/2008 0

Unknown Integrated safety management evaluation, site summary and accounting 

control and correspondence on nuclear materials, dust hazards, and 

Fernald recycled uranium receipts and shipment.

08/28/2003 9

Washington Mills Electro Minerals No relevant documents identified. 03/23/2015 0

TOTAL 219
SEC-00223 06-03-15 Carborundum Company 

77 of 79 

Table A1-2: Databases Searched for Carborundum Company

Database/Source Keywords / Phrases Hits Selected

NOTE: Database search terms employed for each of the databases listed below

are available in the Excel file called “Carborundum Company Rev 01, (83.13) 04-09-15”

Defense Technical Information Center (DTIC)

https://www.dtic.mil/

COMPLETED 03/18/2015

See Note above 5,590 0

DOE CEDR

http://cedr.lbl.gov/

COMPLETED 03/18/2015

See Note above 0 0

DOE Legacy Management 

http://csd.lm.doe.gov/

COMPLETED 01/20/2015

Considered Sites See Note above 25 2

DOE Hanford DDRS

http://www2.hanford.gov/declass/

COMPLETED 02/24/2015

See Note above 0 0

DOE NNSA - Nevada Site Office

www.nv.doe.gov/main/search.htm

COMPLETED 03/18/2015

See Note above 0 0

DOE OpenNet

http://www.osti.gov/opennet/advancedsearch.jsp

COMPLETED 01/19/2015

See Note above 43 5

DOE OSTI Energy Citations

http://www.osti.gov/energycitations/

COMPLETED 06/18/2008

See Note above 149 4

DOE OSTI Information Bridge

http://www.osti.gov/bridge/advancedsearch.jsp

COMPLETED 06/18/2008

See Note above 142 3

DOE OSTI SciTech Connect 

http://www.osti.gov/scitech

COMPLETED 01/19/2015

See Note above 1,360 0

Energy Employees Claimant 

http://www.eecap.org

COMPLETED 04/07/2015

Assistance Project (EECAP) See Note above 0 0
SEC-00223 06-03-15 Carborundum Company 

78 of 79 

Table A1-2: Databases Searched for Carborundum Company

Database/Source Keywords / Phrases Hits Selected

Google

http://www.google.com

COMPLETED 02/20/2015

See Note above 12,402,199 53

HP Journal

http://journals.lww.com/health-physics/pages/default.aspx

COMPLETED 03/18/2015

See Note above 0 0

Journal of Occupational and Environmental Health 

http://www.ijoeh.com/index.php/ijoeh

COMPLETED 03/18/2015

See Note above 15 0

National Academies Press

http://www.nap.edu/

COMPLETED 01/20/2015

See Note above 20 0

National Environmental Publications Information System 

(NEPIS) 

http://nepis.epa.gov/

COMPLETED 01/20/2015

See Note above 516 0

NRC ADAMS Reading Room

http://www.nrc.gov/reading-rm/adams/web-based.html

COMPLETED 01/19/2015

See Note above 298 4

United States Army Corps of Engineers (USACE)

http://www.usace.army.mil/

COMPLETED 01/20/2015

See Note above 0 0

United States Army Corps of Engineers (USACE) - Buffalo 

District

http://www.lrb.army.mil/

COMPLETED 01/20/2015

See Note above 0 0

United States Army Corps of Engineers (USACE) - New 

York District

http://www.nan.usace.army.mil/

COMPLETED 01/20/2015

See Note above 0 0

United States Army Corps of Engineers (USACE) -

Pittsburgh District

http://www.lrp.usace.army.mil/

COMPLETED 01/20/2015

See Note above 0 0
SEC-00223 06-03-15 Carborundum Company 

79 of 79 

Table A1-2: Databases Searched for Carborundum Company

Database/Source Keywords / Phrases Hits Selected

U.S. Transuranium & Uranium Registries 

http://www.ustur.wsu.edu/

COMPLETED 01/20/2015

See Note above 0 0

Table A1-3: Interlibrary Loan Documents Requested for Carborundum Company

Document Number Document Title Requested

Date

Received

Date

NA

Ref ID: 52405

Research Facility for the Synthesis and Fabrication of Refractory 

Plutonium Materials from Transactions of the American Nuclear 

Society (U.S.); Vol: 5:325-326 dated November 1962

10/20/2008 10/20/2008

NA

Ref ID: 56948

Research Facility for the Synthesis and Fabrication of Refractory 

Plutonium Materials from Proceedings of the 10th Hot Laboratory 

Equipment Conference in 1962

10/20/2008 01/07/2009

NA

Ref ID: 140976

The Scratch Heard 'Round the World; The Story of the Carborundum 

Company

01/26/2015 02/03/2015

NA Note On the System Magnesia-Thoria-Hafnia 03/18/2015