## Low Pressure Spray Foam 

## Products Chris Bloom 

### Dow Chemical February 15, 20122 

# Agenda

• Scope
• Objectives
• Overview of SPF Systems
• Key Application Areas
• Exposure Monitoring Summary
• PPE Guidance
• Risk Profile Summary


### • Product Stewardship Activity Summary
• Questions3 

# Scope: Low Pressure SPF

2KLP

OCF 2KHP Industrial 

## • One Component Foams or OCF

• Two Component Low Pressure Foams or 2KLP4 

# Objectives

• Enhance understanding of PU Chemistry as it relates to low pressure SPF products

• Provide a clear differentiation between SPF product 

### types

– Review Phys - Chem attributes and delivery systems

– Review monitoring information

– Review PPE guidance


### • Review the different ‘risk profiles’ associated with low pressure SPF products

• Provide an update on stewardship activities in the area of low pressure SPF products5 

# 1 - Component vs. 

# 2 - Component Systems

• 1 - Component:

– Isocyanate and Polyol combined in one container at time of manufacture

– Mixed at slightly greater than 1:1 into container

– Forms NCO - terminated PU in container

– 5 - 15% PMDI in container as marketed

– Reaction completed at time of application by reaction with ambient moisture

– CO 2 secondary blowing agent /propellant produced :
• 2(R - N=C=O) + H2O --- > R - N - C - N - R + CO2 

### • 2
- Component:

– Isocyanate and Polyol in separate containers

– Mixed 1:1 at time of application; 50% PMDI Even if container is breached, only foam will be emitted6 

# SPF Delivery Systems

• Containers

– Refillable Cylinders:

• 2 - component, Low - P only



### – Single - use Drums / Cylinders:

• 2 - component only, High - & Low - P



### – Pressurized Cans / Single - use cylinders:

• 1 - component only7 SPF Systems

For more available information, see the Spray Polyurethane Foam Health and Safety Website at www.spraypolyurethane.org .8 

# SPF Delivery Modes

• Spray

– 2 - component only, high & low pressure

– Product application: insulation



### • Stream / Bead

– 1 - component & 2 - component, low pressure only

– Product application: adhesive, sealant9 

# SPF System Differentiation

• Basic Categories:

– High - Pressure SPF systems

• Designed for Industrial Use

• 2 - component systems

• Applied at high temps and pressures



## – Low - Pressure SPF products

• 2 - component kits

• 1 - component foam products



### • Applied at ambient temps Focus10 

# Key Application Area for 

# Low Pressure SPF Products

• Improve energy efficiency in residential and commercial structures



## • Low pressure SPF products play a key role in addressing air sealing needs

– Rim joists



## – Attics and crawl spaces12 

# Low Pressure Worker 

# Exposure Monitoring

• Species monitored:

– MDI

– MDI & main oligomer (“3
- ring”, n=1)



## • Occupational Exposure Guidelines

– OSHA: 200 m g/m 3 

## MDI (20 ppb; ceiling)

– ACGIH TLV ® 

## : 51 m g/m 3 

## MDI (5 ppb; 8
- h TWA)13 

# Monitoring Summary

• Both 1 - and 2 - component low pressure foam products have significantly (~10x) lower worker MDI exposure profiles than high pressure foam systems.

• 1 - component foam products have significantly lower exposure profiles than 2 - component low pressure kits.

• Current PPE guidance for 1 - and 2 - component low 

### pressure foam products provides adequate protection.
• Ongoing opportunity to provide enhanced outreach and education to end users regarding safe use and handling techniques.14 

# Applicability to 

# Consumer Related End Uses

• Low - pressure products studied were:

– Representative of products for use in homes (2
- component single
- use kits) by weatherization professionals



### – Representative of extreme
- case consumer use (1
- component foams)
• Professional products (single
- use cylinders) used in exposure studies had higher PMDI content than consumer cans (13
- 15% vs. 6
- 11%)
• More material applied during sampling


## • Respirator use not necessary for typical 1
- 

## component applications.15 

# Exposure Study Using Low Pressure 

# SPF on Weatherization Jobsite

• Actual weatherization job in Connecticut; May, 2011

» Conducted by independent BPI - certified building analyst

» Independent lab for MDI monitoring (OSHA 4247)

• Job scope

» Air seal attic, rim joist in basement with LP SPF

» Mechanical ventilation applied, respirators used, temps & humidity recorded

• Results

» No recorded airborne levels of MDI in work areas during and after foam application, applicator levels well under permissible limits

» No MDI detected after 1 hour in attic, 2 nd , and 1 st floor16



### PPE Guidance for Applicators and Helpers17 

## General Risk Profile Comparison for 

## OCF and 2KLP SPF Products

OCF 2KLP

(bead) 2KLP

(spray) Risk = Hazard x Exposure

Exposure Potential

PPE Sophistication18 

# Product Stewardship Activities

• spraypolyurethane.org website (Nov 10 – Jan 12)

– Total Visitors: 48,572

– Total Page Views: 249,629


### • Enhanced user friendly information on safety considerations when using OCF products

• Enhanced product labeling for 2K kits



### • 2KLP application video (May 1,2011 – Feb 8, 2012)

– Page Views: 920

– Downloads of zip file of video: 59

– Youtube Views: 635


### • Online training course for 2KLP foam application slated for Fall 2012

# APPENDIX20 

# Sampler Types

– Coated Filter

– Impinger

– Impinger + filter21 

# Iso Check Sampler22 

# Impinger / Filter Comparison

• Side - by - side sampling done in Study 2 (2 - component low pressure SPF exposure 

## study)


# • 5 data points; Results:

– Mean Impinger / Filter ratio = 1.7

– Range: 1.1 – 2.823 

## Low - Pressure Spray Foam Worker 

## MDI Exposures 5 studies, 41 personal (task) samples, 68 area / source samples 

## MDI Conc. (mean [range]; m g/m 3 

## )

2
- component SPF 1 - component SPF Applicators 30 [ ND*(6)

– 82 ] 

### ND(6) [ ND(1)

– ND(8) ] 

### Helpers 12 [ ND(6)

– 36 ] 

### n/a Exposure Guidelines 200 (ceiling)

OSHA PEL 51 (8
- h TWA) TLV ® *ND() = not detected @ (detection limit), 1⁄2 Detection Limit used for mean24 

# Exposure Studies: 2 - Component 

# Low - Pressure Kits Study 1: Residential Wall Insulation Application (spray)
• Method: Impinger 

### Sample Type MDI m g/m 3 

### Mean [range] 

### n* #ND 

### Personal
- Applicator 48 [16
- 82] 

### 6 0 

### Personal

– Helper (3
- 10’ from Applicator) 

### 16 [ND(6)
- 36] 

### 6 1 

### Area

– 15 - 30’ from Applicator 1.9 [ND(2)
- 4.1] 

### 8 7

*n= # of samples; #ND = # of samples that were below limit of detection25 

# Low - Pressure SPF 

# Exposure Study Details

• Lab application (4 studies)

– Spray onto cardboard / plastic

– In lab hood (fan off) or plant (general 

## ventilation)

– Extreme - case simulation

• More foam applied over shorter period of time


### • Source samples can be taken near point of application 

## • Application of insulation in home (1 

## study)26 

# Exposure Studies: 2 - Component 

# Low - Pressure Kits ( con’t ) Study 2: Lab Application; Area samples at hood entrance (fan off)
• 3 different single use kits used; 7
- 15 min application
• Methods: Impinger w/ backup filter, Filter Sample Type MDI m g/m 3 Mean [range] n* #ND Personal
- Applicator 37 [13
- 66] 7 0 Area

– Kit A (5 min use periods (3)) Crack filler / sealer
- bead 4.9 [ND(7)
- 9] 4 3 Area

– Kit B (5 min use periods (3)) Insulation

– spray 55 [38
- 74] 3 0 Area

– Kit C (full kit in 12 min) Insulation
- spray 130 1 0 *n= # of samples; #ND = # of samples that were below limit of detection27 

# Exposure Studies: 2 - Component 

# Low - Pressure Kits ( con’t ) Study 3 : Lab Application
• 2 different single use kits, 1 refillable system used


## • 7 - 15 min application
• Area samples:

– near (1
- 3’)

– far (10
- 20’)


## • Method: Iso Check filter sampler

– Dual filter, MDI & oligomers28 

# Study 3 Results ( con’t )

*n= # of samples; #ND = # of samples that were below limit of detection29 

# Exposure Studies: 1 - Component Foam Products Study 3,4,5 : Lab Application
• Adhesive, single use container; 11
- 24 min application

• Area samples at 1
- 20’, source ( 

### £ 18”)
• Methods: Filter sampler (Study 3: IsoCheck ; Studies 4,5: 13mm)

*n= # of samples; #ND = # of samples that were below limit of detection 

### Sample Type MDI m g/m 3 

### ; Mean [range] n* #ND Personal - Applicator ND(6) [ND(1)

– ND(8)] 11 11 Area: Near (1
- 3’) Far (10
- 20’) ND(1) [olig=ND(6)]

ND(0.9) [olig=ND(5)] 1 1 1 1 Area: Source 9.2 [ND(6)

– 51] 15 13