Air Monitoring Investigation 

–

SPF Installation in Residential Structu

July 16, 2009

Brian F. Karlovich, CIH, CSP 

- Bayer MaterialScience 
Study Background

Purposes of Air Monitoring Study: 

 Evaluate potential worker exposures dur

application

 Evaluate potential migration of SPF comp

to adjoining floors

 Evaluate airborne concentrations with di

from applicator

 Evaluate airborne concentrations in truck  Evaluate rate of decline of airborne 

concentrations following the end of spra

 Observe personal protective equipment u

SPF workers
Study Background

Five air monitoring surveys conducted: 

 Pittsburgh, PA area 2007

-08

 Four during summer months, one during  Two during open cell foam applications i

town houses undergoing construction

 One during open cell foam application in 

family home undergoing renovation 

– dif

SPF formulation than others

 Two during closed cell foam applications 

single

-family homes undergoing renovat
Study Background

Month August December June August JInstalled

SFH

Town 

House

Town 

House

Single- Family Home

Single- Family Home

Structure 

Type

O

(

Open Cell 

(Formulation #2)

Open Cell 

(Formulation #2)

Closed Cell 

(Formulation #1)

Closed Cell 

(Formulation #1)

SPF Type

Survey No. 

4

Survey No. 

3

Survey No. 

2

Survey No. 

1
Study Background

Five surveys conducted (cont.): 

 Each structure two to four floors  Each survey 

– SPF applied to perimeter w

partial perimeter wall, and/or underside deck

 Typically one or two windows and/or doo

somewhere in the structure

 Typical SPF crew 

– one applicator and o

two helpers. Applicators and helpers somswitched roles.
Study Summary

Each study included: 

 personal air samples 

– short and long ter

 stationary area samples on each floor 

– t

evaluate potential migration of SPF compto adjoining floors

 mobile area samples to maintain prescrib

distances from applicator 

 post

-spray samples on each floor

 area samples in truck trailer
AIR SAMPLING PLAN SCHEMATIC

BASEMENT2ND FLOOR1ST FLOOR

Worker Worker MobileStationary
Study Summary

Analytes

 MDI and larger molecular weight oligomers of M Bayer Method 1.20.0

 Spill proof impinger with toluene/1

-(2

-pyridyl)pipe

solution

 Backed up with treated 13 mm glass fiber filter wi

pyridyl)piperazine and diethyl phthalate in Milliporcassette 

 Flow rate 1 liter per minute Filter desorbed in field with acetonitrile/dimethylsu

(90:10)

 Analysis 

- HPLC with detection by UV or fluorescen
Study Summary

Analytes

 Amine catalysts 

(types/levels varied by formulation 

– 2 to 5 per formulation, from <1% to about 5%)

 Bayer Method 2.10.3

 XAD

-2 tube

 Flow rate 0.5 liters per minute Analysis: GC

-NPD (or GC

-MS)
Study Summary

Analytes

 Blowing agent 

(HFC

- 245fa or 1,1,1,3,3

-pentafluoropro

 NIOSH Method 2516 

– modified

 Two charcoal tubes in series Flow rate 0.02 liters per minute Analysis: GC

-FID
Summary of Potential Health Effect

Overexposure

CNS IrreHea

Blowing Irritation Irritation Irritation

Agent

IrritationSensitization (few)

IrritationHazy/Halo 

Vision

IrritationSensitization (few)

Amine 

Catalysts

IrritationSensitization

Irritation IrritationSensitization

MDI

Respiratory Eyes Skin Oth

Tract
PERSONAL SAMPLE RESULTS
Airborne MDI Concentrations - Applicator and Helper

s

0

50

100150200250300350400450500

1 2 3 4 5

Survey No.

Concentration (ug/m3)

Applicator Helper 1 Helper 2

OEL 51 ug/m3

For Survey Nos. 2, 4, and 5, Helper conducted some amount of spraying. Survey Nos. 1 and 2 are closed cell; Survey Nos. 3-5 are open cell
Airborne MDI Oligomer Concentrations - Applicator and Helpers

0

100200300400500600

1 2 3 4 5

Survey No.

Concentration (ug/m3)

Applicator Helper 1 Helper 2

MDI OEL 

51 ug/m3

ND – not detected at the analytical limit of quantitation.For Survey Nos. 2, 4, and 5, Helper conducted some amount of spraying. Survey Nos. 1 and 2 are closed cell; Survey Nos. 3-5 are open cell

ND
Short-Term Airborne MDI Concentrations - Applicator

0

100200300400500600700800900

1000

1 2 3 4 

Survey No.

Concentration (ug/m3)

OEL 200 ug/m3

Survey Nos. 1 and 2 are closed cell; Survey Nos. 3-5 are open cell
Short-Term Airborne MDI Oligomer Concentrations - Applicator

0

200400600800

10001200140016001800

1 2 3 4 

Survey No.

Concentration (ug/m3)

MDI OEL

200 ug/m3

ND – not detected at the analytical limit of quantitation.Survey Nos. 1 and 2 are closed cell; Survey Nos. 3-5 are open cell

ND
Total Airborne Amine Catalyst Concentrations - Applicator and 

Helpers

0

100200300400500600700800900

1000

1 2 3 4 

Survey No.

Concentration (ppb) 

Applicator Helper 1 Helper 2

ND – not detected at the analytical limit of quantitation. Survey Nos. 1 and 2 are closed cell; Survey Nos. 3, 4, and 5 are open cell

ND
Airborne Blowing Agent Concentrations - Applicator and Helpers

0

50

100150200250300350

1 2

Survey No.

Concentration (ppm)

Applicator Helper 1 Helper 2

OEL 300 ppm
DISTANCE FROM APPLICATOR RES
Airborne MDI Concentrations with Distance from Applicator

0

102030405060708090

1 2 3 4 

Survey No.

Concentration (ug/m3)

10 feet 20 feet 30 feet

OEL 51 ug/m3

Survey Nos. 1 and 2 are closed cell; Survey Nos. 3-5 are open cell
Airborne MDI Oligomer Concentrations with Distance from Applica

0

1020304050607080

1 2 3 4 

Survey No.

Concentration (ug/m3)

10 feet 20 feet 30 feet

MDI OEL

51 ug/m3

ND ND 

ND – not detected at the analytical limit of quantitation. Survey Nos. 1 and 2 are closed cell; Survey Nos. 3-5 are open cell
Short-Term Airborne MDI Concentrations with Distance from 

Applicator

0

50

100150200250300

1 2 3 4 

Survey No.

Concentration (ug/m3)

10 feet 20 feet 30 feet

OEL 200 ug/m3

ND – not detected at the analytical limit of quantitation. Survey Nos. 1 and 2 are closed cell; Survey Nos. 3-5 are open cell

ND 
Short-Term Airborne MDI Oligomer Concentrations with Distance fro

Applicator

0

50

100150200250300

1 2 3 4 

Survey No.

Concentration (ug/m3)

10 feet 20 feet 30 feet

MDI OEL 

200 ug/m3

ND ND ND 

ND – not detected at the analytical limit of quantitation. Survey Nos. 1 and 2 are closed cell; Survey Nos. 3-5 are open cell
Total Airborne Amine Catalyst Concentrations with Distance from 

Applicator

0

200400600800

10001200

1 2 3 4 

Survey No.

Concentration (ppb)

10 feet 20 feet 30 feet

Survey Nos. 1 and 2 are closed cell; Survey Nos. 3, 4, and 5 are open cell

ND ND

ND – not detected at the analytical limit of quantitation
Airborne Blowing Agent Concentrations with Distance From Appli

0

50

100150200250300350

1 2

Survey No.

Concentration (ppm)

10 feet 20 feet 30 feet

OEL 300 ppm
Migration of Airborne SPF Compound

MDI MDI Oligomers Amine Catalysts Blowing Age

Slight Migration to Lower Floors.

Moderate Migration to Lower Floors.

Slight MigratioLower Floors.*

<5% of concentration on floor sprayed

<45% of concentration on floor sprayed

<10% of concentration ofloor sprayed

Slight Migration to Lower Floors.

Moderate Migration to LoFloors.

<20% of concentration on floor sprayed

<60% of concentration ofloor sprayed

3 None None None NA4 None None None NA5 None None Slight Migration to NA

Lower Floors. <1% of concentration on floor sprayed

Degree of Migration Observed

1 None2 None None

Survey 

No.

Where migration was observed, levels were not in excess of the OELs 

** Post-spray results from attic indicated upward migration from 2nd f
Truck Trailer Results

Where identified, levels were well below the OELs.

MDI MDI 

Oligomers

Amine Catalysts

Blowing Agent

4 no no no na5 no no no na

no no

Survey 

No.

Airborne SPF Compounds Identified in 

Truck Trailer

1 no no3 Yes na

(13 ug/m

3

)

yes (11 ppb) 

yes (1 ppm) yes (31 ppm

Yes (1 ug/m

3) 

Yes (73 ppb)

2 no
POST-SPRAY SAMPLE RESULTS
POST-SPRAY SAMPLE RESULTS

MDI

62 non-detect

Two samples - 5 ug/m3

(from two different surveys)

MDI Oligomers

All non-detect (64 samples)

Amine Catalysts

Identified in Survey #5 only

Blowing Agent

Identified in Survey #1
Post-Spray Relative Airborne Amine Catalyst Concentrations - 

Survey #5

0

0.20.40.60.8

1

0 20 40 60 80 100 120 

Time (minutes)

Fraction of Original
Post-Spray Airborne Blowing Agent Concentrations - Survey 

0

50

100150200250300

0 20 40 60 80 100 120 

Time (minutes)

Concentration (ppm)

2nd Floor 1st Floor Basement

OEL 300 ppm
PERSONAL PROTECTIVE EQUIPMEN
PPE - APPLICATORS

Category of 

PPE

Types of PPE Observed

Hood-type supplied air respiratorFull-face supplied air respiratorHalf-face air purifying respirator (APR) with combination organic vapor/particulate cartridges

Eye Protection

Safety glasses with side shields (where full-face or hood-type respirators were not used)Fabric glovesCoated fabric glovesDisposable coveralls (Kleenguard®, Komfortguard®, 

Tyvek®)

Disposable jacket (Komfortguard®)

Street clothes onlyFabric head/neck coveringDisposable overbootsMake-shift faceshield (overhead transparency material attached to head covering)

OtherRespiratorGlovesClothing
PPE - HELPERS

Category of 

PPE

Types of PPE Observed

Half-face APR with combination organic vapor/particulate cartridgesHalf-face APR with organic vapor cartridgesSafety glasses with side shields NoneDisposable nitrile glovesNoneDisposable coveralls (Komfortguard®)

Street clothes only (short or long-sleeve shirts, panor shorts, athletic shoes or boots) Disposable overbootsMake-shift faceshield (overhead transparency material attached to a hardhat)

OtherRespiratorEye ProtectionGlovesClothing
SUMMARY OF FINDINGS

o Airborne concentrations of MDI exceeded the 8

-hour and 

OELs for applicators for the majority of the surveys. 

Airborne concentrations of MDI exceeded the 8

-hour OEL

helpers only when they conducted some amount of sprayithe work shift. 

Similar results were seen for MDI oligomers (when compa

against the MDI OEL).

o Airborne concentrations of blowing agent did not exceed t

applicators or helpers.

o Airborne amine catalysts were identified for applicators an

Variable concentrations 

- likely due to the different types 

of catalysts in the SPF formulations, and differences in the of the application/job site.
SUMMARY OF FINDINGS

o Airborne concentrations of MDI exceeded the 8

-hour and 

OELs at distances up to 20 feet from the applicator in som

Similar results were seen for MDI oligomers (when compa

against the MDI OEL). 

The MDI concentrations generally displayed a decrease w

distance.

o Airborne amine catalysts were identified at up to 30 feet f

applicator in some surveys. 

The concentrations generally did not display a particular t

distance from the applicator. 
SUMMARY OF FINDINGS

o Airborne blowing agent was identified at up to 30 feet fro

applicator in both closed cell surveys, however the levels wexcess of the OEL. 

The concentrations remained largely unchanged with dista

the applicator.

o Migration of airborne MDI, MDI oligomers, and amine cata

lower floors was observed in some surveys, however airboconcentrations were not in excess of the OELs on those floidentified.

o Some upward and/or downward migration of blowing age

observed in both closed cell surveys, however airborne concentrations were not in excess of the OEL on those floidentified.
SUMMARY OF FINDINGS

o With two exceptions, airborne MDI was not detected in an

spray sample, beginning as soon as 15 minutes following completion of spraying. 

Where identified, the levels were an order of magnitude lo

the 8

-hour OEL. 

Airborne MDI oligomers were not detected in any post

-sp

samples.

o Airborne blowing agent was identified in post

-spray samp

concentrations generally declined with time, but blowing astill present in the final samples that were collected appro2.5 hours following the end of spraying. 

None of the samples exceeded the 8

-hour OEL, however.
SUMMARY OF FINDINGS

o Airborne amine catalysts were identified in post

-spray sam

only one of the five surveys; concentrations generally dectime, but catalysts were still present in the final samples tcollected approximately 2.5 hours following the end of spr

The types and levels of amine catalysts in the SPF formula

applied during this survey were different than the other su

Also, largest amount of foam applied per area.

o Low airborne concentrations of MDI, MDI oligomers, amin

and/or blowing agent were identified in the truck trailer in surveys.
RECOMMENDATIONS

o Respiratory protection is required not only for the applicato

for helpers working on the same floor as the applicator. 

o The following respiratory protection is recommended for bo

applicators and helpers. 

 A full

-face or hood

-type supplied air respirator operated 

positive pressure or continuous flow mode.
RECOMMENDATIONS

o Respiratory protection is also recommended....

 during trimming of SPF, which may release amine cata

the air, 

 during other post

-spray activities in the area where sp

protect against residual airborne SPF compounds. 

o The recommended full

-face or hood

-type supplied air resp

should provide adequate respiratory protection for most apenvironments, and should also protect the eyes from aerosvapors, particularly amine catalyst vapors, some of which chazy/halo vision.
RECOMMENDATIONS

o For protection against accidental sprays of reacting foam, 

contact with aerosols, the applicator should also wear... 

 a disposable coverall (e.g., Tyvek

®

, Kleenguard

®) with 

hood; see

-through materials provide less of a barrier

 disposable boot covers fabric gloves that are fully coated (front and back) in 

such as nitrile, neoprene, or butyl. The fabric componprovide some degree of thermal resistance, while the should prevent the reacting foam from penetrating to 

o Helpers working on the same floor as the applicator shoul

same personal protective clothing 

- boot covers may not b

necessary.
RECOMMENDATIONS

o The equipment in the truck trailer, particularly the connec

should regularly be checked and tightened/secured if nece

Also, leaks should be promptly cleaned up. These measu

help reduce truck trailer airborne concentrations.
RECOMMENDATIONS

o Following installation of SPF, the structure should be vent

either by...

 opening windows and/or doors on opposite sides of th

structure, or 

 by placing fans in windows and/or doors to introduce 

side of the structure and exhaust it at the other 

Objective is to enhance the air exchange rate to flush the 

SPF compounds from the space. 

The amount of time that ventilation should be conducted 

depending on the SPF formulation, size of the space, quaninstalled, ventilation rate, air mixing, etc.