Title: What the Hex is with Chromium
1What the Hex is with Chromium?
- OSHAs Hexavalent Chromium Standard
- Summary of Hazards
- Initial Exposure Determinations in Stainless
Steel Making, Carbon Steel Making and Stainless
Steel Fabricating Industries Welding/Torch
Cutting
B. Quinn, CIH 1/23/07
Welder using Plasma Cutter
2OSHA Hexavalent Chromium Standard
- General Industry - 1910.1026
- Shipyards - 1915.1026
- Construction - 1926.1126
- Most requirements are generally the same for all
industries
3Exceptions to the New Standard
- Does not impact application of some pesticides
(EPA regulated) - Does not impact exposures to Portland cement
- Does not impact situations in which the employer
has objective data demonstrating that a material
containing chromium or specific operation or
activity cannot release Cr (VI) in concentrations
at or above 0.5 µg/m3 as an 8 hour TWA - Partial Exemption if exposure is less than 30
days of the year
4What is Hexavalent Chromium?
- Hex Chrome means chromium with a valence of
positive six, in any form or chemical compound in
which it occurs. This term includes Cr6 in all
states of matter, in any solution or other
mixture, even if it is encapsulated by another
substance. - Stainless steel does not contain hexavalent
chromium. Zero state with Cr III on surface - However, chrome is a raw material used in many of
the specialty metals
5What is Hexavalent Chromium?
- Hex chrome can be generated during certain hot
work processes. In these instances, the chrome
in the metal changes valance upon heating. - The primary route of entry for hexavalent
chromium (Cr6) compounds into the body when in a
fume state would be inhalation.
6Why Is Hex Chrome A Concern?
- POTENTIAL HEALTH EFFECTS
- Lung cancer
- Nasal septum ulcerations and perforations
- Asthma
- Skin ulcers
- Allergic and irritant contact dermatitis
7Health Concerns
Permanent perforation of the nasal septum from
continuous exposure performing chrome plating of
small appliance parts
Chrome hole on finger. Can also occur on hands
or forearms, and on bottom surfaces of feet from
chrome salts permeating through boots or shoes.
8Chromates have Varying Solubilities
- Highly soluble in water
- Sodium dichromate
- Chromic acid
- Slightly soluble in water
- Calcium chromate
- Strontium chromate
- Zinc chromate
- Insoluble in water
- Lead chromate
- Barium chromate
9Carcinogenic Effects Lung Cancer
- Cells uptake Cr(VI)
- Faster for soluble forms of Cr(VI)
- Insoluble chromates concentrate
- Particles lt 10 µm contact target cells
- Cells react with Cr(VI) to form Cr(III) and toxic
byproducts, Reactive Oxygen Species - DNA is damaged
- Cell replication disturbed
10Sources of Occupational Exposure
11Major operations/job tasks resulting in potential
Cr(VI) exposure
- Chrome plating/Electroplating
- Welding on stainless steel or Cr(VI) painted
surfaces - Painting
- Aerospace
- Auto body repair
- Chromate pigmentand chemical production
Chrome Plating Bath
12Major operations/job tasks resulting in potential
Cr(VI) exposure
- Chromium dye and catalyst production
- Glass manufacturing
- Plastic colorant production
- Construction
- Traffic painting
- Refractory brick restoration
- Paint removal from bridges
Bridgework
13Stainless and Carbon Steel operations/job tasks
with potential Cr(VI) exposure
Melting Casting Continuous Teeming Baghouse To
rch Cutting/Oxygen Lancing Grinding Hot
Rolling Welding/Plasma Torch Cutting
14Steel Process Flow
15Steel Process Flow
16OSHA Hexavalent Chromium Standard
- In 2006, OSHA passed a new regulation pertaining
to Hexavalent Chromium. - General Industry Standard 1910.1026
- There are 13 major provisions to the Standard
- The following is a summaryof these provisions
17OSHA Hexavalent Chromium Standard
- Provision 1 -- Scope Who is Covered by the
Standard? - All occupational exposures to Cr6 compounds
except - Where employers have objective data demonstrating
that a material containing chromium or a process
involving chromium cannot release Cr6 in
concentrations at or above 0.5 µg/m3 as an 8-hour
time-weighted average (TWA) under any condition
of use. - Provision 2 Permissible Exposure Limits
-
- PEL 5 µg/m3 TWA
- AL 2.5 µg/m3 TWA (50 of the PEL)
18OSHA Hexavalent Chromium Standard
- Provision 3 Exposure Determination
- Each employer who has a workplace or work
operation covered by this Standard shall
determine the 8-hour TWA exposure for each
employee exposed to Hexavalent Chromium (Cr6). - Two options for determining employee exposures
- Scheduled monitoring method
- Performance-oriented monitoring method
- If initial monitoring indicates exposures above
the PEL or Action Level, future periodic
monitoring is required - Above the AL Monitor every 6 months
- Above the PEL Monitor every 3 months
19OSHA Hexavalent Chromium Standard
- Provision 4 Regulated Areas
- Areas where exposures exceed or can be reasonably
expected to exceed the PEL - Must be demarcated from other areas
- Must limit access to employees who have a need to
be there - Performance wording of warning signs
- Provision 5 Methods of Compliance
- Engineering and work practice controls are the
primary means of achieving exposures below the
PEL. - Use of respirators may be used to achieve the PEL
during - Periods necessary to install or implement
feasible engineering and work practice
controls Maintenance or repair operations where
engineering and work practice controls are
not feasible Operations where all feasible
controls have been used and exposures are still
above the PEL Operations where exposures do not
exceed the PEL for 30 or more days per
year Emergencies
20OSHA Hexavalent Chromium Standard
- Provision 6 Respiratory Protection
- Shall be used in situations as described above
and must comply with the requirements set forth
29 CFR 1910.134. We will review these
requirements in a later slide.
Provision 7 Protective Work Clothing
Equipment
- Must use where a hazard is present or is likely
to be present from skin or eye contact with Cr6 - Must be provided and paid for by the employer
- Remove Cr6 contaminated clothing and equipment
when work shift or task is completed - Clean, store and label Cr6 contaminated clothing
and equipment
21OSHA Hexavalent Chromium Standard
- Provision 8 Hygiene Areas and Practices
Where protective clothing is required, must
provide change rooms and washing
facilitiesEmployees must wash their hands and
face at the end of a work shift and prior to
eating, drinking, smoking
Employer-provided eating
areas must be kept as free as practicable of
Cr6No eating, drinking, smoking etc. in
regulated areas
Provision 9 Housekeeping
All surfaces must be kept as free as practicable
of accumulations of Cr6 Use HEPA vacuums or
other methods that minimize exposure to Cr6
Use of compressed air prohibited unlessUsed in
conjunction with a ventilation system to capture
the dust cloud created by the compressed air,
or No alternative method is feasibleDispose of
Cr6 contaminated waste in labeled, impermeable
bags/containers
22OSHA Hexavalent Chromium Standard
- Provision 10 Communication of Hazards
Training must be provided on the contents of the
Cr6 standard and the purpose and description of
the medical surveillance program required by the
standard Training must be conducted to inform
employees of the protective measures being
instituted to control exposures and means used to
communicate potential exposure areas.
Provision 11 Medical Surveillance
Which employees must be provided Medical
Surveillance? Exposed at or above the Action
Level (2.5 µg/m3) for 30 or more days per
year. Experiencing signs or symptoms of Cr 6
exposure Exposed in an emergency What is Medical
Surveillance? Provisions for conducting baseline
and periodic health assessments of exposed
employeesProvided by or under the supervision of
a physician or other licensed health care
professional (PLHCP)Provided at no cost to
employee and at a reasonable place and time
23OSHA Hexavalent Chromium Standard
- Provision 12 Recordkeeping
Must maintain records of Air monitoring
data,Historical monitoring data,Objective
data,Medical surveillance information,
includingHealth Care Professionals written
opinions,Information provided to the Health Care
Professional
Provision 13 Effective Dates
New OSHA Standard Effective Date May 30,
2006 Key Compliance Dates All provisions
except engineering controls For employers with 20
or more employees Nov. 27, 2006 Engineering
Controls For all employers May 31, 2010
24Sampling Analytical OSHA ID-215 Method
- 37 mm NaOH pre-treated quartz fiber filter
preferred for chrome plating operations - 37 mm PVC filter (5.0 micron pore size, can use
0.8 u as well) can use PVC at chrome plating
but must be post/preped by lab. These must be
analyzed within 6 days or prepared upon receipt
at lab - PVC filters used for welding must be analyzed
within 8 days Iron II interference - Submit to AIHA accredited lab 24 Hr
25Summary Exposure Determinations
- Stainless Steelmaking 6 Melt shops, 4 Casters,
2 Teeming, 5 Hot Rolling Mills, 8 AP Lines, 7
Slitters and Related Torch Cutting/Welding
Operations and baghouses - Approximately, 1000 data points personals and
areas along with settled dust and surface wipes. - Exposures generally under AL sometimes a few
exceeded AL, restricted to older Melt shops,
elevated areas Charging Cranes above PELs (2 to
15 ug/m3), hand torch cutting and welding at AL
or PEL.
26Summary Exposure Determinations
- Carbon Steelmaking HSLA, Galvanizing Lines and
Tin (Chrome) Lines 8 Melt shops, 10 Galvanizing
Lines, 1-Tin Line, and associated welding/torch
cutting stainless and baghouses - Approximately, 500 data points, personals and
area samples - Exposures have been below AL. Several area
samples near spray application areas at galvanize
lines have exceeded AL or PEL
27Hex Cr Sources Steel Industry
28Summary Exposure Determinations
- Welding and/or Plasma Torch Cutting Stainless
and Carbon Steelmaking locations-maintenance and
process lines, fabrication/weld shops on
stainless steel. - Approximately, 100 data points, personals and
area samples. - Exposures vary widely (less than AL to 5X PEL,
dependent on many variables)
29Welding Operations
- Most welding operations join metals by heating
the base and/or filler metal to temperatures at
or above the melting point and vaporization
temperature of the weld joint material. - Stainless steels or other chromium-containing
alloys represent the source of hexavalent
chromium in welding operations.
30Welding Operations
- Except for resistance and laser welding, a weld
pool of liquid metal is formed at the welding
arc. A portion of the metal vapor, including
chromium vapor originating from the base metal,
consumable electrode, surface coating, or surface
contaminants instantaneously reacts with
atmospheric oxygen and condenses into solid
particles (known as fume) to form metal oxides,
such as iron oxide, and chromium oxides.
Metallic chromium when vaporized, may react with
oxygen to form both trivalent chromium (Cr2O3)and
hexavalent chromium (CrO3) oxide-containing fume.
31Welding Operations
- Two General Types of Welding- Manual or Automatic
- Manual - welding gun and electrode holder are
hand held during manual welding operations, the
welders breathing zone is within an arms length
of the arc .
32Welding Operations
- Common types -Manual Welding -Presented in
decreasing order of relative welding fume
generation rate. - Flux Core Arc Welding (FCAW) consists of a wire
electrode with arc shielding provided by flux
contained within the electrode. One FCAW process
variation uses an inert gas fed through the
welding gun to provide additional shielding of
the arc. - Shielded Metal Arc Welding (SMAW), most common
type. A short electrode with a coating. - Gas Metal Arc Welding (GMAW) also known as MIG,
second most common type. A wire electrode with an
inert gas (e.g. argon) which is fed through the
welding gun to provide a shield against
oxidation. - Tungsten Inert Gas Welding (TIG) uses a
non-melting tungsten electrode and in some cases
a metal filler that the welder introduces into
the arc. An externally-supplied inert gas (e.g.
helium, argon) is fed through the welding gun to
shield the arc.
33Welding Operations
- Automatic welding processes - typically performed
with the welding machine operator positioned at a
greater distance from the welding arc. In
addition, automatic welding processes can be
partially enclosed or isolated from personnel in
the welding area. Examples of automatic welding
processes are - Submerged arc welding (SAW) uses a blanket of
granular flux that is fed into the weld zone
ahead of the electrode, and a shielding gas is
not required. - Plasma welding is performed by a plasma welding
torch with a non-melting electrode located within
a copper nozzle that has a small opening at the
tip. The plasma is actually a gas that is heated
to an extremely high temperature. The plasma
gases are normally argon, and the torch also uses
a secondary gas to shield the molten weld puddle. - Laser welding uses a high energy beam process and
the energy density of the laser is achieved by
concentration of light waves. The focal spot
(thousands of an inch in diameter) is targeted on
the weld joint surface.
34Welding Operations
Submerged Arc Welding
Plasma Welding
Laser Welding
35Welding Processes and Fume Generation Rates
(g/min)
- FCAW-CO2 gt1
- FCAW-Ar/CO2 0.6
- GMAW-Steady 0.5
- SMAW 0.4
- GMAW-Pulsed 0.2
- GTAW lt0.1
- SAW lt0.1
36Welder Exposures (µg/m3)
- SMAW 0.1 - 150
- FCAW 0.1 - 38
- GMAW 0.1 - 13
- GTAW LDL- 5
- SAW LDL - 0.7
- Plasma cutting 0.1- 20
- Metal cleaning (Grinding) 0.1 - 610
37Controlling Welding Hex Cr Exposures
- The Hierarchy of Controls - Hexavalent Cr
- 1 - Engineering
- 2 - Administrative
- 3 - Personal Protective Equipment
-
38Controlling Welding Hex Cr Exposures
- Flexible exhaust duct positioned near the welding
arc.
39Controlling Welding Hex Cr Exposures
- Down-draft Welding Tables with Filtration
Another method of extracting fumes at the source
is right at the table. - Advantages Ventilation requires no operator
adjustment, and fume extraction occurs at any
point on the table. - Limitations Less effective on large parts and
part configurations that may interfere with
exhaust air flow.
40Controlling Welding Hex Cr Exposures
- Side-draft hoods and booths Provides directional
exhaust ventilation to draw welding fumes away
from the welder. Also available with production
aids such as a turntable that allows rotation of
larger parts to position the welder away from
welding fume. - Advantages Provides local exhaust ventilation
over a relative large work area. Can accommodate
larger size parts. - Limitations Less effective when welding parts
with configurations that impede air flow. For
some welds, part configuration may require the
welder to be positioned between the source of
welding fume and hood exhaust.
41Controlling Welding Hex Cr Exposures
- Fume Extractor guns Capture welding fumes at the
source through a ventilation intake nozzle
located immediately adjacent to, or integrated
around the welding gun shielding gas/welding wire
nozzle. Used on GMAW and FCAW applications. - Advantages Requires no operator positioning of
the exhaust system. The fume extractor gun can
provide exhaust ventilation in restricted areas
not accessible by other exhaust ventilation
systems. - Limitations Fume extractor guns are typically
heavier, have a larger grip circumference, and
the gun nozzles are larger diameter than
comparable GMAW and FCAW welding guns not
equipped with fume extraction. Less effective
fume collection during welding on angle and
corner section than when welding on flat surfaces.
42Welding Studies Summary (FEG)
- A welding shop study where grade 321 stainless
steel was GMAW welded, use of FEGs achieved a
hexavalent chromium reduction ranging from 26
79 (20.2 µg/m3 reduced to 15 4.2 µg/m3). - Source Kura, 1998.
43Controlling Welding Hex Cr Exposures
- Additional Engineering Controls Process
Modification - Modify the composition of shielding gas
Replace SMAW with GMAW
Reduce Sodium and Potassium Content in SMAW
Welding Electrodes (Rods)
Replace Typical GMAW Welding Systems With
Pulse-Arc GMAW
44Welding Studies Summary
- Hexavalent chromium in SMAW fume ranged between
47 to 62 percent of the total chromium in the
fume measured - Hexavalent chromium in GMAW fume from stainless
steel is approximately 4 percent of the total
chromium in the fume measured. - The large amount of hexavalent chromium found in
most fumes created by SMAW welding of stainless
steel has been shown to be associated with the
sodium and potassium compounds in SMAW welding
fluxes. It is almost certain that the hexavalent
chromium is present in such fumes as chromates of
these metals, Na2CrO4 and K2CrO4. It is possible
that the stability of these compounds compared to
most other metal chromates prevents or minimizes
the processes leading to reduction of hexavalent
chromium in GMAW fume. Sodium and potassium
chromates are also stable at higher temperatures
than most other chromates and this could explain
the much faster formation of hexavalent chromium
in SMAW fume than in GMAW fume.
45Welding Studies Summary (Replace SMAW with GMAW)
- Welding research suggests that chromium-containing
fume created by GMAW welding on stainless steel
can continue to evolve chemically for several
minutes. In some cases, the hexavalent chromium
content in the fume appears to rise to a maximum
approximately 20 seconds after formation of the
fume and then partly decays to trivalent chromium
again. Unlike GMAW fume, no changes in
hexavalent chromium concentrations were found in
SMAW welding fume, suggesting that not all
welding fume is subject to aging. - Limitations GMAW welding equipment is not as
readily transported or moved as SMAW equipment.
Unlike SMAW, GMAW equipment includes 1- a wire
feeder unit, 2- a supply of inert shielding gas
typically from a compressed gas cylinder and 3-
a welding gun supply hose/cable that carries
electric power, electrode wire, and inert
shielding gas to the welding gun. - Sources Gray, et. al., 1983 Karlsen, et al.,
1992 Zatka, 1985
46Welding Studies Summary (Modify the composition
of shielding gas)
- Shielding gases with high oxygen potentials, such
as CO2, produce more fume than argon-based
shielding gases. - Although use of 100 percent carbon dioxide as a
shielding gas for FCAW results in higher fume
generation, it is still the most commonly used
gas for FCAW welding, used in slightly more than
50 percent of FCAW applications, due to low cost
and easy availability. - The second most popular shielding gas for FCAW
consists of 75 argon and 25 carbon dioxide. - Reducing the CO2 content of shielding gas used
for FCAW can reduce the fume generation rate and
potentially the exposure of workers.
47Welding Studies Summary (Modify the composition
of shielding gas)
- Reductions in fume generation rates can be
achieved with FCAW with stainless steel
electrodes. The fume generation rate (FGR) for
an E309LT electrode using 100 percent CO2
shielding gas was measured to be approximately
0.6 grams/minute (g/min). The same electrode
welded using 75 argon-25 CO2 shielding gas
resulted in a reduction of FGR to as low as 0.3
g/min. Additional FGR measurements for E309LT and
E316T electrodes using 95 argon-5 CO2
shielding gas show that FGR could be as low as
0.1 g/min. - Limitations Present commercial FCAW electrodes
for stainless steels are not formulated for 95
argon-5 CO2 shielding gas. Formulation changes
would be required to take advantage of the
reduced FGR. - Source Edison Welding Institute, 2003
48Welding Studies Summary (Reduce Sodium and
Potassium Content in SMAW Welding Electrodes
(Rods))
- The presence of sodium and potassium in the flux
or coating of SMAW stainless steel welding rods
and FCAW welding wire results in the production
of fume containing higher concentrations of
hexavalent chromium. Hexavalent chromium is
produced when welding flux components combine
with atmospheric oxygen to form Na2CrO4 and
K2CrO4. - When the sodium and potassium content of the
coating of E-308 welding rod was lowered from the
range of 2 to 5 percent - typically found in SMAW
welding electrodes - to less than 1 percent, the
emission rate for total chromium was reduced by
30 percent and for hexavalent chromium by 94
percent. Reducing the amount of these elements in
electrodes and fluxes will reduce the production
of hexavalent chromium in the welding fume by
reducing the ratio of hexavalent chromium to
trivalent chromium.
49Welding Studies Summary (Reduce Sodium and
Potassium Content in SMAW Welding Electrodes
(Rods))
- Welding equipment manufacturers presently offer
welding rods that contain lower sodium and
potassium. - Limitations Low sodium and potassium welding
electrodes are not commercially popular because
they reportedly produce slag that is more
difficult to remove and the arc characteristics
create a weld bead with a ropy or wavy appearance
compared to SMAW welding electrodes that
contain typical amounts of sodium and potassium.
Despite these cosmetic issues, there are no
reported weld quality or performance problems
associated with the low sodium or potassium
welding rods on the market.
- Sources Hewitt and Hirst, 1993 Kimura et. al.,
1979 R.K. Tandon, et al., 1986 and Palmer, 1987
50Welding Studies Summary (Replace Typical GMAW
Welding Systems With Pulse-Arc GMAW)
- Advances in welding power source technology
involving the use of pulsed welding current can
reduce fume generation of GMAW compared to
conventional procedures. For example, a
significant reduction of welding fume emission,
by up to 80 percent, is attainable using the
pulsed arc process as compared to the short arc
process. With the pulsed arc, the weld bead is
transferred without short-circuiting, in much the
same way as the spray arc. The pulsed arc welding
process avoids increased fume emission due to
explosive bead detachment as a short circuit
occurs. - The reduction in welding fume that can be
achieved by using pulsed welding current is
demonstrated by shipyard tests. Operator
exposure to hexavalent chromium was measured for
pulsed gas metal arc welding (GMAW-P) of HY80 and
HY100 steels (which contain 0.5-1.5 chromium),
stainless steel (CRES), and nickel alloys. These
tests show the value of pulsed GMAW welding in
reducing hexavalent chromium exposures. The
overall average hexavalent chromium exposure was
0.23 µg/m3 with a median of 0.15 µg/m3 for 8
measurements when welding several base metals
with nickel alloy 625 and 276 alloy electrodes.
This represents a 75 reduction compared to the
GMAW baseline value. - Sources Stern, February 1985 and Edison
Welding Institute, 2003.
51Respiratory Protection OSHA 1910.134-APFs
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52Respiratory Protection OSHA 1910.134-APFs
- Notes1Employers may select respirators assigned
for use in higher workplace concentrations of a
hazardous substance for use at lower
concentrations of that substance, or when
required respirator use is independent of
concentration. - 2The assigned protection factors in Table 1 are
only effective when the employer implements a
continuing, effective respirator program as
required by this section (29 CFR 1910.134),
including training, fit testing, maintenance, and
use requirements. - 3This APF category includes filtering facepieces,
and half masks with elastomeric facepieces. - 4The employer must have evidence provided by the
respirator manufacturer that testing of these
respirators demonstrates performance at a level
of protection of 1,000 or greater to receive an
APF of 1,000. This level of performance can best
be demonstrated by performing a WPF or SWPF study
or equivalent testing. Absent such testing, all
other PAPRs and SARs with helmets/hoods are to be
treated as loose-fitting facepiece respirators,
and receive an APF of 25. - 5These APFs do not apply to respirators used
solely for escape. For escape respirators used in
association with specific substances covered by
29 CFR 1910 subpart Z, employers must refer to
the appropriate substance-specific standards in
that subpart. Escape respirators for other IDLH
atmospheres are specified by 29 CFR 1910.134
(d)(2)(ii).
53Respiratory Protection
- Any NIOSH approved filter
- P-100 (as shown) is best
- Can use up to 10X the PEL (50 ug/m3)
54Respiratory Protection
- Full-Face Respirator
- Any NIOSH approved filter
- Can use up to 50X the PEL (250 ug/m3-for hex
chromium)
55Respiratory Protection
- Powered Respirator (PAPR)
- Used with full-face respirator
- High Efficiency (N,R or P-95) or HEPA (N,R or
P-100) filter preferably P-100 - Can use up to 50X the PEL (unless mfr can attest
to 1000x)
56Respiratory Protection
- Welders Hood/PAPR Combination
- 25x PEL or 1000x PEL with written testament of
Mfr. (125 ug/m3 or 5,000 ug/m3 for hexavalent
chromium)
57Respiratory Protection
- Air Line Respirators Supplied Air
- Constant- Flow
- Positive Pressure
- No filter required
- Can be used up to 25X or 1000X the PEL with Mfr.
Written testament
58Summary
- New Hexavalent Chromium Std.
- Affects several industries chromates-Painting,
electroplating, welding stainless - Stainless steel mfr. Limited exposure sources
older melt shop-elevated areas - Chromic acid areas and operations Carbon Steel
- Welding many variables time,type,controls,
filler rods - Local exhaust ventilation
59References
- www.nsrp.org Navy and National Shipbuilding
Research Program 1998 published report - www.ewi.org/njc the Edison Welding Institute
report contracted by NSRP and published in 2003 - www.osha.gov/SLTC/hexavalent chromium/index.html
- hex chrome compliance assistance - www.lni.wa.gov/safety training kit- ppt. Hex
Cr