Environmental, Safety and Health

Bill Robert, CIH

BASF Corporation

Spray Polyurethane Foam Association

Accreditation Course

January 11, 2009

Note: The environment, health, and safety chapter of the Spray Polyurethane Foam 

Alliance’s Accreditation Program, Course 101 titled, “Introduction to Spray Polyurethane 

Foam”, developed by the American Chemistry Council’s Center for the Polyurethanes 

Industry (CPI), has not been updated by CPI for 2009 and may not be relied upon until such 

time as an updated chapter is released by CPI.
Presentation Agenda

• Video

• PowerPoint presentation

• Q & A session
Introduction

• The two basic chemical ingredients in 

spray foam systems are

– Part A: Diisocyanates (monomeric MDI and 

polymeric MDI)

– Part B: Polyol resins

Diisocyanate + Polyol Polyurethane Polymer + Heat
Part B – Polyol Resin Systems

• Typically made up of:

– Polyols 

– Catalysts (amine or metal) Increase speed 

and temperature of reactions

– Surfactants

– Blowing Agents (CP, HFC’s, water)
Part B – Polyol Resin Systems

• Potential Health effects:

– Polyols (low vapor pressure / low toxicity)

– Catalysts 

• amine – fishy or rancid odor; irritating to eyes, skin and 

respiratory system.

• Metal - irritating to eyes, skin and respiratory system; some 

can result in sensitization. Some can have target organ 

effects.

– Surfactants –low toxicity by all routes

– Blowing Agents – typically displace air in enclosed 

spaces and some can have CNS efffects
Part A - Health Effects - Routes of 

Exposure

• Inhalation

Overexposure = breathing concentrations 

above the exposure limit

• Skin/eye contact

• Ingestion
Occupational Exposure Limits

Published Exposure Limits for Airborne MDI

ACGIH TLV-TWA OSHA PEL-C

0.005 ppm 0.02 ppm

• Polyols

– Neither OSHA nor ACGIH has established exposure 

limits for polyols
Health Effects- Inhalation

• If MDI is sprayed or heated, there is a greater chance of 

overexposure 

• Irritation effects can include:

Coughing; chest-tightness/discomfort; shortness of 

breath; and reduced lung function 

• Overexposure also may result in sensitization; these 

effects can include:

Chest-tightness/discomfort; shortness of breath; 

coughing; wheezing; and possibly an asthma attack

If a worker starts to feel any of the symptoms listed 

above, the worker should inform the 

supervisor immediately!
Health Effects- Sensitization

• Respiratory sensitization can result from:

One massive overexposure

Repeated exposure to airborne 

concentrations above the exposure limit

Sensitive populations can develop 

sensitization at levels below the exposure 

limit.
Health Effects- Sensitization

• Persons that are sensitized may have asthma attacks 

provoked by exposures to concentrations of 

diisocyanates well below the occupational exposure limit. 

• If an individual becomes sensitized, any further exposure 

should be avoided, even in well controlled working 

atmospheres. 

– Use of a respirator or inhaler, to temporarily relieve 

asthma symptoms, is not a solution

• Health effects may occur immediately upon exposure, be 

delayed for several hours after exposure ends, or both 

can occur.
Health Effects- Sensitization

• If diisocyanate sensitization or occupational asthma is 

diagnosed, or if the doctor does not clear the worker to 

work with diisocyanates due to poor respiratory function, 

any contact with diisocyanates may create a serious risk 

to the worker’s health

 Consequences of sensitization:

Worker can no longer work with isocyanates even though 

symptoms generally disappear after contact with isocyanates 

stop (sensitization can be permanent)

Immediate removal of a sensitized individual will reduce the 

likelihood of long term breathing problems

Continued work with isocyanates may lead to more severe 

asthmatic attacks -- extreme asthmatic attacks can be life 

threatening
Health Effects- Sensitization

First Aid

• If someone is suspected of being overexposed, 

move the person to an area with fresh air, and 

try to keep them calm and warm- but not hot 

• Obtain immediate medical attention

• If they are having difficulty breathing, a qualified 

person may provide oxygen

• If they stop breathing, give artificial resuscitation 

and seek emergency medical attention
Health Effects- Skin Contact

• Repeatedly getting MDI on the skin may cause discoloration, staining, 

redness, swelling or blistering; this also could lead to skin 

sensitization. 

• Further, animal tests have indicated that skin contact, followed by an 

inhalation exposure, may result in lung sensitization.

• It is very important to wear gloves when there is the possibility of skin 

exposure to MDI (refer to the supplier/manufacturer MSDS for specific 

recommendations). 

• Any clothing contaminated with MDI should be removed; further, it is a 

good work practice to keep all work clothing at work. Discard items 

which can not be decontaminated, including leather articles such as 

shoes, belts and watch bands. 
Health Effects- Skin contact

First Aid

• If skin contact with MDI does occur

Wipe with absorbent material to remove as much MDI 

as possible

Wash thoroughly with soap and water

Clean as soon as possible after exposure

Organic solvents should not be used as they can promote 

absorption of MDI

For severe exposure, use a safety shower after 

removing contaminated clothing

• If your skin is irritated, seek medical attention 
Health Effects- Eye Contact

• Getting MDI in the eyes can cause tearing and 

irritation (burning/stinging)

• If a worker gets MDI in their eyes:

Wash immediately with a continuous flow of low 

pressure water, preferably from an eyewash fountain, 

for 15 minutes or more

Remove contact lenses if present after the first five minutes 

and continue flushing the eyes.

Seek immediate medical attention
Health Effects- Ingestion

• Swallowing small amounts of MDI may cause 

mild irritation, but no significant adverse effects 

are anticipated. Swallowing large amounts of 

MDI may cause injury.

• If you swallow MDI, do NOT induce vomiting 

Wash out the mouth with water

The person affected should be made to rest; obtain 

medical attention 

• Follow good hygiene practices when working 

with MDI to minimize the possibility of ingestion; 

where MDI is used,

Do not smoke or use other tobacco products

Do not store, prepare, or consume foods
Exposure Control

• Engineering

– Providing adequate ventilation when working in an 

enclosed area (e.g., spray booth).

– Having hand wash stations or showers available in 

work area.

– Decontaminating surfaces that have come into 

contact with isocyanates.

– Controlling unauthorized or unprotected employee 

access to exposure areas.

– Monitor MDI in work areas to ensure levels are below 

exposure levels.
Exposure Control

• Administration

– Workers and staff undergo proper training in how to 

handle isocyanates.

– Workers who will be handling isocyanates, undergo 

medical examinations.

– Material Safety Data Sheets (MSDS) and other 

training materials are available to persons working 

with isocyanates.

– Keep records up-to-date.

– Follow all laws and regulations.
Exposure Control

• Personal Protective Equipment

– Chemical worker’s goggles

– MDI-resistant long-sleeve coveralls or full 

body suits

– MDI-resistant fitted boots 

– Head protection, such as a close-fitting hood

– An approved supplied air respirator or airpurifying respirator (consult your MSDS for 

guidance)
Personal Protective Equipment

Example

• Where there is adequate ventilation and 

the potential for exposure to MDI liquid or 

vapor is minimal, workers may use:

– Safety glasses or chemical worker’s goggles

– MDI-resistant chemical gloves

– Long-sleeve coveralls (heavy cotton 

preferred)

– Safety shoes or boots
Personal Protective Equipment

Example

• Where there is a risk of exposure to MDI liquid 

or vapor/aerosol at/or above allowable exposure 

limits, workers should use:

– An approved air-supplied respirator or airpurifying respirator (consult your MSDS and 

company respiratory protection program for 

guidance)

– Chemical worker’s goggles

– MDI-resistant long-sleeve coveralls or full 

body suit

– MDI-resistant fitted boots and

– Head protection, such as a close-fitting hood
Dermal Protection

• A study, conducted in 1993 by the International 

Isocyanate Institute (III) and published by CPI, 

determined protection times of various gloves 

and suit materials against MDI and TDI.

• Factors considered

– Thickness

– Material composition

– Light duty vs. standard duty

• Note: since the study was conducted, some 

gloves and suits have been updated with newer 

models.
Dermal Protection

• >4 hr break through time:

– Gloves:

• Nitrile, Neoprene, Butyl, 

Laminate PE EVAL, PVC

• <4 hr break through 

time

– Thin natural rubber 

gloves, especially for 

Testing Results Summary: MDI

Laminate PE EVAL, PVC

– ‘Laminated’ disposable 

suits:

• Laminated, Nonwoven

– Reusable suits:

• PVC, laminate, polyurethane

gloves, especially for 

longer projects

– ‘Uncoated’ 

disposable suits

PPE Identified by Material
Respiratory Protection

• OSHA regulations require employers to provide 

respirators where necessary to protect the health of 

employees (29 CFR 1910.134)

• Air-purifying respirator means a respirator with an airpurifying filter, cartridge, or canister that removes 

specific air contaminants by passing ambient air through 

the air-purifying element 

• Air-supplied respirator means a respirator that 

supplies the respirator user with breathing air from a 

source independent of the ambient atmosphere, and 

includes air-supplied respirators (ASRs) and selfcontained breathing apparatus (SCBA) units
Respiratory Protection

• Respirators can protect employees from 

exposure to MDI and may be necessary to 

meet OSHA or other governmental 

workplace requirements 
Respiratory Protection- SARs

• Sources of breathing air include:

– Self contained breathing apparatus (SCBA)

– Air-lines

• Per OSHA, supply air should be equal to 

atmospheric air:

– 19.5 % to 23.5% oxygen

– Maximum 1000 ppm CO2

– Maximum 10 ppm CO
Respiratory Protection- APR

• Three types of Air 

Purifying Respirators:

– Full-face

– Half-face

– Powered APR

• Select cartridge type 

based on chemical 

and physical form of 

hazards present
Respiratory Protection- APR

• In a spray application, if you use airpurifying respirators, make sure that you 

use the proper cartridges with them. 

• In most cases, a combination organic 

vapor cartridge with a particulate pre-filter 

is appropriate. 

• If you have any doubt about which 

cartridge to use, contact the supplier of the 

respirators for advice. 
Respiratory Protection- APR

• To meet the criteria for APR use, OSHA 

requires employers to perform a “Hazard 

Assessment and Respirator Selection”

• Employer must reasonably estimate the 

employees’ exposure to contaminant by:

– Rationale based on applicable data from comparable 

industries and processes 

– Exposure monitoring
Respiratory Protection- APR

• To meet the OSHA criteria for APR use, respirators 

must have a NIOSH certified End of Service Life 

Indicator (ESLI) or employers must follow a cartridge 

change schedule.

• ESLI is a system that warns the user of the approach of 

the end of adequate respiratory end of adequate respiratory protection rotection; e.g., the e.g., the 

sorbent is approaching saturation or is no longer 

effective.

• MDI does not have an ESLI so APR cartridge 

change schedules are typically based on objective 

information or data. 

• For current information on the status of approvals of 

respirators, email NIOSH at pubstaft@cdc.gov, or call 1-

800-356-4674.
Respiratory Protection- APR

• OSHA Respirator Rule:

– User should not rely on 

odor as a signal to 

change respirator 

cartridge for any 

chemical.
Respiratory Protection

Written Respirator Program

• Required by OSHA if employees wear 

respirators – either voluntarily or by 

company policy.

• Applies to all respirators.
Respiratory Protection

Written Respirator Program

Program Elements (OSHA)

1. Identify where respirators are needed

2. Designate Program Administrator

3. Designate Licensed Health Care Professional 

4. Determine type of respirator to be used

5. Arrange for medical examinations

6. Conduct fit testing

7. Designate storage areas/develop maintenance plan

8. Train respirator users 

9. Establish annual program evaluation

10. Maintain written documentation of program
Respiratory Protection

Model Respiratory Protection Program

• Developed by CPI to help 

companies:

– Protect employees from 

respiratory hazards

– Assist in compliance with 

OSHA’s Respiratory Protection 

Program Standard 29 CFR 

§1910.134

• Available on CPI’s website 

www.polyurethane.org
Respirator Protection

Model Respiratory Protection Program

• For your company

– Fill in the all blanks

– Include all

attachments

– Make “company 

specific”
Medical Evaluations

• Medical evaluations are required to determine the 

employees ability to use a respirator, before intended 

use1

• Employees should not be permitted to wear a 

respirator until a physician has determined that they 

are medically able to do so2

• Medical evaluations should include medical 

questionnaires and medical examination during the 

employee's normal working hours or at a time and 

place convenient to the employee3

1,2,3 In accordance with OSHA’s Respiratory Protection Standard (29 CFR §1910.134). 
Fit Testing

• Before an employee uses any respirator with 

a negative or positive pressure tight-fitting 

facepiece, the employee should be fit tested 

with the same make, model, style, and size 

of respirator that will be used on the job1

• Qualitative Fit Test (QLFT) Protocols vs. 

Quantitative Fit Test (QNFT) Protocols2

1,2 In accordance with OSHA’s Respiratory Protection Standard (29 CFR §1910.134). 
User Seal Check

• Each time a respirator is used, “user seal 

check” should be conducted1

– Facepiece Positive and/or Negative Pressure 

Checks

• User seal checks are not 

substitutes for qualitative or 

quantitative fit tests2

1,2 In accordance with OSHA’s Respiratory Protection Standard (29 CFR §1910.134). 
Handling and Storage Requirement

• Polymeric MDI, when shipped in drum 

quantities, is not classified as a hazardous 

product during normal transportation. 

• Many systems have been developed for labeling 

potentially hazardous chemicals. The most 

common two are the Hazardous Material 

Identification System (HMIS) and the National 

Fire Protection Association (NFPA) systems. 
HMIS® Label (Second Edition)

HMIS®
HMIS® Label (Second Edition)

• Uses scale of 0 to 4 

– 0 - Minimal Hazard; 

– 4 - Severe Hazard

• Categories rated:

– Health (blue rectangle)

• 1

st Box for “Chronic Hazard Indicator”

– Flammability (red rectangle)

– Reactivity (yellow rectangle)

– PPE (white rectangle)
Personal Protection Equipment
Polymeric MDI HMIS® Ratings

HMIS®

Polymeric MDI

 2

1

1

X
NFPA® Label

National Fire Protection Association

• Indicates hazards under fire conditions for fire 

fighters in protective clothing

• Uses scale of 0 to 4 

• 0 is lowest hazard; 

4 the highest

• Left diamond: Health

• Top diamond: Fire

• Right diamond: Instability

• Bottom: Special/specific hazards
Other Safety Considerations

Thermal Degradation

• When overheated, polyurethanes and 

other polymers may breakdown and 

produce smoke and/or vapors that 

contain various chemicals. This 

breakdown is known as thermal 

degradation.

• When polyurethanes undergo thermal 

Hot Work Includes:

• Welding

• Heating of 

polyurethane foam 

while working on 

pipes

• When polyurethanes undergo thermal • Heating MDI-based 

degradation some toxic chemicals 

may be emitted. This may or may not 

be seen as smoke or vapors.

• These chemicals may include carbon 

dioxide, carbon monoxide, nitrogen 

oxides, hydrogen cyanide, isocyanates 

and amines.

• Heating MDI-based 

glues

• Soldering

• Treatment with a 

heat gun

• Cutting with torches 

or hot wire

• Hot scissors

• Grinding

• Sawing
Other Safety Considerations

Thermal Degradation

• Improper application of spray foam can be 

another fire hazard because of the high 

temperatures that can be generated. 

• Properly applied spray foam reaches 

approximately 160°F to 200°F during the curing 

process. 

• Spray foam that is applied too thickly can reach 

curing temperatures of about 300°F. In some 

cases, this can ignite the spray foam.
Other Safety Considerations

Energized Equipment and Static Electricity

• Spray foam is often applied near energized 

electrical equipment and lines. Be extremely 

cautious when working near this type of hazard. 

Never let equipment touch or come too close to 

electric lines or equipment.

• Equipping electric equipment that is used in 

spray foam applications with Ground Fault 

Circuit Interrupters (GFI) will help prevent 

electrical shock or electrocution if a short 

develops in the equipment. 
Environmental Reporting

• Title III of SARA...known as EPCRA

SARA – Superfund Amendments and 

Reauthorization Act

EPCRA – Emergency Planning and 

Community Right-to-know Act
EPCRA §311

Hazardous Chemical Inventory Reporting

• Section 311 requires users of any 

substances for which a MSDS must be 

maintained under OSHA and are on site at 

any time above threshold quantities, to 

provide an MSDS, within 90 days, to:

– Local fire department, 

– LEPC (Local Emergency Planning 

Committee) and 

– SERC (State Emergency Response 

Commission)
Threshold Quantities

• For extremely hazardous chemicals, 

threshold quantity is 500 lbs.

• For hazardous chemicals, threshold 

quantity is 10,000 lbs.

– MDI is classified as “hazardous” 
EPCRA §312

Hazardous Chemical Inventory Reporting

• EPCRA §312 requires facilities to file a 

report on any hazardous chemicals 

reported under §311

• This report, called the tier I or II report, is 

due March 1st of each year and must be 

submitted to the LEPC, SERC, and local 

fire departments 
EPCRA §313

Toxic Release Inventory (TRI)

• TRI reporting is required by SARA 313

• TRI is a publicly available EPA database that 

contains information on toxic chemical releases 

and other waste management activities reported 

annually by certain covered industry groups as 

well as federal facilities. 

• MDI, TDI, and HDI are subject to TRI annual 

reporting to EPA in the Diisocyanates Category, 

N120.
EPCRA §313

Toxic Release Inventory (TRI) Reporting

• TRI regulations require that a report be filed by 

an owner/operator of a facility which meets ALL 

of the following criteria:

– Has 10 or more full-time employees

– Is included in designated SIC codes

– Manufactures, processes, or otherwise uses EPCRA 

313 chemicals in quantities greater than the 

established threshold in the course of a calendar 

year. 

Note: Most spray foam operations do not meet the SIC code 

requirements and are exempt from reporting
Tools to Help with TRI Reporting

• Airborne releases are often overestimated, so 

CPI’s Regulatory Compliance Assistance Program 

(RCAP) was developed to help estimate true 

releases of MDI/PMDI.

• www.polyurethane.org  Environment 

emissions 

• RCAP includes: 

– MDI Emissions Estimator Software Version 3.0 

– Reporting Guidelines

– CPI Consultant available for consultation

Updated 

in 2007!
Waste Disposal

• MDI waste products must be disposed of 

according to federal, state and local 

regulations. 

• MDI is NOT a federally regulated hazardous 

waste.
Disposal of MDI

• Although MDI is currently not listed under 

federal RCRA, some states may apply 

specific disposal requirements to MDI as a 

regulated waste stream. 

• Check with appropriate state and local 

regulatory agencies before disposing of 

MDI or MDI-based polyurethane foams.
Disposal of Empty Containers

• Decontamination can help prevent 

exposure to residual MDI in containers 

destined for a scrap dealer or landfill

– Empty MDI containers can be 

decontaminated by filling them with water or 

decontamination solution (5-10% sodium 

carbonate) and allowing them to stand, 

unsealed for at least 48 hours

– Decontamination solutions and rinse water 

should be disposed of properly according to 

federal, state and local laws and regulations
Disposal of Empty Containers

• Depending on the circumstances, there 

are three options typically used for 

disposing of decontaminated steel 

containers that have contained MDI:

– A container reconditioner

– A scrap metal dealer

– An approved landfill
Disposal of Empty Containers

• Containers that have contained MDI should be 

properly disposed of so that they are not 

accidentally used to store another material 

• Storing other materials in containers that 

previously held MDI could lead to a chemical 

reaction and potential worker safety issues

• The use of hot torches can result in a dangerous 

fire or explosion. If a used MDI container must 

be cut, use cool tools. 

• Containers that have held MDI may be 

punctured or crushed to prevent reuse 
Disposal of Empty Containers

• Some sources to find a drum reconditioner:

– Your local Environmental Protection Agency

– Reusable Industrial Packaging Association 

(www.reusablepackaging.org)
Minor Spills of MDI

• Contain minor spills to help prevent further spreading of 

MDI to protect workers and the environment 

• When possible, absorb MDI with sand, wet earth or 

absorbent clays (e.g., vermiculite, Oil-Dri, kieselguhr)

• Add neutralizer to the absorbent materials and carefully 

transfer materials into an open top container

• Transport containers outdoors and treat with neutralizing 

solutions 

– Waste MDI may be neutralized by reacting the product with 

water or caustic solution

– Note: MDI can react with water, so resealing a diisocyanate 

container when it has become contaminated with moisture could 

cause the container to swell and potentially rupture. 
Major Spills of MDI

• Dispose of treated material properly according to 

federal, state and local laws and regulations

• Appropriate PPE should be worn, including 

respiratory protection and protective clothing

• Call your supplier’s emergency response center 

for advice and/or assistance

• If spill involves a tank car or tank truck, call 

CHEMTREC (1-800-424-9300)
CPI Literature

• Model Respiratory Protection Program

• Guidelines for the Responsible Disposal of Wastes and 

Containers from Polyurethane Processing

• Polyurethane and Thermal Degradation.

• PMDI User Guidelines for Chemical Protective Clothing 

Selection. 
Review

1. For protection against the potential adverse 

health effects of isocyanates, the applicator 

should have ________ for all foam spraying 

operations.

a. Rubber boots

b. No respirator 

c. Combination organic vapor/cartridge respirator with 

particulate pre-filter

d. a supplied air respirator (i.e., "Type C" air-supplied 

respirator)

e. Either C or D
Review

2. Isocyanates have been assigned one of 

the lowest allowable exposure limits 

because of their potential adverse health 

effects due to sensitization.

– True

– False
Review

3. Skin and/or respiratory sensitization is not 

considered a potential adverse health 

effect of the materials used in spray foam 

systems. 

– True

– False
Review

4. Which of the following glove materials 

does not provide good protection against 

MDI?

a. Neoprene

b. Cotton

c. 4H or silver shield laminate

d. Nitrile
Review

5. To meet the OSHA criteria for APR use, 

respirators must have a NIOSH certified 

End of Service Life Indicator (ESLI) or 

employers must follow a cartridge change 

schedule. 

–True

–False
Review

6. The _______ regulations require 

reporting to government agencies when 

more than the threshold amount of 

hazardous chemicals is present at a 

single site.

a. OSHA

b. RCRA

c. FIFRA

d. SARA
Review

7. Which of the following materials may be 

generated in a fire involving spray foam 

materials?

a. Cyanide compounds

b. Isocyanates

c. Oxides of carbon and nitrogen

d. All of the above
Review

8. The health hazard associated with an 

HMIS or NFPA ranking of "1" is 

___________ the hazard associated with 

a ranking of 3.

a. greater than

b. less than

c. the same as

d. cannot be determined
Review

9. OSHA standards require that a written 

respiratory protection program be in place 

for all companies that use respirators.

– True

– False
Review

10.For individuals who become sensitized to 

isocyanates, which of the following is the 

correct course of action?

a. Let them continue working in their present job 

because the sensitization will go away.

b. Assign them to jobs in which there is no possibility of 

exposure to isocyanates.

c. Have them get plenty of exercise.

d. Have them wear a respirator.
Review

11.All of the following except one are part of a 

good job site personal hygiene program. 

Which is NOT a work rule?

a. Eating, drinking, and smoking should be prohibited in 

areas where chemicals are in use. 

b. Chemicals should be removed from the skin with 

solvents.

c. Contaminated work clothing and personal protective 

equipment should be thoroughly cleaned before 

reuse.

d. Work clothing that may be contaminated should not 

be worn home.
Review

12.Ground Fault Circuit Interrupters are 

used to ____________ .

a. Reduce the potential for electric shocks.

b. Ensure that a respirator fits properly.

c. Monitor the air for toxic chemicals.

d. None of the above.
Review

13.Isocyanates can react with water and/or 

alcohols if they are accidentally mixed. 

– True

– False
Review

14.Per OSHA, supply air should be equal to 

atmospheric air:

a. 19.5 % to 23.5% oxygen

b. Maximum 1000 ppm CO2

c. Maximum 10 ppm CO

d. All of the above