Coronavirus
Technology Solutions
Capability to
Provide
Efficient Masks
to all Americans
The Opportunity
is Huge and Many
Lives will be
Saved
Request from
Eric Couch for
Submittal to
OSHA
Capabilities of
U.S. Mask Makers
to Expand
Production
HVAC
Buro Happold
has a
People-Centric
Approach
to
Building
Solutions
______________________________________________________________________________
Coronavirus Mask
Decisions
has long been
stating that
tight fitting
efficient masks
can halt the
pandemic. The
medical
community has
now come to the
same conclusion.
The average mask
worn in public
as shown in a
Patient Knowhow
survey is only
20% effective.
So an immense
change in mask
type is needed.
ASTM has
worked hard on
efficacy
standards which
it will publish
next month. Two
levels of
efficiency are
specified. More
importantly the
standards will
provide a
measurement
structure by
which the most
effective masks
can be selected.
The Biden
Administration
is committed to
masks as a
solution.
Several
different
agencies are
involved in
shaping the
government
initiative.
There is the
potential for
minimum efficacy
standards and
for government
funding. The
following is an
email regarding
how suppliers
can interface
with government
agencies to
achieve the
desired results.
It is followed
by an analysis
prepared by
McIlvaine and
then background
information from
mask suppliers.
Comments are
being solicited
from mask
suppliers. This
Alert along with
mask supplier
comments will be
submitted by
McIlvaine to
Erich Couch and
INDA for further
submission to
OSHA.
Eric Couch is
working on the
quick supply of
efficient masks
to
everyone
and is
coordinating
efforts with
various
government
agencies. There
is the
opportunity to
obtain
government
endorsement of
minimum
efficiency
levels and to
also receive
some funding.
Here is what he
emailed us this
morning.
“Truly time
sensitive as
OSHA input is
critical and
due, summarized,
by this
Thursday...hence
request for
input by end of
day tomorrow.
Can you please
assist in
getting the word
out to the
elastomeric mask
fabricator
community?
Dave (Dave
Rousse of INDA)
already has the
nonwoven fabric
industry covered
so this focus is
exclusively the
elastomeric
higher level
assembly
fabricators.
·
Summary: (see
below)
·
Deadline:
Wednesday, Feb
10th
·
Critical window
of opportunity
(this week) to
secure OSHA
“incorporation
by reference” of
the ASTM Face
Covering
Standard.
·
Advisory Panel
Developing
Assessment of US
Capacity (Filter
and Conversion)
which will be
provided to
OSHA. OSHA
cannot implement
an Emergency
Standard if
there is
inadequate
supply or if the
supply is
limited to a few
vendors. He requested
the following
information.
Title: URGENT:
OSHA Mar 15
Emergency
Standard /
Quality Masks /
ASTM Face
Covering
Standard
Objective:
·
Develop support
within Biden
Administration
and CDC
·
Address
misunderstandings
around ASTM
Standard,
supply,
breathability,
and fit.
Summary:
·
Minimum
Filtration Level
“X”
·
Minimum
Breathability
“Y”
·
Minimum Fit “Z”
To secure
support within
OSHA, the CDC,
and Biden’s
Administration
for the
widespread
adoption of the
ASTM standard in
order to improve
the protective
value of face
coverings, we
need all parties
to assist in
mustering
political
support, and in
correcting
misunderstandings
which are
prevalent in the
public
conversation.
Misunderstandings
to Correct:
ASTM Standard is
Either 20% or
50% Filtration:
This is
inaccurate. The
standard
requires actual
filtration test
results be
submitted. In an
attempt to
simplify public
understanding,
two ranges are
identified,
20%-50% (Level
1) and 50%-100%
(Level 2). It is
true that
minimum labeling
requirements
only mandate
indication of
which range a
given mask
meets, however,
numerous example
labels in the
Appendix
illustrate clear
identification
of the exact
performance
level (i.e.
80%). To address
this unfortunate
construct, OSHA
and CDC will
need to
stipulate exact
performance
levels and any
mask vendor will
be compelled to
indicate the
exact
performance
level achieved.
Here is a label
that meets the
minimum labeling
standard and
also provides
performance
levels against
the key
benchmarks (N95,
Cloth, and
Surgical Style)
(NOTE:
Suggestion to
indicate
Surgical Style
at 40%
filtration &
leakage)
Adequate Filter
Media Supply
beyond Frontline
Responders:
While the US has
rapidly
increased fine
fiber meltblown
nonwoven
capacity (e.g.,
N95 capable) to
meet medical
frontline
responder needs,
there is
inadequate
supply of this
high performing
filter material
to meet the
needs of the
extended worker
community and
general public.
However, there
does exist
adequate
capacity to
deliver
filtration that
approaches that
of the N95 to
serve the entire
extended worker
community and
general public
without
affecting supply
to medical
frontline
responders.
There are three
sources of
materials for
the extended
worker and
general public
scope:
·
Excess Meltblown
N95 material
·
New Materials
(i.e. NC State
Nonwoven
Institute
Spunbond
Material)
being
developed
·
Extensive
Capacity of
Other Nonwoven
Materials That
Approach N95
Performance.
Rapid Production
Capacity:
·
Elastomeric Mask
Housings:
While disposable
US N95
conversion
equipment is
constrained
(cost and lead
time), by
emphasizing
elastomeric
designs which
can readily be
scaled up by
duplicating
existing
injection
molding tooling
($20K-$100K /
tool) and
engaging the
extensive
injection
molding machines
within the US,
supply is
unconstrained.
·
Flat Filters:
While formed
disposable mask
fabrication is
highly
constrained,
flat filter
fabrication can
readily be
accomplished
with existing
nonwoven
equipment lines
(i.e. from the
upholstery
industry). Flat
layers are
assembled,
welded, and cut
to shape. The
welding /
cutting tools
can be
replicated for
$100K. It is
worth noting
that flat
filters in
elastomeric
masks tend to
use less
material and
last longer in
comparison to
disposable N95
respirators.
·
Pleated Surgical
Style
“Non-medical”
Masks:
At the beginning
of the pandemic,
the US had ~ 12
companies
producing
disposable
formed N95
respirator
masks. In
response to the
crisis,
approximately 24
companies
entered the
market yet
elected to setup
factories to
produce the
surgical style
pleated face
coverings. There
is adequate US
capacity to
immediately
supply both the
extended worker
and general
public demand.
While pleated
surgical style
masks are
normally for
splash
protection, and
do not make an
effective seal
(~ 40% effective
particle
filtration),
many models are
actually made
with filtration
material that
can achieve very
high levels (~
95%) if they are
sealed to the
face using a
secondary
elastomeric
harness such as
the “Fix the
Mask” brace.
·
Surgical Mask
“Fix the Mask”
Brace:
This simple
solution is made
of medical grade
silicone using
compression
molding.
·
Fit &
Breathability:
The ASTM
standard was
deliberately
developed to
improve
breathability.
Recognizing that
workers and the
public may wear
such protection
for the entire
workday, the
breathability
performance
criteria, in
millimeters of
H2O of pressure
resistance, was
set at a
challenging
level of 5 mmH20
or less.
In
actuality, a
comfortable
range is 5-10 mm
H20.
QUANTITY AND
COST OF MASKS
NEEDED The
majority of N95
and surgical
masks are being
supplied to 3%
of the
population (10
million people)
whose mask use
in three times
greater than
the next
more active
group and 15
times greater
than the
majority of
people
inhabiting
public space.
This ratio is a
function of
viral load and
numbers of hours
of
exposure to that
load. this can
be considered as
“relative mask
duty”. One
extreme is the
nurse in an
isolation ward.
At the other is
the individual
who is only in
public space
when at the
store. This
present group of
10 million can
be labeled as
the “present
target”
Some masks are
designed to be
reusable for up
to 30 days
without filter
inserts. Others
are designed to
last even longer
periods with
periodic filter
inserts. Some
filters with
long life cost
more than $30.
However
the cost per
daily use can be
less than $1. In
contrast someone
may be wearing
several surgical
masks per day.
Approximately
three times as
much relative
mask duty will
be needed for
the public as
presently needed
by the present
target (medical
workers, first
responders, and
those with
industrial
exposure).
If this mask
duty is
primarily
supplied by
surgical masks
with braces it
is possible that
the public
numerical
requirements
will be three
times those of
the present
N95/surgical
mask
users.
On the other end
of the spectrum
where the
relative mask
duty is supplied
by reusable
masks which last
10 times longer
per unit of
relative duty,
then the public
mask numerical
needs are only
30 % of those of
the present
target.
So in terms of
numbers we are
talking about a
range for the
public of 0.3 to
three times the
present target.
However in terms
of material
consumption
there is more
media and other
components in
the reusable
masks. So the
amount of
material will
range from one
to three times.
The cost
per unit of
relative mask
duty will be
similar. So
fitting the
public with
effective masks
will cost three
times what is
being spent on
the present
target.
RATE AT WHICH
PRODUCTION CAN
BE INCREASED
Media
availability is
a limiting
factor on
production
increase.
However,
some mask
suppliers such
as Vogmask have
designed their
masks so that
meltblowns are
just one of many
layers. The
result is that
the meltblown
layer is better
protected and
lasts longer.
Other mask
makers use
materials other
than meltblown
media. There is
no shortage of
media if
limits on
resistance are
nor too strict.
The amount of
filterable media
can be varied.
Resistance
varies as the
square of
velocity. So a
slight increase
in available
media reduces
mask resistance.
As long as cloth
masks are
allowed in
public space,
there is little
incentive for
rapid expansion
of tight fitting
efficient masks.
As soon as this
changes and the
demand is clear,
there could be
rapid expansion.
It is also
likely that some
of the large
companies
supplying cloth
masks could
switch to making
tight fitting
efficient masks.
So we are not
talking about
increases in
numbers of masks
as much as we
are increases in
the number of
effective masks.
THE IMPACT OF
GOVERNMENT
SUBSIDIES
Expenditures by
the government
are best
delivered as
coupons and not
vouchers for
masks or for
purchase and
delivery of free
masks. The
reason is that
the choice may
be a 30 dollar
mask rather than
one for 2
dollars. If a
number of
coupons are
provided they
could be used on
one or multiple
masks.
With the coupons
the market for
the masks is
increased and in
effect assured.
If the coupons
can only be used
for effective
masks, the mask
suppliers will
be willing to
spend the money
to expand.
Respirator
suppliers also
have public mask
versions.
MSA, 3M and
Honeywell all
have public mask
versions.
Armbrust
American
is capable of
gearing up to
manufacture
billions of
masks and now
even has its own
meltblown media
manufacturing.
The company has
been adept at
buying equipment
and moving to
production very
quickly. Many
articles about
the company
appear in the
Alert. There is
also a recorded
interview.
TAIJI Medical
Supplies
Single-Use Face
Masks Designed
to be Protective
and Comfortable
TMS has two (2)
melt-blown
fabric machines
in-house.
Melt-blown
fabric is the
center layer of
each mask and is
what provides
filtration. Many
manufacturers
were hindered
during the
height of the
pandemic as they
rely on sourcing
from overseas.
The company says
it has
combined automation,
vertical
integration and
American
ingenuity to
solve the
problem
Medical-grade
surgical and
protective
face masks are
designed,
developed and
produced
end-to-end in
America
(Lincolnton,
NC).
Twenty
fully-automated
assembly lines
can produce
thousands
of masks per
minute.
The vertically
integrated
factory takes
raw
polypropylene and
transforms it
into surgical
and protective
face masks in
seconds.
Cummins and
Dupont are
Working Together
to Help Address
the Current
Shortage of N95
Masks
According
to Amy Davis,
Vice President
of Cummins
Filtration,
with many of the
world’s leading
mask
manufacturers in
need of the
critical
materials to
assemble the
masks
and struggling
to meet demand,
Cummins will
use pre-existing
filter technology
in partnership
with DuPont to
help fill the
supply void.
"Cummins is
re-evaluating
our supply base
and
manufacturing
capabilities to
identify how we
can support our
healthcare
professionals
who rely on
critical
personal
protective
equipment to do
their jobs,"
Davis said. "Our
NanoNet® Media
can fill a key
supply void and
help address the
mask shortage
facing the
United States
and other
countries around
the world."
The project also
aims to provide
open source
instructions
that other
healthcare
systems and
groups can use
to create their
own respirator
masks.
Cummins’
NanoNet® and
NanoForce® Media
technology,
which uses
DuPont’s Hybrid
Membrane
Technology
(HMT), can
typically be
found in air,
fuel and lube
filtration
products used in
heavy-duty
diesel engines
to prevent
long-term engine
wear, but also
can be used in
the N95
respirator masks
worn by
healthcare
professionals to
filter harmful
airborne
particles that
can spread
COVID-19.
Vogmask is a
U.S. based
supplier with
expandable
supply
capability.
Vogmask has
spent nine years
to achieve
maximum comfort,
attractiveness,
tight fit and
efficiency of
its masks. There
are many
articles on
Vogmask in the
alerts and
presentations in
the McIlvaine
webinars.
NXT Nano can
Ramp Up to Meet
Future Demand
Quickly.
These are
excerpts from
the McIlvaine
interview with
Andy McDowell of
NXT Nano
1. How fast
can they ramp up
production of
high efficiency
media?
2. How
flexible is a
line to make
mask, HVAC,
microfiltration,
or other media?
3. How much
time does it
take to change a
line over to
make a different
product?
We talked to
Andy McDowell,
director sales
and marketing at
NXTNano of
Nano. In the
Alert we covered
their mask
making
activities and
also the extent
of the use of
their media for
gas turbine
intake filters,
HVAC, masks and
microfiltration.
Andy gave some
very useful
answers to our
questions.
Bob: Andy how
long does it
take to build a
new line?
Andy: Only 3 to
4 months and
since we have to
install humidity
control and
other basic
services it is
even easier to
install multiple
lines rather
than just one.
Bob: Can you
give us some
idea of the
production of
one line?
Andy: If we are
making masks and
working 24-7 it
is 86,000
m2/day. If we
are making HVAC
media it is
about 30% more.
Bob: How many
masks can be
produced per m2?
Andy: About 40
surgical grade
masks or 30 N95
grade masks.
Bob: How many
HVAC filters can
be produced per
m2?
Andy: It varies
but a rule of
thumb would be 1
filter/m2.
Bob: How much
time does it
take to change
over from one
product to
another?
Andy: We can
make the change
from one product
to another in a
matter of
minutes not
hours.
Bob: We see a
big opportunity
for the
filtration
industry to take
a positive
rather than
negative
attitude and say
we can invest
in the
production
equipment
necessary to see
that everyone
can be protected
by wearing high
efficiency masks
and spending
time in space
that is filtered
to remove
viruses. Do you
think your
company is
capable of
making major
expansions?
Andy: We just
expanded
capacity and do
not see major
obstacles in
expanding as
warranted.
Buro Happold
has a
People-Centric
Approach
to
Building
Solutions
Covid-19 has
kept commercial
buildings
relatively empty
while workers
are quarantined
at home. This
has left many
wondering how
businesses will
adapt when
employees return
to the
workplace.
Office building
owners will be
required to
re-examine the
existing
measures in
place to reduce
the spread of
infection, as
well as what
improvements can
be made.
Heating,
ventilation, and
air conditioning
(HVAC) are
important
systems to
consider through
this lens
because
infections such
as Covid-19 can
be transmitted
through
aerosolization.
Buro Happold’s
approach to the
built
environment
supports humans
in all their
complexity,
focusing on
people-centric
systems that
prioritize
occupant health
and wellbeing.
As a result,
many HVAC design
measures that we
routinely
implement have
already been
taken to reduce
the spread of
infection within
buildings.
However,
COVID-19 has
prompted an
examination of
how building
systems can be
augmented to
further mitigate
the spread of
airborne
infections.
While some new
technologies
show promise in
helping to
address this
issue, existing
practices can
also be
improved. A
summary of Buro
Happold’s
general
recommendations
can be found in
the table below
and will be
further
elucidated in
the following
sections.
Third party
human health and
sustainability
certification
standards (such
as LEED, WELL,
Living Building
Challenge, and
Reset) are
increasingly
requiring
performance-based
air quality
results through
one-time,
annual, or
continuous air
quality testing.
Advances in
technology have
drastically
reduced the cost
of sensors and
they can now
operate as
stand-alone
monitors or
integrate with
Building
Management
Systems (BMS).
While there are
many options,
Reset Accredited
Monitors are
emerging as the
gold standard
for project
specifications.
Buro Happold’s
WELL Gold
Certified Los
Angeles office
utilizes sensors
to measure a
variety of
indoor air
quality metrics,
including CO2,
total volatile
organic
compounds (TVOCs),
humidity,
temperature, and
particulate
matter. Sensor
data can be
viewed remotely
and can be
integrated with
wider monitoring
practices to
troubleshoot
building health
issues as well
as energy demand
concerns.
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