In a recent cohort study in aluminum foundries and remelting plants an unexpectedly high risk of lung cancer was found in workers in sand foundries. On the basis of present and historical measurement data, we developed a statistical model for exposure to total dust and crystalline quartz for different jobs and time periods. Cumulative dose estimates of total dust and crystalline quartz were calculated and used in a nested case-control study in the cohort. From the cohort of foundry workers (n = 5016), 46 cases of lung cancer were identified. The final analysis was performed on 31 cases and 233 controls with one year or more of employment. Historical measurement data from the 1960s and onward were collected, totaling 203 total dust and 103 crystalline quartz exposure observations. Regression models, using the determinants of job title, time period, type of foundry, and size of production, were developed for assessing historical total dust and crystalline quartz air concentrations. These estimates were used to calculate individual cumulative exposure in the case-control study. In the multiple linear regression analysis, the determinants explained much of the variations in dust level (r(2) = 0.58). The explained variation in crystalline quartz was much lower (r(2) = 0.13). The regression coefficients for the type of foundry, time period, and size of production were statistically significant for total dust. On the basis of the regression analysis, the final models were used to calculate individual cumulative exposures. The calculated cumulative dust and quartz exposures averaged 33 mg/m(3) * year and 0.42 mg/m(3) * year, respectively. The odds ratios (ORs) were not significant, but showed dose-response trends for both dust and crystalline quartz.

Recent outbreaks of hypersensitivity pneumonitis (HP) have been associated with exposures to metalworking (MWF) fluid aerosols. Mycobacteria present in mismanaged fluids have been suggested as the likely culprit. In January 2001, three machinists at a machining plant were hospitalized with HP. Subsequently, additional HP cases developed as well as cases of bronchitis and occupational asthma. In October 2001, an aerosol concentration map was constructed to advise on priorities for corrective actions. In April 2002 after installation of mist collectors, a second map was generated. Mist reductions varied from about 75 percent to an increase of about 20 percent. Mist concentrations increased in the areas near an uncontrolled transfer line. Subsequent to the first mapping exercise, the exposures of 30 HP cases were classified as low, medium, and high based on job location and the map. There were 6 cases among low exposure jobs (4% of exposed), 14 cases among medium exposure jobs (19% of exposed), and 10 cases among high exposure jobs (34% of exposed), suggesting a relation between exposure to contaminated metalworking fluid mist and the development of HP. A combination of interventions (fluid management, mist control, improved fresh air ventilation, and medical surveillance/restriction) eliminated any new cases 11 months after the first diagnosis of HP.

The American Conference of Governmental Industrial Hygienists (ACGIH) has recommended that the threshold limit value (TLV) for mineral oil mists be dramatically lowered, based on epidemiological evidence of respiratory health effects among machinists exposed to various metalworking fluid mists. A review of the literature regarding respiratory health effects from either metalworking or non-metalworking fluids suggest that machinists may have experienced slightly higher prevalence of common respiratory symptoms and mild and reversible cross-shift changes in some measures of pulmonary function. However, the inconsistency and potential for both random and systematic error in this body of literature argue against drawing definitive conclusions. There is also no substantive evidence that any of these effects led to permanent disease or impairment. The most likely causal agents for respiratory effects in these workers are microbial contaminants in water-based metalworking fluids, not straight mineral oils. This is consistent with the epidemic outbreaks of hypersensitivity pneumonitis, bronchitis, and asthma reported at some work sites using water-based metalworking fluids. This highlights the importance of frequent cleaning and fluid changes for metalworking fluid reservoirs, as part of a systematic approach to managing metalworking fluid aerosol exposures. A dramatic drop in the TLV for mineral oil mists would not resolve this problem.

This study was undertaken to determine the impact of exposure to metal removal fluids (MRFs) on the respiratory health of exposed workers. The outcome measure selected was the rate of hospital admissions for nonmalignant respiratory disease episodes as determined from healthcare insurance claims data. A cohort of MRF-exposed employees was assembled from 11 manufacturing facilities where MRFs were extensively used in the manufacture of automotive engines, transmissions, and other machined parts. The MRF-exposed cohort included 20,434 employees of such facilities who worked at any time from 1993 through 1997. A non-MRF-exposed cohort was assembled from other employees of the same company during the same time period, but working in warehouse operations and other manufacturing facilities that did not use MRFs or any known respiratory sensitizing agents. The non-exposed cohort included 8681 employees. The crude hospital admission rate for the MRF-exposed cohort was 44 percent higher than that of the non-exposed cohort over the 5-year study period (6.67 vs. 4.62 per 1000 person years at risk, p < 0.05). With age adjustment, the MRF population's rate was still 35 percent higher, and still statistically significant. A nested case-control study was also conducted to determine whether the risk of hospital admission increased with the level of MRF exposure in the population working in MRF plants. The industrial hygiene reconstruction found the levels of exposures of both cases and controls to be very low, with the vast majority of study subjects (more than 90%) having exposures of less than 0.5 mg/m(3). The case-control study did not find any association between increased levels of MRF exposure and risk of hospitalization. The study did document an elevated risk of hospitalization among a sizable population employed in manufacturing operations where MRFs are used.

The measurement of oil mist derived from metalworking fluids formulated with light mineral oils can be highly inaccurate when using traditional filter sampling. This is due to evaporation of oil from the filter. In this work the practicability of an alternative approach measuring total oil mist and vapor was investigated. Combinations of inhalable particle samplers with backup sorbent vapor traps and standard vapor sampling on pumped and diffusive sorbent tubes were evaluated with gravimetric, infrared spectroscopic, and gas chromatographic analytical methods against the performance requirements of European Standard EN 482. An artificial aerosol was used to compare the methods against a reference method of filter sampler in series with three impingers. Multi-orifice samplers were used with standard 8-mm diameter charcoal tubes at 2 L/min without any signs of channelling or significant breakthrough, as were conical inhalable samplers with XAD-2 tubes at 1 L/min. Most combinations of samplers had a bias of less than 3 percent, but solitary pumped charcoal tubes underestimated total oil by 13 percent. Diffusive sampling was affected by impaction of mist particles and condensation of oil vapor. Gravimetric analysis of filters revealed significant potential sample loss during storage, with 4 percent being lost after one day when stored at room temperature and 2 percent when refrigerated. Samples left overnight in the balance room to equilibrate lost 24 percent. Infrared spectroscopy gave more precise results for vapor than gas chromatography (p = 0.002). Gas chromatography was less susceptible to bias from contaminating solvent vapors than infrared spectroscopy, but was still vulnerable to petroleum distillates. Under the specific test conditions (one oil type and mist particle size), all combinations of methods examined complied with the requirements of European Standard EN 484. Total airborne oil can be measured accurately; however, care must be taken to avoid contamination by hydrocarbon solvent vapors during sampling.

(2003). Letter to the Editor and Rebuttal. Applied Occupational and Environmental Hygiene: Vol. 18, No. 10, pp. 732-734.

(2003). A Checklist for Evaluating Cab Design of Construction Equipment. Applied Occupational and Environmental Hygiene: Vol. 18, No. 10, pp. 721-723.

Beryllium operations and accompanying medical surveillance of workers at Los Alamos National Laboratory began in the 1940s. In 1999 a Former Workers Medical Surveillance Program that includes screening for chronic beryllium disease was initiated. As part of this program, historical beryllium exposure conditions were reconstructed from archived paper and electronic industrial hygiene data sources to improve understanding of past beryllium uses and airborne concentration levels. Archived industrial hygiene sampling reports indicated beryllium was principally used in technical areas-01 and -03, primarily being machined. Beryllium was also used at 15 other technical areas in activities that ranged from explosives detonation to the manufacture of X-ray windows. A total of 4528 personal breathing zone and area air samples for beryllium, combined for purposes of calculating summary statistics, were identified during the records review phase. The geometric mean airborne beryllium concentration for the period 1949-1989 for all technical areas was 0.04 microg Be/m(3) with 97 percent of all sample below the 2.0 microg Be/m(3) occupational exposure limit (OEL). Average beryllium concentrations per decade were less than 1 microg Be/m(3) and annual geometric mean concentrations in technical area-03, the largest user of beryllium, were generally below 0.1 microg Be/m(3), indicating exposure was generally well-controlled, that is, below the OEL. Typical of many retrospective exposure assessments, not all archived data could be extracted and summarized. Despite this, we report a reasonable summary of potential beryllium uses and airborne concentration levels a worker may have encountered from 1949-1989. These data can be used to more effectively identify former worker populations at potential risk for chronic beryllium disease and to offer these workers screening as part of the Former Worker Medical Surveillance Program, and in the event that a case is diagnosed, help to understand historical exposure conditions.

Airborne fungal contamination in the indoor environment is a substantial contributor to indoor air quality (IAQ) problems, yet there are no set numerical standards by which to evaluate air sampling data. Intuitively appealing is the operational model that the indoor air should not be significantly different from the outdoor air, but determining what is "significant" as well as where to sample and how many samples to collect to determine significance have not been firmly established. The purpose of this study was to determine the number of samples and their locations necessary to determine significant differences in airborne fungi between the ambient and indoor environments. Sampling results from several hundred air samples for culturable fungi from various sites were used to derive a probability of detection in the outdoor air for problematic or "marker" fungal species. Under the assumption that indoor fungal growth results in an increase in the probability of detection for a given fungal species, mathematical probability dictates the number of samples necessary in the indoor (target zone) and in the outdoor (reference zone) air to demonstrate significance. Ultimately, it is the sparse distribution of the problematic species that drives the number of required samples to demonstrate a significant difference, which varies depending upon the level of significance desired. Therefore, the number of samples in each zone can be adjusted to reach a target difference in detection frequency, or an investigator can assess a sampling scheme to identify the differences in detection frequency that show significance.

The relationship between asbestos exposure and disease has been well documented, although questions persist as to variation in risk by the type and length of fiber. For a series of jobs with potential asbestos exposure, the primary fiber type (e.g., amosite, anthophylite, chrysotile, crocidolite, or tremolite) and fiber length were identified and the relative exposure intensity was estimated. The resulting job exposure matrix may be useful in epidemiological studies where asbestos is an exposure of interest.