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 

two 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 between what we know and what workers do.

 Studies – worker exposures exceed the OELs.

 Studies – appropriate PPE not consistently used.

 SAR consistently SAR consistently used by sprayers at all used by sprayers at all NIOSH SPFI walk SPFI walkthru 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 airborne chemicals chemicals including including MDI.

 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 Potential advantages advantages – reduced reduced chemical chemical usage; 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 SPF Sprayer Air Supply

Spray-zone

Note: this proposed enclosure has not been tested.

Temporary 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