Case Study: Managing Mould Contamination at a Large Masonry and Brick Manufacturing Facility

Challenge

 
A renowned masonry and brick manufacturing company was confronted with a significant issue of visible mould growth within their production facility. The challenge involved determining the severity of the fungal contamination, assessing the concentration of fungal elements in the indoor air, and understanding the potential health risks posed to the facility's occupants.

Long-term exposure to mould in the working environment poses serious health risks to the occupants of the facility. Moulds, which are fungi, can produce allergens, irritants, and in some cases, toxic substances known as mycotoxins. When present in the air and inhaled, these can cause a range of adverse health effects.

Firstly, individuals may experience allergic reactions, similar to those caused by plant pollen. Symptoms can include sneezing, runny nose, red eyes, and skin rash. People with mould allergies may have more severe reactions, and those with compromised immune systems or chronic lung illnesses can get serious infections in their lungs when exposed to mould.

Secondly, constant exposure to mould spores can lead to the development of asthma in previously healthy individuals, or worsen the symptoms in individuals who already have asthma. Exposure can lead to coughing, wheezing, and shortness of breath.

Moreover, the continuous presence of mould in a working environment can create an unpleasant odour, causing discomfort and reducing the productivity of employees. The psychological stress associated with a persistent unhealthy working environment can also lead to additional health effects such as anxiety and depression.

Hence, in a production facility, visible mould growth is not just a minor aesthetic issue—it's a significant health concern.
 

Solution

 
Our team at Sysco Environmental Ltd undertook a comprehensive inspection and microbiological sampling of the production facility. For this purpose, we used sophisticated tools like a Zefon microbial sampler fitted with Air-O-Cell microbial sampling cassettes to capture airborne microorganisms. 
 
The uniqueness of our service lies in our in-house laboratory, one of a few in the UK capable of offering precise analysis of the gathered samples for total mould spores and fungal fragments. Our lab's capabilities ensure a swift turnaround of results, enabling us to provide our clients with immediate and accurate insights into their indoor air quality. For more details about our laboratory services, please visit our laboratory.

Results

In assessing the mould situation in the facility, an important measure is the concentration of airborne fungal spores. Indoor levels varied between 390 and 930 counts per cubic meter, while an environmental background concentration was estimated at around 890 counts per cubic meter. While these numbers might initially seem modest given the extensive mould colonization covering an area in excess of 150 square meters within the facility, the information gathered paints a more concerning picture when looking at the species distribution and indicators of long-term exposure.

The most prevalent species found in all the air samples was Cladosporium. This genus of fungi is very common in the environment and is known for its capacity to grow on virtually any organic substance. Cladosporium was not only dominating the air samples, but it was also a dominant species colonising most of the wall surfaces. This extensive colonization of surfaces can lead to a higher concentration of Cladosporium spores in the indoor air, which in turn can lead to allergy symptoms and respiratory problems in some individuals.

In addition to Cladosporium, the presence of Chaetomium moulds was detected. Chaetomium is known as an indicator of a high moisture environment, suggesting that the facility has been experiencing long-term issues with moisture control. This moisture issue is likely what has allowed the mould to colonise such a large area of the facility.

The detection of these species, particularly Chaetomium, underscores the importance of not only remediating the current mould issue but also addressing the underlying cause of the excessive moisture that has allowed these fungi to thrive. A comprehensive mould remediation plan would involve removing the current mould growth, cleaning and treating the affected areas, and identifying and fixing the source of the moisture problem to prevent future mould growth.
 

Potential Health Risks

 
The mould contamination presented a substantial health risk to the facility's operatives. Exposure to mould spores can cause a range of health issues, from minor allergic reactions such as sneezing, runny nose, red eyes, and skin rash to more serious health problems like asthma attacks, lung infections, and chronic sinusitis. Given that the operatives were potentially exposed to mould spores for approximately 8-10 hours daily during a typical working week, this increased the risk significantly.

Conclusions and Recommendations

 
Given the high health risk associated with mould spore exposure and the extensive mould colonisation observed, we recommended the following actions:
 
1. Equip the workers with respiratory protection of an FFP3 standard or higher until the area is completely cleared of fungal contamination.
2. Utilise the recently installed ventilation system to its fullest to manage condensation by controlling water vapour levels.
3. Initiate mould removal using suitable methods and contamination control measures.
4. Apply a biocidal treatment to the internal walls post-decontamination to prevent future fungal regrowth.

Future Assistance

 
Sysco Environmental is well-positioned to provide guidance and expert review should the facility choose to engage a third-party provider for mould remediation. This involves a thorough evaluation of the provider's method statement, ensuring that it adequately addresses the extent and nature of the mould infestation. Sysco Environmental would scrutinise the proposed steps for mould removal, treatment, and prevention of future mould growth, evaluating them against the industry's best practices and the unique requirements of the facility.

This expert review process will encompass an assessment of the proposed safety measures, including personal protective equipment for workers, containment strategies to prevent the spread of mould spores during remediation, and plans for proper disposal of contaminated materials. The review also scrutinises the efficacy of the proposed remediation techniques to guarantee that they will not only remove visible mould but also address underlying issues such as moisture control.
If the facility opts not to engage a third-party provider, Sysco Environmental can offer direct assistance in devising a safe and effective mould removal method tailored to the specific conditions and needs of the facility. This plan would adhere to the highest safety standards to protect both the remediation workers and the building's occupants. Equally important, the efficacy of the remediation plan will be assured, aiming not only to remove the current mould growth but also to address the root cause, preventing future recurrences.

In both scenarios, Sysco Environmental brings a wealth of expertise in indoor air quality, industrial hygiene, and mould remediation, ensuring that the approach taken is comprehensive, effective, and prioritizes the health and safety of all facility occupants.
 

Value Delivered

Sysco Environmental’s precise assessment and timely recommendations provided the client with a clear understanding of the mould contamination extent, its sources, and the potential impacts on the health of the building's occupants. Our detailed guidance offered the roadmap for remediation and prevention of future mould issues, thus safeguarding a healthier and safer work environment.