Transcript
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Advisory Committee members during risk mapping session

“WE CAN’T BREATHE”

A RETROSPECTIVE EXPOSURE PROFILE OF THE PEBRA INC. PLASTICS PLANT IN PETERBOROUGH, ONTARIO

(1986-1996)

PREPARED BY

Dale DeMatteo, BA, MHSc and Robert DeMatteo, BA, MA, DOHS

AND

Unifor Local 1987 including: Local President, Mark Clapper, Past President, Rose Wickman, Dave Gooley, Jackie Dufty, Cecil Firlott, Karen Quesnel, and Rick McDougal

FOR

The Occupational Health Clinics for Ontario Workers (June 2020)

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TABLEOFCONTENTS

PREFACEANDINTRODUCTION 3‐4

HISTORYOFPEBRAINC.PLASTICS 4‐5

METHODS 6‐9

GENERALFINDINGS 9‐15

BACKGROUNDTOPLASTICSPRODUCTION 15‐21

COMMONEXPOSUREEXPERIENCESATPEBRAINC. 22‐23

COMPLEXCHEMICALMIXTURES 23‐25

VENTILATIONATPEBRAINC. 25‐28

LIMITATIONOFHYGIENEMONITORING 28‐31

PROBLEMSWITHTHEEXPOSURELIMITS 31‐33

DISCUSSIONANDCONCLUSIONS 33‐37

DETAILEDDEPARTMENTFINDINGS 38‐105

REFERENCES 106‐109

ACKNOWLEDGEMENTS 109

APPENDIXA LiteratureReview 110‐167

APPENDIXB MOL/UnionLogs 168‐210

APPENDIXC ChemicalsUsedatPebra 211‐235

APPENDIXD RoseWickmanLetter 236

APPENDIXE ChemicalBodyBurden 237‐244

APPENDIXF RiskHazardAnalysis 245‐254

APPENDIXG VentraPlantLayout 255

TABLE1 OccupationalDiseaseatPebra 11

TABLE2 ChemicalHealthEffects 19‐22

TABLE3 LowLevelHealthEffects 32

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PREFACE

“Wecan’tbreathe.Wehavetogetoutofhere!”1Aworker’surgentcrytoco‐workers,documented

in a Union Health and Safety Committee log book, is a more dire reflection of thousands of

individualandcollectiveworkrefusalsthattookplaceduringthe“Pebraera”(1986‐1996)atthe

nowVentraPlasticsplantinPeterborough,Ontario.AMinistryofLabour(MOL)officialadmitted

thatworkrefusalsduringthatfirstturbulentdecade“filledtwoentirefilingcabinets”ashecalled

onbothpartiestomeetonneutralgroundandagreetofindasolution–orhethreatened,“Weare

puttingan(MOL,HealthandSafety)officerinthebuilding”.2Interestingly,thefirstPebrafacility

that opened inKitchener,Ontario in 1981,was acknowledged as having amuch less turbulent

history. 3 Tenyears later, in1996,Pebradeclaredbankruptcyandover thenext fiveyears, the

companywassoldthreetimes,eachtimeunderbankruptcyorders.Ithasbeenalongand,asone

MOLinspectordescribed,“rockyroad”4tocompliancewithOntario’sOccupationalHealth&Safety

Act at the plant. Evidence of this “rocky road” is abundant ‐‐ from aWSIB Auditor’s report

awarding Pebra’s Health and Safety Program an embarrassing “7% out of 100%” 5 tomany

examples of recalcitrance, indifference, and outright disregard for workers on the part of

management, and workers themselves ignoring one of the few openly stated “safety rules” by

smokinginwashrooms.

Importantly,what is exposed in this report is evidence of the contradictory nature of ‘scientific

evidence’ as practiced by theMOL that pitswarning information of over‐exposure provided in

chemical manufacturers’ MSDS sheets and worker self‐reports of such exposures, against

questionable air sampling techniques –‐ the later given priority inMOL decisions as towhat is

acceptable evidence of health ‘risks’ to workers, or constitutes a ‘harmful level’ of chemical

exposures. FromthetimePebraInc.openedtheplant inPeterborough,MOLreportsdocumenta

patternofworkerhealthconcernsandproblematicworkareas in the facility ‐‐beginningyears

beforePebraworkersknew sucha thingasa “MSDS” existedor that the chemicals (other than

Isocyanates)theywereexposedtodaily,andinlargeamounts,couldbedangeroustotheirhealth.

INTRODUCTION

ThepurposeofthisresearchprojectwastodevelopretrospectiveexposureprofilesoftheworkprocessesatPebraInc.,nowVentraplasticsfacility,inPeterborough,Ontariobetween1986and1996.This involvedasystematiceffortwith theparticipationofUNIFORLocal1987Workers’Advisory Exposure Committee to collect, document and analyze empirical information abouthowproductionwascarriedoutinthiscomplexplasticsproductionoperation.Thecommittee

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was led by past andpresent local presidents, RoseWickman andMark Clapper, and includedJackie Dufty, Dave Gooley, Karen Quesnel, Cecil Firlotte, and RickMcDougal. This work wasundertaken to document the extent and nature of chemical and physical exposures that arepossibly linked with the various cancers and other diseases that many employees and theirfamilies suffered over the years. Given the complexity of chemical exposures in plasticsproductionprocesses,andevidenceofconsiderableby‐standerexposures,theresearchersrelieduponqualitativeresearchmethodstoprofileexposures,retrospectively.

HISTORYOFTHEPEBRA(NOWVENTRA)PLASTICSPRODUCTIONFACILITY6,2

In1981,aGermanplasticautoparts firmcametoCanadaand first located ina22,000squarefoot facility in Kitchener, Ontario. Initially, automobile parts were made in Germany, thenshipped toKitchener for completion, and finally routed toGM in theUnitedStates. In1984, anewproductionlinewasdevelopedusingaprocesscalled“post‐lamination”formakingautosidemoldingwithcoatedstainlesssteelsheetmetal.

By1986,partsweremanufacturedattheKitchenerplantusinganinnovativeprocess,“reactioninjectionmolding,”broughtfromGermanyandcalled“R‐RIM”. Withproductionexpanding,thecompany set up a second facility in Peterborough, purchasing a 200,000 sq. ft. metal cladstructure, which was expanded in the late 1990s to accommodate its larger thermoplasticinjectionmoldingmachinesandproductionoperations. Thecurrentplantiswellover350,000squarefeet.

Between1987and1989,production inPeterborough focusedonpost‐laminatingsidemoldingand thermoplastic injection molding for auto trim parts. From 1993 to the present, a multi‐million‐dollar, state of the art, robotic paint linewas added. By 1992, the Peterborough plantemployedover400peoplewiththecapacity tocarryoutR‐RIMmolding(introducedin1989),punchingandnotching,partsassembly,injectionmolding,andasemi‐automatedpaintfacility,inadditiontoaNorthAmerican‐widedistributionsystemfortheircompletedproducts.

Over a decade (1986 to 1996), the Peterborough workforce grew from seventy‐five to fivehundred and seventy‐five women and men, with production increasing from one product tothirty different products, importantly, with no change or substantive improvement to theventilation and air intake systems. Initially when most jobs involved close “hand work”, theworkforce includedmore women thanmen (60:40), becoming closer to 50:50 as operationsbecame more automated. Advisory Committee members identified that for every 50 peoplehired,approximately30becamelong‐termemployees‐–apatternthatcontinuestothisday.

By1992,PebraInc.employed3000workersworldwide,withcorporateofficesinTorontoandanengineering/design office in Detroit. Yet by 1996, Pebra Inc.went into bankruptcy and sincethenthePeterboroughplanthasgonethroughanumberofcorporateownershipturnovers:firstJPE Inc., and then Ventra Plastics, which in turn was taken over by Flex‐N‐Gate (its currentowner) but still operating under the Ventra name. Ownership transitions were as follows:PebraInc.1986‐1996;JPE1996‐1998;Ventra1998‐2001;Flex‐N‐Gate/Ventra2001‐Present.

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Along with these corporate transitions, there were a number of historical stages in plasticsproductionattheplantincluding:

1986‐1988: The initial production processes (transferred fromGermany) consisted of 4 smallinjection machines; in the next two years post laminate, roll forming, and manual paint lineoperationswereadded.

1986‐1992:Manualpaint line; from1993‐1996:partially automatedpaint line introducedandlaterexpanded;by2004,thepaintlinewasfullyautomated(robotics).

1988‐2000:TankFarmandR‐RimDepartmentbrought fromGermany,allowing largermoldedpartssuchasrockerpanelsandfasciastobemadeonsite.Duringthatperiodthenumberoflargeclampsincreasedfrom4to8priortoR‐RIMdepartment’sclosure.

1998‐2010: Second buildingwas added (“warehouse”) located onMonaghan Avenue used forstorage,assembly,andshipping.

2004‐present:Fullyautomatedinjection‐moldingclampswithuseofrobotics(nowconsistingof17verylargemachines);amodern,fullyautomated,paintlinewithnewerrobotsaddedin2008.

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METHODS

ARisk‐BasedApproachtoidentifyingworkplacechemicalexposures:

Toaddressthechallengesofidentifying,retrospectively,employees’chemicalexposuresatthePeterboroughPebraplantduring thedecade1986‐1996, aRisk‐BasedApproachwasused forthe purpose of relating work‐acquired diseases to chemical exposures in the workplaceenvironment.Basicconceptsandtenetsofindustrialhygienewereappliedtoidentifyexposurerisk factors during the productionprocesses thatworkerswere either engaged in directly, orexposedtoasbystanders.Theriskfactors,orvariables,thathaveaninfluenceontheextentandnatureofexposuresarewellestablished,scientificallyderived,conceptsinindustrialhygiene.

This approach aligns with the work of Sonia Lal, industrial hygienist with the OccupationalHealthClinicsforOntarioWorkers(OHCOW),whoundertookadetailedretrospectiveexposureassessmentoftheproductionprocessesattheVentraplantin2004‐2005.7SimilartoLal’swork,thiscurrentretrospectiveassessmentreliesuponanumberof“qualitative”riskfactors,similartothatusedbyMaranoetal.intheaircraftindustry.8Inthisregard,weassessedtheproductionprocesses andworking conditionswith regard to theirpotential tohave significantly exposedworkerstochemicalrisks.Theriskfactorsframeworkincluded:

Thephysicalstate(s)of thechemicals(liquid,mist,gas,vapour,solid,dust)androute(s)ofentry(inhalation,absorption,ingestion),

Thequantityofthechemicalused,e.g.,volumeofchemicals,solvents,resins,etc.,

Sizeofthematerialsandsurfaceareasbeingworkeduponorfabricated,

Proximitytothesourceofexposure,

Direct/indirecthandlingofchemicals,

Durationofexposure(includinguseofovertimeand/ormultipleshifts),

State of ventilation systems, e.g., effectiveness of general, natural, and local exhaustventilation,

Provisionofmake‐up(freshaircirculation)air,

Provision of personal protective equipment (PPE) i.e., respiratory protection, clothing (e.g.gloves,coveralls),eyeprotection,

Safeworkpractices/procedures,

Stateofhousekeepingpractices,

Eatinganddrinkingatworkstations,

Workorganization factors, e.g., piece‐rate system,physical effort, and impacton safeworkpractices,

Workers knowledge of and training re: chemicals used, including access to, andunderstandingof,MSDStechnicaldata.

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Qualitativeandparticipatoryresearchmethods:

This study applied a “mixed” qualitative/quantitative approach to gathering and assessinginformation necessary to develop rich, detailed exposure profiles of the industrial processesundertakenattheplasticsfacility.9‐13

Qualitative and “mixed” researchmethods in industrial hygiene and epidemiology have beensuccessfullyusedinsimilarindustrialcircumstanceswherethereare:diversegroupsofworkersholding multiple jobs; numerous, complex industrial processes; and, exposures that havechangedovertheyears8,14‐18 Ratherthanratingindividualexposures,thisresearchfocusesonprofilingtheproductionprocessesandtheirexposurepoints,alongwithworkplacefactorsthatput workers at greater/less risk of being exposed. This approach is best able to address thechallengespresentedbythenatureoftheplasticsproductionprocessescarriedoutatthePebraplant, and the limitations in the availability and reliability of “hard’ exposure data fromindustrial hygienemonitoring. Aswell, detailed descriptions ofworker exposures inmany ofthese industries are limited at best. Published research seldom contains data reflecting thetypical,day‐to‐dayconditionsexperiencedbyworkers.

Informationsourcesandresearchprocess:

This project relied upon four basic sources of information on industrial processes, workingconditions,andthenatureandextentofexposuresincluding:

1)Focusgroup sessions—AdvisoryCommittee:Themainstay of this research effort was theAdvisoryCommittee,madeupofworkermembersof the jointhealthandsafetycommitteeaswell as retirees andworkerswith long experiencewith the plant’s operation. Their collectiveexperience spanned an era from the plants’ opening in 1986 to the present. Theauthors/researchers served as facilitators in what might be called a detailed ‘risk mapping’exercise. The committee became a permanent “focus group” formed by consensus betweenparticipants’ andUnifor Local 1987 executive committeemembers. Otherworkers,with in‐depth experience in particular processes, participated in the focus group’s fact gatheringsessions.

Thecommitteeconsistedofsevenregularmembers,whometoncetotwiceaweekforfourtofivehoursfromJanuarytotheendofApril,2019.Meetingswereorganizedwithreferencetotheindustrialprocessesandworkingconditions foreachdepartmentwithattention todetailson:chemicals,equipmentused,materialsbeingfabricated,thevolumeofproduction,theworktasksandhowmaterialswerehandled,descriptionsofworkconditions,exposurecontrols,accesstoinformation,workpractices,housekeeping, sensoryexperience,andadversehealthsymptoms.The meetings often included other Pebra employees, or retirees, invited for their specialknowledge of the work processes being discussed. Between meetings, Committee membersresearched issues where no confirmation was achieved through phone contact with otherworkers or by seeking further documentation. Additional information was generated bymembers through phone calls, informal discussions, and sharing of primary/historicaldocumentswithinthegroup.

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Thedynamicassociatedwithfocusgroupmethods(theabilitytobothenrichandchallengetheaccuracyofinformationcollected)andconsiderationofparticularprocessesorissueslentitselfto rich discussion and in‐depth understanding of the complex work environment during thePebraera.Throughout,the“constantcomparative”methodassociatedwithqualitativeresearchwasapplied,whereinformationcollectediscontinuallycontrastedandcomparedwithpreviousinformation for its consistency and truth‐value (i.e., reliability). In addition, we soughtagreement and group/individual confirmation to achieve accuracy of information i.e., validityand reliability. In the course of this research,more than 20 individuals contributed, in someway,tothegroupsessions.Thesessions(otherthanactualmapdrawingsessions)weretapedandnotestypedanddistributedtoCommitteeMembersfortheirreviewandcorrections.Withintensivemappingsessionswhereparticipantscreatedriskmapsofvariousdepartments,thesediagrams were photographed for the record. These various types of data collection werereviewed and checked for accuracy then reworked into the resource template that forms thebodyofthiswork.

2)RiskMapping: TheAdvisoryCommitteereliedheavilyuponhazard/riskmappingsessionswithkeyinformants/groupsofinformants,similartothatdescribedinotherresearcheffortstogatherqualitativedataonchemicalexposuresintheplasticsindustryandfoundries18‐23

Risk mapping is a participatory method where workers collectively draw a graphicrepresentation of theirworkplace and the health hazards that affect them. This technique isused to describe the production methods, tasks and materials in order to generate dataconcerningtherisksofexposure(s)usingtheriskfactorslistedabove.Thesephysicaldrawingsoftheworkplaceallowworkerstomoreeasilypinpointandidentifyhazardsandtheparticularformsuchhazards take. Importantly, it assistsparticipants insituatingaworkprocess in thecontext of the broader production process(es) around them as to identify “by‐stander”exposures that are often significant, yet easilymissed,when assessing exposure risks. It is aconcreteapproach todescribingand identifying theday‐to‐day realityof theworkplaceandamethodof identifyinghowworkersperceiveand face thehazards thatworkpresents. It alsoallowsworkersandtechnicianstomesh“science”andworkerexperienceinanefforttovalidateworkerexperiences.Becausethisexerciseinriskmappingisacollectiveactivity,withtheentiregroup contributing to the view of theworkplace, it leads to amore accurate picture ofworkprocessesanddegreeofriskexposures.24

3)Documentation: In addition to these qualitative findings, an effort was made to includehistorical “quantitative”data.DocumentationofexposureconditionsduringthePebraerawasobtained from:1) theOntarioMinistryofLabour Inspectorate reports/investigations;2) JointHealth and Safety Committee minutes/reports/logs; 3) union and employee/employercorrespondence,4)Consultant reportsgeneratedby theemployer;5) relevantMinistryof theEnvironment (MOE) documents as evidence of chemical fumes/exposures experienced andreportedbythesurroundingcommunity‐‐allofwhichsubstantiated,aswellasprovidedacrosscheckon,thereliabilityandaccuracyoffocusgroupgeneratedinformation.

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In addition to supporting/reinforcing focus group generated data, these various sources ofdocumentationexposedapatternofrecalcitranceonthepartofPebratoadheretothelaw,uptoandincludingoutrightdisregard,vergingoncontempt,foritsworkersasreflectedinnumerousincidents.Severalofsuch incidents includedworkersdisciplined for“complaining”aboutpoorair quality or symptoms they experienced, orwhen requesting to have the air tested becausestrongfumeswerepresentandtoldbyamanager:“Thereare3millionchemicals.Whatdoyouwantmetotestfor?YoutellmeandI’lldoit!”

(DiscussionsarecurrentlytakingplacewithOHCOWforthecreationofanexposureprofiledatabaseforthestorageandretrievalofdocumentsreferencedinthisreport, includingMinistryofLabour (MOL) reports, Joint Health and Safety Committee (JHSC) minutes, union Health andSafety(H&S)logs,consultantreports,internalmemorandum,andMSDSs.)

4) Industrial hygiene, occupational health, and related literature reviews: Additionalinformation was obtained through reviews of the scientific literature documenting industrialprocessesandobservedexposuresfrompublishedstudiesofsimilarworkenvironments,aswellas general information identifying and describing various industrial processes. SuchinformationcanbefoundinaliteraturereviewofplasticsproductioninAppendixA

Byincludingthesemultiplesourcesofinformationwewereabletocorroboratethedescriptionofworkprocessesandexposureconditionsthroughthemethodcalled“triangulation”.12,13,25

GENERALFINDINGS

This research is meant to address employees’ concerns that the extent and nature of theirexposuresandworkingconditionswereadverselyaffectingtheirhealth,andwereresponsiblefor the large number of cancers and other diseases (including reproductive problems)experiencedbythewomenandmenwhoworkedthere.Giventhelargenumberofcarcinogenicand endocrine disrupting chemicals (EDC) used at the plant, their perception of a connectioncannotbedismissed.Itwasalsotheirviewthatthecompanyandthegovernmentinspectoratemisrepresented their exposure conditions which undermined their efforts to makeimprovements,andpursuecompensationdiseaseclaimsattheWorkplaceSafetyandInsuranceBoard(WSIB).TheseissuesweresimilarlyaddressedbyLalandWongin2000and20057,26.

Indeed,workerswere routinely exposed to: benzene, silica, resin dust containing isocyanateresidues, asbestos, vinyl chloride, phthalates, acrylonitrile, styrene, 1,3 butadiene, cadmium,lead, trichloroethylene, toluene, methyl ethyl ketone, xylene, epichlorohydrin, Bisphenol‐A,welding fumes,metalworking fluids, and isocyanates tomention but a few. Many chemicalsused in plastics production are classified as mammary carcinogens and hormone disrupters.Manyoftheseareassociatedwithhormonerelatedcancerssuchasbreast,ovarian,prostateandtesticular cancer. These classes of endocrine disrupters include phthalates, phenols andbisphenols known to pose a significant risk to health. Our review of biological monitoringstudies demonstrated that workers in the plastics industry have higher body burdens ofendocrinedisruptingsubstancesthanfoundinthegeneralpopulations,alreadyatlevelsshown

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toharmanimals. Second, these substanceshavea longerhalf‐life thanoriginally believed andbio‐accumulate. These observations were found for a number of endocrine disruptingsubstancessuchasbisphenolA, styrene, acrylonitrileandphthalates.Levels found inworkerswere above those demonstrated to cause changes in the function of human tissue. (seeLiteratureReviewpp.110‐167).

Studies also indicated that air monitoring can underestimate the true body burden of thesesubstances.Whileairmonitoringlevelswerebelowcurrentexposurelimits,bodyburdensweresignificantlyhigherthanlevelsfoundin‘unexposed’populations.

Aswell,endocrinedisruptershavedisruptiveeffectsatinfinitesimallevels.Attimes,lowdosesmay have more powerful effects than higher doses. Consequently, these substances may notexhibit the traditional lineardose‐responsecurve. And since workers are exposed to a complex mix of compounds, the combined effect may exert additive or even synergistic effects.

Healthimpactoftoxicexposuresandpatternsofillnessesamongworkers:

During focusgroupdiscussions,participants identifiedanextensive list ofworkplacediseasesthey believe are related to the large variety of toxic chemicals used in their work producingplastic automotive parts. These included: cancers of the lung, breast, colon, brain, pancreas,salivarygland,thyroid,liver,prostrate,lymphoma,leukemia,Non‐Hodgkin’sLymphoma,kidney,skin; adverse reproductive effects including frequent miscarriages, children born with birthdefects/developmental deficits and difficulty conceiving; as well as other diseases including:chronic obstructive pulmonary disease (COPD), cardiovascular diseases, muscular sclerosis,Parkinson’s disease, aneurisms, dermatitis, chronic bronchitis, neurological disorders, andsensitization to Isocyanates and solvent exposures. To date, a total of 133 workers haveregistered (or been registered by surviving family members) with the Occupational HealthClinicsforOntarioWorkers(OHCOW)forassessmentsofpossibleoccupationalillnesses.Theseinclude33workerswithcancerdiagnoses‐‐twowithmorethanoneconfirmedprimarycancerdiagnosis.27

However, the Advisory Committee was able to identify a much larger group requiringinvestigation, using the union seniority list for the period in question, cross‐referencedwith:OHCOW’s“VentraMasterList”ofclinicregistrants,thelocalunion’scompensationrecords,andlogsdocumentingworkerillnessescompiledbyunionofficers.Inaddition,committeemembersconductedtelephonefollow‐upswithaffectedworkersand/orsurvivingfamilymembers. Thetable that follows exhibits significantly larger incidence of several cancers than would beexpectedinsuchasmallgroupoverlessthan35years,aswellasotherillnessesreportedinthescientificliterature.(SeeAppendixAandCforareviewofthetoxiceffects.)Assessingtheextentof the occupational burden of disease in this groupwould require a rigorous epidemiologicalstudy able to more exhaustively identify and confirm relevant diagnoses, to accuratelydistinguish between metastatic and primary site cancers, and to account for other relevant

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factorssuchasageatdiagnosis,lengthofexposureandsoon.TheAdvisoryCommitteestronglyrecommendsthatsuchastudybeurgentlyundertakeninlightoftheseinitialfindings.

TABLE1

POTENTIALOCCUPATIONALDISEASEAMONGWORKERS

1986‐1996*

OCCUPATIONALCANCERS* OCCUPATIONALILLNESSES(noncancer)

32LungCancersCardiovasculardiseases(58reports)including:

Heartattacks/disease27;bloodpressureissues5;aneurysms5;strokes4.

22BreastCancersReproductiveAbnormalities(36reports)including:

Hysterectomies11;miscarriages10(somemultiple);“women’s’issues”8;birthdefects/diedinbirth3;breastcysts3.

10CancerswithnositeidentifiedNeurologicalconditions(67reports)including:

Chronic:headaches19;mentalhealthissues11;depression10;memoryloss9;Alzheimer’sDisease3;vertigo3;ALS;psychosocialproblems.

8KidneycancersRespiratoryconditions(97reports)including:

Chronic:sinusitis20;difficultybreathing17;cough12;COPD10;sensitization7;lungdisease5;nose/throatissues3.

7GastrointestinalcancersGastro‐Intestinalconditions(29reports)including:

Chronicstomachpain11;twisted/herniatedbowel4;IBS4;perforated/rupturedcolon2;Crohn’sDisease2;perforatedappendix1

37Othercancers(<4percancer)

including:thyroid,liver,brain,skin,bone,nasal,lymphoma,Non‐Hodgkin’slymphoma,salivarygland,bladder,cervical,prostate,mesothelioma,Jaw,andpancreatic.

*TOTALCANCERS…116

MusculoskeletalConditions(137reports)including:

Back20;bilateralshoulders19;bilateralcarpeltunnel16;shoulder18;knee10;bilateraltendonitis8;tendonitis8;neck6;singlecarpeltunnel7;wrist6;knee6.

This table constitutes a review of the union seniority list 1986‐1996 N=521) based on committeemembers’ collective knowledge and a reviewofOHCOWclaims on recordwith the union (including 59reporteddeaths).

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Evidenceofoftenchronic, long‐termillnessesamongemployeeswasaccompaniedbyfrequentincidents where large numbers of workers were overcome by toxic fumes and vapors fromproductionprocesses theymayhavebeenperforming, orbystanderexposuresdue to fugitiveemission from neighbouring departments. These incidents were manifested in reports of:difficultybreathing,tightnessinthechest,irritationoftheupperrespiratorytract,nosebleeds,dizziness, light headedness, confusion, memory lapses, “wobbly” legs, loss of consciousness,nausea,skinrashes,anddermatitis. AsoneMOLinspectornoted:“Theseworkersbelievethatthe air in the plant is not fit to breathe.”4 The range of symptoms noted above is welldocumented in Ministry of Labour inspection reports as well as when workers were sent tohospitalforassessmentandtreatment.Themanyexposure/adverseeffectsincidents,especiallyin the 1990’s, led to frequent work refusals under the Occupational Health and Safety Act(OHSA)thatwereinvestigatedbyMOLinspectors.

Theseanecdotalreportsareconfirmedbythe largenumberofoccupational injuryclaimsfiledwiththeWSIBbyPebraworkers. Forexample,in1990,aparticularlybadyearforplantwideoverexposures,54injuryclaimswerefiledforadverserespiratoryandneurologicaleffectsasaresultofchemicalexposuresattheplant.7

Aswell,evidenceoffrequentchemicalexposuresissupportedbytheverylargenumberofworkrefusalsthatoccurredundertheOHSA. BetweenSeptember4,1990andNovember15,1990therewere20workrefusalsassociatedwithadversehealtheffectsusuallyinvolvingirritationofthe eyes and upper respiratory tract and neurological effects including: dizziness, headache,disorientation, loss of consciousness, nausea and GI tract irritation. In themajority of cases,refusals involved a significant number of workers. In some cases, refusals involved massevacuationoftheplantduetospillsandreleases,orventilationsystemmalfunctions.OnMay7,1990,more than120workerswere involved in awork refusal/evacuation incident. BetweenAugust1990andNovember1990 therewere20 recorded chemical spills or releases, usuallyinvolvingisocyanatechemicals‐‐eitherinthepaintlineorR‐RIMDepartment.Thispatternwasduplicatedovermanyyears.Forexample,onApril27,1993,threewomenbeganvomitingasaresultofareleaseofsolventfumes.Thisledtofurtherrefusalsby51workers,alsoaffectedbyfumes. During themonth of January 1994, fourteenwork refusalswere carried out. Inmostcases, anumberofworkerswere transported tohospital forassessmentand treatment.7 (FordetailedinformationonworkrefusalinvestigationsandspillsseeAPPENDIXB).

AccordingtoaMinistryofLabourreportdatedApril18,1989byConnieDemb,“TheIndustrialHealthandSafetyBranch(IHSB)fileforthe(Pebra)Kitchenerplantshowsageneralhistoryofsubstantialcompliance…ThePeterboroughplant,however,hasbeenthesubjectofmanyordersand investigations since 1986.” During a single “cyclical” plant inspection in 1989 (Report #250328)38ordersand14recommendationswereissuedforcompliance.3

Ms. Demb further documents a 1988 critical injury investigation where a worker fellunconscious from exposure to glues being mixed in an area without appropriate exhaust

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ventilation, resulting in an order that glues must be mixed in a room with appropriateventilation.3

In 1989, theMinistry of Labour issued two orders for the company to comply fully with theprovisionoftheDesignatedSubstanceRegulation(DSR)forIsocyanates,requiring”continuousventilation”topreventpossibleexposurestoIsocyanatesand“inclusion”ofallR‐Rimworkersinan Isocyanate control program. The company appealed the orders arguing that: its controlprogramwasworkingwell; continuous ventilationwas impractical; and levels of Isocyanateswere below the exposure limit. The company further argued that the cost of installing acontinuousventilationsystemwasprohibitivewhilemakingnotsovaguethreatsthat itmighthave to drop expansion plans and move to the United States. In response, the Ministrychallenged management’s assertion that the control program was “working well”. Underexamination,theMOLinspectorreportedthatduringhisvisit,thepaintsprayingoperationwascloseddownbecausefumeswereescapingintothegeneralenvironment.Therewasalsoreportofan Isocyanatespill leadingtoevacuationof theplant. AMOLphysician,Dr.LeonGenesove,identified in his investigation, that fourworkers, already in the ISO control program, had notreceived pre‐placement medicals or training, and were using Isocyanate containing putty –withouttheworkers’knowledgeandawarenessthatitcontainedthechemical.Attheendoftheappealprocess,theMinistry’sorderswereupheld.28(Note:Duringtheappealprocess,fournewworkrefusalswereunderinvestigation).

These incidents, chronicling frequentdailyoccurrencesofadverseeffects, aresignsof chronic“overexposure”tothemultitudeoftoxicandcarcinogenicchemicalsusedintheproductionofplasticautomobilepartsandproductsduringthePebraera. Inconductingthisresearch, thecommitteeascertainedthatproductionattheplantwasrifewithexposureriskfactorsthatcouldbe linkedto: thecharacterofproductionmethods;unsafeworkpractices; inadequatePPEandinsufficient exhaust ventilation; lack of training and information on the hazardous chemicalsbeing used (for bothworkers andmanagers); and limited ‐‐ to no ‐‐ worker participation inhealthandsafetydecisions. Itwasn’tuntil1992thatthecompanyfinallyprovided(andmadeaccessible)thelegallyrequiredMSDSsforthechemicalsusedintheplant.Ittookamassworkrefusal of 250workers that year, in response to the employer’s continued refusal to provideMSDSsandfull‐scalehazard‐specifictraining,toprompttheMOLtofinallyordertheemployerto provideMSDSs and trainworkers onhow to understand anduse the information in them.Reflectingthecompany’scavalierattitudetowardshealthandsafety,workersweretoldinthesecompanytrainingsessionsthatthechemicalstheyused,otherthanISO,werenomoretoxicthan“goop”or “sillyputty” thatchildrenplayedwith. 2Thecompany initially challenged theorder,which was later upheld, and workers were bussed to a near‐by hotel for “retraining” byCanadianAutoWorkers’Union,Health&Safety,andworkereducators.

It is important to note that the company finally complied with this order only after MOLmanager,MartinDonat,threatenedtoassignaninspectortoworkfull‐timeintheplant‐‐atthecompany’sexpense. According to a committeemember,Mr.Donat admitted tounionhealthandsafety reps that theMOLhad “two file cabinets filledwithdocumentsonproblemsat theplant.”2

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It would be an understatement to say that this plant lacked a pro‐active health and safetyculture.Themanufacturers’MSDSsforliterallyhundredsofchemicalsusedthroughouttheplantcite the symptoms workers regularly reported to management as evidence of worker over‐exposure to various chemicals. As indicated previously, evidence of daily over‐exposure isdocumentedinMOLinvestigationsofworkrefusalsundertheoccupationalhealthandsafetyact,which were made worse by the fact that, in most cases, employees were not provided withpersonalprotectiveequipmentand/orlocalexhaustventilationrequiredasstatedonMSDSsforindividualchemicals.Importantly,workers’symptomcomplaintsgivetestimonytochronicover‐exposure based on the information chemicalmanufactures are legally required to provide intheirMSDSs, including the extensive list of chemicals used at the plant. (SeeMOLreports inAPPENDIXB).

LargeNumberofToxicChemicalsUsedinProduction:

Laterinthisreport,whendocumentingthevariousworkprocessesattheplant,amoredirectedlist of literally hundreds of chemicals used in the various processes is identified, includinghazardousingredientsandby‐products.Asexample,notethefollowingcomplexofchemicalsusedinthevariousoperationsassociatedwiththepaintlinealone.Atotalof98chemicaltradenamed products were used directly by workers. These products were used in very largequantitiesduringthedifferentpaintprocesses including: 11primers(adhesionpromoters),8catalysts, 25 thinners/solvents, 8 di‐ionization process chemicals (washes with acids andcaustics),28paintkitchenchemicalmixes,12sludgeroomchemicals,6paintcartmaintenancechemicals along with intensive welding and grinding to remove the build‐up of Isocyanatepaints.Importantly,eachproductcontaineditsownimpressivelistof“hazardousingredients”identifiedintheMSDSs.Forexample,theMSDSsforthe11primercoatsindicatethepresenceof 35 additional “hazardous ingredients” including: toluene, xylene, ethyl benzene, propyleneoxide, carbon black, titanium dioxide, methyl Isobutyl ketone, and MEK, to mention a few.(These commercial products are listed in APPENDIX C along with the hazardousingredients,decompositionproductsandhealtheffectsnotedintheMSDSs).

ReviewofChemicalMSDSs:

During this investigation, several hundred productMSDSswere reviewed. Each productwasdocumentedandits“hazardousingredients,”decompositionproducts,andhealtheffectsnotedalong with recommended control measures. In addition to identifying a large number ofseriouslytoxic,carcinogenic,and/orhormonedisruptingchemicals,wediscoveredinreviewingtheMSDSs that: informationwas often incomplete; the symptoms reported byworkersweredocumented signs of over‐exposure; and that Pebrawas not abiding by the required controlmeasuresstatedintheMSDSs.

Suchin‐plantchemicalexposuresdidnotstopattheplantgate.Therewerefrequentcomplaintsfrom the surrounding community and nearby school, concerning strong chemical odours andparticulateemanatingfromtheplantresultinginadversehealtheffectsanddamagetopropertyfrom particulate and fumes spewing from the plant stacks. Such complaints prompted

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investigationsbytheOntarioMinistryoftheEnvironmentonanumberofoccasions,andareamatterofpublicrecord.

In1994/1995,inresponsetoanumberofcommunitycomplaints(includingthelocalschool)ofchemicalodoursandparticulatecomingfromtheplant,theOntarioMinistryoftheEnvironmentand Energy ordered Pebra to hire a consultant to conduct an environmental emissionsassessmentofchemicalsbeingreleasedintothecommunity.ThatinvestigationrevealedthatPebra used 267,936USG of paint annually, resulting in emissions of 1,389,251 lbs. ofvolatileorganiccompounds(VOC)justfromitspaintlineactivity–whichwasalsoamajorsourceofindooraircontaminationandworkercomplaints.

Total VOC emissions were composed of the following organic compounds: Isobutyl acetate,primary amyl acetate, 1‐methoxy‐2‐propanol acetate, toluene, ethyl benzene, methyl ethylketone,methylN‐amylketone,aluminum,copper,mineralspirits,petroleumdistillate,N‐butylacetate, aliphatic polyisocyanate (HDI), aromatic polyisocyanate (TDI), carbon black, titaniumdioxide,xylene,dimethylglutarate,2‐propanone, ironoxide,aromatichydrocarbonblend,andothers.29

ThisprovidesaddedempiricalevidencetosupportthecontentionthatexposurecontrolsatthePebraplantwereineffective,ornon‐existent,bothinsideandoutsidethefacility,andthattheseexposuresconstitutedathreattothehealthofbothworkersandmembersofthecommunity.

Moreimportantly,whentakentogetherwithsuchriskfactorsasinadequatepersonalprotectiveequipment and local exhaust ventilation; poor health and safety training and general lack ofinformation;extensiveovertimeandmultipleshifts;poorworkpracticesandsafetyculture,andlargequantitiesoftoxicchemicalsdirectlyhandledbytheemployees‐‐theriskofworkerover‐exposure(s) was extremely high. Again, this is reflected in the extremely high incidence ofadverse health effects experienced by employees, and the frequency with which workersexercisedtheirrighttorefusewhenunderassaultbymixturesofmanychemicals.

BACKGROUNDTOTHEGENERALPROCESSOFPRODUCING(POLYMERS)PLASTICS

Plastics consist of polymers composed of a long chain of repeating monomers. They areproducedthroughmultiplestepsindifferentoccupationalsettingsandworkersareexposedtochemicalsofconcernatvariousstagesofprocessing.

Therearethreebasicstagesofproductionandseveraldifferenttypesofplasticsmanufacturingprocesses as described in the Concise Encyclopaedia of Plastics. 30 A comprehensive,descriptionofthetoxicpropertiesofmonomers,additivesandsolventsisprovidedinSheftel’sHandbookofToxicPropertiesofMonomersandAdditives.31

In the first stage of plastics production, petroleum oil and gas go through a process calledcatalytic cracking in which the oil and gas is broken down, through chemical reactions, intodistinct chemicals called monomers. Monomers are the basic building blocks of all plastics.

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Some include such chemicals as vinyl chloride, styrene, bisphenol‐A (BPA), acrylonitrile,butadiene,ethylene,andurethanetomentionafew.Chainsofmonomersarereferredtoaspre‐polymersoroligomers;or ifseveralpolymersarecombined, theyareknownasco‐polymers.These different monomers are highly reactive constituting a seriously hazardous class ofchemicals.

Inthesecondstage,theresultingmonomersaresenttoaresinproducertoundergoaprocesscalledpolymerization.Thisinvolveschemicalreactionsinwhichthemoleculesofthemonomercombinetoformalongchainofmoleculesthataremuchheavierthantheoriginalmonomer.Indoingso,resinproducersconvertmonomersintopolymerproducts.Forexample,inthecaseofthe monomer vinyl chloride, it is transformed into polymerized polyvinyl chloride, and withstyrene, transformed into polystyrene. Other kinds of polymerizations include: nylon,acrylonitrile‐butadiene‐styrene(ABS)andpolyurethanetomentionafew.

Inthethirdstage,thesenewlyformedpolymersareshapedintopellets,powdersorliquidsandshippedtoplasticsproductsmanufacturers(suchasPebra/Ventra)who,inthethirdstage,makethesepolymers intopaints,adhesivesandplasticsproducts includingpipes, fabrics,packagingandautopartstonameafew. Whilepolymersareoftenviewedas“inert”,theyarecapableofharmwhenunboundtracesofreactivemonomersarereleasedwhenheatedduringthemoldingor grinding process andwith the addition of numerous additives including: heavymetals aspigmentsandstabilizers, fireretardants,plasticizers,anti‐oxidants,and fillerssuchassilicaorasbestos. Inthecaseofpolyvinylchloride,acrylic,andpolystyrene,forexample,undercertaincircumstances, tracesofunreactedmonomersarereleased includingvinylchloride,styreneoracrylonitrile. All of these trace monomers are rated carcinogenic. This type of thermalbreakdownalsooccurswitha class ofplasticizersknownasphthalates, apowerful hormone‐disrupting chemical. The different polymers produced are divided into two main classes:Thermoplasticsandthermosets.

Thermoplasticsarelinearorbranchedpolymersthatcanberepeatedlysoftenedandreshapedwith the application of heat and pressure. Within the class of thermoplastics many containvarious additives to impart special characteristics. Some of these include: polyethylene,polypropylene, polyvinyl chloride, polystyrene, acrylonitrile‐butadiene‐styrene, styrene‐acrylonitrile,polyacrylates,fluoropolymers,nylonandcellulosics.

Thermoset materials undergo a chemical reaction that results in a permanent cross‐linkedpolymerthatcannotbere‐heatedandreshaped. Theyareheatresistantandused forvariousfoamproductsandinsulation.Someoftheseinclude:polyurethane,epoxy,aminos,Isocyanatesandpolyesters.

Additives: Additives are often mixed and blended into these different polymers through aprocesscalledcompounding,inordertoprotectthefinalproductfromdegrading‐‐ortoinducespecial characteristics. These additives often include: antioxidants, fillers, pigments(cadmium/lead), flame retardants (brominate/chlorinated compounds, surfactants, extenders,

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emulsifying agents, plasticizers (phthalates), stabilizers (lead), catalysts, extenders andhardeners.

Many fabricating operations perform their own compounding, thus workers handle variousadditives thatareblendedwith thepolymers. Becauseof individual toxicitiesassociatedwithmonomers, polymers, and additives, it is important to know the detailed ingredients in thepolymersandwhat isaddedduringtheentireproductionprocess. It isnotuncommonforanoperation to change over time, as was the case with Pebra, thus it is important to carefullyreview the history of the company’s production processes when assessing exposuresretrospectively.

The additives of greatest concern include: plasticizers composed of phthalate esters such asdiethylhexylphthalate(DEHP)‐‐80%ofwhichareusedinPVCplastics;pigmentssuchaslead,cadmium, chromates, iron oxide, molybdenum, titanium dioxide, and carbon black; flameretardantssuchasantimony,phosphorous,boronandbromineandchlorinated,brominatedandnon‐halogenated phosphate esters that are used extensively in plastic resins; lubricants toenhancemoldflowthatincludesoapsandstearatesaswellasfattyacidsandparaffin.

PlasticsProductsProductionMethods: Among thedifferentmethodsused to fashionplasticproducts, the following: thermoplastic injectionmolding, reaction injectionmolding, extrusionmolding and blow molding best illustrate the major techniques used in the production ofthermoplasticandthermosettingplastics.

Injectionmolding (thermoplastics): The most widely used technique for injection moldinginvolvesmeltingpolymerresinpelletsunderhightemperaturesintoaliquidstate,thenmovingitunderpressurebyareciprocatingscrewtoforce(inject)theliquidintoaclosedmold.Oncecooled thepart is retrievedby theworker, then trimmed,drilled, sanded,painted andbuffed.ThisistheprincipleproductionmethodusedatVentra.

Reaction Injection Molding (RIM): This is similar to injection molding except that thethermosetting polymers used require a catalyst to trigger a reaction causing thematerials torapidly expand in an enclosed mold when both a thermosetting monomer and polymer areinstantaneouslyinjectedintothemold’smixinghead.Thiswaspreviously,theprinciplemethodusedduringthePebraera.

ExtrusionMolding: Extrusionmolding is similar to thermoplastics injection molding exceptthat the resin ispressed throughadieof adeterminedprofile, rather thanan enclosedmold,comingoutofthedieinthepredeterminedshapeandallowedtocoolintheopen.

Combustion and Thermal Decomposition of Plastic: Thermoplastics must be heated tomaintaintheirfluidity;theprocessvarieswiththecompositionofthepolymerandtheadditives.Overheating is a frequent occurrence that results in thermal decomposition resulting in therelease of oligomers, monomers, and other combustion by‐products. The result is a complexmixtureof gases andvapors,dependingon the chemical constituents. At lower temperaturescombustionisincomplete,releasinglargermorecomplexmolecules,whilehighertemperatures

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complete the combustion, producing lowerweightmolecular gases. Some decomposition by‐products have been identified, although generally it is difficult to identify specific pyrolysisproducts.SeedetailedreviewinAppendixA.

Some of the known decomposition by‐products include:monomers, CO, CO2, carboxylic acid,formaldehyde,acrolein,aldehydes,styrene,benzene,ethylbenzene,toluene,HCN,NH3,nitriles,NOx,HCL,phosgene,carbonyl fluoride,carbontetrafluoride,methane,ethane,phenol,acetone.Thiswillalsoincludethemonomersaswell.Thecharacterofthechemicals,inconjunctionwiththetemperature,willdeterminethenatureandidentityofthedecompositionby‐product. Forexample, in the case of PVC used asmeatwrapping, itwas plasticizers in PVC, usually di‐(2‐ethyl) phthalate (DEHP) that vaporizedmore quickly than the polymer, thatwere eventuallyidentifiedastheculpritin“meatwrappers’asthma”.32

Inaddition,secondaryoperations,suchassanding,grinding,sawing,cutting,drying,buffingandtorching molded plastics release plastic contaminants into the atmosphere that are likelyinhaled, ingested and absorbed through the skin in hot, sweaty, work environments. In thisregard, exposuresmight include: fillers such as silica, fibreglass, asbestos; traces of chemicalingredients including fire retardants, plasticizers, heavy metals, and stabilizers; and varioussolventsandmoldreleasingagents.

Studies by Forest et al. 1995, on a variety of commercial plastics undergoing thermoplasticprocessing such as PVC, Nylon 6, high impact polystyrene (HIPS), low density polyethylene(LDPE), and high density polyethylene (HDPE) have demonstrated that, in some cases,monomersweredetectedat levels thatrangedbetween0‐2mg/m3duringnormalprocessingandupto10mg/3duringpurgingoperations.Importantly,theseresearchersidentifiedthatthepositioningoftheairsamplingtraincanhaveadramaticeffectontheresults,aswellastypeofadsorbent materials used to collect the samples (See both section on limitations of airmonitoringandtheplasticprocessingliteraturereviewinAPPENDIXA).33

ChemicalEmissionfromThermalPlasticsProcessing:33

Along with other thermal processing studies, Forrest et al. found a wide range of chemicalspeciesemittedduringthermalplasticprocessing.Whileconcentrationsarelow,weknowverylittleaboutthehealtheffectsofmanyspecies,and,withrespecttocarcinogensthereisnoknownsafe level of exposure. The following identifies some of the species emitted during theprocessing of Acrylonitrile Butadiene Styrene (ABS), High Impact Polystyrene (HIPS), andPolyvinylChloride(PVC).(ForamorecompletereviewpleaseseeAPPENDIXA.)

ABS:chemicalspeciesdetectedduringthermalprocessingincluded:245C‐acrylonitrile,styrene,trichloroethane,111trichloroethane,benzene,trichloroethene,alcohol,toluene,xyleneisomers,benzene,methyl,ethylisomers,benzene,propylisomer,benzeneethyl,methylisomer,dichloroisomerethyl,dimethylisomers,methyldiethylisomer,naphthalene,tetrahydroisomer,siloxane,naphthalene,tetrahydro,methylisomer,BHT,alcohol.

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HIPS:dichloromethane,toluene,alcohol,xylene,propylbenzene,benzene,ethyl,methylisomer,benzene,trimethylisomer,benzene,dichloroisomer,HC.

PVC: acetone, methyl methacrylate, dichloromethane, ethyl acetate, ethane, trichloro, xylene,cyclic alkene, a‐methyl styrene, Benzene, alkyl derivative, benzene, methyl, propyl isomer,benzene,butenylisomer.

Presence of monomers will depend on temperature and the percentage of monomer in thepolyolmixture/composition.

InadditiontoairsamplingtechniquesusedbyForestetal.,anotherwayofdeterminingthelevelofworkerexposures is todirectlymeasureactual concentrationsof thesechemicalsabsorbedintothebody,i.e.thebodyburdenofchemicalsenteringthebodythroughinhalation,ingestion,and absorption through the skin, referred to as a biological exposure index (BEI)whoseconcentrationsaremeasureinbloodorurine.

The literature review in APPENDIX A presents data gathered from a number of studiesmeasuringtheconcentrationofnumeroussubstances(prevalent inthermoplasticsprocessing)in the blood or urine of workers involved in the processing of plastics. In some studies,researchersmeasuredtheairconcentrationsinanefforttodeterminehowthesecorrelatedwithoneanother.Thereviewprovidesatableofdataonactualabsorptionofanumberofchemicalsused in thermal plastic processing as measured in urine and blood of plastics workers.Significantly, these urine/blood concentrations are an order of magnitude higher than thosefoundinreferentpopulations. TheTable inAppendixEpresentsthedata fromthesestudies.What is not yet established, is the impact on human health. However, from the view ofendocrinologiststheseresultsarealarming.

Thetablebelowattemptstoprovidesomeindicationofthepossiblehealtheffectsofsubstancesusedinthermalplasticsprocessing.

TABLE2

HEALTHEFFECTSOFSUBSTANCESPREVALENTDURINGTHERMOPLASTICSPROCESSING

Substance ChemicalCode

MammaryCarcinogen

EndocrineDisruptor

Carcinogens*IARC**EPA

Other+AMES+

Acetone 130.01 Arrhythmia

Reprod.

Acrolein 120‐02 Asthma

Acetaldehyde 120.01 *2B

Acrylamide 260.02 Y *2A/**B2

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Substance ChemicalCode

MammaryCarcinogen

EndocrineDisruptor

Carcinogens*IARC**EPA

Other+AMES+

Acrylonitrile 210.02 Y Y *2A/**B1

Bisphenol‐A ? Y CA

Butadiene 106‐99‐0 Y ? *2B/**B2

CarbonBlack 010.04 ? ? *1

CarbonTetrachloride 190.01 Y Y *2B/**B2

Caprolactum 105‐60‐2

Chlorobenzene 201.04

1,2‐Dichloroethane

1,1‐Dichloroethane

190.07 Y

Y

*2B/**B2

**C

Dichloromethane 190.08 Y Y

1,4Dioxane 100.04 Y ? *2B/**B2

DimethylEther 115‐10‐6

Ether *2B/**B2

EthyleneOxide 110.03 Y *.1

Formaldehyde 120.03 *2A

FormicAcid

MethylEthylKetone 130.03

MethylMethacrylate 142.04

Napthalene 160.05

Isoprene 78‐79‐5 Y *2B

Isododecane

Isopropanol 67‐63‐0

Perchloroethylene 190.10 *2A

PhthalatesAnhydride 151.01 ? Y

Polycyclic Aromatic

Hydrocarbons

160.00

Polyvinyl Chloride

Dust

10.14

Polybrominated

Biphenyls

Y *2B

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Substance ChemicalCode

MammaryCarcinogen

EndocrineDisruptor

Carcinogens*IARC**EPA

Other+AMES+

(PBDE,PBP,TBBPA)

Phosphororganic

Compounds

(TDCP,TBPP,TEHPP,

TPP,TCPP,TDBP)

Styrene 160.04 Y Y *2B

1,1,1,2‐Tetrafluoroethane

811‐97‐2

Tetrafluoroethylene

Tetrafluoromethane

Trifluoroacetylfluoride

Trichloroethylene 190.13 *2A

Trichloroethane 190.12

Toluene 160.02 *2B

VinylChloride 190.14 *1

Xylene160.03 **

METALS

Aluminum 020.01

Antimony

Cadmium 020.12 Y Y *1

Chromium

Compounds

*1

Lead 020.21

020.22

Y

Y

*2B*2B

Tin 020.362

020.361

Y

Titanium 020.48

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Substance ChemicalCode

MammaryCarcinogen

EndocrineDisruptor

Carcinogens*IARC**EPA

Other+AMES+

Zinc 020.392

COMMONLYEXPERIENCEDEXPOSURERISKS

In the course of Advisory Committeemeetings and discussion, there emerged a repetition ofissuesrelatedtoairqualityandchemicalexposuresthatwereissuesofconcerntoallworkersandinallworkareas, inthattheywerewidespreadandviewedas“common”totheplantasawhole.Frequentplantanddepartment‐wideworkrefusals,particularlyastheplantexpandedinsizeandproductionintheearlytomid‐1990s(withnochangesorimprovementstothealreadyinadequate and admittedly “stressed” ventilation and heating systems working to theirmaximum) are an indication of “commonly experienced” air quality/chemical exposureproblems.Majorcontributorstothesecommonhealthconcernsincluded:

thecloseproximityofworkers/productionprocessescontainedinanopen‐conceptbuilding(including a large oval, metal covered, “paint line” in poor repair circling through manydifferentworkareas).

intensificationofworkandtheexpansionofproductionanditsimpactonworkerexposuresandworkeffort;

impact of the business cycle that restricted expenditures on health and safety given thegrowingfinancialinsecurityofthecompany;

on‐goingproblemswithventilationandair‐flowthroughoutthesystemasawhole;

ventilationsystembreakdownsregularlyoccurringthroughouttheline;

inadequatelocalventilationatthepointofproduction;

poor/lackofmaintenanceoffilters,portable/permanentfans,anddown‐drafttables;

negative pressure throughout a basically “open” facility influenced additionally by theopening/closingofdoors/ventsinthepaintkitchen,sludgeroom,tankfarm,andinsidepainttunnel;

24/7productioninoneormoredepartment(s)duringthoseyears;

arotatingworkforceof“assembly”workers;

massive amounts of MEK and/or Pebra 5 (perchloroethylene, tetrahydrofuran andcadmium) used daily by workers (AM/PM/downtime) to clean and wipe down literally“everything” including machines, tables (even cafeteria tables and chairs), floors, andworkers’themselves;Thesechemicalswerealsousedinlargequantitiesinpostlaminating,gluelines,andinassemblyasaglue;

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wide‐spreaduseof“airguns”todispersedustsandparticlewaste;

generallypoor“housekeeping”;

poorpreventivemaintenance;

poorworkpractices;

the regular morning and evening sequential cleaning and purging of all injection moldmachineswithhighlyirritatingspraycleanersincludingpurgingagents,smolderingpurgedpolymers;

continualoversprayingofreleaseagentson large injectionmoldmachines(at timeseveryfewminutes)24/7,toensurecleanreleaseofplasticparts;

exposure to outside/inside vehicle (gas/diesel/propane) fumes, as well as outside fumesfromnearbyfactories;

absenceofappropriatepersonalprotectiveequipment;

poortrainingandenforcementforeffectiveuseofprotectiveequipment;

frequent large volume spills associatedwith handling large amounts of paints/solvents aswell as regular breakdowns in feeder lines/joints behindmold/clampmachines andpaintbooths;

largeamountsofdustandparticlesproduceddaily inallmajordepartments fromsandingbuffing,andgrinding;

open“sluicewaytosludgeroom”systemfordispersalofpaintsandsolventswindingmorethan100feetthroughtheplant;

thelackofattentionandenforcementofregulationsonthepartofmanagementtodealwithproblematic ventilation and heating systems, as well as a general, laissez faire attitudetowardshealthandsafetyattheplant(SeeMOLreports,JHSClogsinAppendixB).

ACOMPLEXCHEMICALEXPOSUREMIX

Handling largevolumesofhighlytoxicandcarcinogenicchemicals: Amajor exposure riskencounteredattheplasticsplantwasthesheervolumeofthelargenumberofdifferentchemicalproducts used containing a wide range of chemical species. Complicating this is the largernumber of species produced during the thermal processing stage, as well as the chemicalreactionsgoingon in thepaint line and in curingovens, causing further vaporizationofpaintchemicals‐‐whichhasawiderangingimpactontheentireplant.

In this latter regard,we have noted previously the large number of chemicals in the form ofprimers, paints, hardeners/catalysts, base coats, thinners, solvents, sludge treatments and themorenumeroushazardousingredients.Thepaintlinealonewasestimatedtouseapproximately250,000USGperyear,emittingoveramillionspoundsofvolatileorganiccompoundsannuallyaswellas25differentsolventsinitsoperations.29Therewere35hazardousingredientsinthe

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11differentprimercoats,manyofwhich:areknownorsuspectedcarcinogens;testpositiveforchromosomeabnormalities;arefetaltoxins;disruptthehormonalbalanceofthebodythusposeaseriousrisktopersonalandreproductivehealth.

These same chemicals are known to have other serious health effects including neurotoxicitythat can lead tobrain and central/peripheralnervous systemdamage fromchronic long‐termexposures.Otherscandamagethekidneys,liver,andgastrointestinaltract.

Added to this chemical burden are the equally numerous chemicals used in injectionmoldingandpost laminatingoperationsinvolvingsignificantamountsofPVCresins,gluesandsolventsincluding: MEK, acetone, toluene, methylene chloride, xylene, alcohols, perchloroethylene,tetrahydrofuran,trichloroethylene,butylacetate,celluloseacetate,butanoate,2‐butoxyethanol,2‐pentanone,4‐methyl,1‐propanol,methyl,2‐propanone,1‐propanol,2methyl,methyln‐amylketone, naphtha, n‐butyl acetate, 1 methoxy‐2‐propanol acetate, ethyl3‐ethoxypropionate,dimethyladipate,dimethylsuccinate,pyrrolidone,propyleneoxide,ethylbenzene,carbonblack,titaniumdioxide,methylisobutylketone,2‐ethylhexylacetate,whitepigment,propyleneglycolmonoethyl ether acetate, ethyl 3‐ethoxypropionate, isopropyl alcohol, 2‐pentanone, 4methyl‐carbon, silica, polytetrane ether glycol, ethyl 3‐ethoxypropionate, n‐pentyl propionate,methylisobutylketone,2‐butoxyethylacetate,andn‐butylacetate.

Readers are encouraged to review the large listing of chemical products with summaries ofMSDS data, including hazardous ingredients, decomposition products, and health effects(APPENDIXC).

Early symptoms of neurotoxic effects have been noted as workers/patients present at theoccupationalhealthclinicaswellasevidenceofsignificantnumberssufferingfromobstructivelungdiseases,includinglungcancer.

What is unacceptable is the number of years it took the company to develop a protectiveexposurecontrolprogram for itsemployees. Thevital ingredients tosuchaprogramarestillmissing and must include: 1. Information and training on hazard recognition and2. Amethod to effectively control exposures, based on a well‐informed hierarchy of controlsstartingatthesource.

MOLinspectionreportsuptothepresentshowacontinuedpatternofnon‐compliancewiththeOHSAanditsregulations.ThisoftenoccurredoverthemostbasicprotectionssuchasprovidingMSDSs, and labelling of toxics and toxic chemical piping required by the Act and ordered byinspectors ‐‐ with the employer arguing that MSDS information was not needed because theoperators are aware of the chemical contents. The provision of training and information onhazardidentificationcontinuestobeaproblem,particularlyforcontractcleaningstaff,unawareof the hazardous chemicals in the paint booths they were cleaning. Another recent exampleoccurredwhenthecompanyrefusedtocomplywiththeprovisionofdrainageinstorageroomswhereflammablechemicalswerebeingstored.SeeAppendixB—FV#5449699.

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TherehavebeenotherinstanceswheretheemployerengagedworkersinproceduresthatwereclearlyhazardousandinviolationoftheActandregulations.Forexample,inordertomaintainproductionwhen robotic painters broke down, the employer orderedworkers to spray paintAD‐Pro outside of the clear coat booth, a very hazardous procedure that not only exposedpainterswhowerenotwearingproperrespiratoryprotection,butcontaminatedotherareasoftheplant.SeeAppendixB—VF#02756flzp263.

Therewerestillinstanceswhereworkerslostconsciousnessasaresultofexposurestochemicalemissionsfromthepaintline.SeeAppendixB—18/09/09;FV#02756FBRP116;13/01/12.

Aswell, problems controlling exposureswith the current ventilation system continue to be amajor issue. Workers’ identified chemical exposures were aggravated by the unanticipatedconsequences of changes to the ventilation system to dealwith environmental contaminationfrom the paint line after installing a thermal oxidizer. The new installation placed the ovensunderpositiveratherthannegativepressure,causingovenoff‐gassesconsistingmainlyofxylenetoflowintothegeneralareasoftheplantwheresome50workerswereadverselyaffectedandsought treatment at the local hospital. There have also been problems with respect to thecontrolofhazardousdustasaresultoflackofpreventivemaintenance.Sourcesofthesedustsvaried, including plastic dust from re‐work/grinding room and dusts associated with vehicleexhaust. Aninspectorwasadvisedbythedoctorassessingworkersintheisocyanatedcontrolprogram thatmostworkers in the sandand trimdepartmentwere suffering fromobstructivelungconditions. Inspection reports indicate that ventilationductshadnotbeencleanedsincetheywereinstalledmanyyearspreviously.See:FV#00588lDZP062;1080113;inAppendixB.

THEVENTILATIONSYSTEM

AFlawedVentilationSystem:Oneofthemostsignificantfactorscontributingtoadversetoxicchemicalexposuresistheflawedfunctioningofthemechanicalheatingandventilationsystemattheplantanditsinabilitytoachievethemainfunctionofcontrollingworkerexposurestoverytoxicchemicals.

ThefollowinghygieneanalysisofthecompanyisventilationsystemisbasedontheprofessionalanalysiscarriedoutbyOHCOWhygienist,SoniaLalin2004.InourownreviewoftheOHCOWreport ‐‐ as well as observations from key informants and focus group participants, togetherwithreportsfromMOLinspectorsandindustrialhygienists‐‐wefindthatherobservationsandassessmentsarewellsupportedbyvariousthirdpartyfindings.7

Major flaws in the ventilation system, continually have caused contaminants from variousproductionprocessestomigratetootherworkareasinsteadofbeingexhaustedoutsideoftheplant. Ineffect, thesefugitiveemissionsrepresentanadditionalburdenofexposures,someofwhichcontainchemicalsthatareimmediatelymorehazardous,suchasisocyanatevaporsfromthe paint line and RIM departments, or fumes and vapors from the thermoplastic injectionmoldingoperations.

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The work area most subject to contaminant migration was the assembly area located in themiddleoftheplant,andbecauseofitslocation,toadjacentdepartmentventilationsystems.Atthe same time, other processes were affected because their local exhaust systems were alsocompromisedduetonegativepressureplantwide.

Inadditiontothegeneralproblemofnegativepressure,wastheaddedeffectofregularusageoflarge, floor standing, oscillating fans in an effort to create air movement to dissipate hightemperatures(rangingfrom80‐100F)inproductiondepartments.Consequently,inanattempttodealwithheatstress,theuseofindependentfloor‐fans,inadvertently,furthersabotagedthelocal exhaust system aswell as creating an air‐borne dust hazard from the trim and sandingoperationsthroughouttheplant.

InadequateMake‐UpAir: Themajorproblemwiththeventilationsystemwasthefactthatitcould not supply sufficient make‐up air to create a balance between in‐take and exhaustventilation.Thesystemcouldnotbringinasufficientlevelofmake‐upairintermsofcubicfeetper minute. Consequently, the general atmosphere was constantly under negative pressure,encouragingcontaminatedairflowsfromotherproductionareasintoadjacentoperations.

MultipleFailuresintheVentilationSystem:Laldiagrammaticallydescribedseveralscenariosthatwouldbeencountered leading tocontaminatedair flowsasa resultofventilationsystemflawsormalfunctions,reflectingroutinedailyoccurrences:

Scenario#1:“NormalConditions:”paintdepartment(mid/west)isunderpositivepressureandblowing air outside its area; Sludge room (north/west) is pulling air into its area and thusexhaustingoutsidevia exterior exhaustunit; theRIMdepartment (north/east) andpost cureoven(mid/east)andareaisexhaustingoutandthuspullingairin;andassembly(middle)undermakeupair andno local exhaust ispossibly affectedby thepaint line fumes ifbalance isnotmaintained. Thus, even when working “normally”, paint/solvent spills in paint line wouldmigratetotheassemblyareas.

Scenario#2:AirflowinSludgeRoomfails:Ifsludgeroomexhaustfanfailsorexternaldoorleftopen,sludgeroomceasestodrawinair fromplantandairpulledfromRIMexhaustwilldrawfumes/vapors/odorsfrompaintline, injectionmoldingandsludgeroom(easterly)overtoandthroughtheassemblyandgluelinescentrallylocatedandventilatedwithmake‐upair.

Scenario #3: Air flow in the RIM department fails/insufficient exhaust draw: causes thenegativeairpressurefromthesludgeroomtopullthecontaminatedair fromRIMdepartmentand paint line toward the sludge room (westerly) right over to the assembly lines, exposingtheseworkerstocontaminantsfromRIMandthepaintline.

In regard to Scenario #3, Lal points out that a RIM department Facility Air Balance StudyconductedbyPebrainJune1993,confirmedthatallsixmake‐upairunitswerenotoperatingattheCFMdesignatedcapacity.7Thereportconcludedthattheareaisundertremendousnegativepressure. Althoughmany fansvary in theirdesigncapacities, theoverallnetpressurization isclose to design capacity level. This tremendous negative pressuredrew fumes fromboth the

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SludgeroomandPaintLineacrosstotheAssemblyarea.7(SeeSoniaLal,VentraRetrospectiveReport)

Theotherwelldocumentedflawintheventilationsystemwasthefactthattheairintakesystemwaslocated inproximitytotheairexhaust, thusdrawingcontaminatedairbackintotheplantthroughthe“freshair”intake.

The following factual account provided in a MOL hygiene assessment exhibits the types ofventilation system problems alluded to above. According to MOL hygiene consultant KimGordoninreport#244814;31/10/88(seeMOLreportsAppendixC):

“PostLamhotgluingoperationinadequateexhaustventilation;RIMmoldingoperationinadequateexhaust ventilation and isocyanate control program had limited worker coverage; RIM needsimmediateattentiontoISO leaks; insidepaint line foundtobeblowingpaintandsolventvaporsintothegeneralworkarea;sludgeroomaconfinedspacenotaddressed.”

Theimportantconclusiontobedrawnfromthefunctioningof theventilationsystemwasthatworkerswerebeingexposedsignificantlynotonlytotheirownprocess/chemicalemissions,butalso emissions fromadjacent operations. Thiswasparticularly significant forworkers on theassemblyandgluelines.Evenwithoutthefailuresdescribedinthescenariosabove,iftherewasapaintorsolventspill inthepaint line,vapors fromthateventwould instantlymigratetotheassemblyarea,exposingworkers tochemicalmixtures that included isocyanate‐ladenpaintaswellasavarietyofchemicalsknown/suspectedtobecarcinogensandhormonedisrupters.

It is important to note that most complaints and adverse health symptoms, includinghospitalizationsandworkrefusals,occurredonassemblyandgluelines. Aswell,observationsrecordedinMOLinspector/hygienereportsdocumentmanyinstancesofairflowfailureslinkedtostrongodors,vaporsandfumesfromadjacentoperations. Wecan’temphasizeenoughhowventilation problems dominated committee discussions and how consequent exposures tocontaminantsledtooccupationaldiseasesamongworkers(SeeAPPENDIXB forsummariesofMOLreportsandunionlogsofincidents).

Theotherimportantevidencesupportingworkers’contentionthattheywerebeingoverexposedto harmful chemicals due to long‐standing faults in the ventilation system came from MOLinspectors’ investigative reports which focused primarily on indoor air quality and chemicalcontamination. AnanalysisofMOL investigations indicates thatamajorityofcomplaintsandwork refusals were related to air quality, specifically adverse health effects/symptoms fromcontaminatedairintheplant.YetairtestsconductedbyinspectorsormanagementconsistentlyfailedtoshowthatcontaminantsexceededTLV/OELlevelsdespitetestsdocumentingthepoorfunctioning of the ventilation system combined with the physiological effects and symptomsworkers reported; these two factors alone support the contention thatworkerswere, in fact,overexposed.

As inspectors routinely reported not being able to find OEL exceedance (sometimes infrustration that “you’ve got to give me something”), their reports described conditions of

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insufficient capture velocity/no exhaust ventilation and major sources of chemicalcontamination (e.g.paint/solvent spills). Suchchallenges to theMinistry’s sampling results, inthecontextoftheirowndocumentationthatincludedhealthsymptomsthatwereclearlysignsofworkeroverexposure,wereneveraddressed.Suchanomaliesarefrequentlynotedininspectorreports found inAppendixB. As well, workers regularly complained to inspectors that thebuilding had been aired out and/or production ceased prior to their visit. In many cases,inspectors would identify significant sources of exposure, e.g. 5 gallon open pails of MEKsoaking glue applicator parts and workers stacking large numbers of freshly glued car partswhile product was flashing off, and in both cases with no personal protective equipment orexhaustventilation‐‐yetinspectorsappearedtorelyonlyonairsamplinginconcludingthatthesituationwas “not likely to endanger.” Committeemembers frequently spoke about workers’frustrationatneverreceivingaMOLreport thatdecided in their favour, “except theones thatdidn’tmatter.”

In one such report an inspector notes in advice to management: “Managementand the JHSCshould continue to work with the employees….with a view to minimizing or eliminating allventilationfaults,inappropriateworkpractices,spills,etc.whichcanresultinexposurestovarioussmokes, fumes, vapors, etc. The general ventilation of the plant should be assessed by anappropriate consultant tominimize thepossibilityof captureof exhaustgasesby theair intakesystem(93E220MOBR,04/05/93)”(SeeAppendixB).

Thisstatement,aswellasothers,constitutesanacknowledgementthat:1.significantexposureswereoccurringroutinelybutwerenotaddressedbytheventilationsystem;2.thatinappropriateworkpracticeswerebeingtoleratedbytheemployer;and3.thatadequatepersonalprotectiveequipmentwasnotprovidedornotusedbyemployees.Itwasclearthattheventilationsystemwasfaulty,thuswasnotprotectingworkersfromtoxicexposures.

ThemajorflawintheMOLenforcementsystemandthewayMOLhygienistspracticedindustrialhygiene was to rely on exposure standards: 1) that are not health based, 2) that had littleempirical evidence to support them, and 3)were sorely out of datewith respect to scientificinformation available at the time.34 As well, their single focus on air concentrations as ameasure of exposure, neglected to take into account exposure via the dermal route or ifswallowed.WhatismostreprehensibleistheextenttowhichMOLoccupationalhygienistsandoccupational health physicians ignored the serious symptoms exhibited by workers duringfrequentover‐exposureepisodes—symptomsthatwereclearlynoted in theproductMSDSsaspredictablesignsofover‐exposure.35

LIMITATIONSOFINDUSTRIALHYGIENESAMPLINGINASSESSINGWORKERHEALTHEFFECTS

Extremelyproblematicistheextenttowhichinspectorsandhygienespecialistsputblindfaithinair sampling during site visits, whether with color‐metric short term grab samples (whoseaccuracyistypically+/‐25percent)orwithlongtermpersonalorareasampling,whileignoringworkers’ symptomology and the general state of the ventilation system. According to the

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AmericanIndustrialHygieneAssociationmanual“Accuracyofdetectortubesisconsideredtobe+‐ 25%...” based on the U.S National Institute of Occupational Safety and Health certificationcriteria.37 Well‐known questions and shortcomings about the accuracy of industrial hygienemonitoringhavebeenwellstudied.36

Some of these concerns include: Conditions at time of testing may not be representative ofconditionsat thetimeofcomplaints. Manytimesworkerspointedoutto inspectorsthattestswereconductedaftertheemployerhadairedouttheplantandshutdowntheoffendingprocessor diminished production levels. Testing for volatile organic compounds and isocyanates isparticularly problematic with respect to the adsorbent materials used in the sampling train.Studiesshowamarkeddifferencewhenusingdifferentadsorbents;Tanex,forexample,isshowntobesatisfactory,butnotinallcases. Inthecaseofisocyanates,therewaslittlemonitoringofisocyanate levelsattheplantespeciallywheninvestigatingworkers’complaintsaboutadverseeffects. Researchers have found thatmeasurements can be affected by the positioning of thesensors during area sampling. In addition, very rarely do analytical labs report the 95%confidenceintervaltoassessstatisticalsignificancethatisnormallyrequiredwhenusingNIOSHmonitoringmethods.

Unrepresentativemonitoring conditions: An example of how results of air concentrationsampling can be manipulated by altering conditions was exhibited in the industrial hygienemonitoring report from theQueensUniversity study thatwas done for Pebramanagement in1988.Atonepointintheirreport,theconsultantsnote:“However,atthetimeofsampling,‘lessthan normal activity’ occurred at this (sanding) table. On two subsequent visits the (non‐exhausted)tablewasstillnotinuse.”Consultantsalsonotedthattheworkcrewwalkedoffforan unscheduled coffee break shutting down production at the time of sampling. And duringsamplingforHDIonthepaintline,theconsultantsnoted:“However,anunpredictedshutdownofthe paint line prevented the collection of a representative long‐term sample. During the 24minute sample period, only 12 minutes of clear‐coat spray painting occurred.” (HygieneConsultants Report, Queens University, Occupational Health Department) The hygiene reportfurther acknowledges that “inside solvent levels may not be reliable, as the sampler tubingdisconnected from the pump, at some time during the sampled period (14/06/88)” (SeeAppendixB).

It is important to note thatwe did not find a hygiene air concentration report that identifiedwhatsamplingstrategywasemployed,whatadsorbentswereused,whatdesorbentswereusedandwhatanalyticalmethodwasused.Nordidanyreportindicatethatthelaboratorycarryingout the analysis was a certified lab. There was no indication of the analytical method thesampling strategy was based upon. Were adsorbents subsequently analyzed by thermaldesorption gas chromatography, or mass spectrometry? Or were adsorbents subsequentlydesorbedviasolventdesorptionpriortoanalysis?Adsorbenttubescanbeveryspecific,andasaconsequence, certain species of plastics at low concentrations and very low occupationalexposurelimits,oftengoundetected.33

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Thereareother factorstobeconsidered inairsampling,basedonsomeofForrestetal.otherfindingswithrespecttoassessingplastic thermalprocessingemissions:1. Purgingoperationsresult in higher concentrations of chemical species; 2, Normal thermal processingwill emit alarge number of species of chemicals including some monomers that require differentadsorbentssuchascharcoalandsolventextraction;3.WhileTenaxissatisfactory,Chromosorband Poropak offer some advantage with the lowmolecular weight/high volatility region, e.g.HIPSinjection;4.Thepositionofthemonitorcanhaveasignificanteffectonresultsaswell,e.g.draftsfromothersourcesorlocationofthemold;5.Backgroundlevelsnotmuchdifferentthanthose near the process, are an indication that by‐stander exposure of other workers wouldoccur.33

TheQueensUniversityConsultants’report furthernotedthatduringthesamplingperiod“lessthannormalactivity”occurredatthetrimtablesandthat“thesludgeroomisoperatingonabatchwater treatment scheduleuntil fullproduction levelsareachieved,” indicating thatsamplingoccurredduringreducedproductionlevelsonthepaintline,andthat“….WhileworkerexposuresinexcessofthesolventTWAEVwillnotoccurunderexistingconditions,thiscouldchangeifproductionlevelsforthepaintlineshouldincrease”(SeethecomprehensiveliteraturereviewinAppendixAandtheconsultants’reportsinAppendixB:ConsultantReports).

DermalRouteofEntry:Mosttestingonlymeasuresairconcentrations,ignoringotherroutesofentry. For example, it is now recognized that there is significant body uptake of chemicalsthrough skin absorption. In this regard, we note the concluding comments in the Queen’sUniversityhygienesamplingreport,dated14/06/88wherethereportstates:

“Askinnotationforasubstanceindicatedthatabsorptionthroughtheskincansignificantlycontributetoaperson’soverallexposuretothatsubstance.Exposurebyskincontactisnotdetectedbyairmonitoring”

IngestionofToxicChemicals:Ingestioncanalsobeacriticalrouteofentrywhenworkerseat,drink, and smoke at work stations. We have provided a review of body burden studies ofchemicalcontaminantsusedprimarilyintheplasticsindustrythroughbiologicalmonitoring,e.g.measuring metabolites of chemicals or chemicals themselves in blood and urine. We havereviewed several studies comparing levels in workers’ bodies with “unexposed” referentpopulationstoascertainwhatisactuallytakenintoworkers’bodies.ThesecanbefoundinthetableinAppendixEandthereferencescitedintheliteraturereviewinAppendixA.

Wenote that levels found in thesebiomonitoringstudies,particularly in thecaseofendocrinedisruptors, are very significant and of serious concern for human health in general, andreproductivehealthinparticular.Comparedtounexposedreferentpopulations,workerstestedhad levels that were significantly higher. These levels have stimulated grave concern byendocrinologists noting that even the levels found in the general referent populations werehundredsoftimeshigherthanthoseshowntoproducemammarytumorsinlabanimals,aswellas other adverse reproductive effects.37What should be alarming to the Occupational Health

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Communityisthatlevelsfoundinplasticsworkersaresignificantlyhigherthanthosefoundinalreadythreatenedgeneralpopulations.

PROBLEMSWITHEXPOSURESTANDARDS:ACGIHTLVSANDOELS

These last research‐based observations on the health effects of substances used in plastics’production raise serious questions about the relevance and validity of the entire system ofexposurelimits.Inadditiontoproblemsmeasuring“exposures”thereistheimportantquestionofwhether these exposure limits are health based limits, i.e. limits that protect the health ofworkers based onmedical evidence.34In recent studies of exposure limits, a large number oflimitshavebeenshowntohaveadversehealtheffectsbelowtheestablishedlimits.Infact,onlya small numberof chemicals havedemonstratedno effects below the established limit.38(SeeAppendixA for a literature review of occupational health in the plastics industry; See alsoCastleman and Ziem “corporate influence”, Ziem and Castleman “historical perspectives”,Rappaport,andStouten.)

In takinganhistoricalperspectiveonthesettingofTLVsandotherOELs,ZiemandCastlemanpoint to the medical inadequacy of the TLV. They identified that with at least 90% of TLVchemicals, sufficient data on long‐term effectswas unavailable, either from animal studies orstudies of industrial workers with long term exposures to known concentrations of thesechemicals. They noted that “the very concept of daily average exposure limit has beenattackedas inconsistentwithwhat isknownabout toxicity ‐‐ evidentlyoriginatingmore fromeconomic than scientific considerations.”40 Indeed, for themost part, regulatory developmenthasbeen in thehandsof industrialhygienistswho lack in‐depthtraining inbiomedicalhealth.While theirknowledge incontrollingexposures isvital tooccupationalhealth, their focusasadiscipline isonmechanical engineeringandpractical imperativesofproductionand impactofcontrols, rather than on biomedical and health concerns arising out of exposures at work. 40AnotherchallengetotheempiricalbasisofTLVsnotedbyZiemandCastleman,isthefailuretouseinformationavailableinthemedicalliterature.Theirinvestigationidentifiedtheabsenceofsystematicliteraturesearchesdoneinpreparingthedocumentationforhundredsofchemicals.Literature reviews were usually done by hygienists or other non‐biomedical professionals.39Consequently, and based on even a limited sampling of the scientific literature on the healtheffects of exposure to a number of theTLV chemicals, ZiemandCastleman found evidence ofprofoundhealtheffectsfromexposuretothosesubstancesat levelsfarbelowtheTLV.39Theyfound,forexample,thefollowing:

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TABLE3

LOWLEVELHEALTHEFFECTS

Acetone neurobehavioraleffectsafter4hrsat250ppm

TLV750ppm(stel)

Cadmium changesinrenalfunctionat0.003mg/m3 TLV0.01mg/m3

Ethoxyethanol lowsperm,red,whitebloodcellat2.6mg/m3

TLV5ppm

Formaldehyde respiratorycancer10yrat0.1to1ppm TLV1ppm

Ethylenediamine respiratorysensitizationat1to10ppm TLV10ppm

Methylchloroform behavioraldeficitsat3hrsat175ppm TLV350ppm

Silica lungscarringat0.5to2.0mg/m3 TLV2.0mg/m3

Styrene asthmaat62mg/m3 TLV215mg/m3

Sulfuricacidmist laryngealcancerat0.2mg/m3 TLV1.0mg/m3

Toluene neurobehavioral 20minat125ppm TLV100/150ppm(st)

TDI asthmawithin1yrat0.002ppm TLV0.005ppm

Amorerecentupdate(2008)totheZiemandCastlemanearlierfindings(late1980s),involvesanindepthreviewofthedocumentationofTLVsbytheHealthCounciloftheNetherlandswhichincluded internationalmedical experts. The health council concluded that the data bases foronly40%ofthechemicalslisted,metthecommittee’scriteriaforhealth‐basedlimits.34

Low‐dosehealtheffects:Whenitcametoassessingworkers’complaintsofsymptomsorodours,inspectorsrarelytreatedtheseassignsofadversehealtheffects,preferringtorelyonshortterm/grabsamplemonitoringdata, or concluding that no adverse effects should be expected at these levels. At times theyattributed worker complaints to “chemophobia” and as “psychological” rather than a truephysiologicaleffect.However,asZiemandDavidoffhaveargued,suchconclusionsarebasedontheerroneousassumptionthatcurrentTLVs/OELsarescientificallysound. In thisregard, themany studies previously mentioned should by now challenge this unsupported assumption.First,theconditionsassociatedwithlow‐levelexposurestochemicalsintheworkplaceremainpoorlyunderstood.Second,itignoreshowlittleweknowaboutlow‐levelexposuresandtoxicityofthemanythousandsofchemicalsfoundintheworkplace–aswellastheglaringabsenceofresearchconductedtofill thisgap.AccordingtotheNationalResearchCouncil’sownestimate,only2%ofatleast60,000chemicalsinusehavebeenstudiedfortheirtoxiceffects.Andmostofthesehavebeenonanimalswithfarfewerstudiesofhumans.Withoutsuchcriticalinformation,preventiontrulyringshollow.

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TheNationalResearchCouncilidentifiesthatchemicalshaverarelybeenevaluatedforchroniclow‐leveleffectsonthenervoussystem,thecentralandperipheralnervoussystem,theimmunesystem, the endocrine system, the reproductive system and for neuro‐behavioural effects. Infact,muchofthelimitedextanttoxicologicaldatabasehasnotbeenusedtoformulateTLVs.

ZiemandDavidoffillustratethatwhentheNewJerseyDepartmentofHealthextrapolatedtheUSEPA’sIntegratedRiskInformationSystem(IRIS)database,identifying‘noeffectlevels’fornon‐carcinogenic chemicals, they found that the ‘no effect levels’ were three orders ofmagnitudebelow the current OELs. In the context of current “knowledge” and “practice” they make astrongcase foracceptingsymptomsandodorcomplaintsasanindicationofphysiologicallybasedhealtheffectsandnotdismissingthemas“chemophobia,”orsomeformofmasshysteria.40

AfurtherissuewithrespecttowhethertheexistingTLVs/OELsprovideprotectionfromharmfulexposures, is thedegreetowhichvested interestssuchasmajorcorporations,employers,andmanufacturers have undue influence in the promulgation of TLVs in particular, and OELsgenerally. This was brought to light initially by Castleman and Ziem in their expose` of theACGIH’sTLVCommittee thatwaspopulatedmainlybycompany industrialhygienists/doctors.TheyexposedthefactthatdocumentationofTLVswas:notscientificallybased;wayoutofdatewithcurrentknowledge;largelybasedontelephonecallsbetweenthecommitteemembersandcompany hygienists; and includedno conflict of interest disclosures.41 These revelations havebeen followedupbyotherresearchersover theyears,againshowing thatstandardswerenotbasedonbiomedicalevidenceandareheavilyinfluencedbycorporateinterests.41‐44

DISCUSSION

The findings of this retrospective exposure study raise major issues about the occupationaldiseaserisksatPebraplasticsovertheyears,andhowtheyhavebeenhandled.

PebraWorkerswereHeavilyExposed:First, it was documented through extensive focus group and key informant interviews andreviewsofhundredsofMinistryofLabourinspectionreports,unionlogs,jointhealthandsafetycommitteeminutes, and private consultant reports, thatworkers at the plant, have for years,laboured under very poor and hazardous conditions. These are characterized by large scaleworker exposures and consequent work refusals including plant evacuations that aredocumentedinthisreport.

Thekeypointisthatover‐exposurewasindicatedbytheworkers’experiencesofphysiologicalsymptoms and adverse health effects during the many events where exposures weredocumented and source(s) of contamination noted. In these cases, major sources wereidentified: paint kitchen spills of paint/solvents; similar spills and leaks in the paint boothscoupledwitherrorsintheventilationsystem’srelativeairpressure;Sludgeroomcontaminantsmigratingtogeneralplantareasasaresultoferrorsintheventilationsystemairflows(doorsleftopenetc.); fumesandvapors fromglue lines,post lamgluing, injectionPVCmolding,andwidespreaduseofPebra5withoutproperexhaustventilationas indicated inMOL inspection

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reports; dust containing silica, fibreglass, urethane and isocyanatemonomer in the trim andsandareaswithpoorly functioning,ornon‐existent,down‐draftunitsaggravatedbytheuseoflarge, standing floor fans that spread dust throughout the plant. In addition, MOL/WSIBassessmentsofthecompany’ssafetyprogramshavebeenextremelycriticaloftheextentofthecompany’snon‐compliancewiththeprovisionsoftheOHSAandthelackofanyhealthandsafetypoliciesandprogramsthatwereinplaceandfunctioning.

Inmostinstancesthephysiologicalsymptoms/healtheffectsexperiencedwereconsistentwiththe health effects and symptoms described in the manufacturers’ MSDSs as signaling over‐exposures. Equally important, the controlmeasures recommended by theMSDSs to controlworker exposureswere rarely inplace. Inmany instances,workerswere sent tohospital forassessment and treatment,withworkers subsequently filingoccupational injury claimsunderthe Workplace Safety and Insurance Act. These factors further confirm that the “putative”exposuresdid,infact,occur.

In caseswhere air samplingwas carried out by theMOL or employer, itwas rare to find airconcentrationsthatexceededtheTLV/OEL.Yettheseairconcentrationfindingscanbeseriouslyquestionedbecauseofthefollowing: 1. Thereisquestionastowhethersamplingwascarriedoutunderrepresentativeconditions;2.Thereisreliableevidencethatsamplingwascarriedoutafter areas were aired out and/or production suspended; 3. Testing was done with draegercolourmetric collection tubes with a low accuracy rate of between ‐+25 percent and areexceedinglyproblematicwhenmeasuringvolatileorganiccompounds;4. Long‐termsamplingdidnotidentifysamplingoranalyticalmethodsusedandrarelytestedforisocyanates;5.ThereisseriousquestionastowhetherTLVs/OELsarehealthbasedlimits.And,whilelimitswerenotexceededat timeofmonitoring, inmanycases, inspectorsnoted that localexhaustventilationwasinadequate,personalprotectiveequipmentwasunavailable,andtheywouldissue“advice”ororderstoaddresssuchinadequacies.

In addition, a review of the industrial hygiene literature pertaining to thermal plasticsprocessinginthisindustryfoundindepthstudiesshowingthatnumerouschemicalspeciesareemitted during thermal processing in addition to original chemical properties. Importantly,biologicalmonitoringstudiesconfirmthatsuchchemicalsenterworkers’bodiesatlevelsseveraltimes higher than identified in “unexposed” referent populations (See literature review inAppendixAandBodyBurdenTableinAppendixE).

These hygiene studies of the plastics industry further confirm the presence and extent ofexposuresthatthiscurrentstudyhasendeavoredtodocument,retrospectively.

ChemicalsUsedinPlasticsProcessingAreHighlyToxic:Automotiveplasticsworkersareexposedtohundredsoftoxiccommercialproductsthatcontaina large range of hazardous ingredients, many of which are designated, or suspected, humancarcinogens and endocrine disruptors capable of causing chromosomal damage, adversereproductiveeffects, andsterility. Manycandamage the functioningof the liver andkidneys.Mostareneurotoxinsthatcanaffectthebrain,centralandperipheralnervoussystems.Asmajor

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irritants, these cause: irritation and inflammation of the lungs and upper respiratory tract;asthma;andchronicobstructivepulmonarydisease(COPD).ThesehealtheffectswerenotedinalargemajorityoftheMSDSsreviewed.

Arecentratingof the toxicityofvariousplastics,bySwedishscientists,demonstrates thehighdegree of toxicity of many monomers. The study ranked 55 polymers used in plasticsproductionaccordingtodegreeoftoxicityandseriousnessofhealtheffectsbasedonmonomersclassifiedasmutagensandorknownorprobable carcinogens. Thirty‐oneof the55polymerscontainedmonomersbelongingtothetwohighest levelsonascaleof five—inparticular,PVC,ABSandstyrene‐acrylonitrile(SAN).45

Animportantfeatureofproductionattheplantwastheuseandhandlingofaverylargenumberof toxic commercial products ‐‐ at least 500, containing, on average, close to 1000 hazardousingredientsthatwerehandleddailyinthecontextofaveryweakexposurecontrolsystem.

Reviewsoftoxicologicaldatabasesandhealtheffects’ informationprovidedinMSDSsindicatethat many of the chemicals are: known or suspected carcinogens; mutagens; fetal toxins;reproductivetoxins;hormonedisruptors;lung;upperrespiratorytract;GIirritants;sensitizers;and those that can damage both kidney and liver (SeeAppendixC for summary ofMSDSs).Importantly,thefactthatchemicalswereusedinlargevolumes,handleddirectly,andinvolveddetailed manipulation of materials without effective exposure controls – (individually and incombination)raisedtheriskofworkerexposures.Suchlargescaleexposurewasconfirmedbyanenvironmentalassessmentidentifyingthatannually,thecompanyusedover250,000USGofpaint, generatingoveramillionpoundsofVOCs.30 Importantly, thegeneralventilationsystemcontributedsignificantlytoexposures.Itsdesignandlayout,practically,ensuredthatchemicalswouldmigrate to, and contaminate, other areas of the plant. Local exhaust to address toxicexposureswasnon‐existent,ineffective,ornon‐functioning.Indeed,thisisthemajorunderlyingcauseoftheintenseexposuresexperiencedbyworkersoverthenearlyfortyyearsthecompanyhasbeeninPeterborough.YetcompanymanagementhascontinuallyresistedworkerandMOLinitiativestoremedytheventilationsystem,uptothepresent.

ManyPlasticChemicalsareEndocrineDisruptors:A significant concern, with respect to the relationship between health impact and level ofexposure, is the fact that a large number of chemicals used in the processing of plastics areendocrinedisruptorsthathaveidentifiedadverseeffectsatextremelylowlevels—givinglietotheoldtoxicologicaldictumthat“thedosemakesthepoison”.WhendealingwithexposurestoEDCs, effects are produced inpart per trillion. Themolecular structure of these chemicals issuch that some are estrogenmimickers and perceived by the body’s endocrine system to beestrogen‐‐ a powerful, known tumor promotor. In other instances, these chemicals have astructure that promotes certain critical hormones that regulate numerous functions of thehuman body. These have been implicated in the development of mammary tumors, thyroidcancer, and disruption of the body’s reproductive system. This iswhy endocrinologists havebeencallingforarethinkingofsociety’sapproachtochemicalriskassessmentformorethanadecade.37,46‐48

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A critical issue that continues to be ignored by officialswith responsibility for protecting thehealthofOntarioworkers, is the impactofmixturesofcarcinogenicand,especially,endocrinedisrupting chemicals (because of their health risk at such minute exposure levels) and thepossibility of synergy. In this regard, a study by Ibarluzea and colleagues on the enhancedbiologicaleffectivenessofatoxicloadofseveralendocrinedisruptingpesticidesactingtogetheronthedevelopmentofbreastcancerhasseriousimplicationsforassessingrisksassociatedwithexposuretosimilarmixturesintheplasticindustry.Theirworkaddssupporttothecontentionthatexposurestocomplexmixturesmustbeconsideredwhenassessingpotentialcausal links,andassessingriskgenerally. Fromanepidemiologicalperspective, it is importanttonotethatthesesameresearchersfoundweakornoassociationwhenchemicalswerestudiedindividually,yetproducedarobustassociation(fivefoldincreasedrisk)whenabodyburdenindexbasedona“collectionofEDCs”wereused in theiranalysis,even in theabsenceofanyknownbody‐massindexriskfactor.49

WorkersExperiencedSignificantAdverseHealthEffects:It is necessary to acknowledge the pattern of harm experienced by employees. The dailyexperienceofworkerswasachemicalassaultontheirsensesthatbeganwiththeconstancyofchemical and solvent odors followed by burning and tearing eyes, difficulty breathing, sorethroats, headaches, dizziness, muscular weakness, nausea and disorientation. These are thedailysymptomsofchemicalassault.

Over time,moreseriousandpermanentdiseaseshaveemerged. Asof thiswriting, some133workershavebeenregisteredwithOHCOWincluding33workerswithcancerdiagnosis.Someof these cancers were diagnosed when workers were in their 30s, a highly unexpectedoccurrence.Insomecases,cancershaveoccurredatmultiplesites,includinginsomeinstancesuptofourdifferentdiagnosedcancers. Inadditiontocancerstherehasbeenapatternoflungandupper respiratory tract disorders includingmany cases of asthma,COPD, and respiratorydistressaswellaswidespreadreportsofheartdiseaseandavarietyofneurologicaldisorders.

While theseOHCOWdata are very serious, amore recent occupational disease survey by theAdvisory Committee shows an even more alarming potential disease trend among theseworkers. That investigationrevealsapossibility of116cancers including32lungcancers,22breast cancers, 8 kidney, 7 gastrointestinal and 47 other cancers including: liver, pancreas,brain,nasalpassages,thyroid,skin,sinus,cervical,bone,lymphoma,Non‐Hodgkin’sLymphoma,salivarygland,bladder,leukemia,mesothelioma,jawcancerandprostatecancer.Thenumberofworkers in this cohort during this 1986‐1996 era numbered approximately 521 withapproximately20percent fallingvictim tosome formof cancer. This isanexceptionallyhighrate of cancer ‐‐muchhigher than expected rate in the general population and evenmore sowhen we compare the incidence rates of the leading cancers in this study—i.e., 32 lung, 22breast,8kidneyand7GIcancers.

We cannot ignore other non‐cancerous occupational illnesses suffered by theseworkers (andthese are based on what is “known” personally by committee members, or that could beconfirmedbydocumentation). Equallydisturbing is the largenumberofserious illnessesthat

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includetodate:41casesofcardiovasculardisease,35casesofreproductiveabnormalities,54neurological disorders, 15 cases of C.O.P.D., 23 GI disorders, 12 cases of asthma, 10 thyroiddisordersand17reportedrespiratoryproblems.

The important message is the fact that the entire group of diseases occurring among theseworkersisconsistentwithwhatisknownaboutthetoxiceffectsofchemicalsusedattheplant.Muchofthescientificliteraturehasidentifiedthesechemicalsintermsoftheircarcinogenicityas tumor initiators, tumor promotors, and immune suppressants. Many others have beenclassified as neurotoxins, respiratory and skin irritants, cardiovascular stressors, immunesuppressants,fetaltoxinsandendocrinedisruptors.

Unfortunately, forworkers, regulatoryauthoritiesat theMinistryofLabour ignored workers’complaints and symptoms, preferring to rely on questionable time weighted average airconcentrationsincomparisontoTLV/OELguidelines—exposurestandardsthatareclearlynotbasedoncurrentmedicalevidence.Reliancesolelyonaveragedailyairconcentrationsdoesnottake into account: the synergistic interaction of a complex mixture of chemicals, the severeimpactofshort‐termpeakexposures,thedermalrouteofexposure,andlevelofphysicalactivity‐‐coupledwithworkinaveryhotworkenvironment(800Forgreater).

CONCLUSION

Areviewoftheseretrospectiveexposurefindingsindicatingheavychronicexposuresasdetailedinproductionprocess templates, in addition todocumented toxicpropertiesof chemicals andtheirby‐products towhichemployeeswereexposed, leads these researchers to conclude thatPebraworkerswereathighriskofharmfromdailychemicalexposures.Itisalsoourviewthatthese workers were frequently exposed to transient peak exposures that exacerbated thephysiologicalimpactofthesechemicalexposures,furtherimpairingtheimmunesystem.

Thisconclusionisbasedontheverypoorexposurecontrols,lackofworkerinformationonthehazardsofthechemicalbeinghandled,inadequatePPE,laxhealthandsafetyculture,thefaultyand ineffective ventilation system and the hazardous production methods used. At the sametime,itisimportanttoacknowledgetherolethatweakenforcementoftheOccupationalHealth&SafetyActanditsregulationsplaysinputtingworkersatrisk.Inmanyinstancestherewasanunwillingnesstotakeseriouslythephysiologicalsymptomsexperiencedbyworkers,resultinginthe unsubstantiated interpretation that such symptoms were signs of minor discomforts or‘chemophobia’.

Itistime,asoccupationalhealthprofessionals,thatweexercisethe“precautionaryprinciple”inthefaceofscientificuncertaintywhenhumanhealthisatrisk.Thisshouldbethestartingpointinoureffortstoprotectworkersfromharm,aswellasinassessingtheharmalreadyinflictedonworkers. We do this in both caseswhenwe giveworkers the benefit of the doubt by actingproactivelytoprovidecare forvictimsandtheir familiesthrough justcompensation,andevenmore importantly by ensuring workers right to physical and emotional well‐being throughregulation,anditsenforcement,intheworkplace.50,51

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DETAILEDDEPARTMENTALFINDINGS

The section that follows represents the body or “substance” of this report ‐‐ that is thearea/department‐by‐departmentbreakdownof the variousworkprocesses and the chemicalsworkersusedand/orwereexposedtoduringthedifferentoperations;and,thetypeandlevelofrisks associated with these various activities and the specific worker categories (set‐up,operator,production,andmaintenance)mostatrisk.

Thebodyofthisreportprovidesdetailedexposureprofilesforthemajorworkprocessescarriedout,andthechemicalsassociatedwiththesedifferentprocesses.Theinformationispresentedincolumnformwith“ProductionProcess”listedontheleftcolumnand“ChemicalExposureRisk”listedontheright.

Fromthe“ProductionProcess”descriptionsweformulatedariskexposureprobabilitythroughidentification of a constellation of risk factors for each process. In describing howworkwascarriedoutweareable to inferrisk factorssuchas:wastheworkerdirectly involved;didtheworkerdirectlyhandlethematerials;whatwasthephysicalstateofthematerial(s);whatwastheprobableroute(s)ofentry;whatvolumewasused;whatwastheproductionrate;howmuchtimewasspentonthetasks;wereexposurecontrolsavailableandadequate;whatisthetoxicityrating of the material; and did workers have knowledge of the hazardous chemicals andprotectivemeasuresrequiredtocontrolexposures?FromAdvisoryCommitteenotes,supportedby MOL and JHSC reports, we were able to systematically document adverse symptoms andcomplaints.

The“ChemicalExposureRisks”setoutintherighthandcolumnariseoutofhowproductionwascarried out for each of theworkprocesses described in the left hand column.The right handcolumn reflects a qualitative assessment of what the exposures were like, given the wayproductionwas carried out byworkers and the existence of the risk factors identified above.Where reliable hard data is available this is presented, but always in conjunction with theworkers’experiencesarisingfromtheproductionprocessitself.

The departments or areas (i.e., processes that shared close physical space or workerclassificationsassociatedwithahighdegreeofmobility)analyzedindepthinclude:

1. ROLLFORM/POSTLAM,ANDINJECTIONMOLDINGOPERATIONS;

2. R‐RIM(ReactionInjectionMolding)OPERATIONS;

3. PAINTDEPARTMENT(INSIDE/OUTSIDE,PAINTKITCHEN/SLUDGEROOM/SLUICEWAYOPERATIONS/CARTMAINTENANCE;

4. ASSEMBLY/QUALITYCONTROL/MAINTENANCE(mobilejobcategories);

5. SHIPPING/LABORATORY

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1.ROLLFORM/POSTLAM,INJECTIONMOLDINGANDASSEMBLYOPERATIONSIntroduction: 1986‐1989: Pebra manufactured metal and plastic body side moldings andurethane body parts for the automotive industry. The major production processes included“rollerforming”andpostlaminatingtoformsidemoldingsforcardoorsthatwerethenshippedtoseveralautomobilecompanies. Italso includedsmall‐scale injectionandextrusionmoldingforsmallautopartsandtrim.

ROLLFORM,POSTLAMANDINJECTIONMOLDOPERATIONS

PRODUCTIONPROCESS CHEMICALEXPOSURERISKS

ROLL FORM/POST LAM, AND INJECTIONMOLDOPERATIONS(1986‐1993):

General Description of Work Processes:Three separate production processes werelocated together in one large open area ordepartment.The twoparallelRoll FormandPost Lam operations together producedmetal automobile side moldings and doorpanels, laminatedorover‐laidwithextrudedstrips of PVC molding and coatings. Thisinvolveda roll‐forming layout thatwasover100feetlong,sixfeetwide,andfivefeettall.Thetworoller formingmachinesshapedthefive inch wide roll of stainless steel sheetmetalintothegeneralshaperequiredforthetrimpartbeingproduced,whichwasthencutinto sheet lengths approximately four feetlong. When the Ford line of products wasadded,partswere largerandpre‐cuttosize,with glue and PVC strips manually pressedontothemetalpiecebyworkersresultingingreater handling/chemical exposure duringtheFordproductrollformingprocess.

Theworker component per shift/per line inthe department included: (non‐Ford) Line:one set‐up, two operators, one stacker, twosaws operators; Ford Line: five press

GeneralChemicalExposureRisks:Thesizeandvolumeof the roll form lineproduction,especially the larger Ford line, generatedsignificantvapors,fumes,andmistsfromthevariouswashing,heating,gluing,coatingandsealingprocesses.

All workers in roll form were exposed to:chemical spray/droplets during wash; gluefumes; PVC fumes. The set up worker wasexposed dermally to glue and degreasingchemicals during fill up. No PPE provided,onlyshopcoatswornbyworkers.Productionworkerswere exposed to heavy fumes fromheated glue and PVC. In Non‐Ford line, gluewas automatically applied and workers’exposures were primarily inhalation anddermallywhenhandlinghotparts.WithFordline, workers manually applied glue at thepresseswith an applicator then pressed thepart with high heat, releasing mists andfumes.

ChemicalExposureRisks: Each of the twolines would produce up to 1000 parts pershift, indicating the high volume of glues,resins, and solvents used in the area. Forexample, each line would utilizeapproximately 5 gallons of glue per shift.

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operators,oneglueset‐upperson.

Adjacent to the two roll form lines was thePost Lamination operation consisting of 12Arbourgs, or small injection mold machines(six per line) that attached PVC covered“plugs” onto the ends of the trim partsproduced by the Roll Form lines. EachArbourgutilized 3 to 4 bags (25kg) of resinper shift. After roll form and fine cutting,parts moved by conveyor belt through PostLam where three Arbourg (small injectionmoldmachines)operatorsonopposite sidesofthelineattachedleftandrightplugstothepart which was then coated in PVC. These“plugs”wereused to attach the trimpart tothecarbody.

After PVC coated plugs were attached,finished pieces were sent to quality controlfor inspection. If a part had small flaws orimperfections it would be sent to the sand,trim,andbuffassemblyareaforrepair,priortopainting,orat timesdirectlytopackagingandshipping.

In the same general area, was a separateInjection Molding operation utilizing fourmid‐sized Injection mold machines. Thisprocess produced small plastic componentsfor a variety of different automobilemodelsand companies. Eachmachine’s hopper wasfilledmanuallybymaterialhandlerorset‐upfrom bags of various resins including PVC,acrylic, polypropylene, styrene, etc. plusotheradditives.

Atthebeginningofashift,moldswerehand

After roll form, parts (with the exception ofFordline)wentthroughanadditionalcuttingandshapingoperationprior tobeingsent topost lam. Inspectorswere locatedat theendandbetweenthetwolines,exposingthemtomistsandgluesfrombothRollFormandPostLamasbystanders.

Chemical Exposure Risks: In the adjacentPost Lam area, twelve Arbourgs (smallinjection mold machines) used largequantities of PVC resins during molding,cleaning,andpurgingoperations, inadditiontolargequantitiesofsolventsincludingMEK,trichloroethylene, acetone, and toluene.TherewasalsosubstantialgluingwithPebra5 (containing perchloroethylene, tri‐chloroethylene, tetrahydrofuran, cad‐mium andMEK) that involved continuallycleaning products with large volumes ofMEK (in big open pails as well as workers’personal containers of the solvent). Thesechemicals were applied at relatively hightemperatures with enhanced vaporizationandincreaseexposurethroughinhalation.

By‐stander Exposure Risks: Inspectors,packers and box builders worked in anassembly area close to Post Lam exposingthemtodustandoff‐gassingaswellasfumesandvaporsfromglue/PVC,asbystanders.

Chemical Exposure Risks: Injection Moldmaterial handler exposed to excessiveamount of dust during filling process withlittle or no exhaust ventilation or PPE.Moldoperatorsandnearbyworkerswereexposedto heavy fumes and vapor from excessiveoverspray and heavy use of toxic cleaners

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cleaned by the mold operator with 201Bcleaner then hand sprayed with RocketReleaseorothermoldreleasebetweenresinshot (every 3 or 4 minutes). The freshlymolded part was trimmed and torched toremove flash and burrs then sent to qualitycontrol. Purging of machines, done severaltimes daily, involved manual loading ofpurging agents and polymers into thehoppers. Purging required highertemperatures creating more intense fumesand smoke as well as hazardousdecompositionproducts.Whensmallregrindmachinewas added,waste plastic (PVC andpolyol) was fed into a grinder, producingheavy fumes and dusts with hazardousingredients.

andotheragentsduringpreparationanduseof molds. Due to high heating of resinduringmoldingprocess, fumesandgasescontaining monomers. Vinyl chloridemonomer (VCM), styrene, acrylonitrile,phthalates, heavy metals, flameretardants and release agentsrepresented a high exposure risk foroperators and those handling newlymoldedparts.Withpurging therewashighrisk of inhalation exposures to resin fumesand vapors containing various chemicalformulations as well as thermaldecomposition products includingacrylonitrile from acrylic resins and strongsolvents such as toluene,MEK, and acetone.Regrind operations created heavyexposures todustandvaporcreatedby thehighheatandbladefrictioncontainingVCM,phthalates,FG,silica,andothertoxins.

1. ROLL FORM PROCESS: The mainlyautomated roll form operation included alayout approximately 100 ft. long and 6 ft.wide. The operation consisted of eightseparate processes including: wash stage(twonozzles,topandbottomusingtapwaterwithdegreasingsolution;blowdrystage(todry parts);heatoven (to preparemetal forgluingatapproximately180Fdegrees);gluestation (felt strip dipped in glueautomatically applied to size and shape ofPVC application); second heat oven (toactivateglue);PVChandfedontothemetalstrip by production worker; PVC pressedinto place (by belts above and below themetal);metalcuttoroughsizebychopsaw.

ForregularRollFormtherewere3workersper shift/per line including: 1) Two Set‐up

The entire roll form area was noted forstrong odours from the glues used inattachingPVC.Manyworkrefusals,especiallyon the Ford line, were due to large sizeproduction, hands on work, and hightemperaturesandbystanderexposures.

Chemical Exposure Risks: Wash anddrying cycle: Set‐up operator was exposedto steam, mist and vapors during the washand drying cycles inmaintaining a constantlevel of degreasing product, includingpossible metal treatments such as anti‐corrosion and anti‐oxidant products, or oilsonthemetalstock.Workersdescribedamistin the surrounding area of the wash cycle.Parts then moved through a hot air blowdrying station to remove moisture, which

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workers to maintain/fill wash station(product additives evaporated quickly andcontinually needed refilling); 2) Productionworker to ensure the rolled sheet metalmovedsmoothlyalongtherollersandtofeedPVContogluedarea;3)Asecondproductionworker to remove and stack parts on skidsacross aisle from saws area (where productwas shaped and fine cut to size). Partshandled at the end of a roll line were veryhot, giving off strong fumes and resulting indermalexposure.

Therollformprocesswasbasicallythesamefor all product lines except the Ford Line,which applied the PVC pieces manuallyrather than mechanically to much largerparts. The part was first masking taped byhand thenheated inanoven.ThePVCpiecewas hand applied, then heated again andhand pressed. The “Ford Line” involvedsubstantially more exposures to thefollowingtoxicchemicals:Pebra5,MEK,PVC,and chemical by‐products from heating andapplication,becauseof the larger sizeddoorpanels, and greater amountof the glueusedcontaining Pebra 5 and MEK. In addition,therewasagreaterdegreeofdirecthandlingduringapplicationofPVCandmanualuseoflarge heated presses. For example, a muchlargerareaoftheFordpartwascoveredwithglue. The swatch of PVC applied wasapproximately 2” wide, covering top andbottom of panels that were approximately48”x24”.Operatorsmanually applieda layerof glue across the large area using a foambrushorrag.

Glue mixing and pouring: The set‐upoperator filled the machine’s glue‐station

createdadditionalaerosolsandmists.

Chemical Exposure Risks: Application ofPebra5/MEKonhotmetalsheets:Theset‐upoperatorwouldover‐see theprocessandwaslikelyexposedtovapourfromthePebra5 coating during the preparatory heating ofthe metal to enhance malleability prior toshapingandapplicationoftheheatedglueonhot metal. This operation was partiallyenclosed and exhausted, but the exhaustsystem was deemed ineffective by an MOLhygienist. Workers also exposed whenaffixing PVC strip. Chemicals:tetrahydrofuran,Perch,TCE,MEK,cadmium.

MOL:891865EAAV10/11/89:workrefusalinFN‐36(FordLine)Twoworkersonthefn‐36 line complained of solvent levels andintoxication. The glue applicator is ventedbut freshly glued parts are stacked on cartswithout ventilation. (See two hygienereportsthatfollow.)

MOL:286154 13/09/89:work refusal FN‐36 (Ford Line): Adverse health effectsexperiencedbyrefusingworker.5USGpailsof glue (A11048) were around the glueapplicator machine and not appropriatelylabelled.GluedilutedwithMEKand toluene.Applicatorwas vented but face velocitywas200fpm. The 5 USG pails used as dippingtankstocleangluestationhead.Pailsdidnothave appropriate ventilation, were notlabelled, and no MSDS. Testing noted withfollowing results: MEK=50ppm;toluene=25ppm; alcohol=not detected.Inspector:notlikelytoendanger.Ordersthatthe dipping pails be located in area with

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applicator with a mixture of Pebra 5 andMEK, which was mixed by paint kitchenoperator in pails, then brought to themachine.

Re: Ford Line: “The partswere four feet inlengthwith large stripsofPVCbeingpresseddownand largeamountsofPebra5andMEKmixusedtocleanpartsresultinginfumesthatwere just terrible.” After the PVC wentthrough the press and was removed byworkeritwasstillhotandwouldoftenburnworkers.“Oftenyou’dhaveastickymessthatwas still smoldering and it always smelledterrible.” (There were 6 of these “presses”associatedwith theFord line.) Committeemember

During the Ford line era people werecontinually going to local hospital withheadaches,nose‐bleedsandblackouts. Onecommittee member described how workerswould have blackouts and not know howtheygothome.

GlueStationCleaning: Uponcompletionofthe roller forming/laminating process thegluestationsthatheldthePebra5/MEKwerepurged with MEK and put in open pails ofMEK overnight. Also likely that methylenechloridewasused.At the next shift prior tostart up, the glue stationswere cleaned andwiped down to get the MEK off the stationparts.Duringthiscleaningoperationtheset‐up operator would be highly exposed toPebra 5 ingredients and MEK. Set‐upoperatorsworelabcoatsandcottongloves.

adequate ventilation and bonding, properlylabelled,andrespiratorsworn.

Chemical Exposure Risks: During gluemixing procedure, production workersinhaled vapors aswell as absorbed solventsthrough skin contact while carrying andpouringthegluemixtureandinhandlingandmovinghot pieces coming off the presses atthe end of the line. Large amounts of gluewere used andworkerswereprovidedwithcottongloves, labcoats, and “dust”masksatbest.OftennoPPEwasusedbyworkersandglovesdeterioratedquickly.

MOL:28831609/05/90:WCBclaiminFordLine: The WCB requested MOL investigateworker’s illness caused by exposure tosolventvaporsintheFN‐36areawhensludgeroom exhaust fan not operating. This fan isassociated with the cooling equipment, alsoproviding a negative air pressureenvironment that prevents chemical vaporsfrom solvents and paints from migrating tothe general work area including the FN‐36area. Itwasnotedbyinspectorthatfanwasnot operating and vaporsweremigrating atthe time of visit. This has been an ongoingproblem that had led to many episodes ofadverse health effects, complaints, workrefusals and MOL investigations. Citingprevious solvent exposuremeasurements inbothFN‐36andsludgeroomareas,hygienistconcludes:“Solventvapor,whilepresent,areat levels such thatworker exposurewill notexceedexposurelimits.” Noteststoconfirmthisconclusionwereindicatedinthereport.

Chemical Exposure Risks: MOL: 292916

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03/10/89: hygiene report Ford glue linerefusal: MEK=50ppm; toluene=25ppm;ethanol=<10ppm. Hygienist indicates thatthese levels may not be representative of afull shift exposure given the brief (10‐15minutes) operating time of the line. Notesalsothat5USGpailofMEKwillhavemadeasignificant contribution to the solventconcentrations. Indicates that it is advisablethat control measures be implemented tolimit solvent exposures on the F‐36 line.AUTHORS’ COMMENT: It is important tonote that as a rule of thumb aconcentrationof¼ of theTLV shouldbetaken as a significant exposure.Hygienistrecommendsinstallationofaheatedflash‐offtunnel with local exhaust ventilation tocontrolvapourconcentrationsandemissions.Also recommends installing drip tray underthe applicator to contain and preventaccumulation of glue drips and spills thatwould vaporize and release into theatmosphere.Thislineuses15USGofdilutedglueper8‐hourshift.Thelineruns24hoursaday,5daysaweek.Oneworkerfeedsmetalstrips into the glue applicator and a secondstacks the glued strips. A vinyl strip is thenbondedtothemetal.

H&S log: 11/05/90: work refusal in PostLam area (glue line/paint kitchen glue spillFN36 approximately 2‐3 USG near sludgeroom.Workersadverselyaffected).

MOL: 228249 20/06/90: FN‐36 refusals:Workers experiencing health problems onthe FN‐36 glue line. Fumes from the paintkitchenandsluiceway.No log forchanges inchemicalconcentrationsingluingoperations.High levels of fumes and smoke during

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purging of the injection molding machinese.g., Arbourgs and Engels. MSDS for resinpellets,useof201B(n‐methyl‐2‐pyrrolidone,ethylglycol,monobutylether).

SawsProcesses inRollForm: 1. FineCut:After “rough cutting” of part at end of RollForm Line, a second, “fine cutting” to shapewas done by two operators at the SawsStation. Precision angle cuts were madeaccording to product specifications then thefinished part was placed on conveyor andsent on to Post Lam. Operators continuallyusedpressurized air guns to clean theworkarea. 2. Sharpening and Shampering: Therewas a second Saws areawhere blades fromthe cutting operation on the two Roll FormLines continually required sharpening and“shampering” (buffing). Thisworkwasdoneby two operators per shift, one whosharpened and one who shampered. Thesharpeningoperatorwouldplaceasawbladeon theirmachine thensharpenedeach toothindividually using a grinding stone. A largemagnifying glass was used to ensure theblade was set at exactly the right angle. Ahandcrankheldthebladeinplace,whiletheoperatoractivatedthegrindwheel.Asecondoperatorthenbuffedthesharpenedbladetoremove burrs or other imperfections thatcouldinterferewithcutting.

Chemical ExposureRisks: Saws: Fine cutoperators were exposed to metal workingfluids, and finemetal and plastic particulatefrom cutting through plastic covered metal.The sawing operation wasmainly a dry cutoperation, which produces very fine dustwith little in the way of dust suppression.Other than dust masks, no PPE was everused.Useofcompressedairgunsaggravatedexposurerisktoinhalationandingestion.

The sawing of stainless steel sheets treatedwith Pebra 5 glue and PVC strip producedveryfineparticulatecontainingchromium6,aswellasresiduesofglueandPVCdustandfumesduringthesawingoperation.

SharpeningandShamperingsawoperatorswerelikelyexposedto:gritfromthestone;heavymetal (possibly carbide) from theblade; and droplets from themetalworking fluids (MWF). The likelyroute of entry involved absorption throughtheskin,ingestionofparticulatesfromMWF,metalsandgritincombination.Inhalationisalso likely, butparticle size fromgrinding isusually greater and more likely ingested.Possible chemicals include: nitrosamines,heavymetals,biocides,PAHs.

2. POST LAMINATING PROCESS: After roll General Chemical Exposure Risks: The

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form and fine cut, parts were notched at asmall station to make holes for clips, thenrestackedonaskidandsentontoPostLamwhere there were 12 small injection moldmachines calledArbourgs.Therewere threeworkers per shift, per line plus the set‐upperson who manually filled all the Arbourghoppers with PVC from a large bag (25 kg)containing small pellets, sending up a cloudof “greasy” PVC dust. Each of the two RollFormLines,wasservicedbysixArbourgs(atotal of 12 in the post lam operations withthreemachineslocatedoneachsideofaline(sixperside).Oneworkerattached theplugon the left side of the part and a secondworkerattachedtherightplug).Theinjectionmolding operation used approximately twotothreelargebagsofPVCpelletsforeachofthetwelveArbourgspershift.

Themoldertookanyburrsoffwithamortarknife,putPebra5onwithgluestickthenputa plug in at either end of the part andclamped it into the Arbourg machine. Theoperator then pressed a button and themachine heated and sealed the end parts.Downthe lineaproduction inspector (3pershift) would take parts off the line, trim offexcess plastic, wipe them off with MEK orPebrathensetthemasideforpackerwhoputthem in boxes, sealed them with tape, thenputtheboxesonaskidforshipping.

Each Arbourg line (six machines) wouldproduce approximately 1000 parts per shiftutilizing approximately 3 to 4 bags of resinper machine, per shift, to coat the injectedparts.Afterplugswereattachedandcleanedtheyweresentontoinspectionandmaybetoa final trim and cleaning with MEK before

manual operation of opening bags of pelletsduring the drying process and pouring intohoppersexposedbothmaterialhandlersandnearbyworkerstoPVCdusts.Further,vinylchloride, formaldehyde and otherchemical vapors were likely during theheating andmeltingprocess as well as atthe point of extrusion. There was theadditional risk of chemical exposures tothermal decomposition by‐products fromheating and over‐heating the combustion ofPVCandcomponentsincludingvinylchloridemonomer. Given the flexibility and rubberytexture, it is highly likely that plasticizerswere in the PVC formulations, which likelyincludedphthalatessuchasDEHPaswellaslead in some formulation. This family ofchemicals is suspectedofbeingcarcinogenicand acts as an endocrine disruptor bymimicking estrogen, a known tumourpromoter.

ChemicalExposureRisk:Workerswouldbeexposed to resin dustswhen opening bagsor drums containing pellets. Exposure toresin dust would also occur during pouringor scooping pellets from containers. Resindust exposure would also occur whenpouring pellets into moldmachine hoppers.Exposure would take place throughinhalation of dusts. This would also occurthrough ingestion and skin absorption.Workers reported that they would find alayerofresindustundertheirbreast,armpitsandingroinareawhenshoweringafterwork.Otherthandustmasksandcottongloves,noPPEwasworn.

Pebra 5was classified by the company as atrade secret and only two ingredients are

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going on to final inspection. Initially at theplant, defective parts were disposed of andnotreground.

Committeemembersdescribe thisoperationas: “extremely hot and smelly with fumessmellingofburntplasticandsolvents,andyouwould leaveworkwitha sore throatand redeyes.”

listed in the MSDS – perchloroethylene andtetrahydrofuran, but cadmium is suspected.The local union leadershipwas advised thatthe Pebra 5 used in the Peterborough plantalsocontainedthemetalcadmium(Seeletterfrom RoseWickman in Appendix D) formerpresidentofUniforlocal1987).

On at least two occasions, a MOLindustrialhygienistnoted that “...Thelocalexhaustventilationattheglueapplicationandglueheatingstationsonthepostlaminaterollforming lines isnoteffective. Itwasobservedthatdrafts interferewiththecaptureattheseareas”. (see MOL report: 89D888EAAV‐15/05/89,findingsduringforty‐fourworkrefusalsinvestigation;andMOLhygienist,Kim Gordon, report dated: 31/10/88).Theseworkrefusalsonthepostlaminvolvedadverse health effects including headaches,light‐headedness,burningeyes, sore throats.(MEK,butylacetate,acetoneaswellasPebra5weresuspectedaspossiblecausesoftheseadversereactions).

MOL: 90E865EAAV 18/05/90: workrefusal glue A‐1104B: butyl alcohol,toluene, MEK, methyl methacrylate,acrylicco‐polymer,ethylacetate,ethanol,isopropyl alcohol, formaldehyde. Hygieneassessmentadverseeffectsfromexposuretogluespillof3to4USGofA‐1104Blocated15ft.westofthegluelineareaonMay10,1990.On May 11, ten workers refused to workbecause of vapors that caused adversephysical effects. Consultant noted severalpreviousworkrefusalsforthesamereasons.See previous investigations in response totheseearlierrefusals.Notealsothatpreviousreports include hygienist recommendations

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to enhance ventilation and create ventilatedflash‐off area to reduce exposure. Chemicalsof concern: MEK, toluene, ethyl acetate,isopropylalcohol,butylalcohol.Ethylacetatelevelsat25‐50ppm.Notedalsowasthedripsand accumulation of glue on the table andfloor underneath the gluing machine. Needforpreventivemaintenance (PM) to addressleaksanddripsnoted.

H&S log: Jan 27, 1994: re: air make‐upshut down/refusal in assembly. “Whenworkers sought (supervisor) to informhimoftheir refusal because of feeling ill theyweretold to wait because we’re in a meeting.(Workers’ response:) Fine, we will call theministry. Then all the supervisors startedcoming to the cafeteria. Our question: Howcome the (airmake‐up) charcoal filterswerereplaced with dust filters? Any (i.e., No)amount of money or training will changethingshere.”

MOL: 060290V3 10/01/90: refusal afterfire in Fn‐36: After a fire occurred onmolding machine #6 in FN‐36 line, 37workers refused to return to work becausethey were not trained on what properprocedurestocarryouttoensuretheirsafetyin theeventof a fire. Inspector issuedorderfor employer to train workers in the plantfire plan and what precautions to take.Inspector noted that workers had neverreceivedinstructionsandtrainingonthefireplan.

Re: MOL visits in response to workrefusals in FordLine: Advisory Committeefelt that the company was advised prior to

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MOL visits: “If you remember, the companyalways knew when they were coming. Nowelding,don’tdoanythingtillthey’regone.It’sfunny, we can’t open up the doors (forventilation) because itwill cause dust in thepaint line but we can open the doors whenthere’sapurgeteamorMinistryofLabour.Sohowisthisworking?”

H&S log: 02/05/94: work refusalassembly line inPost Lamarea over strongoilyodours.

Glue Line Operations in Post Lam: Therewere 8 separate glue lines locatedthroughout the area (generally in eachcorner, although they often moved fromplace to place). Glue was used to attachmylar, PVC or othermaterial, but also “gluelines” could refer to other applications suchas Adpro (as a protective primer) on rawmetal products. Contains: cyclohexane,xylene,ethylbenzene,ethylalcohol, toluene,carbonblack,chloroform.

Each line consisted of amoving carousel onwhich parts were hung and either sprayedmanually with a pressurized hand gun, orsent through a mechanical spray machinethatappliedtheglueautomatically.Theglueproduct was contained in a sealed pressurepot,mixed,andsetupinthePaintKitchen,bythepaintkitchenoperator.Therewererisksassociated with the pressure containersrequiring the attention of a paint kitchenoperator. Following spraying, parts weresentthroughacuringoven,thentakenofftheline and stackedon skids, or inboxes, if the

Chemical Exposure Risks: The gluespraying of large fenders was described as“beingdonecompletely intheopen”,nexttoinjection molding. There was no localexhaust ventilation and the operationposeda significant riskof inhalationandabsorption of glue ingredients. The gluepressurepotscouldcontainPebra5orAdproAdhesion Promoter plus other ingredientsthatmight include:methyl Isobutyl, toluene,n‐butyl acetate, alkyd resin, nitrocellulose,ethyl alcohol, phosphoric acid, xylene,Isopropyl alcohol as well as Pebra 5containing perchloroethylene, tetra‐hydrofuran and possibly cadmium (SeeLetter from Rose Wickman in AppendixD.NoPPEwaswornotherthandustmasksandcottongloves.

MOLHyg.Report31/10/88(KimGordon):Post Lam hot gluing operation inadequateexhaustventilation.

Chemical Exposure Risk: Post Lam glue

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partswerefenders.

Glue Lines in the Post Lam area weresupplied with glues mixed in the PaintKitchenbythePaintKitchenoperator.Thesecould be either Pebra 5 (tetrahydrofuran,perchloroethylene, TCE, cadmium orAdhesion Promoter from 3M(cyclohexane, methyl alcohol, xylene,ethyl benzene acrylate, chlorobenzene,furandione,ethylalcohol).

Glues were contained in a pressure potequippedwithaspraywandthatworkersused to spray glue on the parts. Therewasagreatdealofover‐sprayandtheuseofMEK to cleanhands andparts. Theseweresuppliedateachworkstation.

Glue operations were prevalentthroughout the plant as the vapors andfumespermeatedtheairintheplant.

lines: Glue line operator would incursubstantialexposuresfromsprayingthegluemistsandvaporizationofthegluecontainingMEK.Exposurewaslikelythroughinhalationaswellasdermalabsorptionthroughcontact.MEKsolventwouldlikelydefattheprotectivebarrier of the skin leading to greater risk ofabsorptionandskinirritation.

The glue consisted of a mixture of Pebra 5and MEK prepared in the “paint kitchen.”Since this was carried out manually, it ishighly likely that set‐uppersonnelwouldbesignificantly exposed to the MEK and theingredients in Pebra 5. All adjacentoperations would be exposed to the vaporsfrom the glue application as well as vaporsfromthecuringovens.

NOTE:Intotal,therewereeightgluelinesinRoll Form/Post Lam, similar to thatdescribed above. These included: two inAssembly; two in Roll Form; two with theFordLinepresses;andtwoinPostLam.Thisgenerated a substantial amount of Pebra 5,Adpro, 1104B, etc. chemical vapour in eachwork area as well as adjacent areas.According to informantdescriptionsPebra5was used universally in almost every workprocess and “MEK was used everywhere tosoakpartswithworkersuptotheirelbows initwhencleaningparts.”MEKwassupplied inpumppailstonearlyallworklocationsintheplant.Thiswasusedtocleanparts,aswellasused by workers to routinely clean theirhandsofglueresidue.Itwastypicalformostworkerstohavetheirown“cupfull”ofMEKatworkstations tocleanbothhandsandparts.Theotherglueregularlyusedongluelines was Adpro Adhesion Promoter (see

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opposite column and Appendix E foringredients)

H&S log: July 20, 1990: fumes refusal:“(namesworker)andIwentdowntoglueline.The glue line had a large fan which wasblowingairtowardthetouchuparea.Thefanwasmoved so it wouldn’t be blowing fumestowardsthetouchuparea.”

MOL: 89D888EAAV 15/05/89: workrefusals inPostLam:An investigationof44work refusals in the post lam area due tochemical exposures causing adversesymptoms: headaches, dizziness, eyes, noseand throat irritation andnausea. Hygienistfindings include: inadequate exhaustventilation in the hot glue area of rollform; internal paint line vapors blowinginto the general work area; RIMIsocyanatecontrolprogramdeficientwithrespect to coverage of all workersexposed and inadequate ventilation;failure to comply with confined spaceentry regulations and eye washrequirementsinthesludgeroom.Seealsoreport #288596 reprisal investigationagainsttherefusingworkers.

PVC purging in Post Lam: As with allinjection molding machines, the Arbourgswere purged regularly during maintenanceand at the beginning and end of each shift.(production was 24/7 with two shifts) Thiswas performed by set‐up worker usingvarious purging agents, e.g. Rapid Purge orVentra Purge. These contained a combinedmix of strong solvent and polyol under

Chemical Exposure Risks: PVC purgingoperation:At the start and endof each shiftthe extruding machine was purged with“Rapid Purge” or possibly MEK or othersolventaswellasanacrylicbasedpolyolefintocomplete thepurge. Thepurgedmaterialwouldbeextrudedinapileontothefloorandleftsmoldering. Thisprocessproducedverystrong fumes and smoke containing

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extremely high heat to aid the flow and toburn‐off residues of polyol and additivesused in the previous run. An inspectionreport indicated that these machines werepurgedwith an acrylic resin (MOLhygienistKimGordon,31/10/88).

numerous pyrolysis by‐products andcompoundsknowntobecarcinogenicandendocrine disruptors including benzene,formaldehyde,heavymetals,acrylonitrileand a variety of PAHs. This would alsooccurwhentherewasacolourchange.

Chemical Exposure Risk is high since thepurging operation required cleaning of themolds with solvents and using compressedair toblowoff residueswithdirt anddebrisaddingtotheburdenoftoxicexposures.

Chemical Exposure Risks: high risk ofinhalation of fine plastics particulate, fumesandsmokecontainingVCM,ABS, in additiontoadditivesduringpurging.

Regrind of PVC/Polyol in Post Lam: Thefirstsmallregrindmachine in theplantwas,for a short time, located in theNorthendoftheRollForm/PostLamarea,nearthe4mid‐sized(200‐300ton)injectionmoldmachines.Damaged or defective molded plastic partsweresentthereforregrinding. Thisprocesswasnotadequatelyventilatedandproducedlarge quantities of fine plastic particulate aswell as fumes and vapors from the hightemperatures generated during the grindingprocess. This was the subject of manycomplaints as well as MOL investigations.Frequently, the exhaust system on thegrinding station would be clogged andrendered ineffective. The ground productwas very hot and could not be touched (itwas reportedby inspectors to be stillwarmtothetouchthefollowingday)anditcreateda great deal of fumes and dust in the

Chemical Exposure Risk: Grindingoperationsinhalationofhighconcentrationof fine particulate and fumes containingresidues of various thermoplastics moldingoperations.Monomers,additives,phthalates,stabilizers, flame retardants, etc. SeeAppendixCfor informationonhazardousingredientsinresinproducts.

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atmosphere as well as being layered onsurfaces and in workers’ clothing, includingunderwear.

3. INJECTION MOLDING OPERATIONS:Injection molding operations for productionofsmallautoparts initiallyconsistedof foursmall(300‐400ton)injectionmoldmachines.This operation involvedmanual feeding anddrying of pellets containing polyolsconsisting of PVC and a number of otheradditives. This molding operation wassituatedacrossfromtheRollerForming/PostLamprocesses.

Initially, molding tasks were carried outmanually. Pelletswerecontainedincartons,bags, or barrels and carried and opened bythe material handler/production worker.Pelletswerescoopedorpouredintopailsandmanually poured into hopper/dryers toremove any moisture. When dried, pelletswerepoured intomoldingmachinehoppers.The thermoplastic injectingmoldingprocessinvolvedheatingtheresinsintoaliquidstateat high temperatures then forcing the resininto the internal chamber with areciprocating screw, pressuring this actionvia injectors into the enclosed mold. Thesteamandvapourwouldbe exhausted fromvents built into the mold. The operatorwould remove the part when sufficientlycooled. Depending on specifications andtypes of parts required by a client firm, thepolymer formulations could varyconsiderably. These could include: PVC,polypropylene, polyethylene, and polycar‐bonateswith Bisphenol‐A, among others. Itcould also include other additives including:monomers, phthalates, heavy metals, flame

Injection Molding: Chemical ExposureRisks: Set‐up personnel were exposed toresin dust while manually handling resinpellets or powders. Exposure would likelyinvolve inhalation, ingestion and absorptionof chemicals through the skin. Exposure toResin Fumes/gases was highly likely. Theprocess of heating resins to hightemperatures under heavy pressure wouldrelease substantial vapors and gases frommoldventsduringnormaloperations;furtherexposures would continue when openingmolds to retrieve hot parts, as well ashandling parts released from molds. Alongwith malfunctions leading to fires, theseeventswouldleadtothereleaseofnumerousthermal decomposition by‐products. Thesevaporsandgaseswouldcontainanumberofchemical compounds including residues ofmonomers e.g., vinyl chloride, styrene,acrylonitrile, brominated or chlorinatedflame retardants, anti‐oxidizing agents,phthalates, formaldehyde, benzene, heavymetals from pigments and a broad range ofhydrocarbons. (see literature review inAppendix A re: PVC decompositionproducts).

Chemical Exposure Risks: Much higherexposures occur during purging operationswith purging compounds such as “RapidPurge” in preparation for colour and polyoltype changes, which involved raising thetemperature significantly to assist thepurging process. Along with malfunctionsleadingtofires,theseeventsledtoreleaseof

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retardants, BPA, stabilizers, catalysts,initiators, cross linking agents, fillers,extenders,andmoldreleaseagents.

numerous thermal decomposition by‐products. These vapors and gases wouldcontain a number of chemical compoundsincluding residues of monomers (e.g. vinylchloride, styrene, acrylonitrile), brominatedor chlorinated flame retardants, anti‐oxidising agents, phthalates, formaldehyde,benzene,heavymetals frompigments,andabroadrangeofhydrocarbons.

Note: It is importanttonotethat incontrasttoresinproduction,which typicallyemploysclosed‐looped containment systems keepingexposures and handling to a minimum,molding and fabricating are relatively opensystemsinvolvingdirecthandling.

MOL: 90F865EAAV 04/07/90: hygienereport. Cleaner201B/resin fumesInjection Molding: Workers complainedabout smoke and fumes that were intenseduring the purging operation. Injectionmolding uses PVC, acrylic and polystyreneresinsalthoughthelattertwoarenotusedasmuch. Hygienist notes that during thepurging process various thermaldecomposition by‐products are generatedand that the seven molding machines werenot locally ventilated. Purging started at thebeginningofeachshift aswellasduring thedaywhen necessary. Inspector recommendslocal exhaust ventilation. Testing forhydrogen chloride gas (HCL) was notdetectable near the barrel vent. Nomeasurements taken by the purge wastedroppedonthefloorhowever.

H&S log: 26/06/90: work refusals (9)while working on injection molder. Fumes,

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smoke coming out the 1500‐ton resin pelletdryer.Refusal of assemblyworkers affected,workinginoutsidepaint.

H&S log: 27/01/94: work refusal overcontaminated air in assembly area frominjection molding because the maintenancefailedtoinsertapropercharcoalfilterintheexhaustoftheunit.

MOL: 93EO35EAAW 03/05/93 Hygienistreport re: 13work refusals odour/healthcomplaints: “Itwasnotedduringvisit thatthe company’s detector tube pump had aslight leak.Correctiveactioninthisregardisappropriate. Workers expressed concernedover vapors coming from sludge room.Effluent from a temporary holding tankwasdraining over a mesh basket containingbromicidedisinfectantpucks.Theeffluentwassplashing in the nearbywork area. Repeatedcontactmaycauseskinproblems.”

NOTE:Thevariousmonomersandadditivesdo not permanently bond to the plastic andare released either through vaporization orleaching. The normal injection moldingprocess, involving high temperatures andhigh pressure promotes the release of suchagentsintotheatmosphere.

H&S log: 23/11/94: work refusal (8)fumesfromresinpelletdryerat1500tonmold. Clogged filters in ventilation system.Workers experienced adverse healthsymptoms – headaches, irritated eyes, nose

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andthroat,nausea.Signsofoverexposure.

H&S log: 27/10/94: work refusal (8)workers: strong fumes in assembly areafrom injection molding operations.Imbalanceininjectionmoldingcausedplasticand solvent vapors to flow into the fasciaassembly area.Workers experiencing strongodour,irritatedeyes,noseandthroat.

PurgingOperations in InjectionMolding:Injection molding machines were purged,cleaned andmaintained daily usually at thebeginning and end of a shift. This wouldinvolve manual application of purgingcompounds such as “Ventra Purge” and“RapidPurge”, aswell as solvents including:Trichloroethylene, MEK, Perchloroethyleneandtoluene.

The purging operation involved very hightemperatures (far beyond the normalprocessing temperatures) in addition topouringpurgingagents,polyols,andsolventsinto the machine then forcing the mixthroughtheinjectors,usuallyontothefloorsin a smoldering heap – with strong vaporsandsmokecomingoffthewasteproduct.

High temperatures and the presence ofsolventsandresinswouldattimesleadtothecombustion and the release of combustionby‐products including Polycyclic AromaticHydrocarbons (PAHs), monomers, additivesincludingheavymetals, phthalates, benzene,and formaldehyde. According to workers,events involving combustion during normal

Chemical Exposure Risk: Workers reportthe purge result as “a hot stinky gunk thatwould sit there and smoke and off‐gas andchoke you.” The purged material would beextruded in a pile onto the floor and leftsmoldering. This process produced verystrong fumes and smoke containingnumerous thermal decomposition by‐products/compounds known to be bothcarcinogenic and endocrine disruptorsincluding benzene, formaldehyde, heavymetals andPAHs. Aswell, thiswouldoccurin the event of a change of colour. Purgingalsoinvolvedcleaningthemoldwithsolventsandusingcompressedairtoblowoffresiduedirt,anddebris.

90E865EAAV 06/19/90: Adverse EffectsPurging: Hygiene visit over adverse healtheffects from purging in injection moldingusingPVC,polyethylene,cyclicamide.Strongfumesandsmokeduringpurginganduseofmold cleaner 201B. Thermal decompositionby products. Molding machines not vented.Discussion also regarding high level ofMOLinterventions regarding repeated workrefusalsontheFN‐36gluinglineandworkersbeinghospitalizedonmanyoccasions.MSDS

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operation and purgingwould occur approx‐imatelyninetimesamonth.

used in this investigation only had anincomplete document for 201B and noingredients listed and no MSDS for cyclicamide.MOLhygienistnotedthelackoflocalexhaust controls and hazardous exposuresrecommending the MOL Industrial Healthand Safety Program issue an order to theemployer to provide effective local exhaustventilation,preventivemaintenance,andsafeworkpractices.

H&S log: 12/01/94: refusal in injectionmold:workers(2)refusalfrommoldreleaseagent, possibly Rocket Release. No exhaustventilation in place on molding units.Chemicals aswell as fork‐lift exhaust fumes.Workers experiencing irritated eyes, noseandthroat,dizziness,headaches.

MOL 95I235EOAR 06/11/95 Hygienereport: reE702rocket release (etherblend,dichlorofluoroethane, dimethyl ether): usedwith thermoplastic polyurethane machine:150‐300 applications per shift. “There isvisibleoversprayand isseenasmistattopofinjection molding enclosure. According toMSDS contains a halogenated hydro‐carbon/ether blend. INFORMATIONSUBSEQUENTLY OBTAINED FROM SUPPLIER(not on MSDS) indicates this blend containsdichlorofluoroethananddimethyletherwhichhave suggested workplace environmentalexposure levels (WEELS) of 500 ppm and1000ppm respectively. No exposure limitsestablished in Ontario for these materials.BasedonautomatednatureoftheIMprocess,the distance of workers from source, andavailableinformationonproduct,itisunlikelythatworkersareexposedtoeitherinexcessofsuggested exposure limits. However, the

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provisionofupgraded controlswouldhelp toreduce overspray and minimize productwastage.” (AUTHORS’ COMMENT: Ignoredworkersymptomsandhealtheffects)

RegrindingofPolyolandTPUinInjectionMolding: Damaged or defective moldedplastic parts were reground. The operatorhand‐fed thedamagedpolymer into a large‐bladedgrinder.

The re‐ground polymer was captured in a4’x4’ Gaylord. This process produced largequantities of dust and particulate; themachinewasnotwell‐ventilatedandsubjectto frequent malfunction. In addition toparticulate,theheatgeneratedbythegrinderproduced fumes, smoke, and vapour. Thedust from the grinding operation wasbroadcast to a large area, exposingbystanders.

The Nelmor Model 1012RGII, a portable,electrically powered grinder, was used togrinddefectiveplasticparts‐‐typically1376and 1103 TPU. It was situated in theinjectionmolding area along the northwall.The operator manually fed defective partsinto the loading chute as the parts wereground by rotating blades. The groundplasticwasgravityfedtoanenclosedhopperandtheoperatordumpedthehopperintoanadjacentGaylordbin. Lacking local exhaust,visible signs of fumes and dust beingproduced, were noted by MOL inspectors.(Reportnumber93E326EAAV18/05/93)

ChemicalExposureRisks:Regrindofpolyoland TPU constituted a major source ofexposure to PVC and likely VCM as well aspyrolysis by‐products and compounds.Operators would complain that when theyblew their noses, therewas a large quantityof particulate in the mucus and they wouldfind particulate in the groin areawhen theyshowered.

Chemical Exposure Risks: The regrindprocess was inadequately ventilated, andproduced large quantities of fine plasticparticulateaswellasfumesandvaporsfromhigh temperatures generated during thegrinding process. This was the subject ofmany complaints as well as MOLinvestigations. Frequently, the exhaustsystem on the grinding station would beclogged and rendered ineffective. Workersreported that groundmaterialwas very hotandcouldnotbetouchedordisposedofandthere were “‘lots of’ fumes and dust in theatmosphere and layered on nearby surfaces.”This would constitute a major source ofexposuretomonomersandadditivesaswellas decomposition by‐products andcompounds.

93E326EAAW 18/05/93: Hygienistreport: 4 employees refuse work due tohealth concerns associated with regrindingmachineandvaporsemitted…”Workersmay

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Asproductionexpanded,resultingin24/7operations, the re‐grinderwas employedextensivelyforthreeentireshifts.Becauseof the heat generated, awide variety of air‐borne organic vapors and dusts weregenerated. Indeed, an MOL hygienist notedthatduringhisinspection“….thebladesandresidualgroundplasticmaterialwithinthehousingwasstillwarmtothetouchduringthisvisitfromusethepreviousday.”

Informationobtainedfromthemanufacturerindicates that the major known volatilesreleased during heating (550F) of the 1376resin may include CO2, water,tetrahydrofuran and styrene. Otheremissionsmaybereleasedduringheatingoftheresins.TheMOLhygienistnotedthatthegrinding process, lacking effective exposurecontrols, produced and causeddispersionofemissions to adjacent working areas whereworkers were present, and likely to beexposed.

A 1500 pound TPU dryer was employed toextract moisture from the urethane pelletspriortothermalprocessing.Hotaircurrentswould cause vapors anddust tobe releasedduring the drying cycle. These were notproperlyvented.

be exposed to these emissions undercurrent circumstances due to a lack ofeffective controls.Upgraded controls (e.g.,local exhaust) are considered reasonableand appropriate. Dispersion of airbornecontaminants produced during use of theregrindingmachineintotheadjacentworkareas is likely under currentcircumstances. Information frommanufacturer indicates volatiles releasedduring heating (550F) of the 1376 resinmay include: carbon dioxide, water,tetrahydrofuran and styrene. Otheremissionsmay be released during heating ofthe resin…” Also: 442406 18/05/93: NIOSHcertified dust respirator shall be used byworkers handling or transferring ground upTPU.

93D501EAAV14/04/93:workrefusals(5)re: TPU drying: Local exhaust system fordrying barrel was not locally exhausted ondayofrefusal.

MOL:449334reportonworkrefusal(duetoodours fromTPUdryer)19/03/93: Attimeofvisit,managementindicatedthatonlyaboutonemorehourofTPUproductionwasneededtocompletetheproductionrun.AfterthatitwasnotexpectedtheywouldbedoingaTPUrunforabouttwoweeks.Itwasagreedtherefusingworkerswillnothavetoworkinthe area until the extra hour of productionruniscompleted.

Trim Operation in Injection Molding:After the molded part was released andinspected, it was taken to the trim table

Trimming: Products were trimmed of flashafter being molded using a hand knife.Workersreportedsignificantbuildupofdust

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whereoperatorswouldtrimanyflashwithaknife;thepartwouldthenbeinspected,thenpacked,andsenttoshipping.

anddebrisontablesandfloorarea.

These were not adequately ventilated andinspectoradvisedmanagement thatworkerswere suffering obstructed lung function.Ventilationwasrestrictedbyfeltcoveringontabletoprotectproductswhichalloweddustbuildupanditsmigrationelsewhere.

Injection Thermal‐plastic Molding (Post2000):WiththephasingoutofR‐RIMinthelate 1990s and early 2000s, large scaleinjectionmoldingessentiallyreplacedR‐RIMfor the production of larger parts in greatervolumes. Gradually larger and largerinjection molding machines have beenintroduced to produce large plastic parts.These machines range in size from 3000 to5000tonunits.

Currently, the injectionmolding departmentcomprises a larger area of the plant and islocated in a new addition in the south endwith 17 large injection molding machines.Theseareslightlymoreautomated,requiringless manual handling. However, given thesizeofpartsandvolumeofproduction,thereis a very much larger volume of resins,additives, mold releases, cleaners andpurging agents used in production and agreater likelihoodof substantial exposure tothemoldoperatorsandmaterialhandlers,aswell as exposures to workers in otherdepartments.

Chemical Exposure Risks (Post 2000):Operators spray the large mold withsubstantial amounts of mold release agentusing individual cans of spray (rather thanpressurizedsprayguns).Themistandvaporwould broadcast far beyond the mold itselfandimpactaworkerretrievingpartsastheycome off themold. The surface area is verylarge, producing vapors composedofmoldrelease ingredients in “Rocket Release”(ether blend, dichlorofluoroethane,dimethyl‐ether) and paintable moldrelease (TCE, perch., formaldehyde,methyl dodecyl, phosgene). With theintroduction of increasing numbers of farlarger mold machines and production oflarger parts, the production of plasticcontaminantshavebecomefargreater.

Chemical Exposure Risk when retrievingthe finished part also entails a risk ofexposuretochemicalresidueswhenthemoldopens and the part is handled for furtherprocessing.

ChemicalExposureRisk:Torching‐‐Aspartof the trimming process with thermoplasticparts,wasuseofpropanetorchestoburnoff

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Purging operations have now beenautomatedsomewhat,butfumesandsmokegenerateddoremainthesame.

and smooth excess flash. This processproducedsubstantialthermalcombustionby‐products such as formaldehyde, benzene,vinyl chloride, acrylonitrile, propylene,phthalates, HCL, CO2, CO. These emissionscould be considerable given the size of thepartsatbetweenthreeandfivefeetinlength.This would also include propane gasemissions and carbon monoxide. Thetorchingofexcessflashwouldbecarriedoutevery80secondssteadilyforan8hourshiftby two to three workers without exhaustventilation and adequate respiratoryprotection.

Chemical Exposure Risks: Purgingoperations produce very strong fumes,vapors, and smoke. These include moldrelease,purgingagentchemicals,monomers,additives, and thermal decomposition by‐products from running at the very hightemperatures required as well as risk ofcombustion.

The other exposure risk is from leakage ofhydraulic fluids used to open and closemolds. This leakage is fairly substantial andthesearesuspectedcarcinogens.

Vacuum Hopper System: The newermachines are equipped with a “VacuumHopperSystem”whichtransfersresinpelletsofthermoplasticolefin(TPO)orTPUintotheinjection machines’ hoppers from 6 largesilos located outside the south end of theplant. Aside from this transfer system, thethermoplastic production processes areessentiallythesameasdescribedinthecase

Chemical Exposure Risks: The vacuumhopper system generates heavy particulateasaresultofthehigh‐speedmovementofthepelletswhichproduceslargeamountsofdustdue to collisionof thepellets in the vacuumtube.Thebuild‐upofdustrequiresthattubesbe cleaned and maintained leading toconsiderable release of resin dusts.Maintenance and trouble‐shooting these

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ofsmallerunitsdescribedabove. largeinjectionmoldsrequirestheoperatortochangescreensandfiltersontheunits,andtoclean out the build‐up of resin dustscontaining the pellets various formulationsandadditives.

TPUdrying system: A dryer system is setuptoremovemoisturefromtheTPUpellets.They are pneumatically transferred to thedrying barrel about three feet in diameterandfivefeetinheight.Theelectricallyheatedair at temperatures of 200‐220F isintroducedatthebottomofthebarrelwhichislocallyexhaustedoutside.Thedriedpelletsare transferred to themoldunitwhere theyareheatedto400‐430Fchangingintoaliquidstate and then injected into the mold by areciprocating screw. The local exhaustsystem for the drying barrel also serves themoldinjectorheadofthe3000tonmoldandtwo other injection mold machines (80 tonand175ton).Totalair‐flowisapproximately4500cfm.

ChemicalExposure risks: Dusts from thepelletsandthedryingsystemcontinuetobea risk factor, particularly when cleaningfilters and screens. There is a greater build‐up of dust associated with the vacuumloading system. This includes residues ofchemicals in the formulations includingfillers such as fibreglass and forms of silica,phthalates, hardeners such as BPA andpolycarbonates. Exposures to ventedchemical fumes and vapors emitted wouldoccurduringheatingandinjectionprocesses,includingmoldreleaseagentssprayedontheentiremoldtopreventstickingbetweeneachshot. There is additional risk of exposurewhen repairing vent exhaust ducts. Oversprayofreleaseputsbothoperatorandotherworkersnearbyatriskofexposure.There isthe added risk of exposure to thermaldecomposition by‐products when machinesoverheat.

In1987duringaMOLhygienevisitto“assistwith the new H&S program” an inspectorgavethefollowing“advicetomanagement”inresponse to worker complaints of “possibleexposure to solvent vapor from themarker‐like pencil”(used in the Ford glue line): “1.Respiratorsneednotbeworn ifexposure tosolvent vapors for dust is below therespective TWAEV. However, ifworker asksfor respirator a NIOSH‐approved respiratorshouldbeofferedandtheworkershoulduseit in accordance with manufacturer’s

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2.R‐RIM—REACTIONINJECTIONMOLDINGERA(1989‐2000)

Reaction InjectionMolding (RIM)was introduced during the Pebra era in 1989. In the earlyyearsitwasusedonalimitedbasis,laterreplacingthe“postlaminating/rollerformingprocessfor making sidemolding, rocker panels and fascias. Reaction injectionmolding is similar toinjectionmolding except that the thermosetting polymers used, require a catalyst and curingreaction within the mold. Polyurethane is a widely used thermosetting polymer. Similarly,thermosetfoammoldingsuchas“reactioninjectionmolding”usedatVentrainvolvedinjectingtwochemicals intoamold that,whencombined,expands, taking theshapeof themoldwhichsolidifies intoa thermosettingcellularplastic,usuallypolyurethane. Polyurethaneplasticsarecomplex cellular polymers formed by the reaction of a diisocyanates with a polyhydroxymacroglycol known as a polyol, or a combination of macroglycol and a short‐chain glycolextender. The macroglycols used in the production of polyurethane are usually polyethers,polyesters,oracombinationofboth.

During processing, many other materials are added to alter the resin’s properties. Theseadditives can include heavy metal stabilizers, phthalate plasticizers, antioxidants, blowingagents,leadorcadmiumpigments,brominatedflame‐retardants,curingagents,andlubricants.

R‐RIMDEPARTMENT

PRODUCTIONPROCESS CHEMICALRISKEXPOSURES

Generaldescriptionofworkprocesses:Atthe height of its operation, the RIMdepartment utilized eight large RIM Clamps(10to12ftwideby20ft. tall)thatwerefedby a system of overhead pipes leading from

GeneralChemicalExposuresRisks:Thisareaemployed large amountsof ISO (andother chemicals) in their specializedreaction injection mold process whichproduced large plastic parts. ISOwas the

instructions.2.At amore frequentexposureto solvent vapors, portable fans or localexhaust should be considered.”871537NOVB 14/09/87. (AUTHORS’COMMENT:Thisquestionable typeof advicerepeatedmanytimesoverbyinspectors.)

H&S log: 27/04/93: work refusal (51)after three women began vomiting andexperiencing severe headaches, reducedmotor function, nausea and coughing inassembly and over injection area. Womenweretakentohospital,assessedandtreated.”

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themain polyol and Isocyanate tanks in thetank farmtoamixstation thatprepared thespecificdailymixrequired for thepart tobemolded.Afterthemixwasprepared,thetwoseparate resinswerepipedunder125 lbsofpressure to a series of 3 smaller sets of daytanksfeedingintothe8largeclamps.

Each clamp had 1‐2mold operatorswho bypressing abutton allowedaquick shot fromthe two linesof resin intoamixheadwherean immediate chemical reaction occurredexpandingandfillingthemold.Thenewpartwas removed bymolder, then runnerswerecutoffandthepartwasnotchedattheworkstationthensentontoasandandtrimtablewhere flash and imperfections were cut,sanded,orbuffed. If thepartrequiredmoreextensiverepairitwassenttothegreyputtyarea where holes or areas were filled andthen sent on to be notched or punchedaccording to specifications. The part thenwenttothecureovenbeforeinspection,andwhen approved sent on to the paintdepartment. The full componentofworkersin thedepartment included:3set‐uppeople,13molders,16sand/trimworkers,1materialhandler,1‐2assemblyworkersingreyputty,1‐2 notch and punch workers, 1 cure ovenloader,and2qualitycontrolmonitors.Therewas 1 maintenance person to deal withmalfunctions in the lines and serious spills(mill right, electrician and tool and diemechanic).

The RIM departmentwas south of the TankFarm, separated only by a partial wall. Allworkers who entered the plant walkedthroughtheRIMdepartment.Theemployees’cafeteriawaseastoftheRIMdepartmentonamezzaninelevel. Duringtheearlyperiodthecafeteria was fully open and subject tochemical fumes and particles, but laterenclosed with glass partitions. An enclosedLaboratory department was located below

major (i.e., “only”) concern of workers inthe early Pebra era. Even so, thecompany’s safety record onimplementation and enforcement ofprovincial ISO regulations werecontinually ignored, despite repeated“orders” from MOL inspectors. Otherseriouscontaminantsintheareaincluded:differentcleanersandinnermoldreleasessprayed on the large clamps in largeamounts, large amounts of chemicallycontaminated dust created by assemblyworkers in sand and trim operations (16workers per shift). With all operationslocal ventilation was either lacking orinadequate.

All of the above, including frequent spillsand leaks, were major sources ofinhalationandskinabsorptionrisks.

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thecafeteriaduringthisperiod.

1.TheTankFarm: TheTankFarmwas theresinsupplysourcefortheR‐RIMprocessingoperation. It contained four 5000 gal tanksapproximately 20’ high. Two of the tankscontained polyol and two containedIsocyanates (originally TDI and latter MDI).These supplied the two major moldingredients to the RIMmold clamps. Thesedifferentresinswerekeptseparateuntiltheywere injected into the “mixing head” of amoldwherewhencombinedunderpressure,reacted and expanded to take the desiredproductshapeofthemold.

The tank farm also contained a “mixingstation” where pure polyol was mixed withfiller(s)andotheradditives.ThefarmstoredalargesupplyofWollastonitefiller(replacingfibreglasswhichwasusedinitially)andInnerMold Release (IMR) in 45 gallon drums aswell as other solvents including MEK,trichloroethylene, and acetone. For a shorttime, the Tank Farm housed the “Regrind”operation for grinding defective or damagedthermoplasticsforre‐use.

ChemicalExposureRisks: Whenmixingin Tank Farm there was major risk ofinhalingandabsorbingingredientsduringmixing.Therewasmanualhandlingofandexposure to several products used in theRIM process, in particular, Inner MoldRelease, extenders, surfactants, flakedfillerssuchasWoolastoniteandfibreglasswhichwere described as creating a layerofwhitedustovereverythinginthearea.

In addition,workersmonitored andwererequiredtocleanupspillsand leaks fromthehugesupplytanksofISOandPolyol.

In both cases, workers often did thesetasks bare‐handed, and without any PPEprovided.

3. Distribution of the Batches in RimDepartment: After the polyol mix wascomplete,itwaspumpedtothreepolyol‘day’or holding tanks supplying the eight RIM“clamps” (molds)withmixed polyol. At thesame time methylene bisphenyl Isocyanate(MDI) was pumped to three separateday/holding tanks serving the same eightRIMClamps. In short, eachClampwouldbesuppliedwithapre‐measuredshotofeachofthe two resins thatwas then injected into amixing head where the two resinsinstantaneously mixed, and under pressure

ChemicalExposureRisks:Workerswereoftenexposedtothemixofchemicalsdueto the amount of chemical beingdistributed and the fact both lines wereunder pressure and heated resulting infrequent stress breaks along the complexdistribution system leading from the daytankstotheclamps. Especiallythepolyollineswere susceptible to frequent breaksdue to deterioration and increasedpressure associated with the heavierpolyolproduct.

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expandedintothemold. MOL:325‐71‐224/08/90:InvestigationofISOspill:Amajorspillof25USGofMDIin RIM department near clamp #6.Operatornot informed of spill and notwearing respiratory protection.Supervisorwearing protection but notworkerwhowas told twodays later thatISOspillhadoccurred.

MOL report: 082980 12/05/92: Areabelow (ISO) day tank shall beappropriately cleaned of any isocyanatecontaining material in accordance withAct, also: leak on floors at North side of(day) tanks shall be cleaned up andappropriatedriptraysusedtopreventthespread of the polyol in accordance withAct.

H&Slog:23/01/92:workrefusalinRIMover muriatic acid spill from overflow inday tank, sewage odours. Workersexperiencingnauseafromsewageodours.

H&S log:20/09/94:work refusal inRIMoveranIsocyanateleakinthehosesintheRIMdepartmentthatcoveredthefloor.

Pebra Inc.08/08/90: Company’s officialreporttoMOLre:ISOspill inRIM:ReportdescribesaleakinRIMon07/08/90whena bolt blew off from the mixing head ofClamp #6 during maintenance causing aheavyreleaseofISOfromtheISOdaytank.The maintenance employee put his barehand over the leak to attempt to containthe leak to the front of the Clampuntil itwas cut off at the source. Worker wascoveredinISO,hadtotakeclothesoffandshowerandputona contaminatedTyveksuit. Worker sent to hospital for

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assessment.

4. RimMolding Processes: At the start ofthe shift the mold operator gatherednecessary cleaning solvents and tools,consisting of steel wool, scrapers, rags and201B mold cleaner supplied in buckets.Operator would soak the rags in the 201Bcleaner and scour themoldwith the soakedragstotopandbottomhalvesofthe“clamp”ormold. While theworkerswore neoprenegloves,themoldcleanerrandowntheirbarearms while applying the cleaner to the tophalf of the mold. This resulted in dermalabsorption as well as physical burns. And,becausemoldswereheatedtobetween150Fto180Fdegrees, theneoprene gloveswouldquickly fail to protect workers from contactwith the cleaner. The molds were scouredwithsteelwoolandscraperswhennecessarythroughouttheshift.

In preparation for the mold cycle, theoperator would blow off any loose dust ormaterial with a compressed air gun causingthe residue from the cleaner and loosematerials to become airborne. This wasfollowedwithaspraycoatingofmoldreleaseover the entire mold. The spraying actionwouldscatterthefinemistofmoldreleaseintheoperator’sbreathingzoneaswellasmakecontact with the operator’s skin. Nearbysanders and trimmers were also exposed tothese chemicals. A Committee member whoworked inRIMdescribedhowsprayedmoldrelease “would regularly drift over to theproduction tables,” stating that if moldersdidn’t overspray “it was a fight to get theproductout.”

Next, the mold operator would go to thecontrolpanelandinitiateclosingofthemoldand injection of the polyol and Isocyanateinto the mixing head where these were

Chemical Exposure Risks: During thiscleaning taskwith201B,operatorswouldexperience quite substantial exposuresthrough dermal and inhalation routes.201B cleaner contains N‐methyl‐2‐pyrrolidone (fetal‐toxin), ethyleneglycol,monobutylether, solventblend,MEK, N‐hexane and toluene(neurotoxic, encephalopathy andadverse central nervous system (CNS)effects). The cleaner would be absorbedthrough the skinwhen running down theoperator’s arms; the operator would beinhalingbothvaporsandparticulatewhilescouring the mold. This would involvedailyexposureto thiscleaningagent,3 to4timespershift,whichtookfrom20to30minutestocomplete.

During theplant’s1992 “cyclical”visit,theMOLinspectorissuedanorderthat“containersof201B(aWHMISproduct)shall have legible workplace labelsattached in accordance with Act.” Asecond order stated that: “Areas of thefloors at the back and sides of the clampsshall be cleared of excess plastic debris inaccordancewith section12of theAct.” Athirdorder stated:“Materialssuchasnuts,bolts, rags, flammable containers storedattheentranceoftheventilationsystemshallbe removed in order to allow proper airflow“Anda fourthorderconcluded:“Moldmachine mix‐head valve shall haveelectrical connection repaired or replacedin accordance with the Act.” 08298012/05/92

522258 07/10/94: MOL report (Newtype of) gloves were obviously defectiveandhadtorn.(Worker)claimsskinrashesdue to penetration of solvent and

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combined to produce a chemical reaction inthe heated mold resulting in formation of aplastic part. This violent reaction wouldproduce gases and vapors containingresidues of the polymers and monomers aswellasthemoldreleasestopreventsticking.

While the molds were equipped with localexhaust ventilation, these were situated solowandfartothesidethatthecontaminantswere evacuated only after first entering thebreathingzoneofthemoldoperator.Also,theexhaust ventilation was not continuous. Itwould start when the operator pressed themold release trigger, and stop when triggerwasreleased.

Theoperatorthenretrievedthestillhotpart,cut thegatesand runnerswithablade, then“notched” the part in nearby notchingmachine, next sending the part to trim andsandtable.Theoperatorwouldreturntothemold, blow off any dust and debris withcompressedairgun,andcoatthemoldagainwith mold release agent using a spray gun.The operator would return to the controlconsole, press the switch to close the moldand begin the injection and molding cycleagain.

The operator would repeat this processapproximately 180 to 250 times per shift.Theoperatorwouldinitiateamorethoroughcleaning with 201B mold cleaner, asdescribed above, between 3 to 4 times pershiftdependingon thestateof themoldandconditionofthepartbeingproduced.

concerned temperature of mold causesbreakdown. Inspector (based oninformation received from glovemanufacturer) concluded that “Solvexnitro glove will protect the hands fromexposure to mold cleaning solvent.”Workerofferedbarrier creamand specialunder‐glovetousewith“new”gloves.

614610 09/04/96: MOL report re:refusal in RIM re: R‐602 clamp spray:Workers felt they were being exposed tomist from R602 chemical as they werewearing incorrect respirators. Theyexperiencednausea,reddeningoftheeyes,and headaches. It was established thatincorrectrespiratorswerebeingworn.

MOL: 467970 21/11/94 MOL report:Workers complained of headaches,dizziness, sore throats and one workerwas sicktoherstomachandwithanosebleed;shewassenttohospital.Notrainedpersonavailabletoconductairsamplingatthe time, done later by JHSC with nofindings. Inspector’s decision: “ventilationwillbe improved,nohazardous ingredientsinmoldrelease.”Seebelow:

MOL: 568519 19/10/94 MOL report:UnionH&Srepstateds/hewastrainedinflowratetestingbutnottoldwhattheflowrate should be. Inspector notes: “Duringthisvisittothisworkplace Isawnumerouscontraventions and hazardous conditionsthat the certifiedmembersandother JHSCmembersdidnotnotice. (Names companyH&S rep) alsonoted thatsupervisorsneedtraining in how to discharge their dutiesundertheact.”

Also during the injection and reactioncycle, resin residues containingunreacted

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monomers and release agent vaporswould be given off due to the hightemperature during the mold operation.Also confirmed by Queens UniversityHygiene Report. This would also occurwhenopeningthemoldandretrievingtheproduct.Thiscyclewouldberepeated180to250timespershiftmakingforachronicdaily exposure to these chemicals. It hasbeen noted that exhaust ventilation wassituated so that vapors would reach theworker’s breathing zone before beingexhausted, and was not continuous.Workers were not provided withrespiratory protection or local exhaustventilation and were only provided withcottonglovesduringmoldingcycles.

MOL 31496 28/08/91: A 1991 workrefusal due to heat at clamps. Workersasked to have two additional ten minutebreaks. Inspectoradvisedthere isnoheattemperatureinthelegislation.

Event 3474 (H&S log) 21/04/92: In1992, 9 clamp operators refused toworkdue to the ISO monitor not functioningproperlyduetolackofcalibration.

Chemical Exposure Risks: During themolding cycle, including blowing‐off, dustand debris would expose the operator toparticulate through inhalation as well asresidues of mold release, and resinscontaining Isocyanates, polyol,polyurethane, Wollastonite, and moldrelease. Thiswouldalsoinvolveexposureto mold release during the process ofsprayingdowntheentiremoldcavitywithrelease agent, containingtrichloroethylene, perchloroethylene,methyl‐dodecyl, methyl(2‐phenoxypropyl‐siloxane) in addition to thermaldecompositionby‐productsformaldehyde,

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phosgene, and chlorine. Workersobserved that when spraying the moldrelease on the hot surface, vapor andsteamwouldappearduringapplication.

MOL: Hyg Report 31/10/88 (KimGordon): “RIM molding operation hasinadequate exhaust ventilation and ISOcontrol program had limited workercoverage;need immediateattention to ISOleaks.”

MOL:244814 30/11/88 Assessment ofISO Program: The MOL’s assessment oftheISOcontrolprogramresultedinordersfor the company to provide continuousventilationduring theentireRIMmoldingprocess and to include all RIM personnelin the control program. Up to this point,only the mold release spraying processwasventilatedandonlythemolderswereincluded in the control program. Therewasahighprobabilityofvaporsduringthemold cycle during part extraction andhandling,duringspillsandleaks,aswellaswhile sanding and trimming parts thatwerejust30to60secondsoutofthemold,anddustthatlikelycontainedISO.

Bickis et al. (1988) Evaluation ofairborne midi levels. (Occ HealthCentre,QueensU.)Report re:Methylenediphenyldi‐isocyanate(MDI)exposuresinRIM: This report indicates that “AlthoughMDI is less volatile than many otherIsocyanates,theelevatedmoldtemperaturedoescreateapotentialofoverexposure, ifthe exhaust ventilation is ineffective.Importantly, it should be noted thatbetween 1987 and 1992 the exhaustventilation at the RIM clamps was notcontinuous. It was only operational whenthemoldertriggeredthemoldreleasespraypriortothemoldingcycle.Itwasshutdown

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during themold cycle andwhen themoldwas opened and the part removed. It ishighly likely that over exposure wasoccurringduring thisperiod. ItwasoverayearaftertheMOLorderedtheemployerin1989 to implement continuous ventilationatRIM thatventilationmightbe judgedasadequate.Moreover,according to theMOLreportsthisassessmentwasdeficientinthatitdidnotdesignateallworkers in theRIMdepartment including the sanders, greyputty operators and post cure ovenpersonnelascomingunder the ISOcontrolprogram.”

MOL:28845402/02/90: ISO leak atdaytank: hydraulic fluid (Mesamoll) fromClamp pistons leaking deemed “nothazardous;” two drip trays below daytanks not cleaned, order issued; ISOpumping units are leaking ISO; still notfixed; ISO evacuation procedures andtrainingasper “controlprogram”stillnotcarriedout–ordersissued.

H&S log: 21/11/94:work refusal RIM:workers experienced adverse healtheffectsfromover‐exposuretomoldreleaseR‐602 (soap and alcohol). See MOLreports522291and5222142.

A committee member noted: “Wediscovered the scotchbrite we used forscrubbing themolds contained nickel andhadahazardwarningontheboxsaying itwasacarcinogen.”

H&Slog:17/01/92:workrefusal (5)onMold #4: a defective polyol hosedisconnected fromthemixingheadunderhigh pressure so that workers weresprayed with large quantities of polyol.Workerssoughtmedicalattentionat local

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hospital and went home to shower andchange clothing. No emergency showersprovided.

Chemical Exposure Risks: According toMinistryofLabourinspector,E.Swindells’testimony before the director of appeals,the following exposure risks wereprevalentduringthemoldingprocessandduring the sanding and trimmingoperation:(priorto1991)“….ventilationatthe mold comes on only when the moldspray releasegun isoperated. There isnoventilation during the molding operationitself. Thehighest likelihoodofexposure isat theendof themoldingoperation,whichinvolves chemicals being pumped in fromthedaytank,a30secondreactiontime,andthen the opening of the mold. Anyunreacted isocyanate is then next to thewarmmold,andmaycomeoff inapuff. Itmay also escape if there are any leaks onthe fitting headwhere the chemical comeintothemold.”

MOL hygiene consultant, Kim Gordon,also testified “…thereare limitations toair sampling techniques. OnlyMDI canbe measured. The monitoring does notmeasureshort‐termpeaksorchangesintheequipmentsuchas leaks. The factthattheoperator is4feetawayduringthemoldingoperations is not relevant. Withoutventilation, isocyanateswillnotbe clearedfrom the area, and the operator willimmediatelyapproachthemold.”

Chemical Exposure Risks: Dr. LeonGenesove, medical consultant, testifiedalso “that sanders, de‐flashers andpreparation workers…are presentlyaffected….becauseof theirproximity to theclamps and to any airborne vapors. Theworkersarepositionedontheoppositeside

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ofatablefromthemoldoperators,andarehanded the freshlymolded products,whenonlyoneortwominutesold.Thereisalsoapossible exposure through the sandingprocess, from MDI dust. There is nosamplingmethod for thisand theextentofhazard is unknown.” (Appeal Decision,Eleanor J. Smith, February 28, 1989; FileNumbersAP88‐140andAP88‐159)

The neoprene gloves worn during theapplication of 201B were not effectivebecause they would dissolve when incontact with the mold cleaner and theheatedmold. Andwhen cleaning the tophalf of the mold, the cleaner would rundown the gloves and unprotectedforearms thus causing absorption andchemicalburnstotheskin.

5.Leaks,Spills,andLineBreaksinRim:

Breaks and leaks in resin lines and joints, inadditiontospillswereregularoccurrencesatinjectionmolding, particularly at hose jointsat themixing heads and valves. Since theselines were under great pressure, whenbreachesinthelinesoccurred,isocyanateandpolyolcontaminationwouldbeextensiveandmolding staff highly at risk and lackingprotectiveequipment.

Prior to1993,anyworker in theplantcouldbe calledon to cleanup spills (except in thecaseofIsocyanatewhichcameunderitsownguidelines). In the event of accidents,maintenance staff were called. Later anemergency response team (1993) equippedwithpositivepressurehoodsandTyveksuitswould initiate containment and clean up.Hoseswouldbedrainedofleftoverpolyolandisocyanate in separate open pails. After

Chemical Exposure Risks: When resinhosesblew,eitheratjointsorvalves,moldoperatorswould endure heavy exposuresgiven that these were unexpected eventsand operators were not equipped withappropriate PPE to prevent exposures.Informants described instances in whichoperators would experience a full frontalblast of resin, or where operators wouldbe covered with resin. At these times,inhalationanddermalabsorptionishighlylikely. This is evidenced in thoseexposures that resulted in sensitizationafterexposure.

Chemical Exposure Risks: Risks ofexposure to MDI were high when eithersystem was disassembled. Theatomization of MDI while under highpressureinthesystem,aswellasthelargequantity when disassembling the lanceseals and transfer pumps and valves.Exposure to polyol was also at high riskwhen disassembling polyol lines

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containment and clean up,maintenance andmechanics would clean and rebuild mixingheadsandhose connectionafter soaking thepartsinsolvents,usuallyMEKorTCE.

While leaks and breaks in the supply lineoccurred regularly, leaks and spills weremorelikelytooccurbehindtheRIMmoldandnot be immediately noticed by the moldoperator. If a leak was spotted by anoperator,theywouldshutdownthemoldandcallouttootherworkersandthencallfortheEmergency Response Team (ERT) for clean‐up and repair. Oftenmold operatorswouldbe unaware of leaks (occurring behind theclamps) thus were unable to take controlmeasurestopreventexposures.

Explosionhazardswerealwayspresentwhenworking with Isocyanates. Focus groupinformants recalled close call eventsinvolvingtheinadvertentdumpingofISOina45 gal steel drum that had residue of innermold release in it. That combinationcausedthe ISO to expand violently in the sealeddrum and eventually explode. Fortunatelythisoccurred in theTankFarmaway fromapopulatedarea.

particularly from skin contact whichcaused severe itching and rashes. Theprecautions taken included: positivepressure hoods, Tyvek suits, neopreneglovesandaMDImonitoringalarmwhichwas tooperate throughout therepairandprovide continuous readings. Moldoperators were advised of the work andweretoleavethearea.

Chemical Exposure Risks: Formaintenance staff and ERT staff whowouldbeequippedwithpositivepressurehoods,neopreneglovesandTyveksuits,aswell as Isocyanate monitors, exposureswere likely to be more controlled, butcontinued to carry a risk of exposurebecause equipment was not completelysealed and at times appropriateequipmentwasnotimmediatelyavailable.

6. Rim Trimming and Sanding: After themold operator placed the part on the sandand trim table the assembly worker wouldtrim any excess plastic or flash off the part,then sand it with a retractable palm sander(located over head) to smooth out roughsurfaces on the part. The sander wasretractedbyaspringanddisturbedthebuild‐upofdustwhenithittheshelf.Oncesandingwas complete the worker would hang partsonacartcontainingracks.Thesandandtrimtables were equipped with a down draftsystem designed to prevent exposure.However, since felt pads were laid on thetablesurfacetopreventdamagetotheparts,

ChemicalExposureRisks:Workerswereheavily exposed to resin dusts fromhandling parts and through inhalation ofresinandmoldreleaseresiduescontainedin the dusts thus both dermally andthrough inhalation. Workers describedtheaccumulationofdust innasalpassagemucus,whichwas likelyswallowed. Dustaccumulation was also found underbreasts,armpits,andcrotch/scrotalareas,further contributing to skin absorption ofunreacted monomers, solvent and moldrelease residues. Workers were notprovided with respiratory protection and

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dustwould quickly accumulate and clog theopenings, thus defeating the purpose of anexhaust system. Workers reported veryheavy dust accumulation on all surfaces.“Within 15minutes youwould be covered inthis white dust, and look like a snowman”.Thisdepartmentwasveryhotanddustywithlarge free‐standing fans used to provide airmovementandcooling.

onlycottongloves.

MOL:28844029/03/90:WCBISOclaim:a number of workers developedsensitizationfromisocyanate‐exposuresinsandandtrim.

It is important to note that sanding‐dustcontained residues of Isocyanates,polyurethane, polyol, monomers, moldrelease,andWollastoniteorfibreglass.Theuseofstandingfanscauseddusttobecomeairborne andmigrate widely in the plantcontributing to widespread inhalation ofthedust.MOLinspectoradvisedemployerthat “toomany”workershaveobstructivelungcondition.

WorkersdescribedtheRIMdepartmentas very hot—between 80 and 100F aswell as dusty and extremely smelly (asolvent like irritating odor). It was:“very oppressive to work in.” Astestimony to such exposures, there weremany work refusals with workersbecoming ill with upper respiratoryinflammation,headaches,nosebleeds,eyeirritation, itchy skin, nose burns anddifficultybreathing. Suchoccurrencesaredocumented inMOL investigation reportsofcomplaintsandworkrefusalsundertheOHSA.

H&S log:May9,1990: failure toprovidenecessary protection: “The followingpeople (names) have been asking andaskingforimprovementsandventedtables.Refusedworkbecause filtershavenotbeencleaned out since Christmas. The pluggedfiltersresulted industblowingout intotheairandontopeople.Workerscan taste thedust….itchyskin,burningeyes,bloodynoses.(names Worker without vented table)

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sometimes has to sand and has no ventedtable.Shehasbeenverypatientforoneyearandstillhasn’tgotone.Theyhaveaskedforashopvacandstillnothing.”

7. Rim Grey PuttyOperation: Grey Puttycontained a mixture of diphenyl methanediisocyanate (MDI), talc, silica, MEK andasbestos. After being trimmed and sanded,parts would be examined by the grey puttyoperator who would look for defects andapplygreyputtyonthedamagedsurfacewitha foam‐tipped brush, then rub it off with acloth soaked in solvent. This task wasperformed in a three walled room with aventilation system nearly always renderedinoperativebecauseofexcessivenoise levels(over90db)fromtheceilingexhaustsystem.Putty was applied, rubbed off and sandedwithout respiratory protection, gloves toprotect the skin, or local exhaust to preventinhalation. After smoothing the putty, theoperator would hang the part on a movingrackwherepartsweretakentothecureoven.The grey putty product containedisocyanates, a designated substance, yet foryears workers were unaware of thedangerous ingredient and excluded by thecompany from the plant’s ISO program.(AUTHORS’ NOTE) We learned that severalgrey putty operators died of cancer at arelativelyyoungage).

MOL: Exposure Risks: The Grey Puttycontained HDI, talc, silica, asbestos, MEK.Exposurewas likelythroughinhalationaswell as being absorbed through the skin.Thesolventintheputtywouldexacerbatethe exposure by defatting the skin tissueandthusallowingincreasedabsorption.

MOL: 90GB63MOWV‐C 16/10/90:hygiene monitoring for HDI, MDI:RIM/Grey Putty: No detectable levelsfoundatRIMmoldsandGreyPutty(HDI).Observesthat“comfortfanswereoperatinginthesand/trimwhichcouldpossiblyhaveinterferedwiththemonitoring.”MondurPFandMDIC‐961used(seeAppendixE).

MOL:293324114/03/90:ISOprogramre‐assessed:MOL initiatedanauditof theISO control program found deficient onworker coverage under the program. TheGrey Putty operator was not formallywrittenintotheprogramandhadnotbeenadvisedthattheGreyPuttycontainedHDI.Theproduct,alsocalled“Porenwischfuller3311,” isdilutedwithclearcoathardener(AP19513) and diacetate alcohol. Thecontrol program was found deficient inproviding documentation on engineeringcontrolsandairmonitoringfrequency,andhasnotadequatelyidentifiedworkerswhomust be covered by the program ordeveloped a proper medical surveillanceprogram and reporting procedure foroccupationalillness.

H&Slog:23/02/93:workrefusal ingrey

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puttyarea:chemicalbinbrokenandfumesbuildingup–exhaustfanwasturnedoff.

8. Post Cure Ovens in Rim: After beingprepped for curing, parts were sent byoverhead carousel through an oval trackedconveyor that moved parts through anoverhead oven heated to approximately325F.Theovencuretookabout1.5hourstocycle. Ovens were open at entry and exitpoints.

Chemical ExposureRisks: The thermalcuringoperationwouldproduceanumberof thermal decomposition by‐productsincluding: unreacted monomers,formaldehyde, HCL, NO, CO, CO2,nitrosamines, benzene, phenol, phosgene,acetone, NH, methane, HCN, and styrene,toluene,tomentionsomepossiblethermaldecomposition by‐products. Lowertemperaturesweremorelikelytoresultinthe release of unreacted monomer andthusbemorebiologicallyreactive.

Mostaffectedwasoperatormonitoringthecuringprocesswhomayneedtoentertheoven to clear a jam. Notch and Punchoperators working directly under theovens would be at risk of exposure tovapors from chemical by‐products.Employees in the maintenance officebelowtheovenswouldalsobeaffected.

Workerswhohandled“cured”partswouldincur exposure via dermal route andinhalation of vapour from heated partsthat may contain unreacted monomer,additivesandcombustionby‐products.

9. Touch Up Area in Rim: This area waslocated between post cure ovens and paintline. Fish eyes, blisters and other defectswould be sanded and touched up with thegreyputtyatworktables. Thisworkprocessinvolved a great deal of sanding and wasextremely dusty. Approximately 90%of the

MOL:ExposureRisks: Exposuretodustscontaining MDI, polyol, silica, asbestos,andMEKwasveryhighthroughinhalationofdustandskinabsorption.

CuringoperationsinRIMaddedadditionalcontaminants to the ambient air of theplant thus burdening the work

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workhereinvolvedsanding.

environment with additional risk ofharmful exposures. These bystanderexposuresmustbecountedassignificantlycontributingtoworkerexposures. In thisregard, it is important to emphasize thefact that this building is completely openconcept andventilatedundernegative airpressure,whichcauseslocalgenerationofcontaminants to spread throughout theplantcomplex.

MOL: 90E873EABR 25/06/90: MOLassessment of sanding tables ventilation:MOLhygienist conducted air flow and airmonitoringtestsforthe12standingtablesused to smoothout imperfectionsonRIMmolded polyurethane pre‐painted parts.Theinspectorfoundthattheexhaustgrillson the table were blocked and dustexposure was evident. The face velocitymeasurementsindicatethatexhaustislessthantheminimumrequiredtocapturethedustgeneratedfromsanding.Thefeltpadson the grill clogged with dust, restrictingair‐flow and capture efficiency. Oftenexhaust filters were clogged too.Recommendation not to use felt pads.Preventive maintenance schedule notavailable.

10.Quality Assurance in Rim: After postcure, the finished parts would be examinedbyaninspectorinthequalityassurancearea.Inspector would check for any defects orimperfectionsinapartandcullthoseoutforrepair,touchup,or(initially),tobediscardedaswaste(Later,discardswerereground).

Quality Assurance “Auditors” were in alldepartments except for the insidepaint line.In addition to checking for productionquality, these laboratory technicians testedall chemicals and materials including thevarious resins (e.g. TPO and TPU) thatwere

Chemical Exposure Risk: QualityAssurance QA workers handled freshlypainted or molded parts and performedvarious stress and destructive tests onmaterial,whichposedariskofinhalingorabsorbing the various ingredients in thepaintsandthermalplasticsused.

QA workers were at risk from handlingfreshly painted or cured parts containingresidues from paint, resins and additives.The tests run by quality assurancewouldexpose them to these as a result of

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shipped to Pebra. These personnel wouldhave all necessary information on resinformulationsandadditives.

Operatorswould incur exposure to residueson surfaces by handling the cured parts aswell as the inhalation of vapors since thesewere still rather warm after the post cureprocess. Quality assurance personnel wererequired to perform material integrity testthatinvolvesscrapingwithacoinandcloselyexamining the texture and bonding of thepaints. This would involve exposure to thecontaminants mentioned above, likelywearingonlylabcoatsandgloves.

Potentially, technical staff were subject toexposure to almost every chemical used inthe plant. Lab safety precautions would becrucialforcontrollingtheseexposures.

Once parts passed quality assurance, amaterial handler would carry 8‐10, oftendusty,partsthenplacethemonamovingcartattached to an in‐line dragline destined forthepaintline.Duringthisperiodthehandlerinserted a dry‐wall screw into a slot on thepart, then clamped this onto a rack on thecarttoholdthepartinplace.

physicalbreaksinpartsurfaces.

Dermal and inhalation routes weresignificant.

3.PAINTDEPARTMENT:INSIDE/OUTSIDEPAINT,PAINTKITCHEN,SLUDGEROOM

The Paint Department was, and still is, a massive operation that every part produced wentthrough,prior toassembly. Itwasacomplexsystemwithmanypointswhereproblemscould,anddidoccur,makingqualitycontrolanon‐goingissue.Thereisbothaself‐contained“inside”paint line, and openoutsidepaint assembly area. The original insidepaint line consisted of atunnelled cart track that transported plastic parts through a wash stage then through threeseparatepaintboothsreflectinga threestagepaintapplicationof:primer,basecoat,andhardclear coat.Afterpainting, parts entered a4‐stage cureoven to set andharden thepaint. The“inside”paint line,whileenclosedbymetal cladding,hadanumberofpathways forpaint line

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contaminantstomigratethroughouttheplant.Workersreportedcontinualbreaksinthemetal,from heat and other stressors, which were often repaired with metal coated tape requiringcontinual replacement. In addition to substantial direct exposure to paints and solvents forinside paint workers, there was considerable outside, bystander, exposure due to fugitiveemissions. These exposures were made worse due to ongoing problems maintainingappropriateairpressurebalance throughout thepaint line,andwith theventilationsystem ingeneral,includingseriousdeteriorationofthepaintbooths’stacksinthePebrayears.

Thepaint linewent throughmajor changesafter1993, includingexpansion fromthree to fivebooths (adding secondary base and clear coats) to address ongoing adherence and curingproblemsaswellasextensions in lengthofcureovenand load/unloadareas toaccommodatelarger parts then being produced. After these changes, paint was delivered in premixed 45gallondrumsthatstillallowedformanualadditionofsolventstoadjustviscosity.Thepremixedpaintswerenolongertwo‐partformulationsrequiringacatalyst. Theothermajorchangewasautomationofthepaint linewiththeinstallationofrobotpainters. Despitethesechanges,theperennialproblemwiththeventilationsystemcontinuedtoresultinchemicalover‐exposuresinandoutsidethepaintline‐‐affectingpaintqualityaswell.Workersreportedthat80%ofpaintedpartsproducedinthePebraerarequiredre‐painting.Paintlinesrequiredregularpurgingwithsolvents and purging agents resulting in substantial spills as well as misting of solvents andpaints into the broader environment. Such contaminationswere intensified because the paintlinesystemwasalsounderpressure.MostspillswerecleanedupusingPebra5andMEK,thensqueegeed into the sluiceway leading to frequent, and substantial, contamination andworkerexposurestopaintandheavysolventmistsandvapors.

PAINTDEPARTMENT:INSIDE/OUTSIDE/PAINTKITCHEN/SLUDGEROOM

PRODUCTIONPROCESS CHEMICALEXPOSURERISK

GENERAL OVERVIEW OF PAINTPRODUCTIONPROCESSES:

Preparationofparts:Aspartswerebeingloadedoncartsforpainting(paintlinewiperamp), they were inspected and wipeddownwith a tack cloth, possible soaked inalcohol. During this process no PPE orexhaustventilationwasavailable.

Inside Paint Operations: The (inside)paint line consistedof a large coveredovalconveyorsystemlinkingaprewashstation,

General Chemical Exposure Risk: Thiswas a major area of contaminationassociated with the massive use of paint,solvents and other additives in the multi‐stage coating of everyproduct produced inthe plant. The ventilation system wasinadequate and working “at its maximum”accordingtoaconsultantbrought inbytheMOLtoreviewthesystemin1990.

Many paint and solvent MSDSs had amanufacturer’s health warning noting thatsigns of over‐exposure included thefollowing symptoms: irritated eyes, nose

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three (later expanded to five) enclosedpaint booths, and a cure oven. The paintlineutilizedtwoparallelpumpsystemsthatincluded: 1) a circulating water systemcarrying water and chemical overflow bydeep trough from the paint booths to thesludge pit where contaminants wereremoved, and 2) a series of pressurizedoverhead lines connecting the day’smix ofpaint through a system of pumps leadingfrom the “paint kitchen” to paint booths.Thepumpsystemtransferredpaintsolvent,HDI, and Adpro (an adhesion promoter),from the kitchen to each of the booths.These chemicals were pumped from a 60gallon tank, through a pump surgesuppressor,filterpressureregulator,colourvalve stack, and back pressure valve toanother60gallontank.

At the entrance of the Inside Paint tunnel,wasa6‐stage ‘wash’cyclethatcleanedanddegreased parts to be painted duringseparate wash cycles containing water,hydrochloricacid,causticsoda,sulfuricacidandParcoPlast(descaler).

Initially,partswent throughthreeseparatepaint booths applying a 2K primer coat, a2Kbasecoat,anda2Kclearcoat.Thiswasapartially automated processwith overheadsprayers in the booths. It was reported infocus group sessions that the system wasnotwelldesignedleadingtoagreatdealofoversprayandneed formanualpainters topaint areas missed by the overheadsprayers. The three booths were laterexpanded to five booths, adding a neededsecond application of base and clear coats.(Booth1primer;Booths2and3basecoat;Booths4and5hard,clear‐coat).

Further down the enclosed paint systemwas a 4‐stage curing oven where paint

and upper respiratory tract, dizziness,disorientation, nausea, vomiting, tightnessin chest, and difficulty breathing. Thesesymptomswere frequently exhibited byworkers indicating, in accord withmanufacturers’ warnings, that workerswerebeingover‐exposed.

Chemical Exposure Risks: “We neverpainted a good part…80% of the parts wemadehad tobepaintedagain...theywantedus to rework those parts and start sandingthem(immediatelyoutof thehotoven)andthenputthemthroughthepaintagainsoweweregettingadoubledoseofthestuff.Itwasyears before we made a quality product.”Committeemember

“Inearlyyearsofmanualpaintingtheexcesspaint and solvents from the (inside) paintbooth were vented out putting bystanderworkersatgreaterriskofexposure than thepaintersthemselves.”Committeemember

Chemical Exposure Risks: touch uppainters at risk of exposure throughinhalation and absorption. Many instanceswhere PPE had flaws, exposingworkers toma

Supplyairventedtotheambientairoutsideof the booth. Workers were drawingambientairthatcouldbecontaminated.

Improper fitting suits allowed skin contactwhile in spray booth. There were manyinstances inwhichairpressurebalance ledto major releases of airborne isocyanate

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hardened or “cured.” It was difficult tomaintaintherequiredtemperaturesineachof the four ovens due to leaks and airimbalances in the deteriorating tunnel andstack structures. After exiting theoven/tunnel, parts were inspected andeither approved for shipping or sent to“outsidepaint”assemblyarea for touchup,or rework, prior to final assembly andshipping. In later years if a part wasunsalvageable,itwassentto“regrind.”

Outside Paint: Assembly, QualityControl, Cart Maintenance: In outsideAssembly, production workers inspected,cleaned, repaired, reworked and boxednewly painted parts in preparation forshipment. There were two productionworkerspertable/pershiftassignedtoboth“sand/trim/buff” and “rework” operations(the number and specific tasks of workerswere dependent onwhatwas required forpartsproducedthatday)

In“cartmaintenance,”maleworkers(2pershift) were responsible for keeping theinsidepaintcartsfreeofpaintbuild‐upandproperly functioning. This was, dirty,smelly, heavy work involving welding anduse of power tools, including air chisels,grinders,andhighpressurewatersprayers.

Paint Kitchen: The paint kitchen, wherepaintsandsolventsweremixedandstored,employedtwo“kitchen”operatorspershift.Thiswasadangerousareaduetothetasksinvolved and large amounts of toxicchemicalsthatwereusedandstored inthearea.

SludgeRoom/Sluiceway:The entirepaintoperation was linked to a large 4 ft deeptrough system which continually carried

paints.

Curingovenwasalsoasignificantsourceofrisk of inhalation particularly whenventilation system was not functioningproperly.

Chemical Exposure Risks: Outside Paintand Assembly were at significant risk ofexposuredue todirecthandlingof recentlypaintedparts, some stillwet. Inhalationoffumesanddermalabsorptionwasalsohigh.Exposure to releases from inside paint, aswell as fires, would expose outside paintworkers to very hazardous by‐standerexposures.

See below for specific risk factorsidentified in the outside paint in thissection and details for assemblyoperations

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both “clean” and “waste” water thatcontinually circled beside the paint tunnelending/beginningintheSludgeroomwhichcontained several Olympic pool‐sized,twentyft.deep“pits”wherechemicalwasteproducts were separated into their liquidand solid properties and removed (far tooinfrequently, leading to major contam‐ination and exposure risks for workers).Bothwere a constant source of unpleasantandtoxicfumesforsome‐‐andoftenmany,evenalltheworkersintheplant.

Ventilation Problems: While the painttunnelwasventilatedanddesignedtosuckpaint fumes and vapors inside, to preventexposure of outside workers, if theventilation system was turned off orcompromised, fumes and vapors from thepaintoperationwouldcontaminatetheareaat entry and exit. When this occurred,workerswouldbeevacuatedfromthearea.There were many documented complaints,work refusals, and MOL investigations, inresponsetotheseepisodes.

Chemical Exposure Risk: MOL HygReport31/1088(KimGordon):Ahygieneassessment “…inside paint line found to beblowing paint and solvent vapors into thegeneral work area.” (Inside paint andoutside paint at high risk of inhalationexposureduringtheseepisodes).

DETAILED INSIDE PAINT PROCESSES:The in‐line carts carried parts on racksthrough the paint line which included thefollowingstagesorprocesses:

1. Wash System: An automatic six stagewash systemconsistingof a pre‐rinsewithwater; an HCL bath; a caustic soda bath;parco plast; blow off tunnel; and a dry offwith hot air. Set‐Up workers responsibleforfillingandmonitoringstation.

ChemicalExposureRisks: Set‐upworkersatriskofexposuretovariouscausticagentsbecause of exposure to mists and spraysfrom this process. These ingredients (HCL,Caustic soda, parco plast)were continuallybeing added to the wash water at thedifferent stages. No PPE other than glovesandlabcoatworn.

2. Paint Booths: In the early years, twopaint operators were stationed in each

ExposureRisks:Thepaintdepartmenthadthe largest concentration and variety of

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booth to touchupandapplypaint toareasmissed by the reciprocating overheadsprayers They wore anti‐static boots,gloves, Tyvek suits and respirators (withimproper cartridges) for this application.The painterswould enter the booth, purgethe paint lines and gunswith Pebra 5 andbeginsprayingtheparts.Thehandpainterssprayed the bottom and edges as well asany spotsmissedby theautomatic sprayeroverhead. By 1993 when inside paint wasfirstmodernized all fivepaintboothswerefullyautomaticwithrobotsreplacinginsidepainters.

The paint operators were responsible forcleaning up over‐spray episodes. Thiswould involve removal of their gloves andTyveksuitsandwipingdowntheoverspraywitharagsoakedineitherPebra5orMEK.Theywerealsoresponsibleforclearingcartcollisionstoppagesinthepainttunnel.

Paint Line Set‐up Operator: The set‐upoperatorworePPE,anti‐staticboots,rubbergloves and a respirator and was notrequiredtowearaTyveksuitattheoutset.The set‐up operator’s tasks included:setting the air pressure in the booths,monitoring the paint pressure, repairingoverheadreciprocatingsprayguns,flushingand filling paints, cleaning boothwindows,mixingpaintsattheboothsforcoldandhotpots, and cleaning air caps in containerfilledwithPebra5.

In the early years, an automated cartcarryingpartswouldpassbetweenthetwopainterswhowouldspraythebottomsandedgeswhile an automated reciprocal paintarmsprayedthetopsofparts.Accordingtofocus group worker reports, “most timespainters did not wear proper PPE andrespiratoryprotection.”PaintersworeTyvek

toxicchemicalsusedintheplant. Basedonthe number of different MSDSs there were98 chemical compoundswith eachof thesecontaining a number of chemicalingredients. These ingredients includedprimers, catalysts, solvents/thinners, washcaustics, paint kitchen chemicals, sludgeroom chemicals, and cart maintenancechemicals. For example, in the 11compounds used as primers therewere 35differenthazardousingredientsnotedintheMSDSsforthemainproducts.

Chemical Exposure Risk: The primarysources of VOC emissions from surfacecoating operations (which result almostexclusively from solvent evaporation)include: the application area, flash‐off areaand curing ovens, with less significantsources being the storage and mixing ofcoatings and solvents, surface degreasing,and equipment clean up, including linepurging for colour or material changes.Storage vessels for paints and solvents aswell as mixing kettles usually fitted withbreather pipes from which VOC emissionsemerge.

Chemical Exposure Risk: VOC emissions(coming from 50‐80% of the coatingoperations) arose from the application andcuring of the primer, primer surface andtopcoat,ofwhich75‐90%emitted fromthesprayboothand flashoffarea,and10‐25%frombakeoven.Theremaining20%ofVOCemissions result from final topcoat repair,clean up, and miscellaneous sources,including the coating of small componentsand application of sealants. (Ed Wong,1996) Inadequate PPE would increase therisk of exposure to paint chemicals aswellaspoorworkpractices.

QueensUhygiene report:Aug1988:Re:

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suitsandambientairhoodsonlyintheclearboothwhere theywere “vented” throughaflexible air hose connected to their hoodand leading to the ambient air outside thebooth. This was not a sealed positive airsupply system. The painterswere in factbreathing contaminated ambient air fromtheouterroomandwhatevercontaminatedairtherewasfromthepaintoperation.

All paint booths shared a system forcapturing paint over‐spray. This consistedof electrostatic charged particles drawndowntoagrateoverasluicewayfilledwithwater, aswell as awaterwall that furthercapturedpaintparticulate anddrew it intothe sluiceway. The sluiceway, approx.‐imately 24” wide by 4’ deep, traveledthrough all the booths then down to the“sludge room.” The sludge room containedtwo open pits approximately 75’x12x20’deep and a third about 7’ deepwhere fivepumps moved sludge water overheadthrougha10”pipetothesideofeachbooth.To further assist in preventing fugitiveemissionsofpaintandsolventsvapors, thebooths ventilation system was underpositivepressure. However, thiswasoftensubverted as a result of doors left openwithin the paint line system resulting inmigration of heavy vapors from all boothsincluding the clear‐coat booth, whichcontained Isocyanates and catalysts.Operators described the latermix as large,visible,mushroom‐shapedcloudsofvapourand mist that would flow throughout thepaint line and out into the general area ofthe plant. This latter condition hascontinued to the present day. Workersindicate that the ventilation systemcontinues to fail and expose workers tohighlyreactivepaintfumesandmists.

Chemical Monitor: The tasks of the“chemical monitor” included: testing forproper chemical levels in the 6 stagewash

heat stress in paint booth: the Wet BulbGlobe Temperature (WBGT) “measuredoutside clearcoat booth was 27.2C. Thiswould marginally exceed TLV of 26.7 forcontinuous work of moderate workload.Paintersstandingonearmworkwouldlikelybe classified as light work therefore thepermissibleWBGT index for a paint sprayerinworkclotheswouldbe30C. However, theWBGT device cannot quantify heat stresswithinairrespiratorpaintsuit.Judgingfromthe observed redness of skin and degree ofperspiration, painters likely experiencedconsiderable thermal stresswhile clear‐coatspraypainting.And in the same report:Theinside solvent level…maynotbe reliableasthe sampler tubing disconnected from thepump at some time during sampled period.However, an inside suit solvent level wasdetermined to also be below the analyticaldetection limit.Solvent vapourwasdetectedinsidethesuitofonepainter(on a differentday).Thismayhaveoccurredbeforethehoodwasinplacewhiletheotherpaintertestedhisspraygunwithseveralshortblasts.”

Itisimportanttonotethatanumberofthepaint and solvent chemicals used in thePaintLinehavebeenratedascarcinogenic,fetal toxins, teratogens, mutagens, neurotoxinsandsensitizers.

MOL28846022/01/90:MOL follow‐upre:fumes, ventilation, ISO exposures in paintline: MOL inspector notes previous ordersstillnotcompliedwith:WHMIStrainingnotcompleted;paint fumes frompaint linestilla problem; and no action taken to date.Management suggests workers just moveoutofthewayofthefumeswhichinspectorrejects as a solution not in accord withregulation132.

P90‐01‐70 22/01/90: documentation of

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cycle;monitoringthesludgewaterforpaintand solvent levels; adding chemicals to killpaintandremovingsolidswitha“weirbox”;adjusting pumps for water and chemicalapplications; changing filters for waterwash system and chemical applications;adjustingwaterandairflowinpaintbooths;and monitoring temperatures in paintsystemovens,painttemperatures,viscosity,air temperature and humidity throughouttheinsidepaintoperation.Theirotherdutywastochangerooffilters.

Inside Paint Maintenance (skilled trades):Workers maintained and repaired allcomponents of the inside paint operation.Each shift had dedicated 2 millwrightmechanics and 1 electrician. Their workinvolved the daily rebuild of paintcomponents (e.g.,pumps, airmotors, surgesuppressers, back pressure valves etc.) aswell as responding to any breakdowns.Repair involved soaking components inlarge pails ofMEK and later Flush solvent.Specific chemicals which maintenanceworkers were exposed to included Purgesolvent, HDI, and all paints and solventsusedinthedepartment.

two fires inpaint line, fumescomingoutoftunnel. Paint Line Chemical Monitorrequestedareviewofairsystemreferencingtwofiresinpainttunnelatthemanualpaintgunsite.

MOL 288244 15/06/90: Ventilationevaluation/fires in paint: MOL ordersengineeringevaluationofventilationsystemto correct current imbalance betweenreplacement/exhaust air causing themigration of toxic chemicals from otherdepartments to enter general (assembly)work area. Noted that illegal modificationmade to paint spray system was cause ofseveral fires in paint line due to electricalstatic discharge sparks ignitingpaints/solvents.Orderedtocorrectandnotmake changes without consultingmanufacturerofthepaintsystem.

Chemical Exposure Risks: maintenance.See separate treatment of maintenancepersonnel below. Millwright especiallyexposedbecauseofdetailedworkrepairingandpurgingpaintpumps and lines. Heavyexposure to ISO paints, solvents, andthinnersforprolongedperiods.

MOL: 90D855maav 23/05/90: workersensitization: MOL advised that worker inpaint line had been sensitized toisocyanates. He noted that safe practicesand procedures not strictly followed asrequiredbyISOcontrolprogram.

MOL: 244907 12/04/89: work refusalsInside Paint: “Workers refused to install astairway in the inside paint line due topresence of toluene vapors found previouslyon 10/04/89 thatmight present a fire andexplosionhazard.Fanturnedoffinthesludgeroom caused the migration of toluene to

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migrate into themain plant. Fourworkerswere sent home. A combination of factorsnoted:makeupairunitturnedoffblower inanotherareachangingairflowinplantfrompositive to negative, and water levels insludgeroomweretoohigh.”

MOL: P90‐01‐70 22/01/90: refusal re:paintfumescomingoutofthepainttunnelduetofailedventilationsystemandafireinthepaintline

MOL: (Swindells) 08/02/90 MOLinspector re: ISO controlprogram: “MOLobserved worker entering spray boothwithout respirators immediately after ISOpaint spraying; no ISO control programtraining for painters; worker observedentering ISO booth with respirator notstrappedandfittedproperly–ordersissued.”

H&S log: 07/05/90: work refusal (10)workers: “Workrefusaloverair‐flowprob‐lems in inside paint. Airflow in the wrongdirection and booth filled with cloud ofIsocyanate paint. Maintenance workersentering booth without respiratoryprotection; Scott air‐packs inside the boothand not available for those working in thebooth. Logs show a constant problem withair‐flowthroughouttheyear.Oneworkerwasgiven another person’s respirator to wearand refused.Thepaint vaporandmistwereflowingout into the tunneland intooutsidepaint.”

MOL:288184 13/12/90: work refusalslippery floors: Worker refused afterslipping and falling in the paint booth

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because of slippery grates in the paintbooth. In violation of Act, another workerwas assigned to the booth without beingadvised of the work refusal. Solvents wereused to clean grates coatedwith paint andgrease.

H&S log: 22/04/90: Clear coat hardener(UN1263) spill 200 litres in paint lineloading and unloading area at end of thepainttunnel.Areaevacuated.

H&S log:16/01/91: work refusal in paintline:leakingsolventlineinbasecoatbooth.Airflowwasonlyworking50%capacityduetofansbeingplugged.

“Excess fumes in paint booths wereinitially exhausted into the workenvironment through hoses to reduceexposures to inside workers,” committeemember

“H&S log, May 7, 1990: hazy smoke inpaintboothrefusal insidepaint:“Therewashazearoundthelightsandairflowwasgoingthe wrong way. Again there was a cloudcoming out of the filters. Air Flows beengetting worse and worse by day. Air‐flowproblem documented in log books over andover. Never addressed (After calling MOLabout refusal)Management allwent insideand started moving things and doingsomething to the system before theinvestigation. All the doors wereopened…People inandoutof there like fliesbeforeinvestigationwasdone.”

MOL28846022/01/90: followupvisit reventilation: MOL inspector notes previousorders not complied with. WHMIS training

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not completed; paint fumes frompaint linestillaproblem;andnoactiontakentodate.Other issues noted: JHSC still not doingspecific hazard analysis; ISO units in tankfarm still leaking; cartridge respirators inpaintkitchenstillnotstoredseparatelyandstill absorbing solvents; sludge room stillnot provided with life lines and belts; noWHMIS labels in compressor room; noformalwritten operatingprocedures in thesludge room; improper respirators used insandandtrim;stillnoadequatepoliciesandprocedures manual (suggest WCB“Workwell” Program); failed to get pre‐medicalsforISOworkers.Failuretoconducta first stage work refusal investigation inaccordwithSec.23oftheAct.Ordersissueda second time on this visit. Fires in paintbooth due to electrostatic discharge duringuseofpaintspraygun.

MOL: 288244 15/06/90: Ventilationevaluation ordered/fires in paint: MOLorders an engineering evaluation of theplant’sventilationsysteminordertocorrectthecurrentimbalancebetweenreplacementairandexhaustairwhichcausesanegativepressure environment and causes themigration of toxic chemicals from otherdepartmentstoenterthegeneralworkarea.Itwas noted that illegalmodificationmadetothepaintsprayingsystemwasacauseofseveral fires in the paint line due toelectricalstaticdischargesparksthatignitedthepaints/solvents.Ordered tocorrectandnot make changes without consulting themanufacturerofthepaintsystem.

MOL:288434 11/04/90: Paint Line: ISOsensitization claim WCB. MOL requestsmedical consultant review. Also notedproblemswiththeISOcontrolprogramand

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problemswithskinexposureandrespiratoruseandtraining.

3.CureOven:Afterpartswerecoatedwithfinal clear coat, theywould pass through acuringoven(325F) forseveralhours. Thecuringprocessgeneratedfumesandvaporsfrom curing paints. These fumesmigratedfrom any cracks in the curing tunnelwallsandceilingsaswellasatpointofentryandexitwhen the positive air pressure systemwas compromised. In fact, the exit wasequippedwithajerry‐rigged“windsock”towarn workers waiting at the exit thatcontaminated air was escaping from theoven.

Attimes,thepaintedpartswouldcomeoutof the ovenswith paint runs or “fish eyes”on the painted surface. Thesewould havetobesandedand touchedupand then“re‐cured.”However,therewerealsoinstanceswhere paint failed to cure properly eitherbecause of an oven malfunction or a cartcrash in the tunnel. These uncured partswouldbetakenoff the lineandhandledbyproduction workers, subjecting them touncuredwetIsocyanate.

ChemicalExposureRisk: The Cure Ovenwas a major source of chemicalcontaminationintotheplant.Theheatfromthe oven would cause the paints andsolvents to flash off and escape into thegeneral atmosphere. This was especiallyacute when the introduction of a thermaloxidizer unit caused air pressure in theovens to become positive instead ofnegative. This led to amajormigration ofcontaminationintotheplant.Vaporswouldcontain various ingredients in the paints,solvents,andthinnersthatbecameairborneandwereinhaledbyemployees.

ChemicalExposureRisk:When therewasatemperaturecontrolproblemintheovensuncured monomers coming off productswouldalsobereleasedintotheatmospherecreating inhalation and dermal riskexposures.

DETAILEDOUTSIDEPAINTOPERATIONS:

1. Load and Retrieve: After post cure,parts were retrieved by the armful, thenhung on rackswith alligator clips attachedto paint carts and brought to the outsidepaint area for quality control inspection.Loading the parts from post cure was adusty operation and production workers

Chemical Exposure Risk: materialhandlerswouldbeexposed tohigh level ofdustpickinguppartsthatwerejustsandedandbuffed. Theywouldbecoveredindustcontaining ISO, urethane, monomers, andadditives.

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describedbeingcoveredindust.

Inspection: two inspectors per shiftworked on each side of the line as partscameoutofthecureoven.

Inspectors often handled heated parts, andalso were exposed to off‐gassing fromuncuredpartswhichtheyregularlyhandled.Alsoexposedtoreleasesofvaporandgases.NoPPEworn.

Repair and Rework: Painted parts thatwere damaged or defective were culledfrom the line by an inspector as partsexited. Thesecouldbesent for lightrepair(sanding, buffing, and repainting) or to bereworked (puttied, sanded, and repainted).Repairs were made on some parts byapplyingFinessecreamandthenbuffing.

Chemical Exposure Risks: Assemblyworkers were exposed to considerablecontaminationincludingbreathingof fumesand dust, dermal exposure to solvents,buffing creams, grey putty and touch uppaint. As well, they were exposed tocontaminants from three departmentswhich is documented. Poor/no ventilationor PPE.Manywork refusals, hospital visitsandillnessreports.

MOL: 90E859MAAV 14/05/90:ObstructiveLungDisease:Inspectoradvisedby company doctor that a considerablenumber of workers in sand and trim haveobstructive airways as indicated inpulmonary testing. Likely due to dustexposure from sanding polyurethanepainted parts. Respiratory protectionordered.

PAINT KITCHEN: The paint kitchen waswhere all paint was mixed and stored. Itcontained a number of 85 gallon mixingkettles which fed into the different paintlines. The paint storage/mixing roommeasuresapproximately155’Lx24’Wx25’H.Inthemid‐90s,theareawasdividedintoseparately enclosed mixing and storageareasbutprior(toaseriousaccident)itwasone largeopenareawhere largequantitiesofmoredangerous“live”paintswerestored

Chemical Exposure Risks: “There werealwaysheavysolventsmellsandexposuresinthe self contained kitchen and sludge pitarea.”committeemember

MOL:Duringregularinspectionoftheplantin1991,strongorganicvapoursmellswerenoted in large paint mixing room and insludgeroom.Oneoftheventilationsystemsat south endofmix roomwasnotworking

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inthesamespacewherepaintsweremixedin huge quantitieswith solvents and otheradditives. The area(s) was served by thefollowing mechanical ventilation systems:three independent, roof mounted exhaustfans with vents at floor level providing10,000cubicfeetperminute(cfm);aheatedair supply systemproviding approximately7,000 cfm into this area; and two heatingand air conditioningunitswith a collectiveair flowof14,000cfm,amajorityofwhichwasrecycledair.

Two work shifts were carried out in thestorage area and paint kitchen. The firstwas8hoursandthesecond10hours,both4 days per week. The workers spent themajority of their shifts setting up andmonitoring thepaintmixing.From1988to1991theworkerslackedrespiratorsinthishighly toxic area. Respirators were laterprovided but they were stored in openareasandnotcleanedorprotected.

The three separate coats required for thepaint booths (primer, base and clear coat)were prepared andmixed by the operatorwho wore a Tyvek suit, anti‐static boots,rubber gloves, and safety glasses. Noappropriate respiratory equipment wasworn.Thetasksincludedmixingthepaint,addingsolventsandadditivesmanuallyin5gallon pails, and transferring each to 85gallontanks‐‐oneforeachbooth.Thefinalmix contained 40% solvent and 60%paintplus additives. The paints used containedthe following: MEK, acetone, xylene, andIsocyanate HDI. These are in relativelyequalproportions.

Alltanks,lines,andhardwarewerepurged,washed and soaked in Pebra 5. Itwas alsousedtomopfloorsandcleanuppaintspills.Duringtheearlyperiodallpaintswerehand

adequately (very lowair flow)MOL2801823/09/91.

During follow‐up inspection the followingyear one of 16 orders included: “Theambientairblowerontheeastexternalwallofthepaintkitchenshallbearrangedsothatthe air used from this unit is drawn fromoutdoors inanarea freeofcontamination inaccordancewithsection25(2)hoftheAct,onorbeforeMay22,1992.”

Follow‐up inspection to above identifiedserious “bonding and grounding issues”related to present mix kitchen and spillsystem:“itwasstressedthatperiodiccleanupshould be scheduled to ensure the drainsystem isworking as intended and does notbecome (or remain) blocked. The need forupgrading the use of bonding when anyflammablesarebeingpouredordispensedormixed was discussed and left for furtherreview…ItwasstressedthatproceduresintheMSDSs be followed for spill clean‐up. Thesesolventsandpaintsaregeneratedonadailybasis by cleaning filter units and by back‐flushing/cleaning paint lines. Consequently,someday‐to‐dayprocess isneeded toensurethefumesarekepttoaminimum.”(It took aplant‐wide work refusal a year later forworkerstofinallyhaveaccesstoMSDSsandappropriate training). MOL: 0717017/12/91

Chemical Exposure Risks: This was ahighlycontaminatedareaasoperatorswereexposed to enormous amounts of toxicpaints and solvents handled manuallythroughouttheday.Therewasahighriskofspillsrequiringmajorcleanups.

The risk of exposure via dermal route tofumes, mists and vapors is high when

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mixed.ThosethatincludedsolventsandNo.2Khardenerwerereferredtoasa“hotpot”as opposed to a “cold pot” that did notcontainanyhardenerorISO. Accordingtoworkers who entered the paintkitchen…”therewere times in the kitchen ‐‐mostofthetimes‐‐youcouldn’tbreathe”.

In addition, the contaminated air was notadequately exhausted from the paintkitchen.Theexhauststacks,approximately40’ high and vented externally, were noteffective because of severe corrosion. Itwas likely there was insufficient capacityand velocity to draw the contaminants upthe 40’ span of stack, as well as pastblockages due to the build‐up ofparticulates. The ventilation system wasalsosubvertedbytheopeningofboothandsludgeroomdoors.

At present paint mixing is semi‐automaticrequiring manual addition of someingredients. The kettles are closed duringmixing,andpaintisdeliveredtoboothsviaenclosed lines. This can be contrastedwiththeearlierperiodwhenmixingwasdone manually with operator mixingsolventsandpaintsinequalproportions‐‐ then checking viscosity and addingadditionalsolventorpainttoobtaintheappropriate viscosity. Handling wasmoredirectandexposureslikely.Therewere two paint kitchen operatorspresentforthemajorityoftheshiftwithother workers coming in for briefperiods.

Minorandmajorspillswereroutineeventsrequiring hazardous clean up procedureswith harsh and dangerous solvents. Thespills were usually mopped into thesluiceway. Inaddition,solvents(includingMEK and methylene chloride) were

working on these systems, due to the highsupply pressures under which it works.These operating pressures run from 125‐150psiandareturnpressureof90‐100psi.Theotherriskoccurswhenthecolourvalveopenstoallowaspecificcolourtobesenttothe Mechanical Vapor Recompression, akaMaterials Volume Regulator Panel (MVRPanel),which supplies the ratio of paint tohardener to the paint system. Exposure ismostlikelyduetosolventvapors.

MOLinspectionreportsdescribeworkersasnot well trained in the care/storage andproper fit‐testing of the organic cartridgerespirators, and as well, lacking in goodwork practices and personal hygiene. Forexample:

MOL: 90D854EAAV 05/08/90:Assessment of solvent/HDI exposures inpaint kitchen: worker exposure to HDI(isocyanate) and MEK possibly whenloadingpaintkettles,repairingandflushingsystem, and during malfunctions andmanualspraying.Ordersissuedforskinandrespiratory protection. Worker observedcleaningequipmentpartswithMEKwithoutrespirator and no ventilation. Workingabove pail of MEK is ‘unpredictable’ andmay cause exposure in excess of TLV.Cleaningshouldbecarriedoutinaproperlyventedarea.

ChemicalExposureRisk: In early period,paintmixingwasmanual,mixingmaterialsapailatatimeandpouringratiosofpainttosolvent back and forth. Risk of inhalationandabsorptionveryhigh.

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routinely used to clean paint equipment.When these spills occurred in conjunctionwithmalfunctionsoftheventilationsystem,migration of contaminantswoulddrift intothe general work areas of the plant withserious health consequences for otherworkers.Supplyairwasprovidedby(anoil‐less) air pump located outside the paintkitchen. The air inlet to the pump waswithintheplantonthesideoftheunit.

A trough inside the paint kitchen wasoriginally connected to the sluiceway; it isnowanisolatedopendrytrenchthatservesasaholdingareatocontainspillswhicharecleaned manually. An accident involvingsolventsflowinginthesluicewaythatwereignitedbyhotweldingdebrisdownthelineledtoaseriousfirewhich,ifithadreachedthe paint kitchen, would have created amajor explosion; this near catastrophe ledtomajorchangesinthepaintkitchen.

H&S log:16/05/90:Work refusal: (120)Workers evacuated to cafeteria becauseofamajorreleaseofHDIIsocyanatesinthepaintkitchenwhichrapidlymigratedtotheoutsidepaintarea.Acloudoffinemistpaintmigrated. The ISO monitoring alarm wasmalfunctioning and as paint was beingflushed, the release became uncontrollableand HDI vapour migrated to the outsidewhereotherworkerswereexposed.

H&Slog: 22/08/95:ISOspill:overflowofclear coat catalyst in the paint kitchen,approximately4‐5USG.

H&S log: 12/02/96: work refusal paintkitchen: work refusal regarding irritatingvapour fromdegreasing cleaner (INDO401Natural Solvent Degreaser and Terpenederivative) that was used as floor cleaner,and volatiles from cleaner were enteringpainter’s protective positive flow helmet.MSDS indicates an irritant containingsensitizer and has inhalation hazardwarning. Worker disciplined for raisingissue.

OtherSourcesofPaint‐relatedContamination/Fires: Other sources ofcontamination involved instances of paintspills, which happened frequently. Thesecouldhappenbytippingoveracanofpaint,during purging, or the result of a break inthe paint lines. Spills would involve majorrisks of exposure. In later years, majorspills were cleaned up by Emergency

ChemicalExposureRisk:Spillsofpaintsandsolvents as well as fires in the paint lineweremajorrisksofinhalationtoisocyanatepaint,hardenersandsolventssuchasMEK,acetone, tolueneandbenzene. Fireswouldcreate an even more complex mixture of

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Response Team (ERT), but prior to itsformation, workers were ordered to cleanupspillswithoutproperinformationonthehazardous nature of the clean‐up. Thismainly involved squeegeeing spilled paintintothesluiceway,whicheventuallyflowedinto the city’s sewage system. There aredocumentedinstanceswhereasmuchas80gallonsofhardenerwasspilled,flowingintocitysewers. Largespillsaremajorsourcesof exposures due to their volatility andsurface area. As well, most clean‐upsinvolvedtheapplicationofMEKorPebra5.

In addition to spills, there were numerousinstancesoffiresinthepaintlinerespondedtobythelocalfiredepartment.Sucheventswere a major source of toxic exposurescomposed of thermal decomposition by‐products, for example: monomers, formal‐dehyde, benzene, oxides of nitrogen,nitrosaminesandothers.

decompositionby‐products

In addition, the by‐products of thesechemical substances catching fire presentadditionalinhalationrisks.

CartMaintenance: Tasks associated withcart maintenance include: keeping carts inproper working order; changing wheels,greasing wheels and repairing damagedcarts.Theoperatorwoulddailyremovethebuild‐up of paints on carts using airpowered chisels and drills. Maintenanceand repair also involved the welding ofdamaged parts (welding usually but notalways done by maintenance workers).Because of paint residues containingisocyanates, hardeners, and solvents, thewelding repair operation on carts led tovery hazardous thermal decomposition by‐productsmentionedabove. Whencleaned,the carts were shrink‐wrapped andreturnedtopaintline.

Repairingcartswascomplicatedbyabuild‐up of hardened catalyzed paint thatwouldbe approximately½ to¾ inch thick. This

Chemical exposure risks: High risk ofinhaling toxic and irritatingwelding gassescontaining heavy metals, VCM, ISO fumes,paintparticulates,oxidesofnitrogenaswellasfumesfromdecompositionby‐products.

Because of paint residues containingIsocyanates, hardeners, and solvents thewelding repair operation on carts led tovery hazardous thermal decompositionby‐productsmentioned above. The paintcouldbeburntoffwithweldingtorches,airchiselled off, or ground off by welders.These methods produced substantialconcentrations of fumes, smoke, and fineparticulate composed of the thermaldecomposition by‐products of Isocyanatepaints. Welders described very strongfumes and smoke, affecting not onlywelders and cartmaintenanceworkers,but othersworking in the vicinity. The

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build‐upwasremovedinseveralways,eachpresenting a serious exposure risk. Thepaint could be burnt off with weldingtorches, air chiselled off, or ground off bywelders. These methods would producesubstantialconcentrationsoffumes,smoke,and fine particulate composed of thethermal decomposition by‐products ofIsocyanate paints. Welders described verystrong fumesandsmoke,affectingnotonlyweldersandcartmaintenanceworkers,butothersworkinginthevicinity.Therewereno welding curtains provided to isolatetheseexposures.

Thecartmaintenanceoperationwasadailyoccurrenceinvolving20to30cartspershiftandinthecaseofamajorcrashinthepainttunnel,itcouldinvolveupto100cartsthatneededtoberetrievedfromthetunnel,thencleaned and welded. This intense workwouldproduceenormousamountsofdusts,fumes, smoke and particulate. As well,weldingrodsusedbywelderscouldcontainheavy metals including cadmium, addingcontaminantstothemixoftoxicexposures.Thisoperationcontaminatedapproximately½ of the entire plant when heavy activitytookplace.Aheavycoatingofweldingdustwouldaccumulateonallaffectedsurfaces.

Very high‐pressure (10,000 psi) waterblasting systems used for cleaning paintbuild‐up on carts created fine mists,(containing chemical residues) makingsignificant skin contact, inhalation, andingestionhighlylikely.

Thecartmaintenanceandrepairoperationmoved numerous times during the Pebraera due to complaints from other workersanddepartmentsoverextremelyheavyandstrong welding smoke, fumes, and vapors.Initially, the operation was located in the

intensity of the work and heat generatedduring the processes contributed to dustfumes,gasses,andhigherratesofheartrateandrespiration.

Cart maintenance workers wore no PPEotherthandustmasksandpossiblygloves.

In addition, the use of high pressurewaterblast system increased the risk of inhaling,ingesting, and absorbing any contaminantsinthewaterafterhittingpaintedsurfaces.

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middle of “everything”—with at least½ ofthe plant affected by the fumes from thewelding operation. With growingcomplaints,cartmaintenancewasmovedtothe shipping area ‐‐ which also wasn’tconsidered suitable. The operation wasfinally moved to its current location,somewhatisolated,behindthepaintline.

Inaddition,plasticwrappingwasusedatalatertimeonthecartstoreducepaintbuild‐up and aid paint removal which involvedtheapplicationofathinfilmofPVCthatwastorchedduringthecleaningprocess.

Also, workers would apply grease to cartwheels and burn off old solidified grease,producing thermal decomposition by‐productsaswellasskincontactwithgreaseduringgreasingoperations.

Committeemembersidentifythattherewaslittle local exhaust ventilation andinadequate respiratory protection duringthismaintenanceoperation.

Chemical Exposure Risk: While the PVCdid make it easier to remove paint, theheating and burning of the film and paintproduct created a highly toxic combinationof combustion by‐products that includedphthalates,monomerssuchasvinylchlorideand HCL, CO, CO2, nitrosamines, andbenzenetomentionafew.

Workers reported difficulty breathing andsome have developed COPD, coronarydisease, and neurological injury. As oneworkerputit:“Youknewthatthiscouldn’tbegood,whenyoublewyournoseandthesnotwasthecolouroftherainbow…whatwasthatstuffdoingtous?” Anotherworker said he“… foundthatmyhairwasasstiffasaboardby the end of shift from all the smoke anddustthatwegenerated”.

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4.ASSEMBLY/QUALITYCONTROL/MAINTENANCE(classesofmobileworkers)Introduction: Assembly or Production workers, Quality Control/Inspection workers and theclassofMaintenanceworkersatPebrawereallmobile,workingthroughouttheplantdependingon assignment. Generally speaking, the WSIB or Workplace Safety and Insurance Board, hasdifficulty identifying “risks” in compensation cases when workers are mobile. (This is yetanotherweaknessinOntario’scompensationsysteminadditiontomajorissuessuchasrefusingtoaddress“cluster”casesofdisease,andsettingastandardofproofimpossibletoobtain,despitethelawstatingotherwise.)

Assembly: The job classification,Assemblyor Production Worker included themajority of employees at the Pebra plant.They cleaned, cut, sawed, sanded, patched,trimmed, buffed, notched, punched, shaved,glued, puttied, filed, ground, boxed, moved,and likely other tasks associated with theproductionofplastictrimforautomobilesinthe decade 1986‐1996. Partly because theymadeup the largest componentof theworkforce at Pebra and continually handledsolvents such asMEK and Pebra 5, but alsobecause of major bystander exposures, alarge number of complaints and workrefusals were initiated by these, mostlywomen,workers.

In the numerous assembly operations thereweremanycomplaintsabouttheuseofPebra5 in its various forms and applications: assolvent/liquid for dipping, cleaning andwiping, as a glue to be sprayed or appliedwithfelttipapplicator,asaningredientintheplastic part that could be subjected to heat,scraping, cutting, sanding, buffing thus acomponent of the dusts and particles theywere exposed to. In many cases suchexposures lasted the entire shift. In allencounters with MOL inspectors andhygienists, dermal exposure (thoughacknowledged in advice given) is neverconsidered. Workers described the workenvironment as normally hot and sweatyresulting inmanywearingminimal clothingeven in winter, thus exposure through skinshould be viewed as a major exposure

Assembly(plantwide)ChemicalExposureRisk: Production workers were at risk ofchemical exposure in every department andarea of the plant. Many categories ofassembly workers were highly exposed todust and particles in their daily activitiesfromvarioussourcesincludingplastic,metal,and organic fibres in addition to the fumes,mists anddermal exposures associatedwiththe different processes documentedthroughouttheplant.

MOL: 431932 27/05/94 MOL report:phenol/formaldehyde and dust build‐upBuffingarea:fourbuffingunitsinthebuffingarea produced large amounts of dust frommaterials being buffed e.g. freshly madeplastic and isocyanate painted parts as wellas dust from the buffing disks composed ofvarious grits and phenol formaldehydeadhesives/resins. There was a largeaccumulationofdustonfloorsandintheair.While thebuffingstationwasequippedwithlocal exhaust, the size of the wheelemployedactuallyblockedthe flowofaircausingdispersalintotheatmosphere.

(A worker’s comment paraphrased byinspector is followed by his owncommentary): “…theair in theplant isoftennot fit to breath ‐‐ despite the fact thatnumerousairqualitytestsdonotsupportthisbelief”.

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source.

In a plant wide investigation of workercomplaints conducted by the union in1990, workers identified as majorcontributors to their health issues andcomplaints the following: outdatedMSDSs, missing labels on chemicals,wrong labelson chemicals,employernotcooperatingwith JHSC,employer’s failuretomaintainminutes and to consultwithworkers.325‐71‐203/05/90.

MOL:89L895NOBR30/11/89:refusalandinvestigationintoMSDSforPebra5(focusongluestick):Hygienistnotedworkersreceivedno training in handling Pebra 5 andconflicting MSDS information and concernabout toxic effects of tetrahydro‐furan/perchloroethylene (and likelycadmium).Possibleexposurewhenfillingthefelt tip applicator or replacing felt pad.Hygienist states that exposures toingredients are negligible. No discussion oftoxicityor concern about chronic/prolongedlow‐level exposures given the toxicity ofthese chemicals (and the possibility thatPebra5containscadmium).Penholds15mlof Pebra 5. Air concentration:tetrahydrofuran5 ppm, perchloroethylene2ppm.

Especially affected groups of assemblyworkers(basedonnumberandfrequencyofcomplaints or refusals) included assemblyworkers who worked at sand/trim/bufftablesinOutsidePaint,theFordLineinPostLam, and in the Rim operation. Theircomplaintsaboutthelackoflocalventilationand the company’s failure to provide downdraft tables, fansandvacuumsrequested,orto change/clean/or properly replace filterson their tables or machines went largelyunaddressed during that period and theirfrustrationwasevidentinreports,andotherdocumentationreviewed.

MOL: 90E859MAAV‐C 03/07/90: MOLmedical consultant re: adversehealth/dust/sand/trim: Medical consultantassessed workers’ medical symptoms fromdust (polyurethane/paint), i.e., difficultybreathing, fatigue, dirt of varying colour intheirnoses, itchyeyesanddryskin.“Severalworkers describe symptoms consistent withexposuretoadust.Workersaresandingpartsconsisting of polyurethane with choppedfibreglassandpaintedwithprimer,basepaintandclearcoat.Twoworkerswerefoundbythemedical department to have breathingproblemsrelated to thedust in thearea(thiswaspriortobeingorderedtobeincludedinthe ISO control program)Use of respiratorsordered in response to workers’ complaintsabout insufficient exhaust ventilation on thetables. According to the doctor: “Thesemedical symptoms are consistent withexposure to a fine airborne dust, which onvisiting the area is apparent in spite of theexhaust ventilation” AUTHORS’ COMMENT:He concludes that the dust levels are belowthe TLV. A follow up letter from the samedoctor dated 22/06/90 states that whilerespirators may have stabilized thesymptoms, there was no need to continue

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using them. QueensUniv.Hygienesurvey6/14/15 Aug 88: “…total suspendedparticulate ranging from 0.13‐0.91would beexcessiveinofficeenvironmentbutconsidered“positive” foran industrialestablishment.Thehighestwere detected in RIM/sand and trimareas….assuming that these employees sandand trim for seven hours of aworkday, theiractual time‐weighted average exposureswould have been 7/8 times the measuredvalues.”

Another group of assembly workers withmajorchemicalexposureswerethose,mostlymen, who worked in grey putty, applying ahighly toxic filler substance by hand in aconfined room to repair surfaceimperfections as an attempt to salvagedamagedparts.Exposureswouldbethroughinhalationandskincontact.Theonlyexhaustfan in their small, basically enclosed, areawascontinuallybeingturnedoffduethehigh90+ decibels of noise it produced. Severalmen who worked in this area died quiteyoungfromcancer.

MOL: 90GB63MOWV‐C 16/10/90: hygienemonitoringforHDI(ISO),MDI/ingreyputty:No detectable levels RIM molds and GreyPutty (HDI). Observed that “comfort fanswereoperatinginthesand/trimwhichcouldpossibly have interfered with themonitoring.”NotedthatMondurPFandMDIc‐961wereused.

A third group of assemblyworkers exposedto major chemical contamination (throughinhalation and skin exposure) wereoperators of carousel “glue lines.” Using apressurized glue gun they openly sprayed“glue”aspartsmovedpastthemviaconveyorbelt.Thegluesusedcouldactasanadhesiveorprimer forrawmetal.Thisoperationwasthe source of many by‐stander complaints.Operators wore NO PPE for chemicalexposures in the decade 1986‐1996, otherthancottonglovesandlabcoats.

Chemical Exposure Risks: Exposure viainhalation and absorption high amongassembly lineworkers. Performing detailedworkwithhighvolumeofglues,solventsanddusts.

Othersgroupsofassemblyworkersincludingmaterialhandlers,qualitycontrolpeople,boxbuilders and packers were exposed to off‐

MOL: 90F889MOWV‐C 09/07/90: MOLmedical consultant report as requested byWCB regarding worker health problem

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gassing,dustandsmallparticulatesaswellasdermalexposureswhentouchingorhandlingparts.

relatedtoexposuresinBoxareasofRIMusedasaloadingdock,boxassemblyandstorage.Theconsultant indicates that inan“upsetorspill situation” exposure might be possibleandnonehaveoccurred.Noform7indicatedto establish date of medical report forworker. (No indication of whatchemicals/exposures they reviewed, and nomentionofdieselfumesfromloadingbay).

Chemical Exposure Risks: These workerswould be exposed via inhalation tocontaminated ambient air from assemblyactivities and fugitive emissions from otherdepartments.

Quality control workers/inspectors werelocatedcentraltoproduction,i.e.,betweenorjust after major production lines, oftenexposing them to significant bystandercontamination.

Risk exposures were associated with anyhandling of parts at different stages ofproduction as well as by‐stander exposuresin the areas theyworked, thus the potentialforbothdermalandrespiratoryexposures.

Maintenance: consisted of a number ofskilled tradeworkers, includingmillwrights,electricians, and tool and die workers.Individually,theywereassigned,weekly,toadepartment or work area to maintain andrepairthevarioussystemsintheplant.Theywere available to respond to emergencies(specifictotheirtrade).

All maintenance personnel were equippedwith appropriate respiratory protection inadditionPPEtopreventabsorption.

The normal rotation for maintenanceworkers was to move weekly fromdepartment to department. Maintenanceworkers were likely to be directly involved

Exposure Risks: Resins‐MDI; polyol andsolvents.Exposureriskstoisocyanateresinsand paints as well as other hazardousingredients in RIM and paint line duringcontainment of leaks and spills and whenmaking repairs to pumps and valves andhoses. High exposure risks flushing hosesandpumpsandcleaningthesewithsolvents.

Exposuretosolventsincluding:MEK,TCE,toluene, perchloroethylene, and manyother solvents. Workers incur significantinhalation and absorption exposures duringcleaningandrepairofparts.

Exposure to TCE from large (4x4x2) vapordegreasing tank locatedunder thePost Lam

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(thus exposed to chemicals) in criticalsituations including spill, fires, andexplosions. Millwrights were likely to havethe most chemical exposures due to thespecific type of work they did related topurging and repairing of the complex pumpsystems in the plant. In the decade from1986‐2006 the number of maintenanceworkers increased from 20 to 28 workingthreeshiftsperdaytoensurecoverageofalloperations. Every shift included twomechanics for the paint line and onemechaniceachforRIMandinjectionmolding.

Maintenance Tasks (millwrights): dealingwithleakingvalvesinPolyolorMDIhosesinRIM or leaks, line breaks and pumpmalfunctions inpaint line,aswellas repairsonhydraulicsonclamps.Allinvolvedsimilarfeatures:leakingresinsandpaintscontainingisocyanates and solvents orhydraulic fluids.Work involved shutting down, taking offpressure,purginglinesorpumpsofresidues,cleaning parts in solvents (MEK, TCE,toluene, Pebra 5), isolating leaks, collectingand disposing of chemicals, and repairingdamaged/replacing parts. Tasks alsoinvolved cleaning with compressed air toblowoffsolventsanddirt.

MaintenancepersonnelwereinvolvedinERTbecauseoftheirspecialtasksskillsindealingwithleaks.(Tasksasabove).

Maintenance: Tasks (tool & die): dealingwith repairs tomolds surfaces. Thiswouldinvolve solvents to prep materials forwelding,grinding,andpolishingwithMWFaswellasothertoolingtaskstorepairormakemechanicalparts.

Maintenance (Electrician): dealing withmachine computerization problems and

oven.

These degreasing solvent exposuresparticularly to TCE and Perchloroethylenemayberesponsibleforcasesofkidneycancerand damage to personnelworking near thistank and maintenance personnel whofrequently used this tank. For example, themaintenance office staff would have beenexposed as well as notch and punch staffworkingunderneaththeoveninRIM.

Resin Dusts containing TPO/TPU:Exposure to resin dusts during cleaning ofcanistersandfiltersontheinjectionmoldingclamps. Thiswould involve exposure to thetremendousbuild‐upofresindustsTPO/TPUinductsandfilters.

Chemical Exposure Risks: Inhalation,ingestion and absorption of heavy metals,grinding grits, epoxy resins, MWF includingvarious cutting and cooling oils,nitrosamines, PAHs as well as solvents forcleaningandprepping.

ChemicalExposureRisks:exposureslinkedtofiresandmistsintheareasunderrepairinaddition tobystanderexposures toavarietyof chemicals used in other productionprocesses described in this report. Risk ofinhalationof solventsandelectrical cleanerstoinsurepropercontact.

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operations as well as other electricaloperationsoftheplant.

ERTTeam:In1993anEmergencyResponseTeamorERTwasestablishedattheplanttoreplacethelaissezfaireapproachthatexistedprior,where “anyworker could be called tocleanupaspilloraddressanemergency.“Wewere just told to do it as part of our job”(AdvisoryCommitteemember).

ERT Team Structure: a total of 10 peopleare assigned to the ERT from the unionincluding 2 rotating maintenance workers,three workers on day shift, 3 workers onafternoon shift and 2 from night shift. Theunion ERT team captain is responsible fordetermining when workers can return towork. Only management can shut the plantdown and make decisions on unidentifiedspills. Initially, worker representation wasbased on departments/job categories butlater changed to the current designation byshiftplusmaintenance.(Itwasnotedthatonnight shift the person designated to decidewhethertoclosedownintheeventofaspillis the security guard, as managementrepresentative.) In the case of a spill eitherManagement Rep on JHSC or night guard(after making a call to management) woulddeemifspillwashazardousornotanddecidewhether to call the ERT. The union ERTcaptain decides how many ERT trainedworkersareneededtocarryouttheclean‐up.If a spill is deemed not dangerous shiftworkers clean it up. There is always amaintenance person included in the ERTcalled. “Maintenancealwaysworeanorganiccartridge respirator or a full hood positivepressure respirator during clean ups, eventhough (according to Advisory CommitteeMembers) workers standing next to himwouldnotbewearingPPE.

RIMandInsidePaintLinewere identifiedasareaswheremostemergencyspillsoccurredbecauseoftheuseofISOintheseoperationsand both operations relied on complexdistributionsystemsintheirproduction.Asamaintenance informant stated: “Anywhere inRIM…behind the clamps; in paint it wasanywhere behind the paint booths… becauseallmovementwithintheselinescausesleaksinthe valves…and there was continualmovement.”

Lack of Controls: There was evidence inMOL reports and from worker informantsthat fire and emergency preparation wasclearlylackingasnotedinnumerous“orders”issued for proper training. Inspectors’ citedmany times that workers cleaned up toxicchemicals barehanded and without properbreathing protection. Management seemedequally uninformed as the following storytoldbyaworkerinformantshows:“Wehadaspill inpaint lineandwe’realldressedup inour gear and air packs on andmanagementwas so stupid they brought in a tour. I saidwhatareyoudoinghere?HesaidI’mbringinginatour.And Isaid,get thehellout. Andhesaid,andwhoareyou? Isaidifyoufalldowninhere,I’lldragyououtbyyourfeet….Hewasreallyburnedup,butlaterwhenIexplainedittohim,heapologizedthathedidn’tknowtherisk.”

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5.SHIPPING

ShippingmovedseveraltimesduringthePebraera,includingtoasecondbuildingreferredtoasthe“warehouse”inlateryears,purchasedspecificallytohousestorageandshippingoperations.

Shipping: Parts and materials were allbrought into the plant through the shippingdepartment, and then distributed toappropriateareas,whenandwhererequired.Parts and materials were moved fromshipping to various production operationsthroughout plant by various size lift truckspoweredbypropane.

During the Rim years (1988‐2000) driverstransported open Gaylord boxes filled withWollastonite which would blow out of themovingboxesandintodrivers’faces.

A number of assembly operations werelocated in the second building creatingadditional bystander exposures to thoseworking nearby in shipping. Those sameassembly workers were bystanders to thecontamination linked to shipping activityespeciallydieselexhaustfromwaitingtrucks,whichwas a source of continual complaintsfromassemblyworkerswhowereconstantlytellingdriverstoturnofftheirengines.

Finished parts produced by Pebra workerswouldbepickedupandtakentotheshippingdepartmentthenloadedontotractor‐trailers.These trailers were parked in an enclosedarea, particularly duringwintermonths andkeptrunning,spewingoutlargequantitiesofdiesel fuel emissions. Contamination wasmade worse because of the negative airpressureinthebuilding,whichcauseddieselfumes to be drawn into the shippingdepartment, as well as the rest of thebuilding. Workers often complained aboutthe diesel fumes insisting that bay doors

ChemicalExposureRisks:Fumesandgaseswouldbeemittedbywaitingdiesel‐poweredtrucks as well as from the fleet of propanepowered lift trucks. Risks also exist withbreakage or spillage of materials duringdelivery. This is especially problematicbecausethehazardmaynotbeknownatthetimeandMSDSsnotavailable.

Chemical Exposure Risk: Transportdelivering large quantities of chemicals,parts, etc. contain a substantial build‐up ofcontaminantsfromtheshipmentofchemicalsand other toxic substances likely to off gasduring transport. Workers complained ofbeing overcome when opening the trailerdoorstounloadthetransport.

MOL:28831417/05/90:Inspectionfindshigh CO levels: Fork lift truck tested andareas and found to have high levels of CO;sand and trim‐35ppm, northshipping=70ppm; shipping clerk desk=5‐10ppm.Alsofiltersinsandandtrimrequired(butdidn’treceive)regularmaintenance.

The lab was open access and allowedpedestrian traffic through the lab. It waslocatedunder thecafeteria in thesouth‐east

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remainopenandenginesturnedoff.

LABORATORY: thiswasamaterials testinglaboratory carrying out various tests on theintegrityofpaints,hardeners,coatings,resinsandflameretardantstotestdurabilityunderenvironmental,usage,andmaterialstressors.

Therewerethreetechnologistspershiftwithtwo shifts. One person was dedicated topaintsandtheothertwoweregeneralists.

Tasks involved direct handling of toxicchemicalsandmaterialsattemptingto inflictdamagetomaterialstotestfordurability.

Technologists would carry out tests in saltbaths,blistertestovens,andchipresistance,aswellashumidityandadhesiontests.Mosttest activities were conducted under fumehoodsorventedfumeenclosures.

endofthebuilding.

Chemical Exposure Risks: Materials werecut up, pounded with sharp objects, andheated and torched to measure thermaldecomposition by‐product emissions andflameresistance.Mostchemicalsusedintheplantweresubjectedtovarioustypesoftestsinthelab.Thetestingprocessposedariskofexposuretodustsandfumesduringtestingofpaints,resins,andadhesives.

However, most tests were conducted underfumehoods thatwereviewedbyDr.RolandWongand judged tobewellmaintainedandappropriateatthetime.

Conversely,workerinformantsindicatedthatodors were present in the lab and that labpersonnelhadbeendiagnosedwithleukemiaandadversereproductivefunction.Basedonthis we can assume that substances couldescape capture in fume hoods. As well,frequent pedestrian traffic and opening andclosing of doors would likely interfere withefficiencyofexhaustventilation.

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ACKNOWLEDGEMENTS

Theauthorswishtoacknowledgeanumberofpeopleandtheircontributionstothisretrospectiveexposurestudy.ThisstudywouldtrulynothavebeenpossiblewithoutthededicatedworkoftheUniforLocal1987AdvisoryCommitteeonRetrospectiveExposureProfilingmembers:localpresidentMarkClapper,pastpresidentRoseWickmanalongwithDaveGooley,JackieDufty,CecilFirlott,KarenQuesnel,andRickMcDougal.Wealsoacknowledgethemanyworkerswhocameforwardtoprovideadditionalinformationaboutproductionprocessesandexposureconditionsintheplant.Alloftheseworkersplayedacriticalroleinthecompletionofthisproject.

WealsowishtoacknowledgetheOccupationalHealthClinicforOntarioWorkersforfundingandsupportingthestudyincludingthefollowingstaffmembersinparticular:Torontoclinicdirector,LesliePiekarz,whoassistedwitheditingandproofreadingthisreport;MariaVieirawhotookontheunenviablechallengeofformattingoftablesandchartswithpatienceandgoodwill;andKasiaKerinforensuringdetailswereattendedtoandtheworkoftheAdvisoryCommitteeprogressedsmoothlyattheOHCOWPeterboroughclinic.

Aswell,weacknowledgetheon‐goingsupportandconstructiveinputofDr.NoelKerinwhosemedicalinsightsintotheproductionofoccupationaldiseasewereinvaluabletoouranalysisanddiscussionoftheimplicationsoftheseexposuresforthedevelopmentofthemanycancersandotheroccupationaldiseasesattheVentraPlasticsplant.Finally,weacknowledgeseniorindustrialhygienist,SonyaLalandDr.RolandWong,whoconductedtheearlierexposureprofilesuponwhichthisstudywasbuilt.Tobothweoweagreatdebt.

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APPENDIXA

EXPOSUREPROFILESFORTHEPLASTICSPROCESSINGINDUSTRY

ALITERATUREREVIEWBACKGROUNDER

By

RobertDeMatteoandDaleDeMatteo

For

TheOccupationalHealthClinicsforOntarioWorkers2019

ABSTRACT:Thisliteraturereviewattemptstodescribeandcharacterizetheextentandnatureofworkerexposuretovarioussubstancesusedintheproductionofplasticsproductsandtheirpotential adverse effects on worker health. Of major concern are the endocrine‐disruptingproperties of several of these substances such as bisphenol A and phthalates as well assubstancesidentifiedasmammarycarcinogens. Indeed,accordingtoarecentstudy,almostallcommerciallyavailableplasticproductsreleasechemicalshavingdetectableestrogenicactivity(Yang, et al.,2011).This reviewsummarizesnumerousscientificpublicationson theextentofworkerexposuretothesesubstancesaswellasnumerousstudiesontheirhealtheffectsonlabanimalsandhumans.Methodstocontrolexposuresutilizingindustrybestpracticesbasedonthehierarchyofhygienecontrolsarealsoexplored.

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TABLEOFCONTENTS

INTRODUCTION 114

PLASTICSINDUSTRYECONOMICDEMOGRAPHICPROFILE 115

PLASTICSMATERIALSANDPROCESSES115‐116

CLASSIFICATIONOFPOLYMERS117‐118ThermoplasticsThermosetsPolyethylene–PEPolyvinylChloride—PVCPolypropylene—PPPolystyrene—PSPolyethyleneTerephthalate—PET

COMPOUNDERSANDADDITIVES119‐121Stabilizers,Plasticizers,ImpactModifiers,FlameRetardants,LightStabilizers,Lubricants,Fillers,BlowingAgents,Cross‐linkingAgents,Antioxidants,Antistatics

PLASTICSPROCESSINGMETHODS121‐124InjectionmoldingStepsintheprocessBlowmoldingExtrusionCalenderingCompressionmoldingCastingFoamingRotationalmoldingThermoformingFabrication

JOBTASKSINPLASTICPROCESSING124‐125

THENATUREOFWORKEREXPOSURESTOSUBSTANCESUSEDANDPRODUCEDINTHEPROCESSINGOFPLASTICS125‐126FactorsAffectingWorkerExposuresTheessentialquestionstoaddressare

WHATAREWORKERSPOTENTIALLYEXPOSEDTOINTHEPLASTICSPRODUCTIONPROCESS?126‐127MONOMERS

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E‐Caprolactam,Cas:105‐60‐2140MethylMethacrylateCas:80‐62‐6140Styrene,Cas:100‐42‐5140STYRENES127‐128HealthEffectsofStyrenesVINYLCHLORIDEMONOMER128‐132CAS:75‐01‐4&POLYVINYLCHLORIDEHealthEffectsofVCM/PVCExtentofExposuretoVCM ExposuresDuringPVCProcessingOperations Table1:DegradationproductsfromPVCat170C Table2:ConcentrationsofPVCdegradationproductsinprocessingat165‐200C Table3:ConcentrationsofPVCdegradationproductsinvariousprocesses

ACRYLONITRILE132‐135 HealthEffectsofAcrylonitrile ExtentofWorkerExposuretoAcrylonitrile

PHTHALATES135‐139 HealthEffectsofPhthalates

BISPHENOL‐A140‐142 HealthEffectsofBPA ExtentofWorkerExposuretoBPA

METALS:EXPOSUREDURINGTHERMOPLASTICPROCESSING142‐144 OrganicTin LeadCompounds CadmiumCompounds

FLAMERETARDANTS144‐145 Polybrominatedbiphenyls(PBB) Phosphororogananiccompounds(POC) OccupationalandEnvironmentalExposurestoFlameRetardants

COMPLEXMIXTURES145‐150 EmissionsfromProcessingThermoplastics Abs Hips Hips Hdpe Nylon6 Pp Pvc Ldpeandlldpe San

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Polyethylene Polypropylene Polystyrene Polyvinylchloride Polytetrafluoroethylene

EPIDEMIOLOGICALEVIDENCEOFADVERSEREPRODUCTIVEEFFECTSANDBREASTCANCER150‐151 AdverseReproductiveOutcomesandInfertilityAssociatedwithPlasticsProduction BreastCancerAssociatedwithPlasticsProduction

DISCUSSION151‐152

CONTROLLINGEXPOSURESINPLASTICSPRODUCTION152‐155 TheHierarchyofControls ControllingattheSource Re‐designingtheworkprocess Substitution Isolation ControllingAlongthePath ControlattheWorker TheCostofControls

REFERENCES156‐167

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INTRODUCTION

Thisliteraturereviewisanattempttodescribeandcharacterizetheextentandnatureofworkerexposuretovarioussubstancesused in theproductionofplasticsproductsandtheirpotentialadverseeffectsonworkerhealth.Ofmajorconcernaretheendocrine‐disruptingpropertiesofseveralofthesesubstancessuchasbisphenolAandphthalatesaswellassubstancesidentifiedasmammarycarcinogens.Indeed,accordingtoarecentstudy,almostallcommerciallyavailableplasticproductsreleasechemicalshavingdetectableestrogenicactivity(Yang,etal.,2011)

This literature review summarizes numerous scientific publications on the extent of workerexposuretothesesubstancesaswellasnumerousstudiesontheirhealtheffectsonlabanimalsand humans. Methods to control exposures utilizing industry best practices based on thehierarchyofhygienecontrolsarealsoexplored.

To this end, the literature search included scholarly publications and standard texts thatdescribedandexplainedtheprocessesandsubstancesusedintheplasticsprocessingindustry,industrial hygiene monitoring studies and reviews of occupational exposures in the plasticsindustry,epidemiologicalstudiesthatattemptedtoidentifyadversehealthoutcomesassociatedwith worker exposures in the plastics industry and toxicological reports and reviews.Regrettably, there was a paucity of occupational exposure studies that provided details onexposure risk factors. And even fewer addressed the impact of worker exposure to complexmixtures.

Thefollowingareasareexplored:

1. Thematerialsusedintheproductionofvariousplasticproducts;

2. Thevariousprocessesusedtofashionplasticproducts;

3. The identification of various chemical constituents and by‐products that accompany theprocessingofplastics;

4. The identification of factors that contribute to emissions of these substances during theprocessofproduction;

5. The identification of various job tasks and processes associated with the production ofplasticsproductionthatplaceworkersatriskofexposure.

6. Theidentificationofadverseeffectsassociatedwithworkerexposuretovarioussubstancesusedinplasticsprocessing.

7. Developingeffectiveexposurecontrols.

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PLASTICSINDUSTRYECONOMICDEMOGRAPHICPROFILE

According to Industry Canada (2010), plasticsmanufacturing generates $20.7 billion annuallyandemploysabout91,000people,primarilyinsmallandmediumsizedfirmswithalowlevelofunionization. The majority of firms (48%) are located in Ontario where over 51,000 peopleemployed,followedbyQuebec(35%),PrairieProvinces(13%)andAtlanticProvinces(3%).Theindustry is dominated by three major product lines including packaging (34%), constructionproducts (26%) and automotive components (18%). The automotive component, whichcomprised about 18% of overall industry, dominates plasticsmanufacturing in Essex County,generallyregardedastheautomotivecapitalofCanada.WhileplasticsmanufacturinginCanadais on the rise generally, employment in car partsmanufacturing has declined from a high of18,000 in 2003 to 13,000 in 2009 (Industry Canada, 2010). In general,women hold a higherpercentage of jobs in the plastics industry when compared to other manufacturing sectorsconstitutingabout37%oftheoverallplasticsworkforce. The industry is marked by a highrateofturnover,areflectionoflowwages,poorworkingconditions,andalackofacommitmentto skill upgrading (Industry Canada, Canadian Plastics Products Industry,01/02/2010).Interviews with plastic workers focus groups in Essex County indicated that the femaleparticipationratemaybefarhigherthanthesereportssuggest.

Workers estimated that women participation ranged between 60 and 80 percent in small tomediumsizeplantswith35to500employees.

PLASTICSMATERIALSANDPROCESSES

Plasticsareorganicmaterialsproducedfrompetrochemicalsreferredtoaspolymers.Polymersconsistoflargechainsofmolecules.Tomakethechains,manylinksarehooked,orpolymerizedtogether. To create polymers, petroleum products are heated and broken down into smallermolecules called monomers. Monomers are the building blocks for the creation of polymers.Polymerization is a chemical reaction inwhich themolecules of amonomer such as styrene,vinylchlorideorethylenearelinkedtogethertoformlargemoleculeswithamolecularweightthatisamultipleofthemolecularweightoftheoriginalmonomer.

Whileeachpolymerwillhaveitsdiscretemolecularstructure,itispossiblethatpolymersmaybe contaminated by unreactedmonomers or othermaterials, especially solvents required forpolymerization.

Thusinthepolymerizationprocessmonomersareconvertedintocomplexpolymersintheformofresinsincludingpolystyrene,polyvinylchlorideandpolyethylene.Attimesthetermsplastics,resins,polymersareusedinterchangeablytorefertoplastics.Theseresinsinturnareusedbydownstream industries making plastics products, paints and adhesives; they also includecompoundersthatblendresinswithadditivestoproduceconcentratesandcompoundsusedbytheseindustries.

The following chart describes the total process from raw materials to finished plasticsproductionasfollows(Rosato,1997):

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StartsWith

PetroleumNaturalGasCoalAgricultural

DistilledInto

EthanePropaneBenzeneNaphthaButene

Converted

IntoFeedstocksMonomers

EthyleneStyreneFormaldehydePolyolAdipatePropyleneVinylChlorideCumeneAcrylic

Polymerized

Into

Plastics

PolyethylenePolystyreneAcetalPolycarbonatePolypropylenePolyvinylchlorideNylon

Fabricated

Into

PlasticProducts

PipeAppliancePackagingLuggageMarineAuto‐PartsToysFabricsElectricalMedicalToolsSiding

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CLASSIFICATIONOFMONOMERS

Plasticsarebroadlydividedintotwocategories—thermoplastics(TP)andthermosets(TS).

Thermoplasticsarethemostcommonlyusedmaterialsinplasticsprocessing.Examplesincludepolyethylene (PE), polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC), polyamide(PA)a.k.a.nylon,andpolyethyleneterephthalate(PET).

Thermoplasticssoftenontheapplicationofheatandsolidifywhencooled.Thisabilitytosoftenandsolidifyisreversible,makingtherecyclingofthermoplasticsrelativelystraightforward.

Thermosets are also used in some forms of plastic processing, including fiber‐reinforcedcomposites,andaremostcommonlyusedinformulatedproductslikepaints,adhesivesandinks.Some examples include: phenol formaldehyde, urea formaldehyde, epoxy, polyurethane,unsaturated polyester, alkyd, and silicone. These chemicals are cured via a chemical reactionwhich is not reversible.Unlike thermoplastics that canbe reprocessedusingheat, thermosetsundergodecompositionwhenheatedandcannotberecycled.

Thereareliterallyhundredsofclassesofpolymerswithabout20principalclassesthatareusedin production. Various subclasses have been created by various combinations of polymers,additives, fillers, alloying, blending, etc. These developments have resulted in about 17,000processableplasticsworldwide.(Rosato,1997;Maxwell,1999).

Thefivepolymersthatmakeupthevastbulkofproductiongloballyarethefollowing(BioAutoCouncil,2007):

Polyethylene–PE(highdensity/lowdensity)representing40%oftotalplasticsproductionhasa wide range of properties and is produced in several forms and densities. High densitypolyethylene(HDPE) is theharder formusedinmilkcontainers, lids, laundrycontainers, toys,sportinggoodsandelectricalinsulationandhasrelativelyhightensilestrength andrigidity.Lowdensity polyethylene (LDPE) is a relatively soft form of PE. It is softer andmore flexible andpossesseshigherimpactstrengththanHDPE.

Polyvinyl Chloride—PVC (20%) is produced from vinyl chloride monomer in a variety ofgradesfromflexibletoorigid‐‐fromrigidpipingtothinflexiblefilmbyaddingplasticizersintheproductionprocess.

Polypropylene—PP(19%)isveryversatile,producedinmanygradesandoften iscombinedwithmanyotherpolymers to formcopolymers. Ithas superior resistance toheat and flexuralfatigue. Outside of packaging, PP is used for luggage, molded parts for automobiles andhouseholdappliances.

Polystyrene—PS(9%) isproduced inmanygrades,usuallycombinedwithotherpolymers toremedyitsbrittlenessandpoorheatresistance.AnexpandedversionofPSisStyrofoamusedfortake‐out containers, fast food tubs, egg cartons and as filler for shipping. A large amount isproduced in the formofHigh ImpactPolystyrenebyadding rubber toPS.PS is oftenblended

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withPEthroughtheadditionofmixingagentsbecauseofthenaturalincompatibilityofPSandPE.

Polyethylene Terephthalate—PET (6%) is a form of polyester with a broad range ofmechanicalpropertiesthatmakeitausefulreplacementformetalslikedie‐castaluminumandzinc. Different grades of PET are used in many different processes, e.g., appliances andelectronics, but particularly in stretch injection blowmolding for plastic beverage bottles andfilmproduction.Itcanbeproducedinawiderangeofproperties.

Apolymer is a pure unadulteratedmaterial usually taken as the family name for a group ofmaterials;apolymer isa ‘NothingElseAddedTo”(NEAT)material.Purepolymersareseldomusedontheirown. (Rosato,1997)

Otherpolymerresinsinclude:

AcrylonitrileButadieneStyrene—ABSAcrylic—PMMAPolycarbonate—PCModifiedPolyphenyleneOxide—PPOPolyurethane—PUEthyleneVinylAcetate—EVAPhenolFormaldehyde—PFMelamineFormaldehyde—MFAcetyl—POMPolyamide—PA(Nylon)Polyester—PET,PBTPolypropyleneTetraphthalate—PPTUreaFormaldehydeFoam—UFPolyphenyleneSulfide—PPSStyrene‐acrylonitrile—SAN

The basic rawmaterials used in plastics processing andmanufacture of plastic products areresins.Theresinsareproduced inchemicalplantsbycombining thechemicalelementcarbonwithotherssuchasoxygen,nitrogenandhydrogen.Fromherechemicalplantsshiptheresinstoplasticsmanufacturingplantsintheformofsyrup,powder,granules,pelletsandothereasy‐to‐useconfigurations.

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COMPOUNDERSANDADDITIVES

Oncetheresinsareattheplants,workersmayaddandmixotheringredients.Thismightinvolvethe compounding of polymers bymixing two ormorepolymers to formblends. In addition awholehostofadditivesmaybeintroduced.

Additives are a diverse group of specialty materials. Sometimes they are added by the resinsupplierbeforetheformulationisprocessedandothertimesaddedbytheprocessor.

Someadditivesareprocessingaidssuchasblowing/foamingagents,organicperoxides,moldrelease agents, and lubricants. Other additives used to improve the properties of materialsinclude: antimicrobials, antioxidants, antistatic agents, colorants, flame retardants, impactmodifiersandUVstabilizers.Someadditives,suchasplasticizersandheatstabilizers,enhanceboththeprocessabilityoftheplasticresinandthepropertiesofthefinishedproducts.(Rosato,1997)

Someofthemajoradditivesinclude(Coaker,2000):

StabilizersLead, zinc, cadmium, barium, calcium, azodicarbonamide, antimony tris(isooctylmercaptoacetate).

PlasticizersThereareover500knownplasticizersthatservetogivematerialssoftnessandflexibility.Thesealsoact asprocessingaids.Mostare in thephthalate family.However,dialkylortho‐phthalateandterephthalatecompriseapproximately70%ofallplasticizersusedinproduction.

DOP—di‐octylphthalateDEHP—di‐2ethylhexylphthalateDHP—dihexylphthalateBOP—butyloctylphthalateBBP—butylbenzylphthalateDUP—di‐undecylphthalateDOTP—di‐2‐ethylhexylterphthalateEpoxides—epoxyplasticizersCitrateesters

ImpactModifiersImpactmodifiersaredesignedtoimpartextratoughnesstoplasticmaterial.Therearetwobasictypes ‐‐ predefined elastomers (PDE) and non‐predefined elastomers (NPDE). These mayinclude:

PDEACR—AcrylicMACR—ModifiedAcrylicMBS—Methacrylic‐butadiene‐styrene

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ASA—Acrylate‐styreneacrylonitrileABS—AcrylonitrilebutadienestyreneNPDECPE—ChloronatedpolyethyleneEVA—EthylenevinylacetatecopolymerACRgrafts—PVConrubberacrylicPUelastomersPOelastomers

FlameRetardantsOrganicPhosphateestersBrominatedphthalatesInorganicAlumoniatrihydrateAntimonytrioxideBariummetaborateHuntiteMagnesiumhydroxideAmmoniumoctamolybateMixedmetalcomplexes—Zn,Borate,Zinchydroxystaminate

LightStabilizersTitaniumdioxide2‐(2’‐hydroxyphenyl)benzotriazoles2‐hydroxybenzophenones

LubricantsParaffinwaxesPEwaxesCarboxylicacidAmidewaxes—e.g.ethylenebis‐stearamideLubriciousesters—e.g.metalcarboxylates

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Fillers Carbonblack Calciumcarbonate

BlowingAgents Azodicarbonamide4,4’—oxybisbenzenesulphonohydrazide

Cross‐linkingAgentsPeroxides

AntioxidantsPhenols(suchas4—methyl—2,6—ter—butylphenol)

AntistaticsPolyethyleneglycolalkylesters

ThefollowingisanexampleofatypicalformulationforPVCsiding(Coaker,2000):

PVC(K66)Hi‐tinstabilizerCalciumstearateParaffinwaxPolyethylenewaxTitaniumdioxideCalciumcarbonateAcrylicimpactmodifierProcessingaid—Lubricatingprocessingaid

PLASTICSPROCESSINGMETHODS

There are a variety ofmethodsused to process plastics. Eachmethodhas its advantages anddisadvantages and is best suited for specific applications and resins types. These methodsinclude: injectionmolding, blowmolding, thermoforming, transfermolding, reaction injectionmolding,compressionmolding,casting,extrusion,andfabricating.(Rosato,1997,Croaker,2000,Harper,2006,HarperandPetrie,2003)

InjectionmoldingInjectionmoldingisthemostwidelyusedmethodofprocessingthermoplastics.Inthisprocesspolymersareplacedinahopper.Thehopperthenfeedsthematerialsintoaheatedinjectionunitwhere it ismelted and vented and thenpushed through a long chamberwith a reciprocatingscrew.Hereitisthenmeltedintoafluidstate.

Anozzleislocatedattheendofthechamberwherethefluidisforcedintoacold,closedmold.Thehalvesof themoldareheldshutwitha systemof clamps.When theplastic is cooledand

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solidified,thehalvesareopenedandthefinishedproductejectedfromthepress.

Thisprocessisusedforallthermoplastics. However,thermosetsarenotusuallyprocessedwithinjectionmolding.

Stepsintheprocess(1)Drying,(2)mixingandblending,(3)pouringintohopper,(4)feedingintotheheatedbarrel(5)plasticizingandventing,(6)injectingintoaclosedmold,(7)cooling,(8)moldreleasingand(9)fabricating.

With the exception of drying, mixing and pouring, the plasticizing process is enclosed butvolatiles, fumes, gases and water vapor escape through vents in the barrel and the enclosedmold.

Thereareactivitiesthatseveralprocessesshareincommon.Theseinclude:

Venting andmelt degassing: During injectionmolding, as in extrusion,meltsmust be free ofgaseouscomponents(e.g.monomers,moisture,plasticizers,additives,etc.),soaventedscrewisused to remove these by‐products during themelt. This is referred to asmelt degassing. Theprocessissimilarforextrusionandblowmolding.

Compounding: Most plastics undergo compounding which involves the addition of variousingredientsneededtoprocessplasticsandprovidethedesiredpropertiestothefinalproduct.Themethodsusedforcompoundingcanbeeitherdryblendingormeltmixingandmixingcanbecontinuousorinbatches.Batchingismorelabourintensiveandlesscomplicated.

Purging and cleaning: Purging is a process of cleaning out colour or other resins from thecylinder in injectionmolding, blowmolding, extrusionmachines in order to process differentmaterial or colours. This involves forcing these materials out using other resins or specialpurgingagentstomechanicallypushandscourresiduesoutofthemachine.

Finalcleaningofthedisassembledpartsmaybedonemanuallyinventilatedburnoutovens.

BlowmoldingBlowmolding is usedwhen the plastic itemneeds to be hollow. Amolten tube is created byusing compressed air, which blows up the tube and forces it to conform to the chilledmold.Variationsincludeinjection,injection‐stretch,andextrusionblowmolding.

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Injection blow molding uses a perform, which is taken to a blow mold and filled withcompressedairtoconformtotheinteriorshapeoftheblowmold.

Continuousextrusionblowmolding involves theextrusionofacontinuousmoltenplastic tubewhich is pinched between two mold halves. A blow pin is then inserted into the tube withcompressedairusedtoforcethematerialtoconformtotheshapeofthemold.

ExtrusionExtrusionisusedtomakeproductssuchasfilm,continuoussheets,tubes,profileshapes,rods,coat wire, filaments, cords and cables. Similar to injection molding, dry resin in the form ofpelletsispouredintoahopperandfedintoalongheatingchamberwhereitismeltedanddrivenby a reciprocating screw.At the endof the chamber thematerial is forcedout of a die in theshapeofthefinishedproduct.Astheformedplasticexitsitisplacedonaconveyorandcooledbyair or water. This process is similar to a sausage making machine. It can process allthermoplastics especially polyethylene, polystyrene and PVC. The major difference frominjectionmolding is thatextrusionprocessesplasticsat a lowpressureand is continuous. Aswell,theextrudedproductisnotenclosedinamoldasitpushesoutofthedie.

CalendaringThe calendaring process is used to produce plastic films and sheets. The calendar melts theplasticandthenpassesitthroughthenipsoftwoormoreheatedcounter‐rotatingrollers intowebsofspecificthicknessandwidth.Upstreamofthecalendar,amixerblendstherawmaterial,usually in apowdered form,with additives such asplasticizers, fillers, colourants, etc.Awidevarietyofplasticscanbeused;about80%isPVCbutothersareABS,PE,PPandstyrene.ForPVCmixalladditivessuchasplasticizers,stabilizers,etc.mustbepremixedandthenpassedontoablenderwherethemassisgelled,pressedintoawebandthencalendared.

Unliketheprocessofextrudingorinjectionmolding,theplasticmasscannotbeconfinedwhenbeingcalendared.Inaddition,itisimportanttonotethatthesheetsandfilmsbeingcalendaredhaveverylargesurfaceareas.

CompressionmoldingCompression molding is the most common process used with thermosetting resins such asmelamine,formaldehyde,andphenolformaldehydewithfillers.However,itisnotusuallyusedfor thermoplastics.Material is squeezed into its desired shapewith the help of pressure andheat.Plasticmoldingpowderandothermaterialsareaddedtothemixinordertocreatespecialqualitiesor to strengthen theproduct.When themold is closedandheated, thematerial goesthroughachemical change that causes it toharden into theshapeof themold.Heat,pressureandtimedependonthedesiredoutcomeofthefinalproduct.

CastingPlasticinliquidformispouredintoanopenmold.Commonlyusedforphenolformaldehydeasliquidresinarepolymethylmethacrylateandpolyurethane.

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FoamingFoaminginvolvesthereleaseofgasintoplasticsothatit fillswithbubblesandformswithinatwo part mold. This process is used with polystyrene, polyurethane, and PVC to produceproducts such as packing, sponges, soles, steeringwheels, vending cups, insulation and foamfurniture.

RotationalmoldingMeasuredamountsofplasticareplacedinamoldwhichisrotatedontwoaxesatlowspeedinan oven. This is used with low density polyethylene; polypropylene is used when hightemperaturetolerancesareneeded.Productssuchasstoragetanksaremadeusingthisprocess.

ThermoformingPreformedsheetsarewarmedand thensucked intoamold.Neitherhighheatnorpressure isrequired. This process used mostly for thermoplastic sheets in the production of bath tubs,boats,bowls,etc.

FabricationFabricationisacatch‐allforavarietyofprocessesincludingbonding,carving,cutting,stitching,turning,grinding,sanding,andwelding.

JOBTASKSINPLASTICPROCESSING

Onceresinsreachtheplasticsprocessingplant,workersperformanumberoftasksduringtheproductionprocessfrompreparationtofinishedproduct.Withsomevariationtheseincludethefollowingbasictasks:

Step 1: Resins must be prepared and mixed with other ingredients to form a powder. Thisinvolvesdryeroperators,blenders,andoventenderswhomixandsupplythemoldingpowdertothemoldingmachineoperator.Step2:Themoldingmachineoperator isresponsible forsettingtheheatandpressuregaugesproperly and for pouring the powder in the molding machine hopper and monitoring theprocess.Step3:Asthepowderisheated,itturnsintoaliquidandflowsintoamoldoriscontinuouslyextrudedwhereitisallowedtocoolandhardenintoitsshape.Step 4: The operator then removes the molded plastic pieces from the mold or theextrusion,inspectsthem,andplacesthemonaconveyororonatruckfortransportationtothefinishingroom.Step5:Inthefinishingroom,workersusingsmalltoolsormachinesfinishtheplasticproducts.Drillpressoperators,forexample,removeexcessplastic.Grindersorfillerscleanupedges,andbufferssmooththem.

Step6:Paintinganddecorating:Thisincludesspraypainting,electrostaticspraying,dipcoating,fill‐inmarking,screenpainting,androllercoating.Severalcategoriesofpaintaregenerallyusedincludingwater‐basedacrylicpaintsand lacquerscontainingsolventsandenamels.Dependingon the polymer used the following are employed: urethane, epoxy, polyester, acrylic lacquer,

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acrylicenamel,andwaterborneacrylics.Someplasticsrequireprimersorprotectivetopcoats.Preparatorycleaningofsurfacescaninvolvetheapplicationofsolventssuchasacetone,toluene,trichloroethylene, methyl ethyl ketone (MEK), ether and isopropanol. Application of solventsmay involve wiping, immersion, spraying or vapour degreasing. Where possible, preparationmayincludeprimingthesurfacewithchlorinatedpolyolefinprimers.

Step7:Plasticre‐grindersrunmachinesthatgrindupscrapsofplastic toberecycled.Step8:Afterpassing inspection, theproduct is ready tobe cleaned,packagedandshipped tomarket.Sometimespartsareshippedtootherplantswheretheyareassembledwithotherpartsintoafinishedproduct.

Step8:Purging,cleaningandmaintenance.

In addition tomolding, other processesmight include theproduction of plastic sheets or filmthroughcalendaring.Thecalendaroperator tends to thisprocess.Productsarealso laminatedwithplasticswhich involvecoaterswhooperatemachines that soaksheetsofpaper, fabricorwood with liquid resin. Laminating press operators press plastic‐coated sheets in heavymachines.

THENATUREOFWORKEREXPOSURESTOSUBSTANCESUSEDANDPRODUCEDINTHEPROCESSINGOFPLASTICS

The emission of various chemicals used and produced in the processing of plastics isexceptionallycomplex.Ithasbeenwidelyacceptedthattheprincipalworkplacecontaminantsinthis process are associated with the residual monomers, polymers, and various additivesincluding plasticizers, stabilizers, pigments/colourants, flameretardants, activators, lubricantsandfillers.Thisalsoincludesvarioussolvents,paintsandfinishingagentsusedinthedecorativeprocess.Assessingexposuresintheplasticsindustryisnotastraightforwardendeavorbecauseofthemultiplicityofsubstancesandprocessesusedorgeneratedduringproduction.Itisdifficultto focus on one particular contaminant, since in reality the production process generates amultiplicityofcomplexchemicalmixturesintheworkenvironment.

FactorsAffectingWorkerExposuresThe extent of worker exposure to these is conditioned by numerous factors during theproductionprocessesinwhichtheworkersareengaged.Thesourcesofthesemaystartattimeofdeliveryofrawproductintheformofbulkpowders,granulesandliquidsfromtankerstrucksunloading product to the plant. From here themanual handling of drums—opening, pouring,scoopingandclosingdrumsisamajorsourceofexposuretochemicaldusts.Inaddition,manualblending and mixing and pouring in preparation for thermal processing in various moldingprocessorsisanothersourceofexposures.

Thethermalprocessing isanothersourceofcontamination.Herethevarious formulationsaresubjectedtorelativelyhightemperaturesandpressuresinordertoproducethemoldedplasticsproduct. This process produces a host of fugitive emissions of gases, vapors and fumescontainingacomplexmixtureofresiduesandby‐productsfromthethermaldegradationofthe

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originalresinformulations.

Emission andpotential exposure continues on after thermal processing fromoff‐gassing aftertheproductisejectedfromthemoldorasitleavestheextrusiondies.Fromheretheproductistaken for further fabrication that may produce further dust contamination from drilling,grinding,sanding,buffingandstitchingplasticfabric.

Further finishing of the product involving decorating, painting, coating and printing adds anadditionalsourceofcontaminationandexposure.Solvents,paints,andcoatingsaddanothersetofcomplexmixture.

Finally, the process of cleaning, purging and maintaining the various molding machines willinvolvetheemissionofvariousresinformulationsandsolventsused.

With respect to what contaminants will be generated in this production process and whatworkers are exposed very much depends on the various resin formulations and conditionsunderwhich theyareprocessed ‐‐ that is, thebasicpolymerorblendofcopolymersusedanddifferent additives such as plasticizers, stabilizers, pigments, flame retardants, lubricants,releaseagentsandfillers.Inaddition,thetemperatureandpressureappliedintheprocesswillinfluencetheextentandtypesofchemicalemissionexposuresoftheprimarysubstancesbeingusedaswellasbyproductsof thermaldegradation.Finally,exposureriskwillbe influencebythedegreetowhichtheprocessisenclosed,thesurfaceareaofprocessedmaterialandphysicalstateofthesubstancesreleased.

WHATAREWORKERSPOTENTIALLYEXPOSEDTOINTHEPLASTICSPRODUCTIONPROCESS?

MONOMERS

Monomers are the building blocks of polymers. Although they should be used up inpolymerization, monomer residues may be released during the processing of polymers. Inaddition,thereareoccasionswhereapolymerizationstepisanintegralpartofrubberorplasticprocessing,andonsuchoccasionsfreemonomerisanessentialingredient.Herearesomeexamples:

Theessentialquestionstoaddressare:

Whatareworkerspotentiallyexposedtointheplasticsproductionprocess?Towhatextentareworkersexposedtothesematerials?Whatfactorsinfluencetheextentofworkerexposure?

Whatarethepotentialhealtheffectsfromsuchexposures?

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E‐Caprolactam,CAS:105‐60‐2Caprolactampolymerizationprovidestherouteforcastingpolyamide6(nylon6).Themonomerisalow‐meltingsolidreleasingfumesandvapourthatareirritatingtotheeyes,noseandthroat.Peelingofskinanddermatitishavebeenreportedfromchronicexposure.

MethylMethacrylate,CAS:80‐62‐6MMA is the principlemonomer in casting acrylic production. Handling the liquid can lead toallergicdermatitis,whileMMAvapour is irritatingtoskin,eyesandmucousmembrane. Itcanalsoaffectthecentralnervoussystemsimilartosomeorganicsolvents(e.g.headaches,fatigue,etc.)

STYRENE,CAS:100‐42‐5Styrene is themostcommonmonomer inunsaturatedpolyester formulations.Styrene ismostcommonly releasedmonomer fromvarious styrenebasedpolymers suchasABS,polystyrene,etc.Styreneisanirritanttoeyes,skinandmucousmembrane.

HealthEffectsofStyrene

Occupational exposure can lead to neurological effects and effects on hearing. Styrene isclassifiedasaGroup2BcarcinogenbyIARC.Styreneisidentifiedasasubstanceshowntocausemammarygland tumors in animal studies (Rudel, et al. 2007) andas an endocrinedisruptingsubstance(BrodyandRudel,2003).

Several studies show chromosomal aberration in styrene exposed workers. Chromosomalaberrations were positively correlated with urinary concentrations of styrene in exposedworkers compared to unexposed controls. (Meretoja, et al., 1978; Hogstedt et al., 1979;Andersonetal.,1980;Duvergeretal.,1981;IARC1982b;Camurrietal.,1983;Yageretal.,1990;Maki‐Paakkaneneal.,1991;Tomaninetal.,1992;Tatesetal.,1993;Anwar,etal.,1995)

Ahematologicalstudyofstyreneexposedworkersfoundadirecteffectofstyreneexposureonblooddisordersidentified.Theauthors’suggestthatstudiesshowingnoeffectmaybeexplainedbythelowlevelofexposuresinsuchstudies(0to20ppm).(Stengel,etal.,1990)

ExtentofExposuretoStyreneExposuretostyreneatworkintheprocessingofplasticsmakesasignificantcontributiontothebody burden of styrene compared to a normal population. Styrene concentrations in thereinforcedplastics industryrangesbetween20toover200ppm,dependingontheoperationsconcerned(CrandallandHartle1985;Lemastersetal.,1985). InFrance,45%ofsamples fromthereinforcedplasticsindustryhadstyrenelevelsabove50ppm(Meyer‐BishandProtois,1986citedinStengel,etal.,1990).

Brugnone,etal.,didacomparisonofblood‐styreneconcentrations inexposedworkersvs. the“normal”population,identifyingblood‐styreneconcentrationsinexposedworkersthatwere5.5timeshigherinexposedworkers.The“normal”populationhadblood‐styreneconcentrationof221 µg/l while exposedworkers had average levels of 1211ug/l confirming that styrene can

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accumulateinthebody.Italsoshowedthatstyreneuptakewasdirectlyproportionaltothelevelworkeffort(Brugnone,etal.1993).

In another study of urinary styrene levels in exposed workers in Emilia Romagna, Italy,researchers found that job taskswere themost importantpredictor of styrene exposure.Therangeofexposurewasdirectlyproportionaltothelevelofmanualhandlingofmaterials.Italsoshowedthatwhileventilationresultedinlowerexposure,thedifferencesinaveragevalueswere not verywide. Finally,while exposure to styrene declined between 1978 and 1990, thestudy found that 15% of participants had styrene exposures in excess of the biological limitvalueforthisparticularregionofItaly(Galassi,etal.,1993).

In their study of styrene exposures in 12 categories of the reinforced plastics industry,Lemasters and colleagues found significant differences for styrene exposure levels betweenclosed mold process and open mold process. Average exposure to styrene in open‐moldcompanies(24‐82ppm)wasgenerally2‐3timestheexposureinpress‐moldcompanies(11‐26ppm).Aswell,theresearchersfoundconsiderableoverlapamongjobtitlesclassifiedasdirectlyexposed.Forexample,thoseclassifiedasdirectlyexposedinpressmolding(closed)weresimilarin exposure to those classified as indirect in open mold operations. Indirect exposureclassificationwas based onwork that involved less than 50%direct contactwithwet resins,whiledirectexposurewasbasedonworkinvolvingmorethan50%directcontactwithwetresincontaining styrene. Indirect exposure included assemblers, inspectors, dispatchers, shipperspackerslocatedinthesamevicinityasthoseindirectcontact.Itisassumedthattheseindirectexposuregroupscouldbeexposedtoambientconcentrationsofstyrene.Inautoandtruckpartsmanufacturing,mixershadanaverageexposureof26ppmwhilepressoperatorshadanaverageexposureof30ppm(Lemasters,etal.,1985).

Inalarge‐scalestudyofworkerexposurestostyrenethroughananalysisofairsamplestakenbythe Danish Labour Inspectorate between 1955 and 1988, Jensen et al. found averageconcentrations in the order of 265mg/m3 ranging between 714mg/m3 (1955‐70) and 172mg/m3between1981‐88(Jensen,etal.,1990).

Thesesameresearchersalsofoundthatstyreneemissionsareusuallyaccompaniedbyanumberof co‐contaminants. These included: Acetone at 131mg/m2; dichloromethane at 51mg/m3;xylene at 49 mg/m3; toluene at 113 mg/m3; perchlorehtylene, trichloroethylene, andisododecaneat7,5and4mg/m3respectively.

VINYLCHLORIDEMONOMER,CAS:75‐01‐4ANDPOLYVINYLCHLORIDE,

HealthEffectsofVCM/PVCVinyl Chloride Monomer (VCM) is the basic building block in the production of polyvinylChloride PVC. VCMhas been identified as a human carcinogen by health agencies around theworld. It was first identified as the agent responsible for the development of a rare cancerangiosarcomainPVCproductionworkersintheearly70s.Ithassincebeenlinkedtoanumberof other cancers, in addition to other serious health effects, in exposed workers.While VCM

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concentrationshavebeenreducedovertheyearswiththeestablishmentofstringentexposurestandardsandprocesscontrolsaswellasimprovedformulationscontainingsmalleramountsofVCM, residual VCM is still present in PVC and has been shown to be released in lowconcentrationsinthermoplasticprocessing(Karstadt,1976).

Earlyepidemiologicalstudiesinthe1970ssuggestedthatVCMmightexertamutageniceffectonspermcellsofPVCproductionworkers,leadingtoanincreaseinfetaldeathsamongpregnanciesof workers’ wives (Infante, 1976). This study was consistent with earlier findings thatdemonstratedchromosomeaberrationsinPVCproductionworkers(Ducatman,etal.,1975)andworkshowingthatVCMismutagenicinaSalmonellatestsystem(McCann,etal.,1975).

Morerecentstudiesidentified:increasedriskoftesticularcancerwithexposuretoPVC(Hardell,et al., 1997); increased risk of adverse pregnancy outcomes for women working in PVCprocessingoperations(Ahlborg,etal.,1987);andpossibleassociationofmalebreastcancerandemploymentintherubberandplasticsindustries(Ewertz,etal.,2001).

A number of case reports and epidemiological studies continue to find angiosarcoma andincreasecancermorbidityamongPVCprocessingworkers.These included: acasereportof2casesofangiosarcomaamongPVCextrudersproducingPVCbagsandothercontainers(Maltoni,et al., 1984); a Swedish cohort study showing an increase in cancer morbidity at a PVCprocessingplant(Hagmaretal.,1990);andacohortstudyofworkersatthreePVCprocessingplants (Lundberg et al., 1993) where cancer mortality was close to expected, but a 3 foldincrease inmalignantmelanomawas identified. In the later study, VCM concentrations neverexceeded10ppmbefore1975andweremuchlowerafter1975.

A case control study found an excess risk of pancreatic cancers among workers assigned toprocess PVC and polyethylene resins. Researchers found a sevenfold statistically significantincreaseinriskforthosewhoworkedmorethan16yearsinvinylandpolyethyleneprocessing.Theauthorsconcluded,however,thattheexcessriskwaslikelyassociatedwithvinylprocessing(Selenskas,etal.,1995).

VinylChloridehasalsobeenidentifiedasamammarycarcinogen.VinylChlorideadministeredtomice by inhalation was shown to induce tumors at a variety of sites, including liverangiosarcomaat25ppmandmammarycarcinomasat25,10,5and1ppm(Maltoni,1977).

Results of a cross‐sectional study of mortality among PVC‐fabricating workers observed thatdeath frombreast cancer significantlyexceeded theexpectednumberofbreast cancers in theU.S.population.Inafollowupcase‐controlstudyofthe44breastcancerdeaths,theresearcherswere unable to find a statistically significant increased risk. The authors concluded that theabsence of a statistically significant relative riskdoesnotdemonstrate that there isnotanexcessriskofbreastcanceramongwomenexposedtoPVC(Chiazze,etal.1981).

ExtentofExposuretoVCMStudies conducted by the NIOSH in the 1970s showed RVCM concentrations in plasticsfabricationfacilitiestobelessthanthe1ppmPELandinsomecaseslessthan0.01ppm,thelimit

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of detection. However, certain workstations had values that exceeded the 1 ppm standard(NIOSH,1974).

Tests conducted in1975by theU.S.EnvironmentalProtectionAgencyof automobile interiorsforthepresenceofVCMfoundreadingsashighas1.2ppmandaslowas0.05ppm.Thesecarswere testedonemonth after assembly.We can reasonably speculate thatproductionworkersworkinginthevehiclewouldhaveexperiencedmuchhigherexposuregiventhatPVCfabricsandpartswerejustrecentlymolded.

Despitethegeneral loweringofVCMconcentrations,continuedoccurrenceofangiosarcomaoftheliverinfabricationplantworkerspointstothepossibilityof lowlevelexposurebeingveryhazardous.

AssessingthehealthimpactofRVCMiscomplicatedbythefactthatpolyvinylchlorideresinisacomplexmixtureof a host of additives. PVCbasedmaterialmayhave the following variety ofdifferentingredients:

Stabilizers Leadcompounds(e.g.carbonate,sulphate,phthalate) Cd,Ba,Ca,Tin,Znsaltsandsoaps Organotincompounds

Plasticizers Phthalates,Adipates PolymericPlasticizers(e.g.polypropyleneadipate)

Extenders(replacingpartlymoreexpensiveplasticizers) Chlorinatedparaffin’s(waxesandliquids) Oilextracts

Lubricants(preventingstickingtoprocessingequipment) Al,Mg,CaandPbstearates

Fillers Chinaclay,Cacarbonates

Pigments

Polymericprocessingaidsandimpactmodifiers Butadienebasedrubbers,ABSmaterials BisphenolA Blowingagents(e.g.Azodicarbonamide)

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ExposuresDuringPVCProcessingOperations:PVCisprocessedbyvarioustechniquesincludingextrusion,injectionandblowmolding.Processconditionssuchasheatandpressurevarydependingontheproductandtheformulationofthematerialandequipment.Processingtemperaturesrangefrom140‐250C.CuttingandweldingPVCwill subject the PVCmaterial to elevated temperatures. Under these conditions, a broadrange of degradation products are possible, potentially exposing workers to very complexchemicalmixtures.

Inadditiontothedegradationtemperatureandtypeofprocessing,thevariousadditivesinPVCmaterial greatly affect the compositionof thedegradationproducts.The initialdecompositionreactionisthereleaseofhydrogenchloridewithsubsequentreleaseofaromatichydrocarbons,withbenzenebeingthemostabundantathightemperatures.

Additives,suchasplasticizers(e.g.phthalates)andblowingagents(e.g.azodicarbonamide)arealso emitted. They may react further – for example, di‐2‐ ethylhexylphthalate (DEHP)decomposesintophthalicanhydride.SomeexamplesofdegradationproductsofPVCareshownbelow:

Table1:DegradationproductsfromPVCat170CGroup Compound

Aliphatichydrocarbon C4‐,C8‐,C11‐,C12‐,C13‐hydrocarbonsHalogenatedhydrocarbons 1,1‐DichloroethyleneAromatichydrocarbons TrimethylbenzeneAlcohol 1‐Nonanol

1‐DecanolAlkoxyalcohol 2‐(2‐butoxyethoxy)ethanolAldehyde Formaldehyde

Acetaldehyde Hexanal NonanalKetone CyclohexanoneAcid 2‐EthylhexanoicacidEster Diethylphthalate

Di‐n‐butylphthalateDi‐2‐ethylhexylphthalate

Hydrogenchloride(Andersson,1988)

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Table2:ConcentrationsofPVCdegradationproductsinprocessingat165‐200CProduct Average +

Hydrogenchloride 0.07+0.03Phthalicanhydride 0.001+0.001Vinylchloride <0.003Benzene <0.03Carbonmonoxide <1Aerosols* 0.05+0.1Di‐(ethylhexyl)phthalate 0.3+0.1

*Includephthalate(Madsen,etal.,1988)

Note:TheMadsenstudymeasureddegradationproductsofPVCprocessedat165‐200Ccontaining40‐59%DEHP.

Table3:ConcentrationsofPVCdegradationproductsinvariousprocesses

Method HCL DEHP PhthalicAnhydride Temp% Plasticizer (mg/m3) (mg/m3 (ug/m3) (C) (%)

Extrusion 0.15 0.05 150‐200 2.4Extrusion 0.09 0.30 0.3 150‐195 NkCalendaring 0.15 0.5 0.2 130‐200 6.5‐15Embossing 0.03 0.05 180 NkWelding 0.3 0.3 5.0 400 NkInjection 0.05 0.02 <0.02 180‐190 NkSpreadcoat * 1.2 160‐205 35Blowmold 0.05 ** 150‐190 Compression 0.04 ** 150

Nk=notknown*Diisononylphthalateplasticizer**UnplasticizedPVC(Vainiotalo,etal.,1990)

ACRYLONITRILE

HealthEffectsofAcrylonitrileItmustbenotedthattheAcrylonitrilePeerReviewreportedbelowwasmadeupprincipallyofchemical producers including Dow Chemical, Cytec Industries, Exxon Mobile, Proctor andGamble.The“peerreview”wassponsoredbyindustrybased“AcrylonitrileGroup”.Thiscannotbeconsideredanindependentscientificpeerreviewoftheliterature.

The conclusionsof theAcrylonitrilePeerReviewReportprovideequivocal assessmenton the

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carcinogenicriskofacrylonitrile.Thereviewnotesthatafterareviewoftheextantevidenceoncarcinogenicitythat:Noincreasedcancerriskhasbeen“consistentlyobserved”inseverallargescaleepidemiological studies.Theynote that thesestudieshaveevaluated tumorsof the lung,brain, prostate, and a variety of other organs. The studies have been characterized by lack ofconsistentfindingsandlackofacleardoseresponserelationshipforhumancancer.Thehighesthuman exposures approached or exceeded the lowest exposures found to produce tumors inrats,usingsomedosemeasures.Thepanelconcludesthatthedatafromepidemiologicalstudiesdonot supportanassociationbetweenacrylonitrileand increasedcancer inhumans,but thatsuchariskcannotberuledout.

Incontrast thepanelnoted thatacrylonitrile isclearlycarcinogenic inratsandmicebasedonfindingsofincreasedtumorsatmultiplesitesinoralandinhalationstudies.Andbasedonthisanimaldata,thepanelconcludesthatacrylonitrileispossiblycarcinogenicinhumans.

Despite these evidential limitations, the International Agency for Research on Cancer (IARC)concluded in 1979 and in 1987 that occupational exposure to acrylonitrile is a humancarcinogen.

Inadditionacrylonitrileisamammarycarcinogeninanimals.OraladministrationofANinratsinducedandincreasedincidenceofmammaryglandcarcinomasinbothsexes.

Inhalationstudiesshowedthatacrylonitrileinducedmammarytumorsinfemalerats.(CitedinNTP11thROC,2005).

In a large scale study of clusters of congenital abnormalities(CA) and evidence of mutageniceffectsininfantsborntopopulationslivinginthevicinityofanacrylonitrileproducingfactoryinHungry,Czeizel,etal.,foundaclearassociationwiththetypesofCA,thetimingoftheseclustersandproximitytothefactory.Whiletherewasnoattempttoascertainthelevelofexposures,theresearchersfoundanegativecorrelationbetweenthedistancefromtheplantandtheincidenceofCAs.

These main findings are important to note because of the light the shed on the nature ofexposuresandtheendocrinedisruptingpotentialforacrylonitrile.

TherewasasignificantabsenceofcertainbaselineexpectedCA’s;

ThereweresignificanttimeandspaceclustersofCAs.Theseincluded:aclusterof40casesofpectusexcavatumreportedin1990‐92was77foldhigherthanexpectedandthisparticularCA isusually inherited in autosomaldominantmode; twoclusterofundescended testisbetween1981‐83and1981wasa9 foldhigher thanexpected:Aftertechnologicalimprovementintheplantwhichreducedemissionstherewasnoinstanceofboysbornwithundescendedtestis.Theresearchersalsofoundthattherewasadecreasingriskofundescendedtestiswithincreasingdistancefromtheplant.Theoccurrenceofhypospadiasshowedasimilartrend.

Thisfindingisofparticularinterestinrelationtotheeffectsofendocrinedisrupting

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chemicalsonmalegenitalorgans. Inthisregardthepotentialfor increaseestrogenduring pregnancy and male genital abnormalities and its implications for breastcancerisimportanttonote.

Inanotherstudyofworkerexposuretoacrylonitrileanddimethylformamideinaviscoserayonplant,Major,etal.1998foundthatairconcentrationforbothsubstancesexceededoccupationallimitsandurineANandDMFconcentrationsweredoubledatendofshift.Theexposureworkershowed increase lymphocyte counts and severe liver damage. The exposed workers showedincreasedchromatidandchromosomeexchangeaberrations.

TheauthorsconcludethatoccupationalexposurestoANandDMFinduceconsiderablegenotoxicconsequencesandmayincreasethecancerriskintheexposedhumanpopulations.

InalargecasecontrolstudyconductedinsevenEuropeancountries,Sceloetal.2004,foundastatisticallysignificantincreaseriskoflungcanceramongworkersexposedtoacrylonitrile.Theresearchers also found an indication of a dose‐response relationship. The researchers usedexposureassessmentmethodologyemployedbySiemiatycki,etal.1987withcutoffpointsforacrylonitrile at 0.9 ppm and 4.6 ppm, vinyl chloride at 5 and 25 ppm and styrene at 5 and55ppm.Exposuretothe3agentsinthisstudyoccurredmainlyinthemanufactureofrubberandplasticsproducts.

ExtentofWorkerExposuretoAcrylonitrileAscanbeseenfromtheemissionstudiesreportedabove,themonomeracrylonitrileispresentduringnormalplasticsthermos‐processing.Most,however,showlowconcentrations.Therearefewsystematicstudiesofworkerexposurestoacrylonitrile.Wherethesehavebeenconducted,thestudiesindicatethatworkersarechronicallyexposedandbiologicallytakeupacrylonitrilethroughinhalation,absorptionandingestion.

Of particular significancewas a biologicalmonitoring study conducted amongDanish plasticsworkersbyHouthuijs,etal.in1982.Thisstudyofexcretionpatternsofacrylonitrileinurineofexposedplasticsworkers,foundthat:

ExposedworkershadhigherconcentrationofAN(U)on theirdaysoff than innon‐exposedworkers,andevenhigherconcentrationsduringtheirdaysatwork;

Mean post‐shift AN(U) concentrations of 39 ug/l corresponding with a mean ANconcentrationof0.13ppmwhichwerefoundtobepositivelycorrelated;

ComparisonwithintheexposedgroupshowedthattherearesignificantdifferencesinAN(U)andAN(A)concentrationsbetweenjobcategories,e.g.reactorworkershadsignificantly higher concentrations thanpanel operators (42.9 and 5.4 ug/gAN(U)respectively);

Peak concentration of AN(A) occurred during maintenance work resulting in asubstantialfluctuationfrom0.3ppmto1.8ppminacrylonitrileconcentrationsinair;

Exposed workers continued to have significantly higher AN(U) concentrations on

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theirseconddayoffthanthoseofcontrols,indicatingthatANbio‐accumulatesandisreleasedmoreslowlythanoriginallythought;

Surprisingly, the levels of AN(U) on days that protective devices were usedwerehigherthanondayswithouttheuseofprotectivedevices—researchersattributethistopoorqualityofprotection,badworkpractices,orinsufficientfit.

SimilarbiologicalmonitoringstudieswerecarriedoutbySakurai,etal.in1978amongJapaneseacrylic factory workers using a different analytical method. In this study they found AN(A)concentrationsof4.2ppmamonghighestexposedworkerswithameanAN(U)concentrationof360 ug/l. The lowest exposed group had AN(A) concentration of 0.1 ppm and correspondingAN(U)concentrationsof3.9ug/l.

Inastudytoinvestigatethegenotoxiceffectsofoccupationalexposuretoacrylonitrile(AN)anddimethylformamide (DMF) researchers identified air concentrations of AN and DMF over themaximumallowablelimitsatthetimeofinvestigation.Theyfoundthaturineconcentrationsofbothsubstanceswerealmostdoubleattheendoftheworkshifts(Major,etal.1998).

HealthHazardEvaluationsundertakenbytheU.S.NationalInstituteforOccupationalSafetyandHealth (NIOSH) in 1979 and 1980 of injection molding operations found: (1) average airconcentrationsof:butadiene22mg/m3,styrene420mg/m3,acrylonitrile70mg/m3,MEK590mg/3,MBK410mg/m3andbenzene30mg/m3 in an injectionmolding operationproducingvisors helmets; and (2) average air concentrations of : acrylonitrile 45 mg/m3, styrene 420mg/m3,and1,3‐butadiene2,200mg/m3inaninjectionmoldingoperation.

PHTHALATES

HealthEffectsofPhthalatesAnimal toxicology of several phthalates have been studied with questions raised about therelevanceofanimalfindingstohumans(Doull,etal.,1999;Ema,etal.,1993).Intheearly1990s,some authorities removed DEHP from lists of human carcinogens (EU, 1990; IPCS, 1992).However,theU.S.AgencyforToxicSubstanceandDiseaseRegistrydeterminedthatDEHP“mayreasonably be anticipated as a carcinogen” based on animal data (ATSDR, 1993). DEHP wasidentifiedasarodentlivercarcinogenthroughamechanisminvolvingperoxisomeproliferation(David, et al., 1999) .In 2000, IARC reclassified DEHP to Class C (not classifiable as tocarcinogenicitytohumans).

Inadditiontofindingsoflivercarcinogenesis,Moore(Moore1996,ascitedinKeml,1999)foundincreased incidence of mononuclear cell leukemia above that normally found at backgroundlevelsinthestrainofratusedintheexperiment.

Severalphthalates,DEHP,DBPandDzBP,areteratogenicinanimals(Ema,etal.,1993;Shiota,etal., 1980; Foster, et al., 1980). DBP is toxic to testes, possibly via its metabolite monobutylphthalate(MBP)(Heindel,etal.,1992;Gray,etal.,1984).Otherphthalatemetabolites,MBzPandMEHP,areSertolitcelltoxicantsandteratogenicinanimals(Ema,etal.,1996;Gray,etal.,1999).

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In addition, DBP and DEHP were found to interfere with normal fetal development in maleoffspring (Pirkle, et al., 1995). Several other studies found similar developmental andreproductive effects as a result of phthalate exposure (Gray, et al., 1986; Singh, et al., 1974;Srivastava,etal.,1990).Basedonaninterpretationoftheforegoingresearchfindings,phthalatesvaryinpotencywithregardtoreproductiveanddevelopmentaleffects.Inthisregard,DEHPismostpotentfollowedbyDBPandBzBP(Blount,etal.,2000).

In addition, phthalates have been found to be estrogenic (Joblin, et al., 1995). In this regard,there are two additional studies of importance. This includes Ewertz and colleagues (2001)findingofastrongassociationbetweenmalebreastcancerandemploymentintherubberandplastics industries; andHardell and colleagues (1997) findingof an elevated risk of testicularcancer and exposure to PVC (OR of 6.6 [CI: 1.4‐ 32]. When cases with risk factors such ascryptorchidismor orchiticwere excluded the risk for testicular cancer increased further. Theauthorsfoundnosuchincreasedriskwithexposuretoothertypesofplastics.

In this latter regard, theauthors speculate that themechanism for increased testicular cancerriskmaybetheestrogenicactionofthephthalatescontainedinPVC,sincemostotherplasticsdonotcontainthem,referencingastudyofadversepregnancyoutcomesshowingincreasedrisktomothers’ exposure toPVC (butnot otherplastics) inpregnancy (Ahlborg, et al., 1987 cited inHardell,etal.,1997).

In a study of air impurities in the PVCprocessing, Vainiotalo andPfaffli (1990) found that inaddition tohydrogenchloride, thermoprocessingofPVCreleased theplasticizerDEHPand itsdegradation production, phthalic anhydride PA. The highest single value for DEHP was 1.1mg/m3incalendaringprocessing.DEHPwasfoundin8plantsstudiedandPAwasfoundin5of6plants.

Processes thatproducedhigher concentrationswere calendaring, extrusion andwelding. Thismay be explained by the following: All three processes occur at higher temperatures and arerelativelymoreopenprocesscomparedtoinjectionmoldingoperations.

Whileconcentrationswerebelowthecurrentstandard,withthehighestvaluemeasuring20%oftheTLV,theauthorsnotethatthereleaseofDEHPduringPVCprocessingcausedconsiderablyhigher inhalation exposure than encountered in urban air atmosphere measured at 5‐132ng/m3.ACGIHTLVsforDEHPandPAare5mg/m3and6mg/m3respectively.

TheauthorsobservedthatPAwillalwaysbepresentwhenDEHPisdetected. Inaddition, it isimportant to note that the highest concentrations were found during higher heat operationssuchasweldingwheretemperaturesreached400C.Ineffect,whilethelevelsdiscoveredinthisstudyreflect fairagreementwithotherstudies,higher levelscanbeexpectedas temperaturesriseduringprocessdisturbances,since40to60%ofplasticizersvolatilizeat300C.

Phthalates (phthalate acid esters PAE) are extensively and almost exclusively used in PVCprocessing and workers are exposed mainly by inhalation and skin absorption. Industrialexposure levels of PAE up to 66mg/m3 have been reported in earlier studies in the 1970s

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(Milkov,etal.,1973;Gilloli,etal.,1975;Theiss,etal.,1978).

InahealthstudyofworkersexposedtoPAEduringtheprocessingofPVCresinsplasticizedwithdibutyl phthalate (DBP), DAP‐789, dioctyl phthalate (DOP), diisooctyl phthalate (Diop) andbenzyl butyl phthalate (BBP), Milkov and colleagues identified ambient levels of vapors oraerosolsof plasticizers (mixedesters) at theworking zoneofprimers that ranged from10 to66mg/m3.Similarresultswerefoundatworkstationsformilloperatorsandcalendaroperators.Levelsofbetween1.7and40mg/m3wereobtained in themixturepreparationsectionof theplant.(Milkov,etal.,1973)

Vinylchloridemonomer,carbonmonoxideandhydrogenchloridewere foundbutwerebelowmaximumallowableconcentration.Themajorcontaminantswerethephthalateplasticizers.

A 1985Dutch study byNielsen and colleagues evaluating PAE concentration in air and urineamongworkersprocessingPVCisinstructivewithrespectto jobtasksandextentofexposure.Thestudywasperformed in two filmproductiondepartments.Thin filmwascalendared fromPVCstabilizedwithzincandbariumandplasticizedwithdiiodecylphthalate(DIDP),DEHPandbutylbenzyl phthalate (BBP). Thick film PVCwas calendaredmainlywith DEHP and aliphatichydrocarbonsasplasticizers.PVCwascalendaredatamaximumof180Candbothoperationshadlocalexhaustventilation.

Theresearcherteamfoundthatcalendaroperatorssufferedthehighestexposuresat2mg/m3(40%of theTLVof5mg/m3),anexposure5timeshigherthanother jobcategories(machineattendants‐ 0.2‐0.4mg/m3: repairmen‐0.3mg/m3;mixers‐0.2mg/m3; reserves 0.1mg/m3).The average concentration of PA metabolite in urine of exposed workers was 23 umol/Lcomparedto17umol/Linunexposedcontrols.

Theauthors’notethatthelowerlevelsfoundintheirstudymaybeduetothefactthatearlierstudies focusedmainly on dibutyl phthalate (DBP)which has a higher vapour pressure thanDEHPandDIDP.Additionally,theabsenceofclear‐cutperipheralneuropathymaybeduetotheabsenceofDBPexposures(Nielsen,etal.,1985).

Similarly, Liss and colleagues found significant uptake of DEHP, phthalic anhydride and 2‐ethylhexanol in workers exposed during the manufacture of DEHP. They found significantdifferences inpost‐shift concentrationsand in thepre‐ andpost‐shift changes in totalurinaryphthalateconcentrationsbetweenworkersinjobsconsideredtobeathighriskofexposuretoDEHP and PA vs. those not at risk of such exposure. In comparing urinary concentrations tophthalate in air concentrations the researchers founda correlationbetweenair concentrationexposuresandphthalateuptakeasdeterminedbyanalysisofurinaryphthalatemetabolites.Theheavily exposedworkers had the highest post‐shift urinary phthalate concentrations and thegreatestpre‐andpost‐shiftincrease.

Inaddition,theyidentifiedinstancesinwhichworkersinsomejobcategoriesconsideredtobeat high risk of exposure to PA and DEHP had increases in pre‐ and post‐shift urinaryconcentrationsbutnodetectableexposuretoairbornePAonthedayofurinarysampling.The

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authors suggest that these workers may have had exposures below the detection limit orabsorbed phthalates from a pathway other than inhalation, perhaps percutaneously or orally(Liss,etal.,1985).

InastudyofmetabolitesofDEHPinurinefromworkersexposedwhileprocessingPVCinabootfactory and cable factory, Dirven and associates confirmed the uptake of DEHP throughworkplace exposure. They found that the uptake of DEHPwas 1.2‐2.3‐fold greater after an 8hourshiftthanbeforethestartofworkinthebootfactory,and1.2‐4.5‐foldgreateraftershiftthanbeforeforworkersinthecablefactory.Theyfoundthatthebeforeshiftlevelsforexposedworkers was higher than the level for the non‐exposed group. In this regard, the authorsspeculate that thehalf‐lifeofDEHPmaybe longer than12hours,andcontinuousexposure toDEHPmightresultinhigherlevelsofDEHPmetaboliteinslow‐releasingareasofthebodysuchasadiposetissue.

Factors affecting exposure include the heating of materials, closed vs open processes, theamount of DEHP used in the process. These variations in conditions and procedures werereflected in the variation of both urinarymetabolite levels and ambient air concentrations ofDEHP.Forexample,inthebootfactorythemixingoperationhadhigherairconcentrationsthanduring extrusion. In the case of mixing, the product is warmed and mixed in a semi‐open“papenheimer”at160C. In the cable factory,workersassigned tomixing remained ina soundproofboothmostofthetime,whiletheextrusionprocessforcoatingcablestookplaceinasemiopenprocessat200C(Dirven,etal.,1993).

In a similar biomarker study ofworkers exposed to DEHPwhile processing PVC,Gaudin andcolleagues (2008) identified that exposed workers had much higher concentrations of DEHPmetaboliteinurinethanwasfoundinunexposedcontrols.Theyalsofoundsignificantlyhigherconcentrations in exposed workers at the end of shifts when pre‐ and post‐shift levels were(16.1,58.9ug/lrespectively)compared,withnosuchdifferencefoundforcontrols.Theauthorsnoted that the levels found incontrolswere inaccordwith levels found inahumanreferencepopulationbybothKochetal.,(2003b)andPreussetal.(2005)at10.3‐9.8ug/l(Gaudin,etal.,2008).

In a study ofworkers representing a cross section of industries using urinary biomarkers forphthalateexposure,Hinesandcolleagues foundstrongevidenceofoccupationalexposuretoarange of phthalates including diethyl phthalate (DEP), di‐n‐butyl phthalate (DBP), di(2)ethylhexyl phthalate (DEHP), Dimethylphthalate (DMP), benzylbutyl phthalate (BzBP), di‐isobutylphthalateanddi‐isononylphthalate.

Across industries the research team compared end‐shiftmetabolite concentrations to theU.S.generalpopulationasobtainedthroughtheNationalHealthandNutritionExaminationSurvey(NHANES2001‐2002)andfound:

Levels of DEP and DMP in phthalate manufacturing exceeded general populationlevelsby4‐and>1000‐foldrespectively;

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LevelsofDBPinrubbergasket,phthalatemanufacturingandrubberhoseproductionexceededgeneralpopulationlevelsby26‐,25‐,and10‐foldrespectively;

DEHP in PVC film, compounding and rubber boot production exceeded generalpopulationlevelsby8‐,6‐,3‐fold,respectively.

Somesectorshadconcentrationsabovethegeneralpopulationlevelsevenwhentheparentphthalatehadnotbeenreported.ThiswasthecaseforMBzPinrubbergasket5.8‐fold;rubberboot3.4‐fold;andvehiclefilters1.4‐fold.

The authors noted that factors affecting exposure include: Vapour pressure of the substance;workingonornearprocesseswitheither appliedheat orheatedmaterialswith large surfaceareas.

Other studies involving sampling results in PVC processing industries (Nielsen, et al., 1985;Vianiotalo and pfaffli, 1990; Dirven, et al., 1993) and in phthalatemanufacturing (Liss, et al.,1985)haveshownelevatedprocesstemperaturesandlargesurfaceareaswereassociatedwiththemostexposedworkers.Theauthorsobserved fewopportunities fordermalcontactexceptwhenliquidphthalateorplastisolwashandled.

TheHinesetal.study(2009)identifiedtasksthatmayplaceworkersatriskofexposure.Inthisregardtheynotethefollowingbasedontheirassessmentofthecross‐industryworkprocesses:

Phthalate manufacturing of DMP, DEP, DBP and DEHP occurred in batches or continuousprocesses in presence of a catalyst. Operators could be exposed while taking or analyzingsamplesorwhileperformingmaintenance.

PVCcompoundingproducedpelletsusingDEHPandDiNP.Phthalaterelatedprocessesincludedmixing,extrusionandmilling.

PVC filmproduction usingDEHP andDiNP involved compounding,mixing, paste preparation,extrusion, milling and calendaring. In vehicle filter production, exposure could occur whiledispensingplastisolcontainingDEHP.

Inrubberproducts,exposurecouldoccurduringcompounding,mixing,milling,calendaringandcuring. In rubber hose, exposure could occur during compression molding, stripping andextrusion.Inrubberboot,exposurecouldoccurduringextrusion,injectionbolding,buffing,bootmakingandstripping.

It is interestingtonotethat inmetabolitestudiesthatwerecombinedwithairsampling,urinaryphthalate levelswereseveralordersofmagnitudeabove levels found ingeneralpopulationseventhoughairsamplingshowedlevelsthatwerefarbelowexposurestandardsandintraceamounts.

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BISPHENOL‐A

HealthEffectsofBPAThelevelsofBPAmeasuredinhumanserum,urineandothertissuesarewithintherangeshownto cause effects in laboratory animals, and impact cell function inmechanistic studies in cellculture. Therefore, it is plausible and even likely that these levels are biologically active inhumans,withobviouspotentialtocausediseaseordysfunction.Atthesametime,theincreasedconcentrations observed in workers who are occupationally exposed in addition to generalpopulation’sexposuresmayplacetheseworkersatgreaterriskofadversehealtheffects.

Recent animal studies show that low dose BPA exposures in rats stimulatesmammary glanddevelopment, and that prenatal exposure increases breast tissue sensitivity to estrogen andcancer‐causing chemicals. BPA also increases ductal density in laboratory animals. Bothconditionsareriskfactorsforbreastcancerinwomen(Munoz‐de‐Toro,etal.,2005;Markey,etal.,2001;Durando,etal.,2006).

Several animal studies show that low dose BPA exposures in male rats reduce daily spermcounts.ThiswasalsoreplicatedmalemiceexposedtolowdosesofBPA.Thatalteredhormonelevels may be associated with reduced sperm production, two animal studies showed thatreducedhormonelevelsinratsandmicefollowedlowdoseBPAexposures.(Chitra,etal.,2003;Al‐Hyasat,etal.,2002;Sakaue,etal.,2001;vomSaal,etal.,1998;Akingbemi,etal.,2004;Kawai,etal.,2003).

BPA levels in blood have been associated with a variety of conditions in women includingobesity, endometrial hyperplasia, recurrentmiscarriages, abnormal karyotypes and polycysticovarian syndrome.Twostudies found thatwomenwithPCOShadhigher serum levelsofBPAthanwomenwithout PCOS and that levels of BPAwere positively correlatedwith circulatingandrogenlevels(Takeuchi,etal.2002;Takeuchi,etal.2004).

AnegativecorrelationbetweenBPAandFSHwasfoundamongmeninthestudyofepoxyresinworkers described above (Hanaoka, et al. 2002) however, the epoxy resinworkerswere alsoexposed to organic solvents. Due to the cross‐sectional design of these studies, it cannot bedeterminedwhetherBPA increasesandrogen levelsor if androgen levelsaffectmetabolismofBPA.

Three studies found higher BPA exposure for health‐related outcomes that are 12 associatedwithchromosomalabnormalities.Onestudy foundhighermaternalserumBPAamongwomencarrying fetuses with an abnormal karyotype compared to women carrying fetuses with anormalkaryotype(Yamada,etal.2002).

Maternal age, an important potential confounderwas not controlled in this study. In anotherepidemiology study, an association between serumBPA levels and recurrentmiscarriagewasreported(Sugiura‐Ogasawara,etal.2005);meanBPAlevelsweremorethanthreetimesashighin45womenwithahistoryofthreeormoreconsecutivefirst‐trimestermiscarriagescomparedto32nonparouswomenwithoutfertilityproblems.

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Additionally,among35womenthat thenbecamepregnant, therewassomeevidenceof lowerBPAamongthewomenwhosubsequentlyhadasuccessfulpregnancyascomparedtothosethatmiscarriedagain.

TheeffectsofBPAontheendocrinesystemhavebeenreported.Itsestrogenreceptorbindingcapacity has been observed in earlier studies (Nagel, et al. 1997; Krishnan, et al. 1993).Withrespecttogenitalfunctioninmales,vomSaal,etal.observeddecreasedspermproduction,andTakao,etal.1999observeddecreasedfreetestosteroneandLHinmalemiceexposedtoBPA.Inmen,LHandFSHareinvolvedinspermproductionandandrogensynthesis

In addition, sister chromatid exchange measured in peripheral lymphocytes was positivelyassociatedwithurinaryBPAlevelsinadults(Yang,etal.2006).Thesearecoupledwiththeclearfindingsofcelltransformation(Tsutsui,etal.1998,2000)andcarcinogenicity(NTP,1982;Huff,2001; 2002). Cell transformation has long been considered predictive for mammaliancarcinogenicity(Barrett,1985).

ExtentofWorkerExposuretoBPABPAhasbeenmeasuredinhumanurinefromseveralpopulationsaroundtheworld(Table2).ThesestudiesconfirmwidespreadhumanexposuretoBPA,assuspectedfromthestudiesofBPAin blood. Most BPA in urine is in its conjugated form, i.e. BPA‐glucuronide or BPA‐sulfate.Therefore,mostresearchersuseenzymatic(e.g.glucuronidaseand/orsulfatase)treatmentstomeasure total (free/unconjugated plus 9 conjugated) BPA in urine. Many also test untreatedurinetodeterminelevelsoffreeBPAalone.

The recent study conducted by the US Centers for Disease Control and Prevention (CDC)detectedBPAin95%ofurinesamplesfromareferencepopulationof394AmericanadultsusingisotopedilutionGC‐MS.(Calafat,etal.,2005).ThisstudyreportedaveragelevelsoftotalBPAinmaleandfemaleurineof1.63and1.12ng/ml,respectively.

Similar resultswere also obtained in a study of 90 young girls; BPAwas detected in 94% ofsamples(Wolff,etal.2007).

AnotherstudyalsoexaminedsexdifferencesinurinaryBPAlevelsin30KoreanadultsbyHPLCwithfluorescencedetection.ThisstudyfoundnosexdifferencesintotalBPAmeasures(averagein15menand15women,2.82and2.76ng/ml,respectively).Interestingly,however,menhadsignificantly higher levels of BPAglucuronide (2.34 vs 1.00 ng/ml) while women hadsignificantlyhigherlevelsofBPAsulfate(1.20vs0.49ng/ml)(KimY‐H,etal.,2003).

Inanotherstudyofinterest,BPAwasmeasuredintheurineofmaleworkerswhoapplyepoxyresins containing bisphenolA diglycidyl ether (BADGE).UrinaryBPA levelswere significantlyhigher in 42 men exposed occupationally than in 42 non‐exposed workers. They found asignificant difference in bisphenol A concentrations between exposed (1.06 umol/molcreatinine)unexposedcontrols(0.52umol/molcreatinine.Theresearchersalsonotethatmostofthegeneralpopulations(inJapan)haveconcentrationssimilartothoseofthecontrolsintheirstudy.Intheirview,theincreaseconcentrationsobservedinexposedworkerswasgeneratedby

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theirexposurestobisphenolAinthematerialsusedinproduction(Hanoaka,etal.2002).

TheconsistentfindingthatBPAisdetectedinalmostallindividualsindevelopednationsimpliesthathumansareexposedtoBPAcontinuously.BecauseoftherapidmetabolicclearanceofBPA,andthemeasurablelevelsofBPAthathavebeendetectedinhumanbloodandurine,Welshonsandcolleagueshaveidentifiedtwopotentialissues:1)BPAintakemaybeactuallymuchhigherthan has been suggested, and/or 2) long‐term, daily intake leads to bioaccumulation of BPA,leading to steady‐state levels that are not represented by any of the currentmodels for BPAmetabolismbasedonsingle,acuteadministration(Welshons,2006).

METALS:EXPOSUREDURINGTHERMOPLASTICPROCESSING

Various metal compounds are used in the thermoplastics processing industry. Thesemay beused as heat stabilizers, particularly in the processing of PVC, and colourants in all polymers.Heat stabilizers might include inorganic lead compounds, organic tin compounds, barium,calcium,zinccarboxylates,antimonycompounds,etc.

There are few studies ofmetal exposures in thermoplastics processing.We summarize someworthytonotewithrespecttopotentiallevelsofexposureandworkactivitiesthatputworkersatriskduringtheproductionofplasticsproducts.

OrganicTinInastudyofworkersexposuretoorganictincompoundsusedasstabilizersinPVCprocessing,Boraiko et al. (2005) found thatmean organic tin exposureswere less than 10% of the TLV.Includedweretwocaseswheretheresultswereconsiderablyhigher(e.g.>50%oftheTLV=0.10mg/m3) and one case that was slightly higher (0.102 mg/m3). For these cases, the authorsidentifiedthattheworkersperformedmultipletasksandmanualhandling,asopposedtothoseinvolvingmoreautomatedhandlingandengineeringcontrols.Thesemanualoperationsinvolvedoperatorsopeningdrumsandpouringstabilizersintocontainerstobeaddedmanually.

Theynotedthatmanyoperatorsconductedavarietyofdifferenttasksinaworkshift,resultingindifferentexposurelevelsreportedforsimilartasks.Tasksthatputworkersatgreaterriskofexposureincluded:

Openingandclosingdrumsoftinstabilizerandconnectinganddisconnectingpumpstothesedrums;

PouringoftinstabilizerintocontainerstobeaddedtoabatchofPVCtobecompounded; Cleaningupsmallresidualsformdrumtopsordippipe; Samplingofstabilizerattimeofdelivery; Connectinganddisconnectinghosesattimeofbulkdeliveryandcleaningupresiduals; CleaningmixingvesselsorcontinuouslinesafterPVCcompounding.

Theauthorsreportedthefollowingmaximumlevelsofexposureforeachoperation:

Blending—0.102mg/m3

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Extrusion—0.034mg/m3Injectionmolding—0.007mg/m3Milling—0.064mg/m3Pelletizing—0.006mg/3

TheauthorsconcludethatworkersmayexperienceexposuretoorganictincompoundsduringPVCprocessing.

Thehealtheffectsassociatedwithorganictincompoundsexposure include:adverseeffectsonthe liver,kidneysandurinarytract.ThecurrentTLVof0.1mg/m3isbasedonchanges in theliver,kidney,lung,heart,nervousandreproductivesystemsinrodents(ACGIH,1991)

LeadCompoundsSimilarly, Coyle, et al., found that workers processing PVC were exposed to lead sulfatestabilizers. In this investigation three plastics compounders were found to have severe leadpoisoningasaresultoftheuncontrolleduseofpowderedleadsulfate.Bloodleadconcentrationsforthethreeworkersattimeofdiagnosiswere159,114and108ug/dl.Followupinvestigationof 6 co‐workers identified levels ranging from 4 to 48 ug/dl. For comparison purposes thegeometricmeanBLLfortheU.S.generalpopulationandworkingagedadultsislessthan2ug/dll(CDC,2003).Furtherfollow‐upofworkers’childrenidentifiedonechildwithelevatedBLLof10ug/dl.

Airmonitoringconductedseveralweeksaftertheindexcasewasidentifiedshowedpersonalairlead levelof460‐1,100ug/m3.Air lead levelsayear laterandafter theemployerswitched topellet formulation were still excessive at 20‐400 ug/m3. Even after the employers’ furthereffortstoswitchtoapre‐packagedstabilizerlead,airlevelsremainedexcessive(3‐210ug/m3).Whilethesourceforcontinuinghigh leadair levelswasunclear, theauthors’notedthatwhitepowderwasvisibleonthe floorandsurfaces thoughout theshop, likelykickedupduringdrysweeping. Thepowder, they speculate,may havebeen lead sulfate left over from the originalprocess.

Theauthorsnotethatevenengineeringcontrols,suchasswitchingtoapre‐packagedstabilizer,maynotbesufficienttocontrolleadexposures.

Health effects of lead compounds include toxicity to the nervous system, blood and kidneys.Reproductive effects can occur inmen andwoman. Some effects include: numbness, tremors,impairedhearing,memoryloss,anemia,renalfailureandinfertility.LeadcompoundsasusedinPVCstabilizationareclassifiedbyIARCasGroup2Bcarcinogens.

CadmiumCompoundsInaverylimitedstudyofairconcentrationsofcadmiumcompoundusedaspigmentsinvariousthermoplastics, Bonilla, et al. (1994) found that cadmium concentrations did not exceed theOSHAactionlevelof2.5ug/m3.However,theauthorsnotedthattheirstudyfocusedentirelyonfumesgeneratedbyinjectionmolding,anddidnotincludepotentialexposurefrominhalationofdust resulting from secondary operations involving sanding, sawing, and regrinding thatmay

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generateairborneconcentrationsofcadmiumdust.

FLAMERETARDANTS

There are two general categories of flame retardants with a diversity of chemical types andfunctions:Inorganicflameretardant includemetaloxides,hydroxideandbasiccarbonatesandfunction by the release of an inert gas or by undergoing highly endothermic decomposition.Organic flame retardants include phosphate esters and halogenated materials‐especiallyorganobrominewhichfunctionbyinterceptingtheactivespeciesinthechemicalprocess.

The primary flame retardants used in plastics production are organohalogen‐andorganophosrus‐containingcompounds(Green,inKatz,etal.,1987).

Polybrominatedbiphenyls (PBB) include a class of substances that have been shown to bestrongly estrogenic and in some instances have been classified as Group 2B chemicals.Carcinogensincludinghexabromobiphenylwhichhasprovedtobealivercarcinogeninanimaltests (IARC). Many vivo and in vitro studies show that polybrominated biphenyls interruptthyroid function and are potently estrogenic. Such substances as polybrominated diphenylethers(PBDE),hydroxylatedPBDE’s,petabromophenol(PBP),tetrabromobisphenolA(TBBPA)and polybrominated bisphenol A compounds showed marked estrogenic potencies in vitro.(Meerts,etal.,2000;Meerts,etal.2001;Brouwer,etal.1998,Ucan‐Marin,etal.2009;Crump,etal.2008;Shao,etal.2008;Dang,etal.2007,Reistad,etal.2007;vandeVen,etal.2006;Kudo,etal.2006;Hamers,etal.2006;Schauer,etal.2006;Canton,etal.2005;Kitamura,etal.2002).

Phosphororogananiccompounds(POC) includeanumberofcompoundsusedasretardantsin plastics production. Some of the more common are trybutylphosphate, tris (chloroethyl)phosphate,tris(chloropropyl)phosphate,tris(dichloropropyl)phosphate,tris(2‐butoxyethyl)phosphate, tris (2‐ethylhexyl) phosphate, triphenylphosphate, tricresylphosphate, tris (2,3‐dibromopropyl)phosphate.Theseareshowntobemutagenic invitro(BrumandAmes,1977;van Beerendonk, et al. 1994; Hudec, et al. 1981; Ames, 1979; Gold, et al., 1978; Prival, et al.1977).

OccupationalandEnvironmentalExposurestoFlameRetardantsThereareveryfewoccupationalhygienestudiesofoccupationalexposurestoflameretardants.Ofthosestudiesundertakenthefocuseswasonexposuretohalogenatedflameretardantsandwere not directly related to plastics processing. In two studies, one in Norway and one inSweden,researchersbiologicallymonitoreduptakeofhalogenatedflameretardantsinworkers.TheNorwegian study focusedonmeasureduptake in electronicdismantlingworkers,printedcircuitboardproductionworkersandlaboratorypersonnel(Thomsen,etal.2001).TheSwedishstudy measured uptake in electronic dismantling workers, computer screen workers and acomparative group of hospital cleaners (Sjodin, et al. 1999). In both studies, levels ofbromonated flame retardants in workers were higher than in the general populations andreferentgroup.Inaddition,thelevelsweremuchhigherintheelectronicdismantlinggroupthaninotheroccupations.

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Thesestudiesindicatethatwhilegeneralpopulationsareexposedtoseveralbromonatedflameretardants, the elevated levels in dismantling workers suggests that these workers receivedadditionaloccupationalexposure.

Similarly,astudyofworkersmanufacturing,orhandling,rubbercontainingtheflameretardantdecabromodiphenylether found that rubberworkershadelevated levelsofbrominated flameretardant that were 2.5 to 11 times higher than a referent group of non‐exposed workers(Thureson,etal.2005).

In their review of plastics additives in the indoor environment,Wensing, et al. (2005) foundsignificant concentrations of POC in automobiles when interiors were heated to 65C. In thisregardconcentrationsofTCPPandTDCPPreached11.1and8.4ug/m3respectively.Theyalsofoundthatnewcarsgiveoffsignificantlyhigherconcentrationsthanvehiclesthatare9monthsolder.Thehighestconcentrationatroomtemperaturewas0.48ug/m3.Theselevelsgivesomeideaofwhat levelsmightbe likeduringthethermoplasticprocessingwheretemperaturesareevenhigherandtheproductisnewlyproduced.

COMPLEXMIXTURES

EmissionsfromProcessingThermoplasticsUpto thispointwehaveonlyconsidered theemission,exposureandhealtheffectsofvariousknowningredients, i.e., thechemicalsknowntobeinvolvedintheprocess.Wenowturntoanevenmore complex process inwhich new species of ingredients are created by the chemicalreactionstakingplaceduringthethermoplasticprocess‐‐inadditiontothoseidentifiedintheoriginal formulations.Theresult isacomplexmixofproducts thatarereleased into theworkenvironment.

Several studies have been conducted to identify these chemicals and evaluate the extent ofemissionduringvariousthermoplasticprocesses.

Oneof the fewcomprehensivestudiesof thiskindwasconducted in1995byM.J.Forrestandcolleagues. While a number of studies had attempted to characterize the various substancesproducedwhen thermoplasticmaterials are heated in the laboratory, fewhad tried to collectdatafromactualworkplacesituations.

Forrest,etal.(1995)investigatedtheprocessingofABS,HIPS,PVC,LDPE,HDPE,PP,PAM,SANduringinjectionmoldingandextrusionprocesses.Theresearchtookbothpersonalsamplesandareasamplesforeachprocess.

They detected awide range of chemical species in each processwork environment. In someinstancestheywereabletodetectrelevantmonomers.Theconcentrationsofspeciesdetectedranged between 0‐2 mg/m3 under standard processing conditions and up to approximately10mg/m3 during purging operations. At no time were concentrations above the currentexposure limits. Generally their data show that a higher level of fumes is generated during

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extrusion‐basedprocessesthanduringinjectingmolding.

Somespecificresults:

ABS: A wide range of species at various concentrations. Concentrations were higher duringpurging.Unexpectedly,however, the researchersnotedrelativelyhighconcentrationsofmanyspecies in the background, e.g. the differences between the background levels and thoseobtainedclosetotheinjectionmolderwerequitesmall.

Themonomersacrylonitrileandstyreneandamodifiermethylstyreneweredetected.

Thefollowingquiteextensivelistofcompoundswasdetected:

AcrylonitrileHydrocarbons(c3‐c7)Trichloromethane111trichloroethaneBenzeneTrichloroethaneAlcoholTolueneXyleneisomerStyreneHydrocarbons(c10‐c11)Benzene,methyl,ethylisomersBenzene,proylisomerBenzene,trimethylisomersAlphamethylstyreneBenzene,ethyl,methylisomers,benzene,dichloroiomerAcetophenonBenzene,diethylisomerHydrocarbons(c12‐c14)Benzene,ethyl,dimethlylisomersBenzene,methyl,diethylisomersNaphthalene,tetrahydroisomerBenzene,ethyl,methylethylisomerSiloxaneNaphthalene,tetrahydo,methylisomersBHT

HIPS: During sheet extrusion processes. The species produced were primarily aromatic innature with styrene the most prominent at 1.48mg/m3. Acrylonitrile was noted in lowerconcentrations. These results illustrated that location could influence concentrations.Concentrationswerehigherwheretheprocesswaslocatedadjacenttoasidewallasopposedtomachines located in an open area. In addition to the monomers, a host of aromatics andhydrocarbonswereidentified.

HIPS:During injectionmolding.Awiderangeofspecieswereproducedatsignificantlyhigher

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concentrations than for sheet extrusion. Background levels were not much lower thanconcentrations found next to the process and purging produced significantly higherconcentrations. The monomer styrene was detected in addition to a complex mixture ofaromaticsandhydrocarbons.

HDPE:Duringblowmoldingoperations.Afewspecieswereproducedatlowconcentrations,inparticular,simplehydrocarbonsandtoluene.

Nylon6:Duringextrusionprocessing.Variouschemicalspeciesweredetectedatrelativelyhighconcentrations including background. Background levels were higher than those near theprocess. This anomaly is explained by the other work activities going on in close proximity.Comparativelyhighlevelsofdichlorodifluouromethaneaswellashydrocarbonsandaromaticsweredetectedduringpurging.

PP:Duringtapeextrusionofpolypropylene.Duringthisprocessresearchestookmeasurementup wind and downwind of a noticeable draft. And background during purging was alsomeasured. This process producedmostly hydrocarbons and some aromatics at comparativelyhigh levels.The levelof fumesdownwindwashigher thanupwindconcentrations.Relativelyhighlevelsofdichloromethane,a‐methylstyrene,xyleneaswellasaromaticsandhydrocarbonsweredetectedduringpurging.

PVC:During injectionmolding of unplasticized PVC. Comparatively high concentrationswerefound for awide variety of chemicals.Background levelswerehigher than levels close to theprocess. Monomers found could have originated from additives in PVC compounds beingprocessednearby.Purgingoperationsenhanced theconcentrationof species found.Levels fordichloromethane,ethylacetate,xylene,a‐methylstyreneaswellashydrocarbonsweredetectedathighlevelsduringpurging.

LDPEandLLDPE(lowdensitypolyethylene‐linearlowdensity):Duringblowfilmprocessingofboth compounds.Theprocessingof thisblendproduceda larger rangeof chemical species athigher concentrations. Certain monomers—methyl methacrylate and a methyl styrene werefound,butcouldhavebeenfromanothersource.Purgingdidnotincreaseconcentrationsinthiscase.

SAN:StyreneAcrylonitrilewasmeasureonlyforhydrogencyanide.Nonewasdetected.

Whatthisstudydemonstratesisthatthermoplasticprocessingproducesverycomplexmixturesof residual chemicals from the basic formulations aswell as numerous chemical by‐productsfromchemicalreactionsoccurringunderthermoprocessingconditions.Itdemonstratesthattheextentofexposureisconditionedbyanumberoffactors.Theseinclude:thetypeofmaterial,thetypeofprocess,ventilationandpurgingandcleaningprocesses.

In a study of depolymerization of products in polyacetal POM, polyamide PA 6, andpolymethylmethacrylate PMMAduring thermoplastics processing at 11 plants, Vainiotalo andPfaffli(1984)foundmonomerconcentrationsof0.06‐0.23mg/m3offormaldehydeduringPOM

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processing;0.05‐0.14mg/m3ofe‐caprolactamduringPA6processing;and0.06‐4.6mg/m3ofmethylmethacrylate(MMA)duringPMMAprocessing.TraceamountsofformicacidduringPOMprocessingandammoniaduringPA6processingwere found.NoneexceededcurrentOEL.TheratherhighlevelofMMAisofspecialconcernbecauseofitshighdegreeoftoxicityandeffectsonneurochemicalssuchasacetylcholineesteraseactivity.

Theauthorsalso foundthatplastic fumescontainsmallamountsofothersubstances,e.g., freeradicals,aerosols,andadditiveswhichmaybeharmfultohumanhealth.Allmeasurementsweretaken during normal processing. They noted that a rapid rise in temperature as a result ofprocessdisturbancecouldleadtomuchhigherconcentrationsofmonomers.Inapreviousstudyofemissionsofadditivesinthermoplasticsthesameauthorsfoundlevelsoftheblowingagentazodicarbonamide ranging from 0.002‐17.5 mg/m3. (Vianiotalo and Pfaffli, 1988). In otherresearch on the production of free radicals during the processing of polyethylene andpolystyrene plasticsWesterberg, et al. (1982) found that plastic processing gives rise to freeradicalswithlifetimeslongenoughtoreachthebreathingzoneofworkers.Thetoxicityoffreeradicalscaninitiateaprocessleadingtoseriouscelldamage.

Anothermajorcontributiontotheseexposureandrisksassessmentwastheextensiveliteraturereviewunder taken by theNordic Expert Group for CriteriaDocumentation ofHealthRisk ofChemicals.Theirassessmentinvolvedanevaluationoftheliteratureondegradationproductsofpolyethylene,polypropylene,polystyrene,polyvinylchlorideandpolytetrafluoroethylene intheprocessingofplasticsaswellasabriefreviewofthehealtheffectsliterature.(Zitting,1998)

Abriefsummaryoftheirreviewfollows:

Polyethylene: Studies included measurements and identification of chemicals duringcompression molding, injection molding, blow molding and extrusion. Most PE is formed byextrusion processing. Additives may include: carbon black, titanium dioxide, chromic oxide,antimony trioxide, chlorinated compounds, azodicarbonamide, 4,4‐oxybisbenzenesulphonohydrazide, polyisobutylene, butyl rubber, peroxides, phenols,polyethyleneglycolalkylesters.

Majordegradationproductsareformaldehyde,formicacid,acetaldehyde,aceticacid.Significantamount of aerosols are formed aswell as free radicals. The authors present a long list of 45compounds identified during thermal processing polyethylene at temperatures ranging from264to289C.

Exposure data from several studies indicate low concentrations of aldehydes, keystones andorganicacidsaswellasawholehostofvolatileorganiccompounds.

The health effects literature reviewed indicated adverse neurological adverse effects andrespiratorytractirritationinanimals.Humanstudiesindicateddermatitis,irritationoftheeyesandupperrespiratorytract,bronchialconstrictionandadverseCNSeffects.

Polypropylene:Additivesaresimilartopolyethylene.

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Major degradation products include: acetaldehyde, formaldehyde, acetone, acetic acid andmethylacroleinalongwithsignificantamountsofaerosolsresemblingparaffinwaxfumes.

Again the authors list a long list of chemical compounds in the following categories:hydrocarbons,alcohols,ethers,aldehydes,ketones,acids.

Health effects literature indicated irritation of the upper airways in animals. Human studiesshowed potential bronchial spasms, as well as some studies indicating possible associationbetween work with PP and colorectal cancer, but authors point out that weight ofepidemiologicalevidencedoesnotsupportthisassociation.

Polystyrene:Processedthroughanumberoftechniques.

Degradationproducts includealcohols,aldehydes,andketones. At least190compoundshavebeenidentified.Themostabundantproductwasstyrene.TheseareaccompaniedbysignificantamountsofaerosolsandfreeradicalsinPSprocessingfumes.

Healtheffectsliteratureindicatedadverseliverandlungeffectsinanimals,althoughtheauthordiscountedtheseeffectsasnotrelevanttohumansbecauseofthehighexposuresintheanimalstudies. Only one human studywas reported of adverse pregnancy outcomes amongwomenemployedintheplasticsindustryinCanada(McDonaldetal.,1988).

Polyvinylchloride:TheauthorspointtothelargenumberofadditivesinPVCprocessinganditsuseinallprocessingtechniqueswhichgreatlyaffectthecompositionofdegradationproducts.

Degradation products are complex: The literature indicates that various additives such asphthalatesandblowingagentsincludingazodicarbonamideareemitted.Thesehavebeenshowntoreactfurther,e.g.DEHPdecomposestophthalicanhydride.

The authors cite several studies indicating a larger range of chemical species that include:Aliphatic hydrocarbons, halogenated hydrocarbons, aromatic hydrocarbons, alcohol,alkoxyalcohol, aldehydes, ketone, acid, ester, and hydrogen chloride. Exposure values variedwidelydependingontheprocesstechniquesemployedandmaterialsused.

Thehealtheffectsliteratureindicaterespiratoryirritationinanimalsandhumans.TheauthorsdiscounttheassociationbetweenangiosarcomaandPVCdegradationproducts.

Polytetrafluoroethylene:PTFE is made from tetrafluouroethylene and additives are seldomused.

Majordegradationproducts include:hydrogen fluoride, tetrafluoromethane,carbonyl fluoride,tetrafluoroethylene, Hexa fluoroethane, hexafluoropropene, Octafluoropropene, Octafluoroisobutene,andtrifluoroacetylfluoride.

Healtheffectsliteratureindicatepulmonaryhemorrhageandedemaandpolymerfumefeverinanimals.Edemafrominhalingfumesproducedinweldingandgrindingandpolymerfumefever

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inhumanshavebeenreportedandstudied.

EPIDEMIOLOGICALEVIDENCEOFADVERSEREPRODUCTIVEEFFECTSANDBREASTCANCER

AdverseReproductiveOutcomesandInfertilityAssociatedwithPlasticsProductionThereareseveralstudiesthatfoundanassociationbetweenworkintheplasticsindustryandvariousformsofadversereproductiveoutcomesandinfertility.ThesewereidentifiedbyBaranskiinacomprehensivereviewofrecentliteratureonadverseeffectsofoccupationalfactorsonfertilityandrelatedreproductiveoutcomes.Theseinclude:Spontaneousabortionsinviscoserayonandstyrene industry (Hemminki, 1984); infertility and delayed conception in plastics industry(Rachootin, 1983); Spontaneous abortion in PVC and styrene plastics workers (Lindbohm,1985); spontaneous abortions among phthalate plasticizer workers (Aldyreva, 1975);spontaneousabortionsamongplasticsandrubberproductionworkers(Figa‐Talamanca,1984);menstrualdisordersandinfertilityamongfemaleworkersinsyntheticrubber,caprolactumandstyreneproduction(Sanotsky,1986);spontaneousabortionsamongwomenexposedtoorganicsolvents(Lindbohm,1990);menstrualdisordersandspontaneousabortionsandpolyamidecordproduction (Gaevaja, 1983); spontaneous abortion and premature delivery among womenworkinginPVCandepoxyplasticsproductionSachbazjan,1981);spontaneousabortionamongand congenital malformations in offspring of women working in rubber production;spontaneousabortionamongwomenworkinginrubbertireproduction;increasedoddsratioofadversereproductiveoutcomesforwomenwhoworkedinPVCprocessingandprocessingcoldplastics( Ahlborg, 1987); Reduced fertility in women exposed to organic solvents(Sallman,1995); more recently an increased incidence of infertility among women working in plasticsindustry(Hougaard,2009).

BreastCancerAssociatedwithPlasticsProductionEarly epidemiological evidence showing an association between employment in the plasticsindustry and breast cancer identified elevated breast cancermortality amongPVC fabricatingworkers (Chiazze, et al., 1977).However subsequent case‐control analysisof thedata foundanon‐significant risk of death from breast cancer. The authors concluded that the absence ofstatistical significance did not demonstrate lack of excess risk, since the study lacked thestatisticalpowertodetectthesizeoftherisk(ChiazzeandFerence,1981).

A more recent study identified excess risk of breast cancer in plastics and rubber industryworkers(1.8,95%CI1.4‐3=2.3)aswellasinworkersexposedtoorganicsolventsandbenzene(Patralia,etal.,1998).Twootherstudiesreportanon‐significantincreasedriskamongrubberand plasticsworkers (Bu‐Tian Ji, et al. 2008). Addingweight to a connection between breastcancerandemploymentintheplasticsindustryisthefindingofexcessriskofmalebreastcanceramong workers in the rubber and plastics industry (OR=4.5, 95%CI 0.7‐2.8) (Ewertz, et al.,2001). Male breast cancer is a rare event and its occurrence may indicate the estrogeniceffectivenessofsubstancesusedinthisindustry.

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Two other studies may indirectly implicate these substances with increased risk of breastcancer. An Israeli case‐control study (Shaham et al., 2006) identified increased risk of breastcanceramongwomenworkingintextilesandclothingindustry(OR=1.8,95%CI1.1‐3.0).Intheabsenceofspecificexposuredata, theauthorsspeculate thatexposuretovariouscarcinogenicagents and endocrine disrupting substances used in textilemanufacturingmay play a role inbreastcancerrisk.

Similarly,Labrecheandcolleaguelinkexcessriskofbreastcancerwithoccupationalexposuretosynthetic textile fibers, acrylic fibers, (OR 7.0 and nylon fibers (OR 1.99) when exposureoccurredbeforeage36.TheyfoundthatORdoubledforestrogen/progesteronepositivetumorslined to exposure to acrylic and rayon fibers and nonaromatic hydrocarbons. A threefoldincreasewas linked to exposure to PAHs (Lebreche, et al. 2010). It is important to note thatmoderntextilesconsistmostlyofsyntheticfibersmadefromacrylic,nylon,rayon,polyesters—essentially fromplastic resins treatedwithadditivessuchasplasticizersand flameretardantsthatare recognizedasmammarycarcinogensandendocrinedisrupters.At thesame time, thefinding of increased riskwith exposures before age 36 is also consistentwithwhatwe knowabout risk factors for breast cancer, all of which are related to life‐time exposure to ovarianhormones. Early exposure to xenoestrogens present a window of vulnerability with severalpossibledimensionsforincreasedrisk.

Addingweighttothisevidenceofacausalconnectionisthecase‐controlstudybyBrophyetal.that utilizeddescriptive data from a qualitative study (Brophy et al., 2012;Keith et al., 2011;DeMatteo et al. 2012). That study found a more‐than‐doubling of breast cancer risk amongwomenwhohadworkedinautomotiveplasticsmanufacturingfor10yearsandwereassessedas having been highly exposed to EDCs and/or carcinogens (OR=2.68; 95% CI 1.47‐4.88).Astonishingly, the risk rose to almost five‐fold for premenopausal women (OR=4.76; 95% CI1.58‐14.4). The early onset of breast cancer further substantiated the hypothesis of a causalconnectionbetweenexposuretoEDCsandcarcinogensintheplasticsproductionprocess.

DISCUSSION

Thisreviewbroughttolightsomeverysignificantevidencetopostulateaprobablelinkbetweenworkintheplasticsindustryandbreastcanceraswellasotheradversereproductiveeffects.

Firstly,wewereabletodemonstratethroughareviewofanumberofmonitoringstudiesthatworkerssustainasignificantlyhigherbodyburdenofendocrinedisruptingsubstancesthanthatfound in the general populationswhich are already higher that those found to harm animals.Second, these substances have a longer half‐life that originally believed and tend tobioaccumulate.TheseobservationswerefoundforanumberofendocrinedisruptingsubstancessuchasbisphenolA,styrene,acrylonitrileandphthalates.Forexample,levelsofBPAdetectableinhumanbloodarewithinorabovetherangeofconcentrationsdemonstratedinvitrotocausechangesinthefunctionofhumantissue(vomSaaletal.2007).

Third,severalstudiesindicatedthatairmonitoringcanunderestimatethetruebodyburdenof

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these substances. While most studies indicated that levels were below current occupationalexposure limits, body fluid concentrations were significantly higher than levels found in‘unexposed’referentpopulations.

In this context, it is important to emphasize that endocrine disrupting substances havedisruptiveeffectsatinfinitesimallevels.Attimes,lowdosesmayhavemorepowerfuleffectsthatathigherdoses.Dose ismeasured inpartsper trillion.To illustratehowsmall, this is likeonedropofsubstanceplace in660rail tankcarsextendingalongthetracks for6miles(Goettlich,2005). Consequently, these substances may not exhibit the traditional linear dose‐responsecurve,butaremorelikelytoproduceaninvertedUorU‐shapedcurve(Diamanti‐Kandarakis,et2009).

Additionally,workersareexposedtoacomplexmixofcompoundsthatmayincludeendocrinedisruptingchemicalsandotherco‐contaminants.ThecombinedeffectofdifferentclassesofEDsmaexertadditiveorevensynergisticeffects.StudiesthatinvestigatedthelinkbetweenEDsandbreast cancer produced inconsistent results where exposure to a single substance wasmeasured, while those that considered several co‐ contaminants exposures demonstrated apositive link. In fact, one such study demonstrated that the combined effects of severalenvironmentalestrogensasmeasuredbythetotaleffectivexenoestrogenburden(TEXB)areariskfactorforbreastcanceroverandabovetherisklinkedtoanysinglesubstance(Ibarluzea,etal.2004).

The other major obstacle is associated with the inherent limitations of epidemiology indemonstratingthelinkbetweenoccupationalexposuresanddisease. The problem lies inthe limited statistical power of most studies to actually detect the risk or underlyingrelationship. In this regard, numerous studies reviewed found non‐significant excess riskbecause therewas insufficientstatistical todetectariskof thatmagnitude. In theirreviewof115 occupational breast cancer studies, Lebrech and Goldberg identified that the mediannumberofbreastcancercaseswas19withanaverageof64cases.Onlyfivestudieshadmorethan100cases.Theynotedthateventhough75%ofstudieshadstatisticalpowerabove80%,thesmallnumberofcasesseriously limitedtheability todetectrisk insubgroupsandtest forexposure trends.This inherent limitationwill tend tounderestimateanyconclusionabout theimpactofworkplaceexposuresontheproductionofdisease.Ourchallenge,asresearchers,liesin overcoming the inherent limitations of the dominant scientific paradigm for establishingcausation.

CONTROLLINGEXPOSURESINTHEPLASTICSPRODUCTIONPROCESSDEVELOPINGBESTPRACTICS

TheHierarchyofControlsEffectivecontrolmeasuresintheplasticsindustrymustbebasedonthefundamentalprinciplesofcontrol.Thisembodiesasetofprinciplesthataretraditionallyreferredtoasthehierarchyofcontrols. We can conveniently consider these measures on the basis of ‘where’ the control

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measureisexerted:Atthesource;alongthepathtotheworker;attheworker.

ControllingattheSourceUnderthishierarchy,themosteffectivemethodofcontrollinghazardsistoapplythecontrolatthesourceofthehazardbyeliminatingthehazardaltogetherorisolateitfromtheworker.Itisthebestmethodofcontrolandtheonlyoneacceptableforcarcinogens.Controlatthesourceistypicallyaccomplishedthroughengineeringmethodsthatmayinclude:

Re‐designingtheWorkProcessIt may involve the purchase of new equipment, the addition of safety features to existingequipment,orthecompleteeliminationofahazardousstepintheproductionprocess.

SubstitutionEliminatingthehazardatthesourcebysubstitutingthehazardousagentswithagentsthathavebeen tested and proved to be non‐toxic. This approach is consistent with various ‘toxic usereduction’ (TUR) campaigns and programs. There are countless examples of control bysubstitution, and this should be the first line of attack. At the same time, sometimes a lesshazardoussubstancemaynotnecessarilybesafe.

The case formassive substitution of plastic additives shown to be estrogenic active (EA)wasmadebyYangandcolleagues.Applyingestrogenicbioassaytovariousplastics,theresearchersfound that almost all commercial plastics products release estrogenic chemicals. Becausepolymerization of monomers is rarely complete and additives are not chemically part of thepolymericstructure,chemicalshavingestrogenicactivitycanleachorbereleasedfromplasticsproductsduringproductionandduringnormalusebyconsumers.TheauthorsalsonotethatevenwhenusingallmaterialsthatinitiallytestEA‐free,thestressesofmanufacturingcanchangechemicalstructuresorcreatechemicalreactionstoconvertanEA‐freechemicalintooneswithEA.

This last observation has important implication for the potential to EA chemicals during themanufacturingprocessgiventhephysicalstressesofheatandpressureemployed.

They further note that most of the 500 commercially available plastics products that weresampled,eventhosethatarepresumablyBPAfree,releasechemicalhavingdetectableEA.

Importantly, the researchers indicate that since it is possible to identify existing, relativelyinexpensivemonomersandadditivesthatdonotexhibitestrogenicactivity,evenwhenstressed,thenitispossibletoproducenon‐EAplasticshavingcomparablephysicalpropertiesatminimaladditionalcost.

IsolationThis approachmay employ variousmeasures to isolate the hazard so that theworker cannotcomeincontactwiththeoffendingagent.Anexampleof this involvesenclosingtheprocessatevery step where exposurewould be possible. Several sectors such as the chemical industryemployvariousprocesscontrolstoaccomplishisolatingthehazard.

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Forexample,closedvatsystemshavereducedexposurestosuchcarcinogensasvinylchlorideandbischloromethylethertominimallevels.

Anothermethodofachievinghazard isolation is touseautomatedproceduresandmechanicaldevices that canperform simpleproceduresor employing environmentally controlled cabsorbooths. A combination of these three methods used in the Japanese steel industry broughtexposurestocokeovenemissiondowntonil.

ControllingAlongthePathControls along the path can be situated close to the source. For example, local exhaustventilationislocatedclosetothesourcetointerrupttheflowofhazardousfumestotheworkerbyextractingbeforetheycanreachtheworker. Alternatively, controls can beimplementedalongtheentirepath.Generalventilationisanexampleofthistypeofcontrol.

Localexhaustventilationincludesfixedhoods,solderingbenches,moveablehoodsandductsinweldingoperationsandspraybooths.Properlydesignedandmaintainedlocalexhaustsystemscanbeextremelyeffectivemeansofcontrollingexposuresbecausethisextractsfumesoutofthepathoftheworker.

Generalventilationordilutionventilationsimplyallowsthetoxicsubstancetobecomedilutedthroughouttheentirevolumeofairintheworkplace.Itislimitedtosituationswhereverysmallamountsofanon‐toxicsubstancearereleasedintoalargevolumeofair.Inatoxicenvironmentfoundinmostplasticsplants,itislittlemorethanatechnicaltermforthecompleteabsenceofcontrols.Forthemostpart,itresultsinthespreadofthetoxicsubstancethroughouttheentireworkplace.

Portablebarriersareanotherexampleofcontrolalongthepath.Thesebarriersorscreensmayprovidesomeprotectionfromenergyhazardssuchasnoise,radiationandelectricity.

Finally,generalhousekeepingmeasurescanbeconsideredcontrolsalongthepath.Theyincludeproper cleaning, the disposal of waste and the clean‐up of spills. Utilizing vacuum cleanersinsteadofbroomsormopsisaformofhousekeepingmethodsthatremovethesubstanceformtheworkplace.Theuseofairhoses tocleanmachineryshouldbeopposed,because itspreadsthehazard.

Wetmethodcanbeusedtocontroldustingrinding,drillingandsandingoperationsisanotherexampleofcontrolalongthepath.

ControlattheWorkerControls applied at the worker through the use of personal protective equipment andadministrative controls are the least effective. Examples of controls at the worker includedevicessuchasrespirators,earmuffsorplugs,protectivegloves,safetyglassesoreyeshields.Thesetypesofcontrolsaretheleasteffectiveandcanbeahazardinthemselvesandcan,infact,worsenthehazardousconditions.

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Becausethesearecheaperandeasiertoprovidethanengineeringchangesandlocalventilationor sound absorption, outfitting workers with this protective gear if all too often the firstapproachtoworkplacehazards.

Administrative controls attempt to control theworker rather than the hazard. These includemeasuressuchasprescreeningworkerswhomaybeabnormallysusceptible;rotatingshifts inhazardous areas; and hiring workers who have been sterilized where there are hazards toreproduction.

TheCostofControlsThereisnoquestionthatadequatecontrolscanbecostly.Confrontedwithachoiceofinstallingand maintaining a proper ventilation system or supplying respirators, management willinvariablyargueforthe latter.Notonlydoes itcosta fractionof thecost,but italsoshifts theburdenofresponsibilityfromthecompanytotheworker.

Companiesfrequentlyusetraditionalcostbenefitanalysistojustifytheirposition,stressingthecost of controls and predicting plant closures and unemployment if adequate standards areenforced.

While these scare tactics have been effective barrier to more effective controls and morestringentexposurestandards,inrealitythesefearsarenotwellfounded.

The regulationof vinyl chloride is a case inpoint.When itwasdiscovered in1974 that vinylchloridewasapowerfulcarcinogen,theUSgovernmentintroducedanemergencystandardthatreducedthepermittedexposurefrom500partspermillionto50partsperandthentoanewstandardof1partpermillion.

Thechemicalindustryhadbeenoperatingatexposurelevelsof50ppm,anditpredictedtheendof the plastics industry and the loss of 2 million jobs and $65 billion to $90 billion in lostrevenue. However, quite to the contrary the industry met the standard with only one plantclosure.Atthesametime,fournewplantswerebuiltandthepriceofvinylchlorideatdroppedby10%.

Despitecompanyclaims thatstrictercontrolswill force themtoshutdown,variousstudies inthe US have demonstrated that few plants have closed because of the cost of meeting newstandards.Thoseplantsthatclosedwerealreadymarginalandwouldprobablyhaveclosedeveniftheyhadnotbeenrequiredtomeetnewstandards.

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APPENDIXB

MINISTRYOFLABOUR(MOL)REPORTS1986‐1996and2004‐2018

1986

138009 13/11/86 DSRVinylChlorideassessment INJEC MOLD/POSTLAMDSRassessmentwasorderedforvinylchloridecontainedinGeonVinylCompoundResin. Basedonmanufacturer’s(B.F.Goodrich)opinionVCMcouldnotbereleasedbytemperaturesusedtomeltresin,and DSR not applicable. AUTHORS’COMMENT: However, did not consider other toxic chemicalsreleasedattheseoperatingtemperaturessuchasphthalates,lead,stabilizers,etc.,thataretoxic.Alsothermaldecompositionby‐products includingVCMcanbereleasedduringhighheatmalfunctionsaswellasduringfires—instanceswhichdidoccurfromtimetotime.Workersmanuallypouredanduseddirectly2825kgbagsperday.OrdersalsoissuedforhandlingandstorageofMEK,acetoneandotherflammablesolvents.

1987

168077 23.04.87 cyclicreviewbyMOL PLANT WIDENo.6 in assessment review states: Ontario Regulation 654/86 “control of Exposure to biological orchemical agentswasdiscussed and copies left. Toluene,MEK,Acetone, Perchlorethylene andEthylAcetate are all included in this regulation. No.7)”The Internal Responsibility System appears to beworkingwellinthisworkplace.Attentionshouldbegiventotheordersissuedinthisreport.”OrderIssued {“the flammable material currently stored in open top 5 gallon pails (with no lids) in theFlammableStorageCabinetshallbestoredinproperlysealedcontainersinaccordancewithsection27ofRegulation692.”

876513EAAV07.07.87 Healthcomplaintsthroughphysician POSTLAM

“A letter of complaint received from the director, public health inspection, community healthinspectiondivisionstatingthatsomeworkersatPebrahadcomplainedtoDr.PatrickKilmartin thatthey had been suffering from headaches, dizziness etc., was discussed with the worker H&Srepresentative.Thecompanyproducesautomotivesidemoldings. In thisprocess,stainlesssteelhasglueappliedtoit,thenastainlessstripispassedthroughaninductionheaterwhichisventilated.Afterstripgoeson,thenPVCsoldstripisadded,andthestainlesssteelstripandPVCstrippassthroughapresswheremarriageofthetwopiecestakesplace.Eachstationwherethegluesareaddedhaslocal

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exhaustventilation.Arequesttohavetheoccupationalhealthbranchcompletetestingintheinjectionareawillbeforwardedfortesting,assoonaspossible.“AUTHORS’COMMENT:Ventilationdeterminedtobeinadequatetocapturedrippingfromgluedispenser.

876513EAAV20.07.87 testresultsfrompreviousreport POSTLAM

“Testing(chemicals?),indicatedthatfumelevelsintheseareaswouldnotbeabovetheTWAEVofthechemicalsused.At themoldingmachinewherePebra5used readingsof 20ppm total combustiblesobtainedwhichindicatefumelevelsbelowtheTWAEVof50ppm.

PAINTLINE/SLEUSSWAY/SLUDGEROOM

LetteronPebraInc.stationary 18.09.87 criticalinjuryreport OUTSIDEPAINT

“re:criticalinjuryreportaddressedtoMr.Swindell(InspectorMOL):Incompliancewithsection25ofthe Act, I hereby submit this report of a critical injury as defined by……..which occurred on thesepremisesonTuesday,September14,1987.Incident:Thisworkerwasbeginningherseconddayinouremploy andwas assigned to do touch‐upwork to painted automotive parts. This involvedwipingdown thepartwithmethylethylketone (MEK) to removeanyexcesspaintanddirt.Thisoperationwas taking place in an open area of the plant but without mechanical ventilation. The resultinginhalationof fumesproducedastateofunconsciousness.Shewas immediatelyremovedto freshairandagainbecomeconscious.ShewasthentransportedtoSt.Joseph’sHospitalformedicalevaluation.Nootherworkershaveexperiencedanyadverseeffectsinthisproductionarea.

Yourstruly,LindsayReiach,SafetyandEnvironmentalEngineer.”

MOLreportoftelephonecall18.09.87re:criticalinjuryreport OUTSIDEPAINT

Detailsofoccurrence:

“1workerpassedout–exposuretoMEK.TakentohospitaltreatedandwasOK.ForgetaboutSect25Report.”

Actiontaken:“WCBrequestedtoprepareincidentreportandprovidetoPeterboroughofficeincludingstepstakentopreventrecurrence.”

138473 13.10.87 hydrochloricacidspill/sewersmells OUTSIDEPAINT

“Concentratedhydrochloricacidisstoredoutsideandwhenneededispumpedtoa60gallondaytankatthede‐ionizingarea.Thedaytankisequippedwithanautomaticfillingsystemandhasaventpipethatgoes to roof level. OnOctober8th the lidof theday tankcameoffwhilehydrochloricacidwas

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beingpumpedcausing5‐10gallonstobeforcedoutofthedaytank.Hydrochloricacidwasalsoforceduptheventpipetorooflevel.

“Prior to the acid spill, “sewer like smells” noted by operators in the Paint Assembly area but notreported.(Thenextmorning)operatorscomplainedofnotfeelingwell(dizziness,upsetstomachs)inEastsideofPaintAssemblyarea.Sevenoperatorswenthome.Duringtheacidspillinvestigationandnow thatmanagementwas aware of concernson “bad” sewer smell, itwas established that4 floordrains in the Paint Assembly areawere “dry.”Waterwas added to these drains to ensure that anyassociatedtrapswouldbefunctional.”

Ordersissued for1)“sealingofdrainsinthepaintassemblyareaorensuringthateachdrainhasaproperly functioning trapand thatwater ispresent insuch traps. “2).Allpipesystems in thepaintfacility which contain hazardous materials shall have contents and direction of flow positivelyidentifiedatvalves, fittings,andwherepipepasses throughawallor floor,orwherecircumstancesmakesuchcontentsanddirectionofflowdoubtful.(Severalotherrelatedordersissuedaswell).

Advicegiven:1.Allfloordrainsbecheckedtoensuretheyhaveproperlyworkingtrapsandthatwaterispresent. 2. Consideration shouldbegiven to installing local ventilationonallwork tableswhereMEKand IPSused inPaintassembly. 3.Considerationshouldbegiven toworkersusingprotectivegloveswhenworkingwithMEKand/orIPA,andinparticular,wherenolocalventilationispresent.”

871537NOVB 14.09.87 visittoassistwithnewH&Sprogram PLANTWIDE

MOLVisitmadeatcompany’srequesttoassistwithnewH&Sprogram.

“Duringthisvisit,acomplaintduetopossibleexposuretosolventvaporatthemarker‐likepencilusedwasinvestigated.“

re:solventstestedvsTLV.

Dimethylbenzene0‐30ppm

Isopropylalcohol‐upto300ppm(withtwoworkersworkingitisexpectedthattheconcentrationmayexceed400ppmtheTWAEV).

Advicetomanagement:1.RespiratorsneednotbewornifexposuretosolventvaporsordustisbelowtherespectiveTWAEV.However,ifworkerasksforrespiratoraNIOSH‐approvedrespiratorshouldbeofferedandtheworkershoulduseitinaccordancewithmanufacturer’sinstructions.2.Wherethereismorefrequentexposuretosolventvapors,portablefansorlocalexhaustshouldbeconsidered.

178534 26.10.87 cyclicalinspection PLANTWIDE

Orders:(lackofregularJHSCmtgs)2.ForJHSCtomeeton,orbefore,Nov.15,1987.3.Theneedforformalemergency/evacuationplanwithregardtofiresandchemicalleaks/spills.4.Compliancewith

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WHMIS (labeling, MSDSs, training, history, right to know). 6.” The internal responsibility systemappears to be working fairly well in this work place, however attention should be given to thefunctioningofthesafetycommitteeandtothesuggestionsgiveninthisreport.”(e.g.,regularmeetings,monthlyinspections,co‐chairsfrommanagement/union).AUTHORS’COMMENT:HowcouldtheIRSbeworkingwell,giventheseobservations?

Advicegivennotorders:1.NIOSHrateddustmasks,ratherthansinglestrapmasksshouldbeusedinTrimDept.2.Considerationoftheuseofeyeprotectionwhenpolishing/grinding,anduseoflocalventilation to remove dusts and fumes (from resin, putty, alcohol) 3. All chemicals, and hazardousmaterials,mustbeproperlyidentified;containersofMEKnotadequatelylabeled.4.Manual“topup”ofhoppersonInjectionMoldingMachines.Operatorshavetoclimbupontomachinetoperformthistask.Eitherpermanentplatformswithaccessladdersshallbeprovidedaspersection20oftheRegulationsoraportableplatformshallbeusedwhentoppingup,sothatoperatordoesnothavetoclimbupontomachine(whilecarryingpellets).

Letter/QueensU.hygienist26.10.87 chemicalairtestreport PLANTWIDE

“Airborne levels of HDI and various solvent vapors (MEK, Butyl acetate, BA and Toluene) weredetermined in conjunction with paint mixing and spray operations. ISO levels were alsodetermined….Theavailableairsamplingresults(especiallyinconjunctionwiththeplant’sPPEpolicy)suggestthatPebraworkersarenotover‐exposedtothoseagentssampled.AUTHORS’COMMENTS:

Contraindicationstothisconclusionarereflectedinthefollowingstatements:

“acoupleoftheHDIsamplesdidnotcorrespondwithimmediateisocyanateuse.”

“In another case, production requirements limited the duration of spraying within the samplinginterval.”

“In view of the limited isocyanate sampling conducted (and e.g., not actually sampling the mixingoperation)itwouldbeprudenttorepeatthis,inconjunctionwiththeassessmentoftheRIMprocess,inDecember.”

OTHER/OUTSIDESTORAGE

138213 22.12.87 environmentalspill OUTSIDESTORAGETANK

150gallonsofwastepaint/solventsleakedontogroundfromlead‐inpipe.MOE/firedept.calledandtankwaspumpedout.(clean‐upprocessisdescribedindetail).Insideofbuildingdeterminedas“safe.”

Actiontobetakenandordersissued:“Someunansweredquestionscameupregardingthestructureof the 5000 gallon storage tank and its suitability forusewith flammable liquid. Orders issued for

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filingofdrawinglayoutandspecificationsofthetank.45gallondrumswillbeusedtostorewasteuntilsuchtimeastankstorageisresolved.”

1988

87L537NOZV 14.01.88 HSSSBConsultantReport PLANTWIDE

Visitatrequestofthecompanytoassistthenewnursewithoccupationalhealthprogramatplant.

Important part of nurse’s role inmedical surveillancewill be to reinforce theworkers’ knowledgeaboutthesubstances(isocyanates,PVCs,etc.)withwhichtheyareworking.

Responsibilities: personal exposure records to be completed; responsibility to report possibleindustrialillnesses;keepingofrecordsforemployeesundersurveillance.

230114 15.09.88 ReviewofIsocyanates/chemicals PLANTWIDE

Completetouroftheplantwasmade...duringaCode10inspection(23010514.09.88)Majorareasofconcern were related to the use of isocyanate in the Paint Dept and Rim Dept. MOL will initiateadditionalAirTestinginboththePaintDeptandtheRIM.

CONSULTANTREPORT 06/14/15/.88hygienesurvey/plantemissionauditPLANTWIDE

(QueensU)Hygienesurveyincludedsamplingforairbornecontaminants(solvents,Iso,metals,totalsuspended particles, respirable particulate and nicotine) air quality “comfort” parameters andpreliminarystudyofheatstressandnoiseevaluation.

FindingsandConfounders

“Theavailableairmonitoringresultsshownooverexposuretoairbornecontaminants”althoughthefollowingconfounderwasnoted:

“A skin notation for a substance indicates that absorption through the skin cansignificantly contribute to a person’s overall exposure to that substance. Exposure by skincontactisnotdetectedbyairmonitoring.”

“Symptomsofheadacheandnauseahavebeenassociated,by someemployees,withworkingat theendofpainttunnelorthefinalassembly/touchuppaintingtables.Samplingfortheprimarysolventcomponentsoftheprimer,basecoats,andclearcoatwasconductedattheendofpaintline.Airborneconcentrations of butanols, n‐butyl acetate, isopropanol, MEK, methyl isobutyl ketone and xylenes.

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Airborne concentrations in the breathing zone of paint line inspection personnel were low or notdetected.

Atthefinalassemblyandtouchuppaintingtables,MEKandisopropylalcoholareusedtocleanandfinishpaintedparts.Smallamountsofbasecoatareusedfortouchuppainting;Twoofthethreetablesinthisareahavedowndraftexhaustventilation.Workersindicatedthatthemostobjectionablesolventodorsgenerallyoccurredatthenon‐exhaustedtable.”

“Howeverat the timeofsampling, “less thannormalactivity”occurredat this table.Ontwosubsequentvisitsthenon‐exhaustedtablewasnotinuse.”

“ItisconceivablethatheavyuseofisopropylalcoholandMEKatthenon‐exhaustedtablecould result in airbornemixture levels capable of causing the expressed symptoms ofheadacheandnausea.Isopropylalcoholmaycauseirritationandsymptomsofheadacheand drowsiness in a small percentage of susceptibleworkers at levels below 400ppm(whatabouttheMEK?).Howevertherearenoreportedlong‐termhealtheffectsassociatedwithlowlevelexposuretoisopropylalcohol(whataboutMEK?).”

Recommendation: “Follow‐up sampling todetermine “worst‐case” (i.e.,warmday/heavysolventuse)airbornemixturelevelsofisopropylalcohol,MEKandn‐butylacetateatthefinalassembly/touchuptablesiswarranted.”

Re Testing of Inside Painters: “Due to inherent difficulties of the isocyanate sampling methods,respiratoreffectivenesswasdeterminedbymeasuringsolventlevelsoutsideandinsidethesupplied,air respirator suits during a two hour period of clear coat spray painting. Protective factors,determinedastheratioofoutsideto insidesolvent levels fortheprimarysolventcomponent(HDI),weregreaterthan265and315.”

“The “inside” solvent level (undetectable) determined for (namesworker)may not bereliableasthesamplertubingdisconnectedfromthepumpatsometimeduringthesampledperiod (14.06.88).However an inside suit solvent level for this painterwas determined on(04.05.88)toalsobebelowtheanalyticaldetection limit.” Solventvaporwasdetectedinsidethesuitofonepainteron04.05.88.Thisexposuremayhaveoccurredbeforethehoodwasinplaceandwhiletheotherpaintertestedhisspraygunwithseveralshort“blasts.”

“Smoketubetestingofthethreepaintboothson14.06.88demonstratedthatwhiletheprimerboothwas under a slight negative pressure, thebasecoat and clear coatboothswereunderpositivepressure.Therefore airborne contaminants are likely to leak into surrounding areaswhereworkers are unprotected. This is a particular concern when the contamination may includeisocyanate.

“AirsamplingforHDIwasconductedoutsidetheclearcoatbooth(adjacenttothewestdoor.

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However an unpredicted shutdown of the paint line prevented the collection of arepresentativelongtermsample.Duringthe24minutessampleperiod,only12minutesofclearcoatspraypaintingoccurred.“

RE:totalsuspendedparticulates:“RawmaterialsfortheRIMprocessincludepolyol,isocyanatesandfibreglass. Thesematerials are simultaneously injected into hot, sealedmoldswhere an immediatecuringprocessoccurs.Theendproductisasolid,homogenousblendofpolyurethaneandfibreglass.There are no specific toxic effects, associatedwith polyurethane dust. Therefore itmay bereasonably classified as a nuisance particulate. The time weighted average exposure limit fornuisanceparticulateis10mg/m3.Thislimitwasdesignedtominimizeuncomfortabledepositsintheeyes,nose,andears,topreventchemicalorphysicalinjuryofskinandmucousmembranes,andtoensureadequatevisibilityintheworkplace.Theeffectsofshorttermexposuretofibreglassaresimilartothoseofnuisancedust.Numerousstudieshaveprovidedevidenceofnoadverse long‐termhealtheffectsassociatedwithinhalationoffibrousglass.However,theresultsofsomestudiesareweakly suggestive of a carcinogenic risk associatedwith such long‐term exposures. Nevertheless,basedontheexistingevidence,authoritiessuchastheAmericanConferenceofGovernmentalIndustrialHygienistsand theOntarioMOL still citea limitof10mg/m3 (consistentwith thelimitfornuisanceparticulate).

Palm sanding of (the products of the above injection process) occurs at tables adjacent to the RIMpresses, at thepre‐cure table, and in theSand& trim reworkarea. Workersmayormaynotweardisposable dust respirators while sanding. Personal air sampling was conducted on two separateoccasions to evaluate worker exposures to TSP. Assuming that these employees sand and trim forsevenhoursofaworkday,theiractualtime‐weightedaverageexposureswouldhavebeen7/8timesthe measured values….These levels are close enough to the TWAEV to warrant someinvestigationofexposurecontroloptions(i.e.,an“actionlevel”ofhalftheTWAEVisagenerallyaccepted guideline. The dust respirators currently available in the plant should provide anadequate level of protection to those employeeswho choose towear them.” There is alsoevidencethatemployeesworkinginthevicinityofpalmsandersarenotexposedtohighdustlevels(whatisthat?).Nonetheless,thepreferredmethodsforreducingtheexposureofworkerstoanysubstanceareengineeringcontrols. It is thereforerecommended thatPebraconsiderthepurchaseofcollectorequipment for thesanders. (AUTHORS’COMMENTS:Note thatdustcontainedurethaneandotherchemicalresiduesincludingfibreglass.TheMOLwasadvisedbytheassessingphysicianthattheseworkerswereexperiencingobstructivelungconditions.Dustwasalsoshowntohavebeendepositedonworkers,floorsandworksurfaces.)

RE:Air quality “comfort” parameters.Monitoring of air quality “comfort” parameters (temperature,relative humidity, carbon dioxide etc.) can be helpful in further qualifying the indoor environment.TemperatureandhumidityresultsfellwithintheASHRAEcomfortstandard55‐81(largerange?).CO2levels throughout the Pebra plant ranged between 500 and 600ppm. An ideal “maximum” level of600ppmhasbeenrecommended forofficebuildingsbytheMOL.(Is thisappropriate inactiveplantenvironment?).Thetotalsuspendedparticulaterangingfrom0.13to0.91wouldbeexcessivein

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anofficeenvironmentbutisconsidered“positive”foranindustrialestablishment.ThehighestweredetectedintheRIMandSandandTrimareaswherepalmsandingoccurs.

RE:HeatStress:“Workercomplaintsaboutthe“heat”inthePaintFacilitypromptedapreliminaryheatstressevaluationofthisarea.TheWBGT(WetBulbGlobeTemperature)measuredoutsidetheclearcoat boothwas 27.2C. This indexwouldmarginally exceed the TLV of 26.7 for continuouswork ofmoderate workload. However, it would be permissible for light continuous work (TLV=30C).AccordingtoPebrapersonnel,thepaintboothsaretemperatureandhumiditycontrolledatabout80Fand 40‐45% RH…(Painters) Standing, one arm work…would likely be classified as light work.Therefore the permissibleWBGT index for a spray painter dressed inwork clothes would be 30C.Clearly the thermalenvironmentwithinahooded,suppliedairrespirator‐paintsuit (“spacesuit”) isdifferent fromthatof theclearcoatboothalone.However, theWIBGETdevicecannotquantifyheatstresswithinsuchasuit. Judgingfromtheobservedrednessofskinanddegreeofperspiration,thepainters likely experience considerable thermal stress while clear coat spray painting (what aboutotherpaintbooths?).”

RE:Noise evaluation: “AtPebra, noise levels in excess of 90dBaweredetected in numerous areas,usuallyassociatedwithspecificintermittentoperations.Theseareasinclude:roll forming(blowoff),PostLaminate(cutoff)sawsandairgun,Sand&Trim(palmsanders),RIM(palmsanders)and theboilerroom.(BystanderexposuresofoperatorsinRollFormandPostLamexperiencednoiselevelsof85dBAorgreater).PalmsanderoperatorsinRIM:exposurestolevelsaveragingbetween84‐91dBA.TheRIIMoperatoralsoexperiencedaveragelevelof85dBA.It isthereforerecommendedthatpalmsanderoperators,RIMoperators,spraypainters,Rollformers,andPostLampersonnel(atleastwestofArborgStation6)wearhearingprotectivedevices.”

RECOMMENDATIONS:1.Follow‐upairmonitoringinthefinalassembly–touchuppaintingareaona“worst‐case”dayiswarranted.2.PeriodicevaluationsofIsolevels/controls.3.Dustcontroloptionsforpalmsandersshouldbeconsidered.4.Hearingprotectivedevicesandahearingconservationprogramarerecommendedatnumerouslocations.

ExhaustAirContaminantAudit

“Contaminantconcentrations inairstreamsdischarged from theplantweredeterminedbystandardoccupationalhygienemethods…Typicallyduplicatesampleswerecollectedsimultaneouslyfromtwodifferentregionsofthedischargeairstream,andonmorethanoneoccasion,althoughnotallsampleswereanalyzed.Itmustbeunderstoodthatthisairsamplingwasnotconductedinarigorousmanner,andthatinmanyrespectsitwouldnotmeetspecificstatutoryrequirements(i.e.,MOEtestingcode).Howevertheintentofthisexercisewasnottodemonstratestrictstatutorycompliance,butratherbymeansofaninternalaudittodeterminetherelativedegreeofcontainmentemission.Therehadbeennopreviousempiricalevaluationofemissionlevels.Theresultsareagoodindicationofgaseous‐phase

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contaminant(i.e.,Isoandsolventvapor)concentrationatthetimeofthesamplingalthoughtheymaynotshowatrulyrepresentativesamplinginthecaseofaerosol(mist)emissions.Ofcoursewithanevaluationsuchasthis,theremaybeexpectedtooccuranumberofmismatchesbetweentherequirements for optimal sampling conditions (e.g., Wind direction in the case of re‐entrainment assessment) and production scheduling/difficulties). As noted in the resultstables, thepaint linehad stopped runningby1430hourson the first samplingdaywhereas1515hrswouldbe“typical”Therewerenomorepartsavailabletobepaintedthenextmorningwhenthepaintkitchenwastobemonitored. Onthesecondsampleday,theRimdepartmentreportedlywent tocoffee justaround the time that theMDIsamplingwas initiated,whereasinformationhadbeen that theirbreak shouldoccurat (adifferent time). On this sameday,therewasa“gap” inthepaint linewithrespecttopartsarrivingattheprimerbooth,aroundthesametimethatrooftopHDIsamplingwasinitiated. Therefore8minutesofthe38minuteHDI sampling period did not correspond to an intervalwith expected emissions. Similarly,therewouldhavebeen“gaps”intheoperationofdownstreambooths…Itisnotablethatthosesamplescollected…(some30‐60minutesafterthepaintlinehadreportedlystopped)werestillshowingsignificantButylAcetatecontent(andinfact,becauseofpersistingstrongsolventodoratroof‐top,ithadbeenassumedthatthepaintlineswerestilloperating).Clearlysolventvaporconcentrationsarehigherwhilethepaintlineisoperating,withButylAcetateconcentrationsrangingfrom64‐413mg/m3.ThissolventisnotcurrentlyregulatedunderMOEReg308butitsproposed “ambientAir Standard” in theNov.1987CAPdiscussionpaper isonly0.6mg/m3(onehouraverage).…Ifallstackswereemittinganequivalent level,concentrationwouldbeapproximately10timestheproposedlimit.…andthesolventconcentrationsatthemake‐upairintakesonthepaintlinewouldbeevengreaterthanthis,undertheappropriatemeteorologicalconditions.Typically,theMOEdoesnotconsiderindustrialmakeupairintakeslocatedonthesource building (leaving this to theMinistry of Labour). Although this sampling should beconsideredofatentativenature(forthevariousreasonsoutlined) ithasnotshownanynon‐compliancewith current emission limits – provided theMOE did not choose to regard themakeupairintakes.

RIM

ConsultantReport 25.02.88 MDIAirSampling RIM

Air sampling for MDI was conducted by both MOL, CODE Methods (“Marcal” and “Nitro”) in theReinforced‐Reactive InjectionMoldingProcess during the production of bottomdoor panels. PolyolandIsocyanates(at120F)areinjectedintothesealedmold(whichisatatemperatureof140F).Thepart sits in the mold for approximately half a minute before it is removed. Sampling trains weresuspended from the spot‐lampsoneither sideof themoldand in front of theexhausthoodswhichcomeoninconjunctionwiththeactivationofthe“moldrelease”sprayer.UndertheseconditionsnoairborneMDIwasdetectableatthelefthandexhaustortherighthandexhaust.AlthoughMDIislessvolatilethanmanyotherisocyanates,theelevatedmoldtemperaturedoescreateapotentialofoverexposure, iftheexhaustventilationwere ineffective.Asaturationvaporconcentrationofapproximately0.4ppmhasbeenreportedat140F(AIHAJ47(4):227

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88E762EDAV 17.05.88 InspectorrequestsreviewofMoldRelease RIM

OfficerrequestsreviewofBattenfeldClampReactionInjectionMoldingAreawhereHDIandalcoholbasedMoldReleaseareused.Companyhasdonesomeairtestingbutresultsnotyetreceived.MSDSformaterials are available. Review of updated assessment/control program for RIM areawould beuseful.

88I778 03.10.88 (“PriorityOrder”re:criticalinjuryISOexposure) RIM

MOL report has “Priority” typedon front and followingnote: “due to “highProfile”CAWconcerns,officerrequestsMedicalConsultantvisittoreviewfollowing:

1.Attachedform7re:potentialIsocyanateexposureclaim;

2.ReviewofmedicalaspectsofIsoControlprogram,

3.Reviewofroleof“Co‐ordinatingPhysician”and“ChoiceofDoctor”underIsoregs.

Incident report: An investigation was carried out regarding the accident of (name). The accidentoccurredonOct3, 1988at about 5:00pmat the automatic glue spraybooth. (Name)had just beenstirringtheGluePot(5gallonpail)alongsidetheautomaticgluesprayboothshenshewasovercomebythefumesandpassedout.Thegluepotcontainsamixtureoftoluene,acetone,methylethylketone,ethyl acetate and cyclohexanone. Thebluemixture is prepared in thepaintmix room,however theglueholdingpotlocatedattheautomaticgluesprayboothismixedfromtimetotimeandisdilutedwithmethylethylketonefromtimetotime.

Advicegiventoemployer:

1.Thepostedprocedureinthegluesprayareashouldbeupdatedandshouldreflecttheintentoftheordersissuedinthisreport.

2.Thegluepotlidshouldbeproducedsothatitmoreadequatelypreventsthespreadoffumesfromthegluepot.

3.Considerationshouldbegiventoinstallinglocalventilationwherethegluepotis locatedinorderthatneededadjustmentsanddilutioncouldbemadetotheglueatthatlocation.

Pebrarepresentativeassessmentofincident:

“Astherewerenodirectwitnessestothisincident,commentshaveledmetoconclude:

1.Duringoperationofthismachinery,thegluespraybecameinconsistentandstringy;

2.(Worker)attemptedtorectifythesituationbymanuallystirringthegluepot; thisrequiredhertoremovethelid;

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3.Duringtheprocessof removingthe lidandstirringtheglue,shewasovercomeby the fumesandwasunabletoreachfreshairorassistancebeforefallingunconscioustothefloor.

Although the spray boothmechanical ventilation systemwas operating and severalwindowswerealsoopeninthearea,theydidnotprevent(worker)frombeingovercomebythefumes.

MinistryofLabourReport#244546,Order#0225EIR02604hasinitiatedproceduralchangeswhichwilleliminateanypossibilityofareoccurrenceinthefuture.”

PAINTLINE/SLUICEWAY/SLUDGEROOM

210589 07.06.88 SolventsinSludgeRoom

HSSSBConsultantreport87L524AOBVrelatedtosolventvaporsinthesludgeroomwasreviewedandexplained. A copy of the report shall be posted in the work place. No orders were required as alltestingshowedthatlevelswerebelowtherespectiveTWAEV.

OccHygieneService 03.06.88 AirsamplingofSolvents SLUDGEROOM

Air Sampling was done to measure solvent levels in Sludge Room. In all cases the measuredconcentrationsofairbornesolventvaporwerebelowTWAEVs(MEK,toluene,Methylisobutylketone,andn‐butylacetate).Thesludgeroomiscurrentlyoperatingonabatchwatertreatmentscheduleuntilfullproductionlevelsareachieved.WhileworkerexposuresinexcessofthesolventTWAEVswillnotoccurunderexistingconditions,thiscouldchangeiftheproductionlevelsofthepaintlineshouldincrease.Itmaybedesirabletoincreasetheventilationinthisareaoftheplantatsomefuturedate iftheproduction levels increase. (AUTORS’COMMENTS: Testingcarriedoutunderrestrictiveandunrepresentativeconditions).

87L537NOZV 14.01.88 HSSSBConsultantReport PLANTWIDE

VisitatrequestofthecompanytoassistthenewnursewithocchealthprogramatPebra.Importantpart of nurse’s role in medical surveillance will be to reinforce the workers’ knowledge about thesubstances(isocyanates,PVCsetc.)withwhichtheyareworking.Responsibilities:personalexposurerecordstobecompleted;responsibilitytoreportpossibleindustrialillnesses;keepingofrecordsforemployeesundersurveillance.Tasks:AdministrationofIsoSurveillanceProgram;Recordkeepingofhealth visits; Administering of First Aid; Anti smoking program; standing orders and medicaldirectives(ofPlantPhysician);HearingConservationProgram.

ConsultantReport 25.02.88 MDIAirSampling RIM

Air sampling for MDI was conducted by both MOL, CODE Methods (“Marcal” and “Nitro”) in theReinforced‐Reactive InjectionMoldingProcess during the production of bottomdoor panels. Polyol

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andIsocyantes(at120F)areinjectedintothesealedmold(whichisatatemperatureof140F.Thepartsitsinthemoldforapproximatelyhalfaminutebeforeitisremoved.Samplingtrainsweresuspendedfromthespot‐lampsoneithersideof themoldand in frontof theexhausthoodswhichcomeon inconjunctionwiththeactivationofthe“moldrelease”sprayer.UndertheseconditionsnoairborneMDIwasdetectableatthelefthandexhaustortherighthandexhaust.AlthoughMDIislessvolatilethanmany other isocyanates, the elevated mold temperature does create a potential ofoverexposure, iftheexhaustventilationwere ineffective.Asaturationvaporconcentrationofapproximately0.4ppmhasbeenreportedat140F(AIHAJ47(4):227

88E762EDAV 17.05.88 InspectorrequestsreviewofMoldRelease RIM

OfficerrequestsreviewofBattenfeldClampReactionInjectionMoldingAreawhereHDIandalcoholbasedMoldReleaseused.Companyhasdonesomeairtestingbutresultsnotyetreceived.MSDSformaterialsareavailable.Reviewofupdatedassessment/controlprogramforRIMareawouldbeuseful

210589 07.06.88 SolventsinSludgeRoom PAINT

HealthandSafetySpecialServicesBranch(HSSSB)Consultantreport87L524AOBVrelatedtosolventvapors in the sludge roomwas reviewedandexplained.A copyof the report shallbeposted in thework place. No orders were required as all testing showed that levels were below the respectiveTWAEV.

MOLHyg.R 31/10/88 hygieneassessmentoverworkercomplaints POST LAMAhygieneassessmentcarriedoutbyHygienist,KimGordon:PostLam,Paintline,RIM.Findings:PostLamhotgluingoperationinadequateexhaustventilation;RIMmoldingoperationinadequateexhaustventilation and isocyanate control program had limited worker coverage; RIM: need immediateattentiontoISOleaks:InsidePaintLinefoundtobeblowingpaintandsolventvaporsintothegeneralworkarea;hearingconservationprogramneeded;sludgeroomaconfinedspacenotaddressed.

244814 30/11/88 AssessmentofthePebra’sisocyanatecontrol RIMThe MOL’s assessment of the isocyanate control program resulted in orders for the company toprovide continuous ventilation during the entire RIM molding process and to include all RIMpersonnel in the control program. Up to this point, only the mold release spraying process wasventilatedandonlythemolderswereincludedintheprocess.Theministrynotedthattherewashighprobability of vapors during themold cycle, during part extraction and handling, during spills andleaksaswellassandingandtrimmingpartsthatwerejust30to60secondsoutofthemoldanddustthat likelycontainedisocyanates. Itwasalsonecessarytotraintheworkersonthehazardandsafehandlingofisocyanatesandprovidemedicalsurveillance.ItshouldbenotedalsothatbothMSDSandISO control programmaterial indicates the following physical symptoms indicating over exposure:burning sensation nose, throat, lungs, dry sore throat,wheezing, chest tightness, coughing, reduced

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lung function, lung irritation. Many of these have been experienced by workers during variousincidentsandsomeresultedinhospitalization.Inadditiontotheisocyanateissueitwasfoundthatthepaintsprayingoperationwasblowingfumestothegeneralworkarea,thattheconfinedspaceentryregulationswerenotbeingcompliedwithinthesludgeroomandleakswerefoundintheRIMmoldinghoses.

1989

89A895EAAV23/01/89 Workrefusalinvestigationfibreglassexposure RIMWorkerwhoshovelsfibreglassintoahoppertobemixedwithresintwiceperdayrefusedtoperformthis work because he felt fibreglass presented a danger to his health. Even though the hygienistobservedthedustinessofthistaskbecausethematerialhadtobeaggressivelydisturbedwithapitchfork,thehygienistconcludedthat“…workerexposuretothefibreglasswillnotexceedtheTWAEVandthat theupgradedskinprotection isadequate.” Nomeasurementswere takenandthe fibreglass isconsideredanuisancedustwithaTLVof10mg/m3.

244909 30/01/89 investigateunioncomplaintonWHMIStraining Plant‐wideEmployer refused to consult with workers/union on WHMIS training despite OHSA requirements.MOLadvisedemployerofdutyundertheactas itwason14/09/88report#230105about its legalrequirementtoconsulttheJHSC.

88E762EOAV10/01/89 ReportonISOmeasurementstotheWCB RIMWCB request for information regarding a claimants occupational exposure to isocyanates that isclaimedtobecauseofhisillness. Dr.GenesovetransmitspreviousmeasurementindicatinglevelsofMDIandHDIwerebelowthelimitofdetectionfortheanalyticalmethodsemployedinRIMandPaintLinerespectively.Maintainlevelatlowestpracticallevels.Otherreportsarereferenced.

244907 12/04/89 Workrefusalinvestigationtoluenefumes PAINT‐LINEWorkersrefusedtoinstallastairwayintheinsidepaintlineduetopresenceoftoluenevaporsfoundpreviouslyon10/04/89thatmightpresentafireandexplosionhazard.Fanturnedoffinthesludgeroom caused the migration of toluene into the main plant. Four workers were sent home. Acombinationoffactorsnoted:makeupairunitturnedoff;blowerinanotherareachangedairflowinplantfrompositivetonegative,andwaterlevelsinsludgeroomweretoohigh.

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89D888EAAV 15/05/89 InvestigateofworkrefusalsinthePostLam POST LAMAninvestigationof44workrefusalsinthepostlamareaduetochemicalexposurescausingadversesymptoms: headaches, dizziness, eyes, nose and throat irritation and nausea. Hygienist findingsinclude: inadequate exhaust ventilation in the hot glue area of roll form; internal paint line vaporsblowing into the general work area; RIM isocyanate control program deficient with respect tocoverageofallworkersexposedandinadequateventilation;andfailuretocomplywithconfinedspaceentryregulationsandeyewashrequirements in thesludgeroom. Seealsoreport#288596reprisalinvestigationagainsttherefusingworkers.

250328 12/10/89 Cyclicalinspection:38orderissued PLANT WIDEreviewedIsocyanatecontrolprogramtraining;availabilityofMSDSs;WHMIStraining;confinedspaceentry; isocyanate leak/spill; paint kitchen respirators; sludge room; WHMIS labelling; compressedcase;andseveralotherissuesaddressedwithorders.

293223 03/11/89 RespiratoruseontheFN‐36(Ford)Pebra5 POST LAMPreviouswork refusal (28615413/09/89)promptedorder for respiratorsuseuntil airmonitoring.ConsultationwithunionandmanagementaboutrestricteduseofPebra5;and,advicefromhygienistthatlevelsdon’trequirerespirators.

89I865EAAV10/11/89 workrefusalFN‐36MEK,toluene,ethanol POST LAMHygienereportseefulltreatmentbelow. 2workersonthefn‐36linecomplainofsolventlevelsandintoxication. The glueapplicator is ventedbut the freshly gluedparts are stackedon cartswithoutventilation.

286154 13/09/89 workrefusaloverglueapplication‐strongfumes POST LAMAdversehealtheffectsexperiencedbyrefusingworker.5USGpailsofglue(A1104B)werearoundtheglueapplicatormachineandnotappropriatelylabeled.GluedilutedwithMEKandtoluene.Applicatorwasventedbutfacevelocitywas200fpm.The5USGpailsusedasdippingtankstocleangluestationhead. Pailsdidnothaveappropriateventilationandnot labeledwithnoMSDS. Testingnotedwithfollowing results: MEK=50 ppm; toluene=25 ppm; alcohol=not detected. Inspector: “not likely toendanger.” But writes orders that the dipping pails be located in area with adequate ventilation,bondingbeproperlylabeled,andrespiratorsworn.

292916 03/10/89 Hygienereportre:theglueline286154refusal POST LAMHygiene sampling report (89I865EAAV/10/11/89) indicates: MEK=50 ppm; toluene=25 ppm;ethanol=<10ppm. Hygienist indicates that these levels may not be representative of a full shift

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exposuregiventhebrief(10‐15minutes)operatingtimeoftheline.Notesalsothat5USGpailofMEKwillhavemadeasignificantcontributiontothesolventconcentrations. Hygienistindicatesthatit isadvisable that control measures be implemented to limit solvent exposures on the FN‐36 line.(AUTHORS’COMMENTS: It is importanttonote thatasaruleof thumbaconcentrationof¼of theTLVshouldbetakenasasignificantexposure.Hygienistrecommendstheinstallationofaheatedflash‐off tunnel with local exhaust ventilation to control vapor concentrations and emissions. Alsorecommends installingadrip trayunder theapplicator tocontainandpreventaccumulationofgluedripsandspillsthatwouldvaporizeandreleaseintotheatmosphere.Thelineuses15USGofdilutedglueper8hourshift.Thelineruns24hoursaday5daysaweek.Oneworkerfeedsmetalstripsintotheglueapplicatorandasecondstacksthegluedstrips.Avinylstripisthenbondedtothemetal.

89L895N0BR30/11/89 workrefusalinvestigationuseofPebra5,MSDS POST LAMWorkrefusaloverfumesfromandnotraininginhandlingPebra5andconflictingMSDSinformationand additional concerns about toxic effects of tetrahydrofuran/perchloroethylene. Hygienist statesthatexposurestoingredientsarenegligible.Anddescribespossibleexposureswhenfillingthefelttipapplicatoror replacing the feltpadaspossibleexposurerisks. Nodiscussionof toxicityorconcernaboutchronic/prolongedlowlevelexposuresgiventhetoxicityofthesechemicalsandthepossibilitythatPebra5containscadmium. Penholds15mlofPebra5. Airconcentration: tetrahydrofuran5ppm;perchloroethylene2ppm.

1990

060290V3 19/01/90 workrefusal37workersafterfire FN‐36Afterafireoccurredonmoldingmachine#6intheFN‐36line,37workersrefusedtoreturntoworkbecausetheywerenot trainedonwhatproperprocedures tocarryout toensuretheirsafety in theeventofafire. Inspectorissuedorderforemployertotrainworkersintheplantfireplanandwhatprecautionstotake.Inspectornotedthatworkershadnotbeengiveninstructionandtrainingonthefireplan.

P90‐01‐70 22/01/90 paintfumescomingoutoftunnel.2firesnoted PAINTLINEInspectorrequestreviewofairsystemandreferencestwofiresinthepainttunnelatthepaintgun.

288460 22/01/90 MOLfollowupvisitre:ventilation/isoexposures PAINTLINEMOLinspectornotespreviousordersnotcompliedwith:WHMIStrainingnotcompleted;paintfumesfrompaintlinestillaproblemandnoactiontakentodate. Managementsuggestworkersjustmoveoutof thewayof the fumeswhich inspectorrejectsasasolutionnot inaccordwithregulation132.

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Other issuesnoted: JHSCstillnotdoingspecifichazardanalysis; isounits in tank farmstill leaking;cartridge respirators in paint kitchen still not stored separately and still absorbing solvents; sludgeroom still not provided with life lines and belts; no whmis labels in compressor room; no formalwrittenoperatingproceduresinthesludgeroom;improperrespiratorsusedinsandandtrim;stillnoadequate policies and procedures manual (suggest “WCB Workwell Program; failed to get pre‐medicalsforisoworkers.FailuretoconductafirststageworkrefusalinvestigationinaccordwithSec.23oftheAct. Orders issuedasecondtimeonthisvisit.Fires inthepaintboothduetoelectrostaticdischargeduringuseofpaintspraygun.

288454 02/02/90 hydraulic fluid/iso leaks at the day tank RIMHydraulic fluid (MESAMOLL) from Clamp pistons leaking deemed “not hazardous”; two drip traysbelowdaytanksnotcleanedandorderissued;isopumpingunitsareleakingisoandstillnotfixed;isoevacuationproceduresandtrainingasper“controlprogram”stillnotcarriedout—ordersissued.

SWINDELLS 08/02/90 MOLinspectorre:ISOcontrolprogram PAINTLINEMOLobservesworkerenteringsprayboothwithoutrespiratorsimmediatelyafterisopaintspraying;noisocontrolprogramtrainingforpainters;workerobservedenteringisoboothwithrespiratornotstrappedandfittedproperly—ordersissued.

293241 14/03/90 MOLISOcontrolprogramre‐assessed RIM/PAINTMOL initiated an audit of the ISO control program found deficient on worker coverage under theprogram. The Grey Putty operator was not formally written into the program and had not beenadvisedthattheGreyPuttycontainedHDI.Theproductalsocalled“Porenwischfuller3311”isdilutedwithclearcoathardener(AP19513),anddiacetatealcohol.Thecontrolprogramwasfounddeficientin providing documentation on engineering controls, and air monitoring frequency, and has notadequatelyidentifiedworkerswhomustbecoveredbytheprogramandhasnotadequatelydevelopeda propermedical surveillance program and reporting procedure for occupational illness. (See alsoHygieneassessment90A856EOBR).

250328 14/03/90 WHMIStrainingnotcompleted. PLANTWIDEWHMIShadnotyetbeencompletedsinceorderedinNovember1989.Otherreportsnoted309782,293237,288460,250328

288440 29/03/90 workersdevelopsensitizationfromisocyanate SAND/TRIM

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288434 11/04/90 ISOsensitizationclaimwcb PAINTLINEMOL request medical consultant review. Also, noted problems with the ISO control program andproblemswithskinexposureandrespiratoruseandtraining.

288335 25/04/90 Electrostaticdischargecausingfiresinpaint PAINTLINEMOLnotes theneed tobalance the ventilation system, and employerhas addressed theproblemofelectrostaticdischargecausingfiresbyreplacingappropriateelectricalinsulation.

90D854EAAV 05/08/90 assessmentofsolvent/HDIexposures PAINTLINEWorker exposure to isocyanate (HDI) andMEK possible when loading paint kettles, repairing andflushing system, during malfunctions and manual spraying. Orders issued for skin protection andrespiratory protection. Worker observed cleaning equipment partswithMEKwithout a respiratorandnoventilation.WorkingabovethepailofMEKisunpredictableandmaycauseexposureinexcessofTLV.Cleanshouldbecarriedoutinaproperlyventedarea.

288316 09/05/90 workrefusalinvestigation10workersFN‐36glue POST LAMWorkerscomplainedof feelingsick fromfumes intheFN‐36 line‐glue lineareaandheatpressarea.Butylacetate,MEKandtolueneandethylacetateintwogluesused.Therewasaspillof3to4USGofA1104glueatthenorthdoorofthepaintkitchen.Testsshowedethylacetateatbetween25and50ppm,ethylacetateat<10ppmandtolueneat<50ppm.Inspectornotedtokeepfreshgluedpartsintheflashareafor30minutesanddriptrays forthegluingmachinetobecleaneddaily. Floorswithexcessglueshouldbecleaneddaily,keepdoortopaintkitchenclosed.Previouslytheventilationwasjudgedtobeineffective.AlsoreportindicatesaseriesofallegationsofviolationsoftheactaswellassubversionoftheIRS.

90E873EABR 25/06/90 MOLassessmentofsandingtablesventilation TOUCH UPMOLhygienistconductedair flowandairmonitoringtests forthe12sandingtablesusedtosmoothoutimperfectionsonRIMmoldedpolyurethanepre‐paintedparts.Inspectorfoundthatexhaustgrillsonthetableareblockedanddustexposureisapparent.Thefacevelocitymeasurementsindicatethatexhaustislessthantheminimumrequiredtocapturethedustgeneratedfromsanding.Thefeltpadsonthegrillclogwithdustandrestrictairflowandcaptureefficiency,andpossiblethatexhaustfiltersare clogged. Recommend not to use felt pads. Preventive maintenance schedule (PMS) were notavailable.

90G872MOWY 06/09/90 investigationofworkerhealthproblems SLUDGE ROOMTheWorkersCompensationBoardrequesttheMOLinvestigateaworker’sillnesscausedbyexposure

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tosolventvaporsintheFN‐36areawhensludgeroomexhaustfanwasnotoperating.Thisfanwhichis associated with the cooling equipment also provides a negative air pressure environment thatpreventschemicalvaporsfromsolventsandpaintsfrommigratingtothegeneralworkareaincludingtheFN‐36area(FordLine).Itwasnotedintheinvestigativereportthatthefanwasnotoperatingandvaporsweremigratingduringthistime.Thereportalsonotethatthewatercarryingpaintoversprayand solvents is treated with detack and flocculant. Normally the air flow is from the generalproductionareaoftheplantintothesludgeroom,exceptwhentheexhaustfanisnotconnected.Thentheairandcontaminantsfromthesludgeroomwillflowtotheproductionareas.(seealsoMOLReport#s:90F866MAAAV‐C;87J535EAA;87L524AOBV/87J535EAA).AUTHORS’COMMENTS:Thishasbeenanongoingproblemthathasledtomanyepisodesofadversehealtheffects,complaints,workrefusalsandMOLinvestigations.Citingprevioussolventexposuremeasurements inboththeFN‐36areaandthesludgeroom,thehygienistconcludes:“Solventvapor,whilepresent,areatlevelssuchthatworkerexposurewillnotexceedexposurelimits.”

288184 13/12/90 workrefusalinvestigationslipperyfloors PAINT BOOTHWorker refused after slipping and falling in the paint booth because of slippery grates in the paintbooth.InviolationoftheAct,anotherworkerwasassignedtotheboothwithoutbeingadvisedoftheworkrefusal.Solventsusedtocleanthegratescoatedwithpaintandgrease.

288424 22/05/90 investigationISOleakfromdaytank RIMMDIwasatomizedfromabreachinthegasketwhilestillunderpressure.Theoperatorwastryingtocontainleakbyapplyingpressure. Operatorwasnotwearinganyprotectiveequipmentandregularoveralls. Alarm sounded from themonitor and recorded42ppbofMDI. Workerswere evacuatedfromtheRIM.OrderissuedtoprovideappropriatetrainingandPPEwhenperforminganytestsontheequipmentaspartofcontrolprogram.

288338 15/05/90 inspectiontoaddresshandlingMEK PAINT/SLUDGEROOMInspectorordersaddressingtheuseofdiptankswithMEKtocleanequipmentinpaintlineandstorage,anduseof45USGofMEKinthesludgeroom.Ordersissuedforadequateventilation,andbonding,tocontrolriskoffireandexplosion.

90E859MAAV 14/05/90 obstructivelungdisease SAND/TRIMInspectoradvisedbycompanydoctorthataconsiderablenumberofworkers insandandtrimhaveobstructive airways as indicated in pulmonary testing. Likely due to dust exposure from sandingpolyurethanepaintedparts.Respiratoryprotectionordered.

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325‐71‐2 03/05/90 investigationofworkercomplaints PLANT WIDEInvestigationofcomplaintsfromunion: outdatedMSDSs,missinglabels,wronglabels,employernotcooperatingwithJHSC;failuretomaintainminutes,notconsultationontesting.

90E865EAAV11/05/90 investigationof12workrefusalsglue/solvent FN‐36Investigationof12workersrefusingtoworkontheFN=36glueline. Twoworkerssenttohospital.Thisworkrefusalissimilartoseveralothersonthisline.

90D855maav23/05/90 investigationreworkersensitizedtoiso PAINTMOLadvisedthatworkerinpaintlinehasbeensensitizedtoisocyanate.Noted,thatsafepracticesandproceduresnotstrictlyfollowed,asrequiredbyIsocontrolprogram.

288314 17/05/90 inspectionfindshighCOlevels SAND/TRIMFork lift truck tested and areas found to have high levels of CO: sand and trim=35 ppm; northshipping=70ppm;shippingclerkdesk=5‐10ppm.Alsofiltersinsandandtrimregularmaintenancerequired.

90E865EAAV18/05/90 workrefusalinvestigationglueA‐1104B FN‐36 POST LAMHygieneassessmentadverseeffectsfromexposuretogluespillof3to4USGofA‐1104‐Blocated15’westofthegluelineareaonMay10,1990.OnMay11,10workersrefusedtoworkbecauseofvaporsthat caused adverse physical effects. Consultant notes several previouswork refusals for the samereasons. See previous investigations in response to these earlier refusals. Note also that previousreportsindicatehygienistrecommendationstoenhanceventilationandcreateventilatedflashoffareato reduce exposure. Chemicals of concern: MEK, toluene, ethyl acetate, isopropyl alcohol, butylalcohol.Ethylacetatelevelsat25‐50ppm.Notedalsowasthedripsandaccumulationofglueonthetableandfloorunderneaththegluingmachine.NeedforPMtoaddressleaksanddripsnoted.

288421 30/05/90 hygienere:PVC/polyethylene/cyclicamide/MDI INJECTION MOLDHygiene visit (90E865EAAV JUNE 19, 1990) over adverse health effects from purging in injectionmoldingusingPVC,polyethylene, cyclic amide. Strong fumesandsmokeduringpurginganduseofmold cleaner 201B; also thermal decomposition by‐products. Moldingmachines not vented. AlsodiscussionregardingthehighlevelofMOLinterventionsregardingrepeatedworkrefusalsontheFN‐36gluinglineandworkershospitalizedonmanyoccasions.MSDSusedinthisinvestigationonlyhadanincompletedocumentfor201BandnoingredientslistedandnoMSDSforcyclicamide.

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351617 15/06/90 workrefusalinvestigation/glue/solvent FN‐36/POST LAMWorkrefusal/WCBrequestforMOLmedicalconsultantre:workerhealthproblemsfromexposuretosolventsandglueintheFN‐36areaapplyingglue.Seepreviousreportsidentifyingmajorandminoringredients90E865EAAV;90C900MOWV‐C.

288315 16/05/90 MOLordereddrawingsofpaintlineextension PAINTLINE

250328 20/06/90 orders issued for WHMIS training see Report # 288263 orders alsoissuedre:MEK/diptanktocleanparts.TrainingisrequiredonPPE.

228249 20/06/90 investigationseveralworkrefusals FN‐36/PAINT/RIMWorkers experiencing health problems on the FN‐36 glue line. Fumes from the paint kitchen andsluiceway,nologforchangesinchemicalconcentrationsingluingoperation,highlevelsoffumesandsmoke during purging of the injection molding machines‐Arbourgs and Engels, MSDSs for resinpellets,useof201‐BinRIM,cleaningofspraypainters’hood.

288244 15/06/90 Ventilationevaluationordered/firesinpaint PAINTLINEMOLordersanengineeringevaluationoftheplant’sventilationsysteminordertocorrectthecurrentimbalancebetweenreplacementair andexhaustair,whichcausesanegativepressureenvironmentandthemigrationof toxicchemicals fromotherdepartments toenter thegeneralworkarea. Itwasalsonotedthatillegalmodificationmadetothepaintsprayingsystemwasacauseofseveralfiresinthe paint line due to electrical static discharge sparks that ignited the paints/solvents. Ordered tocorrectandnotmakechangeswithoutconsultingthemanufacturerofthepaintsystem.

90E859MAAV‐C 03/07/90 molmedicalconsultantre:adv.health/dust SAND/TRIMMedical consultant assesses workers medical symptom from dust (polyurethane/paint)includingdifficulty breathing, fatigue, dirt of varying colour in their nose, itchy eyes and dry skin. “Severalworkers describe symptoms consistent with exposure to a dust.” Workers are sanding partsconsisting of polyurethanewith chopped fibre glass and paintedwith primer, base paint and clearcoat.Twoworkerswerefoundbythemedicaldepartmenttohavebreathingproblemsrelatedtothedustinthearea.(occurredpriortothembeingorderedincludedintheisocyanatecontrolprogram.)Useofrespiratorsorderedinresponsetoworkerscomplaintsaboutinsufficientexhaustventilationonthe tables. Reported by doctor: “These medical symptoms are consistent with exposure to a fineairbornedustwhichwasapparent,inspiteoftheexhaustventilation.”Buthestillconcludesthatthedust levelsarebelowtheTLV. A followup letter fromthedoctordated22/06/90expressesavery

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contradictoryviewontheuseofrespiratorse.g.respiratorsmayhavestabilizedthesymptoms,butnoneedtocontinueusingthese.Theotherissueidentifiedwasre:theexhaustfromtheforklift

90F866MAAV‐C 03/07/90 hygieneassessmentglueA‐1104B/A‐1610B FN‐36Work refusal of 5 workers experiencing nausea, dizziness, sore throat, head ache, burning eyes,fatigue,difficultybreathingandheartpalpitations. Theseworkerswerehospitalized. SimilarhealtheffectsontheFN‐36linewerepreviouslyassessed:09/89;11/89.Hygienistsuggestthatsourcesofthesesymptomsisfromthesolventscomingfromtheglue,thethinners,thepaintkitchen,thesludgeroom,sluiceway,poorworkpractices in thepaintkitchenand inadequateventilation.The followingchemical breakdown is noted fromMSDSs: MEK, toluene, ethanol, butyl alcohol, phenol, isopropylalcohol,propyleneoxideandethylacetate.TheFN‐36runs6daysperweek,46hoursperweekandthreeshiftsperday. Agluelineheatpress is inoperationwherevariouslengthsofsteelarecoatedwitha thin stripof glue,which isput inaheatpresswhereaplastic strip is laminated to thesteel.After the glue is applied the parts are stacked and allowed to flash on a skid and give off vapors.Inspector does not address the health effects but simply advises the employer and inspector that“workerexposuretothesolventsisunlikelytoexceedanyexposurelimit.”

90F865EAAV04/07/90 hygienereportcleaner201B/resinfumes INJECTIONMOLDINGWorkers complained about the smoke and fumes that were intense during the purging operation.Injectionmolding uses PVC, acrylic and polystyrene resins although the latter two are not used asmuch. Hygienistnotes thatduring thepurgingprocessvarious thermaldecompositionby‐productsare generated and that the 7 molding machines were not locally ventilated. Purging starts at thebeginningofeachshiftandaswellasduringthedaywherenecessary. Inspectorrecommendslocalexhaustventilation.TestingforHCLwasnotdetectablenearthebarrelvent.Nomeasurementsweretakenbythepurgewastedroppedonthefloor,however.RIM:WorkersalsocomplainedabouttheuseofmoldcleanerChem‐Trend201Bwhichcontainsn‐methyl‐2‐pyrrolidone,ethyleneglycol,monobutylether,solventblendisappliedwithasoakedragandneoprenegloves.

90E845MOWV‐C 06/07/90 Medicalconsultantreportrewelding POST LAMMedicalassessmenttoaddresshygienereport90D855MAV(MAY1990)andarequestfromtheWCBregarding an employee who developed medical symptoms attributed to welding fume exposures.Reportdoesnotreallyaddresstheissueofwhetherthesymptomsarecausedbytheweldingfumes.Just attempts to minimize by referring to tarps installed to isolate welding operation, mild steelwelding less hazardous and volume of the workplace. AUTHORS’ COMMENTS: Ignores substantialwelding during cart maintenance to heat dry isocyanate paints and PVC wrap to extremely hightemperatures

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90F889MOWV‐C 09/07/90 medicalreportre:medicalproblems BOX AREA/RIMMOL medical consultant report as requested byWCB regarding worker health problem related toexposureintheBoxAreasofRIMusedasaloadingdock,boxassemblyandstorage. Theconsultantindicatesthatinan“upsetorspillsituation”exposuremightbepossiblebutnonehaveoccurred.Noform7indicatedtoestablishdateofmedicalreportforworker.

325‐71‐2 24/08/90 investigationofa25USGisocyanatespill07/08/90 RIMAmajorspillof25USGofMDIintheRIMdepartmentnearClamp#6.Workernotinformedofspillandnotwearingrespiratoryprotection.Supervisorwaswearingprotection,butnotworker.Workertoldtwodayslaterthatspillhadoccurred.

90E873EABR07/08/90 Hygienereportsandingdustpaintedparts SAND/TRIMDust sampling at sandand trim tables—0.2 to2.9mg/m3 in response toworkerhealth complaintsabout exposure to dust from sanding painted plastic parts. AUTHORS’ COMMENTS: Assessed asnuisancedust,regardlessofdustcontainingresiduesofresinandpaintcomponentsandpossibilityofunreactedisocyanatemonomer,andotheradditivesinplasticsandpaints).“Nuisancedust”TLVof10mg/m3applied.

90G845MOWV‐C 31/09/90 WCBrequestworkerhealthproblem POST LAMWorkerexposuretoPebra5gluecontainedingluestickingredients includePerchloroethylene20%andTetrahydrofuran80%. (Adversehealtheffectsfromexposuretothesechemicalshasbeendealtwith previously). This hygienist’s findings contradict previous MOL investigations concerning theinadequateventilationandstorage.offreshlygluedparts.See90F889mowv‐c

90GB63MOWV‐C 16/10/90 hygienemonitoringforHDI,MDI RIM/GRAY PUTTYNo detectable levels in RIMmolds and Grey Putty (HDI) area. Observes that “comfort” fans wereoperatinginthesand/trimwhichcouldpossiblehaveinterferedwiththemonitoring.MondurPFandMDIc‐961used.AUTHORS’COMMENTS:thismeasure(fan)alsospreaddusttothegeneralworkareaaffectingotherworkers.

1991#285955 11.03.91 fiberglassdust/coldair RIM

Callinitiateddueto2concerns:allegedhighlevelsoffiberglassdustinRIMdeflashandsandingareaandlackofventilation;Makeupairunitsblowingcoldaironnightshiftworkers.Solutionsagreedtowerethat:1.trialdustcollector,currentlybeingusedinRIMdeflashareas.Considerationofairtesting

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indeflash,butfeltitmaybebettertousemoneyforventilationsystemsinceairtestingquotesareinexcessof$3000.2.SupervisorsinRIMovenareainstructedtoleaveoneorbothairmakeupunitson,withsomeheat,toresolvecoldairproblem.

901811AOBR 11.02.91.11.03.91 visitre:Isospill RIM

350employeesworkingthreeproductionshifts,5daysperweekinRIM,andtwoproductionshiftsinotherareasoftheplant.OnAug.7,1990outsidecontractworkerdoingmaintenanceset‐upworkonclamp6causedapressureadjustmentboltthatwasadjustedtoofarleadingtotheboltcominglooseand MDI spraying out of the bolt hole. The worker who was sprayed immediately showered andwashedhimselfwithwater.Apparentlythespilloutoftheboltholeextendedasfaras20ft.throughacombinationofsprayandpuddling.Thecontractworkerwassprayedontohisshoulderbutnotontohisface.TheMDIwouldhavebeen50‐60%diphenylmethanediisocyanateandthetemperaturewasprobably31to32C….apparentlyconcernsraisedregardingthemannerandtimeofadvisementofthespilltoworkersattheotherclamps.

31496 28.08.91 heatissue RIM

Workrefusalduetoheatatclamps.Workersaskedtohavetwoadditionaltenminutebreaks,oneat6:50 to 7:00pm, and another at 8:30 to 8:40pm. JHSC have verbally agreed to a hot weather plan,whichcomesintoeffectwhenatemperatureof28isreachedusingaWGBTgauge.

Inspectoradvisedthereisnoheattemperatureinthelegislation.ThepolicywillbereviewedatnextmtgofJHSC.

POSTLAM

90H862MOWV‐C 20.02.91 WCBcasere:solventexposure POSTLAM/FORDLINE

Visit made at request of WCB after a worker’s health problem was attributed to solvent vaporexposurewhileworkingintheFN36glueline. ThesolventvaporsapparentlywerecomingfromtheFN36areaandpaintsludgeroom.SincethetimeoftheconcerntheFN36areahasbeenmovedandnow removed from the plant. This company has been visited previously by HSSSB on numerousoccasions and is considered most recently in report #90I811AOBR. Testing indicated that workerexposurewhilepresentwaswellbelowanyexposurelimit.

Comment: Solvent exposures in the old FN36 glue line area were thoroughly investigated andquantifiedbytheHSSSB.

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PAINTLINE/SLEUSSWAY/SLUDGEROOM

28018 23.09.91 strongorganicsmells PAINT/MIX/SLUDGE

Duringregularinspectionofplantstrongorganicvaporsmellswerenotedinlargepaintmixingroomand in sludge room. One of the ventilation systems at south end of mix room was not workingadequately(verylowairflow).Officerrequestsreviewofthesetwoareasbyhygieneconsultant.Thecompanyand JHSCteamappears tobemakinggoodprogressandmuch improvementwasnotedascomparedtopreviousinspections.

Follow up hygiene report focuses on three chemicals MSDSs: Pebra purge, clean chem 2K‐550,Urethanegraderetardingthinnera4thMSDSisincludedbuthasnoproductname.

91I897EAAV 9.12.91HSSSBairtests PAINTKITCHEN/SLUDGE

Allresultslessthan1.0ppm.

#07170 17.12.91 sleusswayconcerns PAINTSLUICEWAY

Concernsasaresultofinspectionofpaintmixroomandspillchanneldrainsystemandbondingandgroundingissues.“Attimeofinspection,theexcessmaterial(water,solvents,andpaints)inthefloordrawsystemwasbeingpumpedoutofthesystem.Thefloordrainsystemisconnectedto2x5000galholding tanksandexcessmaterialwouldnormallydrain into theseholding tanks.BetweenDec20thandendofyearduringshutdownacompletecleanupofpintkitchenincludingdrainsystemhasbeenscheduled. Itwasstressed thatperiodiccleanupshouldbescheduled toensure thedrainsystem isworkingas intendedanddoesnotbecome (or remain)blocked. Theneed forupgrading theuseofbondingwhen any flammables are being poured or dispensed ormixedwas discussed and left forfurther review.Order leftunder section26(4)b forproperandappropriatebondingandgrounding.Sincemanydifferenttypesofsolventsareusedinthepaintkitchenitwasstressedthattheproceduresinthemsdsbefollowedforspillcleanup.…thesesolventsandpaintsaregeneratedonadailybasisbycleaningfilterunitsandbybackflushing/cleaningpaintlines,consequentlysomedaytodayprocessesareneededtoensurethefumesarekepttoaminimum.

91I897EAAY 23/10/91 Significantexposure:MEK,Xylene,Acetone PAINT LINE/SLUDGEInspectorfinds“significantriskofexposuretoMEK(2‐butanone),Xylene(dimethylbenzene),Acetone(2‐propanone) paint mixing room and sludge room because of the volume of chemicals used andexposure controls, particularly the lack of training forworkers using organic cartridge respirators.Subsequentairsamplingdidnotdetectthesechemicals.

1992

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EventID2577 21.01.92 refusaloverlackofWHMIStraining PLANT

Twoworkrefusals,oneworkerrefusedtodojanitorialcleaningworkbecauseshehadnothadspecifictraining.ThisworkerwasworkingwithWHMISchemicalsat timeofrefusal.Orders issuesunderO.REG644/88SEC.7(1).Basedonworkbeingdoneattimeofworkrefusaladecisionwasgiventhatthephysicalconditionoftheworkplacewasnotlikelytoendanger.Howeveritwasrecognizedthatbothworkers (in various jobs in the RIM dept) do require appropriate specificWHMIS training and anorderwasissuedforthistoecompletedonorbeforeJanuary29,1992.

082989 12.02.92 repeatvisitre:smoking PLANTWIDE

Ameeting was held withmanager/worker rep of JHSC to review status of Act in this work place.ReferencewasmadetoasimilarvisitonDec11,1991regardingsmokingintheworkplace.Thesafetycommittee has recommended that the large cafeteria be the DESIGNATED SMOKINGAREA and thesmallcafeteriabenonsmoking.Thisclearlywouldgivebetterseparationbetween thesmokingandnon‐smokingareas.Theaboverecommendationisintheprocessofbeingsenttoseniormanagement.

92C845EOAV08.04.92 ISOprogram PLANTWIDE

510productionworkersatplant,ofwhich350havetakenpartinisoprogram(i.e.pulmonaryfunctiontesting,chestx‐ray,medexam).AvarietyofISOcontainingpolymerichexmethylenedi‐isocyanateorHDIpaintsareusedinpaintkitchen.Advice:“Althoughcontrolmeasuresareinplace,theIsocyanatecontrolprogramshouldbedocumentedandacopyoftheprogramprovidedtoJHSCmembers.

082980 12.05.92 cyclicvisitreport PLANTWIDE

(16 issueswereaddressed inreport.Thoserelatedtohousekeeping/chemical issuesare includedinthis summary). (#12) “Fibreglass removal fromused tote boxesdiscussed. PPEappears tobeused,however itwasrecommended thataHEPSvacuumbeusedrather thanregularvacuum inorder toensurethatverysmallfibersoffiberglassarenotbeingforcedbackintotheair.”(#13)“PreventativemaintenancewasdiscussedwithrespecttomoldmachinesinRIMwhereoccasionalleaks(blowout)anddislodgedparticlesoccurred”

(#14) “Cleaningoutof filtersonbuffingmachinesshouldbedoneoftenenoughso that theair flowdoesnotdeteriorate.Checkscouldbedonewithanairflowvelometer.”(#15)“SandandTrimtablesinRIMarecurrentlynotventilated(locally)howevermanagementisconsideringlocalventilationoncethetablesaremovedtotheirnewlocationsnearerthemoldmachines. Meanwhileifoperatorsneedrespirators for thiswork they canbeobtained.”Order issued: The ambient air bloweron the eastexternalwallofthepaintkitchenshallbearrangedsothattheairusedfromthisunitisdrawnfrom

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outdoorsinanareafreeofcontaminationinaccordancewithsection25(2)hoftheActonorbeforeMay22,1992.Orderissued:WestToolRoom:Floorareashallbeclearedofobstructionsandhazardsfromwoodpiecesleftonfloor.Orderissued:RIMMoldMachines.Materialssuchasnuts,bolts,rags,flammable containers storedat the entranceof the ventilation systemshall be removed inorder toallowproper air flow.Order issued: RimDept. “containers of 201B (aWHMISproduct) shall havelegibleworkplacelabelsattachedinaccordancewithAct.OrderIssued:RIMdept.“#6Moldmachinemixheadvalve shall have electrical connection repairedor replaced in accordancewithAct. OrderIssued: RIM Dept. “Area below (Iso) day tank shall be appropriately cleaned of any isocyanatecontainingmaterialinaccordancewiththeact.OrderIssued:RimClamps.“Areasofthefloorsatthebackandsidesoftheclampsshallbeclearedofexcessplasticdebrisinaccordancewithsection12ofAct.Order Issued: Polyol storage area: “Leakon floors atN. sideof tanks shall be cleanedup andappropriatedriptraysusedtopreventthespreadofthepolyolinaccordancewithAct.

092948 16.07.92 ISOprogramgrievance RIM

re:preliminarydiscussionduetorecentsituationinRIM.ARIMdept.workerfromSandandTrimthatisincludedintheIsoProgramwasconcernedduetoshortnessofbreath.Asaresulttheworkerwasexaminedby theplantphysicianandnurseandapulmonary function testdone.WorkerandUnionwereclaimingthatworkershouldbepaidforvisitsto2nddoctorandspecialistundersection26oftheAct.Companyindicatestheywillnotpay.Grievanceisinprocess.

Event3474 21.04.92 isometrynotworking RIM

9workers refused towork due to isometer not functioning properly because of lack of calibration(RIMDEPT).F.O.notifiedbyphone.Decision:“notlikely”toendanger.

PAINT

92A833BOAV06.01.92 risksinpaintkitchen/maintenance PAINT/MAINTENANCE

Hygienevisit:Hygieneconsultantreviewedthehandlingofwastepaintsandsolventsinpaintkitchen.1.Operators shouldbeusingappropriate gloves.2.Operatorsdoingmaintenanceworkor changingfilters and cleaning tanks at end of run should be encouraged to use organic vapor cartridgerespiratorsduringthework.3.AirsupplyforAirsupplyUnitrespiratorforthepaintkitchenshouldbeconnectedsothat“OUTSIDEAIR”isbeingused.Onemeanswouldbetoconnecttothebreathingairsupplyonthefirstpaintsprayboothsystem.4.TheareaundertheISO“daytank”needsappropriatecleanup.Ascheduleofcleanupshouldbeestablishedinordertoensuretheareaiskeptreasonably

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cleanedupatalltimes.OfficerrequestsreviewofISOcontrolprogramincludingmedicalaspectswithplantnurse.

132254 01.10.92 refusalduetofibreglassrashes PAINT/CURE

Workerrefusaltoworkonthepaintcurefixturesbecausewhenhehandledthefixtureshewasgettingrashes from the fibreglass in the fixtures. JHSCheldan investigationandoffered the followingPPEequipment:tyvexcoverallsuitwithlongsleeves,respirator,glovesandsafetyglasses.ItwasindicatedthatifappropriatePPEarewornthenthereshouldnotbeanysignificantskinhazard.

1993

POSTLAM/ASSEMBLY

93EO35EAAW 18.05.93 odor/healthcomplaints POSTLAM/ASSEMBLY

Hygienist report: 12 employees complain of headaches, dizziness, light headedness, metal taste,acetone‐likeodor,sicktostomach,onesenttohospital(notarefusee).Tracelevelsonlyfoundinairtesting. Inspector advice: “Ongoing efforts to ensure plant ventilation system operates properlythroughout the work shifts are appropriate. The use of cooling fans may help to increase workercomfort.Workerexposurestocarbonmonoxide,carbondioxide,nitricoxide,nitrogendioxide,acetoneandmethylethylketone,intheareasofconcern,arecurrentlywithintherespectiveexposurelimits.”

93EO35EAAW 03.05.93 odors/healthcomplaints POSTLAM/ASSEMBLY

Hygienist report: re:13workers refusal.Nonoticeableodors/air testingdone. “Itwasnotedduringvisit that the company’s detector tube pump had a slight leak. Correction action in this regard isappropriate. Workers expressed concern over vapors coming from sludge room. Effluent from atemporary holding tank in sludge room was draining over a mesh basket containing bromocidedisinfectantpucks.Theeffluentwassplashing inthenearbyworkarea.Repeatedcontactmaycauseskinproblems.Appropriaterepairsarerequiredforthecompany’scolourimetricdetectortubepump.Considerationshouldbegiventoongoingrefreshertrainingintheproperuse,careandlimitationsofdetectortubesampling.”

93E22OMOBR04.05.93 odors/healthcomplaints POST LAM/STE ASSEMBLY(seeabove)

OHSB report of above case: On April 27, 1993, several workers complained of “diesel” odors,experiencinglightheadedness,nausea,eye,noseandthroatirritation,headaches,problemsbreathingand vomiting. Worker sent to nearby hospital. On May 3, 1993 a similar incident occurred.

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Reassessmentby(hygienist)detectednosignificanthazard…thecauseoftheseincidentsisnotknownalthoughtheremayhavebeenaspillofMEKin thepaintkitchenandmalfunctionof theventilationwhichisappliedtothebarrelofthe3000toninjectionmolder.Althoughsuchexposurecanproduceuncomfortableanddistressingsymptoms,itisnotlikelytoresultinpermanenttissuedamageorotherserious harm in either short or long term. The affectedworkerswondered if there were any testswhichmightdetectsolventsincommonuseinthisplantlikeacetone,MEKandxylene.Theurinecanbeexamined;suchtestingshouldbedoneattheendofworkshift.Acetone:100mg/L,MEK:2mg/L,xylene:1.5g/gcreatinine.Thegeneralventilationshouldbeassessedbyanappropriateconsultanttominimizethepossibilityofrecaptureofexhaustgasesbyairintakesystem.Disposablerespiratorsforusewithorganicvaporsshouldbeavailable…”

INJECTIONMOLD/REGRIND

93E326EAAW 18.05.93 vapors/healthconcerns INJECTIONMOLD/REGRIND

Hygienist report: 4 employees refused work due to health concerns associated with regrindingmachine and vapors emitted during regrinding of plastics. “Workers may be exposed to theseemissions under current circumstances due to a lack of effective controls. Upgraded controls (e.g.,localexhaust)fortheregrindingmachineareconsideredreasonableandappropriate.“Dispersionofairbornecontaminantsproducedduringuseoftheregrindingmachineintotheadjacentworkareasislikelyundercurrentcircumstances.Informationfrommanufacturerindicatesvolatilesreleasedduringheating (550F) of the 1376 resinmay include carbon dioxide, water, tetrahydrofuran and styrene.Otheremissionsmayalsobereleasedduringheatingoftheresin.”

442406 18.05.93 fumes/healthconcerns INJECTIONMOLD/REGRIND

4 persons refusedwork in injectionmolding because of fumes coming fromNelmorGrinder. Theyreportedheadaches,sicktostomach,drymouth,drysorethroats,burninglips,fatigue.ScrapTCUwasbeinggroundnearby.TPUwasalsobeingprocessedontheline(#1376and#1103).HSCconfirmedtheodor.Atinspectionat4:25pmthefollowingwasnoted:a)afairlystrongplasticodorwaspresentaroundthegrinder.B)Thebottomholdingtraythatcatchesgroundproducthadbeenremovedandwasfullofproductthatwasstillwarm(at8:00amthenextdayitwasstillwarm).C)Thesectionofthegrinderthatdoesthegrinding/cuttingwasalmosttoohottotouchbybarehands.D)thegrinderhadno local ventilation Order: appropriate engineering controls such as ventilation to ensure that gasfumes or mist generated….is adequately captured and does not enter into the work area andappropriate NIOSH certified dust respirators shall be used by workers handling or transferringgroundupTPU.

93E326EAAW 18.05.93 vapors/healthconcerns INJECTIONMOLD/REGRIND

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Hygienistreport:4employeesrefuseworkduetohealthconcernsassociatedwithregrindingmachineandvaporsemittedduringregrindingofplastics.“Workersmaybeexposedtotheseemissionsundercurrentcircumstancesduetoalackofeffectivecontrols.Upgradedcontrols(e.g.,localexhaust)fortheregrindingmachineareconsideredreasonableandappropriate.“Dispersionofairbornecontaminantsproducedduringuseof theregrindingmachine into theadjacentworkareas is likelyundercurrentcircumstances. Information frommanufacturer indicatesvolatiles releasedduringheating (550F)ofthe1376resinmayincludecarbondioxide,water,tetrahydrofuranandstyrene.Otheremissionsmayalsobereleasedduringheatingoftheresin.”

93D501EAAV 14.04.93 healthconcerns INJECTIONMOLD(TPU)

5workerconcernsassociatedwiththedryingofTPU1376(Polypurgrey).Localexhaustsystemfordryingbarrelalsoservicestheinjectorheadofthe3000tonmolder(plustwootherinjectionmoldingmachines). Local exhaust system for drying barrel was not locally exhausted on day of refusal.Inspectorcomments: “duringdryingofTPUpelletsat reported temperaturesomeairborne irritantsmaybeproduced…..notlikelytobeinexcessoftherelevantexposurelimitsbuttheymaybesufficienttocausediscomfortorirritation.Dryingresinpelletsatthelowestpracticaltemperaturewillhelptominimize formation of thermal degradation by‐products. Advice tomanagement: A potential likelyexistedforworkerdiscomfortduringtheinitialtimeoftheworkrefusalsduetoalackofeffectivelocalexhaust ventilation. Good work practices including use of existing exhaust ventilation as well aspreventivemaintenanceanduseofthelowestpracticaltemperaturetominimizeformationofthermaldegradationby‐products.

H&Seventform 24.02.93 workerssprayedwithhydraulicsprayINJECTIONMOLD

RE:3000tonmoldinplantmakingabanging/scrapingnoise.Moldcausedahydraulicelbowfittingtoblowoffandsprayhydraulicoilontoworkers.(Adjustmentsmadebymaintenanceaswellasmtgtodiscussissue.

449334 19.03.93 odorandhealthconcerns INJECTIONMOLD/ASSEMBLY

5workersrefusedtoworkinassemblybecauseof“odors”believedtobecomingfromthe3000tonInjectionmoldingmachineadjacenttotheassemblyarea.

Observation: the 3000 ton machine was processing TPU at about 220 degrees (highest in rangeprovided).Dryerunitwasinoperationbutnotventedtotheoutdoors. Localventilationtothewestendofthebarrelwasworkingwellattimeofinspection.Attimeofvisit,managementindicatedthatonlyabout1morehourofTPUproductionwasneededtocompletetheproductionrun.AfterthatitwasnotexpectedtheywouldbedoingaTPUrunforabout2weeks.ItwasagreedthataMOLhygienistwillbeinvolvedintheinvestigationwhenthenextproductionrunofTPUismade.Itwasagreedthatthe refusing workers will not have to work in the area until the extra hour of production run iscompleted.Temporaryventilationventswillbeconnectedtodryerunit toventexhaust tooutdoors

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beforeanyfurtherrunsofTPUaremade.Furthersuggests,thatwhenpurgingtakesplace,theexcesshotplasticthatfallsoutofbarreltobedirectedintopailofcoldwater.“Thisshouldhelpcontrolthespreadofadditionalpurgingfumes.“

449329 26.03.93 healthconcernsINJECTIONMOLD/FINISHEDPROD

Continuationofworkrefusal449334(seepreviouspage)

“Ventilationhadbeeninstalledondryunitof3000tonmoldmachineanddryingwasoperatingattimeoftoday’sinspection.Thebarrelendofthemachinealreadyhadlocalventilationandthiswasworkingtoday. When purging is done and excess material comes out (1‐10 lbs) this material is now putdirectlyintoalargepailofwatertopreventspreadoffumes.Basedonadvicefromhygienistthatthedryer unit be vented (which was done) it was felt that adjacent workers are not likely to beendangered.”Inanotetothehygienisttheinspectorsays:Re:Pebra.(Company)managedtoputoffdecisionuntilTPUisusedagain,butwouldlikeinspectortogointoassistatthattime.

PAINT/SLEUSSWAY/KITCHEN/SLUDGEROOM.

509310 22.12.93 odor/healthconcerns PAINT/SLUICEWAY

Followupordertoworkrefusal.Concernsonsolventsmellbelievedoriginatinginsluicewaybetweenpaint facility and sludge room. “The sluiceway on the floor outside the last wall of the paintkitchen…shallbesealedormoreadequatelycoveredtopreventfumesandvaporsfromenteringtheinjection molding area and assembly area in accordance with section 25(2)h of the Act. Ordercompliedwithatthetimeofinvestigation.

“Duringinspectionoftheareathefollowingwasnoted:a)Metalplatesplacedlooselyoversluicewaywere not sealed in anyway and gaps between adjacentmetal plateswere as large as 2”. b) Filterscreens were still left on floor area adjacent to where these filter screens are changed in thesluiceway….Screenfiltersonthesluicewayarenormallychanged/cleanedonceaday.Ifanemergencyoccursfilterswould/couldalsobechangedorcleaned.Whenfilterischanged/cleaned,sluicewayhastobeopenedupanditislikelysomeorganicsolventodorswouldbereleasedintothearea.”

Inspectornotes:On21.12.93aproblemoccurredinthepaintfacility.Somecartscrashed.Thepaintlinewasstoppedandthepaintspraygunswouldhavebeenflushedwithsolvent.Thebackwashandsolventsfromthepaintfacilitymovethroughthesluicewaytothesludgeroomand“itmayhavebeenpossiblethatsomeofthesolventleakedoutfromthesluicewayasaresult.”

442316 23.03.93 fumesandhealthconcerns PAINT/SLUDGEPIT

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Accordingtoemployerreport,workerassignedtocleanscreensinsludgeroomrefused.Managementofferedworker respirator and ambient air supplybuthe still refuseddue to fumes, odors fromoldpaint.Inspectorcomparestestingresultsofareaidentifiedfromareportonthesameareaandnotesthatat6ppm,“solventvaporisnotlikelytoendangerworkertoenterandworkinthisarea.”

467796 13.12.93 poorairquality PAINT/LOAD/UNLOAD“15workersrefusedtoworkinNEcornerofPaintbecauseofsmellandunknownairqualitytesting:carbonmonoxide5ppmandcarbondioxide1000ppm(7:00pm)testing:carbonmonoxide5ppmandcarbondioxide1200‐1300ppm(10:00pm)Humidity32%.GasfiredceilingfurnacesrecentlycheckedbyConsumersGasatapreviousworkrefusal,02.12.93.Atthattime,5gasfiredceilingfurnaceswereloggedoutofservicebecausetheydidnothave“draftinducers”onthem.Thesearestillclosedoffandoutofservice.Oneairmakeupunitabout40feettothewestoftherefusalareawasturnedoff1weekagowhenanotherworkrefusaloccurred.Itisstillclosedoffuntilitisserviced.Onmidnightshiftthepartscartswerehighpressurewashedinareajusteastofpaintfacility”.

Theexcesswateronthefloorswassqueegeedintothewashwatersumpareanearbyraisingthetopcover plate…..(it was) still raised at time of this investigation. Plate should be closed properly andremainclosed.Sincechangetowinterheatingabout4weeksago,therehavebeenseveralairqualitytype refusals. The heating units have been addressed through Consumers Gas however it isrecommendedthatallappropriateheatingunitsbemadeoperationalassoonaspossiblebefore thereally coldweather comes. It is recommended that a reviewof the suggestions/ideas to reduce thechangeofcontaminatingtheairintheassemblyareabemadeasdiscussedwithPebrabytheMOLonMay31,1993(attachedtoreport).

467875 15.09.93 airquality PAINT/INSPECTION

14workerspresentfordiscussionandconsultationonexhaustfansandmake‐upairfanswhichhadbeenthetopicofworkrefusalearlierintheday.Communicationsbetweenworkersandmanagementwasdiscussedandhowtesting in theareasneardoorsand fanscouldbecompletedaswellashowthese results could be communicated. The end result was that a better system of communicationwouldbedeveloped.Orders:Employershallpostacopyoftheoccupationalhealthandsafetypolicyinthe workplace in accordance with section 25(2)k of the act. The employee shall ensure that theenclosed workplace shall be at a temperature of not less than 18 C during operational shifts inaccordancewithsection129(1)lboftheact.(Temperatureatthetimeofinspectionwasonly15C).

RIMDEPARTMENT:

Report(noauthororfileno.)onrimairexhaustunits June93ventilationproblem RIM

Therimareaservedby6makeupairunitsandexhaustedby16fans.(MoldUnits,MU1‐MU6,MU15)

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MU1 andMU3work in conjunctionwith return fans,MU2 fanwas found turned off and started inordertoobtaincapacity,MU15isheatingunitthatoperatesonlyinwinter.

Conclusion: the area is under a tremendousnegativepressure.Althoughmany fans vary from theirdesigncapacities,theoverallnetpressurizationisclosetothedesigncapacitylevel.

Managementeventform 15.09.93 poorairquality RIM

30workersrefusedtoworkcomplainingaboutpoorairquality,feelingsick/tired.

467673 15.09.93 airquality RIM

30‐35workersinRIMrefusedunsafeworkbecauseofairquality.Workersstatedtheyhadheadaches,weregettingsleepyandgenerallyfelttired.TheybelievedthattheairintheRIMareawasthecauseoftheir refusal. Testswere done for carbonmonoxide, carbon dioxide, sulfur dioxide, acetone, hydrocarbons, hydrogen sulfide, and toluene. Results showed no evidence of overexposure (only highreading600forcarbondioxide).

Dailytestingforthesechemicalistobecompletedatthebeginningofshiftandinearlyafternoonforatwoweekperiodtoobtainapattern.Readingsaretobeposteddaily.

Carbondioxideat600ppmdoesnothingmorethancreateacomfortfeelinge.g.,tired,sleepy,possibleheadachesasindicatedbyDr.Waddell.Decision:“Notlikelytoendanger.”

OTHER/PLANTWIDE

467796 02.12.93 gassmell GENERALASSEMBLY

Workersrefusingtoworkbecauseofgassmell inassemblyarea.CertifiedJHSCmembershavedoneextensivetestingoverpast2days.ContractorandConsumersGascalledin.

449329 26/04/93(5refusals)duetofumesfromPURpelletdryer INJECTION MOLDINGHygiene visit followed initial work refusal investigation (see 93D501EAAV, 15/04/93). Adverseeffects fromfumes/vapors fromheatedpolyurethane(i.e.polypurGray1376whichcontainscarbonblack)thermoplasticpelletsmoldersandassemblers.Hygienistfindsthatduringtheinitialdayofthework refusal the drying barrel was not locally exhausted. The dried tpu pellets are molded atapproximately 400‐430 F (204‐221C). Hygienist noted that drying TPU pellets at the reportedtemperaturessomeairborneirritantsmaybeproducedatlevelbelowtheTLV.

INJECTIONMOLD/REGRIND

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93D501EAAV 14.04.93 healthconcerns INJECTIONMOLD(TPU)

5workerconcernsassociatedwiththedryingofTPU1376(Polypurgrey).Localexhaustsystemfordryingbarrelalsoservicestheinjectorheadofthe3000tonmolder(plustwootherinjectionmoldingmachines). Local exhaust system for drying barrel was not locally exhausted on day of refusal.Inspectorcomments: “duringdryingofTPUpelletsat reported temperaturesomeairborne irritantsmaybeproduced….notlikelytobeinexcessoftherelevantexposurelimitsbuttheymaybesufficienttocausediscomfortorirritation.Dryingresinpelletsatthelowestpracticaltemperaturewillhelptominimize formation of thermal degradation by‐products. Advice tomanagement: A potential likelyexistedforworkerdiscomfortduringtheinitialtimeoftheworkrefusalsduetoalackofeffectivelocalexhaust ventilation. Good work practices including use of existing exhaust ventilation as well aspreventivemaintenanceanduseofthelowestpracticaltemperaturetominimizeformationofthermaldegradationby‐products.

442316 23.03.93 fumesandhealthconcerns PAINT/SLUDGEPIT

accordingtoemployerreport:workerassignedtocleanscreensinsludgeroomrefused;mgmt.offeredhelper,respirator,ambientairsupplybuthestillrefusedduetofumes,odorsfromoldpaint.Inspectorcompares testing resultsof area identified froma reporton the samearea andnotes that at 6ppm,“solventvaporisnotlikelytoendangerworkertoenterandworkinthisarea.”

RIM

Reportonrimairexhaustunits June93ventilationproblem RIM

Therimareaservedby6makeupairunitsandexhaustedby16fans.(MU1‐MU6,MU15)

MU1 andMU3work in conjunctionwith return fans,MU2 fanwas found turned off and started inordertoobtaincapacity,MU15isheatingunitthatoperatesonlyinwinter.

Conclusion: the area is under a tremendousnegativepressure.Althoughmany fans vary from theirdesigncapacities,theoverallnetpressurizationisclosetothedesigncapacitylevel.

Managementeventform 15.09.93 poorairquality RIM

30workersrefusingtoworkcomplainingaboutpoorairquality,feelingsick,feelingtired.

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467673 15.09.93 airquality RIM

30‐35workersinRIMrefusedunsafeworkbecauseofairquality.Workersstatedtheyhadheadaches,weregettingsleepyandgenerallyfelttired.TheybelievedthattheairintheRIMareawasthecauseoftheirrefusal.Testsdoneforcarbonmonoxide,carbondioxide,sulfurdioxide,acetone,hydrocarbons,hydrogensulfide,andtoluene. Resultsshowednoevidenceofoverexposure(onlyhighreading600forcarbondioxide).

Testingforthesechemicalstobecompletedatthebeginningoftheshiftandinearlyafternoonforatwo‐weekperiodtoobtainapattern.Readingsaretobeposteddaily.

“Carbondioxideat600ppmdoesnothingmorethancreateacomfortfeelinge.g.,tired,sleepy,possibleheadachesasindicatedbyDr.Waddell.Decision:Notlikelytoendanger.”

OTHER/PLANTWIDE

467796 02.12.93 gassmell GENERALASSEMBLY

Workersrefusingtoworkbecauseofgassmell inassemblyarea.CertifiedJHSCmembershavedoneextensivetestingoverpast2days.Contractorandconsumersgascalledin.

449329 26/04/93 wk.ref.(5)fumesfromPURpelletdryer INJECTION MOLDINGHygiene visit followed initial work refusal investigation (see 93D501EAAV ‐‐15/04/93) Adverseeffects fromfumes/vapors fromheatedpolyurethane(i.e.polypurGray1376whichcontainscarbonblack)thermoplasticpelletsmoldersandassemblers.Hygienistfindsthatduringtheinitialdayofthework refusal the drying barrel was not locally exhausted. The dried tpu pellets are molded atapproximately 400‐430 F (204‐221C). Hygienist note that drying TPU pellets at the reportedtemperaturessomeairborneirritantsmaybeproducedatlevelbelowtheTLV.

442406 18/05/93 fumes/dustNelmorgrinderTPU110‐1376 REGRIND AREAInvestigationofworkrefusalby4workersintheassemblyareaonMay17,1993overadverseeffectscaused by fumes from the grinding operation. Workers experiencing headaches, nausea, fatigue,burning lips,anddrysore throat. Mistand fumeswerevisiblearound there‐grindarea. Inspectornotes:strongplasticresintypeodor;groundplasticstillwarm2hoursafterused;thecuttingbladesweretoohottotouch;nolocalexhaustventilation;MSDSindicatedthat“inhalationofdustmaycauselungandthroat irritation; fumesmaybeemitted in the formofoligomers. Localexhaustrequired.”Fiveordersissued.

1994

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PAINT/KITCHEN/SLUDGEROOM/SLEUSSWAY

94A143EAAW/449499 12.01.94 odors/health concerns PAINT/LOAD/UNLOADUnmaintainedpropane fork lift truckcreatinghigh levelsofcarbonmonoxide fumes;800“shots”ofreleasefor2‐3secpershift–releaseis70%methylenechlorideandsuspectedcarcinogen,ventilationonlyduringpurging.Inspectoradvice:”Asuitablesubstitutewouldthereforebedesirable”

ID431932 06.01.94 re:fibreglasswarning BUFFING/OUTSIDEPAINT

Workers concerned bywarning label on polypur that it contains crystalline silica. Do not inhale ofswallowdust;Inspector’sAdvice:ensureventilationisrunningandrespiratoryprotectionused.

(Ear#93F018AAAR)15.11.94 buffingwithnovent BUFFING/OUTSIDEPAINT

Workerswereconcernedaboutanumberofchemicalsused inbuffing thatwouldbe in thedust,astherewasnoventilationorrespiratoryequipmentinuse.TestingbyHSSSBconsultantsfoundnothingover TLVs (total dust, flrmaldehyde, phenol). (AUTHORS’ COMMENT: In our Advisory Committeemeetingsseveralworkersdescribedbeingconcernedwhentheyfoundoutthescotchbritetheyusedtobuffwithcontainednickelandawarningofthepresenceofnickelwaslistedontheboxtheproductwascontainedin).

RIM

ID442438 27.01.94 multipleairqualitycomplaints RIM

Query“purgeintoplant”.AMUtiedintoventilationonclamp1and2.IfexhaustshutofforflowswitchmalfunctioncauseAMUtopurge.Ministrycalled.

509143 07.10.94 lackoflabelsonhydraulichoses RIM

522258 07.10.94 poorqualityofnewgloves/rash RIM

(H&S management: “Gloves were obviously defective and had torn. Claims shin rashes due topenetrationofsolvent.Concernedtempofmoldcausesbreakdown.”Inspector(basedoninformationreceivedfromglovemanufacturerstates“solvexnitroglovewillprotectthehandsfromexposureto

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themoldcleaningsolvent.”Workerofferedbarriercreamandspecialunderglove tousewith “new”gloves).

94K197EAAW 9.11.09odors/healthconcerns RIM

No reason identified for workers concerns. Air sampling was done in plant almost 2 hours later.Inspector’s comments: “Avarietyof solventsused inplant,manyofwhichhave relatively lowodorthresholds…oftenwellbelowtheexposure limits.” HeAdvises: “Ongoingeffortsshouldbemadetoinvestigatesourcesofunusualodorsassociatedwithhealtheffectsintheplantassoonasispractical.”

467970 21.11.94 odors/healthconcerns RIM

Workerscomplainedofheadaches,dizziness,sorethroatandonesicktostomach/nosebleedsenttohospital.Notrainedpersonavailabletoconductairsamplingatthetime,donelaterbyJASCwithnofindings.Inspectordecision:“ventilationwillbeimproved,nohazardousingredientsinmoldrelease.”

OTHER/WASHROOM/PLANTWIDE

568519 19.10.94 INSPECTORNOTESINADEQUACIESINH&SPROGRAM

“UnionRepstates(H&Srepwastestedinflowratetestingbutnottoldwhattheflowrate“shouldbe”.Inspector further notes: “During visits to this workplace, I saw numerous contraventions andhazardous conditions that the certified members and other JHSCmembers did not notice. (NamescompanyH&Srep)alsonotedthatsupervisorsneedtraining inhowtodischargetheirdutiesundertheact.”

431932 27/05/94 phenol/formaldehyde+dustbuild‐upBUFFING AREATherearefourbuffingunitsinthebuffingareaproducingalargeamountofdustfromthematerialsbeingbuffede.g. freshlymadeplastic and isocyanatepaintedparts aswell asdust from thebuffingdisks composed of various grits and phenol formaldehyde adhesives/resins. There was a largeaccumulation of dust on floors and in the air. While the buffing station was equipped with localexhaustthesizeofthewheelblockedtheflowofairandcauseddispersalintheatmosphere.Worker’scommentsparaphrasedbyinspectorfollowedbycommentary“…theairintheplantisoftennotfittobreath;despitethefactthatnumerousairqualitytestdonotsupportthisbelief”.

1995

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INJECTIONMOLD

522864 19.10.95 vapors(E702)moldmachine INJECTMOLDING

HSCSreprequestedvisitrevaporscomingoffmoldmachines.MoldReleaseE702or“rocketrelease”givingoffmist.TestingtobedoneinternallyandreportfromInspectorBurkelater. Itwasobservedthat (workers)were notwearing the provided respirators. Otherworkers on othermachineswerewearingtherespirators.WorkersarerequiredasperOHSAct,Sec25‐1‐dtheemployershallensurethatprotectivedevicesprovidedareused!”

95J235EOAR 06.11.95 concernsre:E702rocketrelease INJECTMOLDING

(TPUmachineapplies150‐300applicationspershift).”Thereisvisibleoversprayandisseenasmistattop of IM enclosure. According toMSDS, product contains a halogenated hydrocarbon/ether blend.INFORMATION SUBSEQUENTLY OBTAINED FROM SUPPLIER (not on MSDS) indicates this blendcontains dichlorofluoroethan and dimethyl ether which have suggested WEELS of 500 ppm and1000ppmrespectively. THEREARENOEXPOSURELIMITSESTABLISHED INONTARIOFORTHESEMATERIALS.BasedonautomatednatureofthisIMprocess,thedistanceofworkersfromthesource,andavailable informationonproduct, it isunlikelythatworkersareexposedtoeither(chemical) inexcess of suggested exposure limits. However, the provision of upgraded controls would help toreduce overspray and minimize product wastage. “Workers smoking in wash rooms. Designatedsmokingareais incafeteriabutmanagementisnotstrictabout it.ComplainanthasmadenumerouscomplaintstoJHSCbutnoactiontaken.”

95B224XAAC 17.02.95 noiseleveltesting INJECTIONMOLD/COMPRESSOR

Noiselevelsnotedrangingfrom89‐94.5DB.Appropriatehearingprotectionprovidedandworn.Moldrepairisconductedinthecompressorroomonanintermittentbasis.Twomenwouldrepairmoldsfor4‐8 hours several times per week. Ongoing efforts to reduce noise exposure through engineeringcontrolsareappropriate.

568291 17.02.95 noiselevel/overheadcrane INJECTIONMOLDING

Inspector:“All(sound)levelsappeartobewithinacceptablelimits.Theemployerisadvisedtoreviewthe operational procedures in the work area with a view to increasing the level of effectivecommunicationbetweenworkerswhenmore thanoneworker is required tomoveamoldbyusingtheoverheadcranesystem.Thisofficersuggeststhattheworkersintheareacouldbeinvolvedintheprocesstoassistwiththereview.”

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PAINTLINE/SLEUSSWAY/SLUDGEROOM

95B223EAAW 23.02.95 refusalover“finesse” OUTSIDEPAINT/BUFFING

Workershealthconcernsoveruseof“Finesse”.Aftersanding,3M“finesse‐It”compoundsareappliedbysqueezebottle.Uptoseveraldropsmaybeappliedperoccasion.Pneumaticpolisherusedtobuffthepartwiththecompound.MSDS–compoundcontains50%wateraswellasStoddardsolvent,and13084anisoparaffinichydrocarbonandlesseramountsofotherpetroleumderivatives(20%)andlessthan1%morpholine.Repeated/prolongedcontactwithskinshouldbeavoided.Somesplatteringmayoccur.”Advicetoemployer:Provisionofaguardoralternateworkstationdesignwouldbeofbenefit.“…….unlikelytoexceedrelevantexposurelimits(eventhoughthefullingredientlistismissing?).

OTHER/WASHROOM

29671 12.10.95 smokingregulations WASHROOMS

EventReport 03.04.96 smoking WASHROOMS

“Complaintsnotbeingresolved”

Requestforservice 03.04.96 refusalre:R‐602spray RIMCLAMPS

Re:“clamps1,2,5 “exposuretomistfromsoapspray”

522910 03.04.96 refusalre:R‐602spray RIMCLAMPS

Re:Refusalduetotheallegedexposureto“mist”fromR‐602.Atpresentonlyadust/mistrespiratorisused on voluntary basis and is not adequate for this application. Sampling is to be conducted. Ininterimworkersadvisedthattheymaywear…organic/vapor/particulatepre‐filterandfurtheradviceistofollow.Nodecisionisgivenre:workrefusaluntiltestresultsaregathered.”

614610 09.04.96 airsampletestsre:R‐602 RIMCLAMPS

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“FourworkersinRIMmoldareausingR602,analcohol‐basedsoapsolution,sprayingitonthemoldstoloosentheproduct.WorkersfelttheywerebeingexposedtomistfromtheR602chemicalastheywerewearing incorrectrespirators.Theyexperiencednausea,reddeningof theeyesandheadaches.Theyestablishedthatincorrectrespiratorswerebeingworn.”

594989 29.04.96 refusalre:R‐602spray RIMCLAMPSrecommendationsfromtheMOLhygienistmentionedinthisreportarebeingcompliedwith.Airsamplingtaken.”

96D068EABR 09.04.96 labresultsforR‐602 RIMCLAMPS

“Workerexposureton‐propylalcoholofR‐602soapsolutionrangedfromnon‐detectableto16ppm.Timeweightedexposureresults(5‐11ppmwellwithincurrent200pmTLV).(Noindicationthatanyconsiderationoftheprevalenceofmanyfansintheareaused,andtheirpossiblecontribution)

VentraMOLmorerecentreportsforperiod2006‐2018

FV5449699 05.10.04 re:ordersissued lettertocompanyfromRobertMolinaP.Eng.

InresponsetoyourrecenttelephonecallinreferencetoordersissuedonSept29,2004thefollowingapply:

1.Theindustrialregulationsareexplicit,flammableliquidsshallbelocatedinaroomequippedwithadrain and liquid tight ramped sill. Both your flammable liquid storage room and mixing roomcurrentlydonothaveadrainnorliquidtightrampedsill.OrderNo.1specificallystatesthatVentraproposeaplantodealwiththisnon‐conformancebyOct13,2004.Youmentionedthatyoufeelyoualreadymeet the requirements of this section. If this is the case then propose your argument andrationale under an equivalency approach before Oct 13, 2004 for audit. Having said this, I find itdifficulttoacceptanequivalencyfordrainage.

2. In response to Order no. 4, according to your voicemail message you believe that the order iscompliedbecausetheoperatorsinsidethemixingroomdonotrequirelabelingsincetheyareawareofthecontentsofthepotsandtotes.Ifthisisthecase,thenpleaseputyourargumentinwritingasanequivalency, and the issue will be reviewed. Clearly there is currently no pipe labeling inside themixingroom,whichisanon‐conformance.

FV5449699 12.11.04 re:ordersissued VisitbyRobertMolina

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OrdersNos.3and4asdetailedinSept29,2004inspectionreportareconsideredcomplied.Themini‐paintkitchenasbeeninstalledwithalocalizedventilationsystemwithtwoinletseachwithacapacityof100cfm,thesystemisconnectedtothepaintlineexhaust.Labellingonpipeswasinstalled.

OrderNo.1asdetailedintheSeptember29,2004reportisyettobecompleted,anequivalencyhasbeen submitted and rejectedwhile another argument has been proposed by the consultant and iscurrentlyunderreview.

17580(hygienistreport) 22.03.06re:vaporsfrom3MAdpro4298UV INJECTIONMOLDING

Complaints by operator during trial run of new product of vapors from adpro product. It wasdiscoveredthatsolenoidairvalveusedinconjunctionwithAdproand(emergencystop)dischargedair containing vapors into the work area by glue line. Volume estimated to be about 20ml. withemergency stop activated twice per hour.Not believed concentrations exceeded exposure limits inReg 833/90. Has since been ducted into gluing chamber and seal improved on doorwhere Adprocontainer located.MSDS lists ingredients tobecyclohexane,xylene,ethylbenzeneandethylalcohol.MSDSrecommendsskinprotectionwhenhandling.

ID5079018 12.04.06 refusalre:Parcopurge PLANTWIDE

Followup on internal resolution ofworkplace refusal onApril 7, 2006. Once per year,water linesdescaled with parco purge A500, which contains from 16‐40 percent hydrochloric acid. The acidreactswithscaleinthelinestoproducecarbondioxide,oxidesofsulphurandothergasses.Usually,descalingisconductedafterhours,however,thistimeitwasconductedonanoperatingshift.Thoughnormalprecautionsweretaken,itappearsthatsomeofthesereactiongassesenteredtheworkplaceandsomeworkerscouldsmelltheseodours.IndiscussionwithMr.TerryMorgan,itdoesnotappearthatanyofthesefugitiveemissionswereofanysuchconcentrationthannormal.Employerstatedthatthe descaling will be conducted “off shift” as had been done in the past. In addition they will beswitchingtode‐ionizedwaterwhichwillreducescalebuildup.TheemployerisadvisedtoconsulttheMSDS forParcoPurgeA500, section8where it is listed that the respirator cartridgebe ‘acidmist.’Shouldtheoperatorwork inareaswithanumberofcontaminantsthenamulticartridgeshouldbeconsidered.

Event#1080113 10.07.06 re:fumesfromcureoven CUREOVEN

Re:Workersworkingwithcuringovens.Employerrecentlychangedventilationsystemandpluggingleaks.Ovenisunderpositivepressuretemporarilyinsteadofnegativepressure.Smellofoff‐gassesinthe air. Company has air sampled – results on Friday. Hygienist attended workplace. Suggestedworkerswear facemasks. Or employerwillmoveworkers to anotherwork location. Not likely toendanger.”

Hygienist report: #5079062: Ventra Plastics has completed an installation of a thermal oxidizer tocontrolplantemissionsresultinginapositivepressurebeingformedinoven.Ovenvaporsidentified

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consistingmostlyofxyleneleakingintoplant. Approximately50workersdetectedvaporsintheairand some soughtmedical treatment….It is believed that leaks in oven are in the process of beingsealed.Inaddition,theexhaustflowratefromovenhasbeenincreasedfrom2700CFMto4350Cfm.Theresultofthischangeisunknown.Employercanprovidefacerespiratorstoworkersprovidedthattheyarefittestedandtrainedtousethem.Thereappearstobenolikelihoodofoverexposure.

Employercriticalinjuryreport 18.09.09 re:lossofconsciousness PAINTLOADING

Whileloading,workerwenttorackandpickedupa10lb.part.Whilewalkingtoline,hefaintedandfelltothefloor.Reportconcludesworkerhadpre‐condition(blackedoutonreport).

P/PID17580 01.10.09 concernre:ventilation GRINDINGROOM

“Therearenowtwogrindingmachineswithinthisarea,andtheproposalbroughtforwardisthat,theinside doorwould remain closed (other than to bring in product), and the outside doorwould beopened at the discretion of the workers in the grinding area to allow cool air into the room. Theemployer would install a security type gate around the outside door which would preventunauthorized access or egress from the grinding room area. Phase two of this arrangementwouldinvolve new bags are to be introduced to reduce/eliminate dust, and if this does notwork, a newextractor fan is tobe installed intheoutsidewall,aswellasa fanforreplacementwarmairontheinsidewall. The inside doorwould then remain closed to reduce the noise level from the grindingroomintootherareasoftheplant.

FV02756FLZP263 27.06.12 manualspraypainting PAINTLINE

Robotfrompaintboothbrokedownandtokeeplinerunning,manualsprayingofAdprowasinitiated.Sprayingwasdoneoutsideof(clearcoat)booth.

“Ifitisdesiredtoplaceanoperatorinaroboticcellforwhateverreasonariskassessmentshouldbecompleted and adequate safeguards put in place to ensure the operator can not come within theoperating arc of the adjacent robot. Ideally physical barriers should be employed to eliminate thepossibility of contact. In addition the operator needs to have access to an emergency stop. Thematerial being used Adpro is highly flammable and has a relatively low explosive limit. With theinformationavailableat this timethematerialbeingsprayedshouldonlybesprayed insideaspraybooth.Noinformationonairmovementorairqualityexiststodemonstratethatsprayingoutsidethebooth is not hazardous. Persons painting should be adequately protected. It may be advisable toemployairsuppliedsuitsandrespirators. Inanycase,anassessmentshouldbedone toensure thecorrectsuitmaterial is inuseandthatpersonswearingrespiratorshavebeenfittestedandtrainedaccordingly.”

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FV02756FBRP116 13.01.12 workerunconscious NOAREAIDENTIFIED

“Theincidentisbelievedtoberelatedtoapreexistingmedicalcondition.Asaprecautionarymeasure,air sampling for carbonmonoxideandcarbondioxidewas conducted in theplant today.Nounsafereadingswererecorded.

FV03480FBXM019 18.01.12 AIRQUALITYASSESSMENT PLANTWIDE

Inspection was conducted on January 13, 2012. Measurements were taken with a TSI QTrak IAQmonitorwhichmeasurescarbondioxide,carbonmonoxide, relativehumidityand temperature.ThemonitorwascalibratedinOctober,2011.

Carbondioxiderangedfrom570to1070(withspikeof2500aftergeneralventilationisturnedon).Carbonmonoxiderangedfrom0.8to3.6ppm

WorkerComplainttodistrictoffice 23.2.12 re:Isoexposure

“Callerstates thatworkershadrefusedworkandthat theworkrefusalprocesswasnotadheredtobecausetheemployerthoughtthatitwasafrivolouscomplaint.Otherworkerswantedtorefusebutallfearfortheirjobs.Anodourthatisbelievedtobeisocyanatesfromthepaintingthatworkersdowascausingdrythroats,scratchythroats,tighteningofthethroatandgeneralunwellness.Employerhad said that workers were faking. This has been on going for near three months.Workers wereunsureifalloftheMSDSsheetshadbeenprovided.Caller indicatedthatshewouldlikea follow‐upwith the assigned officer and a copy of the F/” query: 1. Work refusal, 2. Iso control program, 3.Sensitization,4.Airquality.

FV02756GQCQ591 29.08.13 re:chemicalexposure SLUDGEPIT

Several(contractcleaning)workerssustainedchemicalburnswhenexposedtocausticsolutionwhilecleaningthepaintsludgepit.Thesolutionwasdrippingfromahoseattachedonthegratingsabovethem. The pump had been disconnected, however, the solution siphoned through the hose. Orderissuedtocontractcompanytoprovidepersonalprotectiveequipmentforcleaner.

AsecondorderissuedtoVentratorevisetheirproceduretoensurethatchemicalscannotdrip intothepitswhileworkersareinthem.

FV02925KMTP083 13.08.16 heatstressprogram PLANTWIDE

Complaintreceivedregardingheatstressandcurrentpolicyofbreaks.Callerstatesthatemployerhasturned the AC off in cafeteria to reduce energy consumption and has not provided cool down

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alternatives.Temperaturesreaching95‐96Fandworkersexperiencingheatstress.SafetytalksgiventosupervisorsaretobedeliveredtoworkersonSunday.Severalstationshavelargefans,employerworkingongettingmoreforotherareas.

FV00588KVBR024 15.11.16 re:Blastshackrebuild PAINTLINE

Shackconstructedofmetalcladdingwithinsulationbetweenwallsandceiling.Attimeofinspection,ceilingwassagging,waterdrippingfromit,rustymetalaroundlightfixtures,rustyatbottomedgesatfloorlevel,rustyoncoverattankatbackofboothandmouldanddirtonthelightcoveringinsidethebooth.Orderissuedforrebuildandthatitbewellmaintained.

FV00588LDZP062 23.02.17 re:ventilationconcern PLANTWIDE

Concern that ventilation system was not being maintained and dust on top of general ventilationsystem inbldg.hazardous toworkershealth.Sourceofdust likelycombinationofplasticdust fromrework,dirtdustfromforktrucks,dustfromgrindingroomanddustonportableracks.Itwasstatedthat “ducting has never been cleaned since it was installed many years ago. Recommends morecleaning on regular basis i.e., racks,metal duct work, extensions, sock venting and other surfaces.Employerscouldalsoinvestigatebetterfiltersfortheairmakeupunittocapturefinerparticulate.

FV00588LPMS652 17.08.17 re:trainingoutsidecleaners PAINTBOOTHS

Compliance required by Ventra in training contract workers on protection from paint fumes andIsocyanates and use of respirators when cleaning Paint Booths. Employer to ensure that allinformationre:sprayboothhazardsarecommunicatedtooutsidecontractor.

FV00588MJBP278and281 27and30.04.18 Re:dieselfumessharedspaceSOUTHENDBLDG

Problemwithdieselfumesenteringbldg.whentrucksaremaintenance.QuerychangingfancontrolstoKenworthsideofsharedareatocontrolwhendieselfumes/grindingarebeingproduced.“Kiddie”(homeuse)monoxidemetersusedbyVentraarenotsuitableforindustrialuse.

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APPENDIXC

CHEMICALSUSEDINVENTRAPLASTICSPRODUCTIONPROCESSES

*Carcinogenesis;**AdverseReproductive;***Mutagenesis;****ED

ISOCYANATEPOLYMERRESINS

IsocyanatesGroupshavingNitrogen‐Carbon‐Oxygen(NCO) Methylenebisphenyldiisocyanate(MDI)R‐RIMDepartment

Methylisocyanate(MIC),toluene2,4diisocyanate(TDI)

Polymethylenepolyphenylisocyanate(PAPI)

Naphthalenediisocyanate(NDI)

Hexamethylenediisocyanate(HDI)Paintdepartment/greyputty

ProductName:MondurPFC‐961

HazardousIngredients:aromaticisocyanatespre‐polymer(polyurethane),monomeric,4,4dphenylmethanediisocyanate(MDI)polymericSynmodifieddiphenylmethanediisocyanate,diphenylmethanediisocyanate(2,2,4)

DecompositionProducts:vaporformduringNoprovided

HealthEffects/Symptoms/Overexposure:irritatingeyes,skin,upperrespiratorytract,sensitization,ratedascarcinogenic,positivemutagenicandgenotoxic.

ProductName:Teflon(polytetrafluoroethylene‐PTFE)*

HazardousIngredients:Polytetrafluorethylene

DecompositionProducts:Hydrogenfluoride,carbonylfluoride

HealthEffects/Symptoms/Overexposure:irritatingtoeyesandrespiratorysystem‐choking,coughing,kidney/liverdamage,cancer.

ProductName:MondurPF

HazardousIngredients:MDI

DecompositionProducts:CO,Co2,NOx,HCN,MDI

HealthEffects/Symptoms/Overexposure:irritationofeyesandupperrespiratorytract,sensitization

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ProductName:Cycoloy(resin)MC8800‐BK1005;(SabicInc.)

HazardousIngredients:Silica*,magnesiumoxide,acrylonitrile*butadiene*styrene*(ABS),carbonblack*,bisphenolA(BPA),flameretardant*,colourants.

DecompositionProducts:acrylonitrile*,styrene*,butadiene*,nitriles,Nx,HCN,benzene*,ethylbenzene*,toluene*

Secondaryoperations:sanding,grinding,buffingproducesdust,smoke,condensates.

HealthEffects/Symptoms/Overexposure:Irritationoftheeyes,upperrespiratorytract,skin,nausea,headacheschills,fever

ProductName:AS700LW‐2(MylexPolymersInc.)

HazardousIngredients:1‐Octene‐ethylene‐copolymers,carbonblack*,copolymerpolypropylene,talc*

DecompositionProducts:CO,CO2,aliphaticaldehydes,formaldehyde*,acrolein*,carboxylicacid,NO,smoke.

HealthEffects/Symptoms/Overexposure:irritationofeyes,upperrespiratorytract,lungs,ski

ProductName:AS172L‐O2US(MylexPolymers)

HazardousIngredients:carbonblack*,copolymer–ethylenebutane‐1,copolymerPolypropylene,talc*.

DecompositionProducts:CO,CO2,NOx,smoke,aldehydes*,carboxylicacid,acrolein*.

HealthEffects/Symptoms/Overexposure:irritationeyes,upperrespiratorytract,skin,

ProductName:HP‐2105HSEAdhesionPromoter(Rohm‐HassInc.)

HazardousIngredients:xylene*,toluene*,ethylbenzene*,cyclohexanone,carbonblack*,chloroform*,MEK***,naphtha,1,2,4trimethylhexzene,isobutylisobutyrate,isobutanol.

DecompositionProducts:Notindicated

HealthEffects/Symptoms/Overexposure:liver/kidneydamage,tetaltoxins,pituitarygland,thyroid,testicularcancer.

ProductName:Bayflex110‐50IMR(InnerMoldRelease)componentAU‐125‐A(RIM)

HazardousIngredients:diphenylmethane,diisocyanateMDI‐prepolymerMDI‐modifieddiphenylmethanediiscyanate,TDI‐monomericMDIpositiveforAmestest*/***.

DecompositionProducts:notprovided

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HealthEffects/Symptoms/Overexposure:irritatingeyes,respiratorytract,skin,sensitizationandcancer.

ProductName:UrethaneHardener

HazardousIngredients:alphaticPolyisocyanat,1,6‐hexamthylene,diisocyanatebasedadduct,homopolymerofHDI,aromatic100,butylacetate,hexamethlenediisocyanate

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritationoftheeyesandupperrespiratorytract,cough,tightnessinchest,headache,dizziness,andnausea.

POLYMERRESINS(Thermoplastic)

ProductName:Multranol4050‐polyetherpolyol

HazardousIngredients:poly(oxyalkylene)Polyol

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:notprovidedProductName:TEGOSTABB8418

HazardousIngredients:Polysiloxanepolyether

DecompositionProducts:CO,CO2,siliconedioxide,prop65chemicals

HealthEffects/Symptoms/Overexposures:notprovided

ProductName:BLACK(PerroCorp.)

HazardousIngredients:carbonblack*,polyesterpolyol

DecompositionProducts:CO,CO2,NO,sulfurgases,PAHs*

HealthEffects:Carcinogenic,irritatingtoeyes,skin,respiratorytract.

ProductName:BayerMondurxp‐743(MDI)

HazardousIngredients:diphenylmethanediisocyanates,polyisocyanatebasedMDI

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritationofeyes,skin,lungs,nausea,corrosive,sensitization.

ProductName:BayerMondur1402

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HazardousIngredients:MDI,higheroligomers,phenylisocyanate.

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritationtoeyes,upperrespiratorytract,lung,inflammation,sensitization.PositiveAmestest.

ProductName:MobayNB358329(polyoxyalkylene.

HazardousIngredients:zincstearate,diethyltoluenediamine(DETA),Organotin,aliphaticamine,poloxalkylenediamine.

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritatingtoeyes,respiratorysystem,skin.Adversebloodeffects.

ProductName:PolypropyleneCopolymerwithTalc

HazardousIngredients:1‐Propene,polymerwithethanetalc

HealthEffects:reportedasnoharmfuleffectsorsymptoms

ProductName:K‐438‐Additive9438

HazardousIngredients:Polyoxyalkleneamine,metallicsoap/polyether,polyol‐blend.

DecompositionProducts:CO,CO2,NOx,aminevapors.

HealthEffects/Symptoms/Overexposure:irritationeyes,upperrespiratorytract,pulmonaryedema,skinirritation.

ProductName:BLACK(PerroCorp.)

HazardousIngredients:Carbonblack*,polyesterpolyol

DecompositionProducts:CO,CO2,NOx,sulfurgases,polycyclicaromatichydrocarbons(PAH)*compounds.

HealthEffects/Symptoms/Overexposure:irritationofeyesandupperrespiratorytractandcarcinogeniceffects.

ProductName:95120_HCUR560CAPHCayenneRed.

HazardousIngredients:MEK,isobutylalcohol,melamineresin,ethylbenzene*,isobutylacetate,n‐amylacetate,methylalcohol,MAK,Cyclohexanone,propyleneglycolmethyletheracetate,methylatedmelamine‐formaldehyde*resin,aluminum,Formaldehyde*.

DecompositionProducts:CO,CO2,acrylicmonomers*,formaldehyde*,NOx.

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HealthEffects/Symptoms/Overexposure:CNS,dizziness,headaches,lossofcoordination,nausea,irritationofeyes,skinandrespiratorytract.

ProductName:67502BarrierCoat

HazardousIngredients:Sameasaboveplus:modifiedbenzotriazole,carbonblack,naphtha,xylene**.

DecompositionProducts:sameasabove

HealthEffects/Symptoms/Overexposure:Irritationofeyes,upperrespiratorytract,skinandCNSeffects.Possiblecarcinogeneticeffects

ProductName:60230‐TPUR560CAFH

HazardousIngredients:Sameasaboveplus:methylpyrrolidone,ethyl‐beta‐ethoxypropionaleamorphoussyntheticsilicagel.

DecompositionProducts:sameasabove

HealthEffects/Symptoms/Overexposure:irritationtoeyes,GI,respiratorytract,andCNSeffects

ProductName:HP21054BHSTAdhesionPromoter

HazardousIngredients:Xylene**,ethylbenzene*,toluene*,carbonblack*,naphthac8‐c10,cyclohexanone,

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritationtoeyes,skin,respiratorytractandCNSeffects‐dizziness,nausea,headache.

ProductName:AdhesionPromoter4296T(ScotchMount)Primer

HazardousIngredients:MethylIsobutylKetone,toluene*,N‐butylacetate,alkydresin,nitrocellulose,ethylalcohol(ethanol),phosphoricacid,xylene**,isopropylalcohol.

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritationeyes,nose,throatupperrespiratorytract,skin.CNSeffects.

ProductName:HP21054HSEAdhesionPromoter

HazardousIngredients:ethylbenzene*,xylene**,mixedwithHC

DecompositionProducts:

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HealthEffects/Symptoms/Overexposure:

ProductName:3MAdhesionPromoter4298T

HazardousIngredients:Cyclohexane,methylalcohol,xylene**,ethylalcohol*,ethylbenzene*,acrylatepolymer,2,5–furandione,isopropylalcohol,4,4‐isopropylidendiphenol*(ECHpolymer,chlorobenzene,benzene*.

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:carcinogenicchemicals,irritationtoeyes,upperrespiratorytract.

ProductName:A‐1104‐B(BFGoodrich)

HazardousIngredients:MEK**,toluene*,butylalcohol,ethylacetate,ethanol,phenol*,Isopropylalcohol

DecompositionProducts:Co,Co2,smokealiphaticsandothers.

HealthEffects/Symptoms/Overexposure:irritationtoeyes,noseandthroat,nausea,CNSeffects‐dizziness,lassitude,braindamage,kidney/liverdamage.

ProductName:SolventCement

HazardousIngredients:Toluene*,MEK**,acetone,ethylacetate

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritationofeyes,upperrespiratorytract,nausea,headaches,CNSeffectsdizziness.

Productname:A‐1610‐B

HazardousIngredients:MEK**,Toluene*,ethanol,butylalcohol,Isopropylalcohol,propylene‐Propyleneoxide,phenol*.

HealthEffects/Symptoms/Overexposure:sameasaboveirritationandCNSeffects.

ProductName:HP21054‐4B1(adhesive)

HazardousIngredients:toluene*,xylene**,ethylbenzene*,carbonblack,cyclohexanone

Sameasabove

THINNERS/SOLVENTS/CLEANERS/REDUCERS

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ProductName:R790‐T2Kreducer

HazardousIngredients:MEK,propyleneglycolmethyletheracetate,N‐Amyl,isobutylacetate,2‐ethylhexylacetate,xylene,butylacetate‐n.

DecompositionProducts:Notprovided

HealthEffects/Symptoms/Overexposure:CNSeffects,irritationtoeyes,skinandrespiratorytract.

ProductName:HiSol10(SHI7000)Petroleumdistillate(Morton)

HazardousIngredients:Xylene**,Naphthac8‐c10,ethylbenzene*.

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritationtotheeyes,skin,respiratorytract,CNS‐dizziness,liver/kidneydamage,avoidinhalation.

ProductName:16771Thinner(Morton)

HazardousIngredients:MEK,isobutylacetate,propyleneglycolmethylacetate,ethylhexylacetate

DecompositionProducts:Notprovided

HealthEffects/Symptoms/Overexposure:CNS‐dizziness,headache,etc.Irritationtoeyes,skin,respiratorytract,nausea,vomiting.

ProductName:Hisol10(AHC)Solvent

HazardousIngredients:Naphtha,petroleum

DecompositionProducts:HydroCarbons

HealthEffects/Symptoms/Overexposure:irritationtoeyes,lung,GItract–airpurifiedrespirator

ProductName:T16776thinner(Morton)

HazardousIngredients:Isobutylacetate,propyleneglycoletheracetate,dimethyladapate.

T16776(continued)

HealthEffects/Symptoms/Overexposure:irritationtoeyes,skin,respiratorytract,CNSeffects‐dizziness,headachenausea,diarrhea.

ProductName:Pebra5(S‐58)PebraInc.

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HazardousIngredients:Tetrahydrofuran,Perchloroethylene(containstrichloroethylene)andcadmium.

HealthEffect/Symptoms/Overexposure:irritationtoeye,skin,respiratorytract,CNSeffectsetc.

ProductName:Baytec505c505

HazardousIngredients:Dimethyltoluenediamine(DETA),Benzenediamine,2,4diethyltoluenediamine,2,6ditto.

DecompositionProducts:aromaticaminesvapors,CO,CO2.

HealthEffects/Symptoms/Overexposure:methoglobenemia,cyanosis,irritatingtoeyes,skin,respiratorytract,tumorsonliver,breast,thyroid,mutagenicity.

ProductName:SwishStripnon‐amoronatedstripper

HazardousIngredients:Sodiumcarbonate,sodiummetasilicate,monoethanolamine,sodiumhydroxide,dipropyleneglycolmethylether,nonylphenolethoxylate.

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritatingtoeyes,skinandrespiratorytract.

ProductName:Indicator2/and99

HazardousIngredients:isopropanol***,

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:positivemutagenicityirritatingtoupperrespiratorytract.

ProductName:DiacetoneAlcohol‐2BUnionCarbide

HazardousIngredients:(ketone)4‐hydroxy‐4‐methyl‐1‐2‐pentanone

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:kidneydamage

ProductName:XenitCitrus

HazardousIngredients:dimethylcarbinol,Citrusdistillates

DecompositionProducts:notprovided

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HealthEffects/Symptoms/Overexposure:eyeandupperrespiratoryirritation,drynessinmouth,numbnessontongue.

ProductName:SolventBlend

HazardousIngredients:MEK**,N‐hexane,toluene(benzene*)

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritationofeyesandupperrespiratorytract,CNSeffects,neurotoxic.

ProductName:Indo401(degreaser)

ProductName:ButyrateCutSV4280

HazardousIngredients:CelluloseAcetateButanate,ButylAcetate,MethylEthylKetone

DecompositionProducts:C0and/orC02

HealthEffects/Symptoms/Overexposure:Noseandthroatirritation;harmfulifinhaled;mayaffectbrainornervoussystemcausingdizziness,headacheornausea.Reportshaveassociatedrepeatedandprolongedoverexposuretosolventswithpermanentbrainandnervoussystemdamage.Ingestionmaycausenausea,vomiting,headache,dizzinessandstuporfromirritationofdigestivetract.Directcontactwithvaporsmaycausetearing,rednessandswelling.

ProductName:ClearLacquerSV4369

HazardousIngredients:2‐Butoxyethanol,2‐Pentanone,4‐Methyl‐Toluene,1Propanol,2Methyl

DecompositionProducts:C0andC02

HealthEffects/Symptoms/Overexposure:Irritant:Inhalation:allergicrespiratoryreaction.Overexposuremaycauseliverandkidneydamage,noseandthroatirritation,neurologicalincludingdizziness,headache,nausea;Ingestion:maycausetoxicencephalopathy,liver/kidneydamage,canenterlungsduringswallowingorvomiting,cancauselunginflammationanddamage.Prolongedexposuretovaporsandmistsmaycauseblooddisorders,permanentbrainandnervoussystemdamage.

ProductName:ElastomericClearBase,SV4214

HazardousIngredients:ButylAcetate,Complexorganiccompound

DecompositionProducts:C0and/orC02

HealthEffects/Symptoms/Overexposure:Irritation:Inhalation‐noseandthroatirritation,neurologicalsymptomsincludingdizziness,headache,nausea.Ingestion–maycauseliverand

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kidneydamage.Reportshaveassociatedrepeatedandprolongedoverexposurewithpermanentbrainandnervoussystemdamage.

ProductName:BakingEnamelThinnerSV1986

HazardousIngredients:AromatichydrocarbonBlend

DecompositionProducts:C0andC02

HealthEffects/Symptoms/Overexposure:Irritant:Inhalation:mayaffectbrainornervoussystemcausingdizziness,headacheornausea,inpoorventilationmayproduceunconsciousnessandasphyxiation.Maycausetearing,rednessandswellingofeyes.Ingestion:nausea,vomiting,headache,dizzinessandstuporfromirritationofdigestivetract.Longtermuse,brainandnervoussystemdamage.

ProductName:UrethaneGradeThinnerSV4305

HazardousIngredients:2‐Propanone,MethylEthylKetone,AromatichydrocarbonBlend1,AromatichydrocarbonBlend2

DecompositionProducts:C0andC02

HealthEffects/Symptoms/Overexposure:Irritant:Inhalation:mayaffectbrainandnervoussystem causing dizziness, headache, or nausea. In poor ventilation may produceunconsciousness and asphyxiation. Eye contact: burning, tearing, redness and swelling.Ingestion:nausea,vomiting,headache,dizzinessandstuporfromirritationofthedigestivetract.

ProductName:SV4239RedSpotPaintandVarnishCo.

HazardousIngredients:Propanol,Methyl

DecompositionProducts:C0andC02

HealthEffects/Symptoms/Overexposure:Irritant:Inhalation:mayaffectbrainandnervoussystemcausingdizziness,headache,ornausea.Eyecontact:burning,tearing,rednessandswelling.Ingestion:noevidenceofadverseaffects

ProductName:MedUrethaneGradeThinnerSV4167

HazardousIngredients:2‐Propanone,ButylAcetate,Oxo‐DecylAcetate

DecompositionProducts:C0and/orC02

HealthEffects/Symptoms/Overexposure:Inhalation:mayaffectbrainandnervoussystemcausingdizziness,headache,ornausea.Inpoorventilationmayproduceunconsciousnessandasphyxiation.Eyecontact:burning,tearing,rednessandswelling.Ingestion:nausea,vomiting,headache,dizzinessandstuporfromirritationofthedigestivetract.

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ProductName:Methyln‐amylketoneSV455

HazardousIngredients:Methyln‐amylketone

DecompositionProducts:C0and/orC02

HealthEffects/Symptoms/Overexposure:Inhalation:maycausedrowsiness,eyeirritation

ProductName:PetroleumSolventSV1986

HazardousIngredients:SolventNaphtha

DecompositionProducts:C0and/orC02

HealthEffects/Symptoms/Overexposure:Moderatelyirritating:lowtomoderatetoxicity

ProductName:SolventBlendSV4167

HazardousIngredients:NButylAcetate,1Methyl1‐2Pyrrolidone,Acetone,DimethylGluterate,DimethylAdipate,DimethylSuccinate

DecompositionProducts:C0and/orC02

HealthEffects/Symptoms/Overexposure:Irritant:highvaporconcentrationsorcontactwitheyescausesirritation,tearingandburning.Long‐termexposuretohighvapormayproducevisionimpairment.Inhalationcancausedizziness,headache,nausea,andvomiting.Poisonousifswallowedcausingblindness,narcosis,headache,nauseaandvomitingleadingtosevereillnessandperhapsdeath.

ProductName:T580Thinner

HazardousIngredients:Xylene

DecompositionProducts:C0and/orC02

HealthEffects/Symptoms/Overexposure:Irritant:Inhalation:nasalandrespiratoryirritation,dizziness,weakness,fatigue,nausea,headache,possibleunconsciousness/asphyxiation.Ingestion:nausea,vomitinganddiarrhea,aspirationintolungscancausechemicalpneumonitiswhichcanbefatal;Eyecontactcancauseirritation,seekmedicalattentionimmediately.SpecialPrecautions:Overexposurehasbeenfoundtocauseliverabnormalities,kidneydamage,eyedamage,anemiainanimalsandissuggestedascauseofcardiacabnormalityinhumans.StateofCalifornialistsproductunderProposition65aspossiblecarcinogen.

ProductName:T65717Thinner

HazardousIngredients:Isobutylacetate

DecompositionProducts:notprovided

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HealthEffects/Symptoms/Overexposure:missingdata.ThischemicallistedunderCaliforniaProposition65aspossiblecarcinogen.

ProductName:T16646Thinner

HazardousIngredients:IsobutylAcetate,MethylEthylKetone

DecompositionProducts:C0and/orC02

HealthEffects/Symptoms/Overexposure:Airsupplyrespiratorrequired.Gogglesandgloves.ChemicallistedunderCaliforniaProposition65aspossiblecarcinogen.

ProductName:SV4261Thinner

HazardousIngredients:Ethyl3‐Ethoxypropinate

DecompositionProducts:C0and/orC02

HealthEffects/Symptoms/Overexposure:noevidenceofadverseeffects.Adevelopmentaltoxicitystudyfoundslightfetotoxicityinlittersofratsatconcentrationsof1000ppm.Reportshaveassociatedprolongedoverexposuretopermanentbrain,andnervoussystemdamage.

ProductName:UrethaneGradeRetardingThinnerSV4430

HazardousIngredients:AromaticHydrocarbonBlend,DimethylGlutarate,DimethylAdipate

Decomposition:C02and/orC0

HealthEffects/Symptoms/Overexposure:Ifpoorventilation,mayproduceunconsciousnessandasphyxiation.Mayaffectthebrainornervoussystemcausingdizziness,headacheornausea;Ingestion:Maycausenausea,vomiting,headache,dizzinessandstuporfromirritationofdigestivetract.Reportshaveassociatedprolongedoverexposuretopermanentbrain,andnervoussystemdamage.

ProductName:UrethaneGradeThinnerSV4563

HazardousIngredients:AceticAcid

Decomposition:C0and/orC02

HealthEffects/Symptoms/Overexposure:Noevidenceofadverseexposureaffects.Notcredible.Seebelow.

ProductName:UrethaneGradeThinnerSV4562

HazardousIngredients:AceticAcid

Decomposition:C0and/orC02

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HealthEffects/Symptoms/Overexposure:maycausenoseandthroatirritation,harmfulifinhaled.Mayaffectthebrainornervoussystemcausingdizziness,headacheornausea.

ProductName:T16720Thinner

HazardousIngredients:2‐EthylenexylAcetate,1‐Methoxy‐2‐PropanolAcetate,Xylene

Decomposition:C0and/orC02

HealthEffects/Symptoms/Overexposure:Irritant:Inhalation:dizziness,weakness,fatigue,nausea,headache,possibleunconsciousnessandasphyxiation.Ingestion:nausea,vomitingdiarrhea,aspirationmaycausechemicalpneumonitiswhichcanbefatal.ThischemicallistedunderCaliforniaProposition65aspossiblecarcinogen.

ProductName:T740Thinner

HazardousIngredients:1‐Methoxy‐2‐propanolacetate

Decomposition:C0and/orC02

HealthEffects/Symptoms/Overexposure:Cancauseirritationoftheeye,respiratory,anddigestivesystems.Reportshaveassociatedrepeatedandprolongedoccupationaloverexposurewithpermanentbrainandnervoussystemdamage.ThischemicallistedunderCaliforniaProposition65aspossiblecarcinogen.

ProductName:SH16200Solvent

HazardousIngredients:Xylene

Decomposition:C0and/orC02

HealthEffects/Symptoms/Overexposure:Cancauseirritationoftheeye,respiratory,anddigestivesystems.Reportshaveassociatedrepeatedandprolongedoccupationaloverexposurewithpermanentbrainandnervoussystemdamage.ThischemicallistedunderCaliforniaProposition65aspossiblecarcinogen.

ProductName:T16703Thinner

HazardousIngredients:IsobutylAcetate,1‐Methoxy‐2‐PropanolAcetate

Decomposition:C0and/orC02

HealthEffects/Symptoms/Overexposure:Cancauseirritationoftheeye,respiratory,anddigestivesystems.Reportshaveassociatedrepeatedandprolongedoccupationaloverexposurewithpermanentbrainandnervoussystemdamage.ThischemicallistedunderCaliforniaProposition65aspossiblecarcinogen.

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PAINTKITCHEN/PAINTLINE

ProductName:Almatex

HazardousIngredients:1,6hexamethylene,diisocyanate,baseaductaliphaticpolyisocyanate,xylene,n‐butylacetate

DecompositionProducts:CO,CO2,NOx,HCN,HDI,xylene,butylacetate

HealthEffects/Symptoms/Overexposure:irritatingtoeyesandupperrespiratorytract,lungshortnessofbreathlikelyduetoxylene,butylacetate.

ProductName:Histol10

HazardousIngredients:naphtha,petroleumdistillates

DecompositionProducts:CO,CO2,HCs

HealthEffects/Symptoms/Overexposures:irritationtoeyes,upperrespiratorytract,skin,GI.Localexhaustrequired.

ProductName:SolventBasedPrimerA‐1104‐B

HazardousIngredients:dutylalcohol,toluene*,MEK**/***,methylmethacrylate,acrylicco‐polymer,ethylacetate,ethanol,isopropylalcohol,formaldehyde.

HealthEffects/Symptoms/Overexposure:irritationofeyes,upperrespiratorytract,skin;brainandCNSdamage,fetaltoxin.

ProductName:Ashland,Xylene**aromaticHC

HealthEffects:irritationofeyes,andupperrespiratorytract,skin,GItract;CNSeffects,pneumonitis.Fetaltoxic.

ProductName:Bayflex210ComponentA,AromaticIsocyanatepolymer

HazardousIngredients:Isocyanate

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritatingtoeyesandupperrespiratorytract,skin,runnynose

ProductName:BaseCoatBlack

HazardousIngredients:butylacetate,butanol,xylene**,2‐butoxyethylacetate,dipentene

DecompositionProducts:notprovided

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HealthEffects/Symptoms/Overexposure:irritatingtoeyesandupperrespiratorytract.

ProductName:ClearCoat

HazardousIngredients:butylacetate,Methoxypropylacetat,xylene**.

ProductName:2K–Pur‐Primer

HazardousIngredients:N‐methylpyrrolidone,methylisobutylacetate,aromaticHCmixtureC9‐C12.HealthEffects:notprovided

ProductName:BaseCoatWhiteSameasaboveinBlack

ProductName:Hardener2KPrimer

HazardousIngredients:butylacetate,methoxypropylacetate,aromaticHCmixtureC9‐C12,HDI,polyisocyanate.

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritationeyes,upperrespiratorytract,skin,sensitization

ProductName:Polyester

HazardousIngredients:butylacetate,methloxypropylacetate,xylene.

DecompositionProducts:styrene*andorganicperoxides

HealthEffects/Symptoms/Overexposure:irritationandburns

ProductName:2KPUR‐GrayPrimer

HazardousIngredients:Butylacetatemethyloxypropylacetate,xylene**.

HealthEffects:irritationeyes,upperrespiratorytract.

ProductName:BaseCoatBeechwoodMetallic

HazardousIngredients:butylacetate,xylene**,butanol,dipentent,butylglycolate

HealthEffects:irritationeyes,upperrespiratorytract,skin

ProductName:00111287Reducer

HazardousIngredients:butylacetate

ProductName:ClearCoatHardener

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HazardousIngredients:HDI,xylene**,n‐butylacetate

DecompositionProducts:CO,CO2,NOx,HCN,HDI.

HealthEffects:irritationtoeyes,upperrespiratorytract,skin,sensitization

ProductName:BoothCoat:

HazardousIngredients:Whitepetrolatum,dye

DecompositionProducts:NO,CO,CO2

HealthEffects/Symptoms/Overexposure:irritationofeyes,skin,nose,throatandupperrespiratorytract.CNSeffects‐depression

ProductName:89238HCURwhiteautocoating

HazardousIngredients:titaniumdioxide*,melamineresin,ethylbenzene*,xylene**,formaldehyde,MEK**,methylalcohol,n‐Aylacetate

HealthEffects/Symptoms/Overexposure:CNSeffects,irritatingtoeyes,skinupperrespiratorytract.

ProductName:Tergitol(DowChemical)NP‐Surfactant(isospillcleanup)

HazardousIngredients:4‐nonylphenolbranchedethoxylated,poly(ethyleneoxide),dinonylphnylpolyoxyethylene**

HealthEffects/Symptoms/Overexposure:fetaltoxin

ProductName:ButylCellosolve

HazardousIngredients:2‐butoxyethanal

DecompositionProducts:notreported

HealthEffects/Symptoms/Overexposure:KidneyandLiverdamage

ProductName:DiacetoneAlcohol

HazardousIngredients:notprovided

DecompositionProducts:Acetone,Mesityloxide,ketones

HealthEffects/Symptoms/Overexposure:irritationoftheskin,eyes,noseandthroat.Kidneydamage,redbloodcelldamage(hemolysis)anemia.

ProductName:DBEDibasicester

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HazardousIngredients:dimethylglutarate,dimethyladapate,dimethylsuccinate,methanol,hydrogencyanide

DecompositionProducts:methanolreleased

HealthEffects/symptoms/Overexposure:notprovided

ProductName:EktasolveEBAcetate

HazardousIngredients:2‐Butoxyethylacetate

DecompositionProducts:peroxides,CO,CO2

HealthEffects/Symptoms/Overexposure:bloodcelldamage,kidneydamage

ProductName:SolventBlend

HazardousIngredients:MEK**,acetone**,toluene*

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritationtotheeyes,burning,tearing

ProductName:PMAcetate

HazardousIngredients:Propyleneglycol,Methyletheracetate

DecompositionProducts:CO,CO2,NOx,smoke.

HealthEffects/Symptoms/Overexposure:brainandCNSdamage

ProductName:Isopropylalcohol99anhyol

HazardousIngredients:notprovided

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritationoftheeyes,skin,lunganddigestivetract.

ProductName:N‐methyl‐2‐pyrrolidone**(Chem‐TrendInc)

HazardousIngredients:notprovided

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritationofskin,eyes,lungsandadversereproductiveeffects.

ProductName:MoldCleaner405/201BusedinRIM

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HazardousIngredients:N‐methyl‐2‐pyrrolidone**,ethyleneglycol,monobutylether,solventblend

DecompositionProducts:notprovided

HealthEffects/symptoms/Overexposure:irritationofeyes,upperrespiratorytract,skin,chemicalpneumonitis.Adversereproductiveeffectsalsonotedanimalsandhumans.

ProductName:Hexane(liquid)UN#1808.

HazardousIngredients:naphtha,cyclohexane,n‐hexane

HealthEffects:/Symptoms/Overexposure:peripheralnervoussystem,depression,avoidbreathingvapors.,irritatingtoeyes,respiratorytract,headache,dizziness,adverseimpactonCNSpotentiatedwithexposuretoMEK,MIBICandtesticulardamage.

ProductName:Arcosolv(PMacetate)

HazardousIngredients:1‐methoxy‐2‐propanolacetate,2‐methoxy‐1‐propanolacetate.

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritationofskin,eyes,lungs

SLUDGEROOMCHEMICALS

ProductName:Vanchem1208

HazardousIngredients:Formaldehyde*

DecompositionProducts:Aldehydes

HealthEffects/Symptoms/Overexposure:irritationeyes,noseandthroat.Carcinogenicrisk.

ProductName:Vanchem1824

HazardousIngredients:Aluminumchloride***

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritationofeyes,nosethroatandskin.Positivemutagenicdata.

ProductName:Bromocide

HazardousIngredients:1‐bromo‐3‐chloro‐5,5dimethyldantoin

DecompositionProducts:notprovided

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HealthEffects/Symptoms/Overexposure:irritationtoeyes,noseandthroat,skin

ProductName:disinfectantflammable#9833

HazardousIngredients:ethanol,triethylene,propyleneglycolmonoethylether,liquidpetrogas

HealthEffects/Symptoms/Overexposure:irritatingtoeyesandupperrespiratorytract,avoidinhalation.

ProductName:TEXOLP135(detactifier)

HazardousIngredients:Formaldehyde*

HealthEffects/Symptoms/Overexposure:irritationtoeyes,skin,respiratorytract.Cancer

ProductName:TitratingSolution89

HazardousIngredients:Sodiumhydroxide(NaOH)

HealthEffects/Symptoms/Overexposure:notprovided

ProductName:TitratingSolution61

HazardousIngredients:HCL

ProductName:EndBacII

HazardousIngredients:isobutene,propane

ProductName:Dustbane

HazardousIngredients:crystallinesilica

ProductName:ParcoBiocide2426

HazardousIngredients:1polycoxyethylene‐(dimethyl‐1‐minfo)ethylene(dimethyli‐minio)ethylenedichloride.

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritantProductName:ParcoPurge

Ingredients:Mayhaveheavywastemetals

ProductName:PenetratingOil.

HazardousIngredients:1,1,1trichloroethane,Petroleumdistillates,petroleumlubricants

DecompositionProducts:notprovided

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HealthEffects/Symptoms/Overexposure:respiratoryirritation,unconsciousness,dizziness,headache,CNSdamage,liver,lungsandkidneydamage,ventricularfibrillation.

ProductName:LubricatingGrease(ShellgreaseEP2)

DecompositionProducts:CO,CO2,HCL,SO2,SO3,NOx,POx,smoke

HealthEffects/Symptoms/Overexposure:upperrespiratoryirritation,lungfibrosis

MOLDRELEASES,CLEANERSANDPURGINGAGENTS

ProductName:StonerRocketReleaseE‐702

HazardousIngredients:halogenatedHC,etherblend,diichlorofluoroethanedimethylether

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:notprovided(150to300applicationspershift)

ProductName:PaintableMoldRelease

HazardousIngredients:TCE*,perchloroethylene*,methyldodeoyl,methyl(2‐Phenoxypropyl‐siloxane.

DecompositionProducts:HCL,silicondioxide,formaldehyde*‐,Phosgene+Chlorine.

HealthEffects/Symptoms/Overexposure:Irritationofeyes,nose,throat.CNSeffects

ProductName:SoapSolutionR‐602moldrelease(RIM)

HazardousIngredients:N‐propylalcohol

HealthEffects/Symptoms/Overexposure:irritant,respiratoryprotectioncartridgerespl

ProductName:MoldCleaner201B(RIM)

HazardousIngredients:N‐Methyl‐2‐Pyrrolidone**,ethyleneglycol,monobutylether,solventblend

DecompositionProducts:notprovided

HealthEffects:irritant,fetaltoxin

ProductName:RapidPurge

HazardousIngredients:inertminerals,inorganicsalts,organicsalts,TPO(thermoplasticPolyolefins)

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DecompositionProducts:Co2,CO,N,ammonia

HealthEffects:notprovided

ProductName:VentraPurgeSolvent(AshlandDist.Co.)

HazardousIngredients:Toluene(benzene*),MEK**,MBK,n‐hexane,EBKinMEK

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritationtotheeyes,stinging,tearing,swelling,respiratorytract—inhalationandskinabsorption,tolueneeffectsonCNS,cardiacarrest,kidneyandliverdamage.Californiastatelegislationrequiringreportanycarcinogenicandreproductivetoxins.

RCTW‐2006moldrelease(sameasmoldreleaseNo.602

FILLERS/PUTTIES/BUFFINGCOMPOUNDS

ProductName:PromatPorefiller3311PURfiller

HazardousIngredients:notprovided

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:notprovided

ProductName:Finesse051144‐76504*

HazardousIngredients:AluminumOxide,naphtha,mineraloil,glycerin,morpholine,carbonblack*

DecompositionProducts:phenolformaldehyde

HealthEffects/Symptoms/Overexposure:irritationtoeyes,andupperrespiratorytract.CNSeffects,headaches,dizziness.Warningavoidbreathingvapor.

ProductName:GreyPutty‐3MFlexiblePastePutty5903

HazardousIngredients:HDI,isopropylalcohol,talc,polyurethane,Silica*,toluene(benzene*)

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposures:irritatingtoeyes,skin,respiratorytract,sensitizationfromHDI(isocyanate)

ProductName:BayflexBlackPasteN

HazardousIngredients:carbonblack*,polyether

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232

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritationofeyesandupperrespiratorytract,cancer

ProductName:UnionCarbide‐cyclohexanone(ketones)

HazardousIngredients:notprovided

CATYLISTS/HARDENERS(PAINTS)

ProductName:86191‐CC2KB(catalyst(silver)

HazardousIngredients:MEK**/****,ethylbenzene*,toluene*,MAKIsobutylacetate,n‐amylacetate,aluminum,naphtha,mineralspirits,xylene**,Propyleneglycolmethyletheracetate.

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:edc,carcinogens,fetaltoxics,liver/kidneydamage

ProductName:DABCOT‐12Catalystforpolyurethanes

HazardousProducts:dibutyltindilaurate

DecompositionProducts:CO,CO2,tinoxides,organicacidvapor,

HealthEffects/Symptoms/Overexposure:irritatingtoeyes,skin,respiratorytract,liver,kidneydamage,shortnessofbreath,CNSeffects,decreasedfertility.

ProductName:AlmaxClearCoatHardener

HazardousIngredients:N‐butylacetate,Methoxypropylacetate,xylene**,isopolymer.

DecompositionProducts:CO,CO2,NOx

HealthEffects/Symptoms/Overexposure:irritatedeyes,upperrespiratorytract.

ProductName:AlmatexHardenerforprimer.

HazardousIngredients:n‐butyl,xylene,iso‐polymer

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:Brain,CNSdamage,irritationofeyes,upperrespiratorytract.

ProductName:10002KistReducedClearCoat/2kist/2KC

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HazardousIngredients:propylene,glycol,methyletheracetate,MKMAK,diisobutylketone,ethylbenzene*,2‐ethylhexylacetate.

DecompositionProducts:notprovidedrecorded

HealthEffects/Symptoms/Overexposure:irritationeye,skin,respiratorytract.Cancer

ProductName:R‐7902KClearcoatforHCUR560B/Ss

HazardousIngredients:n‐amylacetate,MEK**,propyleneglycoletheracetate,xylene**,kBenzotriazole,methylamylketone*.

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:CNSeffects,irritationofeyes,skinGIandrespiratorytract.

ProductName:P‐3ClearMasking2484*

HazardousIngredients:Glycerin,triethanolamine,mayproducenitrosaminesifmixedwithNitrogen

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposures:irritatingtoeyes,skin,respiratorytract.Gloveprotection

ProductName:2004‐C2KCCatalystfor2kc(HDI)

HazardousIngredients:P(HMDI)hardener,isobutylacetate,butylacetate,naphtha,1,2,4trimethylbenzene,ethylbenzene*,xylene**.Hexamethylenediisocyanates(HMDI)

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:irritationtoeyes,skin,upperrespiratorytract,sensitization,CNSeffects,Kidney,bloodformingsystemreproductive,cancer.

ProductName:Bayflex110‐50IHRcomponentB(RIM)isocyanate.

HazardousIngredients:Poly(oxyalkylene)polyolsystem,diethyltoluenediamineDETA,organotin,aliphaticamine.

HealthEffects/Symptoms/overexposure:irritatingtoeye,respiratory,skin,sensitization,methemoglobinemia(turnblue)interferewithoxygeninblood.

ProductName:Total

HazardousIngredients:sodiummetasilicate,n‐alkyldimethylarylammoniumchlorides,nonylphenoxypolyethoxyethanol.

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HealthEffects/Symptoms/Overexposure:irritationoftheeyes,skinrespiratorytract—rubberglovesrequired

ProductName:Speedstripper(corrosive)

HazardousIngredients:ethyleneglycol,monoethylether,sodiumxylene,monoethanolamine,sodiummetasilicate.

HealthEffects:notprovided

ProductName:OverandUnder

HazardousIngredients:dipropyleneglycolmethylether,tributoxyethylphosphate,diethyleneglycol,acrylicpolymer.

HealthEffects:notprovided

ProductName:Encounter969402

HazardousIngredients:Octylphenolethoxylate.

HealthEffects:notprovided

ProductName:MC‐15‐6000

HazardousIngredients:MEK**,Toluene(benzene*),isopropylalcohol,n‐propylacetate,ethylacetate,acrylicpolymersolids

HealthEffects/Symptoms/Overexposure:irritationtoeyes,skinGI,Lung,CNSeffects,chroniclungdisease(COPD.

ProductName:R‐185‐1(Flash)**

HazardousIngredients:toluene(benzene)*,titanium*dioxide,isopropylalcohol,xylene**,Methylpyrrolidone,n‐isobutylalcohol,ethylbenzene*,carbonblack*.

DecompositionProducts:notprovided

HealthEffects/Symptoms/Overexposure:CNSeffects,irritationtoeyes,GIandrespiratorytract.Kidney/liver/lungdamage,adversereproductiveeffects—testes,birthdefects

ProductName:MortonT‐16806

HazardousIngredients:Isobutylacetate,MEK**,dibasticester

DecompositionProducts:notprovided

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HealthEffects/Symptoms/Overexposure:irritationtoeyes,upperrespiratorytract,GI.CNSeffectsandcanpotentiatetheperipheralnervoussystemviaMethylN‐ketoneN‐hexane.liver/kidneydamage

ProductName:Dibasicester

HazardousIngredients:diethylgluterate,dimethyladipate,dimethylsuccinate.

HealthEffects/Symptoms/Overexposure:irritationtoeyes,skinrespiratorytract,GItract

ProductName:MortonT16776solventblend

HazardousIngredients:Isobutylacetate,glycoletherPMacetate

HealthEffects/Symptoms/Overexposure:notprovided

ProductName:MortonT16796thinner

HazardousIngredients:propyleneglycol,methyletheracetate,diisobutylketone,MEK**,2‐ethylhexylacetate,dimethyladipate.

HealthEffects/Symptoms/Overexposure:irritationofeyes,skin,respiratorytract,kidneyliverdamageandCNSeffects.

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APPENDIXD

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APPENDIXE

WORKEREXPOSURESTOSUBSTANCESPREVALENTINTHEPLASTICSINDUSTRY

TABLEOFRESULTSOFMONITORINGSTUDIES

CHEMICALUSEDINPLASTICS

AIRCONCENTRATION URINECONCENTRATION BLOODCONCENTRATION REFERENT/CONTROLPOPULATION

Styrene:Meyer‐BishandProtois,1986

45%ofplantsinstudyhadlevelgreaterthan50ppm

Lemasters,etal.,1985

AutoPartsProductionMixers:11‐26ppmPressMold:20‐30ppm

CrandleandHartle,1985

Hull:35‐122ppmDeck:37.2‐124ppmParts:29.7‐97ppm

Brugnone,etal.,1993

204ug/l

1590ug/l(endshift)94ug/l(16hrsafter)

0.22ug/l(blood)‘normal’0.006ug/l(air)

Galassi,etal.,1993

227mg/m3(hand)134mg/m3(spray)85mg/m3(automated)

682mg/g404mg/g243mg/g

186mg/g(nonexposed)50ppm=584mg/g(BEEL)900mg/g=(BLV)

Crandall,1985 20‐200ppm

Apostoli,etal.,1983

361‐488mg/m3

348mg/l1375mg/l183mg/l526mg/l

573ug/l2575ug/l

TLV(TWA)215mg/m3=495mg/l(Umu)260mg/l(Uphu)811ug/l(blood)

Styrene:Stengel,etal.,1990

0‐100ppm

15‐3740mg/g(C)

BloodParametersAffected:MCHC(‐)

54.8mg/g(C)

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CHEMICALUSEDINPLASTICS

AIRCONCENTRATION URINECONCENTRATION BLOODCONCENTRATION REFERENT/CONTROLPOPULATION

1‐49ppm50‐99ppm>100ppm

376.7mg/g896.1mg/g911.2mg/g

MCV(+)Neutraphils(‐)Monocytes(+)

AnwarandShamy,1995

328.44mg/g(C)

BloodParametersAffected:ChromosomeAberration(+)

50.09mg/g(C)

Jensen,etal.,1990

265mg/m3(1950‐88)714mg/m3(1955‐70)172mg/m3(1981‐88)Co‐contaminants:Dichloromethane51mg/m3Xylene49mg/m3Toluene113mg/m3Perchloroethylene7mg/m3Trichloroethylene5mg/m3

Styrene:Kolstad,etal.,2005

<1970=738.3mg/m31970‐74=401.3mg/m31975‐79=306.4mg/m31980‐89=174.9mg/m31990‐96=84.5mg/m3

PlasticProcessing:165.9mg/m3HandLamination:

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CHEMICALUSEDINPLASTICS

AIRCONCENTRATION URINECONCENTRATION BLOODCONCENTRATION REFERENT/CONTROLPOPULATION

427mg/m3

Hartle,1978

TruckParts:9‐60ppm

Schumacher,etal.,1981

TruckParts:9‐60ppm

Dement,1973

Tub/Shower40‐100ppm

Crandall,1981

Tub/Shower40‐100ppm

Acrylonitrile:Houthuijs,etal.,1982

0.13ppm

39ug/gWorkdayconcentrationsfornonsmoker:Range10‐152ug/gAN(U)Mean42.9ug/gAN(U)Dayoffconcentrations:Mean12.2ug/g

Nonsmoker2.0ug/g

Acrylonitrile:Sakurai,etal.,1978

0.1 ppmAN(A)4.2ppmAN(A)

3.9ug/lAN(U)360ug/lAN(U)

NoAN(U)detectedinurineofcontrols

Scelo,etal.,2004

0.9‐4.6ppmpositiveassociationwithlungcancer

Phthalates:VainiotaloandPfaffli,1990

DEHP1.1mg/m3

Environmental:5‐132ng/m3

Nielsen,etal.,1985 DEHP: 25umol/L(PAmetabolite) 17umol/L(PAmetabolite)

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CHEMICALUSEDINPLASTICS

AIRCONCENTRATION URINECONCENTRATION BLOODCONCENTRATION REFERENT/CONTROLPOPULATION

2mg/m3calendaring0.2‐0.4mg/m3mach.atten0.3mg/m3repair0.2mg/m3mixer

23umol/L

Milkov,etal.,1973Gilloli,etal.,1975Theiss,etal.,1978

PhthalateAcidEster:66mg/m3

Liss,etal.,1985

PA:4‐203ug/m3

6.8‐9.9nmol/mlpostshift4.9‐5.6nmol/mlpreshift

5.9nmol/mlpostshift6.7nmol/mlpreshift

Dirven,etal.,1993

Boot:Mixing261ug/m3

Boot:MEHP:32.7‐48.9nmol/ml

Extruder120ug/m3Cable:Mixing180ug/m3Extruder239ug/m3

Cable:MEHP:16.2‐34.5nmol/ml

Thesearebeforeandaftershiftvaluesrepresentinga2.3and4.5foldincrease.

Gaudin,etal.,2008

MEHP:25.2ug/gpreshift55.9ug/gpostshift

MEHP:13.2ug/gpreshift13.5ug/gpostshift

Koch,etal.,2003bPreuss,etal.,2005

Referentpopulations:9.8‐10.3ug/g

Hines,etal.,2009 PhthalatesManufacture:DMP‐1210ug/g(+)ssDEP‐716ug/g(+)ssDBP–402ug/g(+)ssDiBP‐3.59ug/g(+)

HAINES(2001‐2002)DMP‐1.0ug/gDEP–181ug/gDBP‐16ug/gDiBP‐2.3ug/g

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CHEMICALUSEDINPLASTICS

AIRCONCENTRATION URINECONCENTRATION BLOODCONCENTRATION REFERENT/CONTROLPOPULATION

BzBP– 19.8ug/g(+)DnOP‐6/35ug/g(+)DEHP‐25.4ug/g(MEHP)PVCFilm:DMP‐1.29ug/gDEP‐60.2ug/gDBP‐13.1ug/gDiBP‐2.74ug/gBzBp‐14.9ug/g

BzBP– 12.0ug/gDnOP–2.24ug/gDEHP–3.96ug/g(MEHP)17.2ug/g(MEHHP)11.4ug/g(MEOHP)

DnOP‐2.51ug/gDEHP‐151ug/g(MEHHP)84ug/g(MEOHP)

Phthalates:Hines,etal.,2009

AutoFilterManufacture:DMP‐1.43ug/g(max.)DEP‐102ug/gDBP‐24ug/gDiBP‐2.80ug/gBzBP‐17.0ug/gDnOP‐4.5ug/gDEHP‐124ug/g(MECPP)10.2ug/g(MEHP)27.ug/g(MEOHP)PVCCompounding:DEP‐164ug/gDBP‐30.9ug/g

DiBP‐6.63ug/gBzBP‐17.9ug/gDnOP‐7.72uggDEHP‐102ug/g(MEHHP)12.2ug/g(MEHP)60.8ug/g(MEOHP)

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CHEMICALUSEDINPLASTICS

AIRCONCENTRATION URINECONCENTRATION BLOODCONCENTRATION REFERENT/CONTROLPOPULATION

RubberHose:DMP‐1.94ug/gDEP‐68ug/gDBP‐168ug/gDiBP7.52ug/gBzBP‐10ug/g

DnOP‐3.48ug/gDEHP‐5.4ug/g25.2ug/g15.5ug/g

Phthalates:Hines,etal.,2009

RubberBootDEP‐183ug/gDBP36.4ug/gDiBP‐9.26ug/gBzBP‐40.4ug/gDnOP‐3.92ug/gDEHP‐5.37ug/g(MEHP)59.6ug/g(MEHHP)36.9ug/g(MEOHP)69.3ug/g(MECPP)RubberGasket:DMP‐1.12ug/gDEP‐143ug/g

DBP‐418ug/gDiBP7‐.42ug/gBzBP‐70.1ug/gDnOP‐6.62ug/gHEHP‐12.1ug/g(MEHP)54.6ug/g(MEHHP)33.4ug/g(MEOHP)69.3ug/g(MECPP)

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CHEMICALUSEDINPLASTICS

AIRCONCENTRATION URINECONCENTRATION BLOODCONCENTRATION REFERENT/CONTROLPOPULATION

NailSalon:DMP‐6.19ug/gDEP‐199ug/gDBP‐34.2ug/g

DiBP‐6.26ug/gBzBP‐4.59ug/gDnOP‐1.33ug/gNailSalon(contd)

Phthalates:Hines,etal.,2009

DEHP‐19ug/g(MEHP)34.4ug/g(MEHHP)17.9ug/g(MEOHP)

Bisphenol‐AHanoaka,etal.,2002

EpoxyResinWorkers:1.06umol/mol(C)

Controls:0.52umol/mol(C)

Calafat,etal.,2005 1.12‐.63ng/ml(urine)

KimY‐H,etal.,2003 2.76‐2.82ng/ml(urine)1.00‐2.34ng/ml(urine)(BPAglucuronide)0.49‐1.20ng/ml(urine)(BPAsulfate)

BrominatedFlameRetardants

ThuressonandJakobsson,etal.,2005

RubberWorkers:Polybrominateddiphenylether(PBDE)270ng/gl.w(max.)35ng/gl.w.(median)

Referent:2.49ng/gl.w.(median)

Thomsen,etal.,2001 ElectronicsDismantling:BDE‐8.8ng/gl.w.TriBP

Referent/Labworkers:BDE‐3.0ng/gl.w.

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CHEMICALUSEDINPLASTICS

AIRCONCENTRATION URINECONCENTRATION BLOODCONCENTRATION REFERENT/CONTROLPOPULATION

12‐81ng/gl.w.

HeavyMetals:Tin(Organic)Boraiko,etal.,2005

PVCProcessing:0.1‐0.102mg/m3Blending‐0.102mg/m3

Extrusion‐0.034mg/m3Injection‐0.007mg/m3Milling‐0.064mg/m3Pelletizing‐0.006mg/m3

LeadCompoundsCoyle,etal.,2005

PVCProcessing:460‐1,100ug/m3*20‐400ug/m3**3‐210ug/m3***

PVCProcessing:108‐159ug/dl

2ug/dlgeneralpopulation

LeadCompoundsCoyle,etal.,2005

*Manualhandlingofpowderedleadsulfate**Manualhandlingofpellets***Prepackagedleadstabilizer

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APPENDIXF

RISKHAZARDANALYSISPOSTLAMANDROLLRFORMPRODUCTION

RISKHAZARDANALYSISProductionProcess ProductionTasks RiskFactors ChemicalExposureRisksRollerFormingtoshapepartsfromrollofstainless5”widesteelstockona100’rollingmill

Operatorguidesmaterialduringhighheat/pressurewashanddegreasing

Finemistandsteamproducedduringwashcontaminatedwithdegreaserandmetalcoatings

Inhalation/absorptionofmistandsteamcontaminatedwithsolvents,TCE,Toluene,Acetone

ApplicationofglueandattachmentofPVCstrip

Metalgoesthroughahotairblowdryerandthenpassesthroughanovenforgluing.Stripisattachedmanuallyongluedsurfaceandpressedonwithopposingrollers.

Applicationofglueandspillsanddripsproducevaporsfromgluingoperation.Localexhaustnotadequate(MOL).Pebra5gluefumesheavy.SoakpartsinMEK

InhalationandabsorptionoffumesfromPebra5contain:Perchloroethylene,TCE,andTetrahydrofuran,MEKandcadmium.Exposureriskhigh

Sheetsroughcuttosize Automaticcutwithshears.Takentosawoperation

Gluecontinuestoflash,washstickyhandsinMEK

InhalationoffumesfromglueandabsorbedMEK

Roughcutsheetcutbysaw Sawoperatorsetspartinjiganddrysawsparttoexactshape

SawproducesfineparticulateofSS,glue,PVC

Inhalationoffineparticulate:chromium,perch,tetra,TCE

PartsstackandtakentomoldpressforPVCoverlay;12presses

Moldoperatortrimsshavings,appliesPebra5,setspartinpress

Fumesfromglueflash,PVCprocess.Highvolume,noexhaust

InhalationofPVCandgluefumesgoingon12moldsatatime.

PostLam“FordLine”:FN‐36 Partsprecutandwashedasabove Finemistwithdegreaser Inhalation/ingestionofmistApplicationofGlueonprecutpart24”x48”AndattachmentofPVCstrip

GlueappliedmanuallywithglueapplicatorfilledwithPebra5andattachmentofPVCstrip

Largervolumeofgluehandleddirectlyandpartsstackedtoflash,noexhaustventilation.

Inhalationandabsorptionofglueforoperatorandby‐standersveryhigh.MOLordertocorrect.

Parttoinjectionmoldforoverlay Glueappliedatendswithplugsandplacedininjectionmold

FumesfromglueflashandheatedPVCwithoutexhaustventilation

HighriskInhalationofheavyfumesfromPVCandPebra5

Arbourgmoldset‐upforlamination

ManualpouringofPVCpelletfrom25kgbagsintohoppers.Applyingmoldreleaseagents4X/SHIFT

OpeningandpouringofpelletshighPVCdustandmoldreleasevapors.Noisolation.

InhalationofPVCdustandmoldreleasetooperatorandby‐standershigh.Noexhaust

Purgingandcleaningofmolds Pouringpurgingmix(RapidPurge)andinitiatingpurgingprocess,purgewastesmolderingandsmoking.Solventcleaning

Higherriskofexposuretoresindecompositionbecauseformulationandhighheatapplication.Applicationofsolventsonheatedsurfaces.

Veryhighriskofinhalationofsmokeandfumesfrompurgingprocessmaterialsandsolventstooperatorandby‐standers

Sawsharpeningoperation SharpenedsawteethwithgrindingwheelinMWF

Mistanddropletscontaininggrindingwheelgritandepoxy

HighriskexposuretoMWFdropletswithgrit,metals,resins

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INJECTIONMOLDINGTHERMOPLASTICOPERATION1986‐1996FOURSMALLSIZE200TO300TONMOLDS

RISKHAZARDANALYSISProductionProcess ProductionTasks RiskFactors ChemicalExposureRisksLoadingResins Hopperswerefilledmanually

frombagsofvariousresins.PVC,acrylic,polypropylene,styrene,etc.plusmanyadditives

Littleornolocalexhaustventilation,lotsofdustfromopeningpelletcontainersandpouringintohoppers

Riskofinhalationandskinabsorptionfromdustinhotsweatyenvironment.

Moldscleanedandtreatedwithmoldrelease

MoldssprayedwitheitherRocketReleaseorpaintablemoldreleaseagentsonhotmoldsurfaces201Bcleaner

Appliedwithpropellantlotsofoversprayofmoldreleasesonhotsurfaceofmoldproducesheavyfumesandvapor

Highriskofinhalationexposuretovaporsfromheatedreleaseagentsformoldoperatorandby‐standersfromoverspray

Handlingejectedparts Materialhandlers manuallyhandledfreshlymoldedparts

Hot,freshlymolded,partscontinuetooff‐gas

Inhalationandabsorptionfromhandlingparts

Trimandtorch Trimworkerhandlespartstotrimwithexactoknifesandusespropanetorchtosmoothedges

Handlingfreshlymoldedwithresinandmoldreleaseresiduesandfumesfromtorching

Inhalationoffumesandvaporsfromtorching,aswellasdustfromsanding

Moldingprocess Settemperatureandinitiatethemoldingcycle.Resinsheatedtomeltingandinjectedintomoldwithreleaseofgases

Highheatingofresinduringmoldingcycleproducesfumesandgasescontainingmonomers,additivesandvarietyofby‐productswithnolocalexhaust

Highinhalationriskofexposuretomonomers‐VCM,styrene,acrylonitrile,phthalates,heavymetals,flameretardantsandreleaseagents.

PurgingandCleaning Moldoperatorsmanuallyloadingpurgingagentsandpolymersintothehoppers.

Manuallypouringpurgingresinsandsolvents.Purgedwithacrylicresins.Creationofdustsandvapors.Purgingathighertemperaturescreatesmoreintensefumeandsmokeandhazardousdecompositionproducts

Highriskofinhalationexposuretoresindustscontainingvariouschemicalformulationsaswellasthermaldecompositionproductssuchasacrylonitrilefromacrylicresinsandstrongsolventssuchastoluene,MEK,acetone.

RegrindingOperations:smallduringthisperiodgrindingPVCandpolyol.Expandedtoseverallargegrinders.

Grinderoperatorloadsandtendsgrinderwithwasteplastic‐TPU(gray)andTPO(black)

Producesheavyfumes/dustswithhazardousingredientsandby‐products.Localexhaustinadequateanddisabled

Riskofinhalationofdustandvaporcreatedbythehighheatcausedbybladefriction.VCM,phthalates,FG,silicaetal.

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REACTIONINJECTIONMOLDINGOPERATION(R‐RIM)

1989‐2000ProductionProcess ProductionTasks RiskFactors ChemicalExposureRisksPreparationofcomponentstobeinjectedintomoldsconsistofisocyanateMDIandPolyolmixedinthe“TankFarm”areabehindmoldingarea.PolyolandMDImovedseparatelythroughheatedpipingunderpressurefrom5000USGtanks.

Polyolismixedsemimanuallyatthe“mixingstation”withWollastonite,extenders,surfactants,catalysts,crosslinkingamines,InnerMoldRelease(IMR).IMRdrawnfrom45USGdrumspigotintoopenbucketandthenpouredintomixer.

IMRwaspouredmanuallyfrombucketsintomixer;Wollastonitepouredinsemiopenwithsignificantairbornfibres;otheringredientalsomixedmanually.ManyleaksandspillsofISOandPolyolnotedatvalvesandpipejoints

InhalationanddermalabsorptionriskfrommanualpouringofIMRwithspills.InhalationriskwiththepouringofWollastonite(tremolite),aswellasexposuretoMDIfromleakyvalvesandperformingmaintenanceandcleanup

RIMinjectionmoldingoperationwithMDIandPolyolreadytobeinjectedintothe8clampsmixingheadandinjectors.

CleaningMoldwithclampopenmoldoperatorcleansmoldwithcleaner201Bwithscraper,brush,steelwoolandragwithneopreneglovesandeyeprotectionworn..

Applicationofcleaneronhotmoldsurfaceproducesfumesandvaporsfromcleaningragsoakedincleaner.Upwardreachonthetopclampcauses201Btodripdownoperator’sarm.Usedafterevery2‐3shots(66times/shift)

Inhalationandabsorptionriskhighgivenvaporproducedwhen201B(N‐methyl‐2‐pyrrolidone,ethyleneglycol,monobutylether)contactsheatsurface.Andisabsorbeddermallywhenrunningdownoperator’arm.

Moldreleaseapplication OperatorappliesmoldreleaseR602onallareasofmold

R602isappliedwithamanuallyoperatedspraygunwithagreatdealofoversprayandcreationofvaporswhensprayhitsheatedsurface.180‐200shots/shift

Asobservedthroughvideoaccount,operatoraswellastrimtableoperatorshavehighriskofinhalingthemistandvaporscontainingN‐propylalcoholwithsoap.

MoldingProcesscommences Operatorclosesclampfromcontrolpanelandinitiatesreactioninjectionmolding

Thetwocomponentsareinjectedintothemixheadandcombinetoreactandexpandassoonastheymeettofillthevoidinmold.Gasesandvaporsareproducedandescapethroughvents.Exhaustnotcontinuous.Shutoffwhentriggerreleasedonmoldreleasesprayer.

Highriskofinhalingchemicalby‐productsandunreactedmonomersofISOandpolyolsinceexhaustisnotcontinuous.Operatoraswellastrim/sandoperatorclosebysharesriskofinhalation.Operatorrepeatsprocess180‐250/day.Chronicexposurepredictable.

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REACTIONMOLDINGOPERATION(CONTINUED)ProductionProcess ProductionTasks RiskFactors ChemicalExposureRisksRetrievingpartsfrommold Operatorretrievespartfromhot

moldandtrimsgatesnotchespartandplacestheseintheadjacenttrimtable.AndbeginstoclearclamofremaininggatesandmaterialswithancompressedairgunandspraysR602moldrelease

Hotpartstilllikelyoffgassingcontaminatedresiduesthathavejustbeenformedsecondsago.Thepartsarethenhandledbythetrimandsandpersonnel.

HighriskofinhalationofvaporsandgasesfromClampventsduringandaftermolding.Alsofromfreshlyformedpartshandledbytrimandsandpersonnel.

Sandandtrimprocess SandandtrimusepalmsandertosandandknifestotrimRIMparts

Sandingoperationproducesgreatamountofdustcontainingurethaneandotheradditivesandmonomers.Accumulationofdustsonworkersandworksurfaces.Areaveryhot.Largefanusedtocooldispersesdustfurther.

Highriskofinhalationofdustcontainingurethane,iso,monomers,Wollastonite,fibreglassandotheradditives.Reportsindicateworkerswithobstructivelungproblemsfrommedicalpre‐screening.

GreyPuttyoperation Greyputtyoperatorexaminespartsanddecideswhetherpartneedstobeputtied.

Puttyisappliedinanunventilatedareawithafoambrushbarehandedandwithoutrespiratoryprotections.ContainsHDI(ISO)asbestos,silica,MEK

Puttyoperatorathighriskofinhalationandabsorptionofputtyingredientsthroughskin.WorkernotadviseditcontainedHDI,Porenwishfuller3311dilutedwithaclearcoathardeneranddiacetatealcohol.

PostCureOvens325oF AfterGreyPuttyapplication,partshungonracksoncarouselconveyorintotheovenfor1.5hrs.Afterwhichoperatorwouldremovepartsandplaceonracksforfurtherinspection.

Theheatinthecureovenwouldproducevariousgases/vaporsthatwouldescapefromthesemienclosedoven.Strongodorspresent.AmaintenanceofficeandnotchingprocessunderneathovensplusaTCEvapordegreasingtank4X4x2.

HighriskofinhalationofvaporsandgasescontainingISO,HDI,MDI,polyoladditivesaswellasdecompositionproductsNx,benzene,nitrosamines,phenol,styrene,etal.forovenoperatorsandby‐standersworkingunderneaththeoven.

TouchupareaforRIMbetweenpaintlineandpostcureoven

Checkfordefectsandsand,touchupwithGreyputtyat12tables

90%ofworkinvolvesandingverydustyandpoorlyvented

HighriskofinhalationofdustwithMDI,HDI,silica,asbestos,FG

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LARGEINJECTIONMOLDINGTHERMOPLASTICFOURLARGER3000TO4000TONAUTOMATEDMOLDS(1993‐2000)

ProductionProcess ProductionTasks RiskFactors ChemicalExposureRisksPelletdryingoperation Operatorinitiatespellettransfer

toa1500tondryerwherepelletsareheatedtorelativelyhightemperaturestoremovemoisture.

Vaporsreleasedintogeneralatmosphere.Workersdetectstrongplasticodorsinsurroundingareas.Heavydustwhenchangingfilters.

Highriskofinhalationofsolventcomponentsofresinundermoderateheating.Alsodustcontainingresincomponentsadditivessilica,FG,polymers,monomers.Risktooperatorsandby‐standers.

Pelletstransferfromdryertomoldchambersviahighvacuum

Operatorinitiatespellettransfer.Pelletsmoveathighspeedwithlotsoffriction.

Highspeedmovementofpelletscreatesagreatdealofdustcapturedinfiltersandcanisterswhichmustbecleanedfrequently

Highriskofexposuretoresindustsduringfiltercleanoutandmaintenance.Dustcontainingsilica,monomers,additives

Preparationofmoldforthermalprocessing

Operatorscleanmoldperiodicallywith201BandsprayRocketReleaseovermoldsurfaces.

MoldcleanerandRocketReleaseisappliedmanuallyonhotsurfaceproduceshighlevelofvaporsfromcleanerandreleaseagent.150‐300apps/shift.Alsoagreatdealofoverspray.

Highriskofinhalationandabsorptionofcleanersandreleaseagentsbyoperatorandby‐standerscontainingTCEandperchloroethylene,formaldehyde,methyldodecyl,

Thermalprocessing Operatorinitiatesthermalprocessofheatingresinpelletsintoliquidstateandinjectingintomold.

Thermalprocessproducesvaporandgasesthathavetobereleasethroughmoldventsconnectedtoexhauststacknotadequateforextraction.

Highriskofinhalationstoresindecompositionproducts:Example:Cycoloyresin‐silica,magnesiumoxide,acrylonitrile,butadiene,styrene,carbonblack,BPA,flameretardant,colourants

Retrievingmoldedparts Partremoval doneroboticallyandthenhandledbymaterialhandlers

Warmpartcontinuestoreleasegasesandvaporshandledbymaterialhandlers.Moldreleasesprayedfornextshot

Riskofinhalationofvaporsfromfreshlymoldedpartsbymaterialhandlersalsoexposedtomoldreleasebeingsprayed

Trimmingandtorchingparts Materialhandlerstrimpartswithpropanetorchandknife

Trimmingpartwithpropanetorchwouldproducefumesandvaporsfromtorchingplasticpart.CO,CO2alsoproduced

Highriskofinhalingfumesandvaporsfromtorchedplasticaswellaschemicalsfrommoldreleaseandpropanetorch.

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LARGEINJECTIONMOLDINGOPERATION(CONTINUED)ProductionProcess ProductionTasks RiskFactors ChemicalExposureRisksPurginginjectionmolds Set‐upoperatorpourspurging

mixtureandsolventintoscrewhead,orpurgemixautomaticallyintroducedfromcontrolpanel

Theheatedpurgingmaterialswouldproduceveryheavysmokeandvaporsfromlargemassofthermalplasticssmolderingonfloorfor20‐30minutes.

Veryhighriskofinhalingsmoke,fumesandgasesfrompurged::RapidPurge‐‐polyol,toluene(benzene)MEK,MBK,n‐hexane,formaldehyde,benzene,PAH

SEVERALTHERMOPLASTICSRE‐GRINDINGOPERATIONSProductionProcess ProductionTasks RiskFactors ChemicalExposureRisksGrindingWasteTPO/TPU.Asproductionincreasedthenumberoflargegrindersincreasedto4largegrindersandbecame24/7operationsfor3consecutiveshifts.

Grinderoperatorsfeedsdamagedplasticsintolargegrinderstomakefineresinparticulatetobereusedinthethermalplasticsoperation.

Largegrindersproducedfineparticulatethatescapedfromthetroughbecauseexhaustventilationcloggedortoolowcapturevelocity.Heatfromfrictioncreatedvaporsandfumes.MOL

Highriskofinhalationoffineparticulate,fumesandvaporsfromgrindingoperationstooperatorsandby‐standersinthegeneralworkareas.Particulatecontainsplasticmonomersandadditivessilica,FG,andsolvents

GLUELINEPRODUCTIONPROCESS

ProductionProcess ProductionTasks RiskFactors ChemicalExposureRisksUsedtoattachmylar,PVCorothermaterialstothepartsonahangingcarousel.Therewere8gluelinesthatcouldbeshiftedfromplacetoplaceasproductiondemanded.

GluelineoperatorsappliedeitherPebra5toglueandorAdproAdhesionPromoterasaprimer.Approximately400parts/shift.

Gluesandprimerweresprayedonmanuallyfromapressurepotfilledinthepaintkitchen.Pebra5containedPerch,TCE,tetrahydrofuran,cadmium.Adpro‐toluene,n‐butylacetate,alkydresin,ethylalcohol,xylene,methylisobutyl,phosphoricacid

Highriskofinhalingandabsorbingthevaporsasgluesandcoatingflashoffwithoutlocalexhaustventilation.SeeMOLhygienereportoninadequateventilationonglueline.Generalcontaminationgiventhenumberofgluelines.

ASSEMBLYLINESPROCESSES

ProductionProcess ProductionTasks RiskFactors ChemicalExposureRisksTherewerenumerousassemblylinesthroughouttheplant‐touchup,sanding,coating,gluing,painting,installing,attachingontableswith

Sanding,touchup,painting,filling,coating,gluing,installingandattaching.400to500partspershift.

Highvolumehandlingofglues,ISOpaints,coating,solvents(MEK),noexhaustventilation.Fumesfromotherarease.g.paint,sludge,injection,RIM.

Highriskinhalation/absorptionofchemicalsinuse:MEK,Pebra5,Adpro,ISO,putty,etal.FumesfromotherdepartmentsbecauseofGeneralventilation

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conveyor.8/shift. flaws.PAINTLINEEARLYPERIODINSIDE/OUTSIDE

ProductionProcess ProductionTasks RiskFactors ChemicalExposureRisksPaintKitchen:Paint/gluemixingarea.Allpaintsandgluesmixedandpaintpumpscontrolledandflushed.

Duringearlyperiodpaintkitchenoperatormanuallymixedallpaints/solvents/catalysts/adhesivesbythepailfullthenpouredinto85gallonpaintpressuretanks.Pressure&flowmonitoredandadjusted.Paintlines(topaintbooths)flushedbyoperatorandset‐uppersonnelforproductchanges.

Directhandlingofallpaints,thinners,solvents,washeswithlargequantitieswithlimitedPPE.Pouringandmixingwithvolatilechemicals,MEK,TCE,Toluene,HDI,catalysts,paints,primersandPebra5.ClearingandpurgingpaintlineswithVentraPurge.PoorexhaustventilationandFrequentspills

PaintKitchenpersonnelathighriskofinhalationandabsorptionofVentrapurgeingredients:toluene,benzene,MEK,n‐hexane;AlsotoHDIpaints,hardeners,catalysts.Pebra5perch,terahydroxyfuran,TCE,AdproAdhesionPromotersingredients.

Multistageprepandpaintprocess.Majorsourceofsolvent,thinnerandisocyanaterelease‐250000USG&1.3MlbsVOCs

EarlyPeriod:Freshly moldedpartsloadedontocartsontrack,inspected&tackwipedalcoholsoakedrags.

Outsidepaintpersonnelhandlingfreshmoldedparts,wipeddownwithalcohol.Poorventilationcausesfugitiveemissionsfrompaintlineandsludgeroom,moldoperations

Highriskofinhalationforoutsidepaintassemblyworkersofvaporsfrompartsandfugitiveemissionfrompaintline,sludgeroomandpaintkitchenfrequentlyinvestigatedduetospills/leaks

Preppingandpaintsprayprocessintheearlyperiod:PreWash

Drawnintotunnelforanautomated6stageplasticchemicalwashesandrinsescontainingacids,caustics,ParcoPlastatwashstations.

Residuesoflargevarietyofcausticandacidwashesunderhighpressuregeneratemistsandvapors.

Possibleinhalationandskincontactifisolationandventilationnotfunctioningproperly.

3isolatedpaintboothsunderpositivepressure:1setup,3touch‐upperbooth,1chemicalmonitor,2paintkitchenoperator.

Nextmovethrough3booths:first,2Kprimercoat;second,2Kbasecoat;andthird,2Kclearcoat.Automatedbutstaffedwith2touch‐upspraypainters.(“touchup”includedpaintingbacks,endsandplacesmissed)

TouchuppainterinboothwearingTyveksuitsandhoodswithhoseconnectedtooutsideambientair,notairsuppliedwhilesprayingHDI,hardenersandcatalystwiththinners.Agreatdealofoverspray.

Highriskofinhalationandabsorption(contact)withISOpaintsandothercoatingsbecauserespiratoryandskinprotectionnoteffective.Ambientairwouldincludecontaminants.

Cureoven,inspectionandassembly

Inspectorat“hardgate”endofoventunnel,sand,trim,rework&buffing

Fumesfromovenleaksandfugitiveemissionsfrompositivepressure,dustfromsandingandbuffingandtouchuppaint.

Highriskinhalationtopaintvapors&dustandpaintvaporcontainingHDI,andsolventvapors.

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PAINTLINE(CONTINUED)LATERPERIODPOST1993AUTOMATED&INOVATED

ProductionProcess ProductionTasks RiskFactors ChemicalExposureRisksPaintlineexpandedabout1993toadd2newboothsdesignedtoprovide2coatsofbaseand2coatsofclear.One‐Ovenat325oFwasexpandedtoaccommodatelargerpartsandlengthencuringprocess.Second‐FullscaleRobotsprayersIneachboothtakingplaceoftouchuppainters.Third‐PaintformulationschangedtoBASF&MortonsystemswithisocyanateHDIinclearcoatsprays.Fourth‐FlushlineswithMEK/VentraPurge–manyskidsfilledwith45USGdrumsstoredandheavilyused.

Mixingpaintsandthinnersfrom45USGdrumsusing30pumps.Workersmaintainthemixingprocessandmonitorlinesystemtoensurenocloggingoflines.Workersmonitortheprocessoutsideofboothsandonlyentertheboothstoadjustorrepairrobotics.PreparationofgluesforassemblyandgluelinesFlushpaintlinesforcolourchangeandendofdayshift.

Largervolumeofproductionandchemicalusage.Largerspillsandleaks.Fumesfromovenleak.Largervolumeofemissionintheplantandintheenvironmentaswellasinthesluicewayandsludgeroom.Maintainingandrepairingpumpsriskofspillsandleaks.GluemixinggeneratesfumesandvaporsofMEK,AdPro,4296and4298.FlushinganddraininglinesinvolvedspillthatwentintoSluiceway/sludgeroom.Andfugitiveemissiontootherareasduetoventilationimbalances.

Highriskofinhalationexposureduetopoorworkpractices—sprayingoutsidetheclearcoatboothwhenrobotswentdown;enteringboothswithoutrespirator.Largervolumeofproductionandchemicaluseincreasedriskofexposure.Paintscontained:MEK,acetone,xylene,HDISluicewaybecameamajorsourceofchemicalvapormigrationwhenventilationwentdown.Continualspillsandfiresinthepaintlinewasamajorsourceofexposuretodecompositionproducts.PAHs,Nitrosamines,HDI,benzene,formaldehyde

ChemicalMonitoring Chemicalmonitor:testedpropermixinwashsolutions,monitorsludgewater,addchemicalsto“kill”paint,removesolidsfromweirboxinsludgetank,changefilters,adjustairflow,viscosity,temperaturesinboothsandline.

Detailedhandlingamultitudeofchemicals,wastesandtreatmentchemicalsupclose.Removingsludgefromthetanksandweirbox.

Highriskofinhalationofacombinationoftoxicfumesmonitoringandtreatingthetanksinthesludgeroom.

PaintCartMaintenance:repair,maintainandcleanpaintcarts

Repairbrokencarts,replaceorgreasewheel,removebuild‐upofisocyanatepaints.Usegrinder,chisels,torches,highpressurewater.30to100carts/shift

Toremovepaint3/4”:weldingtorch,grinders,airchisels.TorchingPVCshrinkwrapproducetoxicgases.Weldingandgrindingbreakscreatefumes

Highriskofinhalingverytoxicandirritatingweldinggasescontainingheavymetal(cd):VCMtorchingshrinkwrapplusawholehostofweldingfumes.

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SLEUSSEWAY& SLUDGEROOMProductionProcess ProductionTasks RiskFactors ChemicalRiskExposuresTheSluicewayisawaterfilledmoatthatwindsitswayinacontinuouslooppassingthroughoutthepaintlinethroughalltheboothsintothesludgepitsofthesludgeroomandagaininacontinuousloop.Thesluicewayservesthepurposeofpickingupalltheexcessoversprayofpaintsandsolventsanddeliveringthesetoxicwastestothesludgepitsfortreatmentandremoval.Thetwoopensludgepitsmeasured75’x12’x20’where5pumpsmovethewaterbacktothepaintbooths.Andventilatedbytwolocalexhaustfanstomaintainnegativeairpressure.

Twoworkersandasupervisorwererequirednearthesludgeroomondayshift.Oneofwhichwasachemicalsupplierrepresentative.AswelltheChemicalMonitoralsomonitoredandservicedthesludgeroompits.Thesewereservicedbyaddingaseriesofchemicaltreatmentstoaddressbiologicalcontaminationanotherasadetackifiersothatpaintsolidscouldberemovedanddeliveredtothelocalwastedump.Thesechemicalsaddedanadditionalburdenoftoxicchemicalstothesludgeroommix.

Boththesludgeroomandthesluicewaywereamajorsourceofchemicalmigrationtootherareasoftheplantparticularlywhennegativepressureinthesludgeroomwaslost.Theseinitialodorsthatworkersdescribeasliterallybreath‐takingandsuffocating.Thesluicewaywasalsoamajorsourceofcontaminationtootherareasoftheplantwhenasolvent/paintspillorleakoccurredincombinationwiththesluicewaywaterbeingexposedbyamissingsteelgrate.Treatmentworkerswerenotwearingrespiratoryprotectionandnotfollowingconfinespaceregulations.

Highriskofinhalationofalargevarietyofsolvents,paints,isocyanatesincombinationandaspeakexposures.Theseexposuresinclude:MEK,xylene,acetone,methylenechloride,TCE,toluene,nitrosamines,benzene,isocyanates,formaldehyde,biocides,andbacteriaandfungus.MOLidentifiedsomeofthesechemicalthreats.Theseareathreattothetreatingworkers,butalsothoseinthegeneralareasoftheplantwhomaybeinthepathofthesefugitiveemissions.Especiallywhenthereisalossofnegativepressure

ASSEMBLYANDQUALITYCONTROL

ProductionProcess ProductionTasks RiskFactors ChemicalExposureRisksAssembly/ProductionWorkerswerethelargestgroup.Therewerenumerousassemblylinesthatbeganwith“outsidepaint”.Theassemblyworkforcewashighlymobile.Qualitycontrol/inspection

Assemblyworkersperformedavarietyoftasks:cleanedwithsolvents,cut,sawed,sanded,patchedwithputty,trimmed,buffed,notched&punched,shaved,glued,puttied,filled,ground,boxedandlikelyothertasksassociatedwiththeproductionofplasticautotrim.Qualityconductdestructivetests

Largevolumeofsolventusageondetailedwork;appliedlargevolumeofglues/adhesives;HDIputty;applyingtouchupHDIpaints;largeamountofsandingandbuffingproducegreatamountofdusts&solventfumes.Qualityassurancehandlingandperformingphysicaltestinproximitytoassemblyactivities

Highriskofinhalationoffumesfromsolvents,paintsandadhesivesanddustscontainingHDI,urethane,monomers,formaldehyde,additives.Seelistofchemicalingredients.Highriskofinhalationoffugitiveemissionsfrompaintline,sludgeroom,andinjectionmolding.Qualityassurancesharerisks.

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MAINTENANCEOPERATIONSProductionProcess ProductionTasks RisksFactors ChemicalExposureRisksMaintenance: consisted of anumber of skilled tradeworkers, includingmillwrights, electricians, andtool and die workers.Individually, they wereassigned, weekly, to adepartment or work area tomaintain and repair thevarious systems in the plant.They were available torespond to emergencies(specifictotheirtrade).

Millwright: purging and repairsto the complex pump systems inthe plant also involved in cleanup and containment of pills andleaksaspartoftheERT.Detailed clean and soaking ofpump, valves, piping insolvents—MEK, toluene, TCE,acetone.Draining lines of HDI, MDI andhydraulic fluids into openbuckets.Usingcompressedair toblowoffdirt and chemicals to clear linesandparts.Detailed close work with partssaturated in solvents for longperiods.Cleaning filters and canisters ininjection molding machines withcompressedair.

Handlinglargevolumesofresins,paintsandcoatingscontainingisocyanates,Solventsandotherchemicalsusedfortreatments.Detailedworkwithdirecthandlingoftoxicmaterials.Producingfinemistsanddustswithcompressedair.Largevolumesofpaintsandresinswhencontaining&cleaningupleaks,spills.Purginglineswithpaintsandresinsreleaseslargequantitiesofthesechemicalsthataredifficulttocontrol.Finedustfromcleaningfiltersonvariousmachines.

Millrights:Highriskofinhalationandabsorptionofpaints,resins,solventsandothertoxicchemicals.Exposurestoliquid,mists,vaporsandparticulatearehigh,withfrequentpeakexposuresduringmaintenanceoperationsandemergencyresponsestospills,firesandleaks.

ToolandDie:Machiningandmillingofmachineryusedinproduction.ElectricalMaintenance:Electricalrepairandmaintenanceandelectricalsafety

ToolandDie: Taskdealingwithrepairstomoldssurfacesusinggrinders,polishers,weldingandresurfacingtools.Drillingandtappingforfastenings.Thiswouldinvolvesolventstoprepforwelding,grindingandpolishingwithMWFandmakingparts.

Carriedoutmaintenanceofelectronicsoncontrolmodulesandelectricalrepair.

Theuseofsolventsinpreparationofmachiningandweldingactivityproduceschemicalvapor.Grinding,polishingandmachiningmetalsproducesveryfineparticulatecontaminatedwithheavymetals,grindinggritandMWF.Thesearedonecloseupandwithoutexhaustventilation.Useofsolventstocleanconnectionsandworkingclosetoproductionactivity

Highriskofinhalation,ingestionandabsorptionofsolvents,fineparticulateandMWF.Inhalationriskforweldingfumesandmetalsaswellasdecompositionby‐productsduringweldingandmachining.Highriskofinhalationofsolventfumesaswellasfugitiveemissionfromotherproductionactivities.

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APPENDIXG

PLANTLAYOUTSEEBELOW


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