Outbreak of lung disease at Powertrain in 2004: HSE update

E049:06 28 April 2006

The Health and Safety Executive (HSE) today gave an update on its investigation into the outbreak of occupational lung disease at the Powertrain Limited plant in Longbridge, Birmingham. HSE's investigation began in March 2004, and to date 101 workers at the former car plant have been diagnosed mainly with either occupational asthma or extrinsic allergic alveolitis. Both diseases cause breathing difficulties, which are severe and in some cases can be long lasting.

Sandra Caldwell, Director of HSE's Field Operations said at a press briefing held in Birmingham today:

"The outbreak at Powertrain is thought to be both the world's largest linked to metal working fluids, and the largest single outbreak of occupational asthma. It has changed the perception of the risk arising from the exposure to mist from metalworking in the UK. HSE is making available the lessons learned from the outbreak and has taken action to prevent a recurrence. HSE is determined that workers elsewhere in this sector should get better protection against contracting these diseases, which have the potential to seriously impair the breathing and health of those affected by them.

"The HSE investigation has been long and thorough, and we now know that the cause of the disease was mist from metalworking machines, which was widespread throughout the factory. While we do not know the precise agent within the mist that triggered the outbreak, we did find links to bacteria, and used metalworking fluid. Other possible causes, such as metals leaching into the mist from the machining and washing of components, have been closely investigated and are thought unlikely to have caused the outbreak."

As a result of the outbreak HSE has updated its guidance on metalworking and this is now available at www.hse.gov.uk/metalworking. In the light of the increased risk revealed by the outbreak, this guidance makes it clear that:

• risk assessments must deal with the risks of occupational asthma and extrinsic allergic alveolitis;
• direct means of monitoring bacterial contamination in metalworking and wash fluids, such as dip slides, must be used;
• exposure to mist needs to be prevented or better controlled; and
• health surveillance must be carried out where there is exposure to mist.

The guidance has been developed with the help of experts both within and outside HSE and in conjunction with other stakeholders. Longer-term investigations and research into aspects of the outbreak continue.

HSE is also checking standards at other large companies. Conditions have been found to be variable. Where there has been cause for concern, HSE inspectors have served Improvement Notices. A report on this intervention will appear at www.hse.gov.uk/metalworking. A questionnaire to help firms check that they are properly assessing risks is available online at www.hse.gov.uk/metalworking/questionnaire.pdf [120kb]

For smaller companies, a series of roadshows will take place across the UK over the next two years. These are being organised in conjunction with the United Kingdom Lubricants Association Metalworking Fluids Product Stewardship Group (UKLAMWPSG). HSE will organise follow up visits by its inspectors to those who don't attend to ensure the messages are getting through.

HSE served three Improvement Notices on Powertrain Ltd in 2004 once the scale of the outbreak became apparent. The notices required Powertrain to take action in line with the increased risk and they were complied with. The company went into administration in 2005 and the assets were subsequently sold to Nanjing Automobile (Group) Corporation and removed to China. No further action is proposed by HSE.

'Outbreak of Respiratory Disease at Powertrain Ltd, Longbridge, Birmingham - Emerging Lessons' can be found on the HSE website at www.hse.gov.uk/metalworking/experience/powertrain.pdf

Notes to editors

1. HSE and other agencies, notably the Birmingham Chest Clinic (BCC), are completing their investigation into the outbreak of lung disease at the Longbridge factory in Birmingham. HSE began its investigation in March 2004, following an approach from the BCC. The main diseases diagnosed are occupational asthma (87 cases) and extrinsic allergic alveolitis (24 cases). Occupational asthma can cause attacks of wheezing, coughing, chest tightness or shortness of breath. Extrinsic allergic alveolitis can cause coughing, breathlessness, chills, sweats and joint pain, which may feel like a bout of flu. There may also be weight loss. Some breathing difficulty can be long term.
2. Previous reports of industrial lung disease to HSE have been only of isolated, sporadic individual cases. Most of the Powertrain workers diagnosed with lung disease recalled the onset of their breathlessness as dating from 2002 onwards, although some recall onsets in previous years. Onsets of breathlessness peaked in March 2003, and the last date of onset was in June 2004.
3. HSE's enforcement database lists details of notices served on companies; see www.hse.gov.uk/notices/. Notices served on metalworking fluids can be found via the advanced search facility by inserting the words 'metalworking fluids' in the 'case summary' field. HSE takes its decisions on prosecutions in line with the Code of Crown Prosecutors; this is available at www.cps.gov.uk/publications/docs/code2004english.pdf
4. Information about occupational asthma can be found on the HSE website at www.hse.gov.uk/asthma/index.htm and on metalworking generally at www.hse.gov.uk/metalworking

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