DOE Review 10/02/2015 

Division of Compensation Analysis and Support

Technical Basis Document for the Electro Metallurgical 

Company 

Niagara Falls, New York 

Document Number:

DCAS-TKBS-0007

Effective Date: 09/24/2015

Revision No.: 01

Page 1 of 37

Subject Experts: Sam Glover and David Allen

Approval: 

James W. Neton, Associate Director for Science

 Signature on file Date: 09/24/2015

 

Supersedes:

DCAS-TKBS-0007

Rev. 00 

TABLE OF CONTENTS

Section Page

1.0 Introduction .......................................................................................................................... 3

2.0 Site Description and Operational History .......................................................................... 4

3.0 Process Description for First and Second Operational Periods ....................................... 8

4.0 Internal Dose .......................................................................................................................16

5.0 External Dose ......................................................................................................................21

6.0 Occupational Medical Dose ...............................................................................................34

7.0 References.....................................................................................................................................34
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RECORD OF ISSUE/REVISIONS

ISSUE

AUTHORIZATION

DATE

EFFECTIVE

DATE REV. NO. DESCRIPTION

02/14/2011 02/15/2011 00 Changes Battelle-TBD-6001 Appendix 

to a standalone document. Change is 

primarily format only. Does not 

incorporate review comments.

03/24/2015 Draft 01-Draft A Revision to incorporate Special 

Exposure Cohort designation 

information throughout the document. 

Added and revised information 

throughout the document regarding a 

correction in the start date for MED 

work. Substantial update of the 

document with re-analysis of the 

external and internal dosimetry data. 

Constitutes a total rewrite of the 

document.

04/01/2015 Draft 01-Draft B Revision to incorporate an additional 

figure.

06/01/2015 Draft 01-Draft C Incorporated changes based on review 

comments.

06/30/2015 06/30/2015 01-Draft D Additional comments incorporated.

9/1/2015 9/1/20145 01-Draft E Incorporated comments from review.

9/22/2015 09/24/2015 Rev 01 Incorporated comments from review to 

incorporate a GSD of 3 uncertainty for 

external and internal dose.
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1.0 Introduction

Technical basis documents and site profile documents are not official determinations made by 

the National Institute for Occupational Safety and Health (NIOSH) but are rather general 

working documents that provide historical background information and guidance to assist in the 

preparation of dose reconstructions at particular Department of Energy (DOE) or Atomic 

Weapons Employer (AWE) facilities or categories of DOE or AWE facilities. They will be 

revised in the event additional relevant information is obtained about the affected DOE or AWE 

facility(ies). These documents may be used to assist NIOSH staff in the evaluation of Special 

Exposure Cohort (SEC) petitions and the completion of the individual work required for each 

dose reconstruction. 

In this document the word “facility” is used to refer to an area, building, or group of buildings 

that served a specific purpose at a DOE or AWE facility. It does not mean nor should it be 

equated to an “AWE facility” or a “DOE facility.” The terms AWE and DOE facility are defined 

in sections 7348l(5) and (12) of the Energy Employees Occupational Illness Compensation 

Program Act of 2000 (EEOICPA), respectively. An AWE facility means “a facility, owned by 

an atomic weapons employer, that is or was used to process or produce, for use by the United 

States, material that emitted radiation and was used in the production of an atomic weapon, 

excluding uranium mining or milling.” 42 U.S.C. § 7384l(5). On the other hand, a DOE facility 

is defined as “any building, structure, or premise, including the grounds upon which such 

building, structure, or premise is located ... in which operations are, or have been, conducted by, 

or on behalf of, the [DOE] (except for buildings, structures, premises, grounds, or operations ... 

pertaining to the Naval Nuclear Propulsion Program),” and with regard to which DOE has or had 

a proprietary interest; or “entered into a contract with an entity to provide management and 

operation, management and integration, environmental remediation services, construction, or 

maintenance services.” 42 U.S.C. § 7384l(12). The Department of Energy (DOE) determines 

whether a site meets the statutory definition of an AWE facility and the Department of Labor 

(DOL) determines if a site is a DOE facility and, if it is, designates it as such.

Accordingly, a Part B claim for benefits must be based on an energy employee’s eligible 

employment and occupational radiation exposure at a DOE or AWE facility during the facility’s 

designated time period and location (i.e., covered employee). After DOL determines that a claim 

meets the eligibility requirements under EEOICPA, DOL transmits the claim to NIOSH for a 

dose reconstruction. EEOICPA provides, among other things, guidance on eligible employment 

and the types of radiation exposure to be included in an individual dose reconstruction. Under 

EEOICPA, eligible employment at a DOE facility includes individuals who are or were 

employed by DOE and its predecessor agencies, as well as their contractors and subcontractors at 

the facility. Unlike the abovementioned statutory provisions on DOE facility definitions that 

contain specific descriptions or exclusions on facility designation, the statutory provision 

governing types of exposure to be included in dose reconstructions for DOE covered employees 

only requires that such exposures be incurred in the performance of duty. As such, NIOSH 

broadly construes radiation exposures incurred in the performance of duty to include all radiation 

exposures received as a condition of employment at covered DOE facilities in its dose 

reconstructions for covered employees. For covered employees at DOE facilities, individual 

dose reconstructions may also include radiation exposures related to the Naval Nuclear 
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Propulsion Program at DOE facilities, if applicable. No efforts are made to determine the 

eligibility of any fraction of total measured exposure for inclusion in dose reconstruction. 

NIOSH does not consider the following types of exposure as those incurred in the performance 

of duty as a condition of employment at a DOE facility. Therefore these exposures are not 

included in dose reconstructions for covered employees (NIOSH 2010): 

• Background radiation, including radiation from naturally occurring radon present in 

conventional structures

• Radiation from X-rays received in the diagnosis of injuries or illnesses or for therapeutic 

reasons

The following information from the Department of Energy’s Office of Health, Safety and

Security EEOICPA Find Facilities webpage defines the EEOICPA covered periods for the 

Electro Metallurgical Company (DOE 2013). 

Site: Electro Metallurgical Company

Location: Niagara Falls, New York

Covered Period: 8/13/1942-12/31/1953 

This document contains a summary of the description of the site as well as the Atomic Energy 

Commission activities performed there, and provides the technical basis to be used to evaluate 

the occupational radiation doses for EEOICPA claims.

The Secretary of Health and Human Services has designated a class of employees from the 

Electro Metallurgical site for inclusion in the Special Exposure Cohort (SEC). The approved 

class consists of all employees of the Department of Energy, its predecessor agencies, and their 

contractors and subcontractors who worked at the Electro Metallurgical site in Niagara Falls, 

New York, for the period from August 13, 1942 through December 31, 1947 for a number of 

work days aggregating at least 250 work days, occurring either solely under this employment, or 

in combination with work days within the parameters established for one or more other classes of 

employees included in the Special Exposure Cohort (NIOSH 2012). 

NIOSH has determined, and the Secretary, Health and Human Services has concurred that it is 

not feasible to estimate internal exposures with sufficient accuracy for all workers at the site for 

the period August 13, 1942 through December 31, 1947 at the Electro Metallurgical Company 

(NIOSH 2012, HHS 2012). Any available personal monitoring data should be used to 

reconstruct an individual’s exposure at Electro Metallurgical during this time period. However, 

unmonitored internal exposures during this time period cannot be reconstructed. 

2.0 Site Description and Operational History

The Electro Metallurgical Company (a subsidiary of Union Carbide and Carbon) entered into a 

contract with the Manhattan Engineer District (MED) (Contract No. W-7405-Eng.14) to design, 

engineer, construct, and operate a uranium plant/facilities that transformed metal salt into metal. 

Construction started on December 29, 1942 (MED 1943a). Electro Metallurgical was also 
 

 

 

 

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requested to begin casting of metal ingots immediately using existing equipment in order to 

increase metal production; Electro Metallurgical reported that in November 1942 that they had 

initiated the process using existing facilities (MED 1943b). The metal ingots cast at Electro 

Metallurgical were sent to the University of Chicago for analysis. It is not known exactly how 

much metal was cast in their existing facility but 175 pounds were cast in the last week of 

December 1942 (MED 1943b). The plant became operational in March of 1943. Figure 1 shows 

the layout of the facility which helps show the level of intermixing of process and non-process 

areas. 

Figure 1: Layout of the Electro Metallurgical facility (AEC 1949 p51). 

The Electro Metallurgical Company uranium operations were located south of Pine Avenue and 

east of its intersection with Packard Road, Niagara Falls, New York. Available information 

indicates that uranium operations (including the business office, lunchroom, and shipping areas) 

were conducted within a single building. The building was a one-story cinder block and wood 

structure, which measured approximately 50 feet by 219 feet located in an area now occupied by 

the current Building 166 of the Union Carbide Corporation building complex (DOE 1986). In 

addition to the area plant, there was also an addition known as the Magnesium Room, measuring 

77 feet by 19 feet. Equipment installation was performed by Electro Metallurgical personnel, 

who made numerous minor changes after operations had started, but before the plant was 
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reported 100% complete. As a result, the actual completion date for the construction (June 15, 

1943) was reported after operations had started in the new facility. Electro Metallurgical was 

also tasked to conduct ore processing research as part of its initial contract. This program was 

conducted for a short time beginning in April 1945 and concluding in August 1945 using small 

quantities of low-grade African ore (MED 1945). Very little specific information is available to 

NIOSH regarding operational exposure levels for the ore research during this early period nor of 

the clean-up of those operations. By employing a wet process involving chemical leaching, the 

exposure potential from these processes was likely low (MED 1945b; MED 1945c). This work 

occurred during the time period in which Electro Metallurgical has been designated as included 

in the Special Exposure Cohort. 

The Electro Metallurgical Company, a subsidiary of Union Carbide and Carbon Corporation, 

was liquidated on November 30, 1948 and the company and all its assets were assigned as the 

Electro Metallurgical Division of Union Carbide and Carbon Corporation (UCC 1948). 

Electro Metallurgical purchased the building and equipment from the AEC at the end of the final 

contract that concluded on June 30, 1953. This transfer terminates the facility from being a 

covered facility and there is no residual period because it was a DOE facility. Cleanup of the 

facility to contemporaneous release standards was a condition of the sale of the property by the 

AEC to Union Carbide. The plant and equipment were decontaminated through washing, 

vacuuming, and in some locations, removing concrete floors and wooden platforms. These 

decontamination activities occurred after the sale of the property. A survey in October 1952 

provided baseline data as well as recommendations for the cleanup to approve the transfer (AEC 

1953b). A condition of the transfer of the property was that Electro Metallurgical Company 

would complete the required cleanup to specified tolerance levels within 1 month of the transfer 

as indicated in the sale agreement (AEC 1953a). The AEC came to the site on August 11, 1953 

(after the end of the covered period) to conduct the post cleanup surveys and found the company 

was in the process of completing the decontamination that included the removal of certain 

structures that were permanently contaminated. AEC personnel provided further instructions to 

Electro Met on how to complete the decontamination and how to burn and dispose of the 

uranium residues in wood structures. The AEC completed the survey on August 14, 1953 (AEC 

1953c). The AEC used the results from this survey to conclude that Electro Met had met the 

conditions for the facility to be released to the company and issued a report September 28, 1953 

(AEC 1953C, AEC 1953d). 

Process descriptions from early 1943 (MED 1943d) describe that a series of bombs failed in the 

furnaces causing them to blow the mixture into the furnaces and shoot flames and sparks 

upwards (e.g. a blowout). The document describes that while no damage was done to the 

equipment, the effect on moral on the women operators forced a stop work until the cause could 

be determined. The cause was found to be an increase in the moisture content of the dolomite 

liner which had risen from 0.3 to 1% and changes to material specifications corrected the issue. 

Other tests are described during this early period which included variations in the bolting 

patterns of the reduction bombs which resulted in horizontal flames during the blowouts from 

these experiments. The report described the activity as “does not appear safe or desirable for a 

bomb of this size”. All of these activities occurred during the period designated as and SEC at 

Electro Metallurgical. The reporting of a large number of women operators during this time 
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period does not match with what HASL observed in 1948 (all men were noted to be working in 

the plant in November 1948 (AEC 1949G)) and further establishes the inability to properly 

match personnel with job titles at this facility.

The Area Plant building was demolished in 1957 (DOE 1985 p25). 

Some information is available regarding construction contractors who worked in the Area Plant 

during early operational periods. A detailed description of the building in 1946 and contractors 

who built it is described in a report (MED 1943A). Construction activities were conducted 

during uranium production operations. Various reports further describe that the main Electro 

Met plant provided service personnel to assist with maintenance of the Area Plant from its main 

group of personnel (not dedicated to the Area Plant) and this status changed from time to time as 

various periods of standby and work during standby occurred. 
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3.0 Process Description for Operational Periods

The Area Plant received uranium tetrafluoride from Union Carbide’s Linde Air Products 

Division plant at Tonawanda, New York (Linde Ceramics Plant), and converted it into uranium 

metal in a small contained facility located on the main company’s property as described in the 

site description section of this document. The plant converted uranium tetrafluoride to uranium 

metal by heating the uranium salt with magnesium and casting into 110-135 kilogram ingots and 

then the ingots were recast into billets. The uranium metal products were shipped to numerous 

facilities which included Hanford Engineer Works, Argonne National Laboratory, DuPont’s 

Chamber Works, Simonds Saw and Steel, Revere Copper and Brass, and Joslyn Manufacturing 

and Supply Co (DOE 1985, page 24-25). Process residues were shipped to other sites, including 

Lake Ontario Ordnance Works, Mallinckrodt Chemical Company, Vitro Manufacturing, DuPont 

Chambers Works, and Hooker Electrochemical, for uranium recovery, storage, or disposal. 

Electro Met also recast scrap metal from Simonds Saw and Steel, Chapman Valve 

Manufacturing Company, and American Rolling Mill Company. Electro Met’s contract also 

contained a provision for conducting research and development (DOE, 1986). 

Production of uranium on the premises began prior to completion of the building which was 

officially completed in June of 1943. Three shifts per day were run over the entire processing 

history based on reports reviewed by NIOSH. Uranium production operations were suspended 

from September 1, 1946 through September 30, 1947 (DOE 1986). Operations continued from 

October 1947 until production of uranium metal was stopped on September 28, 1949 and placed 

in standby on September 30, 1949 (DOE 1986). Average production rates are included in Table 

2. The production area continued to be used by other operations during this time period and a 

documented cleanup of the facility did not occur until after the facility was transferred from the 

AEC to Electro Metallurgical. (DOE 1985, p 24). 

Design capacity of the plant was approximately 50 tons of uranium metal (as billets) per month. 

During operations from April 1943 through August of 1946 (when the plant was placed in 

standby mode) the plant produced approximately 44 tons of metal billets per month. After 

restarting operations, Electro Met produced approximately 26 tons of metal billets per month 

during fiscal year 1948, and approximately 35 tons of metal billets per month during fiscal year 

1949 (NYOO 1951, p. 38). Operational and standby periods are outlined in Table 2 below. Time 

periods in which no uranium work was occurring are defined as “standby,” even though other 

non-radiological processes may have been occurring. The table includes operations conducted 

during the “Standby Period” of which NIOSH is aware. The “Standby” contracts required 

Electro Met to maintain the equipment and processes in a state of readiness and in other cases 

they used the contaminated equipment for other production in support of AEC operations.
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Table 1 provides a list of job titles, summary of duties they were reported to do, and typical areas 

that they occupied at the Area Plant. HASL reports on the Area Plant include job descriptions 

and areas where they worked in the plant (AEC 1949b and MED 1949b), and a more complete 

description is dated November 2, 1948 (AEC 1948a, pp 39-41).

Additional documentation shows the organizational chart of the Area Plant of Electro Met. Both 

the HASL reports and the organizational chart show that some work was shift work (3 shifts per 

day) and others work groups only operated one shift per day (Figure 2). A group of main plant 

employees reportedly to number around 30 provided support to the Area Plant in a part time 

capacity (electricians and pipe fitters) which ranged from a few days per year or a few days per 

month (AEC 1948a, p 32). NIOSH is unaware of any complete list of personnel for the Area 

Plant at Electro Met during its operational history. Construction workers companies other than 

Electro Metallurgical completed work in the Area Plant during active operations as previously 

described in this report (MED 1943A).
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Table 1: Job titles and descriptions at Electro Met (AEC 1949b)

Job Type Title Description

Supervisory General Foreman, Shift Foreman, 

Foreman

Plant area

Guard Two guard stations –guard office and general plant area. The plant guard had 

different duties (entered the green salt area) than the other guards (AEC 1949f).

Storekeeper, Storeroom attendant Storeroom

Operations workers Laborer Support of other operations workers

Bomb Topper, Jolter North central of area. Packs and seals top of reaction vessel (bomb). Wheels 

reaction vessel to vice, closes top, inserts gasket, seals and bolt, then wheels reaction 

vessel to next processing station

Green room operator Closed room, North of bomb topping area. Wheels dolly into green salt room. 

Places funnel on bomb. Preps mix of UF4 and magnesium. Charges bomb with 

mixture and cleans out mixture. Cleans up work area.

Head Reaction Operator Center of area. Inspects and places reaction vessels into furnace by means of an 

electric hoist. Heats furnace to temperature, keeping data records on furnace 

operations.

Head Remelt Operator, Furnace 

Operator 

East end of area. Operates high-frequency electric vacuum furnace to melt and cast 

metal. Places ingot molds, charges, and seals furnaces. Removes ingot molds and 

preps furnace for next heat. Cleans furnace –scoops out sand and screens into a 

bucket; empties screened sand from bucket into bottom section of furnace and levels 

it off. Weighs and records weight of charge and finished ingots.

Janitor Cleaning plant area, office area, locker room, lunch room, receiving and shipping 

areas.

Handyman, Repairman Plant area, receiving and shipping area. Maintained graphite furnace parts. Used 

reamers, seaters, facers and other tools to shape graphite parts.

Utility Men Opens bomb lid. Shovels slag from floor and removes bomb to storage area.

Bomb unloading and chipping, Utility 

Men

Utility room (West center of area). Opens bombs, jolts out doughnuts or derbies, 

chips doughnuts or derbies, chips doughnuts in chipping booth, shovels slag into the 

bifurcation, barrels and weighs slags.

Repairman Furnace Parts, Graphite man South east end of area. Maintains graphite furnace parts. Brushes and blows out the 

crucibles and molds.

Special Saw Operator North Eeast end of area. Sets up and operates power hack saws to cut metal bar stock 

to length. Stamped identification marks on samples.

Laboratory Chemist Chemistry Laboratory area. Sample prep room.

Technical, Junior Technician Duties not described in reports

Laboratory Handyman Chemistry Laboratory area. Prepares uranium metal samples in sample prep room. 

Cleaned laboratory table.
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Figure 2: Organizational structure of Electro Met (UCC 1949 page 41)

The AEC involvement with the site ended when contract W-7405-Eng. 14 expired on June 30, 

1953 (DOE 1986) which coincided with the sale of the building to Electro Met. No 

documentation was found indicating there were other sources of radiation beyond what has been 

described at Electro Metallurgical during the covered period between 1942 and 1953. Processes

used in the Area Plant caused uranium progeny to be non-uniformly distributed and/or 

concentrated in the materials and equipment causing documented high beta doses to some 

workers. The Area Plant did not have a routine external dosimetry program during most of its 

operations and only had occasional health physics support in the later operational years on an ad 

hoc basis. Further details are discussed in the external dosimetry section. 

The Area Plant was the subject of numerous internal and external exposure concerns through the 

entire operating history. Initial beta dose measurements in processes that concentrate uranium 

progeny and evaluation of the contamination of gloves and re-used protective gear led to 

recommended changes in work habits and more frequent changing of protective gear (e.g. 

weekly changes of leather gloves for some operations). Essentially no changes to ventilation or 

work practices for the reduction of internal exposures were reported to occur until the extremely 

high measurements obtained by HASL in December 1947 were reported to have resulted in 

improved plant housekeeping and operational procedures (AEC 1951, p 52). However, HASL 
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personnel stated that the reduction they measured in August of 1948 may have been influenced 

because the doors of the plant were open (due to the heat) when they made the measurements 

unlike measurements made during the cold winter months. The 1949 report (issued immediately 

prior placing the facility in standby in October 1949) indicated that the facility should receive a 

thorough vacuum cleaning and washing of the entire area (AEC 1951, page 52) however no 

confirmatory report in NIOSH’s possession indicates such a cleaning occurred. 

NIOSH has obtained only limited data regarding contaminated laundry from Electro Met (which 

was processed offsite at Linde in the Tonawanda facility). Laundered clothing limits were set at 

500 dpm/100 cm2. Available measurements start in 1948 and show that Electro Met exceeded 

those limits. One memo quotes that coveralls from Electro Met were determined to produce up 

to 15 mrep/hr fields at 1” when being laundered by the Linde laundry facility (AEC 1948a page 

42). However, since NIOSH is relying on measured external dose, this contamination is already 

considered in the external dosimetry being evaluated. The historical records available to NIOSH 

include other measured contamination levels of laundry from Electro Met if warranted for a 

particular dose reconstruction (AEC 1947, MED 1943b).

Very limited bioassay data are available for the site. The urine data (see AEC 1950c) include 

results principally from December 1947 and late 1949 which effectively bounds the time frame 

of the second operational period at Electro Met. 

NIOSH will include a third operational period for six months in 1951. Uranium handling from 

January –June 1951 likely occurred based on a contract that: “... directed Union Carbide to 

conduct research and development of methods of forming metal that would minimize 

unnecessary machining, finishing, and waste” under AEC contract AT-(40-1)-1090. Although 

the contract is not specific, the metal involved is presumed to be uranium based on DOE reports 

(DOE 1985, p 24). Additional information describing research work on “fissionable material” 

by the Area Plant during this time reinforces that it was uranium metal research (MED 1942 page 

145). No exposure data are available for this period for the uranium metal forming contract. 

However NIOSH will use the data collected during the second production phase to determine 

dose to personnel (external and internal) as described in the appropriate sections. 
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Table 2: Electro Metallurgical Operating History

Description Non-uranium Start date Stop Date Uranium metal production rates*

related 

standby 

operations

Operations 1 n/a 08/13/1942 08/31/1946 ~44 tons/mo

Standby 1 Calcium metal 09/01/1946 09/30/1947 n/a

production 

Operation 2 n/a 10/301/1947 09/30/1949 ~26 tons/mo (10/47-6/48)

~35 tons/mo (6/48-6/49) 

Standby 2 n/a 10/01/1949 01/01/1951 n/a

Zr Production April 1950 September 1950 n/a

during standby 

Operations 3*** n/a 01/01/1951 06/30/1951 Not provided (research quantities)

Standby n/a 06/30/1951 06/30/1953 n/a

*production average provided on page 38 of AEC 1951 
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3.2 Summary of standby operations 

3.2.1 1st standby period

The Area Plant was in full operation for nearly four years. The MED ordered that production 

cease on August 1, 1946 and the plant was prepared to be placed in standby condition during the 

month of August. The first standby ran from September 1, 1946 through September 30, 1947. 

This first standby period occurred after nearly four years of production under war time standards. 

The MED requested Electro Metallurgical to check and maintain the equipment to insure it 

would be functional to allow a quick resumption (less than one month notice) of production 

activities during periods of uranium production suspension (MED 1942, p63). Electro Met also 

used the facility during this time period to produce calcium metal (MED 1942, pp 66-67). 

NIOSH has no information regarding cleanup of the facility to place it in standby condition. It is 

clear that at least some Electro Met personnel continued to occupy these areas. The contract at 

the time (MED 1942, p63) specifically mentions that the separate guards and maintenance 

personnel assigned to the Area Plant would not be required but that the personnel would be 

pulled from the main force of Electro Met and that this re-organization of personnel would occur 

no later than October 1, 1946. Because this and other activities may have continued to have 

created an exposure potential. 

3.2.2 2nd and 3rd standby periods and transfer to Electro Met

The Area Plant was again placed in Standby Condition in September 1949 after two years of 

operations. Records indicate that the production activities at the Area Plant ceased on September 

30 (1949) and that work to place the facility in a state of active stand-by was started immediately 

(AEC 1949d, page 9). One document states that in October 1949, the plant was placed on 

standby after a thorough vacuum cleaning and washing of the entire area (AEC 1951, p52) but 

this is the only document that NIOSH knows of that mentions this cleanup and the information 

regarding a cleanup is contrary to other information available. 

A survey of the Area Plant was made in the areas where the three guards and maintenance men

would be expected to occupy at the beginning of the 2nd Standby period. All areas were below 

the maximum of 6 mrep/hour (beta and gamma) according to the report (MED 1943B p8). The 

memo made recommendations to keep the occupants away from certain areas and that the 

individuals were expected to wear a film badge for the first two weeks (approximately 

November/December 1949) to validate the dose was below the limit and then the film badge 

service would only be done occasionally to serve as a check. NIOSH does not have any badge 

results from this period nor any reports to confirm these assumptions. 

In April 1950, under AEC contract AT (30-1) -861, the Area Plant was reactivated for casting 

zirconium metal sponge into ingots for the Navy Critical Requirement program under contract to 

Titanium Alloy Manufacturing company (TAM). The zirconium metal operations did not pose a 

radiological hazard other than exposure to residual uranium remaining since cessation of 

uranium operations in 1949 according to the reports. Initial projections of the Zr sponge project 
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and details of the expected number of employees are available to NIOSH (SRDB 59219). They 

were reported to be conducted in the furnace area of the plant (one of the highest radiation zones 

during operations). The June 1950 Tonawanda monthly report (AEC 1950A) reported that for 

the month of June 1950 Electro Met produced 63 zirconium ingots. The plant was returned to 

standby in September 1950 upon completion of the Zr work. Additional uranium handling from 

January –June 1951 may have occurred based on a contract that: “... directed Union Carbide to 

conduct research and development of methods of forming metal that would minimize 

unnecessary machining, finishing, and waste” under AEC contract AT-(40-1)-1090. Although 

the contract is not specific, the metal involved is presumed to be uranium. (DOE 1985, p 24). 

No exposure data (internal or external) are available for this period for the uranium metal 

forming research contract. No cleanup information is available to NIOSH.

Monthly reports describe some conditions during this second standby period. The plant was 

inspected April 14, 1950 and described as being in very good condition and that three 

maintenance men were still on the payroll for standby (AEC 1950b, p16). Some activities 

continued to be reported such as the shipment of graphite molds to Hanford at the instruction of 

the NYOO in March of 1950. 

The AEC construction of new production facilities in the early 1950’s allowed for the permanent 

closure of the Area Plant. Electro Met and the AEC agreed to the transfer of the property to 

occur on June 30, 1953 with the stipulation that Electro Met clean the site up to the agreed upon 

levels. On Aug 11, 1953 members of the AEC traveled to Electromet and found that Electromet 

personnel were in the process of removing wooden structures from around the vacuum casting 

furnaces, piping and other structural equipment (AEC 1953C). Electro Met planned to continue 

to use the facility for commercial radiation work. 

One DOE report from 1985 mentions that the area was used for the production of titanium just 

prior to the demolition of the plant (DOE 1985, page 25). However, NIOSH has no information 

regarding these activities. Demolition of the plant occurred in 1957, well after the June 30, 1953 

sale of the plant to Electro Metallurgical company.

A survey of the facility was conducted December 10-12, 1952 and a report issued February 3, 

1953 with recommendations on cleanup and release of the facility (AEC 1953c, page 1). These 

December 1952 surveys were described as being conducted using 1 1/8” Whatman filters for 

smears over a 150 cm2 area. General air samples were also collected using Whatman #41 filter 

paper (1 1/8”) at 20 L per minute in locations such as the graphite burnout, vacuum casting and 

the billet saw area. Direct measures of beta/gamma radiation was measured using survey meters. 

The gross contamination measurements were taken before and after wiping the equipment with a 

rag to determine degree of decontamination that may be expected with a simple ‘rough’ cleaning 

method (AEC 1952, p2). 

Additional surveys of the facilities by the AEC were conducted August 11 and 14, 1953 (DOE 

1985, page 25) and the facility certified for release from the AEC to Electromet September 28, 

1953. Electromet had decontaminated the plant and equipment prior to the survey (DOE 1985, 

page 28). A DOE follow-up measurement was completed August 24, 1976 but the facility had 
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been demolished and the debris removed. The bill of sales of the property and conditions in that 

document clearly indicates the transfer occurred on June 30, 1953 (AEC 1953e). 

4.0 Internal Dose

4.1 Operations and Standby Periods 1942-1947 

NIOSH has concluded that it is not feasible to estimate internal exposures with sufficient 

accuracy for all workers at the site for the period August 13, 1942 through December 31, 1947 at 

the Electro Metallurgical Company (NIOSH 2012). Any available personal monitoring data 

should be used to reconstruct an individual’s internal exposure at Electro Metallurgical during 

this time period. However, unmonitored internal exposures during this time period cannot be 

reconstructed. 

A small group of employees at the Area Plant have bioassay data available to NIOSH during this 

period. These values should be used with standard dose reconstruction methods to assess intake 

rates of uranium during the period. 

4.2 Operations and Standby Periods 1948-1953 

Air sample data was principally collected in two large efforts by HASL with additional samples 

collected by Union Carbide health physics personnel in what appears to be an ad hoc fashion. 

Air samples for the first of the two HASL reports were collected principally in November of 

1948 (identified as Electro Met-1, AEC 1949B) and determined that the time weighted average 

exposure was 577 times the maximum permissible level for some members of the Area Plant. 

While there are some measurements conducted for various operations by Union Carbide health 

physics personnel from Linde (the Tonawanda, aka Linde Ceramics site), they appear to be ad 

hoc and without further write-up. These include a report provided in early 1948 which include 

relatively high air concentration results but not nearly as high as those obtained by HASL in its 

first report (AEC 1948C, page 3). These differences may be attributable to difference in 

methods between Union Carbide and HASL. The Union Carbide’s method descriptions include 

the use of weighing the filter papers used to collect the airborne uranium instead of the well 

documented radiometric methods using filter paper collection used by HASL. 

The second large air sample campaign was conducted in August of 1949 (identified by HASL as 

Electro Met-2; AEC 1949F) at the very end of the operational period. The time weighted 

average (TWA) values determined from these measurements was lower than reported from the 

November 1948 samples and this was attributed to some changes that occurred to the practices 

and ventilation as well as the fact that the facilities doors were open in August unlike during the 

November measurements. NIOSH has chosen to only use the data from the November air 

sampling campaign because the later data was collected following undisclosed changes that 

occurred some point in the process and it is unclear when they happened. NIOSH believes this is 

a claimant favorable approach because the data collected in August of 1949 determined a lower 

time weighted averages than the November 1948 data. Furthermore, HASL ascribed that at least 

some of the reduction in intake rates observed from the November 1948 to the August 1949 

surveys included the open windows and doors in the Area Plant during the latter survey. 
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NIOSH has chosen to use the highest TWA determined by HASL during the November 1948 

sampling (i.e. the green salt room operator) along with an uncertainty of geometric standard 

deviation (GSD) of 3 as the air concentration data for use during all operational periods at 

Electromet beginning January 1, 1948. These values were used to estimate ingestion intakes 

per the requirements of OCAS-TIB-0009 (NIOSH 2004) during both the operational and standby 

periods. 

Uranium operations were suspended twice at the site during the period 1948 through 1953. As 

previously mentioned, the AEC requested the plant machinery be operated periodically to insure 

it could be brought online quickly. The uranium inventory was likely significantly reduced. 

Therefore, during those times, all personnel will be assigned intake rates based on the TWA for 

the highest non-operational job title rate determined at Electromet during this November 1948 

exposure assessment. This is intended to account for internal dose that would be received from 

uranium contamination that may have remained in and around the process equipment. TWA 

determined by HASL for these non-operator job categories ranged from 2 to 3 times the 

maximum permissible level for job titles including guards, janitors and repair men. A claimant 

favorable value of 210 dpm/m3 (3 times the maximum permissible level) with a GSD of 3 will be 

used to uranium air concentration data during standby periods, however the ingestion intakes . 

Dose from uranium will be evaluated in a claimant favorable fashion using either type M or type 

S solubility. The dose estimate should be based on the one that produces the highest dose. The 

time weighted averages indicated a normal work day of 515 minutes, 8 hours of work plus 20 

minutes for lunch and 15 minutes in the locker room to change clothes. The dose estimate is

based on this 515 minutes per day, 5 days per week and 50 weeks per year. 

The ingestion for each period was determined using the methods and assumptions from TIB-009 

based on air concentration data. Substantial floor contamination was clearly present as sweeping 

up of residues generated air borne concentrations up to 97,000 dpm/m3

. 

TIB-009 default rates were adjusted for the 515 min/work day schedule for Electro Met (for 

mode 2 ingestion rates, mode 3 is unaffected) for a value of 0.2057 times the air concentration 

and scaled to a calendar day intake rate by multiplying by 250 days of work per 365 day year. 

NIOSH will assume that the ingestion rate does not change during the standby period as no 

cleanup of the facility is assumed to have occurred. Table 4 summarizes the internal dose for 

personnel at the Area Plant during the covered period. 

No internal dose prior to 1/1/1948 will be assigned at Electro Met as previously described based 

on inclusion in the SEC. Internal dose can be determined in the SEC period for individuals with 

uranium bioassay data using standard assumptions. 

Figure 3 shows the values and dates of samples for the limited uranium bioassay campaigns that 

were conducted at the Area Plant. The very high uranium concentration data determined in the 

urine provides further support for the high intake rates determined by HASL and used for dose 

reconstruction by NIOSH beginning January 1, 1948.
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Table 3: Time weighted average (TWA) exposures by job title as determined by HASL in Electromet-1 

Report (AEC 1949B) 

Job Title TWA 

Multiples of 

the Preferred 

Level

(70 dpm/m3)

General Foreman* 3.1

Foreman* 3.3

Shift foreman* 3.5

Head remelt operator 12.6

Furnace operator 12.6

Head reaction operator 5.5

Green salt room operator 577.0

Bomb topper 5.1

Bomb unloader 17.0

Saw operator 4.0

Repair man (furnace parts) 32.0

Repair man* 3.0

Handy man* 2.0

Store room attendant* 0.9

Storekeeper* 0.5

Janitor* 2.7

Guards* 2.6

Office personnel* 0.4

Technician 1.0

Laboratory handy man 26.6

Chemist* 0.8

*Air samples used in evaluating exposures for marked job titles 

were general air samples of the areas frequented by personnel (as 

determined by HASL) 
 

 

 

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Table 4: Summary of Internal Dose at Electro Metallurgical Plant 

Description Start Stop Air 

Concentration 

(dpm/m3) 

Calendar 

Day 

Intake 

Rate 

(dpm/ 

calendar 

day) 

Ingestion 

(dpm/calend 

ar day) 

Distribution 

Operation 1 08/13/1942 08/31/1946 SEC Period based on internal dose of uranium – no 

internal dose calculation using air sample data. Dose 

calculations using bioassay data collected for an 

individual feasible may be feasible (only for those with 

bioassay data). 

Standby 1 09/01/1946 09/30/1947 

Operations 2 10/01/1947 09/30/1949 Second operational period is partially in the SEC period 

10/01/1947 12/31/1947 SEC Period 

1/1/1948 9/30/14949 40,390 416,017 5691 GSD=3 

Standby2 10/01/1949 01/01/1951 210 2163 5691 GSD=3 

Operations 3 01/01/1951 06/30/1951 40,390 416,017 5691 GSD=3 

Standby 3 06/30/1951 06/30/1953 210 2163 5691 GSD=3 
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Figure 3: Plot of the log normal distribution of air sampling data at the Area Plant from HASL Electromet-1 

with reference lines for the intake rates to be used during operations and standby periods (SRDB 8931)

Z-score

-3 -2 -1 0 1 2 3

Air Concentration (dpm/m3

) 1e+0

1e+1

1e+2

1e+3

1e+4

1e+5

1e+6

1e+7

577 MAC during operations (40390 dpm/m3)

3 MAC during standby (210 dpm/m3)
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Bioassay data 

Figure 4: Uranium bioassay conducted at the Area Plant and operational periods. Operational Periods at Electro Metallurgical 

0

20

40

60

80

100

120

ElectroMet Operational Periods and Bioassay Data

1/1/1941

1/1/1942

1/1/1943

1/1/1944

1/1/1945

1/1/1946

1/1/1947

1/1/1948

1/1/1949

1/1/1950

1/1/1951

1/1/1952

1/1/1953

mg uranium per L urine

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

5.0 External Dose 

The Area Plant at Electro Met was an important uranium metal production facility for the 

Manhattan Project and continued to play an important role for the AEC during the 1947-1949 

time period. Electro Met ran three shifts of workers to meet delivery needs when it was 

operational as noted in various reports. During standby periods the plant was sometimes used for 

non-uranium production activities during which time NIOSH has no indication that a cleanup 

occurred as noted in Table 2. 

Area Plant Work Force

Contemporaneous reports provide that some 50-70 persons operated the Area Plant, others also 

mention that others from the plant provided support as needed with an estimated 30 additional 

persons who are not recorded including electricians and pipe fitters. Comparison of records 

available to NIOSH indicate that there are individuals with internal dosimetry monitoring 

(urinalysis) that were not badged. NIOSH does not have available to it a list that it considers 

complete with all the names and exposure potentials during all the operational or standby periods 

and the HASL reports are snap shots in time which record only the current job titles and persons 
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and did not describe that they were comprehensive regarding personnel who may have conducted 

those operations. 

Additional documentation shows the organizational chart of the Area Plant as previously 

discussed. Both the HASL reports and the organizational chart show that some work was shift 

work (3 shifts per day) and others work groups only operated one shift per day (Figure 2). Other 

sources site that another group of employees of approximately 30 supported the Area Plant part 

time (electricians and pipe fitters) which ranged from a few days per year or a few days per 

m8onth (AEC 1948a, p 32). NIOSH is unaware of any complete list of personnel for the Area 

Plant at Electro Met during its operational history. As previously mentioned, construction 

workers from other companies completed work in the Area Plant during active operations (MED 

1943A).

Operations that affect external dose

The Area Plant conducted operations that converted ‘green salt’ to uranium metal. These 

operations involved a number of jobs that exposed workers to enhanced beta fields because of 

operations which concentrated uranium progeny on the surfaces of the metal and also surfaces 

and residues of the production process (e.g. molds and slag). The Area Plant employed various 

operations that concentrated progeny of uranium and from the early operations onward it was 

realized that high beta dose was related to several operations. One such report in April of 1949 

(AEC 1948a, p34) describes furnace operators being exposed as measured with a film badge at 

“approximately 500 to 700 mr per week” well above the recommended levels and values up to 

1900 mrad/week non-penetrating dose were measured in 1949. 

Other factors that may affect the determination of dose include including the wearing of 

excessively contaminated gloves (values up to 2 R per 8 hour day were measured in 1944 (MED 

1944, p5)) which continued to be mentioned as a problem even in 1949 well after 

recommendations were made to correct the issue to maintain doses within tolerance levels (AEC 

1948a, p 34). 

In 1948 it became apparent that the laundry from the Area Plant, which was actually laundered at 

Linde Ceramics, was contaminated. Levels up to 15 mrad/hr beta were measured on coveralls 

from the Area Plant by direct reading instruments. However, since doses are being based on 

measured photon doses, the issue of the contaminated laundry will not affect the assignment of 

dose at Electro Met.

Available Data 

Limited external dosimetry data was collected over the operating history of the Area Plant. Very 

little personal external dosimetry is available during the first production phase at Electro Met. 

Many of this small group of measurements conducted in this first period were determined to be 

fogged. NIOSH has not found substantial changes that occurred for the first period with the 

exception of recommendations for changing out protective clothing (e.g. leather gloves) that was 

noted in 1944 (MED 1944). Whether any change was made to the actual practices during this 

time period is not known but seems unlikely given the continued poor reports that occurred even 

through the second operational phase.
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A more substantive measurement of external dose was conducted during the second operational 

period. NIOSH has personal external dosimetry results for 58 employees representing 21 job 

titles at the Area Plant during June 1948 through September 1949 time period. Some of these 

names match up with those who obtained internal monitoring but others do not. Analysis of this 

data set provides for a claimant favorable dose reconstruction method (all workers at the 95th

percentile) as compared to operator category of TBD-6000. 

Additional recommendations were made following the HASL facility review in November of 

1948 and were summarized as proposed changes in a May 1949 report to reduce both internal 

and external exposures (MED 1943b, p 16). The products and production methods for uranium 

metal used at the Area Plant create enhanced beta dose fields and Electro Met reported that a 

number of individuals exceeded weekly tolerance limits during the time periods when they 

badged the employees. Enhanced beta fields were related to specific processes and job 

categories. No TWA external dose estimates are available from HASL for Electro 

Metallurgical.

NIOSH will (i) use data collected during the second operational period to estimate external dose 

during the first operation period, (ii) the first standby period, (iii) the second operational period, 

(iv) the second standby period, (v) the third operational period, and (vi) the third standby period. 

Specifically, during the operation phases NIOSH will use the 95% of the lognormal distribution 

of the external dose data collected during the second operational period for all workers at Electro 

Met and use the geometric mean (GM) for all workers in the standby periods. The analysis and 

summary of the dose by period is provided below and additional information provided below. 

Each of these values will be assigned as the geometric mean for the period with a GSD of 3. 

Film badge results taken between June 1948 and September 1949 were found for 58 employees 

at Electro Metallurgical (AEC 1948b, AEC 1949a, AEC 1949c, AEC 1949e). Figure 5 shows 

the positive photon data for the results available to NIOSH for the second operational period. 

The data included a broad spectrum of titles and provided both beta and gamma dosimetry data

as well some ring badge dosimetry. The data was reviewed and duplicates eliminated and only 

external dosimetry records which included name and title was used for this analysis. Other data 

was duplicative, represented partial exposures during the week, or the badge was not worn. All 

badges identified as being “scapular” were also deleted (76 measurements). Scapular badges 

represented an experimental program whose intent was to compare the badge readings from 

underneath the clothing to readings outside the clothing and also to determine if any 

contamination affected the readings (AEC 1948a p28). However, results from the scapular 

program showed impossible readings from the Area Plant as mentioned in a 1948 memo to 

Electro Met. The values indicated that the current badge program was likely measuring dose 

under the clothing as the scapular values were below values being reported (that the scapular 

badges were being above the clothing and the normal badge in underneath the clothing) inverted 

(higher than the base line measurements). A small number of scapular data are included in the 

NIOSH dataset and indeed these values include data which appears to be reversed badging. The 

scapular data indicates that the external dose values for the Area Plant, and in particular the beta 

measurements, may have been under reported since it is likely they were obtained from under the 

employees clothing. It is unknown the degree of proper badge placement versus those who may 

have not properly wore their badges. Determination of beta dose would be impacted 
 

 

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substantially more that the gamma dose and therefore a claimant favorable multiplication of the 

gamma dose by 10 will be used rather than the actual measured data set based on TBD-6000. 

Figure 5: External dosimetry data from the second operational period at the Area Plant (only positive data 

shown). 

G raph of P os itive G am m a D os im etry R es ults A nd 

O p e ratio nal S tatus at E le c tro m e t 

1/1/1943 

1/1/1944 

1/1/1945 

1/1/1946 

1/1/1947 

1/1/1948 

1/1/1949 

1/1/1950 

1/1/1951 

1/1/1952 

1/1/1953 

1/1/1954 

Gamma Dose (mrem/week) 

0. 1 

1 

10 

100 

1000 

10000 

Uranium Production Peri ods(greed dotted line) 

Table 5 provides a summary of the data available by job title and summarizes whether what 

fraction of the data was above the detection limit of the time (50 mrem/week gamma and 50 

mrad/week beta). Photon data was analyzed using a rank order analysis of the lognormally 

distributed data for both the beta and gamma weekly doses. It is obvious that analyses and 

graphs of positive gamma dose will be biased high since a substantial portion of the data is less 

than the detection limit. These graphs serve as a check of the distribution by job title using box 

and whisker plots and they were reviewed to verify that no stratification of the data was required. 

Review of the data by job title and comparison to the 95% level for both beta and gamma dose 

does not produce any job that required consideration for stratification analysis as will be 

described below. The rank ordered distribution of photon dose and corresponding 95% values 

are shown in Figure 6 and the beta distribution in Figure 7 and the statistical analysis of the 
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badge results summarized in Table 6. NIOSH will used the 95% photon dose for all workers 

during the operational phases and the geometric mean of the distribution of the photon dose 

during standby periods and apply them geometric mean for the period with a GSD of 3. The 

analysis of the positive photon doses are shown in a box and whisker plot which verifies that 

there is no need for additional stratification based on photon dose measurements (Figure 8).

Table 5: External Dosimetry Monitoring by Job Title at Electro Met

title Measurements 

Available

# Gamma 

<MDA

# Beta 

<MDA

% Gamma 

>MDA

% Beta 

>MDA

Bomb Topper 101 80 42 20.8% 58.4%

Foreman 32 28 25 12.5% 21.9%

Furnace Operator 134 107 6 20.1% 95.5%

General Foreman 34 28 29 17.6% 14.7%

Guard 33 31 25 6.1% 24.2%

Handyman 78 70 35 10.3% 55.1%

Head Reaction Operator 109 93 61 14.7% 44.0%

Head Remelt Operator 152 122 16 19.7% 89.5%

Janitor 77 64 48 16.9% 37.7%

Jr. Chemist 3 1 0 66.7% 100.0%

Laboratory Handyman 71 61 54 14.1% 23.9%

Laborer 258 219 66 15.1% 74.4%

Operator 228 174 43 23.7% 81.1%

Repairman 94 79 36 16.0% 61.7%

Repairman Furnace Pts. 54 44 11 18.5% 79.6%

Shift Foreman 97 81 72 16.5% 25.8%

Sp. Saw Operator 46 38 12 17.4% 73.9%

Storekeeper 27 22 16 18.5% 40.7%

Storeroom Attend 73 64 42 12.3% 42.5%

Tech. Assistant Jr. 74 62 49 16.2% 33.8%

Utility Man 203 162 74 20.2% 63.5%

total 1978 1641 766 17.0% 61.3%

Beta Dose

Non-penetrating beta dose is primarily associated with the hands and forearms, and then other 

skin surfaces, of a worker who handles uranium metal in close proximity. Battelle-TBD-6000, 

Section 6.3, details a method to estimate skin doses for the hands and forearms of a worker who 

handles uranium metal as well as the other skin surfaces. NIOSH will use 10 times the photon 
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dose used for dose reconstruction to determine “other skin” dose during all periods value rather 

than rely on the measured beta doses because of bias regarding the badge location as previously 

discussed (that the badges may have been worn under the clothing). 

Comparison of the measured beta/gamma dose ratio was determined by job title only for positive 

beta and gamma measured values (Figure 10). The values for the enhancement of beta dose for 

3operations that concentrate uranium decay products as described in TBD-6000 section 3.3.1 

which says the whole body beta dose may approach 10 times the whole body photon dose. 

Evaluation of the beta/gamma ratio for various job titles for badges where both the photon and 

beta dose were positive indicates a geometry mean value of approximately 5 for some jobs where 

both results on a badge are positive (Figure 9). This is substantially less than the routine 

assumption of 10 times the gamma dose and the results are questionable because of the noted 

that improper badge usage was noted and was found to cause substantial problems evaluating the 

scapular badge results. Review of the limited badge data identified as scapular which was 

correctly paired with a second badge typically indicated that the beta dose above the clothing 

was approximately two to four times the level under the clothing. This data set is only for four 

workers, with 8 paired measurements and for a very short time period. Therefore, the beta dose 

for “other skin” shall be based on 10 times the gamma dose for the period in question. Also, 

while NIOSH has several hundred ring dosimeter values, they were without worker titles and 

offer little information about how they were worn (with or without protective gear). Furthermore 

the ring badges were worn by only a fraction of the employees and only for a limited time. 

Therefore NIOSH will rely on the calculated dose rates for the operator category from TBD6000 to determine the beta dose to the hands and forearms of workers during operational times as 

a claimant favorable determination. NIOSH will used the geometric mean of the lognormal 

distribution of whole body photon dose times 10 during standby periods to determine all skin 

dose (hands, forearms, and other skin). 
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Figure 6: Rank ordered probability plot of Electro Metallurgical Weekly Photon Dose Data above the 

detection limit for all monitored workers at Electro Metallurgical 1948-1949

 

 

z-score

0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0

ln(weekly gamma dose) (mrem))

3.5

4.0

4.5

5.0

5.5

6.0

Intercept=	3.300

slope=	0.7161

R 2=	0.9674
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Figure 7: Rank ordered probability plot of Electro Metallurgical Weekly Beta Dose Data above the detection 

limit for all monitored workers at Electro Metallurgical 1948-1949 

 

z-score

-1 0 1 2 3 4

ln(weekly beta dose (mrad))

3

4

5

6

7

8

9

Intercept=	4.501

slope=	0.9594

R 2=	0.9865
 

 

 

 

 

 

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Table 6: Weekly dose values determined from the badges of monitored workers at Electro Met during the 

period 1948-1949. 

Weekly 

Beta Dose 

(mrad) 

Weekly 

Gamma 

Dose 

(mrem) 

Graphical Slope 0.9594 0.7161 

Analysis of Intercept 4.501 3.300 

natural log 

transformed 

data 

R2 0.9865 0.9674 

Calculated GM 90.11 27.11 

values for GSD 2.61 2.05 

weekly 

dose 

95th % 

(mR) 

436.7 88.06 

The external dosimetry summary at Electro Met includes: 

1-The external dose from Table 7 shall be used to determine dose for all Electro Met employees. 

2-Photon and Beta dose during operations was determined using the 95th percentile of all badged 

worker data (for comparison, the operator category from TBD-6000 whole body dose is 2500 

mrem/year and the beta dose is 25000 mrad/year)) 

3- Photon dose during standby was determined using the geometric mean of all badged worker 

data 

4- Non-penetrating dose to other skin is assigned based on the recommended 10 times the 

photon dose to account for incorrectly worn badges. The values based on the badge results (95th 

and geometric mean) are provided for comparison to the assigned value. 

5- The non-penetrating dose to the hands and forearms is based on the data from section 6.3 of 

TBD-6000 and is used during the operational period only. Beta doses to the hands and forearms 

during standby periods are determined using whole body skin dose values (10 times the GM of 

photon dose). 

6-The annual dose values shall be assigned as the geometric mean for that period with an 

uncertainty equal to a GSD of 3. 

7-Values in Table 7 represent the dose for a calendar work year and should be scaled to the 

appropriate employment by scaling the weekly value to a normalized 50 work weeks per 

calendar year. Hence the 95 percentile penetrating photon dose of 88.06 mrem/week was scaled 

by multiplying by 50 weeks per work year. For a worker determined to work 12 weeks in the 

operational phase for 1947, that worker would be assigned a photon dose of (4403 mrem/yr)x(12 

weeks/52 weeks/yr)=1016 mrem (constant distribution). 
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Table 7: External dose summary for Electro Met based (annual value base on a 50 week work year)

Description Start Stop Photon 

whole 

body1,3

(mrem/year)

Nonpenetrating 

dose to 

other skin to 

assign2,3,4,5

(mrad/yr) 

Non-penetrating 

dose to hands 

and forearms2,6

(mrad/year)

Operation 1 08/13/1942 08/31/1946 4403 44030 276000

Standby 1 09/01/1946 09/30/1947 1356 13560 13560

Operations 2 10/01/1947 09/30/1949 4403 44030 276000

Standby 2 10/01/1949 01/01/1951 1356 13560 13560

Operations 3 01/01/1951 06/30/1951 4403 44030 276000

Standby 3 06/30/1951 06/30/1953 1356 13560 13560

1-assigned as photons with an energy of 30-250 keV and converted to organ doses using the 

appropriate dose conversion factors 

2-assigned as electrons with an energy >15 keV 

3-Dose during operations determined based on the 95th percentile, standby based on the 

geometric mean of the measured dose for badged employees during operations. Both applied as 

the period specific geometric mean with a GSD of 3. 

4-Dose to the other skin non-penetrating based on badge results which were noted to be 

improperly worn. Provided for comparison to assigned doses only. 

5- Skin non-penetrating dose determined based on 10 times the photon dose to be assigned 

6- Metal worker operator dose to be assigned for the hands and forearms non-penetrating dose 

during operations (TBD-6000) and the same as other skin during standby periods. 
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Figure 8: Comparison of the 95th percentile weekly gamma dose (z-score derived) to the positive gamma dose by worker title for the period 1948-1949. 

The geometry mean of the positive data from one group group exceeded the 95th but additional review verified the 95th percentile was claimant 

favorable for all groups. 

Bomb Topper

Foreman

Furnace Operator

General Foreman

Guard

Handyman

Head Reaction Operator

Head Remelt Operator

Janitor

Jr. Chemist

Laboratory Handyman

Laborer

Operator

Repairman

Repairman Furnace Pts.

Shift Foreman

Sp. Saw Operator

Storekeeper

Storeroom Attend

Tech. Assistant Jr.

Utility Man

102

4

5

6

7

8

9

2

3

Weekly Gamma Dose (mrem)

Guards: only 2 of 33 measurements 95th percentile

 were >mda
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Figure 9: Comparison of the 95th percentile weekly beta dose (z-score derived) to the positive beta dose for all worker job titles. The GM for any job 

title was not found to exceed the 95th percentile dose for all the data. Dose was natural log transformed prior to analysis (95% value=437 mrad/week).

Bomb Topper

Foreman

Furnace Operator

General Foreman

Guard

Handyman

Head Reaction Operator

Head Remelt Operator

Janitor

Jr. Chemist

Laboratory Handyman

Laborer

Operator

Repairman

Repairman Furnace Pts.

Shift Foreman

Sp. Saw Operator

Storekeeper

Storeroom Attend

Tech. Assistant Jr.

Utility Man

102

103

4

5

6

7

8

2

3

4

5

6

7

8

2

Weekly Beta Dose (mrad)

95th percentile
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Figure 10: Beta/gamma ratio of positive weekly dose values by job title where both measurements were greater than the minimum detectable amount.

Bomb Topper

Foreman

Furnace Operator

General Foreman

Guard

Handyman

Head Reaction Operator

Head Remelt Operator

Janitor

Jr. Chemist

Laboratory Handyman

Laborer

Operator

Repairman

Repairman Furnace Pts.

Shift Foreman

Sp. Saw Operator

Storekeeper

Storeroom Attend

Tech. Assistant Jr.

Utility Man

100

101

2

3

4

5

6

7

8

2

3

4

5

6

7

8

2

Beta/Gamma Ratio (both measurements positive)
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6.0 Occupational Medical Dose

A memo reviewing the medical program at Electro Metallurgical was written by the MED in 

1945 (MED 1945a). The memo recommended pre-employment, annual and termination X-rays. 

No information regarding occupational medical dose was found in any of the site research or 

Computer Assisted Telephone Interview materials. A memo in 1949 from the AEC to Electro 

Met however, confirmed that they were using x-ray equipment installed at the plant to conduct 

examinations (AEC 1948a p 33). Information to be used in dose reconstructions, for which no 

specific information is available, is provided in ORAUT-OTIB-0006, Technical Information 

Bulletin: Dose Reconstruction from Occupationally Related Diagnostic X-Ray Procedures 

(ORAUT 2011). The assumed frequency in this document is PA chest X-ray for preemployment, annual, and termination examinations between the years 1942 and 1953 (the 

covered period). Annual organ doses are entered into the NIOSH-IREP program as the annual 

dose due to an acute exposure to photons (E=30-250 keV). The distribution is assumed to be 

normal with a standard deviation of 30%. 

 

7.0 References

AEC 1947. Radiation Monitoring Progress Reports 1948 and Health Physics Department 

Progress Reports 1947 – 1948. US Atomic Energy Commission. 1947-1948. [SRDB Ref ID 

7665] 

AEC 1948a. Memos and Reports of Readings, Samples, Results pertaining to Health Hazards at 

Electrometallurgical Co. Job Descriptions of Hourly Paid Classifications. US Atomic Energy 

Commission. 1948-1953. [SRDB Ref ID 8897] 

AEC 1948b. Dosimetry Results, March 1948 - January 1949. US Atomic Energy Commission. 

1948. [SRDB Ref ID 11547] 

AEC 1948c. Dust Hazards at Electro Metallurgical Company. US Atomic Energy Commission. 

June 1948. [SRDB Ref ID 85789] 

AEC 1949a. Film Badge Results January 3, 1949 -September 26, 1949. US Atomic Energy 

Commission. 1949. [SRDB Ref ID 11548] 

AEC 1949b. Atomic Energy Commission. ELECTROMETALLURGICAL CO.: Occupational 

Exposure to Radioactive Dust. US Atomic Energy Commission, New York Operations Office, 

Medical Division, March 23, 1949. [SRDB Ref IDs 8912, 8939, 59207]. 

AEC 1949c. Film Badge Results, March-May 1949. US Atomic Energy Commission. 1949. 

[SRDB Ref ID 8875]

AEC 1949d. Monthly and Progress Report for September 1949. US Atomic Energy 

Commission. September 1949. [SRDB Ref ID 60387 (previously identified as SRDB Ref ID 

37945)]
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AEC 1949e. Film Badge Results June 7, 1948-June 20, 1949. Atomic Energy Commission. 

1949. [SRDB Ref ID 11543] 

AEC 1949f. Occupational Exposure to Radioactive Dust August 17-19, 1949. US Atomic 

Energy Commission. November 10, 1949. [SRDB Ref ID 8930] 

AEC 1949G. Health Hazards in NYOO Facilities Producing and Processing Uranium. US 

Atomic Energy Commission. April 1, 1949. [SRDB Ref ID 8880] 

AEC 1950a. Tonawanda Area Progress Report June 1950. US Atomic Energy Commission . 

June 1950. [SRDB Ref ID 132713] 

AEC 1950b. Tonawanda Sub-Office Weekly Progress Report 1950. US Atomic Energy 

Commission. February 1950. [SRDB Ref ID 132714] 

AEC 1950c. Assorted Electro Metallurgical Urinalysis Data sheets. US Atomic Energy 

Commission. 1947-1950 [SRDB Ref ID 8944]. 

AEC (U.S. Atomic Energy Commission) 1951, Report by the Manager of New York Operations 

Office and the Director of Production, The Production of Uranium Feed Materials, May 22, 

1951. US Atomic Energy Commission. May 22, 1951. [SRDB Ref ID 4125]. 

AEC 1952a. Dismantlement, Decontamination, Exposure Information: Loading and Unloading 

Rail Cars (1947-1952). US Atomic Energy Commission. December 18, 1952. [SRDB Ref ID 

16316] 

AEC 1952b. Tonawanda Area Progress Report August 20, to September 20, 1952. US Atomic 

Energy Commission. September 1952. [SRDB Ref ID 59212] 

AEC 1953a. Sale Agreement and Property Information Pertaining to Disposal of the Plant. US 

Atomic Energy Commission. April 9, 1953. [SRDB Ref ID 59339] 

AEC 1953b. Dismantlement of Electromet Company - Contract Number W7405-ENG-14 

Radiation Survey of December 10-12, 1952. US Atomic Energy Commission. February 3, 1952. 

[SRDB Ref ID 59265] 

AEC 1953c. Dismantlement of Electromet Co., Decontamination Survey of August 11 and 14, 

1953. US Atomic Energy Commission. September 29, 1953. [SRDB Ref ID 8893] 

AEC 1953d. Dismantlement of Electromet Company - Contract Number W7405-ENG-14. US 

Atomic Energy Commission, November 1953. .[SRDB Ref ID 59321] 

AEC 1953e. Disposal of Government Property. US Atomic Energy Commission, June 23, 

1953. [SRDB Ref ID 59319] 
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DOE 1985. Formerly Utilized Sites Remedial Action Program: Elimination Report for the 

former Electro Metallurgical Company, Niagara Falls, New York. DOE 1985. [SRDB Ref ID 

9036, pp 21-30]. 

DOE 1986. Formerly Utilized Sites Remedial Action Program: Elimination Report for the 

former Electro Metallurgical Company. DOE 1985. [SRDB Ref ID 9036, pp 21-30]. 

DOE 2013, Office of Health, Safety and Security, EEOICPA web site.

http://www.hss.energy.gov/healthsafety/fwsp/advocacy/faclist/findfacility.cfm

HHS 2012. Designating a Class of Employees from Electro Metallurgical Site. HHS 

Designation of Additional Members of the Special Exposure Cohort under the Energy 

Employees Occupational Illness Compensation Program Act of 2000. [SRDB Ref ID 146854] 

MED 1942. Electro Metallurgical Contracts 1942-1945. US Manhattan Engineer District. 

[SRDB Ref ID 59338] 

MED 1943a, Construction of Electro Metallurgical Company Area Plant; U.S. Army Corps of 

Engineers Completion Report, Tonawanda Area – Manhattan District; 1943 [SRDB Ref ID

59225]. 

MED 1943b, Weekly Report for December 26, 1942 to January 1, 1943, U.S. Engineer Office, 

New York, New York, January 2, 1943 [SRDB Ref ID 30778]. 

MED 1943c. Reports and Memos containing Radiation Contamination Data 1943 through 1959 

at Electro Metallurgical Co. US Manhattan Engineer District. [SRDB Ref ID 35738] 

MED 1943d. Production Report on Tuballoy by Electro Metallurgical Company – NNES 

Division VII, Volume 2B. US Manhattan Engineer District. [SRDB Ref ID 112671] 

MED 1944. Medical Hazards at Electro-Metallurgical Co. US Manhattan Engineer District. 

June 1944. [SRDB Ref ID 16247] 

MED 1945a, Memo from B.J. Mears, Captain, Medical Corps., to Area Engineer, Tonawanda 

Area, Tonawanda, New York, May 4, 1945 [SRDB Ref ID 21849]. 

MED 1945b. Status of the Low Grade African Ore Beneficiation Program. US Manhattan 

Engineer District. October 24, 1945. [SRDB Ref ID 91908] 

MED 1945c. Status of the Low Grade African Ore Beneficiation Program. US Manhattan 

Engineer District. December 6, 1945. [SRDB Ref ID 91957]

NIOSH (National Institute for Occupational Safety and Health) 2004, Estimation of Ingestion 

Intakes, Rev 0, OCAS-TIB-0009, National Institute for Occupational Safety and Health, Office 

of Compensation Analysis and Support, Cincinnati, Ohio. 
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NIOSH 2010, Radiation Exposures Covered for Dose Reconstructions Under Part B of the 

Energy Employees Occupational Illness Compensation Program Act, Rev 1, OCAS-IG-003, 

NIOSH 2012, Special Exposure Cohort Petition Evaluation Report - Petition SEC-00136, 

Division of Compensation Analysis and Support, Cincinnati, Ohio. 

ORAUT (Oak Ridge Associated Universities Team) 2011, Technical Information Bulletin: Dose 

Reconstruction from Occupationally Related Diagnostic X-Ray Procedures, ORAUT-OTIB0006, Rev 04. June 20, 2011. 

ORAUT 2012, Technical Information Bulletin: Dose Reconstruction During Residual 

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

March 5, 2012. 

UCC 1948. Corporation Changes. Union Carbide and Carbon Corporation. November 24, 

1948.[SRDB Ref ID 59240] 

UCC 1949. SF Material Accounting Procedure Manual for the Electro Metallurgical Division of 

the Union Carbide and Carbon Corporation. Union Carbide and Carbon Corp. July 11, 1949. 

[SRDB Ref ID 85780] 

Documents that contain air concentration data for Electro Metallurgical include SRDB Ref ID’s 

5809,7726, 7727, 8889, 8912, 8930, 8943, 90364, 11542, 16247, 35738, and 35762. 

Air sample reports air included in the following SRDB Ref ID’s: 8912, 9036, 16280, 59207. 

Bioassay data are included in SRDB Ref ID’s 8887, 8944, 11452, 35738. 

External data are included in SRDB Ref ID’s 11547 and 11548. 

While other files may contain data, they are duplicates of the information contained in the 

references above.