Bakelite and Asbestos

Bakelite was a revolutionary plastic material that promised unlimited possibilities for manufacturing and design, and today, many collectors hunt for original Bakelite products in vintage and antique shops.  But many formulations contained asbestos fibers that exposed countless workers and consumers to the risk of mesothelioma, lung cancer, and other fatal diseases, and multiple lawsuits have been filed against Union Carbide Corporation seeking compensation for the harm that its Bakelite material caused.

The History of Bakelite

Bakelite’s history began when Leo Baekeland set out to create a better synthetic material. He combined two compounds derived from coal tar and wood alcohol—phenol and formaldehyde—to produce what he called “the material of a thousand uses.” In 1909, the United States Patent and Trademark Office officially recognized his achievement, granting him patent protection for his revolutionary thermosetting resin.[1]

What set Baekeland’s plastic apart from earlier versions was that it was made entirely with artificial materials. This difference allowed manufacturers to stop depending on natural resources, opening the door to mass production of complex shapes and designs that had previously been impossible to achieve.

Baekeland invented his product at the same time that Henry Ford was introducing assembly line production, and Bakelite’s distinct characteristics—exceptional heat resistance, electrical insulation, and durability—made it an ideal material for industrial purposes.

Commercial Success and Widespread Adoption

By the 1920s, Bakelite was being widely used by manufacturers, and goods made from Bakelite were popular with consumers. It made previously inaccessible goods more affordable, and its ability to be molded into intricate designs and shapes made it the material of choice for everything from telephone handsets to car components.

Manufacturers began using Bakelite for electrical applications, taking advantage of its superior insulation properties. Consumer goods companies used it to make kitchen appliances, jewelry, cameras, and countless other household items, while the automotive industry utilized it for steering wheels, gear knobs, and various interior components.

Why Asbestos Was Used in Making Bakelite

As exceptional a product as Bakelite was, it had its drawbacks. It could be extremely brittle, and that presented a challenge for manufacturers. To address this problem, they began mixing in small amounts of asbestos into their formulations. The mineral was already highly valued at the time as another “wonder material,” and adding it to the Bakelite recipe both solved the brittleness issue and gave the plastic even more heat resistance and electrical insulation.[2]

The addition of the brown amosite variety of asbestos allowed products made with Bakelite to keep their structural integrity, even under extreme conditions, so manufacturers saw adding the mineral as the perfect solution. Bakelite products manufactured between 1909 and 1974 could contain up to 5% asbestos by weight.[2] The health consequences of this unfortunate decision would not become apparent for decades.

Corporate Evolution and Continued Production

In 1922, three companies—General Bakelite Company, Condensite Company, and Redmanol Chemical Products Company (established by L.V. Redman)—merged their operations to create the Bakelite Corporation, but the company’s patent protections on Bakelite expired in 1927, allowing other manufacturers to begin producing their own versions of the product. At the same time, three phenol formaldehyde material suppliers in England combined to form Bakelite Limited. The British entity was purchased by Union Carbide Corporation in 1939. Under Union Carbide’s ownership, production of the material expanded significantly, reaching new markets and applications.[3]

World War II made significant changes in the use of Bakelite. Factories shifted from making consumer and civilian goods to fulfilling military contracts, and the material began being used in aircraft parts, military communications equipment, and other defense-related products. 

Consumer and Industrial Popularity

When the war ended, Bakelite’s moldability revolutionized consumer product design, enabling manufacturers to create items that were both functional and attractive. Kitchen appliances began adding Bakelite handles that stayed cool, even when they were connected to hot metal parts. The material’s electrical resistance made it ideal for radio housings, telephone equipment, and early electronic devices.[1]

The jewelry industry also embraced Bakelite, creating colorful bangles, buttons, and decorative items that imitated versions made with more expensive materials. Photographers valued Bakelite camera housings for their durability and light weight, and even children’s toys included the material.

Beyond consumer goods, Bakelite was used extensively in industrial applications. Electrical manufacturers relied on it for circuit breakers, switchboards, and insulation components, and the material’s resistance to heat and chemicals made it invaluable for automotive parts, including brake components and engine-related parts.

The aerospace industry also recognized Bakelite’s potential, incorporating it into aircraft propellers, drop tanks, and various structural components where weight reduction was critical. The military took advantage of the material’s heat resistance, using it in missile casings and rocket components.

Common Bakelite Products Containing Asbestos

Bakelite was incorporated into a wide range of items, and many of them were made with Bakelite that contained asbestos fibers. These products included:

• Electrical Components: Circuit breakers, electrical panels, insulators, and switchboards that required superior electrical resistance and heat dissipation.
• Household Items: Kitchen appliance handles, utensils, hair dryers, toys, and various consumer electronics that benefited from heat resistance and durability.
• Automotive Parts: Steering wheels, brake pads, gear knobs, and dashboard components designed to withstand temperature extremes and mechanical stress.
• Communication Equipment: Telephone handsets, radio housings, and early electronic device casings that required electrical insulation and structural integrity.
• Industrial Equipment: Specialized tools, machinery components, and equipment housings used in various manufacturing and processing applications.

Understanding Asbestos Contamination in Bakelite

While Bakelite’s hard plastic nature and relatively low asbestos content (typically under 5%) initially suggested minimal health risks, this assessment proved dangerously incorrect. The integration of asbestos fibers within the plastic matrix created a deceptive sense of security, as the material appeared stable under normal conditions.

Despite the strengthening benefits that asbestos added to Bakelite, it also added a level of danger. Cutting, sanding, drilling, or any other type of mechanical damage could release microscopic asbestos fibers into the surrounding environment, and when these virtually invisible particles became airborne, they created inhalation risks for workers and those who were nearby. This was especially true during manufacturing processes, but any worker manipulating Bakelite products could be affected.

Who Was at the Greatest Risk of Asbestos Exposure from Bakelite?

Any worker who had regular contact with asbestos-containing Bakelite products was in danger of inhaling asbestos fibers and being sickened years later. These included:

• Manufacturing workers involved in Bakelite production, molding, and finishing operations 
• Electrical technicians installing, maintaining, or replacing Bakelite electrical components 
• Mechanics working with Bakelite brake pads, steering components, and other automotive parts 
• Construction workers involved in building renovation or demolition projects encountered asbestos-containing Bakelite products in electrical systems, appliances, and structural components.
• Factory workers involved in making, repairing, or refurbishing consumer goods containing Bakelite faced exposure through cutting, sanding, and other fabrication activities.

Vintage Collections and Ongoing Hazards

The popularity of vintage collecting has led to new exposure risks as enthusiasts look for decades-old Bakelite items without understanding the danger posed by its asbestos content. Cameras, jewelry, appliances, and other collectible items manufactured before 1974 may contain asbestos fibers that can be released when items deteriorate or undergo restoration.[1]

Polishing, drilling, or structural repairs can disturb embedded asbestos fibers, creating inhalation hazards in home workshops and restoration facilities. Additionally, the characteristic strength and durability that made Bakelite so popular decades ago also means that many asbestos-containing products remain in use today. Electrical panels, appliances, and industrial equipment manufactured decades ago may still be functioning, creating ongoing exposure risks during building renovation and demolition projects. Proper identification and safe handling procedures are essential to prevent exposure during these activities.

The Risks of Asbestos Exposure

Asbestos exposure has been linked to several serious health conditions, each leading to disabling or deadly outcomes:

• Pleural Mesothelioma
• Peritoneal Mesothelioma
• Pericardial Mesothelioma
• Lung Cancer
• Asbestosis
• Pleural Illnesses

The latency period for asbestos-related diseases typically ranges from 20 to 50 years, meaning individuals exposed to asbestos-containing Bakelite products decades ago may only now be experiencing symptoms. This extended delay often complicates diagnosis and treatment, as patients and physicians may not initially connect current health problems with historical occupational exposures.

Union Carbide’s Response to Litigation

As awareness of asbestos dangers grew throughout the 1970s and 1980s, Union Carbide Corporation began being named in asbestos lawsuits, and many of them focused on the asbestos-containing Bakelite products. An analysis of the company’s response to these challenges revealed a pattern of defensive strategies designed to minimize liability and challenge causation claims.[4]

Even though internal company studies conducted in the 1970s had documented concerning asbestos exposure levels among workers handling Bakelite products, and a 1973 industrial hygiene assessment that found airborne asbestos concentrations far exceeding established safety limits, the company continued defending against claims that its products posed health risks, relying on studies conducted by scientific consulting firms it had hired to conduct retrospective exposure studies.[5] 

A comprehensive review by David S. Egilman of Brown University examined the studies commissioned by Union Carbide and concluded that much of it was “deliberately designed to minimize asbestos exposure estimates for litigation purposes rather than for legitimate scientific research. It identified multiple methodological problems, including the use of different raw materials than original formulations, manufacturing processes that artificially reduced asbestos content, and work simulation timing that artificially lowered exposure calculations. These practices were characterized as “corrupt science” designed to produce predetermined conclusions supporting corporate legal defense rather than determining accurate exposure levels. [5]

Landmark Decision in Bakelite Lawsuit

Among the many lawsuits filed against Union Carbide Corporation citing exposure to asbestos-containing Bakelite products was a claim that resulted in a landmark legal decision often cited as a legal standard.[6]

Frank Kestenbaum filed a mesothelioma claim against several companies, including Union Carbide Corporation. He’d been exposed to asbestos in Bakelite products while working as a salesman and branch manager at Cadillac Plastic & Chemical between 1969 and 1972, and asserted that it had led to his development of pleural mesothelioma. Union Carbide argued that the case should be dismissed because all Bakelite resins were free of asbestos.

The court found sufficient evidence to question Union Carbide’s claims, noting testimony that roughly 40% of the company’s phenolic resins had contained asbestos in 1969. The decision was the first successful challenge to the company’s summary judgment attempts in Bakelite exposure cases. The case ultimately settled for $1.1 million and established an important precedent against dismissing a case when a genuine dispute of material fact exists.

Legal Rights and Options

People who’ve developed mesothelioma and other asbestos-related diseases after having been exposed to asbestos-containing Bakelite products may be able to seek compensation from responsible parties, but these claims are complex and require deep knowledge and experience in asbestos litigation. 

Successful lawsuits typically require comprehensive documentation of work history, product identification, and medical evidence linking exposure to disease development. The decades-long latency period for asbestos diseases often complicates these efforts, as witnesses may be unavailable and records may be incomplete or destroyed.

Essential Legal Support 

An experienced asbestos attorney will provide crucial services and support, including: 

• Comprehensive review of employment records, work site documentation, and product identification to establish all potential locations where asbestos exposure occurred
• Determination of all potentially liable entities, including manufacturers, distributors, employers, and property owners 
• Access to databases documenting asbestos use in specific products and facilities
• Coordinating occupational health specialists, industrial hygienists, and medical experts to provide expert testimony establishing the scientific connection between workplace exposure and disease development
• Identification and interview of former colleagues and coworkers who can provide testimony regarding workplace conditions, safety practices, and the presence of asbestos-containing materials.

Legal claims for asbestos-related diseases are subject to statutes of limitations that make prompt action after diagnosis important. Though these deadlines vary by jurisdiction, they make it essential that you connect with qualified legal counsel as quickly as possible to preserve rights and maximize potential compensation.