BOF Cote / BOF Patch — NARCO Basic Oxygen Furnace Refractory Products

Product Description

BOF Cote and BOF Patch were specialty refractory products manufactured by North American Refractories Company (NARCO) for use in basic oxygen furnace (BOF) steelmaking applications. These products were produced and distributed primarily during the period spanning approximately 1965 through 1975, a decade that coincided with the rapid expansion of basic oxygen furnace technology across the American steel industry.

The basic oxygen furnace, which displaced the older open-hearth steelmaking process throughout this era, required continuous refractory maintenance to withstand the extreme thermal and mechanical stresses generated during steel production. Molten metal temperatures inside a BOF vessel regularly exceed 2,900 degrees Fahrenheit, creating conditions that progressively erode the furnace lining. BOF Cote and BOF Patch were formulated specifically to address this challenge — BOF Cote as a protective coating applied to furnace linings and BOF Patch as a patching and repair compound used to fill voids, spalled areas, and worn sections of the refractory lining between production heats.

NARCO was among the leading refractory manufacturers in the United States during the mid-twentieth century, supplying steel mills, foundries, and industrial facilities with a broad range of high-temperature materials. The company’s BOF product line was widely used at integrated steel plants throughout the industrial regions of the United States, including facilities concentrated in Pennsylvania, Ohio, Indiana, West Virginia, and other steel-producing states.

Asbestos Content

BOF Cote and BOF Patch, as formulated during the 1965–1975 production period, contained asbestos as a component of their refractory composition. Asbestos was incorporated into refractory products of this type for several functional reasons. Its thermal resistance properties helped the material withstand rapid temperature cycling, its fibrous structure contributed to the binding and cohesion of the patching compound, and it provided a degree of thermal insulation that could slow heat penetration through applied coatings and patches.

The inclusion of asbestos in refractory patching and coating materials was common industry practice during this period, and NARCO’s BOF product line reflected that standard formulation approach. Trust fund documentation and litigation records associated with NARCO products confirm the asbestos-containing nature of these refractory compounds. The specific fiber types used in industrial refractory applications of this era typically included chrysotile and, in some formulations, amphibole varieties, though the precise mineral composition of individual NARCO product batches is reflected in product and trust documentation.

It was not until the 1970s, following the publication of epidemiological research linking asbestos exposure to serious disease, that regulatory attention began to focus on asbestos-containing refractory materials in industrial settings. OSHA’s first asbestos standards took effect in 1972, though widespread reformulation of refractory products continued into subsequent years as regulations evolved.

How Workers Were Exposed

Industrial workers employed at steel mills and metalworking facilities that used basic oxygen furnace technology faced potential asbestos exposure through the handling, application, and maintenance of products such as BOF Cote and BOF Patch. The nature of refractory repair work in BOF operations created several distinct exposure pathways.

Mixing and preparation was a primary source of exposure. Workers who prepared BOF Patch compounds for application often handled dry or semi-dry refractory materials that could release respirable asbestos fibers during mixing, especially in enclosed or poorly ventilated areas near the furnace vessel.

Application work brought workers into close proximity with asbestos-containing materials. Refractory repair crews who applied BOF Cote or BOF Patch to furnace linings — often working under hot conditions and time pressure between production heats — handled these materials directly and could disturb fiber-containing surfaces during application.

Maintenance and removal activities posed significant exposure risk. As applied refractory coatings and patches deteriorated under operating conditions, they required removal before fresh material could be applied. Scraping, chipping, or pneumatic removal of worn refractory material containing asbestos could generate substantial airborne fiber concentrations.

Nearby trade workers in the steel mill environment — including crane operators, millwrights, electricians, and general labor — could experience secondary or bystander exposure when refractory repair work was performed in shared workspaces without adequate containment or respiratory protection.

The BOF operating environment itself compounded exposure risks. Steelmaking facilities were often loud, physically demanding, and not historically equipped with the ventilation and personal protective equipment infrastructure that later OSHA standards would require. Workers in these environments frequently spent entire careers in close contact with asbestos-containing refractory materials without awareness of the associated health hazards.

Diseases associated with occupational asbestos exposure, including mesothelioma, asbestosis, and lung cancer, can have latency periods of twenty to fifty years, meaning workers exposed to NARCO BOF products during the 1965–1975 period may be receiving diagnoses today.

NARCO filed for bankruptcy protection as a result of the volume of asbestos-related personal injury claims associated with its refractory products. As part of the bankruptcy resolution process, the North American Refractories Company Asbestos Personal Injury Trust was established to compensate individuals harmed by exposure to asbestos-containing NARCO products, including BOF Cote and BOF Patch.

Trust Name: North American Refractories Company Asbestos PI Trust

Product and Manufacturer Eligibility: BOF Cote and BOF Patch are documented NARCO products. Claimants who can establish occupational exposure to these specific products during the covered production and use period may be eligible to file a claim with the Trust.

Claim Categories: The NARCO Asbestos PI Trust processes claims across standard asbestos disease categories, which typically include:

  • Mesothelioma — the highest-compensated disease category, associated with asbestos fiber inhalation
  • Lung Cancer — compensable with supporting medical documentation and smoking history disclosure
  • Asbestosis — a progressive fibrotic lung disease requiring pulmonary function and imaging documentation
  • Other Asbestos-Related Conditions — including pleural disease, evaluated based on medical evidence and exposure history

Filing Eligibility Considerations: Eligible claimants generally include workers with documented occupational exposure to NARCO products, as well as, in some circumstances, household members who experienced secondary exposure through contaminated work clothing. Claimants must provide medical documentation of an asbestos-related diagnosis and exposure evidence connecting their disease to NARCO products.

Individuals who believe they were exposed to BOF Cote, BOF Patch, or other NARCO refractory products should consult an attorney experienced in asbestos trust fund claims. Legal counsel can evaluate available product identification evidence, employment records, and medical documentation to determine eligibility and assist with the claims process. Filing deadlines and trust claim procedures are subject to the Trust’s current Distribution Procedures, which govern how claims are evaluated and compensated.