Evaluation of Occupational Hazards in Foundries

download Evaluation of Occupational Hazards in Foundries

of 30

Transcript of Evaluation of Occupational Hazards in Foundries

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    1/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005

    Correspondence to:Adel M. Zakaria,Occupational Health Department,High Institute of Public HealthAlexandria UniversityE-mail: [email protected]

    Evaluation of Occupational Hazards in Foundries

    Adel M. Zakaria* Kamal H. Noweir*

    Gamal El-Maghrabi**

    * Occupational Health Department, High Institute of Public Health,

    Alexandria University.

    ** Occupational Safety and Health Department, Ministry of Labor, Behira.

    ABSTRACT

    The working environment of foundries is hazardous and characterizedby multiple simultaneous chemical, physical and mechanical hazardsexposure, which would lead to injuries of foundry workers. The aim of thepresent work is to evaluate occupational hazards in four foundries, two inAlexandria: El Nasr and Ramsis, and two in Behira: Misr Spinning andWeaving and Misr Rayon companies. Levels of total and respirable dust, freesilica % in total dust and lead concentration in total and respirable dust;NO2, SO2 and CO concentrations; noise and heat stress levels have beendetermined in the present work.

    Occupational injuries data were analyzed in a three years period from

    1998 to 2000. The results of the present work revealed;1. The levels of total dust and respirable dust exceeded the threshold limit

    values at knockout and cleaning operations at El Nasr Company.2. Free silica percentage exceeded permissible levels in all operations

    except pouring in El Nasr Company.3. CO levels in Misr Spinning and Weaving Company were higher than

    threshold levels.4. Noise levels in knockout and cleaning operations at the four companies

    were exceeding the threshold limit values.5. Heat stress levels in melting and pouring operations in El Nasr and in

    pouring operation in Ramsis Company were higher than the maximumpermissible levels.

    6. The age group 31-40 years has recorded the highest average incidencerate of injuries of age groups (P

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    2/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    434

    7. Lower extremities and higher extremities have recorded the highestaverage incidence rate in the four companies (P

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    3/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    435

    Physical hazards, which are mainly associated with various

    foundry processes are noise, vibration and heat.(5,6)

    The foundry industry includes; pourers, moulders, core workers

    and cleaning room operators in addition to crane operators, electricians

    and welders.

    Foundry workers accidents can result in injuries from (i) manual

    and mechanical materials handling; (ii) work equipment and

    machinery; (iii) walking and working surfaces; (iv) foreign particles in

    the eye; (v) contact with hot material; (vi) falling objects and (vii) fire

    and explosion.(7)

    Manual materials handling is the most prevalent causes of injury to

    foundry workers due to overexertion and poor lifting techniques.(8-10)

    Traumatic injuries and burns have been received by workers

    handling castings, hot core and molten metal because of inadequate

    personal protective equipment and poor work practices.(9)

    Semiautomatic and automatic machinery presented hazards from

    moving parts and flying or ejected materials. Improper maintenance,

    repair, guarding and use of grinders and abrasive wheels may also

    result in worker injury. Poor house keeping and poorly lighted area

    result in slips, trips and other types of falls on walking and working

    surfaces.(7)

    Higher temperature environment foundry increases the strength on

    mechanical handling devices. In addition, some of these devices are

    continuously vibrating, resulting in mechanical stress on nuts, bolts,

    chains and cables; which eventually may result in equipment failure,

    may lead to major explosions, fires, spills and burns.(7)

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    4/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    436

    The objective of the present work is to evaluate extensively the

    main chemical and physical occupational exposures in the working

    environment; and to analyze injuries data in four foundry plants in

    Alexandria and Behira in three years from 1998 to 2000.

    MATERIAL AND METHODS

    The present study has been conducted in four foundry plants

    (manual and automatic) where the number of workers is more than 50

    workers. In Alexandria governorate; Ramsis and El Nasr foundries, and

    in Behira governorate; Misr Company of Spinning and Weaving and

    Misr Company of Synthetic Rayon in Kafr El-Dawar have been chosen

    to be surveyed. In table (1) a brief description of each of the four

    foundries are presented.

    Table (1): Description of the Four Foundries Surveyed.

    Parameter El Nasr RamsisMisr for

    SpinningMisr Rayon

    Sector Business Private Business Private

    No. of workers 410 53 210 51

    No. and type of

    furnaces

    3 large electric

    furnaces

    2 small electric

    furnaces

    5 furnaces:

    3 electric and

    2 crucible (light

    fuel oil)

    2 small crucible

    (light fuel oil)

    Mode of

    operation

    Highly automated Manual Automated Manual

    Casting type Iron Iron Iron, aluminum

    and copper

    Lead, aluminum

    and copper

    Safety

    performance

    1. Good

    housekeeping

    1. Bad

    housekeeping

    1. Fair

    housekeeping

    1. Fair

    housekeeping

    2. Available

    PPE

    2. Non available

    PPE

    2. Lack of safety

    measures

    2. Lack of safety

    measures

    3. Highly

    qualified

    safety staff

    2. No safety

    staff

    3. Non available

    PPE

    3. Non available

    PPE

    4. Adequatesafety

    measures and

    rules

    4. Lack of safetymeasures

    4. Non qualifiedsafety staff

    4. Non qualifiedsafety staff

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    5/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    437

    Methods

    Sampling locations and durations

    Air samples have been taken at breathing zone of workers. Area

    samples were taken as near as possible to work stations. Personal

    samples (attached to workers bet and collar) were taken as well.

    Samples were taken at the main steps of casting, moulding, melting,

    finishing, and cleaning. Air samples were taken for 2-3 hours.

    Chemical pollutants

    Total suspended particulate TSP

    Total suspended particles were determined gravimetrically.

    Membrane filter attached to a calibrated personal pump (MSA) was

    used to collect particulates at a rate of 0.8 L/min.(11)

    Respirable dust

    Respirable dust samples were taken typically as TSP, except that a

    10 mm nylon cyclone is put prior to the filter holder to separate

    particulate > 10 m and pass through particulate < 10 m to be trapped

    on the filter.(11)

    Sulphur dioxide

    Sulphur dioxide is absorbed by aspirating a measured air sample

    by a calibrated electrical diaphragm pump through a solution of

    potassium tetrachloromercurate, TCM. This procedure results in the

    formation of the dichlorosulfitomercurate which is determined

    colorimetrically at 548 nm.(12)

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    6/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    438

    Nitrogen dioxide

    Nitrogen dioxide is absorbed from a measured volume of air

    sample by a calibrated electrical diaphragm pump through aqueous

    triethanolamine solution, subsequent analysis is preformed using an

    azo-dye forming reagent. The color produced by the reagent is

    measured in a spectrophotometer at 540 nm.(13)

    Carbon monoxide

    Carbon monoxide is determined by a self calibrated direct readinginstrument; Multilog 2000 Quest Technologies, USA.

    Free silica

    Free silica percentage in total dust samples was determined by

    spectrophotometric method.(14)

    Lead

    Lead in total and respirable particulate samples are extracted by a

    mixture of nitric and hydrochloric acids. The analysis is subsequently

    made by atomic absorption spectroscopy using the 217.0 nm lead

    line.(15)

    Physical hazards

    Noise

    Noise levels have been measured by a calibrated sound level meter

    at 114 dB(A) nearby the workers locations at knocking out and cleaning

    operations. The average level was computed.(16)

    Heat stress

    Heat stress, wet bulb globe temperature (WBGT) has been

    evaluated by Botsball nearby the workers locations in front of the

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    7/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    439

    furnaces during melting and pouring operations. The average heat

    stress has been computed for each operation.(17)

    Accidents records

    The raw accidents records have been taken from the four

    companies files for the period from 1998-2000. The raw accidents

    records have been organized and recalculated so as to demonstrate

    incidence rate of injury per 100 full time workers of injuries causes,

    injuries means, injured parts of body and age groups.

    Frequency rate (FR) and severity rate (SR) were computed using

    the forthcoming formulas. The injury in the formula is the injury which

    disables the injured worker for more than the day or shift during which

    he was injured.(18)

    FR =hoursworkedTotal

    reportedinjuriesofNumber 610

    (Total worked hours = number of workers working days 8)

    SR =hoursworkedTotal

    injurytoduelostdaysofNumber 310

    The injuries data were analyzed by chi-square test.(19)

    RESULTS

    Chemical pollutants

    Total dust

    Concentrations at the four major operations of casting in the four

    surveyed companies are presented in figure (1). It is apparent that the

    highest levels of total dust at the four operations have been observed in

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    8/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    440

    El-Nasr Company. In contrary the lowest levels have been recorded in

    Ramsis Company.

    0

    1

    23

    4

    5

    6

    7

    8

    9

    Moulding Melting Pouring Shake-out

    and cleaning

    El-Nasr

    Ramsis

    Misr Spnning

    Misr Rayon

    Fig (1): Total dust different operations in the four companies (mg/m3)

    Tota

    ldustconcentration

    (mg/m3)

    Respirable dust

    Respirable dust data at the four major operations of casting in the

    four surveyed companies are presented in figure (2). The same trend

    observed with total dust is repeated with respirable dust, El-Nasr was

    the highest and Ramsis was the lowest in all operations.

    Free silica percentage in total dust

    The free silica percentage in total dust at the four operations of

    casting is presented in figure (3). Ramsis Company recorded the highest

    free silica percentage in the four operations, followed by El-NasrCompany where as Misr Rayon Company recorded the lowest

    percentage in the melting and pouring operations.

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    9/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    441

    0

    0.5

    1

    1.5

    2

    2.5

    3

    3.5

    4

    Moulding Melting Pouring Shacke out

    and cleaning

    El-Nasr

    Ramsis

    Misr Spnning

    Misr Rayon

    Fig (2): Respirable dust different operations in the four companies

    (mg/m3)

    Respirabledustconcentration

    (mg/m3)

    Company process

    0

    0.5

    1

    1.5

    2

    2.5

    3

    M oulding Melting Pouring Shacke out

    and cleaning

    El-Nasr

    Ramsis

    Misr Spnning

    Misr Rayon

    Fig (3): Free silica perecentage in total dust different operations in

    the four companies

    Freesilicapercen

    tage

    Company process

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    10/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    442

    Airborne lead concentrations

    Figure (4) presents the concentration of lead in total and respirable

    dust in melting and pouring operations in Misr Rayon Company, since

    it was the only company which was casting lead. It is clear that lead

    concentrations in total and respirable dust were very close. However,

    lead concentrations in both total and respirable dust were higher in

    melting than in pouring operation.

    0

    20

    40

    60

    80

    100

    120

    melting pouring

    total dust

    respirable dust

    Fig.(4): lead concentrations (g/m3) in total and respirable

    dust at melting and pouring operations in Misr Rayon

    company

    Leadconcentration

    Gaseous levels

    Figure (5) represents the average NO2 concentration in melting and

    pouring operations in the four companies. In general, melting operation

    has recorded higher levels of NO2 than those of pouring operation in

    the four companies. El-Nasr Company has recorded the highest and

    lowest levels of NO2 in melting and pouring operations respectively.

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    11/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    443

    0

    10

    20

    30

    40

    50

    60

    70

    Moulding Pouring

    El-Nasr

    Ramsis

    Misr Spnning

    Misr Rayon

    Fig (5): No2 concentrations at (g/m3) different operations in

    the four companies

    No2concentration(g/m3)

    SO2 levels

    Figure (6) represents the average SO2 concentration in melting and

    pouring operations in the four companies. The highest levels were

    observed in Ramsis Company in the two operations, whereas the lowest

    levels were recorded in Misr Weaving Company.

    CO levels

    Figure (7) represents the average CO levels in charging, melting

    and pouring operation at Misr Weaving Company. The highest average

    levels have been recorded in pouring operation.

    Physical hazards

    Noise levels

    Figure (8) represents the noise levels at shake out and cleaning

    operation, which is the noisiest operation in casting. El Nasr Company

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    12/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    444

    has recorded the highest levels among the four companies, whereas

    Misr Rayon Company has recorded the lowest levels.

    0

    100

    200

    300

    400

    500

    600

    Moulding Pouring

    El-Nasr

    Ramsis

    Misr Spnning

    Misr Rayon

    Fig (6): So2 concentrations at different operations in the four

    companies

    So2co

    ncentration(g/m3)

    020

    40

    60

    80

    100

    120

    140

    160

    180

    200

    charging melting pouring

    Fig (7): Co concentrations (ppm) at the different operations of coke fueled

    furnace in Misr Weaving company

    Coconcntration(ppm)

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    13/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    445

    86

    88

    90

    92

    94

    96

    98

    100

    102

    El Nasr Ramsis Misr spinning Misr Rayon

    Fig (8): Average noise levels in shakeout and cleaning operation at

    the four companies (dBA)

    A

    veragenoiselevels(dBA)

    Heat stress levels

    Heat stress levels (WBGT) of melting and pouring operations in the

    four companies are presented in figure (9). Heat stress levels recorded

    in El-Nasr Company were the highest in the two operations, whereas

    Misr Rayon has recorded the least levels.

    Accident records

    Age group

    Figure (10) represents the average three years incidence rate of

    injury (per 100 workers) as related to age groups in the four companies.

    Ramsis Company has recorded the highest incidence rate in all age

    groups. The highest incidence rate has been recorded in age group 31-

    40, while the lowest has been recorded in age group 51-60 years.

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    14/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    446

    0

    5

    10

    15

    20

    25

    30

    35

    Melting pouring

    El-Nasr

    Ramsis

    Misr spinning

    Misr rayon

    Fig.(9): Average heat stress levels in melting and pouring at

    the four companies

    AverageHeatStress

    Fig.(10) Correlation between age and average No.

    of injuries/100 workers in the four companies

    0

    10

    20

    30

    40

    50

    60

    AverageNo.

    ofinjuries/100wo

    rkers

    20-30

    31-40

    41-50

    51-60

    El-Nasr

    Ramsis

    Misr Spining

    Misr Rayon

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    15/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    447

    Injured body parts

    Figure (11) represents the average three years incidence rate of

    injury (per 100 workers) versus the injured body part in the four

    companies. In general, Ramsis Company has recorded the highest

    figures of injured body parts. Lower extremities and higher extremities

    in order have been recorded the highest incidence rate of injury among

    body parts, there was no injury of neck in the four companies.

    Fig.(11) Correlation between injured part and average No.

    of injuries/100 workers in the four companies

    0

    10

    20

    30

    40

    50

    60

    AverageNo.ofinjuries/100workers

    Head

    Neck

    Trunk

    Higherextremities

    Lowerextremities

    Others

    El-NasrRamsis

    Misr Spining

    Misr Rayon

    Cause of injury

    Figure (12) illustrate average three years incidence rate of injury

    (per 100 workers) by the cause of injury in the four companies. Workingenvironment and transportation were major causes of injury in Ramsis

    Company, in the mean time they recorded the highest figures. Biologic

    agents was not responsible for any injury in the four companies.

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    16/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    448

    Fig.(12) Correlation between causes of injury and average No.

    of injuries/100 workers in the four companies

    0

    5

    10

    15

    20

    25

    30

    35

    40

    45

    AverageNo.ofinjuries/100workers

    Mach

    ienes

    Transportation

    andObject

    Lifting

    EquipmentandHazard

    ousinstru

    ments

    HazardousM

    aterial

    WorkEnviro

    nment

    Bilogical

    Agent

    O

    thers

    El-Nasr

    Ramsis

    Misr Spining

    Misr Rayon

    Means of injury

    Figure (13) represents average three years incidence rate of injury

    (per 100 workers) as related to means of injury in the four companies. It

    is obvious that explosion, hazardous materials and electrical current did

    not lead to any injury in the four companies. Contact with hot objects

    followed by faulty action and striking against and exhaustion were the

    major means of injury. Ramsis Company has recorded the highest

    figures among the four companies in all means of injury.

    Injury indices

    Figure (14) represents frequency rates and severity rates ( 100) of

    different companies in the years 1998-2000. Ramsis foundry has

    recorded the highest frequency and severity rates in the three years of

    study. The lowest frequency rate was recorded in Misr Rayon Company

    in the three years.

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    17/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    449

    Fig.(13) Correlation between mean of injury and average No.

    of injuries/100 workers in the four companies

    0

    5

    10

    15

    20

    25

    30

    35

    AverageNo.ofinjuries/100workers

    Falling

    Fallingobjects

    Faultyaction&strikingagents

    Caught

    betweenobjects

    Exhaustion

    Contacth

    otobjects

    Electricalcurrent

    Hazardousmaterial

    Explosion

    Others

    El-Nasr

    Ramsis

    Misr Spining

    Misr Rayon

    Fig. (14): Injures parameters at El Nasr, Misr Rayon, Misr spinning &

    Ramsis company in years 1998-2000

    0

    100

    200

    300

    400

    500

    600

    1998

    1999

    2000

    1998

    1999

    2000

    1998

    1999

    2000

    1998

    1999

    2000

    Frequency

    Severity

    El-Nasr Ramsis Misr Spining Misr Rayon

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    18/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    450

    DISCUSSION

    Chemical hazards

    Airborne particulate

    Total dust

    The TLV of total dust in foundries could be taken as 10 mg/m3

    referring to nuisance dust (Law No. 4, 1994), (20) however, the existence

    of free silica and different metal fumes might decrease markedly total

    dust TLV, which might be computed from the following formula.(1)

    TLV of total dust (mg/m3) =3

    30

    +%silicafreeAverage

    The computed TLV of total dust and average total dust

    concentrations at different operations in the four companies are

    presented in table (2).

    Table (2): Computed TLV's of Total Dust on the Basis of Average Free

    Silica Percentage and Average Total Dust Concentration at

    Different Operation in the Four Companies.

    El Nasr Ramsis Misr Weaving Misr RayonCompany

    ProcessAv.

    ConTLV

    Av.

    ConTLV

    Av.

    ConTLV

    Av.

    ConTLV

    Moulding 3.59 5.6 0.55 6.17 - 5.8 - 5.17

    Melting 3.58 6.33 0.89 7.7 1.45 6.77 1.83 5.63

    Pouring 0.91 6.6 0.57 7.34 1.02 6.1 0.93 5.88

    Shakeout and

    cleaning8.31 5.57 0.58 6.98 - 6.28 - 5.5

    The average concentration of total dust at shake-out and cleaning

    operations in El Nasr Company was much higher than the computed

    TLV, which might increase the liability of exposed workers to silicosis

    risk.(21)

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    19/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    451

    As shown in figure (1), the high-recorded levels of total dust

    concentration in El Nasr Company might be attributed to the heavy

    work load and extensive activities in the company, since at the study

    period there was a contract between the company and Alexandria

    governorate to produce a big number of decorative light columns.

    Much lower levels of total dust were recorded in 12 foundries in

    Japan.(22) The range was 0.14-1.55 mg/m3 compared to 0.55-8.31 mg/m3

    in the present study reflecting bad house keeping and lack of control

    measures, which was observed in the surveyed foundries.

    Respirable dust

    Respirable dust concentrations were following the same trend

    observed with total dust concentrations as shown in figure (2). The

    same reason, which interprets the higher results of total dust in EL Nasr

    Company is plausible for those of respirable dust. The average

    concentration of respirable dust in pouring operation is higher than

    total dust in EL Nasr Company, which is unlogic. However, this

    observation is interpreted by the non-simultaneous sampling of total

    and respirable dust for technical reasons.

    Free silica percentage

    Free silica percentage as shown in figure (3) is somewhat

    misleading, because total dust concentrations in the different operations

    are not the same. Hence, expressing free silica in g/m3 would change

    markedly the data trend observed in figure (3). El Nasr Company will

    be the highest in all operations except pouring operation, and Ramsis

    would rank in the fourth position after it was the first. The

    concentration of free silica in g/m3 at EL Nasr Company in moulding,

    melting and shake-out and cleaning were 84.7, 56.8 and 198.6 g/m3

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    20/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    452

    respectively. These values exceed the NIOSH recommended TWA of 50

    g/m3,(5) which emphasized what mentioned earlier of the high risk of

    silicosis in EL Nasr Company. The levels of free silica in g/m3 in the

    other companies are below NIOSH limit. In a similar study,(23) the range

    of silica was 50-970 g/m3.

    Airborne lead concentration

    Misr Rayon Company was the sole company casting lead. The

    average levels of lead concentration, as shown in figure (4), in total dustin melting and pouring were 0.09 and 0.075 mg/m3 respectively

    whereas the average level of lead in respirable dust in melting and

    pouring were 0.103 and 0.08 mg/m3 respectively. Although the levels of

    total dust are higher than those of respirable dust, the average lead

    levels in respirable dust are slightly higher than those of total dust in

    the two operations. This might be interpreted by the minute grain size

    of lead oxide fumes.

    The TLV of lead in Law No. 4, 1994 (Egyptian Environmental Law,1994) is 0.15 g/m3.(20) The average levels of lead in total and respirable

    dust in both melting and pouring are below this limit. Meanwhile the

    levels reported in the present study are lower than those reported in the

    US (24) where lead levels ranged from 60 to 330 g/m3, which might be

    attributed to the intermittent work practice and low workload in Misr

    Rayon Company.

    Gaseous levels

    NO2 levels

    The two main mechanisms of NOx formation might interpret the

    obtained results of NOx. The thermal NOx mechanism arises from the

    thermal dissociation and subsequent reaction of nitrogen and oxygen

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    21/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    453

    molecules in combustion air. The fuel NOx mechanisms arise from the

    evolution and reaction of fuel-bound nitrogen compound with

    oxygen.(25)

    In general, the average concentration of NO2 in the four companies

    during melting and pouring operations as shown in figure (5) were

    below the threshold limit value of 6 mg/m3 stated in Law No. 4, 1994.(20)

    Thermal mechanism of NOx formation is predominant in EL Nasr

    and Ramsis companies, whereas the fuel NOx mechanism is

    predominant in Misr Spinning and Misr Rayon companies, since the

    furnaces in the former two are electric and in the latter two are fossil

    fueled furnaces.

    SO2 levels

    Sulphur dioxide may be formed when high sulphur content charge

    materials are added to furnaces. The presence of sulphur in fuel,

    especially coke, gives rise to sulphur dioxide emissions. The highest

    levels of SO2 observed in Ramsis Company, as shown in figure (6),might be attributed to charges of low quality scrapes and combustion

    technology used in the old low capacity furnace around which the work

    stations are allocated. Similar to NO2 concentration, SO2 concentrations

    were far below the threshold limit values of 5 mg/m3 stated in the Law

    No. 4, 1994.(20) Very high SO2 concentrations of 25-250 ppm have been

    measured nearby coke fueled furnace in an American foundry.(26)

    CO levels

    CO emissions are generated from incomplete combustion of carbon

    additives and dirt and scale on the scrap charge. It may be produced in

    significant quantities during preheating of the furnace charges melting

    or pouring, ladle of core curing, or by decomposition of sand binder

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    22/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    454

    system and carbonaceous substances when contacted by the molten

    metal.(3) CO levels have been measured in Misr Weaving Company

    since the cupola furnace is coke fueled, and there is a great likelihood of

    CO emission. As shown in figure (7) the highest levels were recorded in

    pouring operation. Fortunately, pouring operations takes few minutes

    for each batch. However, all the average levels were exceeding the

    threshold limit values of 50 ppm stated in the Egyptian Environmental

    Law. It is noteworthy that similar results were recorded in Finland. In a

    survey of 52 iron, 5 steel and 100 copper alloys foundries, the mean COconcentration around the cupola averaged 240 ppm and 110 ppm in the

    casting area.(27)

    Noise levels

    Noise levels were measured during shake-out and cleaning

    operations, the most noisy operation being in casting. The highest

    recorded noise levels in El Nasr Company might be attributed to the

    high workload, extensive activities in the company at the period of the

    study besides the huge size of produced casting. However, workers

    were wearing earplugs during practicing shake-out and cleaning.

    Although the noise levels were lower in the other three companies, they

    still exceeded the 90 dB(A) limit in the Egyptian Law. (20) Workers were

    not wearing earplugs in these operations in these departments which

    might threaten their hearing acuity.

    It is normal that shake-out and cleaning operations are being

    associated with noise levels of 90-110 dB(A). Also, noise levels of 100-

    110 dB(A) have been regularly measured during routine fettling in both

    ferrous and nonferrous foundries.(6,28)

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    23/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    455

    Heat stress levels

    Extreme heat exposure is known to occur during melting and

    pouring operations. Hence heat stress levels (WBGT) were measured at

    the two operations. Shown in figure (9), EL Nasr Company has

    recorded the highest levels in both operations. The WBGT in pouring

    operation was higher than that in melting operation in El Nasr

    Company. This might be attributed to the huge amount of molten metal

    handled during pouring which emits great amount of radiant heat.

    The high capacity of furnace and bad working practice are possible

    reasons of high heat exposure in El Nasr and Ramsis companies

    respectively. The work in the foundries is a heavy work and it is almost

    continuous. However, if the worker is expected to work 75% of the

    work shift and the work is considered heavy, the equivalent permissible

    heat stress in the Law No. 4, 1994 is 26C.(20) the results of heat levels

    were higher in El Nasr Company in both operations. A proper solution

    should be taken including isolation of workers, and decreasing of

    working time at those areas as possible. Levels of WBGT between 30 to

    50 C have been measured in several foundry surveys. At WBGT levels

    over 30C, the risk of incurring heat illness progressively increases, with

    the level of risk being higher for the heavier physical work.(2,29)

    Accident records analysis

    Age group

    Ramsis Company has recorded the highest incidence rate in all

    groups among the four companies especially in age group 31-40 and 41-50 (P

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    24/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    456

    company, the workers were highly turned over, even more than once in

    the year which might interpret this high incidence rate. In the mean

    time, this extremely high incidence rate of injury might reflect the bad

    safety performance in general, which has been observed by the authors,

    lack of personal protective equipment, besides, non existence of

    specialized safety measures.

    The age group 31-40 years has recorded the highest incidence rate

    of injury in the four companies within the four age groups (P

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    25/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    457

    It is quiet obvious that Ramsis Company has recorded a significant

    increase of injuries incidence rate for all body parts compared with the

    other three companies (P

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    26/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    458

    Company has recorded the highest incidence rate of injury of all

    categories. However, there was highly significant increase in injuries

    due to contact with hot objects and exhaustion (P

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    27/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    459

    severity rates have been observed in all the companies except in Misr

    Rayon Company. This might be attributed partly to the informal

    instructions and advices to the safety staff of the companies throughout

    the study period.

    CONCLUSION

    Foundry workers may be exposed to a variety of numerous health

    hazards and accidents, owing to inherent hazardous conditions in

    foundries including chemical, physical and mechanical agents. The four

    surveyed foundries for chemical and physical hazards and accidents

    records in the present work were different mainly in applied technology

    and capacity and workload. The results of the present study revealed

    that the majority of the assessed occupational chemical hazards were

    within threshold limits values with some exceptions; whereas physical

    hazards were exceeding threshold limit values.

    The analysis of accident records in three years from 1998 to 2000

    have emphasized the difference between private and business sectors

    companies. The administration attitude targeting toward productivity

    and profitability in private sector, represented by Ramsis Company,

    besides, lack of safety plan or measures, safety staff and personal

    protective equipment, all have adversely affected injuries incidence

    rates, frequency and severity rates in the company.

    The synergistic interactions between the diverse acting

    occupational hazards, which have not yet been totally studied, might

    create much serious situation than the results actually showed.

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    28/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    460

    REFERENCES

    1. Burgess WA. Recognition of health hazards in industry: a review ofmaterials and processes. 2nd ed. New York: John Wiley & Sons 1995. P.

    303-17.

    2. MacBain B, Strong RC. Foundries: In Encyclopedia of occupationalhealth and safety. 3rd ed. Geneva: ILO 1983. P. 916-23.

    3. Lucas A. Proposed Air quality Standards: A Threat to the foundryindustry. Modern Casting 1997; 32.

    4. EPA: Emission factors for iron foundries Criteria and toxic pollutants.EPA control technology center. Research Triangle Park. EPA/2-90-044,August 1990.

    5. NIOSH. Recommendations of Control of Occupational Safety and HealthHazards. Foundries Department of Health and Management Services.

    DHHS (NIOSH) September 1995; Publication No. 85-116.

    6. Code practice on safety and health in non-ferrous metals industries.Meetings of Experts on Safety and Health in the Non-ferrous Metals

    Industries. Geneva: 2001.

    7. O'Gara K. Work injuries and illness in California quarterly. SanFrancisco: California Depart. of Ind. Relat. Div. of Labor Statistics andResearch 1978; Publication No. IAQ-45.

    8. McLean A. Summary of plant observation report evaluations for therecommended standards for occupational exposure in foundries.

    Virginia: JRB Assoc, Inc 1979.

    9. OSHA. Hazard analysis and evaluation system applied to the naturalemphasis program (foundries): Preliminary identification of proprietary

    hazards. US Department of Labour: Contact J-9-F-5-013 S, Task order No

    7. 1977.

    10. Industrial Commission of Ohio. Accidents statistics iron foundries, steelfoundries, and aluminium and non ferrous metals. Columbus, Ohio:

    ICO, Division of Safety and Hygiene 1980.

    11. Ceue Hee SS. Respirable/total air sample in non ferrous foundry. ApplInd Hyg 1989; 4,3: 57-60.

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    29/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    461

    12. Recommended method of analysis for sulfur dioxide content of theatmosphere colorimetric (704). In: Katz M, editor. Methods of air

    sampling and analysis. 2nd ed. American Public health Association 1977.

    13. Analytical method for nitrogen dioxide in air (181). In : Katz M, editor.Methods of air sampling and analysis. 2nd ed. American Public Health

    Association 1977.

    14. Noweir KH. Comparative study of the different methods for analysis offree silica in airborne mineral dust. PhD Thesis. University of Alexandria,

    High Institute of Public Health 1979.

    15.

    Analytical method for lead in air (813). In : Katz M, editor. Methods ofair sampling and analysis. 2nd ed. American Public Health Association

    1977.

    16. Anne M, Venetta R, Rapph C, JR. Heat Stress: In : Di Berardinis LD,editor. Handbook of occupational safety and health. 2nd ed. John Wiley &

    Sons, Inc, 1999. P. 791-823.

    17. Lichtenwalner CP, Michael K. Occupational noise and hearingconservation. In : Di Berardinis LJ, editor. Handbook of occupational

    safety and health. 2nd ed. John Wiley & Sons, Inc 1999; P. 825-930.

    18. Brancholi M. accidents statistics: In Encyclopedia of Occupational healthand safety. 3rd ed. Parmeggioni L (ed). Geneva: ILO, 1983. P. 32-5.

    19. Howell DC. Fundamental statistics for the behavioural sciences. 3rd ed.USA: Wadworth Inc, Chap 19, ITP, 1995.

    20. Cabinet of Priministry: Priminister Decree 338, 1995. Law No. 4 1994. 3rded. Egypt.

    21. Heppleston AG. Silica, pneumoconiosis, and carcinoma of lung. Am JInd Med 1985; 7: 285.

    22. McKinley B. Air emissions from foundries: a current survey of literature,supplies and foundry men. In Transactions of American Foundry Men's

    Society. Proceedings of the 97th Annual Meeting 1993.

    23. Audiz J, Brown JW, Ayer HE, Samuels S. A report on silica exposurelevels in United States foundries. Am Ind Hyg Assoc J 1993; 44: 374.

    24. CDC. Surveillance of occupational lead exposure United States.MMWR 1987; 38: 642-6.

  • 7/29/2019 Evaluation of Occupational Hazards in Foundries

    30/30

    The Journal of the Egyptian Public Health Association (JEPHAss.), Vol.80 No.3& 4, 2005 .

    462

    25. Kirk & Othmer Encyclopedia of Chemical Technology. 3rd ed. New York:John Wiley 1981; Vol 13: 552.

    26. Kaiser F. Why Melt Cupola? Modern Equipment Company, Inc 1994.27. Tubich GE. Carbon monoxide in the foundry. AFS Transactions 1975; 83:

    345-8.

    28. Rizk SA. The industrial noise and accidents: a possible link. Egypt JOccup Med 1987; 11: 175-82.

    29. Ramsey JD, Budford CL, Beshir MY, Jensen RC. Effects of workplacethermal conditions on safe work behavior. Journal of Safety Research

    1983; 14: 105-14.

    30. Nikoli N, Morvic T. The analysis of work related injuries in a tractorfactory. Am Ind Hyg Assoc J 1994; 450-7.

    31. Moselhi M, Abou-Taleb A, Goada F, El Sharkawy K. Retrospective studyon industrial accidents in Amirya Petroleum Refinery Company over ten

    years 1980-1989. Bull High Inst Public Health 1995; 25(3): 533-46.

    32. Wire TM. Causes of injuries in the foundry industry. AFS Transactions1974; 82: 295-8.

    33. Zakaria AM, Ahmed MH, El-Shazly M, EL-Maghraby G. An analyticalstudy of accidents in Behira Governorate in the period 1990-1995. BullHigh Inst Public Health 1997; 27(4): 663-82.

    34. Zakaria A, Mansour S. Accidents trends in Alexandria National Iron andSteel Company from 1988 to 1999. 5th IEA Eastern Mediterranean

    Regional Scientific Meeting. Bahrain: October 2000.

    35. El-Ahmar A, Issa A, El Dakhakhny A, Abdel Moneim I. Occupationalhazards related to the work in the workshop of a major construction

    contractor in Alexandria. Bull High Inst Public Health 1996; 26(2): 289-

    310.

    36. Kamel MI. Epidemiologic pattern of work injuries in Egypt. 5 th IEAEastern Mediterranean Regional Scientific Meeting. Bahrain: October

    2000.