An evaluation of a local exhaust ventilation control system for a foundry casting-cleaning operation

A study was conducted to evaluate the effectiveness of a local exhaust ventilation system for a foundry casting-cleaning operation in which a worker cleaned gray iron castings using a variety of handheld chipping and grinding tools. The operation originally had an exhaust system consisting only of an exhaust duct terminating approximately 1 m (3 ft) above the floor and 2 m (6 ft) from the casting-cleaning workstation. An earlier evaluation of this original control system found time-weighted average exposures to respirable silica ranging from 124 to 160 micrograms/m3. The local exhaust ventilation system evaluated in this present study consisted of a downdraft booth outfitted with a turntable for manipulating the castings. The modified local exhaust ventilation system was installed at this facility and connected to the existing plant exhaust ventilation system through the original ductwork. A direct-reading instrument was used to measure the operator's respirable aerosol exposure concentrations during a single day both before and after the installation of the new workstation. The same worker was sampled both times. The operator's activities were recorded on videotape so that the exposures associated with the various tools could be determined. While day-to-day variability could not be accounted for, depending on the type of tool used the local exhaust ventilation system reduced exposures by 59 to 79% during casting cleaning by the sampled worker when compared with the original configuration. These reductions were statistically significant.