Workplace monitoring of refractory ceramic fiber in the United States

This paper summarizes data from a comprehensive workplace exposure monitoring program for refractory ceramic fiber (RCF) conducted since 1990, including data collected under a 5-year consent agreement (1993-1998) between the U.S. Environmental Protection Agency and the Refractory Ceramic Fibers Coalition. It presents additional data and analyses, which complement an earlier article published in this journal (L. D. Maxim et al., 1997, Regul. Toxicol. Pharmacol. 26, 156-171). As part of this exposure monitoring program, data were collected at plants operated by RCF manufacturers and at customer facilities. Beginning in 1993, at least 720 samples (each sample consisting of one or more cassettes) were collected annually, distributed according to a stratified random sampling plan. The strata consisted of workers in eight functional job categories (FJCs) at manufacturing and customer plants. Time-weighted average (TWA) and task length average data were gathered and analyzed using phase contrast optical microscopy and (for a subset of samples) transmission electron microscopy methods. Data on respirator usage (by type) were also collected. Statistical analysis indicates that there are significant differences in TWA fiber concentrations (exposure) among FJCs (installation, finishing, and removal categories have the highest average concentrations), that workplace concentration data are approximately lognormally distributed, and that weighted average fiber concentrations decreased over the period from 1990 to 1998-although trend curves leveled out as exposures have decreased and further improvements became more difficult. Material differences exist in exposure between RCF manufacturers and their customers (largely because the mix of jobs differ), but these differences have narrowed over the years. Respirator usage varies with exposure. Respirator data are used to derive improved estimates of actual worker exposure. Alternative criteria for selecting FJCs for control efforts are defined and illustrated. Lessons learned for future monitoring efforts are summarized.

The random-effects model applied to refractory ceramic fiber data

Refractory ceramic fiber (RCF) is a valuable, high-temperature, insulating material with a variety of industrial uses. Because some fibers are respirable by humans and RCF is relatively durable in simulated lung fluids, RCF may pose a health hazard in the workplace. The RCF industry has established a comprehensive product stewardship program (PSP) to identify, quantify, and manage risks. One key element of this PSP is a workplace monitoring program. This paper analyzes monitoring data collected as part of a Consent Agreement with the U.S. Environmental Protection Agency over the period from 1993 to 1998. More specifically, this paper applies the random-effects model (REM) to data collected at several Unifrax plants and applicable to several groups of workers. The REM fits the RCF data well. Depending upon the plant and the functional job category values of the variance of the log-transformed time-weighted average workplace concentrations range from slightly less than 0.5 to 1.0. The estimated intraclass correlations (ratio of the between-worker variance to the total variance) were less than 0.4, and most were less than 0.2. Implications of these findings are examined. Use of the REM in the development of a workplace respiratory policy is described. Finally, two possible criteria for measuring compliance with an occupational exposure limit are reviewed: an "overexposure" criterion developed by Rappaport and co-workers and a conventional "no exceedance" criterion reportedly used by regulatory agencies. The overexposure criterion is logically correct for potential toxicants with chronic effects. For representative values of statistical parameters for RCF from the plants considered, the overexposure criterion is less stringent.

Respirable crystalline silica exposure associated with the installation and removal of RCF and conventional silica-containing refractories in industrial furnaces

Installation and removal of conventional refractories and refractory ceramic fiber (RCF) in industrial furnaces may lead to occupational exposure to respirable crystalline silica (including quartz, cristobalite, and tridymite). Exposure to elevated concentrations of these materials has been linked to adverse respiratory effects, including silicosis and lung cancer. Unlike conventional refractories, RCF does not contain any of these materials as produced. However, depending upon time and temperature during the service life of the insulation, RCF may partially devitrify, creating the potential for exposure upon removal of after-service insulation. For removal of after-service RCF, exposure data collected as part of a 5-year consent agreement with EPA are presented and analyzed. Because of relatively low concentrations of these materials, limitations on the sensitivity of the analytical method, and the relatively short duration of furnace removal activities, many measurements are less than the limits of detection (LODs), creating challenges for data analysis. Several methods of analysis of censored data are illustrated and the theory of maximum likelihood estimates is generalized to cover the case of multiple LODs. Average exposures to these materials associated with removal of after-service RCF are compared to those in various industries.

The development and use of respirator response functions as part of a workplace exposure monitoring program for control of potential respiratory hazards

The traditional hierarchy of measures for control of potential respiratory hazards in the workplace includes (in order of preference) engineering controls, workplace practices, and use of respiratory protection. Although third in this hierarchy, respirators can be an important component of the control mix-particularly for difficult-to-control jobs, as an interim measure (pending implementation of other controls), and in cases where exposure is intermittent. One of the problems associated with the use of respirators as a control measure is that valid and adequate data on respirator usage are often not available. Absent these data it is difficult to determine the practical effectiveness of respirators and exposure calculations which include the protective effect of respirators are speculative. This paper presents models (and appropriate statistical fitting techniques) suitable for quantification of respirator usage and defines three potentially useful measures of effectiveness for a respirator program. These models are illustrated with monitoring data on refractory ceramic fiber (RCF) developed as part of a Consent Agreement between the RCF industry and the U.S. Environmental Protection Agency. For this substance there are extensive and comprehensive monitoring data available. The models and methods of analysis may prove applicable for other potential respiratory hazards in the workplace.

A multiyear workplace-monitoring program for refractory ceramic fibers: findings and conclusions

Results of a monitoring program carried out by members of the Refractory Ceramic Fibers Coalition as part of a Consent Agreement with the U.S. Environmental Protection Agency to measure workplace concentrations of refractory ceramic fiber (RCF) are presented. More than 700 personal monitoring samples were collected and analyzed annually from workers in RCF production and processing plants, as well as from those employed by customers/end users. The data indicate that (i) approximately 90% of time-weighted average (TWA) workplace concentrations are below the industry's recommended exposure guideline of 1 fiber per cubic centimeter TWA; (ii) workplace concentrations vary with functional job category; (iii) concentrations are approximately lognormally distributed; (iv) workplace concentrations are generally decreasing; (v) there are significant differences in workplace concentrations among plants operated by both RCF producers and customers; (vi) equations can be developed to interconvert data analyzed using different measurement techniques and counting rules; (vii) usage of respirators varies with the functional job category of the worker and the average fiber concentration; and (viii) workplace samples differ from those used in animal inhalation experiments in terms of the ratio of respirable particles to fibers.