Acrylonitrile Compliance Plan — 29 CFR 1910.1045
Written compliance plan for acrylonitrile exposure. PEL 2 ppm TWA; Ceiling 10 ppm 15-min; Action Level 1 ppm. Covers acrylic fiber production, ABS resin manufacturing, nitrile rubber, and chemical synthesis using acrylonitrile.
When this template is required
Required wherever acrylonitrile exposure occurs. PEL: 2 ppm 8-hour TWA; Ceiling: 10 ppm 15-min; Action Level: 1 ppm. Acrylonitrile is used to produce acrylic fibers, ABS resins, nitrile rubbers, and as a chemical intermediate. IARC classifies acrylonitrile as Group 1 (carcinogenic to humans).
Why this template
Group 1 carcinogen
IARC classifies acrylonitrile as Group 1 (carcinogenic to humans) based on animal evidence and limited human evidence. The standard's controls reflect both the carcinogen risk and the acute toxicity.
Acute toxicity
Unlike most Subpart Z substances, acrylonitrile has substantial acute toxicity — it can cause cyanide-like poisoning (acrylonitrile is metabolised to cyanide). Acute high-exposure incidents require immediate medical response.
Both Ceiling and TWA
Acrylonitrile has both an 8-hour TWA (2 ppm) and a Ceiling (10 ppm 15-min). The Ceiling is more stringent than typical STELs.
Polymer manufacturing focus
Acrylic fibers, ABS, and nitrile rubber are the dominant uses. The plan addresses polymerisation reactor handling, monomer storage, and finishing operations.
What you receive
- Acrylonitrile Compliance Plan (Word .docx) — written program per (a)-(r)
- Initial exposure determination procedure (PEL: 2 ppm TWA / 10 ppm Ceiling; Action Level: 1 ppm)
- Air monitoring schedule (initial + periodic + change-triggered)
- Methods of compliance — engineering & work practice controls hierarchy
- Respiratory protection program crosswalk (with 1910.134)
- Medical surveillance protocol (examination by or under the supervision of a licensed physician, blood/biological tests as applicable)
- Regulated area designation procedure (where exposures exceed the PEL)
- Housekeeping and hygiene procedures
- Employee training outline (annual refresher requirement)
- Recordkeeping requirements (exposure and medical records: at least 40 years, or duration of employment plus 20 years, whichever is longer)
- Acute toxicity emergency procedure
How you get it
This document is written and reviewed against the standard it cites, and it is ready now. The download link is emailed as soon as your payment clears.
Revisions included — if something about your operation changes what the document should say, reply to the delivery email and we will amend it.
Who buys this
- Acrylic fiber production
- ABS (acrylonitrile-butadiene-styrene) resin manufacturing
- Nitrile rubber manufacturing
- Chemical synthesis using acrylonitrile as feedstock
- Adiponitrile / hexamethylenediamine production
Frequently asked
What products contain acrylonitrile?
Acrylonitrile (CH2=CHCN, vinyl cyanide) is the monomer for several polymers: acrylic fibers (Orlon, Acrilan), ABS plastic (used in pipes, auto parts, consumer products), styrene-acrylonitrile (SAN), nitrile rubber (oil-resistant gaskets, gloves), and adiponitrile (intermediate for nylon 6,6). Most acrylonitrile is consumed in polymer production at large chemical complexes.
Why is acrylonitrile acutely toxic?
Acrylonitrile is metabolised in the body to cyanide (via cytochrome P450). Acute high exposures can produce cyanide-like effects — headache, nausea, dizziness, weakness, and at very high exposures, loss of consciousness and death. The acute toxicity is why acrylonitrile has a Ceiling (10 ppm 15-min) in addition to the TWA (2 ppm).
What's the medical surveillance protocol?
1910.1045(n)(1)(i) requires medical surveillance for every employee who is or will be exposed at or above the action level, without regard to respirator use — there is no minimum number of exposure days. The initial examination covers work and medical history with attention to skin, respiratory and gastrointestinal systems and to non-specific CNS symptoms; a physical examination giving particular attention to the peripheral and central nervous systems, gastrointestinal system, respiratory system, skin and thyroid; a standard chest X-ray; and further tests of the intestinal tract, including fecal occult blood screening, for workers aged 40 or over (1910.1045(n)(2)). Periodic examinations follow at least annually. Where an employee develops signs or symptoms that may be associated with acrylonitrile exposure, the employer provides an appropriate examination and emergency medical treatment (1910.1045(n)(4)).
Is acrylonitrile still widely used?
Yes — global production exceeds 6 million metric tons annually, primarily for ABS plastic and acrylic fibers. US production is concentrated in a handful of large chemical complexes. The total worker population covered by the standard is modest (a few thousand directly exposed workers in primary production).
What about ABS plastic consumers?
ABS plastic itself doesn't contain free acrylonitrile (it's bound in the polymer). Downstream operations using ABS (injection molding, machining of finished parts, paint application) typically don't have acrylonitrile exposure unless the polymer is heated to degradation temperatures. The plan is focused on primary production and polymerisation operations.