Chromate - Compendium
analyses and studies
The evaluations, studies and analyses focus on the massively underestimated health and environmental risk in the energy-generating industry:
the formation of carcinogenic chromium (VI) compounds (chromates), among other things, and precisely because of the use of calcium-containing insulation materials in particular.
The investigations clearly show that the previous practice of neutralization with neutralization fluids is only a short-term emergency measure, and that even the wearing of protective equipment does not represent a sustainable solution.
Rather, it becomes clear that in the long term, only the substitution of the problematic materials with alternatives that are free of alkali and alkaline earth metal oxides, and in particular calcium-free, can effectively eliminate the risk of the formation of hexavalent chromium compounds.
The individual analyzes shed light on both the medical and technical aspects as well as the legal requirements and economic implications of this issue.
The studies show the actual exposure at the workplace, determined by the most modern analytical methods and confirm the danger for humans and the environment, unfortunately not just since today, but strictly speaking, since the beginning of the use of earlier asbestos substitutes.
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We substituted asbestos and created another threat, unnoticed and unrecognized for a long time.
The documents available here are aimed at decision-makers in industry and public authorities, as well as anyone who is not only interested in better occupational safety and environmental protection, but also strives to apply it.
As soon as new findings or further measurements are documented, you will find these updates available for free download on this page.
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To view or download the PDF files, either click on the images, the orange button or the underlined study names in blue.
large study on chromates in the workplace
analyses and reports
01
In engine compartments with calcium-containing insulation, massive exceedances (210-290%) of the chromium(VI) limit values were measured.
Even light maintenance work in clean systems produces carcinogenic chromates. Substitution with calcium-free materials is urgently required. Immediate measures for occupational safety are necessary.
02
EU regulations require strict minimization of chromium(VI) exposure in the workplace.
Instead of focusing on protective equipment, replacing calcium-containing thermal insulation with calcium-free insulation must be a priority.
The STOP principle applies internationally: substitution of technical, organizational and personal protective measures.
03
The case study analyses the substitution of alkali and alkaline earth metal-containing insulating materials to prevent the formation of carcinogenic chromium (VI) compounds.
Insulations containing calcium in particular can form chromates at high temperatures.
The study shows that calcium-free alternatives eliminate exposure, meet legal requirements and make economic sense.
04
The study investigates how insulating materials containing alkali and alkaline earth metals destabilize the passive layer of stainless steel hot parts at temperatures up to 600°C and can thereby form carcinogenic chromium(VI) compounds.
05
The study analyses psychological barriers that hinder understanding of chromium(VI) risk minimisation.
Biases such as cognitive dissonance, status quo bias and confirmation bias lead authorities and industry to cling to ineffective protective measures such as PPE instead of assessing the situation pragmatically.
Training, expert involvement and public pressure are necessary.
06
Calcium chromate and other chromates are highly toxic and carcinogenic.
The study shows that inhalation and skin contact can cause DNA damage, lung cancer, COPD and neurological disorders.
Particularly dangerous are reactive intermediates that cause cell damage and increase long-term health risks.
07
The case study shows deficiencies in the assessment of chromate formation by calcium-containing insulation systems.
Manufacturers and authorities underestimate the danger of calcium chromate.
Misleading protective measures such as neutralization solutions create the illusion of safety instead of eliminating the cause.
Long-term risks for workers remain.
studies and evaluations
01
Comprehensive study on chromium (VI) exposure when working with high-temperature insulation containing (alkaline earth) metals.
Measurements of chromate contamination in the air and dust document the exceedances of limit values and analyze carry-over risks.
The study shows that chromium (VI) is already released during maintenance work on insulating materials, which poses considerable health risks.
The study also contains technical, organizational and personal protective measures, regulatory assessments and recommendations for the substitution of problematic insulation.
02
The subsidiary study investigates the chromium (VI) contamination in insulation cassettes on gas engines.
Analyses show that metal housings containing chromium in combination with calcium-containing insulating materials form carcinogenic chromates.
Particularly dangerous are “oxygen-open” areas where, for example, calcium-containing fibres are exposed.
The study confirms risks of spread through dust deposits and skin contact that extend far beyond the immediate work area.
Limit values are systematically exceeded, which requires both technical and organizational protective measures.
03
The follow-up study investigates chromium (VI) exposure during handling of used insulation materials.
Air measurements show that even normal maintenance work on insulation elements releases carcinogenic chromates and limit values are exceeded.
Particularly problematic is the unintentional spread through dust deposits, work clothing and air currents.
Even innocent people are at risk. The study shows that conventional protective measures are inadequate and recommends a fundamental reassessment of occupational safety and a long-term substitution of calcium-containing insulation.
04
Practical experience confirms the systematic chromium (VI) contamination from calcium-containing insulations determined in previous studies.
Measurements in power plants, combined heat and power plants and industrial plants show that chromates are regularly released and workplace exposure limits are exceeded.
Manufacturer warnings and laboratory evidence show that this risk is not limited to isolated cases. The results underline the need to prioritize decontamination and substitution rather than symptom control and to rethink existing safety measures.