Some beryllium processes, especially machining, are associated with an incr
eased risk of beryllium sensitization and disease. Little is known about ex
posure characteristics contributing to risk, such as particle size. This st
udy examined the characteristics of beryllium machining exposures under act
ual working conditions. Stationary samples, using eight-stage Lovelace Mult
ijet Cascade Impactors, were taken at the process point operation and at th
e closest point that the worker would routinely approach, Paired samples we
re collected at the operator's breathing zone by using a Marple Personal Ca
scade Impactor and a 35-mm closed-faced cassette. More than 50% of the bery
llium machining particles in the breathing zone were less than 10 mu m in a
erodynamic diameter. This small particle size may result in beryllium depos
ition into the deepest portion of the lung and may explain elevated rates o
f sensitization among beryllium machinists.