Exposures to 1,6-hexamethylene diisocyanate during polyurethane spray painting in the U.S. Air Force.

1,6-Hexamethylene diisocyanate (HDI) exposures were measured during polyurethane enamel spray painting at four Air Force bases. Breathing zone samples were collected for HDI monomer and polyisocyanates (oligomers) using three sampling methods: NIOSH Method 5521, the Iso-Chek sampler, and the total aerosol mass method (TAMM). Exposures to HDI monomer are low when compared to current occupational exposure limits; the highest 8-hr time-weighted average (TWA) exposure found was 3.5 micrograms/m3, below the American Conference of Governmental Industrial Hygienists (ACGIH) threshold limit value (TLV) of 34 micrograms/m3. HDI oligomer levels were higher; mean task exposures indicated by either the Iso-Chek sampler or TAMM are above the Oregon ceiling limit of 1 mg/m3. Eight-hour TWA exposures, however, were much lower, with only one exceeding the Oregon standard of 0.5 mg/m3. Poor worker practices commonly observed during this study included: standing in downwind positions so paint overspray passed through breathing zones; spraying toward other painters; and using excessive paint spray gun air cap pressures. Workers should stand in upwind orientation relative to the aircraft being painted, causing overspray to move away from the painter's breathing zone; adjust their position to prevent spraying other painters or limit paint application to one worker at a time; and use air cap pressure gauges prior to spraying to limit spray gun air cap pressures and reduce paint overspray generation rates. These improved techniques will result in reduced worker exposures to isocyanates.

Exposures to jet fuel and benzene during aircraft fuel tank repair in the U.S. Air Force.

Jet fuel and benzene vapor exposures were measured during aircraft fuel tank entry and repair at twelve U.S. Air Force bases. Breathing zone samples were collected on the fuel workers who performed the repair. In addition, instantaneous samples were taken at various points during the procedures with SUMMA canisters and subsequent analysis by mass spectrometry. The highest eight-hour time-weighted average (TWA) fuel exposure found was 1304 mg/m3; the highest 15-minute short-term exposure was 10,295 mg/m3. The results indicate workers who repair fuel tanks containing explosion suppression foam have a significantly higher exposure to jet fuel as compared to workers who repair tanks without foam (p < 0.001). It is assumed these elevations result from the tendency for fuel, absorbed by the foam, to volatilize during the foam removal process. Fuel tanks that allow flow-through ventilation during repair resulted in lower exposures compared to those tanks that have only one access port and, as a result, cannot be ventilated efficiently. The instantaneous sampling results confirm that benzene exposures occur during fuel tank repair; levels up to 49.1 mg/m3 were found inside the tanks during the repairs. As with jet fuel, these elevated benzene concentrations were more likely to occur in foamed tanks. The high temperatures associated with fuel tank repair, along with the requirement to wear vapor-permeable cotton coveralls for fire reasons, could result in an increase in the benzene body burden of tank entrants.

Modeling breathing-zone concentrations of airborne contaminants generated during compressed air spray painting.

This paper presents a mathematical model to predict breathing-zone concentrations of airborne contaminants generated during compressed air spray painting in cross-flow ventilated booths. The model focuses on characterizing the generation and transport of overspray mist. It extends previous work on conventional spray guns to include exposures generated by HVLP guns. Dimensional analysis and scale model wind-tunnel studies are employed using non-volatile oils, instead of paint, to produce empirical equations for estimating exposure to total mass. Results indicate that a dimensionless breathing zone concentration is a nonlinear function of the ratio of momentum flux of air from the spray gun to the momentum flux of air passing through the projected area of the worker's body. The orientation of the spraying operation within the booth is also very significant. The exposure model requires an estimate of the contaminant generation rate, which is approximated by a simple impactor model. The results represent an initial step in the construction of more realistic models capable of predicting exposure as a mathematical function of the governing parameters.