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A case-control study was conducted to evaluate the risk of chronic beryllium disease (CBD) and beryllium sensitization (SENS) associated with various levels of historical beryllium exposure at the Rocky Flats nuclear weapons facility. Fifty CBD and 74 SENS cases were matched to controls of the same age group, race, gender, and smoking status. A job exposure matrix was developed from job history data and fixed airhead (FAH) exposure data available from 1960 to 1988. Job titles and building areas were assigned factors based on exposure relative to a machinist in the Building 444 Beryllium Shop. Concurrence on these factors was obtained from past and present Rocky Flats industrial hygienists. Using the matrix, long-term mean and cumulative exposures were estimated for each subject. Both exposure estimates (p < 0.0001) and years of employment (p = 0.010) were found to be significantly higher for CBD cases as compared with their controls, but not so for the SENS cases as compared with their controls. Logistic regression analyses showed statistically significant relationships between both cumulative and mean exposure and CBD, but not for SENS. These findings suggest that reduced worker exposures might lower the future incidence of CBD, but may not necessarily lower the incidence of SENS.

The purpose of this study was to determine how two types of sampling data could be used for an exposure assessment in a beryllium shop at the Department of Energy's Rocky Flats Plant. Beryllium exposure was assessed via fixed airhead (FAH) sampling, in which the filter cassette was affixed to the machine, generally within a few feet of the worker's breathing zone. Approximately 500,000 FAH samples were collected for beryllium over three decades at the site. From 1984 to 1987, personal breathing zone (PBZ) samples also were collected as part of the evaluation of a new high velocity/lcw volume local exhaust ventilation system in the beryllium shop. FAH data indicated that four statistically different exposure periods existed from 1970 to 1988, as the FAH annual arithmetic means varied with changes in the local exhaust ventilation system and production levels. A matched comparison between the FAH and PBZ sample data found no direct linear correlation (R2 = 0.014); however, the mean PBZ results were higher than the mean FAH results (p = 0.0001). The mean PBZ level was 1.04 micrograms/m3 while the FAH average was 0.16 microgram/m3 (permissible exposure limit for beryllium: 2 micrograms/m3). A health surveillance program to identify cases of chronic beryllium disease (CBD) and beryllium sensitization has been implemented at Rocky Flats. To date, 53 cases of CBD and 86 cases of sensitivity to beryllium have been diagnosed. Continuing studies are evaluating semiquantitative dose response relationships for CBD using the exposure data discussed herein.

The hypothesis was tested that beryllium metal particles have a uniformly thick surface coating of beryllium oxide and that smaller particles should have a higher oxide fraction by mass because they have a higher surface to volume ratio. The mass fraction of oxygen, physical density, and specific surface area were determined for size-fractionated samples of respirable beryllium metal particles. The largest particles analyzed (count median diameter 4.6 microns with geometric standard deviation 1.6) contained 7% +/- 1% beryllium oxide by mass; had a physical density of 1.90 +/- 0.02 g/cm3; and had a specific surface area of 4.0 +/- 0.3 m2/g. The smallest particles analyzed (count median diameter 0.4 micron with geometric standard deviation 1.8) contained 31% +/- 3% beryllium oxide by mass; had a physical density of 2.00 +/- 0.17 g/cm3; and had a specific surface area of 20.8 +/- 2.1 m2/g. These shifts in density and oxide content with size and surface area are consistent with a beryllium metal core of density 1.84 +/- 0.02 g/cm3 (1.848 g/cm3 is theoretical); a beryllium oxide layer of density of 2.53 +/- 0.16 g/cm3 (3.025 g/cm3 is the perfect crystalline density); and an oxide layer thickness of 49 +/- 4 A for all particle sizes. These results indicate that the inhalation toxicity of beryllium metal particles may be similar to that of beryllium oxide formed at low temperatures.