**Daniel Almaguer**  **, M.S.** National Institute for Occupational Safety and Health (NIOSH) 

## Spray Polyurethane Processes

National Institute for Occupational Safety and Health (NIOSH)

Disclaimer: The findings and conclusions in this presentation are those of the author(s) and do not necessarily represent the views of the National Institute for Occupational Safety and Health (NIOSH). Mention of company names or products does not constitute endorsement by the Centers for Disease Control and Prevention (CDC) or NIOSH.

## Who is NIOSH?
 The National Institute for Occupational Safety and Health  Created under the OSHAct of 1970  **Mission**

– ensure safety and health at work for all people through research and prevention.  Responsible for conducting occupational safety and health research.  Education and Training.  To provide leadership in research to prevent work-related illness, injury, disability, and death.

## Division of Applied Research & Technology **Engineering & Physical Hazards Branch**  Engineers, Industrial Hygienists, Physicists, other disciplines.  Identify and evaluate occupational exposures  Develop and evaluate engineering controls for preventing or reducing exposures  Disseminate information on hazards, exposures, and control solutions to industry and professionals

## NIOSH Alert on Truck Bed **- Liners**  **Applicable to all SPF Operations** 

**Contains Recommendations for:**  **Workers**  **Employers**  **Future Research**  **Engineering controls**  **Exposure monitoring**  **Respiratory protection**  **Medical monitoring**   **Surveillance**  **Decontamination**

# Why NIOSH issued Alert

 Reports of occupational asthma

– detailed in NIOSH Alert.  Isocyanates
– cause occupational asthma.  Workers with asthmatic symptoms from isocyanate exposure often continue to have symptoms even after exposures have ended.  Affected workers often have to leave their jobs to prevent progression of respiratory symptoms.

## NIOSH Assessment of Spray **Polyurethane Products Industries**
 Comprehensive study of the spray polyurethane truck bed-liner (TBL) process (2003 -2006).  Preliminary assessment of the Spray Polyurethane Foam (SPF) insulation process - 4 sites (Aug. 2009).  Review of industry information on the SPF process.  **Concluded that based on the similarities --** **these tw** **o spray polyurethane processes (TBL and SPF) are essentially the same (i.e. same chemicals and**  **equipment).**

# Importance **of worker issues** 
 Worker exposures not always considered in developing “green” products and practices.  Workers/applicators generally have higher exposures compared to homeowners or consumers.  Controls and training to reduce worker exposures generally likely to reduce exposures for homeowners.  A truly comprehensive approach to sustainability and green practices needs to include occupational safety and health aspects.

## Industrial Hygiene

**Hierarchy of controls**  Elimination  Substitution

– replace high hazard with low hazard  Engineering

– ventilation, enclosure  Administrative

– training, job rotation, procedures, policy  Protective Clothing and Equipment

– respirators, ear plugs, gloves

# SPF Recommendations

 Hazard Communication  Wear Personal Protective Equipment (PPE) - sprayer and helper.  Full-Face Supplied-Air Respirator (SAR)  chemical protective clothing (i.e. disposable coveralls and gloves).  Limit access to spray area.  Only trained workers with proper PPE.  Isolate process to prevent chemical migration to other areas to ensure others are not exposed.  Provide adequate ventilation to remove chemicals.  Exhaust to unoccupied area.  Prevent access to exhaust area.  Do not re- enter spray area without appropriate PPE.  Need to determine appropriate time period.

## Use of PPE at SPF sites

**Implementation Gap**
 **Gap betw een**  **wh at**  **we kno** **w and w** **hat wo**  **rk ers**  **do.**  Studies

– worker exposures exceed the OELs.  Studies

– appropriate PPE not consistently used.  SAR consistently used by sprayers at all NIOSH SPFI walkSAR consistently used by sprayers at all SPFI walk thru sites.  Studies

– use of chemical protective clothing (coveralls, gloves, booties) by helpers was inconsistent.  Ensure consistent use of PPE throughout industry

– respiratory, eye and skin.

## Initial **Assessment of SPF**

 The industry has a wealth of information on spray polyurethane products.  Published studies indicate that the information is not consistently reaching the worker.  We need to work collaboratively to protect the health of the SPF workforce and the consumer/occupant.  Ensure that correct information gets to the workers.

# Challenges **for SPP industries**

 Develop engineering control strategies to protect all workers during all phases of the operations.  Preparation  Spraying  Trimming  Clean-up.  Controls need to be adaptable to a wide variety of applications and foam densities.  Indoor and outdoor  New construction and retrofits  Residential (attic retrofits)  Commercial  1⁄2-pound (low density), 2 -lb. (medium), and 3 -lb. (high) foams

# Challenges **for SPP industries**

 Develop strategies to isolate (enclose) process.  Prevent migration of chemicals to other areas.  Develop ventilation system for enclosures.  Reduce airborne chemicals including MDI.

airborne chemicals including  Air supply and exhaust needed.  Exhaust to unoccupied location.  Determine appropriate time(s) period to re- enter areas without PPE.  Dependent on ventilation rate.

## Potential **Controls used at SPF sites**

 Explore ways to isolate (enclose) process.  Used plastic sheeting to cover wall studs.  Used metal grating to control expansion of foam.  Potential advantages

– reduced chemical usage; chemical Potential advantages reduced chemical chemical vapors and aerosols likely trapped behind plastic film resulting in lower airborne chemical concentrations.

Panel system

# Controls **used at SPF sites**
 Use air movers to exchange air in the spray zone. Reduce airborne chemical concentrations. Air supply and exhaust needed.  Exhaust to unoccupied location.

# General **Guidelines**  Enclose the spray zone as much as possible  Supply air at one end of spray zone  Direct airflow past spray zone  Exhaust air at opposite end of spray zone  Create negative pressure within the enclosure

## Potential **Schematic of Enclosure**

Air Exhaust Air Supply SPF Sprayer Spray-zone



### Note: **this pr oposed enclosur** **e has not been tested.**  Tem porary Wall

– isolates (encloses) spray-zone Air Supply Fan
– located in window or door Air Exhaust Fan
–with filter, located in window or door
Spray zone

– must be under negative pressure to prevent chemical migration to adjacent work areas

# Moving**forward**
 Government/industry partners working together to comprehensively address worker, homeowner, consumer exposures associated with SPF  Practitioners need to be aware of potential hazards and solutions -- even for “green” products and technologies

# Contact **Information** Daniel Almaguer, M.S. NIOSH, Division of Applied Research and Technology, Engineering and Physical Hazards Branch 4676 Columbia Parkway, Mail Stop R- 5 Cincinnati, OH 45226 Phone: 513 - 841 -4232 Fax: 513 - 841 -4506 Email: dla3@cdc.gov