Environmental samples were collected during typical working shifts (day, evening, night) in the foundry in an attempt to evaluate the workers' exposures to total particulate, respirable silica, metals, isopropyl alcohol, and sulfur dioxide. Personal breathing zone samples were obtained on a number of foundry occupations, including molding, furnace tending, and maintenance. Area samples were also placed throughout the foundry near jobs thought to have excessive exposures.The environmental results indicate that one of the major health hazards at the Blaw Knox Rolls foundry is exposure to free crystalline silica. To summarize, 22 (42%) of all (personal and area) samples collected exceeded the NIOSH Recommended Exposure Level (REL) of 50 :g/m 3 for respirable quartz and 13 (23%) exceeded the OSHA Permissible Exposure Limit (PEL) of 100. It was also determined that a health hazard exists from employee overexposure to nickel, lead, chromium, sulfur dioxide and isopropyl alcohol. The metals chromium and nickel were found in excess of the NIOSH RELs of 0.001 mg/m 3 and 0.015 mg/m 3 , respectively. Lead exceeded the OSHA PELs of 0.05 mg/m 3 . Concentrations of sulfur dioxide ranged from 0.40 to slightly above 7 ppm, with the highest concentrations measured near the furnaces in Bay M and the horizontal spin spray coater in Bay J. Three sulfur dioxide samples exceeded both the NIOSH REL and the OSHA PEL of 2 ppm time-weighted average (TWA) exposure, with many more at or above the 1 ppm action level. A personal breathing zone sample for isopropyl alcohol showed an exposure of 708.2 ppm. This concentration exceeded both the NIOSH REL and the OSHA PEL of 500 ppm for a short term exposure limit (STEL) to isopropyl alcohol.A medical survey was conducted which focused on the respiratory health of the exposed workers. The survey included a chest x-ray, a lung function test, and a self-administered respiratory questionnaires.Of the 183 current workers, 129 (70%) participated in the medical survey. The mean age of those who participated was 43 years and the average tenure was 17 years. Pneumoconiotic changes with a median profusion reading of 1/0 or greater on the 12 point International Labor Organization (ILO) scale were considered to be present on the chest x-rays of two (1.6%) of the workers. Such x-ray markings can result from the inhalation of silica dust and other dusts. Obstructive lung function abnormalities were observed in 23% of the participants. Seventy-five percent of participants were current or former smokers and more than 10% had worked in other dusty trades prior to their Blaw Knox employment. No workers were determined to have restrictive lung function abnormalities.This Health Hazard Evaluation (HHE) report and any recommendations made herein are for the specific facility evaluated and may not be universally applicable. Any recommendations made are not to be considered as final statements of NIOSH policy or of any agency or individual involved.Additional HHE reports are available at http://www.cdc.gov/niosh/hhe/...