## Overview **of**

**Spray Polyurethane Foam Systems** 

**CPI -** **SPFA Do**  **- It**  **- Yourself**  **Workgroup**

December 1, 2009 Dial: 1 - 800 - 691 - 0264, Passcode : 273290 9:30 a.m. – 11:15 a.m. EDT2 

# Agenda

• Welcome & Introductions (Neeva - Gayle Candelori & Chris Bloom)

– Webinar Scope

– Webinar Goals
• Overview of SPF Systems (Mark Spence)

– Basic PU Chemistry

– Spray PU Foam Characteristics
• Worker Health & Safety with SPF Systems (Mark Spence)

– Worker Exposure Monitoring

– PPE Guidance

– Applicability to DIY Uses
• Summary & Conclusions (Mark Spence) • Discussion & Next Steps (Chris Bloom)

# DIY Work Group

• **DIY Work Group**

– **Brief Background**

– **Scope** 

## • **Key Objectives for Webinar**

# DIY Work Group

For purposes of the DIY Work Group, we are generally saying a

DIYer = Consumer
• **DIY Work Group Objective**

– To enhance the DIY users understanding of effective practices regarding the safe use and handling of SPF products. **Some Common Acronyms Defined:** OCF = One Component F oam 2KLP = T wo Component Low Pressure Kits 2KHP = T

wo Component High Pressure Systems

# DIY Work Group Scope

**2KHP Industrial**  **DIY W** **ork Group Scope**  **Professional Consumer** 
**OCF 2KLP** 

## DIY Work Group: **Scope Summary Scope**  **Summary :**  • **OCF products available to DIYers / Consumers** • **2KLP Kits available to both ‘professionals’ and DIYers / Consumers** 

**---------------------------------------------------------------------------** • **2KHP Systems**  **are not generally available (or marketed)**  **to DIYers / Consumers**

– **anecdotal information indicates that these systems are not being**  **obtained by DIYers**

## DIY Work Group: **Webinar Objectives**
• **Enhance understanding**  **of PU Chemistry** • **Provide a clear differentiation between**  **SPF product**  **ty pes**  **(with a focus on those available to**  **DIYers / consumers)**

– **Review Phys**  **- Chem**  **attributes**

– **Review some existing monitoring**  **information**

– **Review PPE guidance**  

### • **Clarify t**  **he potential ‘risk profile’ associated**  **with SPF products**  **available to DIYers / consumers**

# Overview **of SPF Systems**

## Basic PU Chemistry

• Polyurethane is formed by the mixing and reaction of two components:

– “A Side” – diisocyanates

– “B Side” – polyol blendBasic PU Chemistry

## “A side” **– Polymeric MDI (PMDI)** 

– A mixture of homologous compounds:

• 45 - 55% MDI monomer (n=0):

– 90+% 4,4’ - isomer
• 45 - 55% MDI oligomers (n=1,2,3...)

– 50% “tri - iso ” or “3 - ring” (n=1)

– 25% “4 - ring” (n=2)

– 12% “5 - ring” (n=3) Basic PU Chemistry

## MDI Properties **Property MDI Monomer**  **Poly meric MDI**  Melting Point ( ° C) 40 5 Boiling Point ( ° C) >300 >300 Va por Pressure (Pa) 6.2x10 -4 @ 20 ° C 3.1x10 -4 @ 20 ° C Saturated vapor conc. ( g/m3) 64 @ 20 ° C 32 @ 20 ° C Basic PU Chemistry

## “B side” **– Polyol**  **Blend**

• Properties of PU result from polyol structure, additives composition:

– Polyol (>60%) • (affects structure: e.g., linear vs. branching)

– Blowing agents • (low -boiling liquids, e.g., pentane, dimethyl ether, hydroflorocarbons; forms foam, determines foam characteristics)

– Fire retardants • (modifies fire characteristics of foam)

– Surfactants • (affects foam cell size, structure)

– Catalysts • (tertiary amine or organo-metallic; stabilize reactants & accelerate reaction) Basic PU Chemistry

## PU Terminology

• Cream Time – Mix of isocyanate & polyol (brown liquid) turns opaque tan (reaction begins)
• Tack -Free Time – Foam surface no longer sticky; second layer of foam can be applied
• Cure Time – Maximum foam physical properties achieved Basic PU Chemistry

## SPF System Characteristics

• Basic Categories:

– High - Pressure SPF systems • 2 - component systems



## – Low- Pressure SPF systems • 2 - component kits • 1 - component foam products

### 1 **- Component**  **vs. 2 -** **Component Sy** **stems**

• 2 - Component:

– Isocyanate and Polyol in separate containers

– Mixed 1:1 at time of application; 50% PMDI • 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** SPF Systems

# 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 only SPF Systems

## SPF Delivery Modes

• Spray

– 2 - component only, high & low pressure

– Product application: insulation, coating


### • Stream / Bead

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

– Product application: adhesive, sealant SPF Systems**SPF Systems**

# Worker **Health & Safety**

**with SPF Systems**

## Worker Exposure Monitoring

• Species monitored:

– MDI

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


## • Occupational Exposure Guidelines

– OSHA: 200 g/m 3 

### MDI (20 ppb; ceiling)

– ACGIH TLV® 

### : 51 g/m 3 

### MDI (5 ppb; 8 - h TWA) Exposure Monitoring

# Sampler Types

– Coated Filter

– Impinger

– Impinger + filter Exposure Monitoring

# Iso Check **Sampler** Exposure Monitoring

## High **- Pressure**  **Spray Foam Worker MDI Exposures**  **10 studies, 240 +**  **task and shift samples**



### MDI Conc. (mean [range]; g/m 3 

### ) All samples 8 - h TW A Applicators **577** [5 – 2100] 

### 320 [10 – 460] 

### Helpers **11 3**  [0.1 – 408] 

### 51 [1 – 308] 

### Exposure Guidelines 200 (ceiling)

OSHA PEL 51

TL V® Exposure Monitoring

## Low**- Pressure**  **Spray Foam Worker MDI Exposures**  **5 studies, 41 personal (task) samples, 68 area / source samples** 

***ND() = not detected @ (detection limit), 1⁄2 Detection Limit used for mean**



### MDI Conc. (mean [range]; 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 TW A) TL V® Exposure Monitoring

## 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) Exposure Monitoring

## Exposure Studies: **2 -** **Component Low** **- Pressure**  **Kits** Study 1: Residential Wall Insulation Application (spray)

• Method: Impinger

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

ype MDI 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 Exposure Monitoring

## 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/b ackup filter, Filter Sample Ty pe MDI 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 Exposure Monitoring

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

## 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 – 2.8 Exposure Monitoring

## 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 & oligomers Exposure Monitoring

## Study 3 Results (con’t) Sample Ty pe MDI g/m 3 ; **Mean** [range] n* #ND Personal - Applicator **5.7** [ND(6) - 13] [olig= ND(10)– 10] 6 5 Area, Kit 1: 1 - 3’

10 -20’ Adhesive: bead 1 [olig=10] ND(0.9) [olig=27] 1 1 0 1 Area, Kit 2: 1 - 3’

10 -20’ Single - use kit: spray ND(6)– 17 [olig=ND(6)–20] ND(1)– ND(6) [olig= ND(1)– ND(6)] 3 2 1 2 Area, Kit 3: 1 - 3’

10 -20’ Refillable kit: spray 6 - 8.4 [olig=ND(10)–50] ND(2)– ND(6) [olig= ND(1)–250] 2 2 0 2 Exposure Monitoring

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

## 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) Sample T

ype MDI 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 Exposure Monitoring

*n= # of samples; #ND = # of samples that were below limit of detection**PPE Guidance for Applicators and Helpers**

## Applicability to **Do -**  **It -** **Yourself Uses**
• Low- pressure products studied were:

– Representative of products for DIY use (2 - component single use kits)

– Representative of extreme - case DIY 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 DIY application.

## Summary & Conclusions

• 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 DIY audiences regarding use and handling techniques – to be addressed in Tier 2.

## DIY Work Group **:**

**Webinar Objectives (re -** **visited)**
• **Enhance understanding**  **of PU Chemistry** • **Provide a clear differentiation between**  **SPF product**  **ty pes**  **(with a focus on those available to**  **DIYers / consumers)**

– **Review Phys**  **- Chem**  **attributes**

– **Review some existing monitoring**  **information**

– **Review PPE guidance**  

### • **Clarify t**  **he potential ‘risk profile’ associated**  **with SPF products**  **available to DIYers / consumers**

### General Risk Profile Comparison **for**

**SPF DIY Products** 

PPE Sophistication Risk Po tential **OCF 2KLP**  **(bead) 2KLP** 

**(spray) Area of DIY WG**  **focus going**  **forward**

# Discussion