Characterization of metalworking fluid exposure indices for a study of acute respiratory effects

Although metalworking fluids have been widely used throughout industry for decades, occupational exposures to metalworking fluid aerosols and their constituents have not been well characterized. This article describes an exposure assessment for a study of metalworking fluid aerosols and acute respiratory effects. This exposure assessment was unique in its inclusion of multiple exposure measures relevant to a complex environment, and extensive personal sampling for bacteria and endotoxin. The specific objectives were to: (1) obtain indices of personal exposure to metalworking fluid aerosols in an automotive transmission plant, either directly (by sampling) or indirectly (by estimation), and (2) identify and adjust for sources of error in exposure/dose measures, where possible. No prior studies have characterized personal exposures to metalworking fluid aerosols so extensively. Exposure data were obtained during a pilot phase and three principal rounds of data collection over a 15-month period in conjunction with spirometric testing. Subjects worked in one of two machining departments, Case and Valve Body, or in a comparison department, Final Assembly. The primary exposure measures for this study were thoracic fraction particulate, thoracic fraction bacteria (viable plus non-viable), and total endotoxin. Mean personal air concentrations of thoracic particulate across all study rounds were 0.13 mg/m3 in Final Assembly, 0.32 mg/m3 in Valve Body, and 0.56 mg/m3 in Case. Average personal exposures to thoracic fraction bacteria were 0.38 bacteria/cc in Final Assembly, 0.87 bacteria/cc in Valve Body, and 2.66 bacteria/cc in Case. Average personal endotoxin measurements, collected in Round 3 of the study, were 16.4 endotoxin units (EU)/m3 in Assembly, 34.7 EU/m3 in Valve Body, and 234 EU/m3 in Case. Sump fluid contained on the order of 10(8) bacteria/ml, and 10(4)-10(5) EU/ml. Air concentrations of thoracic particulate, thoracic bacteria, and total endotoxin were highly correlated in metalworking operations. Thus, reducing airborne particulate levels should also reduce ambient bacteria and endotoxin, which are suspect agents of respiratory impairment. The elevated endotoxin levels in Final Assembly were unexpected, and suggest an independent source of endotoxin contamination in this department.