Alcoa Worldwide Health

Standards

Occupational Health Training

16 April 2002
EHS Value & Policy

 EHS Value:
 We will work safety in a manner that promotes the health and
well-being of the individual and the environment.

 EHS Policy:
 It is Alcoa’s policy to operate worldwide in a safe, responsible
manner which respects the environment and the health of our
employees, our customers and the communities where we
operate. We will not compromise environmental, health or
safety values for profit or production.
Alcoa Occupational Health

 Health:
 Industrial Hygiene and Occupational
Medicine

 Worldwide Health Standards (WWHS’s)

 Address Industrial Hygiene and
Occupational Medicine Issues
How Does Alcoa Manage Health
Issues?
Ensure consistent, appropriate management of workplace
exposures and health issues through a comprehensive
set of tools:
 WWHS’s
Identify minimum
 Health Standards requirements

 Gap Analysis
Identify actions needed to
 Health Plan meet Alcoa’s Standards

 Audits
Measure effectiveness of
 Metrics/Scorecard Health Programs
 What are the Worldwide Health
Standards (WWHS)?
 International minimum guidelines in
occupational medicine and industrial hygiene
 Concise guidelines which address:
 Business Unit responsibilities
 Management of employee health
 Management of the work environment

 Necessary to meet occupational health

aspects of the EHS Value and Policy
Alcoa WWHS’s
Qualification of personnel
Standardization of medical records
Plant medical facilities and equipment
Laboratory services
Management of medical records
Fitness to work
 Pre-placement & Return to work
Alcoa WWHS’s
Medical surveillance and biological
monitoring
Emergency medical response
 Workplace
 Community
Substance abuse testing
Heat stress medical surveillance
Alcoa WWHS’s
Bloodborne pathogens
Mobile equipment operators
Respirator users
Health promotion evaluations
Alcoa World Wide Health
Protocols
WWHS Gap Analysis

WWHS Action Plan

 Industrial Hygiene
Standards of Practice
Hearing
Ionizing
Respiratory Conservation
Radiation;
Protection Metal Supplies
& Radio-
INDUSTRIAL activity
HYGIENE
Asbestos, WORLDWIDE
Refractory HEALTH Heat Stress
Ceramic Fibers STANDARD

Medical
Coal Tar Pitch,
Surveillance;
Records Beryllium, Lead
Medical
Management
Evaluations
What is Industrial Hygiene?
Industrial hygiene is a process for:
 Managing the health risks associated with workplace exposures to chemical,
physical and biological agents.
 Preventing occupational illnesses and disease.
Health Issues in Alcoa
Noise
Metals (Nickel, Chromium, Cobalt, Beryllium)
Crystalline silica
Carbon Monoxide
Oil mist
Mineral fibers (Refractory Ceramic Fibers, Asbestos)
Epoxy resins/Formaldehyde
Coal tar pitch/HF
Heat stress
Radiation (Isotopes, X-Ray, Lasers)
Lead
What is the process for
managing workplace exposures?

 Recognize exposures.

 Differentiate “acceptable” from

“unacceptable” exposures.

 Control “unacceptable” exposures.

 Occupational Health Process
Medical
Surveillance

Management Health Hazard Controls:

Hazard Communication
Support & Risk Exposure
Engineering Controls
Health Identification Assessment Work Practice Controls
Professionals Personal Protective Equipment

Employee
Epidemiologic
Health
Evaluations
Protection
Management Support & Health
Professionals
The industrial hygiene program must be
under the supervision or review of an
“industrial hygiene professional.”

IH Professional = ABIH Certified Industrial

Hygienist (i.e. CIH) in the United States.

BOH British Occupational Hygienist

Risk Identification
 Initial program
development

 Review of new
materials proposed
for use

 Project EHS Reviews

Materials/Chemical Inventory
Raw materials Adhesives
Process additives Welding, soldering and
brazing materials
Process intermediates
Insulations
Products
Refractories
Waste products Compressed gases
Process lubricants Resins
Mechanical lubricants Pesticides
Coatings Cleaning agents
Solvents Laboratory reagents
Materials / Chemicals
Inventory: MSDS Management
Exposure assessment objectives

Identification of health hazards through

the differentiation of acceptable and
unacceptable exposures.

Development and maintenance of a

database.
Scope of Exposure
Assessment

ALL EMPLOYEES

ALL DAYS

ALL ENVIRONMENTAL AGENTS

All Environmental Agents
Chemical: dusts, mists, fumes, vapor, gases,
liquids, etc.

Physical: noise, heat, ionizing radiation,

lasers, microwaves, infrared, ultraviolet,
vibration, etc.

Biological: pathogenic bacteria, molds,

spores, etc.
All Employees:
Similar Exposure Group (SEG)
Process

Job

Task

Environmental agent
Exposure Assessment
Outcomes
 Unacceptable (> OEL)

 Significant (30 - 100% OEL)

 Insignificant

 Uncertain
Occupational Exposure Limits
Full shift time-weighted average

Peak limits:
--Ceiling
--Short term exposure limits (STELs)

Excursion limits
 How do Industrial Hygienists
judge exposures?

 Sampling data

 Screening measurements

 Experience elsewhere

 Chemical & physical characteristics

IMPORTANT NOTE CONCERNING
UNACCEPTABLE EXPOSURES

Personal protective equipment

does not make an
unacceptable exposure an
acceptable exposure
Qualitative Exposure Assessment
-- Deliverables--

1. Exposure assessment database

2. List of Unacceptable Exposures
3. Sampling Plan
5. List of SEGs qualifying for medical
surveillance
5. List of SEGs qualifying for
environmental agent specific education
& training
HYGenius V2: Alcoa’s Exposure
Assessment Data Management System

Alcoa’s tool to manage all exposure

assessment data
Web enabled application able to support
all European based languages
Common data structure to facilitate
data sharing
HYGenius V2
SEG Manager to create and manage IH
department/job structures’
Creation of common department/job
nomenclature
Intelligent calculations
Baseline analysis
Numerous reports
EHS Metric 5 statistics
Technical support
 Exposure Assessment Process
QUALITATIVE
EXPOSURE
ASSESSMENT

UNACCEPTABLE UNKNOWN SIGNIFICANT INSIGNIFICANT

IMPLEMENT QUANTITATIVE
NO ACTION
CONTROLS ASSESSMENT
Exposure Measurements
 Why? To resolve Uncertain exposures

 Why? To establish minimum baseline

data if exposure occurs 12 or more days
per year.
Quantitative assessments
Collect six (6) or more personal samples
for each SEG judged significant or
unacceptable.
Quantitative Exposure Assessments
 Personal monitoring
 Random sampling strategy
 Standard methods: Sampling & Analysis
 Proficient laboratory analysis (UEC)
 Interpretive reports
 Timely and effective feedback to all
employees in the SEG
 Quantitative database
 Communication of sampling results:

 Interpretive reports should be

communicated to management, all
affected employees and appropriate staff
in an effective and timely fashion.
Significant and Unacceptable Exposures
• Provide education and training on health risks
• Create knowledge, skill and motivation to:
 Follow safe job procedures

 Appropriately wear personal protective

equipment
 Appropriately respond to an

incident
Reassessments

QUALITATIVE: Reassess when there is

a significant change in the process,
division of labor or environmental
agents.

QUANTITATIVE....periodic surveillance
 Health Hazard Control Process
Medical
Surveillance

Management Health Hazard Controls:

Hazard Communication
Support & Risk Exposure
Engineering Controls
Health Identification Assessment Work Practice Controls
Professionals Personal Protective Equipment

Employee
Epidemiologic
Health
Evaluations
Protection
Hierarchy of Health Hazard Control

 Elimination . . . greatest extent feasible

 Substitution . . . greatest extent feasible
 Engineering . . . greatest extent feasible
 Work practice controls
 Administrative controls
 Personal protective equipment
Engineering Controls
Feasibility assessments

Implementation plans

Alcoa Balanced Scorecard milestones

Monitor if performance can decline or fail.

 Medical Surveillance
Medical
Surveillance

Management Health Hazard Controls:

Hazard Communication
Support & Risk Exposure
Engineering Controls
Health Identification Assessment Work Practice Controls
Professionals Personal Protective Equipment

Employee
Epidemiologic
Health
Evaluations
Protection
Identify Employees Who Qualify
for Medical Surveillance
 Airborne exposures:
 TWA assessments: 12 or more days per
year >50% OEL (varies)
 Peak assessments: 12 or more times per
year >100% OEL (varies)
 Skin contact and inadvertent ingestion:
 Qualitative assessment reveals significant
or unacceptable skin exposures.
Specific Industrial Hygiene
Standards
Hearing Conservation and Noise Control
Respirator selection and use
Beryllium
Ionizing Radiation / Lasers
Asbestos
Refractory Ceramic fibers
Lead
Oil Mist
Silica
Heat Stress
Toxic Substances Control Act-TSCA
Alcoa’s Hearing Conservation and
Engineering Noise Control Program

 There is a recognition in Alcoa that:

 A large percentage of our population is exposed to
harmful levels of noise.
 The risk of noise-induced hearing loss is significant.
 Hearing ability affects an individual’s social and
communications functions.
 Hearing loss impacts on the ability of employees to do
their jobs effectively and safely since their capacity to
understand speech and warning signals may be
impaired.
Alcoa Dual Strategy for Prevention of
Workplace Noise Induced Hearing
Loss

• Worldwide Health Standard for Hearing

Conservation and Engineering Noise Control

• Alcoa Balanced Scorecard Strategic Milestone

Alcoa’s Hearing Conservation and
Engineering Noise Control Program
 The Hearing Conservation and
Engineering Noise Control Protocol has
six elements:
 Noise Exposure Assessments
 Engineering Noise Control
 Hearing Protection
 Audiometric Testing / Hearing Loss Criteria
 Hearing Conservation Training
 Recordkeeping
Engineering Controls
 Engineering controls are implemented to reduce
exposures to less than 85 dBA TWA.
 When controls will not reduce noise to below 85 dBA,
incremental engineering controls that minimize the
noise hazard are implemented.
 Engineering noise control action plans are written to
define the problem, determine engineering solutions
and establish implementation timing.
 Plans are adopted by management.
Alcoa Balanced Scorecard
Strategic Milestone
EHS Health Hazard Control
 Noise3 - 20% or more reduction in the noise dose
for the 10 highest risk unacceptable noise job
classifications by 2001
 3Reference the Priority Rating guidelines in Chapter
4.4.1. of the Alcoa Hearing Conservation and
Engineering Noise Control Guidance for Compliance
document to establish the 10 highest risk noise
unacceptable job classification mean baselines.
Metric #5
Unacceptable Noise Exposures

Select Doubling Rate: 5

Reduction
Unacceptable SEG Goal from Actual Percent
Baseline Qtr 1 Percent of Percent of
Shift Number (Get from Occupational Percent of Percent of Reduction Reduction
Exposure Exposure OEL for Goal (with
Length Noise Priority Exposure OEL for Baseline from from
Value Value Qtr 1 average) for
(Hours) Ranking sheet, Limit (OEL) Baseline Dose Baseline Baseline
(dBA) (dBA) Exposure Qtr 1
column F) (Baseline - for Qtr 1 for Qtr 1
20%)
8 1 85 94 348 278.40 85.00000 100 248.0 278.4% 56.0%
8 2 85 93 303 242.40 85.00000 100 203.0 242.4% 48.0%
8 3 85 92 264 211.20 85.00000 100 164.0 211.2% 42.0%
8 4 85 91 230 184.00 85.00000 100 130.0 184.0% 37.0%
8 5 85 90 200 160.00 85.00000 100 100.0 160.0% 32.0%
8 6 85 89 174 139.20 89.00000 174 0.0 0.0% 0.0%
8 7 85 88 152 121.60 88.00000 152 0.0 0.0% 0.0%
8 8 85 87 132 105.60 87.00000 132 0.0 0.0% 0.0%
8 9 85 86 115 92.00 86.00000 115 0.0 0.0% 0.0%
8 10 85 85 100 80.00 85.00000 100 0.0 0.0% 0.0%
Average
of
Groups 202 161 117 85 107.6% 22.0%
Task Analysis

Shift Length in hours: 8

Title
Current Conditions With Changes Implemented
(F) New
(A) (B) Noise (C) Time (G) Time (H) New (I) New
(D) Dose for (E) TWA Noise
Job Classification Description Level for of Task in of Task in Dose for TWA for
Task for Task Level for
of Task Task Minutes Minutes Task Task
Task
Operator Task 1 93 60 37.89% 78.00 83 60 9.47% 68.00
Task 2 105 60 200.00% 90.00 95 60 50.00% 80.00
Task 3 89 60 21.76% 74.00 89 60 21.76% 74.00
Task 4 94 60 43.53% 79.00 94 60 43.53% 79.00
Task 5 90 60 25.00% 75.00 90 60 25.00% 75.00
Task 6 90 60 25.00% 75.00 90 60 25.00% 75.00
Task 7 90 60 25.00% 75.00 90 60 25.00% 75.00
Task 8 90 60 25.00% 75.00 90 60 25.00% 75.00
(J) Total 480 403.18% 95.06 480 224.76% 90.84
(K) Goal Desired 322.55%
(L) Goal Achieved 224.76%
What is Noise Control?
Reduction of noise through implementation of
some “engineering change.”
Can include:
 Enclosures
 Damping
 Barriers
 Quiet Motors
 Cushioning
 Respiratory Protection
 Written program and coordinator
 Templates available for written program
 Proper selection
 Dust masks = respirators
 Training, fit testing, medical surveillance
 “Voluntary” users also part of program
 Inspection and maintenance
 Process to review/improve engineering controls
 Rules and enforcement
Beryllium
Alcoa airborne limits- ten fold lower
than OSHA
Restricted Work Areas
Laundered clothing, showers, restricted
eating/smoking, etc.
Medical surveillance- blood lymphocyte
test
 Ionizing Radiation/Lasers
TO ENSURE THAT RADIATOIN HAZARDS ARE IDENTIFIED, EVALUATED, CONTROLLED

 Written program
Radiation Safety Officer
 Inventory of radiation sources
Exposure Assessment
 Communication and training
 Employee and area monitoring
 New process/project review
Engineer to ALARA (as low as reasonable attainable)
 Safe work instructions and protective equipment
 Inspections (leak tests) and maintenance
 Rules and enforcement
WWHP: Assessing Metal Supplies

for Radioactivity
Issue: Illegal disposal of radioisotopes and
NORM in metal feedstocks.

Standard requires a formal assessment of all

metal supplies.

If the assessment reveals a significant risk,

must establish a program for monitoring
incoming metal supplies for radioactivity.
Asbestos
TO IDENTIFY AND MANAGE ASBESTOS CONTAINING MATERIALS

 Surveys
 Written procedures
 Purchasing controls
 Monitoring (bulk samples, area, employees)
 Communication and training
 Disposal practices
 Replacement programs
 Inspection and maintenance, project reviews
 Rules and enforcement
 Asbestos: Uses
Used extensively until 1980 in:

Fireproofing structures
Thermal insulation systems
Plaster Asbestos is a
naturally
Acoustical surfacing occurring
mineral.
Floor and ceiling tiles
Brakes, clutches, etc.
Unless positively known otherwise, assume these
types of materials constructed prior to 1980 contain
asbestos.
 Occupational Exposure
Limits

 OEL = 0.1 f/cc [fiber per cc of air] as an

8 hour TWA [time weighted average]

 EL (Excursion Limit) = 1.0 f/cc averaged

over 30 minute sampling period
Medical Surveillance
Required for employees who:
 Are exposed at or above the
Occupational Exposure Limit
(OEL) or Excursion Level (EL)
for 30 or more days/year,
or
 Perform Class I, II or III work for 30 or more
days/year regardless of exposure,
or
 Wear negative pressure respirators
Regulated Areas
Requirements:
 Marked
Asbestos Work:
 Limited access (authorized only) No Entry

 Respirators used

 No smoking, eating, drinking, chewing

gum or tobacco, or applying cosmetics

 Supervision of work by competent person

Fiber Glass Continuous
Wool Filament
Fiber Glass

Man-Made Vitreous Fiber Family

(MMVF)

Mineral Wool Refractory

Rock/Slag Ceramic Fiber
Wool RCF
Refractory Ceramic Fibers

Concern that this asbestos substitute

also poses health risks
 Mandatory procedures for:
 Safe use
 Handling
 Disposal
 Refractory Ceramic Fibers (RCF)
Health Effects
 Occupational exposure to RCF is associated
with increased risk of pleural plaque and
chronic lung symptoms of coughing and
chronic respiratory illnesses.
 No definite or significant association has been
found between RCF and a measured or
measurable decline in lung function.
 Until further data is available RCF should be
regarded as a possible cause of chronic lung
disease.
 Refractory Ceramic Fibers (RCF)
Health Effects
 When heated, refractory ceramic materials
will undergo partial conversion to
cristobalite.
 "After service” dusts from ceramic fiber
insulating materials may contain crystalline
silica (cristobalite) at >20% if surface
temperatures are >1000°C.
 Crystalline silica was recently classified
IARC as a Group 1 Human Carcinogen.
 Crystalline silica is also associated with
lung fibrosis (silicosis).
Refractory Ceramic Fibers (RCF)
Occupational Exposure Level

 OEL: 0.2 fiber/cubic centimeter (f/cc) as

an 8-hour Time-Weighted Average
(TWA).

 Ceiling limit: 1.0 f/cc based on a 30

minute sample.
Refractory Ceramic Fibers (RCF)
Medical Surveillance

 30 days or more per year at 0.1 f/cc as a time

weighted average.

 Exceed the ceiling limit of 1.0 f/cc 30 times or

more per year.
Silica: Health Effects

 Toxicity is dependent on two factors:

 Deposition of silica dust within the

lower respiratory tract.

 Stimulation of chronic inflammatory

process-causing fibrosis.
Silica: Health Effects
 Carcinogencity:

 Silica is a lung carcinogen

 IARC Classification-1: Human

Carcinogen
Silica: Occupational Exposure
Limit
 Occupational exposure limit:
 0.05 mg/m3 8-TWA respirable crystalline
silica
 Action level
 0.025 mg/m3 8-TWA respirable crystalline

silica
Silica: Medical Surveillance

 Baseline and periodic medical exam

 Periodic exposure history
 Pulmonary function tests
 Chest x-rays
Oil Mist

 Three categories of oil mist

 Straight oils: consist of mineral oils with
no water.
 Soluble oils: consist of higher viscosity
oils emulsified with water.
 Synthetic oils: consist of water-based
alkaline solutions containing acid salts
and, in some cases, ethanolamines.
Oil Mist

 Metalworking Fluids (MWF) are used in Alcoa

for cutting, grinding, rolling, extruding,
forging and drilling of aluminum. The
functions of MWF are to:
 Lubricate
 Dissipate heat
 Remove debris
Oil Mist: Health Effects

 Various MWF and their components

can act as:
 Irritants

 Sensitizers

 Carcinogens
Oil Mist: Health Effects
 Irritation effects

 Respiratory irritation-industrial
bronchitis

 Skin irritation-dermatitis
Oil Mist: Health Effects
 Sensitization effects

 Respiratory-occupational asthma

 Dermal-contact dermatitis
Oil Mist: Health Effects
 Carcinogenic effects

 Respiratory tract

 Gastrointestinal tract

 Skin
Oil Mist: Controls

 Alcoa OEL: 0.5 mg/m3

 Alcoa action level: 0.25 mg/m3

 Engineering controls

 Personal protective equipment

 Work practice/personal hygiene

 What Are
PCBs?
 Man-made chemicals -
polychlorinated biphenyls

 May be liquid or solid

 Stable, hence long-lasting

 Where Are PCBs Likely to Be
Found?
Permitted current use
 Closed electrical equipment like
transformers and capacitors
 Old fluorescent light ballasts

Residuals
 PCB-contaminated materials:
 Sludges and oils
 Potential Health Effects of PCBs
 Based on human exposure to high
levels of PCBs:
– Chloracne

 Based on animal studies:

– Cancer
– Liver effects
– Immune system effects
– Reproductive effects
 Reproductive
 Concerns
Animal studies found that certain Laboratory Studies
kinds of PCBs cause low birth
weight and some stillbirths

 Studies with humans have been

inconclusive

 Nevertheless, it is wise to avoid

direct contact with PCBs
Permissible Occupational Exposure
Limits

 PEL depends on the level of chlorine

in the PCBs

 1 mg / cubic meter - 42% chlorine

 0.5 mg / cubic meter - 54%

chlorine
Note - These are air levels. PCBs also
carry a skin notation
 PP
E
 When working with PCB-containing
materials at levels > 50 ppm,
protective clothing is required

 Type of PPE depends on the job

 Disposable clothing is preferred

 Hygiene Practices and Facilities
Routine exposure:

 Wash hands with soap and water upon leaving a

PCB-contaminated work area

In case of spills, splashes:

 Remove wet clothing, then wash or shower

 Discard soaked shoes, then shower
 Flush eyes with running water, seek medical help
 Medical
Surveillance
 Routine medical evaluation for occupational
PCB exposure is not indicated

 Workers may request PCB medical

evaluation
Occupational Lung Diseases:
Potential Causative Agents
Fibrosis - Silica, asbestos, beryllium
Lung Cancer - CTPV, asbestos, silica, nickel,
chromium, beryllium
Occupational Asthma - isocyanates, bacteria,
fungi, rosin, aldehydes
Potroom Asthma - possible agents include,
sulfur dioxide, fluorides, alumina dust
Fibrosis
Introduction of certain types of dusts such as
silica that leads to a series of events
damaging the lung:
 an excessive inflammatory response.
 impairment of the cell matrix repair
mechanism.
 cell proliferation in the lung of fibroblasts.
 restriction of air flow in the lung.
Chronic condition - symptoms do not improve
after exposure ceases.
Lung Cancer
Mechanism not completely understood.
Some workplace carcinogens may act directly as
initiators (irradiation).
 React directly with DNA
Some workplace carcinogens are converted
metabolically that react with DNA (BaP).
Some workplace carcinogens act to promote tumors
depending on their physical characteristics
(asbestos).
Occupational Asthma
Immunological reaction which causes an
airways obstruction.
Symptoms of wheeze and cough.
Low exposures both respiratory and skin can
cause reaction.
Once an individual is sensitized, extremely
small exposure can cause reaction precluding
working in the environment.
Potroom Asthma
Incidence of potroom asthma varied
widely.
 Low in US

 High in Australia/NZ/Norway

Healthwise study in Australia to better

understand disease.
 Prospective longitudinal study

following individuals through time.

 Lead
To ensure employee exposure to lead is controlled and
that lead paints are not used or disturbed without
proper control measures.

 Lead Containing Paints

 Eng Standard 18.20.2
 Identify lead containing paints
 Engineering Control
 Waste disposal
 PPE
 Training
Alcoa WWHS for Heat Stress
& Heat Stress Guideline

Intent: Prevent heat exhaustion, heat cramps,

heat stroke, etc.

Exposure assessments performed by an industrial

hygiene professional.

Identify SEGs with significant or unacceptable

exposures to heat stress.

Choice of qualitative or quantitative criteria.

Alcoa WWHS for Heat Stress
& Heat Stress Guideline
Basic practices: Education & fluid replacement
(applies to most every workplace)

Additional practices: Medical surveillance and

other controls....if “Significant” heat stress

Potroom practices for acclimatization, work breaks

and overtime --based upon physiological surveys.
Toxic Substance Control Act-TSCA

To monitor and manage compliance issues

associated with the Toxic Substance
Control Act, or similar regulations.

 TSCA-like regulations in other countries where

you market your products
 Recording/reporting of allegations of significant
adverse reaction to health or the environment
Alcoa Intranet Links

WWHS’ and Industrial Hygiene Standards

can be found on EHS Standards Page

http://prdweb.ami.alcoa.com/ehs_standards/
Alcoa Intranet Links

http://prdweb.ami.alcoa.com/ehs_standards/
Alcoa Intranet Links

http://prdweb.ami.alcoa.com/ehs_standards/