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IN-DEPTH SURVEY REPORT: STYRENE AND NOISE EXPOSURES DURING FIBER REINFORCED PLASTIC BOAT MANUFACTURING AT

A survey was performed to assess the occupational exposures to styrene and noise, and to evaluate the effectiveness of engineering controls for styrene in two distinct fiberglass reinforced plastic (FRP) boat manufacturing plants. The primary objective of this study was to quantify the exposures occurring in both an open and closed mold plant and to evaluate the installed engineering controls to reduce styrene exposure. The effectiveness of the styrene controls examined in this study was evaluated by measuring styrene personal breathing-zone and general-area samples during typical work shifts. The ventilation system in Plant 7, the closed mold plant, appeared to be relatively effective for controlling the amount of styrene-area vapors released into the air. Area sample results showed that styrene vapor concentrations in the air were controlled from 0.14 parts per million (ppm) in areas upwind of the styrene emitting source, to 3.7-12.2 ppm inside the actual Virtual Engineered Composites (VEC) cells. Personal breathing-zone exposures for employees working in the molding areas ranged from non-detected to 20.7 ppm for the operators and sprayers respectively. The measured concentrations were likely due to the gelcoating operation which is an open mold-type operation in which styrene vapors are released into the air. While these full shift samples were not above the NIOSH Recommended Exposure Level (REL), a comparison between the sprayers who spray gelcoat and the operators who do not suggests that short-term exposures during gelcoat spraying may be a concern. Area samples taken in the resin mix room and gelcoat storage room showed concentrations ranging from non-detected to 39.0 ppm. Results for the open mold plant (Plant 6) were markedly different, indicating the installed control systems were not as effective in controlling styrene exposures. The personal breathingzone exposures, in Plant 6, ranged from 22.8 to 103 ppm with geometric mean exposures ranging from 30.3 ppm (gelcoater) to 82.8 ppm (hull roller). The general-area concentrations measured ranged from 2.2 ppm in the northeast region to 28.7 ppm in the southwest region. Upgrades to the local exhaust ventilation system in Plant 6 should be a priority. The current ventilation system is not working to its maximum potential and thus allowing workers to be exposed to concentrations of styrene vapors above the NIOSH REL and near the OSHA Permissible Exposure Level (PEL). In Plant 7, the source(s) of the fugitive styrene emissions in the resin and gel coat storage rooms should be identified and controlled. The exposures measured in the gelcoat room are assumed to be a result of agitating, pumping, and handling of gelcoat. The exposures measured in the resin mix room are assumed to be from the addition of material to the resin tanks. Since this survey was completed, Larson/Glastron has identified the fugitive styrene emission source. Our recommendation is to confirm that the styrene source was found and that the new engineering controls applied are working adequately to keep styrene emissions under control. Improvements to the local exhaust ventilation systems in the VEC cells should also be considered to address the potentially high short-term exposures occurring during gelcoating. Some of these exposures could exceed the American Conference of Governmental Industrial Hygienists (ACGIH) 15-minute short-term exposure limit (STEL). Regarding the noise measurements, all personal and area measurements taken in Plant 6 and 7 were below the OSHA PEL of 90 dBA. The gelcoater and gunner exposures are above the NIOSH Recommended Exposure Level (REL) and OSHA Action Level (AL) of 85 dBA. In a number of cases, measured noise levels indicated that