Fiberglass Manufacturing Research Articles

Design, manufacture and testing of fiberglass reinforced parabola trough for parabolic trough solar collectors

The design and manufacture of a smooth 90° rim angle fiberglass reinforced parabolic trough for parabolic trough solar collector hot water generation system by hand lay up method is described in this paper. The total thickness of the parabolic trough is 7 mm. The concave surface where the reflector is fixed is manufactured to a high degree of surface finish. The fiberglass reinforced parabolic trough was tested under a load corresponding to the force applied by a blowing wind with 34 m/s. Distortion of the parabola due to wind loading was found to be within acceptable limits. The thermal performance of the newly developed fiberglass reinforced parabolic collector was determined according to ASHRAE Standard 93 [ASHRAE Standard 93, 1986. Method of testing to determine the thermal performance of solar collectors. American Society of Heating, Refrigerating and Air-Conditioning Engineers, Atlanta, GA]. The standard deviation of the distribution of the parabolic surface errors is estimated as 0.0066 rad from the collector performance test according to ASHRAE Standard 93 (1986), which indicates the high accuracy of the parabolic surface.

Mortality and cancer incidence in Ontario glass fiber workers

In a previous cohort study of glass fiber manufacturing, we found a significant increase in lung cancer. This study extends the follow-up period. We conducted a historical prospective study of 2557 men employed in producing glass wool. We obtained work histories, causes and dates of death, and date and site of cancer diagnoses. We computed standardized mortality and incidence ratios (SMR, SIR). The overall SMR for lung cancer was 163 (95% CI = 118-221). The SMR did not vary consistently by duration of employment and time since first employment. However, plant workers with >20 years' employment and >40 years since first exposure had an SMR for lung cancer of 282 (95% CI = 113-582). The SMR dropped with later date of first exposure, but the trend was non-significant. There was an unexpected overall increase in kidney cancer incidence. The increase in lung cancer is greater than in other cohorts of glass fiber workers. Since exposure data are lacking from the early years of the plant, we cannot state if the excess was due to glass fibers, other work exposures or other reasons.

Regulatory Road Map for Formaldehyde Emissions and other Hazardous Air Pollutants in Fiberglass Insulation Materials in the United States

This paper provides a perspective of air pollution control regulations in the United States that affect the Wool Fiberglass Manufacturing Industry. In addition, it analyzes regulations specifically targeted towards formaldehyde emissions from these operations and evaluates what lies ahead under existing Clean Air Act requirements. This paper addresses only the regulatory climate in the United States. However, based on history, other countries such as Canada and European Union tend to mirror US laws that are eventually followed by other developing countries.

QUANTITATIVE RISK ASSESSMENT OF DURABLE GLASS FIBERS

This article presents a quantitative risk assessment for the theoretical lifetime cancer risk from the manufacture and use of relatively durable synthetic glass fibers. More specifically, we estimate levels of exposure to respirable fibers or fiberlike structures of E-glass and C-glass that, assuming a working lifetime exposure, pose a theoretical lifetime cancer risk of not more than 1 per 100,000. For comparability with other risk assessments we define these levels as nonsignificant exposures. Nonsignificant exposure levels are estimated from (a) the Institute of Occupational Medicine (IOM) chronic rat inhalation bioassay of durable E-glass microfibers, and (b) the Research Consulting Company (RCC) chronic inhalation bioassay of durable refractory ceramic fibers (RCF). Best estimates of nonsignificant E-glass exposure exceed 0.05-0.13 fibers (or shards) per cubic centimeter (cm 3) when calculated from the multistage nonthreshold model. Best estimates of nonsignificant C-glass exposure exceed 0.27-0.6 fibers/cm 3. Estimates of nonsignificant exposure increase markedly for E- and C-glass when non-linear models are applied and rapidly exceed 1 fiber/cm 3. Controlling durable fiber exposures to an 8-h time-weighted average of 0.05 fibers/cm 3 will assure that the additional theoretical lifetime risk from working lifetime exposures to these durable fibers or shards is kept below the 1 per 100,000 level. Measured airborne exposures to respirable, durable glass fibers (or shards) in glass fiber manufacturing and fabrication operations were compared with the nonsignificant exposure estimates described. Sampling results for B-sized respirable E-glass fibers at facilities that manufacture or fabricate small-diameter continuous-filament products, from those that manufacture respirable E-glass shards from PERG (process to efficiently recycle glass), from milled fiber operations, and from respirable C-glass shards from Flakeglass operations indicate very low median exposures of 0, 0.0002, 0.007, 0.008, and 0.0025 fibers (or shards)/cm 3, respectively using the NIOSH 7400 Method ("B" rules). Durable glass fiber exposures for various applications must be well characterized to ensure that they are kept below nonsignificant levels (e.g., 0.05 fibers/cm 3) as defined in this risk assessment.

Design of a phase/Doppler light-scattering system for measurement of small-diameter glass fibers during fiberglass manufacturing

We present fundamental studies examining the design of a phase/Doppler laser light-scattering system applicable to on-line measurements of small-diameter (<15 mum) fibers during fiberglass manufacturing. We first discuss off-line diameter measurement techniques currently used in the fiberglass industry and outline the limitations and problems associated with these methods. For the phase/Doppler design study we have developed a theoretical computer model for the response of the measurement system to cylindrical fibers, which is based on electromagnetic scattering theory. The model, valid for arbitrary fiber diameters and hardware configurations, generates simulated detector output as a function of time for a finite absorbing, cylindrical fiber oriented perpendicular to the two incident laser beams. Results of experimental measurements are presented, confirming predictions of the theoretical model. Parametric studies have also been conducted using the computer model to identify experimental arrangements that provide linear phase-diameter relationships for small-diameter fibers, within the measurement constraints imposed by the fiberglass production environment. The effect of variations in optical properties of the glass as well as fiber orientation effects are discussed. Through this research we have identified phase/Doppler arrangements that we expect to have future applications in the fiberglass industry for on-line diameter monitoring and process control.

Historical cohort mortality study of a continuous filament fiberglass manufacturing plant. II. Women and minorities.

An historical cohort mortality study was undertaken at Owens Corning's continuous filament fiberglass manufacturing plant in Anderson, South Carolina. The cohort included 1074 white women, 130 black women, and 494 black men who worked for a minimum of one year from the opening of the plant in 1951 through December 31, 1991. This represents the largest single cohort of white women assembled to date in either a wool or continuous filament fiberglass manufacturing facility and represents the first study of a cohort of black men and women in the man-made vitreous fiber industry. Over 95% of the women and minorities included in this report held production positions in the plant. There were no significant excesses or deficits in mortality by cause, including cancer causes, among white women, with the exception of motor-vehicle accidents, when compared with national mortality. Among black men, standardized mortality ratios (SMRs) for heart disease are significantly below one, and SMRs for all cancers combined are below unity on both national and local standards. Lung cancer SMRs are below unity for both white women and black men.

Spectral attenuation of fluoride glass fibers

Intrinsic crystallisation is invoked at each process stage during the manufacture of fluoride glass fibers. Thermal history and crystallisation distributions were calculated by numerical simulation of the entire fibre manufacturing process, from the preform to fibre drawing. Assuming a gaussian field distribution for single-mode fibre, the attenuation due to crystallisation was calculated using classical scattering theory. Results show strong dependence on the temperature of the core melt and fibre drawing conditions. The former can be reduced to acceptable levels under normal manufacturing conditions. During fibre manufacture it is necessary to maximise both fibre tension and speed in order to reduce additional attenuation to a level below that of Rayleigh scattering.

Historical Cohort Mortality Study of a Continuous Filament Fiberglass Manufacturing Plant

An historical cohort mortality study of a continuous filament fiberglass manufacturing plant was undertaken to determine whether an elevated lung cancer risk would be observed on a cohort basis. A nested case-control study of white male lung cancer deaths was incorporated into the study design. An interview survey to obtain information on sociodemographic factors, including smoking, and an historical environmental reconstruction to identify elements in the plant environment to which workers might be exposed were included in the study design. Respirable glass (Beta) fibers were produced only from 1963 to 1968. The lung cancer odds ratio (OR) among those workers exposed to respirable glass fibers is below unity, as are ORs for exposure to asbestos, refractory ceramic fibers, respirable silica (except for the lowest exposure level), total chrome and arsenic. There is a suggestion of an increase with exposure among smokers only for exposure to formaldehyde, although the OR for the highest level is based on only one case and is not likely to be meaningful. None of these plant exposures suggests an increase in lung cancer risk for this population. Although the lung cancer standardized mortality ratios are slightly elevated, results of the case-control investigation confirm that neither respirable glass fibers nor any of the substances investigated as part of the plant environment are associated with an increase in lung cancer risk for this population.

Endotoxin exposure‐response in a fiberglass manufacturing facility

Endotoxin exposure‐response in a fiberglass manufacturing facility

Endotoxin exposure‐response in a fiberglass manufacturing facility

Endotoxin exposure‐response in a fiberglass manufacturing facility

Endotoxin exposure-response in a fiberglass manufacturing facility.

Peak expiratory flow (PEF) and workplace exposure to endotoxin, phenolic resin, and formaldehyde were measured to investigate asthma symptoms and medication use among employees in a fiberglass wool manufacturing plant. Self-recorded PEF was obtained from 37 workers, for a total of 181 days off work and 187 days at work with concurrent personal exposure monitoring. Pre- and post-shift spirometry were obtained on at least 2 days. The 8 hr time-weighted average personal exposure ranges were endotoxin; 0.4-759 ng/m3; phenolic resin, 5.7-327 micrograms/m3; and formaldehyde, 1.2-265 micrograms/m3. Amplitude percent mean peak flow was associated with years since starting regular work in the highest endotoxin exposure area, although current assignment in that area was associated with reduced amplitude--evidence for a healthy worker effect. Exposure-response was analyzed by regression of lung function change on exposure using generalized estimating equations with robust variance estimates. Endotoxin exposure above 4 ng/m3 (8 hr time-weighted average) was associated with a decline in lung function across the work shift, and with drops in lung function 16-20 hr after exposure. Phenolic resin exposure was not consistently associated with decrements, and formaldehyde was not associated with decrements in lung function.

Wear resistance of PVD coatings in plastics processing

In view of the increasing filler content, processing temperatures and throughput in plastics, wear in processing will remain a problem. This is particularly true of processes where no surface damage is permitted because of the subsequent change of dimensions or the intoxicating effects of the loosened particles, as is the case, for instance, in the manufacture of polymeric optical glass fibres. In particular, raw materials that exhibit abrasiveness as well as corrosiveness create a severe complex tribological load. The surface of processing equipment must be hard enough to withstand the mechanical attack of the hard glass fibres and should also be corrosion resistant. The potential of PVD coatings for wear protection in plastic processing has been studied when exposed to solid as well as molten plastic raw material. Wear tests have been carried out for commercially available glass fibre-reinforced polyamide (PA) and glass fibre-reinforced polyphenylene sulphide (PPS). The methods used were the platelet apparatus for the molten materials and the DKI universal wear and friction tester for the solid raw material. It was found that PPS (compared with PA) created higher abrasion in the solid zone and lower abrasion in the plasticized stage, although it may have higher corrosiveness. Among the PVD coatings tested the best results were achieved with CrN. In comparison with standard metals used for plastics machining the results show that, in general, PVD coatings offer a good opportunity for wear protection: not so much in the solids conveying zone but more so in the melt zone. As yet little is known about the scope of multi-layered PVD coatings, in which by combining the individual layers a combined wear resistance against complex loads may be achieved.

A scheduling decision aid in glass fiber manufacturing

A decision aid for scheduling production in glass fiber manufacturing industry is described. The methodology combines a linear programming (LP) optimization model with a heuristic model. The LP model determines production goals; the heuristic model then uses the LP output to incorporate system-specific constraints in developing processing sequences.

Adjustment for the confounding effect of cigarette smoking in an historical cohort mortality study of workers in a fiberglass manufacturing facility.

In 1986 a statistically significant lung cancer SMR based on U.S. white male national mortality rates was reported for male fibrous glass workers for follow-up through 1982 of a cohort of U.S. man-made mineral fiber workers. The Newark, Ohio, plant of Owens-Corning, which comprised 38% of the fibrous glass workers in that cohort, also exhibited a statistically significant lung cancer standardized mortality ratio based on U.S. white male mortality rates. A case-control study of the Newark workers demonstrated that a history of cigarette smoking and not exposure to respirable glass is the most important factor in lung cancer risk for workers at the Newark plant. We provide an estimate of the extent of confounding by cigarette smoking for the Newark plant nationally based lung cancer standardized mortality ratio with data not previously available and which suggests that adjusting for the confounding effect of cigarette smoking could reduce the lung cancer standardized mortality ratio to a non-statistically significant level.

Glass fiber manufacturing and fiber safety: the producer's perspective.

Historically, the potential health effects of airborne fibers have been associated with the dose, dimension, and durability. Increasing focus is being placed on the latter category. Concern about airborne fiber safety could be reduced by manufacturing fibers that are not respirable; however, due to performance and manufacturing constraints on glasswool insulations, this is not possible today. These products are an important part of today's economy and as a major manufacturer, Owens-Corning is committed to producing and marketing materials that are both safe and effective in their intended use. To this end, manufacturing technology seeks to produce materials that generate low concentrations of airborne fibers, thus minimizing exposure and irritation. The range of fiber diameters is controlled to assure effective product performance and, as far as possible, to minimize respirability. Glass compositions are designed to allow effective fiber forming and ultimate product function. Fiber dissolution is primarily a function of composition; this too, can be controlled within certain constraints. Coupled with these broad parameters is an extensive product stewardship program to assure the safety of these materials. This article will discuss the factors that influence glasswool insulation production, use, and safety.

Glass Fiber Manufacturing and Fiber Safety: The Producer's Perspective

Glass Fiber Manufacturing and Fiber Safety: The Producer's Perspective

A case-control study of malignant and non-malignant respiratory disease among employees of a fiberglass manufacturing facility. II. Exposure assessment.

A case-control study of malignant and non-malignant respiratory disease among employees of the Owens-Corning Fiberglas Corporation's Newark, Ohio plant was undertaken. The aim was to determine the extent to which exposures to substances in the Newark plant environment, to non-workplace factors, or to a combination may play a part in the risk of mortality from respiratory disease among workers in this plant. A historical environmental reconstruction of the plant was undertaken to characterise the exposure profile for workers in this plant from its beginnings in 1934 to the end of 1987. The exposure profile provided estimates of cumulative exposure to respirable fibres, fine fibres, asbestos, talc, formaldehyde, silica, and asphalt fumes. Employment histories from Owens-Corning Fiberglas provided information on employment characteristics (duration of employment, year of hire, age at first hire) and an interview survey obtained information on demographic characteristics (birthdate, race, education, marital state, parent's ethnic background, and place of birth), lifetime residence, occupational and smoking histories, hobbies, and personal and family medical history. Matched, unadjusted odds ratios (ORs) were used to assess the association between lung cancer or non-malignant respiratory disease and the cumulative exposure history, demographic characteristics, and employment variables. Only the smoking variables and employment characteristics (year of hire and age at first hire) were statistically significant for lung cancer. For non-malignant respiratory disease, only the smoking variables were statistically significant in the univariate analysis. Of the variables entered into a conditional logistic regression model for lung cancer, only smoking (smoked for six months or more v never smoked: OR = 26.17, 95% confidence interval (95% CI) 3.316-206.5) and age at first hire (35 and over v less than 35: OR = 0.244, 95% CI 0.083-0.717) were statistically significant. There were, however, increased ORs for year of employment (first hired before 1945 v first hire after 1945: OR = 1.944, 95% CI 0.850-4.445), talc (cumulative exposure >1000 fibres/ml days v never exposed: OR = 1.355, 95% CI 0.407-5.515), and asphalt fumes (cumulative exposure >0.01 mg/m(3) days v never exposed: OR 1.131, 95% CI 0.468-2.730). For non-malignant respiratory disease, only the smoking variable was significant in the conditional logistic regression analysis (OR = 2.637, 95% CI 1.146-6.069). There were raised ORs for the higher cumulative exposure categories for respirable fibres, asbestos, silica, and asphalt fumes. For both silica and asphalt fumes, ORs were more than double the reference groups for all exposure categories. A limited number of subjects were exposed to fine fibres. The scarcity of cases and controls limits the extent to which analyses for fine fibre may be carried out. Within those limitations, among those who had worked with fine fibre, the unadjusted, unmatched OR for lung cancer was (1.0 (95% CI 0.229-4.373) and for non-malignant respiratory disease, the OR was 1.5 (95% CI 0.336-6.702). The unadjusted OR for lung cancer for exposure to fine fibre was consistent with that for all respirable fibre and does not suggest an association. For non-malignant respiratory disease, the unadjusted OR for fine fibre was opposite in direction from that for all respirable fibres. Within the limitations of the available data on fibre, there is o suggestion that exposure to fine fibre has resulted in an increase in risk of lung cancer. The increased OR for non-malignant respiratory disease is inconclusive. The results of this population, in this place and time, neither respirable fibres nor any of the substances investigated as part of the plant environment are statistically significant factors for lung cancer risk although there are increased ORs for exposure to talc and asphalt fumes. Smoking is the most important factors in risk for lung cancer in this population. The situation is less clear for non-malignant respiratory disease. Unlike lung cancer, non-malignant respiratory represents a constellation of outcomes and not a single well defined end point. Although smoking was the only statistically significant factor for non-malignant respiratory disease in this analysis, the ORs for respirable fibres, asbestos, silica, and asphalt fumes were greater than unity for the highest exposure categories. Although the raised ORs for these substances may represent the results of a random process, they may be suggestive of an increased risk and require further investigation.

A case-control study of malignant and non-malignant disease among employees of a fiberglass manufacturing facility.

A case-control study was conducted to determine the influence of non-workplace factors on risk of respiratory disease among workers at the Owens-Corning Fiberglas plant in Newark, Ohio. Cases and controls were drawn from a historical cohort mortality study conducted on behalf of the Thermal Insulation Manufacturers Association (TIMA) of workers employed at Newark for at least one year between 1 January 1940 and 31 December 1963 and followed up to the end of 1982. The TIMA study reported a statistically significant increase in respiratory cancer (compared with national death rates). Interviews were completed for 144 lung cancer cases and 299 matching controls and 102 non-malignant respiratory disease cases and 201 matching controls. Unadjusted odds ratios (ORs) were used to assess the association between lung cancer or non-malignant respiratory disease and birthplace, education, income, marital state, smoking with a duration of six months or more, age at which smoking first started, and duration of smoking. Only the smoking variables were statistically significant. For lung cancer, of the variables entered into a conditional logistic regression model, only the smoking OR of 23.4 (95% CI 3.2-172.9) was statistically significant. For non-malignant respiratory disease no variables entered into the final model were statistically significant. Results of the interview portion of our case-control study clearly indicate that smoking is the most important non-workplace factor for risk of lung cancer in this group of workers. Smoking does not seem to play as important a part, however, for non-malignant respiratory disease. Prevalence of cigarette smoking at the Newark plant was estimated for birth cohorts by calendar year. Corresponding data for the United States were compiled from national smoking surveys. Prevalence of cigarette smoking for Newark in 1955 appears to be sufficiently greater than the corresponding United States data in 1955 to suggest that some of the previously reported excess of lung cancer for Newark based on United States mortality may be accounted for by differences in the prevalence of cigarette smoking between white men in Newark and those in the United States as a whole.

A case-control study of malignant and non-malignant respiratory disease among employees of a fiberglass manufacturing facility.

A case-control study was conducted to determine the influence of non-workplace factors on risk of respiratory disease among workers at the Owens-Corning Fiberglas plant in Newark, Ohio. Cases and controls were drawn from a historical cohort mortality study conducted on behalf of the Thermal Insulation Manufacturers Association (TIMA) of workers employed at Newark for at least one year between 1 January 1940 and 31 December 1963 and followed up to the end of 1982. The TIMA study reported a statistically significant increase in respiratory cancer (compared with national death rates). Interviews were completed for 144 lung cancer cases and 299 matching controls and 102 non-malignant respiratory disease cases and 201 matching controls. Unadjusted odds ratios (ORs) were used to assess the association between lung cancer or non-malignant respiratory disease and birthplace, education, income, marital state, smoking with a duration of six months or more, age at which smoking first started, and duration of smoking. Only the smoking variables were statistically significant. For lung cancer, of the variables entered into a conditional logistic regression model, only the smoking OR of 23.4 (95% CI 3.2-172.9) was statistically significant. For non-malignant respiratory disease no variables entered into the final model were statistically significant. Results of the interview portion of our case-control study clearly indicate that smoking is the most important non-workplace factor for risk of lung cancer in this group of workers. Smoking does not seem to play as important a part, however, for non-malignant respiratory disease. Prevalence of cigarette smoking at the Newark plant was estimated for birth cohorts by calendar year. Corresponding data for the United States were compiled from national smoking surveys. Prevalence of cigarette smoking for Newark in 1955 appears to be sufficiently greater than the corresponding United States data in 1955 to suggest that some of the previously reported excess of lung cancer for Newark based on United States mortality may be accounted for by differences in the prevalence of cigarette smoking between white men in Newark and those in the United States as a whole.

Chemical Reactions in the Manufacture of Waveguides for Long Distance Optical Data Transmission

One of the modern high technologies which has advanced enormously in the last few years is glass fiber technology. This is used in the manufacture of glass fibers for lighting purposes and for the optical transfer of analog and digital data with a high transfer density. The technical demands made on the glass fibers required for data transfer, the optical waveguides, are extremely high and are already fulfilled to a large extent by industry. At present about four million kilometers of fiber, worth ca. 800 million DM are produced worldwide (10% in the Federal Republic of Germany). Numerous chemical processes take place during the manufacture of optical waveguides. However, in contrast both to the high and constantly growing demands on the quality and to the increasing production volume of such fibers, little is in fact known about the reactions involved. The present article will attempt to develop a picture of the multifarious reactions occurring in the course of this technical process on the basis of literature data and our own studies.