ASTM E2889-23

Standard Practice for Control of Respiratory Hazards in the Metal Removal Fluid Environment

SIGNIFICANCE AND USE
4.1 Exposure to aerosols in the industrial metal removal environment has been associated with adverse respiratory effects.  
4.2 Use of this practice will mitigate occupational exposure and effects of exposure to aerosols in the metal removal environment.  
4.3 Through implementation of this practice, users should be able to reduce instances and severity of respiratory irritation and disease through the effective use of a metal removal fluid management program, appropriate product selection, appropriate machine tool design, proper air handling mechanisms, and control of microorganisms.
SCOPE
1.1 This practice sets forth guidelines to control respiratory hazards in the metal removal environment.  
1.2 This practice does not include prevention of dermatitis, which is the subject of Practice E2693, but it does adopt a similar systems management approach with many control elements in common.  
1.3 This practice focuses on employee exposure via inhalation of metal removal fluids and associated airborne agents.  
1.4 Metal removal fluids used for wet machining operations (such as cutting, drilling, milling, or grinding) that remove metal to produce the finished part are a subset of metalworking fluids. This practice does not apply to other operations (such as stamping, rolling, forging, or casting) that use metalworking fluids other than metal removal fluids. These other types of metalworking fluid operations are not included in this document because of limited information on health effects, including epidemiology studies, and on control technologies. Nonetheless, some of the exposure control approaches and guidance contained in this document may be useful for managing respiratory hazards associated with other types of metalworking fluids.  
1.5 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.6 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

General Information

• Status: Published
• Publication Date: 30-Sep-2023
• ICS: 13.040.30 - Workplace atmospheres
• Technical Committee: E34 - Occupational Health and Safety
• Drafting Committee: E34.50 - Health and Safety Standards for Metal Working Fluids

Relations

• Replaces: ASTM E2889-12(2017) - Standard Practice for Control of Respiratory Hazards in the Metal Removal Fluid Environment
• Effective Date: 01-Oct-2023
• Refers: ASTM D7049-24 - Standard Test Method for Metalworking Fluid Aerosol in Workplace Atmospheres
• Effective Date: 01-Mar-2024
• Refers: ASTM E2523-23 - Standard Terminology for Metalworking Fluids and Operations
• Effective Date: 01-Nov-2023
• Refers: ASTM E2564-23 - Standard Practice for Enumeration of <emph type="ital">Mycobacteria</emph> in Metalworking Fluids by Direct Microscopic Counting (DMC) Method
• Effective Date: 01-Oct-2023
• Refers: ASTM E2563-23 - Standard Practice for Enumeration of Non-Tuberculosis <emph type="ital">Mycobacteria</emph > in Aqueous Metalworking Fluids by Plate Count Method
• Effective Date: 01-Oct-2023
• Refers: ASTM E2564-18 - Standard Practice for Enumeration of <emph type="bdit">Mycobacteria</emph> in Metalworking Fluids by Direct Microscopic Counting (DMC) Method
• Effective Date: 01-Oct-2018
• Refers: ASTM E2523-13(2018) - Standard Terminology for Metalworking Fluids and Operations
• Effective Date: 01-Oct-2018
• Refers: ASTM E2563-18 - Standard Practice for Enumeration of Non-Tuberculosis <emph type="bdit">Mycobacteria</emph > in Aqueous Metalworking Fluids by Plate Count Method
• Effective Date: 01-Oct-2018
• Refers: ASTM D7049-17 - Standard Test Method for Metalworking Fluid Aerosol in Workplace Atmospheres
• Effective Date: 01-Oct-2017
• Referred By: ASTM E1497-23 - Standard Practice for Selection and Safe Use of Water-Miscible and Straight Oil Metal Removal Fluids
• Effective Date: 01-Oct-2023
• Referred By: ASTM E2693-19 - Standard Practice for Prevention of Dermatitis in the Wet Metal Removal Fluid Environment
• Effective Date: 01-Oct-2023
• Referred By: ASTM E2148-21 - Standard Guide for Using Documents Related to Metalworking or Metal Removal Fluid Health and Safety
• Effective Date: 01-Oct-2023
• Referred By: ASTM E2275-19 - Standard Practice for Evaluating Water-Miscible Metalworking Fluid Bioresistance and Antimicrobial Pesticide Performance
• Effective Date: 01-Oct-2023

Overview

ASTM E2889-23, published by ASTM International, provides essential guidelines for the control of respiratory hazards in the metal removal fluid (MRF) environment. This standard is critical for industries engaging in wet machining operations-such as cutting, drilling, milling, or grinding-where employees may be exposed to mists and aerosols generated by metal removal fluids. Exposure to these aerosols has been associated with significant adverse respiratory effects, making the adoption of best practices essential for workplace safety and regulatory compliance.

Key Topics

• Occupational Exposure Risks: Metal removal fluids can become airborne as aerosols or mists, creating respiratory risks such as irritation, asthma, chronic bronchitis, hypersensitivity pneumonitis, and, in some cases, association with increased cancer risk.
• System Management Approach: This practice emphasizes the implementation of a comprehensive fluid management program. It includes appropriate fluid selection, optimized machine tool design, effective air handling mechanisms, and diligent microbial control.
• Aerosol Characteristics: Metal removal fluid aerosols consist of various particle sizes, chemical components, and biological agents (bioaerosols). Both fluid composition and contamination significantly influence the hazard level.
• Engineering Controls: Proper machine tool design, enclosure, mist collection, ventilation, and maintenance are critical elements in limiting the generation and release of hazardous aerosols.
• Microbial Control: The standard provides guidance on monitoring and controlling microbial growth within metal removal fluids, which is crucial due to the additional respiratory hazard posed by microbial byproducts such as endotoxins.
• Product Selection and Fluid Management: Selecting fluids with lower misting and toxicity potential, maintaining correct concentration, and controlling contamination are prioritized to reduce occupational exposure.

Applications

ASTM E2889-23 is widely applicable in industrial sectors using metal removal fluids in wet machining processes. It provides practical value in the following areas:

• Manufacturing Facilities: For any facility utilizing cutting, milling, grinding, or drilling involving metal removal fluids, implementing this standard helps protect workers from airborne hazards.
• Workplace Safety Programs: The document supports health and safety managers in developing comprehensive programs targeting respiratory risk reduction.
• Machine Tool Procurement and Design: Guidance for selecting and designing machinery and enclosures that minimize exposure potential.
• Maintenance Operations: Practices for monitoring, maintaining, and improving air handling, mist collection systems, and fluid reservoirs.
• Fluid and Biocide Handling: Safe and appropriate use of metal removal fluids, additives, and antimicrobial pesticides to prevent respiratory and other occupational health issues.
• Regulatory Compliance: Following this standard aids in meeting OSHA and EPA requirements related to personal protective equipment, hazard communication, and airborne contaminant limits.

Related Standards

ASTM E2889-23 references and complements a range of essential standards and guidelines, including:

• ASTM D1356: Terminology Relating to Sampling and Analysis of Atmospheres
• ASTM D2881: Classification for Metalworking Fluids and Related Materials
• ASTM D7049: Test Method for Metalworking Fluid Aerosol in Workplace Atmospheres
• ASTM E1497: Practice for Selection and Safe Use of Water-Miscible and Straight Oil Metal Removal Fluids
• ASTM E2693: Practice for Prevention of Dermatitis in the Wet Metal Removal Fluid Environment
• OSHA 29 CFR 1910.132: Personal Protective Equipment
• OSHA 29 CFR 1910.134: Respiratory Protection in the Workplace
• EPA 40 CFR 156: Pesticide and Device Labeling Requirements

Practical Value

Implementing ASTM E2889-23 helps organizations:

• Reduce instances and severity of respiratory irritation and disease among workers.
• Improve overall workplace air quality.
• Ensure safer fluid handling and maintenance practices.
• Strengthen risk management related to airborne hazards in metal removal environments.

Adopting this standard is a proven step toward a safer, healthier, and more regulatory-compliant industrial workplace.

Standards Content (Sample)

This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation: E2889 − 23 An American National Standard
Standard Practice for
Control of Respiratory Hazards in the Metal Removal Fluid
Environment
This standard is issued under the fixed designation E2889; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope* 2. Referenced Documents
2.1 ASTM Standards:
1.1 This practice sets forth guidelines to control respiratory
D1356 Terminology Relating to Sampling and Analysis of
hazards in the metal removal environment.
Atmospheres
1.2 This practice does not include prevention of dermatitis,
D2881 Classification for Metalworking Fluids and Related
which is the subject of Practice E2693, but it does adopt a
Materials
similar systems management approach with many control
D7049 Test Method for Metalworking Fluid Aerosol in
elements in common.
Workplace Atmospheres
E1302 Guide for Acute Animal Toxicity Testing of Water-
1.3 This practice focuses on employee exposure via inhala-
Miscible Metalworking Fluids
tion of metal removal fluids and associated airborne agents.
E1370 Guide for Air Sampling Strategies for Worker and
1.4 Metal removal fluids used for wet machining operations
Workplace Protection
(such as cutting, drilling, milling, or grinding) that remove
E1497 Practice for Selection and Safe Use of Water-
metal to produce the finished part are a subset of metalworking
Miscible and Straight Oil Metal Removal Fluids
fluids. This practice does not apply to other operations (such as
E1542 Terminology Relating to Occupational Health and
stamping, rolling, forging, or casting) that use metalworking
Safety
fluids other than metal removal fluids. These other types of
E2144 Practice for Personal Sampling and Analysis of En-
metalworking fluid operations are not included in this docu-
dotoxin in Metalworking Fluid Aerosols in Workplace
ment because of limited information on health effects, includ-
Atmospheres
ing epidemiology studies, and on control technologies.
E2148 Guide for Using Documents Related to Metalworking
Nonetheless, some of the exposure control approaches and
or Metal Removal Fluid Health and Safety
guidance contained in this document may be useful for
E2169 Practice for Selecting Antimicrobial Pesticides for
managing respiratory hazards associated with other types of
Use in Water-Miscible Metalworking Fluids
metalworking fluids.
E2275 Practice for Evaluating Water-Miscible Metalwork-
ing Fluid Bioresistance and Antimicrobial Pesticide Per-
1.5 This standard does not purport to address all of the
formance
safety concerns, if any, associated with its use. It is the
E2523 Terminology for Metalworking Fluids and Opera-
responsibility of the user of this standard to establish appro-
tions
priate safety, health, and environmental practices and deter-
E2563 Practice for Enumeration of Non-Tuberculosis Myco-
mine the applicability of regulatory limitations prior to use.
bacteria in Aqueous Metalworking Fluids by Plate Count
1.6 This international standard was developed in accor-
Method
dance with internationally recognized principles on standard-
E2564 Practice for Enumeration of Mycobacteria in Metal-
ization established in the Decision on Principles for the
working Fluids by Direct Microscopic Counting (DMC)
Development of International Standards, Guides and Recom-
Method
mendations issued by the World Trade Organization Technical
E2657 Practice for Determination of Endotoxin Concentra-
Barriers to Trade (TBT) Committee.
tions in Water-Miscible Metalworking Fluids
E2693 Practice for Prevention of Dermatitis in the Wet
This practice is under the jurisdiction of ASTM Committee E34 on Occupa-
tional Health and Safety and is the direct responsibility of Subcommittee E34.50 on
Health and Safety Standards for Metal Working Fluids. For referenced ASTM standards, visit the ASTM website, www.astm.org, or
Current edition approved Oct. 1, 2023. Published October 2023. Originally contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM
approved in 2012. Last previous edition approved in 2017 as E2889 – 12 (2017). Standards volume information, refer to the standard’s Document Summary page on
DOI: 10.1520/E2889-23. the ASTM website.
*A Summary of Changes section appears at the end of this standard
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
E2889 − 23
Metal Removal Fluid Environment 3.2.1 dilution ventilation, n—referring to the supply and
E2694 Test Method for Measurement of Adenosine Triphos- exhaust of air with respect to an area, room, or building; the
phate in Water-Miscible Metalworking Fluids dilution of contaminated air with uncontaminated air for the
E3265 Guide for Evaluating Water-Miscible Metalworking purpose of controlling potential health hazards, fire and explo-
Fluid Foaming Tendency sion conditions, odors, and nuisance-type contaminants. From
Industrial Ventilation: A Manual of Recommended Practice.
2.2 OSHA (U.S. Occupational Safety and Health Adminis-
3.2.2 extractable mass, n—the material removed by liquid
tration) Standards:
29 CFR 1910.132 Personal Protective Equipment extraction of the sampling filter using a mixed-polarity solvent
mixture as described in Test Method D7049 or NIOSH Method
29 CFR 1910.134 Use of Respiratory Protection in the
Workplace 5524.
3.2.2.1 Discussion—This mass is an approximation of the
29 CFR 1010.1020 Access to Employee Exposure and
Medical Records metal removal fluid portion of the workplace aerosol.
29 CFR 1910.1048 Formaldehyde
3.2.3 metal removal fluid (MRF), n—any fluid in the sub-
29 CFR 1910.1200 Hazard Communication
class of metalworking fluids used to cut or otherwise take away
material or piece of stock. E2148
2.3 EPA (U.S. Environmental Protection Agency) Stan-
3.2.3.1 Discussion—Metal removal fluids include straight or
dards:
neat oils (Classification D2881) not intended for further
40 CFR 156 Labeling Requirements for Pesticides and
dilution with water, and water-miscible soluble oils,
Devices
semisynthetics, and synthetics, which are intended to be diluted
2.4 Other Documents:
with water before use. Metal removal fluids become contami-
ANSI Technical Report B11 TR 2-1997 Mist Control Con-
nated during use in the workplace with a variety of workplace
siderations for the Design, Installation and Use of Ma-
substances including, but not limited to: abrasive particles,
chine Tools Using Metalworking Fluids
tramp oils, cleaners, dirt, metal fines and shavings, dissolved
National Center for Manufacturing Sciences Metal Working
metal and hard water salts, bacteria, fungi, microbiological
Fluid Optimization Guide
decay products, and waste. These contaminants can cause
ACGIH Industrial Ventilation: A Manual of Recommended
changes in the lubricity and cooling ability of the metal
Practice for Design
removal fluid as well as have the potential to adversely affect
ACGIH Industrial Ventilation: A Manual of Recommended
the health and welfare of employees in contact with the
Practice for Operation and Maintenance
contaminated metal removal fluid. E2148
NIOSH Criteria for a Recommended Standard: Occupational
3.2.4 metal removal fluid aerosol, n—aerosol generated by
Exposure to Metalworking Fluids
operation of the machine tool itself as well as from circulation
OSHA Metalworking Fluids: Safety and Health Best Prac-
and filtration systems associated with wet metal removal
tices Manual
operations and may include airborne contaminants of microbial
NIOSH Method 5524 Metalworking Fluids (MWF) All Cat-
origin.
egories
3.2.4.1 Discussion—Metal removal aerosol does not include
background aerosol in the workplace atmosphere, which may
3. Terminology
include suspended insoluble particulates.
3.1 For definitions and terms relating to this guide, refer to
3.2.5 total particulate matter, n—the mass of material
Terminologies D1356, E1542, and E2523.
sampled through the 4 mm inlet of a standard 37 mm filter
3.2 Definitions of Terms Specific to This Standard:
cassette when operated at 2.0 L/min, as described in Test
Method D7049.
3.2.5.1 Discussion—As defined in Test Method D7049, total
Available from United States Government Printing Office, Washington, DC
particulate matter is not a measure of the inhalable or thoracic
20402 or at eCFR, 29 CFR Part 1910, https://www.ecfr.gov/current/title-29/subtitle-
particulate mass.
B/chapter-XVII/part-1910?toc=1.
Available from United States Government Printing Office, Washington, DC
3.3 Acronyms:
20402 or at eCFR, 40 CFR Part 156, https://www.ecfr.gov/current/title-40/chapter-
3.3.1 GHS, n—globally harmonized system
I/subchapter-E/part-156.
3.3.1.1 Discussion—GHS is an acronym for the Globally
Available from American National Standards Institute (ANSI); see B11
Standards, Inc. (www.ansi.org). Harmonized System of Classification and Labeling of Chemi-
Available from National Center for Manufacturing Sciences, Report 0274RE95,
cals.
3025 Boardwalk, Ann Arbor, MI 48018.
Available from ACGIH at https://portal.acgih.org/s/store#/store/browse/detail/
4. Significance and Use
a158a00000CgqcfAAB.
Available from ACGIH at https://portal.acgih.org/s/store#/store/browse/detail/
4.1 Exposure to aerosols in the industrial metal removal
a154W00000BOaw1QAD.
environment has been associated with adverse respiratory
Available from National Institute for Occupational Safety and Health (NIOSH)
effects.
at https://www.cdc.gov/niosh/docs/98-102/.
Available from U.S. Occupational Health and Safety Administration (OSHA)
4.2 Use of this practice will mitigate occupational exposure
at https://www.osha.gov/metalworking-fluids/manual.
and effects of exposure to aerosols in the metal removal
Available from National Institute for Occupational Safety and Health (NIOSH)
at https://www.cdc.gov/niosh/docs/2003-154/pdfs/5524.pdf. environment.
E2889 − 23
4.3 Through implementation of this practice, users should and fill with mucous, reducing airflow and producing shortness
be able to reduce instances and severity of respiratory irritation of breath and a wheezing sound. A variety of components,
and disease through the effective use of a metal removal fluid additives, and contaminants of MRF can induce new onset
management program, appropriate product selection, appropri- asthma, aggravate pre-existing asthma, and irritate the airways
ate machine tool design, proper air handling mechanisms, and of non-asthmatic employees.
control of microorganisms. 5.3.4 Chronic bronchitis is a condition involving inflamma-
tion of the main airways of the lungs that occurs over a long
5. Respiratory Health Hazards Associated with Metal
period of time. Chronic bronchitis is characterized by a chronic
Removal Fluids
cough and by coughing up phlegm. The phlegm can interfere
with air passage into and out of the lungs. This condition may
5.1 General:
also cause accelerated decline in lung function, which can
5.1.1 Metal removal fluids (MRF) can cause adverse health
ultimately result in heart and lung function damage.
effects through skin contact with contaminated materials,
5.3.5 Hypersensitivity pneumonitis (HP) is a serious lung
spray, or mist and through inhalation from breathing MWF
disease. Recent outbreaks of HP have been associated with
mist or aerosol.
exposure to aerosols of synthetic, semisynthetic, and soluble
5.1.2 Skin and airborne exposures to MRF have been
oil MRF. In particular, contaminants and additives in MRF
implicated in health problems including irritation of the skin,
have been associated with outbreaks of HP (NIOSH 1998a). In
lungs, eyes, nose, and throat. Conditions such as dermatitis,
the short term, HP is characterized by coughing, shortness of
acne, asthma, hypersensitivity pneumonitis, irritation of the
breath, and flu-like symptoms (fevers, chills, muscle aches, and
upper respiratory tract, and a variety of cancers have been
fatigue). The chronic phase (following repeated exposures) is
associated with exposure to MRF (NIOSH 1998a). The sever-
characterized by lung scarring associated with permanent lung
ity of health problems is dependent on a variety of factors such
disease.
as the kind of fluid, the degree and type of contamination, and
5.3.6 Other factors, such as smoking, increase the possibil-
the level and duration of the exposure.
ity of respiratory diseases. Cigarette smoke may worsen the
5.2 Skin Disorders:
respiratory effects of MRF aerosols for all employees.
5.2.1 Skin contact occurs when the worker dips his/her
5.3.7 Respiratory effects have been observed among work-
hands into the fluid or handles parts, tools, and equipment
3 12
ers with exposures below 1.0 mg/m to diverse fluids, with
covered with fluid without the use of personal protective
water-reduced fluids generally appearing more potent. Poorly
equipment, such as gloves and aprons. Skin contact may also
controlled fluids have generally been more likely to be asso-
result from fluid splashing onto the employee from the machine
ciated with adverse effects.
if guarding is absent or inadequate. For further information,
5.4 Cancer:
refer to Practice E2693.
5.4.1 A number of studies have found an association be-
5.3 Respiratory Diseases:
tween working with MRF and a variety of cancers, including
5.3.1 Inhalation of MRF mist or aerosol may cause irritation
cancer of the rectum, pancreas, larynx, skin, scrotum, and
of the lungs, throat, and nose. In general, respiratory irritation
bladder (NIOSH 1998a). No authoritative review of studies of
involves some type of chemical interaction between the MRF
workers exposed to MRF has been conducted since 1999,
and the human respiratory system. Irritation may affect one or
although additional data have been published. Studies of MRF
more the following areas: nose, throat (pharynx, larynx), the
and cancer reflect the health experiences of workers exposed
various conducting airways or tubes of the lungs (trachea,
decades earlier. This is because the effects of cancers associ-
bronchi, bronchioles), and the lung air sacs (alveoli) where the
ated with MRF may not become evident until many years after
air passes from the lungs into the body. Exposure to MRF mist
the exposure. Airborne concentrations of MWF were known to
or aerosol may also aggravate the effects of existing lung
be much higher in the 1970s and 80s than those today. The
disease.
composition of MRF has also changed dramatically over the
5.3.2 Some of the symptoms reported include sore throat;
years. The fluids in use prior to 1985 may have contained
red, watery, itchy eyes; runny nose; nosebleeds; cough; wheez-
nitrite, mildly refined petroleum oils, and other chemicals that
ing; increased phlegm production; shortness of breath; and
were removed after 1985 for health concerns. Based on the
other cold-like symptoms. These symptoms may indicate a
substantial changes that have been made in the metalworking
variety of respiratory conditions, including acute airway
industry over the last decades, the cancer risks have likely been
irritation, asthma (reversible airway obstruction), chronic
reduced, but there is not enough data to prove this.
bronchitis, chronically impaired lung function, and hypersen-
sitivity pneumonitis (HP). When symptoms of respiratory
6. Fluid Properties Associated with Adverse Health
irritation occur, in many cases it is unclear whether the disease
Effects
was caused by specific fluid components, contamination of the
6.1 Aerosol Physical Properties:
in-use fluid, products of microbial growth or degradation, or a
6.1.1 Metal removal fluid aerosols consist of a broad range
combination of factors.
of particle sizes. Airborne particles shrink as water and other
5.3.3 Exposure to MRF has been associated with asthma. In
asthma, airways of the lung become inflamed, causing a
reduction of the flow of air into and out of the lungs. During an
Gauther, S. L., “Metal Working Fluids: Oil Mist and Beyond,” Applied
asthmatic attack, the airways become swollen, go into spasms Occupational & Environmental Hygiene, Vol 18, 2003, pp. 818–824.
E2889 − 23
volatiles evaporate; particles farther from point of generation 6.3.1.1 Aerosols in the metal removal environment may
are smaller. The “inhalable” fraction includes very large differ significantly from the components of virgin metal re-
particles excluded by the closed face filter used by NIOSH moval fluid dilutions. In addition to avoiding the use of
0500 for “total particulate.” “Total” particulate includes par- possible irritants in the original design, formulators must
ticles larger than those in the “thoracic” fraction. Smaller account for possible changes in chemistry, microbiology, levels
particles are more easily captured by machine tool ventilation of contamination, and alterations in physical misting when
exhaust, but may pass through an air cleaner. Particles may be developing a metal removal fluid.
generated by evaporation and condensation from air cleaner
6.3.1.2 The pH of a metal removal fluid dilution impacts
filter media. Larger aerosol particles are more likely to be
corrosion, materials compatibility, microbial resistance, and
controlled by enclosures. Controlling metal removal fluid
emulsion stability in addition to acting as a possible source of
emissions on one machine will not affect background aerosol
operator irritation. It is important that the pH of a working fluid
or other aerosol generated by other work stations; all machine avoid extremes, generally between 5 and 10. The fluid should
tools need to be considered together. Air sampling using filter
also be buffered within the target range of the fluid such that
methods captures no measurable water. Oil evaporates when small amounts of contaminants do not create wide shifts in pH.
captured on a filter, while non-oil additives to water-soluble
6.3.1.3 Even at a stable and buffered pH, metal removal
fluids do not.
fluid formulations should limit or eliminate chemicals that pose
irritation threats. These chemicals include volatile amines,
6.2 Bioaerosols:
aldehydes, ketones, alcohols, ethers, and multifunctional or-
6.2.1 Bioaerosols include:
ganics. Some of these materials may only be present as
6.2.1.1 Whole microbes (archaeal, bacterial, and fungal):
contaminant byproducts of primary components, or may only
cells and viruses;
be generated within an in-use fluid through contact with
6.2.1.2 Microbial cell fragments: segments of cell wall
machining components. An awareness of possible secondary
material;
reactions between the fluid and machine/workpiece substrates
6.2.1.3 Biomolecules: predominantly carbohydrates,
is key.
endotoxins, lipids, nucleic acids, and proteins;
6.3.1.4 A recognized source of respiratory irritation in the
6.2.1.4 Metabolites: innumerable microbial waste products
metal removal fluid environment is microbiological contami-
(predominantly carbohydrates, organic acids, complex poly-
nation. A fluid formulated with materials that inhibit microbial
mers (biofilm matrix), exotoxins, and microbial volatile or-
growth and eradicate microbial contamination is necessary to
ganic chemicals—MVOC).
mediate irritating worker mist contact. Unfortunately, many of
6.2.2 Factors affecting bioaerosol generation include:
the chemicals that are effective fluid preservatives can also
6.2.2.1 Bioburden in recirculating, bulk MRF: the bioaero-
contribute to irritating aerosols. Therefore, an effective formu-
sol component of the total aerosol generated from MRF comes
lation utilizes these preservatives within their well-defined
directly from the microbes and microbially produced mol-
inhibitory concentrations and within a product chemical matrix
ecules present in the bulk fluid. Except for MVOC, the
that does not magnify their irritation potential.
introduction of which into the airspace is dictated by the
6.3.1.5 While mist is a physical phenomenon, metal re-
physical-chemical properties of individual MVOC molecules,
moval fluid chemistry can play a role in enhancing or reducing
bioaerosol generation is proportional to bulk fluid bioburden.
mist generation in equivalent situations. Unfortunately, the
6.2.2.2 Biofilm communities growing on MRF system sur-
dynamics of fluid chemistry and mist are not well understood.
faces are in dynamic equilibrium. Once they have formed,
However, there exist effective chemical additives that increase
biofilms tend to slough off portions of the mass that are at the
droplet size and, as a result, reduce mist. These materials are
fluid-biofilm interface as new biofilm material is generated.
generally unstable and must be added to a system continually
The details of this equilibrium vary widely among systems.
over the life of a fluid system.
(1) Biofilms that exist in high turbulent-flow conditions
6.3.1.6 The tendency of a diluted, water-miscible metal
tend to be thinner than those growing in stagnant or slow
laminar-flow environments. removal fluid to foam can influence mist generation. See Guide
E3265.
(2) Biofilms growing in high turbulent-flow conditions
tend to be more tenacious (more difficult to remove) than those 6.3.2 Contamination Considerations:
growing in stagnant or low flow-rate environments.
6.3.2.1 Diluted metal removal fluids quickly become con-
(3) Biofilm communities are typically comprised of micro-
taminated in use. Some contaminants, such as alkaline
bial consortia, complex communities of diverse species which
materials, pH boosters, and similar materials, can increase the
function in ways that resemble multi-cellular organisms, ex-
respiratory hazard.
creting and secreting the full range of bioaerosol constituent
6.3.2.2 Minimize tramp oil contamination such as leaking
molecules listed in 6.2.1.
hydraulic fluids, way lubricants, and gear box lubricants. Of all
(4) The factors described in 6.1 and 6.3 can affect the
potential contaminants, tramp oil has the most significant effect
persistence and distribution of microbes and biomolecules in
on increasing airborne concentrations of metal removal fluids.
MRF. Consequently, these factors will also affect bioaerosol
6.3.3 Tankside Additive Considerations:
generation.
6.3.3.1 As supplied, antimicrobial pesticides and other ad-
6.3 Chemicals:
ditives for tankside addition can present greater health and
6.3.1 Formulating Considerations: safety risks than the metal removal fluid. Further, additives and
E2889 − 23
antimicrobials are less likely to be handled automatically or 8.5 Select fluids that are appropriate for the machining
with special delivery equipment than metal removal fluid process, are cost effective, can be safely disposed when they
concentrate, so greater care and attention are required to reduce are no longer economically feasible to re-use, have supplier
risks of exposure. support, and are used with a fluid management program.
6.3.3.2 Antimicrobial pesticides are designed to kill micro-
8.6 As the concentration of metal removal fluid in the
organisms and therefore have significant biological activity. To
machining system sump or reservoir increases, the level of
avoid potential for harm by mishandling or misapplication,
chemicals in the metal removal fluid aerosol increases and the
antimicrobial pesticides must be handled with care. The user
net exposure is greater. Maintaining proper metal removal fluid
shall read, understand, and follow all appropriate instructions
concentration while in use enhances machining performance
for handling, storage, and use of each antimicrobial pesticide as
and minimizes exposure potential.
specified by the antimicrobial pesticide manufacturer on the
Safety Data Sheet.
9. Methods for Metal Removal Fluid Mist Minimization
9.1 Minimizing Insoluble Particulate Matter:
7. Metal Removal Fluid Management Practices
9.1.1 The difference between total particulate matter and
7.1 Management of metal removal processes is the most
extractable mass, as measured by Test Method D7049, is an
important step in minimizing exposure to metal removal fluid estimate of the insoluble particulate matter in the machining
aerosols. As factors affecting aerosol generation are
environment. Minimize insoluble particulate matter such as
interdependent, a systems approach to metal removal process may be generated by dry machining, welding operations, and
management will be the most effective approach.
so forth.
9.1.2 Estimate the background level of insoluble particulate
7.2 Aerosolization of metal removal fluids may result in
by evaluating exposures in the workplace away from metal
airborne exposure not only to the formulated components of
removal fluid operations.
the fluid, but also to contaminants introduced into the fluid
9.1.3 Keep the metal removal fluid clean. Minimize accu-
systems while in use, including microbial contaminants.
mulation of grinding swarf from cast iron grinding operations
7.3 Establish a metal removal fluid control program (see
or aluminum and silicon from aluminum machining operations
Section 12). Additional detailed guidance may be found in
through proper design, selection, and maintenance of metal
Practice E1497 and in Metal Removal Fluids: A Guide to Their
removal fluid filtration systems.
Management and Control. Consult with your metal removal
9.2 Minimizing Extractable Mass Concentration:
fluid suppliers.
9.2.1 Minimize extractable mass concentration. The amount
and average particle size of aerosol generated is dependent on
8. Product Selection
the amount of energy imparted to the fluid. Energy may be
8.1 Fluids vary in their misting characteristics. Select fluids
imparted to the fluid through high-pressure spray application,
with an understanding of their misting characteristics, bearing
high-speed tools, parts, or machines, and any other activity that
in mind available engineering control measures. Some fluids
causes the bulk fluid to generate a mist of liquid droplets. The
mist less, other factors being equal. Misting characteristics may
transfer of energy from the machine to the fluid can be reduced
change significantly with contamination. Some fluids retain
by several means. Combined means may also be required.
entrained air, causing a significant increase in mist generation,
9.2.2 In addition to product selection, proper maintenance
possibly in areas away from the metal removal fluid operation.
of metal removal fluid sump concentration, and the design,
Polymeric additives may be useful in reducing aerosol from
selection, and maintenance characteristics noted earlier in this
straight or neat oils and some water-miscible metal removal
section, excessive generation of metal removal fluid aerosol
fluids. Components or contaminants may be more concentrated
can be affected by parameters such as compressed air blowoffs
in the aerosol phase relative to their concentrations in the bulk
and higher-than-optimum fluid flow rates, pressures, and tool
fluid.
feeds and speeds.
9.2.3 Optimize machine tool feeds and speeds consistent
8.2 Practice E1497 and Metal Removal Fluids: A Guide to
with part finish, dimension, and productivity requirements.
Their Management and Control describe product selection
Excessively high speeds and feeds increase the amount of
criteria. While specifically directed towards water-miscible
aerosol generated.
metalworking fluids, the same principles generally apply to
9.2.4 Minimize fluid flow rates consistent with desired part
selection of neat or straight metal removal fluids.
finish and dimension and movement of generated chips or
8.3 Select fluids with an understanding of their acute and
swarf. If feasible, reduce or temporarily interrupt fluid flow
chronic toxicity characteristics. Guide E1302 references pro-
when the metal removal operation is not occurring. Higher-
cedures to assess the acute toxicity of water-miscible metal-
than-required flow rates increase aerosol generation.
working fluids as manufactured. Review the Safety Data Sheet,
9.2.5 Reduce fluid pressure consistent with machine tool
required by 29 CFR 1910.1200, for health and safety informa-
design and chip removal requirements. Use flooding instead of
tion for the metal removal fluids being considered for the
spray application whenever possible.
operation.
9.2.6 Consider the geometry of fluid application. Minimize
8.4 Select fluids that minimize components that can be the number of directional changes the fluid must make before
irritating or can produce noxious odors. reaching the cutting zone.
E2889 − 23
9.2.7 Control sources of nonmetal removal fluid mists, such operations performed, existing ventilation patterns, ceiling
as from parts washers or mist lube systems. height, and ultimate disposition of the collected mist.
10.12 Introduce a sufficient amount of make-up air into the
10. Machine Tool Design and Maintenance – Engineering
plant ventilation system, particularly where machine enclo-
Control Methods
sures are not present or local exhaust is ineffective. In colder
10.1 ANSI B-11 TR 2-1997 provides guidance concerning weather, when doors and windows are shut, or in hotter
consideration for the design of metalworking fluid delivery weather in facilities with air conditioning, the amount of plant
systems, of machine tools, of machine enclosures for the make-up air affects both the amount of insoluble particulate
control of airborne contaminants, of exhaust ductwork from and extractable mass from metal re
...

This document is not an ASTM standard and is intended only to provide the user of an ASTM standard an indication of what changes have been made to the previous version. Because
it may not be technically possible to adequately depict all changes accurately, ASTM recommends that users consult prior editions as appropriate. In all cases only the current version
of the standard as published by ASTM is to be considered the official document.
Designation: E2889 − 12 (Reapproved 2017) E2889 − 23 An American National Standard
Standard Practice for
Control of Respiratory Hazards in the Metal Removal Fluid
Environment
This standard is issued under the fixed designation E2889; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope Scope*
1.1 This practice sets forth guidelines to control respiratory hazards in the metal removal environment.
1.2 This practice does not include prevention of dermatitis, which is the subject of Practice E2693, but it does adopt a similar
systems management approach with many control elements in common.
1.3 This practice focuses on employee exposure via inhalation of metal removal fluids and associated airborne agents.
1.4 Metal removal fluids used for wet machining operations (such as cutting, drilling, milling, or grinding) that remove metal to
produce the finished part are a subset of metalworking fluids. This practice does not apply to other operations (such as stamping,
rolling, forging, or casting) that use metalworking fluids other than metal removal fluids. These other types of metalworking fluid
operations are not included in this document because of limited information on health effects, including epidemiology studies, and
on control technologies. Nonetheless, some of the exposure control approaches and guidance contained in this document may be
useful for managing respiratory hazards associated with other types of metalworking fluids.
1.5 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility
of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of
regulatory limitations prior to use.
1.6 This international standard was developed in accordance with internationally recognized principles on standardization
established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued
by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
2. Referenced Documents
2.1 ASTM Standards:
D1356 Terminology Relating to Sampling and Analysis of Atmospheres
D2881 Classification for Metalworking Fluids and Related Materials
D7049 Test Method for Metalworking Fluid Aerosol in Workplace Atmospheres
E1302 Guide for Acute Animal Toxicity Testing of Water-Miscible Metalworking Fluids
E1370 Guide for Air Sampling Strategies for Worker and Workplace Protection
E1497 Practice for Selection and Safe Use of Water-Miscible and Straight Oil Metal Removal Fluids
This practice is under the jurisdiction of ASTM Committee E34 on Occupational Health and Safety and is the direct responsibility of Subcommittee E34.50 on Health
and Safety Standards for Metal Working Fluids.
Current edition approved Oct. 1, 2017Oct. 1, 2023. Published October 2017October 2023. Originally approved in 2012. Last previous edition approved in 20122017 as
E2889 – 12.E2889 – 12 (2017). DOI: 10.1520/E2889-12R17.10.1520/E2889-23.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM Standards
volume information, refer to the standard’s Document Summary page on the ASTM website.
*A Summary of Changes section appears at the end of this standard
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
E2889 − 23
E1542 Terminology Relating to Occupational Health and Safety
E1972 Practice for Minimizing Effects of Aerosols in the Wet Metal Removal Environment (Withdrawn 2017)
E2144 Practice for Personal Sampling and Analysis of Endotoxin in Metalworking Fluid Aerosols in Workplace Atmospheres
E2148 Guide for Using Documents Related to Metalworking or Metal Removal Fluid Health and Safety
E2169 Practice for Selecting Antimicrobial Pesticides for Use in Water-Miscible Metalworking Fluids
E2275 Practice for Evaluating Water-Miscible Metalworking Fluid Bioresistance and Antimicrobial Pesticide Performance
E2523 Terminology for Metalworking Fluids and Operations
E2563 Practice for Enumeration of Non-Tuberculosis Mycobacteria in Aqueous Metalworking Fluids by Plate Count Method
E2564 Practice for Enumeration of Mycobacteria in Metalworking Fluids by Direct Microscopic Counting (DMC) Method
E2657 Practice for Determination of Endotoxin Concentrations in Water-Miscible Metalworking Fluids
E2693 Practice for Prevention of Dermatitis in the Wet Metal Removal Fluid Environment
E2694 Test Method for Measurement of Adenosine Triphosphate in Water-Miscible Metalworking Fluids
E3265 Guide for Evaluating Water-Miscible Metalworking Fluid Foaming Tendency
2.2 OSHA (U.S. Occupational Safety and Health Administration) Standards:
29 CFR 1910.132 Personal Protective Equipment
29 CFR 1910.134 Use of Respiratory Protection in the Workplace
29 CFR 1010.1020 Access to Employee Exposure and Medical Records
29 CFR 1910.1048 Formaldehyde
29 CFR 1910.1200 Hazard Communication
2.3 EPA (US(U.S. Environmental Protection Agency) Standards:
40 CFR 156 Labeling Requirements for Pesticides and Devices
2.4 Other Documents:
ANSI Technical Report B11 TR 2-1997,2-1997 Mist Control Considerations for the Design, Installation and Use of Machine
Tools Using Metalworking Fluids
Metal Working Fluid Optimization Guide,National Center for Manufacturing Sciences National Center for Manufacturing
SciencesMetal Working Fluid Optimization Guide
Metal Removal Fluids,ACGIH A Guide To Their Management and Control, Organization Resources Counselors, Inc.Industrial
Ventilation: A Manual of Recommended Practice for Design
Industrial Ventilation:ACGIH Industrial Ventilation: A Manual of Recommended Practice for Operation and Maintenance
Criteria for a Recommended Standard:NIOSH Criteria for a Recommended Standard: Occupational Exposure to Metalworking
Fluids
Metalworking Fluids:OSHA Metalworking Fluids: Safety and Health Best Practices Manual
NIOSH Method 0500:5524 Particulates Not Otherwise Regulated, TotalMetalworking Fluids (MWF) All Categories
3. Terminology
3.1 For definitions and terms relating to this guide, refer to Terminologies D1356, E1542, and E2523.
3.2 Definitions of Terms Specific to This Standard:
3.2.1 dilution ventilation, n—referring to the supply and exhaust of air with respect to an area, room, or building,building; the
Code of Federal Regulations available Available from United States Government Printing Office, Washington, DC 20402.20402 or at eCFR, 29 CFR Part 1910,
https://www.ecfr.gov/current/title-29/subtitle-B/chapter-XVII/part-1910?toc=1.
Code of Federal Regulations available Available from United States Government Printing Office, Washington, DC 20402.20402 or at eCFR, 40 CFR Part 156,
https://www.ecfr.gov/current/title-40/chapter-I/subchapter-E/part-156.
Available from Association for Manufacturing Technology, 7901 Westpark Drive, McLean VA 22102.American National Standards Institute (ANSI); see B11 Standards,
Inc. (www.ansi.org).
Available from National Center for Manufacturing Sciences, Report 0274RE95, 3025 Boardwalk, Ann Arbor, MI 48018.
Available from Organization Resources Counselors, 1910 Sunderland Place, NW., Washington, DC 20036 or from members of the Metal Working Fluid Product
SM
Stewardship Group (MWFPSGACGIH at https://portal.acgih.org/s/store#/store/browse/detail/a158a00000CgqcfAAB. ). Contact Independent Lubricant Manufacturers
SM
Association, 651 S. Washington Street, Alexandria, VA 22314, for a list of members of the MWFPSG .
Available from American Conference of Governmental Industrial Hygienists, 1330 Kemper Meadow Drive, Cincinnati, OH 45240-1634.ACGIH at https://
portal.acgih.org/s/store#/store/browse/detail/a154W00000BOaw1QAD.
Available from U.S. Department of Health and Human Services, Public Health Service, Centers for Disease Control and Prevention, National Institute for Occupational
Safety and Health, Cincinnati, OH 45226.Health (NIOSH) at https://www.cdc.gov/niosh/docs/98-102/.
Available from USU.S. Occupational Health and Safety Administration, 200 Constitution Avenue NW, Washington, DC 20210 or at http://www.osha.gov/SLTC/
metalworkingfluids/metalworkingfluids_manual.htmlAdministration (OSHA) at https://www.osha.gov/metalworking-fluids/manual.
Available from U.S. Department of Health and Human Services, Public Health Service, Centers for Disease Control and Prevention, National Institute for Occupational
Safety and Health, Cincinnati, OH 45226 or at. http://www.cdc.gov/niosh/docs/2003-154/pdfs/0500.pdfHealth (NIOSH) at https://www.cdc.gov/niosh/docs/2003-154/pdfs/
5524.pdf.
E2889 − 23
dilution of contaminated air with uncontaminated air for the purpose of controlling potential health hazards, fire and explosion
conditions, odors, and nuisance-type contaminants, fromcontaminants. From Industrial Ventilation: A Manual of Recommended
Practice.
3.2.2 extractable mass, n—the material removed by liquid extraction of the sampling filter using a mixed-polarity solvent mixture
as described in Test Method D7049. or NIOSH Method 5524.
3.2.2.1 Discussion—
This mass is an approximation of the metal removal fluid portion of the workplace aerosol.
3.2.3 metal removal fluid (MRF), n—any fluid in the subclass of metalworking fluids used to cut or otherwise take away material
or piece of stock. E2148
3.2.3.1 Discussion—
Metal removal fluids include straight or neat oils (Classification D2881),) not intended for further dilution with water, and
water-miscible soluble oils, semisynthetics, and synthetics, which are intended to be diluted with water before use. Metal removal
fluids become contaminated during use in the workplace with a variety of workplace substances including, but not limited to,to:
abrasive particles, tramp oils, cleaners, dirt, metal fines and shavings, dissolved metal and hard water salts, bacteria, fungi,
microbiological decay products, and waste. These contaminants can cause changes in the lubricity and cooling ability of the metal
removal fluid as well as have the potential to adversely affect the health and welfare of employees in contact with the contaminated
metal removal fluid. E2148
3.2.4 metal removal fluid aerosol, n—aerosol generated by operation of the machine tool itself as well as from circulation and
filtration systems associated with wet metal removal operations and may include airborne contaminants of microbial origin.
3.2.4.1 Discussion—
Metal removal aerosol does not include background aerosol in the workplace atmosphere, which may include suspended insoluble
particulates.
3.2.5 total particulate matter, n—the mass of material sampled through the 4-mm 4 mm inlet of a standard 37-mm 37 mm filter
cassette when operated at 2.0 L/min, as described in Test Method D7049.
3.2.5.1 Discussion—
As defined in Test Method D7049, total particulate matter is not a measure of the inhalable or thoracic particulate mass.
3.3 Acronyms:
3.3.1 GHS, n—globally harmonized system
3.3.1.1 Discussion—
GHS is an acronym for the Globally Harmonized System of Classification and Labeling of Chemicals.
4. Significance and Use
4.1 Exposure to aerosols in the industrial metal removal environment has been associated with adverse respiratory effects.
4.2 Use of this practice will mitigate occupational exposure and effects of exposure to aerosols in the metal removal environment.
4.3 Through implementation of this practice, users should be able to reduce instances and severity of respiratory irritation and
disease through the effective use of a metal removal fluid management program, appropriate product selection, appropriate
machine tool design, proper air handling mechanisms, and control of microorganisms.
5. Respiratory Health Hazards Associated with Metal Removal Fluids
5.1 General:
5.1.1 Metal removal fluids (MRF) can cause adverse health effects through skin contact with contaminated materials, spray, or mist
and through inhalation from breathing MWF mist or aerosol.
5.1.2 Skin and airborne exposures to MRF have been implicated in health problems including irritation of the skin, lungs, eyes,
nose, and throat. Conditions such as dermatitis, acne, asthma, hypersensitivity pneumonitis, irritation of the upper respiratory tract,
and a variety of cancers have been associated with exposure to MRF (NIOSH 1998a). The severity of health problems is dependent
on a variety of factors such as the kind of fluid, the degree and type of contamination, and the level and duration of the exposure.
E2889 − 23
5.2 Skin Disorders:
5.2.1 Skin contact occurs when the worker dips his/her hands into the fluid or handles parts, tools, and equipment covered with
fluid without the use of personal protective equipment, such as gloves and aprons. Skin contact may also result from fluid splashing
onto the employee from the machine if guarding is absent or inadequate. For further information, refer to Practice E2693.
5.3 Respiratory Diseases:
5.3.1 Inhalation of MRF mist or aerosol may cause irritation of the lungs, throat, and nose. In general, respiratory irritation
involves some type of chemical interaction between the MRF and the human respiratory system. Irritation may affect one or more
the following areas: nose, throat (pharynx, larynx), the various conducting airways or tubes of the lungs (trachea, bronchi,
bronchioles), and the lung air sackssacs (alveoli) where the air passes from the lungs into the body. Exposure to MRF mist or
aerosol may also aggravate the effects of existing lung disease.
5.3.2 Some of the symptoms reported include sore throat,throat; red, watery, itchy eyes, runny nose, nosebleeds, cough, wheezing,
increased phlegm production, shortness of breath,eyes; runny nose; nosebleeds; cough; wheezing; increased phlegm production;
shortness of breath; and other cold-like symptoms. These symptoms may indicate a variety of respiratory conditions, including
acute airway irritation, asthma (reversible airway obstruction), chronic bronchitis, chronically impaired lung function, and
hypersensitivity pneumonitis (HP). When symptoms of respiratory irritation occur, in many cases it is unclear whether the disease
was caused by specific fluid components, contamination of the in-use fluid, products of microbial growth or degradation, or a
combination of factors.
5.3.3 Exposure to MRF has been associated with asthma. In asthma, airways of the lung become inflamed, causing a reduction
of the flow of air into and out of the lungs. During an asthmatic attack, the airways become swollen, go into spasms and fill with
mucous, reducing airflow and producing shortness of breath and a wheezing sound. A variety of components, additives, and
contaminants of MRF can induce new onset asthma, aggravate pre-existing asthma, and irritate the airways of non-asthmatic
employees.
5.3.4 Chronic bronchitis is a condition involving inflammation of the main airways of the lungs that occurs over a long period of
time. Chronic bronchitis is characterized by a chronic cough and by coughing up phlegm. The phlegm can interfere with air passage
into and out of the lungs. This condition may also cause accelerated decline in lung function, which can ultimately result in heart
and lung function damage.
5.3.5 Hypersensitivity pneumonitis (HP) is a serious lung disease. Recent outbreaks of HP have been associated with exposure to
aerosols of synthetic, semi-synthetic,semisynthetic, and soluble oil MRF. In particular, contaminants and additives in MRF have
been associated with outbreaks of HP (NIOSH 1998a). In the short term, HP is characterized by coughing, shortness of breath, and
flu-like symptoms (fevers, chills, muscle aches, and fatigue). The chronic phase (following repeated exposures) is characterized
by lung scarring associated with permanent lung disease.
5.3.6 Other factors, such as smoking, increase the possibility of respiratory diseases. Cigarette smoke may worsen the respiratory
effects of MRF aerosols for all employees.
3 12
5.3.7 Respiratory effects have been observed among workers with exposures below 1.0 mg/Mmg/m to diverse fluids, with
water-reduced fluids generally appearing more potent. Poorly controlled fluids have generally been more likely to be associated
with adverse effects.
5.4 Cancer:
5.4.1 A number of studies have found an association between working with MRF and a variety of cancers, including cancer of
the rectum, pancreas, larynx, skin, scrotum, and bladder (NIOSH 1998a). No authoritative review of studies of workers exposed
to MRF has been conducted since 1999, although additional data have been published. Studies of MRF and cancer reflect the health
experiences of workers exposed decades earlier. This is because the effects of cancers associated with MRF may not become
evident until many years after the exposure. Airborne concentrations of MWF were known to be much higher in the 1970s–80s
1970s and 80s than those today. The composition of MRF has also changed dramatically over the years. The fluids in use prior
Gauther, S. L., “Metal Working Fluids: Oil Mist and Beyond,” Applied Occupational & Environmental Hygiene, Vol 18, 2003, pp. 818–824.
E2889 − 23
to 1985 may have contained nitrite, mildly refined petroleum oils, and other chemicals that were removed after 1985 for health
concerns. Based on the substantial changes that have been made in the metalworking industry over the last decades, the cancer risks
have likely been reduced, but there is not enough data to prove this.
6. Fluid Properties Associated with Adverse Health Effects
6.1 Aerosol Physical Properties:
6.1.1 Metal removal fluid aerosols consist of a broad range of particle sizes. Airborne particles shrink as water and other volatiles
evaporate; particles farther from point of generation are smaller. The “inhalable” fraction includes very large particles excluded
by the closed face filter used by NIOSH 0500 for “total particulate.” “Total” particulate includes particles larger than those in the
“thoracic” fraction. Smaller particles are more easily captured by machine tool ventilation exhaust, but may pass through an air
cleaner. Particles may be generated by evaporation and condensation from air cleaner filter media. Larger aerosol particles are more
likely to be controlled by enclosures. Controlling metal removal fluid emissions on one machine will not affect background aerosol
or other aerosol generated by other work stations; all machine tools need to be considered together. Air sampling using filter
methods captures no measurable water. Oil evaporates when captured on a filter, while non-oil additives to water-soluble fluids do
not.
6.2 Bioaerosols:
6.2.1 Bioaerosols include:
6.2.1.1 Whole microbes (archaeal, bacterial, and fungal)fungal): cells and viruses;
6.2.1.2 Microbial cell fragments: segments of cell wall material;
6.2.1.3 Biomolecules: predominantly carbohydrates, endotoxins, lipids, nucleic acids, and proteins;
6.2.1.4 Metabolites: innumerable microbial waste products (predominantly carbohydrates, organic acids, complex polymers
(biofilm matrix), exotoxins, and microbial volatile organic chemicals–MVOC).chemicals—MVOC).
6.2.2 Factors affecting bioaerosol generation include:
6.2.2.1 Bioburden in recirculating, bulk MRF: the bioaerosol component of the total aerosol generated from MRF comes directly
from the microbes and microbially produced molecules present in the bulk fluid. Except for MVOC, the introduction of which into
the airspace is dictated by the physical-chemical properties of individual MVOC molecules, bioaerosol generation is proportional
to bulk fluid bioburden.
6.2.2.2 Biofilm communities growing on MRF system surfaces are in dynamic equilibrium. Once they have formed, biofilms tend
to slough off portions of the mass that are at the fluid-biofilm interface as new biofilm material is generated. The details of this
equilibrium vary widely among systems.
(1) Biofilms that exist in high turbulent-flow conditions tend to be thinner than those growing in stagnant or slow laminar-flow
environments.
(2) Biofilms growing in high turbulent-flow conditions tend to be more tenacious (more difficult to remove) than those growing
in stagnant or low flow-rate environments.
(3) Biofilm communities are typically comprised of microbial consortia;consortia, complex communities of diverse
species,species which function in ways that resemble multi-cellular organisms;organisms, excreting and secreting the full range of
bioaerosol constituent molecules listed in 6.2.1.
(4) The factors described in 6.1 and 6.3 can affect the persistence and distribution of microbes and biomolecules in MRF.
Consequently, these factors will also affect bioaerosol generation.
6.3 Chemicals:
6.3.1 Formulating Considerations:
6.3.1.1 Aerosols in the metal removal environment may differ significantly from the components of virgin metal removal fluid
dilutions. In addition to avoiding the use of possible irritants in the original design, formulators must account for possible changes
in chemistry, microbiology, levels of contamination, and alterations in physical misting when developing a metal removal fluid.
E2889 − 23
6.3.1.2 The pH of a metal removal fluid dilution impacts corrosion, materials compatibility, microbial resistance, and emulsion
stability in addition to acting as a possible source of operator irritation. It is important that the pH of a working fluid avoid
extremes, generally between 5 and 10. The fluid should also be buffered within the target range of the fluid such that small amounts
of contaminants do not create wide shifts in pH.
6.3.1.3 Even at a stable and buffered pH, metal removal fluid formulations should limit or eliminate chemicals that pose irritation
threats. These chemicals include volatile amines, aldehydes, ketones, alcohols, ethers, and multifunctional organics. Some of these
materials may only be present as contaminant byproducts of primary components, or may only be generated within an in-use fluid
through contact with machining components. An awareness of possible secondary reactions between the fluid and machine/work
piece machine/workpiece substrates is key.
6.3.1.4 A recognized source of respiratory irritation in the metal removal fluid environment is microbiological contamination. A
fluid formulated with materials that inhibit microbial growth and eradicate microbial contamination is necessary to mediate
irritating worker mist contact. Unfortunately, many of the chemicals that are effective fluid preservatives can also contribute to
irritating aerosols. Therefore, an effective formulation utilizes these preservatives within their well-defined inhibitory concentra-
tions and within a product chemical matrix that does not magnify their irritation potential.
6.3.1.5 While mist is a physical phenomenon, metal removal fluid chemistry can play a role in enhancing or reducing mist
generation in equivalent situations. Unfortunately, the dynamics of fluid chemistry and mist are not well understood. However,
there exist effective chemical additives that increase droplet size and, as a result, reduce mist. These materials are generally
unstable and must be added to a system continually over the life of a fluid system.
6.3.1.6 The tendency of a diluted, water-miscible metal removal fluid to foam can influence mist generation. See Guide E3265.
6.3.2 Contamination Considerations:
6.3.2.1 Diluted metal removal fluids quickly become contaminated in use. Some contaminants, such as alkaline materials, pH
boosters, and similar materials, can increase the respiratory hazard.
6.3.2.2 Minimize tramp oil contamination,contamination such as leaking hydraulic fluids, way lubricants, and gear box lubricants.
Of all potential contaminants, tramp oil has the most significant effect on increasing airborne concentrations of metal removal
fluids.
6.3.3 Tankside Additive Considerations:
6.3.3.1 As supplied, antimicrobial pesticides and other additives for tankside addition can present greater health and safety risks
than the metal removal fluid. Further, additives and antimicrobials are less likely to be handled automatically or with special
delivery equipment than metal removal fluid concentrate, so greater care and attention are required to reduce risks of exposure.
6.3.3.2 Antimicrobial pesticides are designed to kill microorganisms and therefore have significant biological activity. To avoid
potential for harm by mishandling or misapplication, antimicrobial pesticides must be handled with care. The user shall read,
understand, and follow all appropriate instructions for handling, storage, and use of each antimicrobial pesticide as specified by
the antimicrobial pesticide manufacturer on the material safety data sheet.Safety Data Sheet.
7. Metal Removal Fluid Management Practices
7.1 Management of metal removal processes is the most important step in minimizing exposure to metal removal fluid aerosols.
As factors affecting aerosol generation are interdependent, a systems approach to metal removal process management will be the
most effective approach.
7.2 Aerosolization of metal removal fluids may result in airborne exposure not only to the formulated components of the fluid,
but also to contaminants introduced into the fluid systems while in use, including microbial contaminants.
7.3 Establish a metal removal fluid control program (see Section 12). Additional detailed guidance may be found in Practice E1497
and in Metal Removal Fluids,Fluids: A Guide Toto Their Management and Control. Consult with your metal removal fluid
suppliers.
E2889 − 23
8. Product Selection
8.1 Fluids vary in their misting characteristics. Select fluids with an understanding of their misting characteristics, bearing in mind
available engineering control measures. Some fluids mist less, other factors being equal. Misting characteristics may change
significantly with contamination. Some fluids retain entrained air, causing a significant increase in mist generation, possibly in
areas away from the metal removal fluid operation. Polymeric additives may be useful in reducing aerosol from straight or neat
oils and some water-miscible metal removal fluids. Components or contaminants may be more concentrated in the aerosol phase
relative to their concentrations in the bulk fluid.
8.2 Practice E1497 and Metal Removal Fluids,Fluids: A Guide to Their Management and Control describe product selection
criteria. While specifically directed towards water-miscible metalworking fluids, the same principles generally apply to selection
of neat or straight metal removal fluids.
8.3 Select fluids with an understanding of their acute and chronic toxicity characteristics. Guide E1302 references procedures to
assess the acute toxicity of water-miscible metalworking fluids as manufactured. Review the material safety data sheet, Safety Data
Sheet, required by 29 CFR 1910.1200, for health and safety information for the metal removal fluids being considered for the
operation.
8.4 Select fluids that minimize components that can be irritating or can produce noxious odors.
8.5 Select fluids that are appropriate for the machining process, are cost-effective, cost effective, can be safely disposed when they
are no longer economically feasible to re-use, have supplier support, and are used with a fluid management program.
8.6 As the concentration of metal removal fluid in the machining system sump or reservoir increases, the level of chemicals in
the metal removal fluid aerosol increases and the net exposure is greater. Maintaining proper metal removal fluid concentration
while in use enhances machining performance and minimizes exposure potential.
9. Methods for Metal Removal Fluid Mist Minimization
9.1 Minimizing Insoluble Particulate Matter:
9.1.1 The difference between total particulate matter and extractable mass, as measured by Test Method D7049, is an estimate of
the insoluble particulate matter in the machining environment. Minimize insoluble particulate matter such as may be generated by
dry machining, welding operations, and so forth.
9.1.2 Estimate the background level of insoluble particulate by evaluating exposures in the workplace away from metal removal
fluid operations.
9.1.3 Keep the metal removal fluid clean. Minimize accumulation of grinding swarf from cast iron grinding operations or
aluminum and silicon from aluminum machining operations through proper design, selection, and maintenance of metal removal
fluid filtration systems.
9.2 Minimizing Extractable Mass Concentration:
9.2.1 Minimize extractable mass concentration. The amount and average particle size of aerosol generated is dependent on the
amount of energy imparted to the fluid. Energy may be imparted to the fluid through high-pressure spray application, high-speed
tools, parts, or machines, and any other activity that causes the bulk fluid to generate a mist of liquid droplets. The transfer of
energy from the machine to the fluid can be reduced by several means. Combined means may also be required.
9.2.2 In addition to product selection, proper maintenance of metal removal fluid sump concentration, and the design, selection,
and maintenance characteristics noted earlier in this section, excessive generation of metal removal fluid aerosol can be affected
by parameters such as compressed air blowoffs and higher-than-optimum fluid flow rates, pressures, and tool feeds and speeds.
9.2.3 Optimize machine tool feeds and speeds consistent with part finish, dimension, and productivity requirements. Excessively
high speeds and feeds increase the amount of aerosol generated.
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9.2.4 Minimize fluid flow rates consistent with desired part finish and dimension and movement of generated chips or swarf. If
feasible, reduce or temporarily interrupt fluid flow when the metal removal operation is not occurring. Higher-than-required flow
rates increase aerosol generation.
9.2.5 Reduce fluid pressure consistent with machine tool design and chip removal requirements. Use flooding instead of spray
application,application whenever possible.
9.2.6 Consider the geometry of fluid application. Minimize the number of directional changes the fluid must make before reaching
the cutting zone.
9.2.7 Control sources of nonmetal removal fluid mists, such as from parts washers or mist lu
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