### Thank You To Our Sponsor

# The New Era of Spray Polyurethane Foam – 

# Leading the Way in Product Stewardship

## Energy Efficiency and the Story of

Spray Polyurethane Foam

• My Story...How I Got Into Spray Foam
• Key Product Benefits, e.g.,

– Retrofitting,

– Energy Efficiency

– Renewable Content
• How I’ve Seen Spray Foam Grow in the Past Few Years

## But It’s Not Just My Experience Talking...
• Home Improvement (Renovation) is Up.
• Increased Interest in Energy Savings, particularly in the Commercial Sector
• Green building programs
• Energy tax credits / stimulus funds

## Let’s Look At What The Data Shows... US Production of Spray Foam (Mlbs) 2004 2006 2008 Residential Wall Insulation (Open Cell) 30 55 70 Residential Wall Insulation ( Closed Cell) 15 20 45 Commercial Wall Insulation* 20 20 75 Residential Roofing 5 10 15 Commercial Roofing 100 110 110 Industrial Insulation 40 45 50 Total 2K SPF for Insulation 210 260 365 DIY OCF ( Foam in a can) 45 53 55 Total 255 313 420 * inc agricultural and military structures ** excludes some non insulation uses0 20,000 40,000 60,000 80,000 100,000 120,000 140,000 160,000 180,000 200,000

0 500,000 1,000,000 1,500,000 2,000,000 2,500,000 3,000,000

2002 2003 2004 2005 2006 2007 2008 Refurbishment spend (million US $) Home Starts US Home Starts vs. Renovation & Maintenance and Remodelling Spend 2002-2008

Home Starts R & M Remodelling 

## Trends in the US Housing Market

### So Why Are We Here Today...

• Rapid growth of SPF brings with it need for increased outreach and communications on safe use and handling. • That’s why we are pleased to have launched our industry product stewardship initiative on spray foam. • And, we are even more please to be working together with our federal agency colleagues to make these activities a success.

### Today’s Session Format

• Structure for Session:

– Two Panel Sessions and One Presentation

– Panel 1: Federal Agency Panel • Moderator: Bill Hanson, U.S. EPA

– Presentation • Neeva- Gayle Candelori, CPI • Kurt Riesenberg, SPFA

– Panel 2: Joint Industry/Agency Panel • Moderator: Jim Chapman, Bayer MaterialScience LLC

– Closing Remarks There will be ample time throughout the session for Q&A.

### Today’s Session Content


## • Key Topics to be Covered:

– Research



### – Effective Workplace Practices

– Marketing Claims

– Hazard Communications



### – Outreach and Communications10 

# Issues and Challenges Related to the Safe Use of 

# Spray Polyurethane Foam (SPF) Insulation Polyurethanes 2009 Technical Conference EPA, NIOSH, OSHA, CPSC in cooperation with ACC-CPI and SPFA

October 6, 200911



### Federal Panel Participants

 Bill Hanson, Co- Moderator, Environmental Protection Agency • Introduction and Setting the Stage  Mary Cushmac, Environmental Protection Agency • Brief Overview of Concerns  Treye Thomas, Consumer Product Safety Commission • Assessing Health Risks in Consumer Products  Janet Carter, Occupations Safety & Health Administration • An OSHA Perspective on Employer Responsibilities  Daniel Almaguer, National Institute for Occupational Safety and Health • Spray Polyurethane Processes12 

## Green Building Benefits of SPF  

### EPA Green Building Objective • Promote effective green building practices and products  

### Why SPF is valuable: • An important tool to help achieve energy efficiency goals • Excellent insulation and air leak sealant13 

## Why Is the Federal Workgroup

Concerned?  SPF components are hazardous • Side A: Diisocyanates • Side B: Amine catalysts, flame retardants and blowing agents  SPF application in buildings requires safe practices for workers and occupants; consistent application  Consumers need information on safe practices  Residential DIY spray foam poses special challenges  Marketing should fully inform consumers of SPF attributes without misleading claims.14 

### Advertising and Marketing Claims
 “No off -gassing”, “non -toxic”, “safe”...foam  “green” and “environmentally friendly”  ...”is plant

- based”  “Made from soy beans”  Little is revealed about isocyanates, or anything toxic in the foam  Marketers not aware of components  TV programs showing improper protection  Videos showing untrained usage15



## Collaboration to Date  

## Discussed issues with Industry (CPI and SPFA et al.) – June 25, 2009  

## Industry response :  Letter to Federal Workgroup with details of planned enhanced product stewardship activities Tier 1 and Tier 2 activities Arranged site visits for EPA, NIOSH, OSHA  Invitation for EPA, NIOSH, OSHA, CPSC participation in special session on SPF insulation issues at Polyurethanes 2009 Technical Conference, October 6

.16 

## Product Stewardship Goals 1. 

### Improve availability of accurate and 

### comprehensive hazard & risk information 2. 

### Develop and communicate improved “ Best Practices” to prevent exposures 3. 

### Address and eliminate inaccurate or misleading marketing claims 4. 

### Conduct research to address exposure assessment and data gaps17 

## Key Challenges Going Forward  How to quickly communicate hazard /safety information to workers and occupants? • ACC-CPI and SPFA have developed important “Tier 1” information that is ready for outreach and adoption. • Industry and government outreach is essential.  How can practices be enhanced to improve protection? • Role of engineering controls and ventilation • Potential value of SPF worksite management plans? • Occupant re-entry considerations?  How do we protect DIYs?  How to augment health and safety training? • Value of applicator certification  How do we mutually address research needs?18 

# Overview of EPA Interests in Spray Polyurethane Foam Special Session on SPF Insulation Health & Safety, Product Stewardship 2009 Polyurethanes Conference October 6, 2009 Mary Cushmac Office of Pollution Prevention and Toxics U.S. Environmental Protection Agency19 

## Interest with SPF Insulation (SPFI)  

### SPFI is similar to spray- on truck bed liner (TBL) operations, the subject of the 2006 NIOSH Alert on spray application of MDI - based isocyanates.  Side A is the same, i.e., MDI - based isocyanates.  Isocyanate vapors and aerosols are generated.  Studies show isocyanates exceed occupational exposure limits in both operations.  Workers need to wear the same personal protective equipment (supplied air respirators, eye protection, and chemical - resistant gloves/clothing).20 

## Interests with SPF Insulation (con’t)  

### However, for SPFI:  Hazard communication and training may be inadequate.  Aerosols and vapors may migrate to other floors.  Dust from trimming operations may contain isocyanates, especially if the foam is not fully cured.  Guidance is needed on ventilation, exposure controls, clean up, and a safe re - entry time.  

### A focus on energy efficiency may spur 

### widespread use of SPFI in schools and homes.  

### Therefore , we need to ensure that SPFI operations are carried out in a safe and 

### healthful manner.21 

# Health Concerns for Isocyanates  Isocyanates cause asthma and are reported to be the leading attributable cause of work- related asthma.  Isocyanates are potent lung and skin sensitizers (allergens), irritants, and can trigger severe or fatal asthma attacks in sensitized persons at low levels.  NIOSH issued Alerts in 1996 and 2006 to warn workers about exposures to isocyanates to prevent asthma & death.  The European Union has issued new regulations for consumer products containing MDI.22 

## Hazard Communication and the Consumer Right-to - Know  Many applicators, DIYs, consumers, homeowners, and decision makers are unaware of the potential hazards.  Some marketing information is misleading – focuses on “green” aspects and does not address potential hazards.  EPA has compared Material Safety Data Sheets and found that the health and safety information for MDI - based isocyanates (Side A) is not consistent among distributers of SPF insulation.  Therefore , we need to ensure  Accurate and comprehensive health and safety information, and  Effective hazard communication throughout the value chain.23



## Best Practices Approach EPA Design for the Environment (DfE) Automotive Refinishing Partnership  

### EPA initiative designed to reduce exposures to isocyanates during spray painting by identifying and promoting best practices.  

### A successful government/industry partnership.  

### DVD with testimonies from NASCAR star and industry on best practices.  

### Model for SPFI approach. www.epa.gov/dfe/pubs/projects/auto www.epa.gov/collisionrepair24



## Key Objectives  Accurate and comprehensive hazard communication throughout the product value chain.  Accurate marketing claims.  Best Practices as standard operating procedures to prevent exposures to isocyanates.  Accurate exposure assessment of different applications & product formulations  Measuring total isocyanates  Answering the question – When is it safe for occupants, residents, and school children to re enter the premises after SPFI application?

## Assessing Health Risks in Consumer

Products Treye A. Thomas, Ph.D. Office of Hazard Identification and Reduction U.S. Consumer Product Safety Commission

The views expressed in this presentation are those of the CPSC staff, have not been reviewed or approved by, and may not necessarily reflect the views of the Commission.

# Who is CPSC?

• The U.S. Consumer Product Safety Commission is an independent regulatory agency created in 1973.
• Mission: To protect the public from unreasonable risk of injury and death associated with consumer products.
• Jurisdiction includes thousands of different types of products sold to consumers for personal use in or around the household or school and in recreation.

– Toys, electronic equipment, appliances, clothing/textiles, household cleaners/chemicals, and building materials

# Regulatory Authority
• Consumer Product Safety Act (CPSA), 15 U.S.C. § 2051 -2084 • Federal Hazardous Substances Act 

### (FHSA), 15 U.S.C. § 1261 - 1278 • Consumer Product Safety Improvement 

### Act of 2008 (CPSIA)

# Definitions of Toxicity

• CPSC regulates many chemical hazards under the Federal Hazardous Substances Act (FHSA) (15 U.S.C. 1261 - 1278)
• Under the FHSA, the term "hazardous substance" is defined as: “Any substance or mixture of substances which (i) is toxic, (ii) is corrosive, (iii) is an irritant, (iv) is a strong sensitizer, (v) is flammable or combustible, or (vi) generates pressure through decomposition, heat, or other means, if such substance or mixture of substances may cause substantial personal injury or substantial illness during or as a proximate result of any customary or reasonably foreseeable handling or use, including reasonably foreseeable ingestion by children."

## Federal Hazardous Substances Act
• Risk- based • Includes acute and chronic effects • Reliable human data preferred • Does not require pre - market approval • Manufacturers ensure that their products are not hazardous & are properly labeled • Hazardous children’s products are banned • Manufacturers must report “substantial product hazards” (CPSA)

# Risk Assessment Paradigm

• Hazard Identification

– Is it toxic? • Dose Response Assessment

– How toxic is it?

– What is the acceptable daily intake (ADI)? • Exposure Assessment

– How much contacts your body? • Risk Characterization

– Does the intake exceed the ADI?

## Chronic Hazard Guidelines (CHG)

• In 1992, the Commission issued guidelines for assessing chronic hazards under the FHSA
• Provides guidance on

– Determining toxicity (e.g., carcinogenicity, neurotoxicity, bioavailability)

– Acceptable Daily Intake (ADI)

– Threshold for uptake into body

– Assessing exposure

– Risk assessment approaches and acceptable risk
• Intended to assist manufacturers in complying with the FHSA

# Options
• Labeling 

### • Product Recalls • Product Bans 

### • Voluntary Standards • Mandatory Standards • Other

# Contact Information CPSC Website - www.cpsc.gov Questions - tthomas@cpsc.govJanet Carter Health Scientist Directorate of Standards and Guidance Polyurethanes 2009 Technical Conference 6 October 2009 

## Considerations for 

## Applications Using Spray Polyurethane Foam Insulation: An OSHA Perspective

# Discussion Outline • OSHA roles and responsibilities 

### • Concerns with SPFI • Employer responsibilities

– Communications

– Training

– Exposure control and PPE

– Ventilation 

### • Summary/Concluding Remarks

## OSHA’s Role and Responsibilities • Agency Mission – “assure safe and 

### healthful working conditions for working men and women”

– Safety and Health Standards

– Enforcement of Standards

– State assistance

– Provide research, training, education, information

# Concerns with SPFI
• Isocyanates have been reported to be the leading attributable chemical cause of workrelated asthma (WRA)

– Other health effects attributed to isocyanate exposure 

### • Information may not be reaching all users across the entire value chain • Inconsistent worker protection

# Employer Responsibilities
• Hazard Communications 

### • Train workers • Appropriate Exposure Control System 

### • PPE for ALL exposed workers • Ventilation

# Hazard Communications MSDS – current deficiencies and inconsistencies

– Hazard and exposure control information varies widely.

– Recommendations on respiratory protection vary.

– Only a few MSDSs mention the possible need for respiratory protection for “adjacent workers.”

– MSDSs indicate that adequate ventilation is needed but provide no guidance or suggestions on ventilation methods or what constitutes adequate ventilation.

– Few MSDSs mention that skin contact may cause an allergic reaction/sensitization.

– Several MSDSs mention that dust can be generated during cutting or abrasive processes, however, hazards are identified as “mechanical irritation” and do not mention the possible presence of MDI.

# Hazard Communications MSDS – more complete information

– Identify known hazards and exposure routes • Includes skin and other relevant health effects beyond asthma

– Identify appropriate first- aid and medical measures

– Identify appropriate exposure controls and PPE (skin and respiratory)

– Address need for adequate ventilation • Includes use of filters (bed - liner guidance) • Generation of dust – may contain isocyanates

# New Communication Rule • Current - Hazard Communication – 29 CFR 1910.1200 (general industry)

– Others apply for construction; maritime; long shore • New - Global Harmonization System (GHS)

– Proposed rulemaking • For MSDS

– ANSI 400 standard

– 16 Section format » Already in use with current standard

– Comment period ends December 29

– Announcement for public hearings soon

# Training • Employers need to train workers on:

– Hazards associated with use of ALL hazardous chemicals including Isocyanates

– Proper control measures

– Proper use of PPE

– Protecting those in adjacent areas

– Appropriate ventilation

# Appropriate Exposure Control
• Exposures should be controlled whenever possible

– PPE should be last resort • Primary worker (spray applicator):

– Full saran - coated body cover (no exposed skin)

– Gloves

– Appropriate respirator with full face mask • Helpers (need to evaluate on case - by- case basis)

– Full skin protection and gloves (no skin exposed)

– Full face mask

# Ventilation Considerations
• Ventilation crucial for worker safety 

### • Only vent to outside using approved filter

– Protect workers or passer- by’s outside

– Similar to booths used in truck bed - liner industry

## Summary/Concluding Remarks
• Communication is key to safe use and handling of SPFI • OSHA issued publications in alliance with API for Truck Bed - liners:

– “ Spray on Truck Bed Liner Applications Using MDI/PMDI; Seven Important Points” and “ Considerations for the Application of Spray-On Truck Bed Liners TBL”

– Developed for employers, the document includes information on how to recognize MDI - related hazards and reduce employees' exposure to MDI

– Similar hazards

– Similar remedies

# Additional Information
• OSHA assistance

– OSHA has free consultation program • Small and medium sized businesses

– All 50 states participate

– “Full service consultation" • Covers all working conditions, includes assistance in establishing effective workplace safety and health programs, with emphasis on preventing worker injuries and illnesses. Assistance may also include training and education for the employer and his or her employees and supervisors as well.

– “Limited service consultation” • Consultant focuses on more specific workplace problems or specific issues or hazardous processes relating to a particular business

– Information available on website: www.osha.gov

# Spray Polyurethane Processes

Daniel Almaguer, M.S. M. Kathleen Ernst Disclaimer: The findings and conclusions in this presentation are those of the authors 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 workrelated illness, injury, disability, and death.

# DART - EPHB Division of Applied Research & Technology (DART) Engineering & Physical Hazards Branch (EPHB)  Conduct research on engineering controls (e.g. ventilation) to reduce exposures to hazardous agents.  Engineers, Industrial Hygienists  Identify, evaluate, design and disseminate information on engineering controls.

## Methylenebis(phenyl isocyanate)

MDI Health Effects  Result from inhalation and skin exposures. 

###  Irritation and Lung Injury  Respiratory Sensitization  Dermal Sensitization  Acute exposure for some sensitized individuals may prove fatal (Feb. 2003).

## NIOSH Truck Bed -Liner (TBL) Alert - 2006 Contains Recommendations for:  Workers  Employers  Future Research  Engineering controls  Exposure monitoring  Respiratory protection  Medical monitoring  Surveillance  Decontamination

# Why NIOSH issued TBL Alert
 Reports of occupational asthma
– detailed in Alert.  Isocyanates
– are the leading attributable chemical cause of occupational asthma in the United States.  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  Conducted 4 Spray Polyurethane Foam Insulation (SPFI) site visits.  Conducted a comprehensive study of the spray polyurethane TBL process.  Conducted a review of industry information on the SPFI process. 

###  Presentation of what we know about the similarities between the TBL and SPFI spray polyurethane processes.

## SPFI and TBL Process Similarities
 SPFI process is essentially the same process outlined in the 2006 NIOSH TBL ALERT.  Spray polyurethane processes use isocyanates.  A- side and B - side: same chemicals  Same equipment: proportioning units, hoses, spray guns.  Similar airborne concentrations - exceed the applicable occupational exposure criteria.  SPFI industry should follow recommendations detailed in TBL Alert.

# TBL and SPFI Process Two Part Chemical Application  Part A
– Isocyanate  MDI  pMDI  Part B
– Polyol Resin  Amine catalyst  SPF has a blowing agent  Fire retardant Applied using hand -held pressurized spray gun system

## Industrial Hygiene

Hierarchy of controls  Elimination  Substitution
– replace high hazard with low hazard 

###  Engineering
– ventilation, enclosure  Protective Clothing and Equipment
– 

### respirators, ear plugs, gloves  Administrative
– training, procedures, policy

## SPFI and TBL Recommendations
 Wear Personal Protective Equipment (PPE).  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 SPFI sites

Implementation Gap  Studies
– worker exposures exceed the OELs.  Studies
– appropriate PPE not consistently used.  SAR consistently used by sprayers at all NIOSH 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.  Gap between what we know and what workers do.

# Sources of OS&H Information
 NIOSH Website: www.cdc.gov/NIOSH 

###  NIOSH 800 Number -- 1 - 800- CDC -INFO  OSHA Website: www.osha.gov  Manufacturers or Product Distributors  Center for the Polyurethanes Industry website
– www.polyurethane.org
– many 

### publications on MDI and other isocyanates.

# Contact Information Daniel Almaguer, MS NIOSH Division of Applied Research and Technology Engineering and Physical Hazards Branch 4676 Columbia Parkway, Mailstop R-5 Cincinnati, Ohio 45226 Phone: (513) 841 -4221 FAX: (513) 841 -4506

## CPI -SPFA Enhanced Product

Stewardship Program Neeva- Gayle Candelori, CPI Kurt Riesenberg, SPFA

### Overview

• Who are CPI and SPFA?


### • Product Stewardship History
• 2009 Enhanced Product Stewardship Program

### Who is CPI

CPI is part of the ACC, the largest trade association 

### for the chemical industry, and its Plastics Division, the lead organization for plastics resin producers

### Who Is SPFA? 

## Spray Polyurethane Foam Alliance is the voice and educational and technical resource for the spray polyurethane foam industry.

### Product Stewardship History

• Guidance documents / videos
• Training programs
• RCAP
• Truck Bed Liners 67

### Truck Bed Liner Program

• Multi -year project, included alliances with OSHA Regions IV, V, and VI. • Alliances focused exclusively on use of MDI in spray- on truck bed liner applications. • Resulted in extensive training programs and guidance materials.

– Joint CPI/OSHA Training Seminars

– Website

– Guidance documents

– Speaking engagements

– Trade Shows

– Video

### SPF Health and Safety Website www.spraypolyurethane.com

### SPF Posters

### SPF Guidance Documents

### Video: Safe Handing of MDI

### Educational Outreach

• Site Visits - SPF Contractor Site Visits (4) / Systems House Site Visit (1)

– Open cell vs. closed cell

– Residential (new construction/renovation) vs. Commercial

– Trimming, ventilation, dust and exposure techniques • CPI - SPFA Workgroups

## Panel 2: Overview  Overview of MDI Industrial Hygiene Data 

###  Effective Work Practices  Hazard Communications / Marketing Claims  Training / Certification

### Review of Available MDI Industrial Hygiene Data

• Mark Spence, Spence Consulting


### • Dan Almaguer, NIOSH
• Brian Karlovich, Bayer MaterialScience

# Overview of MDI



# Industrial Hygiene Data Mark Spence, Spence Consulting77



## Spray Foam Worker Exposures

• 10 studies, 240 + task and shift samples MDI Conc. ( g/m3) All samples 8 - h TWA Applicators 5 - 2100 10 - 460 Helpers 0.1 - 408 1 - 308 Exposure Guidelines 200 (ceiling) OSHA PEL 51

TLV®

## Spray Foam Worker MDI Exposures
• Spray foam application - highest worker MDI exposure potential of any MDI use

– Second only to vehicle spray painting for highest worker exposure potential to diisocyanates


### • Both Applicator and Helper have potential for exposure above OELs

## Spray Foam Worker

MDI Exposures (con’t)
• Applicator levels 2 -4 x Helper levels • Both roles: highly variable results

– Indoor higher; Outdoor more variable

– Factors causing variability: • Natural ventilation • Atmospheric and seasonal conditions • Building characteristics • Surface area and thickness of foam sprayed • Applicator’s experience level80



## Conclusions & Suggestions

• Spray Foam Worker MDI Exposures well documented

– Good IH program important for exposure control

– Measures for controlling MDI exposures would typically be expected to be adequate to control exposure to other formulation components (e.g., blowing agents, amine catalysts)

– Research suggestion: develop further data on worker exposures to other formulation components • Exposure Monitoring

– Impinger- based sampling method most definitive

– Filter- based sampling methods more practical

– Research suggestion: develop data to use filter method with correction factor(s) • Exposure Control

– Work practices, work zones, clearance time: good operating discipline

– Research suggestion: develop data / procedures for work zone and clearance time determination

# Spray Polyurethane Processes

Daniel Almaguer, M.S. M. Kathleen Ernst Disclaimer: The findings and conclusions in this presentation are those of the authors 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.

## Lesage et al (2007)
 Five residential SPFI sites 

###  Two-component spray foam  Personal impinger samples  MDI ranged up to 2.1 mg/m3 

###  9/13 exceeded OSHA PEL
 NIOSH REL = 0.2 mg/m3 ; 10-min. ceiling

= 0. 05 mg/m3 ; 8 - 10 hour TWA  OSHA PEL = 0.2 mg/m3 ; 15 -min. ceiling

## Lesage et al (2007)
 Area samples: 1 - 3; 3 - 6; 6- 12 meters from spray  Average monomer concentration above PEL at distances less than the 6- 12m range.  Post spray
– most below limit of quantitation  MDI concentration rapidly decreases after spraying.  15 -minute highest = 0.019 mg/m3  MDI detected up to 45 -minute after application.  1 to 24-hours after application - below the LOQ.
 NIOSH REL = 0.2 mg/m3 ; 10-min. ceiling

= 0. 05 mg/m3 ; 8 - 10 hour TWA  OSHA PEL = 0.2 mg/m3 ; 15 -min. ceiling

## Lesage et al (2007)
 Particle size  20% spray foam respirable 

###  HCFC
– 141b
– blowing agent  Below the AIHA WEEL 

###  Surface wipe sampling for MDI  Positive on freshly applied foam  15 minutes after application - negative

# IRSST (2009)
 Institut de recherche Robert- Sauvé en santé et en sécurité du travail (IRSST)
– The Quebec Institute for Occupational Safety and Health Research  20 SPFI sites
– wide variety of applications  Residential and Commercial  Indoor and outdoor  Winter and summer resins  Area impinger samples for MDI  Document Safety and Health practices

## IRSST (2009)

MDI Concentrations  Spray zone
– MDI ranged up to 0.591 mg/m3  Outside spray zone:  Helpers – MDI ranged up to 0.170 mg/m3  Workers nearby – MDI ranged up to 0.011 mg/m3

 NIOSH REL = 0.2 mg/m3 ; 10-min. ceiling

= 0. 05 mg/m3 ; 8 - 10 hour TWA  OSHA PEL = 0.2 mg/m3 ; 15 -min. ceiling

## IRSST (2009)

PPE usage  Only 1/19 sprayers wore full-face supplied- air respirator  None of the helpers wore full-face SAR  10 wore no respiratory protection  2/19 sprayers wore appropriate coveralls with hood  1/19 helpers wore appropriate coveralls with hood

# Overview of MDI

Industrial Hygiene Data Brian Karlovich, Bayer MaterialScience LLC

## Spray Foam Worker

MDI Exposures (con’t) Five air monitoring surveys conducted by BMS:  Pittsburgh, PA area 2007 - 08  Four during summer months, one during winter  New town houses undergoing construction, and single -family homes being renovated  Both open cell and closed cell foams installed

## Spray Foam Worker

MDI Exposures (con’t) Five surveys conducted (cont.):  Each structure three to four floors  Each survey – SPF applied to perimeter wall, partial perimeter wall, and/or underside of roof deck  Typically one or two windows and/or doors open somewhere in the structure  Typical SPF crew – one applicator and one to two helpers. Applicators and helpers sometimes switched roles.

## Spray Foam Worker

MDI Exposures (con’t) Purposes of Air Monitoring Study:  Evaluate potential worker exposures during SPF application  Evaluate potential migration of SPF compounds to adjoining floors  Evaluate airborne concentrations with distance from applicator  Evaluate airborne concentrations in truck trailer  Evaluate rate of decline of airborne concentrations following the end of spraying  Observe PPE use by SPF workers

## Spray Foam Worker

MDI Exposures (con’t) Survey No. 1 Survey No. 2 Survey No. 3 Survey No. 4 Survey No. 5 SPF Type Closed Cell (Formulation #1) Closed Cell (Formulation #1) Open Cell (Formulation #2) Open Cell (Formulation #2) Open Cell (Formulation #3) Structure Type SingleFamily Home SingleFamily Home Town House Town House SingleFamily Home Month Installed August December June August July

## Spray Foam Worker

MDI Exposures (con’t) Each study included:  personal air samples – short and long term  stationary area samples on each floor – to evaluate potential migration of SPF compounds to adjoining floors  mobile area samples to maintain prescribed distances from applicator  post- spray samples on each floor  area samples in truck trailer

## Spray Foam Worker

MDI Exposures (con’t)

## Spray Foam Worker

MDI Exposures (con’t)

## Spray Foam Worker

MDI Exposures (con’t)

## Spray Foam Worker

MDI Exposures (con’t)

## Spray Foam Worker

MDI Exposures (con’t) Migration of Airborne MDI

Where migration was observed, levels were well below the OEL.

## Spray Foam Worker

MDI Exposures (con’t) TRUCK TRAILER SAMPLE RESULTS

• MDI and PMDI identified in only one of five surveys.
• Levels well below occupational exposure limit.

## Spray Foam Worker

MDI Exposures (con’t) POST-SPRAY SAMPLE RESULTS MDI 62 non - detect Two samples - 5 ug/m 3 (OEL is 51 ug/m3) (from two different surveys) MDI Oligomers All non - detect (64 samples)

## Spray Foam Worker

MDI Exposures (con’t) OBSERVED PPE APPLICATORS • Supplied air or air purifying respirators in all cases. • Eye protection where 1⁄2 mask respirator used • Disposable coveralls in most cases • Fabric head/neck covering common • Various glove types HELPERS • Air purifying respirators in all cases. • Protection for eyes, hands, and/or body sometimes worn, other times not worn.

## Spray Foam Worker

MDI Exposures (con’t)

 LEARNINGS  Respiratory protection may be needed for both the applicator and for helpers working in close proximity to the applicator (e.g., on the same floor).  Consider the use of a full -face or hood -type supplied air respirator for both applicators and helpers  Respiratory protection may also be desirable  during trimming of SPF, pre - cure  during other time - proximate post- spray activities in the application area

## Spray Foam Worker

MDI Exposures (con’t)

 For protection against accidental sprays of reacting foam, as well as contact with aerosols, applicator can also wear...  a disposable coverall (e.g., Tyvek ® , Kleenguard ®) with attached hood  disposable boot covers  fabric gloves that are fully coated (front and back) in materials such as nitrile, neoprene, or butyl.  Helpers working near the spray foam application (e.g., on the same floor) may have the same exposures as applicators, and if so, the same personal protective clothing is appropriate (boot covers may not be necessary). LEARNINGS

## Spray Foam Worker

MDI Exposures (con’t)

 Ventilation of the structure during and after the installation can significantly reduce MDI exposures.
 Ventilation time will vary depending on the SPF formulation, size of the space, quantity of SPF installed, ventilation rate, air mixing, and other relevant factors. LEARNINGS

## Effective Workplace Practices

Materials Overview

### Effective Workplace Practices

• Dan Almaguer, NIOSH • Brian Karlovich, Bayer MaterialScience 

### • Jim Andersen, BASF Corporation • Bill Robert, BASF Corporation • Bob Duke, Carolina Comfort Foam

# Spray Polyurethane Processes

Daniel Almaguer, M.S. M. Kathleen Ernst Disclaimer: The findings and conclusions in this presentation are those of the authors 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.

# Challenges for SPP industries

 Develop engineering control strategies.  Protect all workers.  What controls do contractors currently use?  We did see some controls at SPFI sites
– best practices.  Explore ways to isolate (enclose) process.  Prevent migration of chemicals to other areas.  Explore strategies to ventilate enclosure.  Reduce airborne chemicals including MDI.  Air supply and exhaust needed.  Air movers were used at a few sites.  Exhaust to unoccupied location.  Determine appropriate time period to re- enter areas without PPE.  Dependent on ventilation rate.

### Seven Important Points for SPF

Contractors – Interior and Exterior Brian Karlovich, Bayer MaterialScience LLC
• Documents modified from an existing CPI Document: Spray On Truck Bed Liner Applications Using MDI/PMDI; Seven Important Points
• One document for interior applications and one for exterior, since applications and specific guidance are different

### Seven Important Points for SPF

Contractors – Interior and Exterior Brian Karlovich, Bayer MaterialScience LLC • Covers A- side only • Seven points include: 1. What is MDI? 2. Potential Health Hazards 3. Personal Protective Equipment 4. Respiratory Protection 5. Containing the Work Area/Ventilation 6. Completing the Job 7. Emergencies – Spills, Fires, etc.

### SPF Insulation Health & Safety Q&A – Interior and Exterior Brian Karlovich, Bayer MaterialScience LLC • One document for interior applications and one for exterior, since applications are different.
• Q&A format

• Covers both A- and B - side materials

### SPF Insulation Health & Safety Q&A – Interior and Exterior Brian Karlovich, Bayer MaterialScience LLC Q&A’s include... • What are the chemicals used in SPF?
• What are the potential health hazards of SPF chemicals?
• What PPE is appropriate for applicators?

### SPF Insulation Health & Safety Q&A – Interior and Exterior Brian Karlovich, Bayer MaterialScience LLC Q&A’s (cont.)
• What PPE is appropriate for helpers?
• What PPE is appropriate when handling liquid chemicals?
• What PPE is appropriate when handling cleaning solvents?

### SPF Insulation Health & Safety Q&A – Interior and Exterior Brian Karlovich, Bayer MaterialScience LLC Q&A’s (cont.)
• When to consider ventilation of the work area
• Typical first aid measures

### SPF Insulation Health & Safety Q&A – Interior and Exterior Brian Karlovich, Bayer MaterialScience LLC Q&A’s (cont.)
• Addressing spills
• Handling and disposition of empty drums
• Where to get more information

### SPF Insulation Health & Safety Q&A – Interior and Exterior Brian Karlovich, Bayer MaterialScience LLC Q&A’s (cont.) • What are some effective work practices to consider? Interior

– Request that the building be vacated

– If not feasible, use barrier tape and signage to discourage entrance to the spray area

– Shut down and seal off HVAC components

### SPF Insulation Health & Safety Q&A – Interior and Exterior Brian Karlovich, Bayer MaterialScience LLC • What are some effective work practices to follow? (cont.) Interior

– Avoiding spraying foam too thickly can help prevent possible fires

– Ventilating and prohibiting access by others for a period of time following installation can help reduce exposures

– Post signs that warn of the danger of exposing SPF to heat/flame, until the SPF can be covered

– Practice good housekeeping

### SPF Insulation Health & Safety Q&A – Interior and Exterior Brian Karlovich, Bayer MaterialScience LLC
• What are some effective work practices to consider? (cont.) Exterior

– Develop an Overspray Mitigation Plan • Discuss with building owner in advance • Relocate vehicles • Protect surfaces that could be damaged • Do not spray in higher winds • Use windscreens

### SPF Insulation Health & Safety Q&A – Interior and Exterior Brian Karlovich, Bayer MaterialScience LLC
• What are some effective work practices? (cont.) Exterior

– Shut down HVAC system and seal off air intakes

– Practice good housekeeping

## Good Safety Practices Posters Jim Andersen, BASF Foam Enterprises 

### • Posters available for download FREE! • Following Tasks:

– Drum Handling

– Gun Maintenance

– Equipment Storage

– Spill Containment

– Application

– PPE

## Exterior PPE Poster Bill Robert, BASF Corporation


### • PPE is Critical for this Job • Respiratory Protection • Eye Protection • Skin Protection

– Eyes

– Hands (gloves)

– Shoes / Booties 

### • MSDS’s

## Interior PPE Poster Bob Duke, Carolina Comfort Foam
• Simple, easy to read and reference. • Provides all personnel with a table of PPE needs. • Highlights need for Supplied Air in an indoor application. • Table provides guideline for all operating personnel.

## Marketing Claims Hazard Communications 

## Role of Supply Chain

### Marketing Claims/Hazard

Communications/Role of Supply Chain and Federal Government
• Monica Karamagi, Huntsman International LLC • Cynthia Graham, Huntsman International LLC 

### • Janet Carter, OSHA

### Marketing Claims

Monica Karamagi, Huntsman International LLC


### • Background • FTC and Enforcement • CPI/SPFA response • Tier 1 documents • Areas of Concern 

### • Example • Tier 2 activities

### Marketing Claims

Monica Karamagi, Huntsman International LLC


### • Areas of Interest: • Recycled Content • Non -toxic • Energy Efficiency

### Marketing Claims

Monica Karamagi, Huntsman International LLC

EXAMPLE OF A POOR CLAIM: • Spray Foam Product is marketed as “safe and non toxic” to consumer • HOWEVER – Product MSDS states product is hazardous • Claim implies product does not present any risks • Protective measures may not be taken EXAMPLE OF A BETTER CLAIM: • SPF liquid chemicals are hazardous during installation • Proper PPE is necessary. • Finished foam is non -toxic after 24 hours.

## Hazard Communications

Cynthia Graham, Huntsman International LLC 

## Employer Responsibility • Develop a written HazCom program • Provide a List of Hazardous Chemicals • Ensure Accessibility to MSDSs • Provide proper PPE for each job • Provide Employee Training

## Hazard Communications

Cynthia Graham, Huntsman International LLC 

## Worker Responsibility • Read the entire MSDS • Be knowledgeable of the chemicals you are using • Understand the hazards • Use the correct PPE • Be prepared in the event of an upset situation

# Training and Accreditation

Programs

### Training/Accreditation Programs

• Jim Andersen, BASF Corporation


### • Rick Duncan, SPFA
• Janet Carter, OSHA

### Industry Training Programs

Jim Andersen, BASF Foam Enterprises


### • There are two types of industry- offered training:

– Specific customer- supplier training programs, typically offered by the supplier.

– Trade - association offered training programs, typically offered by SPFA, CPI, NRCA, ICAA. Rick Duncan will follow me and discuss the later.

### Industry Training Programs

Jim Andersen, BASF Foam Enterprises
• Supplier- customer training programs

– Foam Mechanic and Materials Courses

– Qualified Applicator or Certified Applicator

– Consultant Training

– On the Job Training

– Little or no Union training specific to spray foam

### Industry Training Programs

Jim Andersen, BASF Foam Enterprises


## • Most programs -

– Teach basic safety requirements



### – Teach safety aspects of equipment

– Teach materials and how they are applied

### Industry Training Programs

Jim Andersen, BASF Foam Enterprises


### • Training also involves a hands on clinic work (e.g., “behind the gun,”) and demonstrations 

### • Equipment operation and trouble shooting • Product and Application Quality Control Checks

### Industry Training Programs

Jim Andersen, BASF Foam Enterprises

• There is generally a test • Courses may or may not be recognized as SPFA Accredited • Not every business owner, installer or worker participates in a formal training program • Most training is obtained when equipment is purchased and manuals are read

## SPFA Accreditation Training

• Developed and presented by supplier and contractor experts 

### • Offered annually at SPFA conference • Comprehensive test for each course tests understanding of course materials 

### • Select courses required for SPFA Accreditation

## SPFA Accreditation Training

• 101 - Fundamentals of Spray Polyurethane Foam Covers fundamentals of SPF chemistry, equipment and HSE topics. • 101 - R - Fundamentals of Spray Polyurethane Foam and Covering Systems Application of spray foam roofing and coatings. • 101 - BE - Fundamentals of Spray Polyurethane Foam and Covering Systems for the Building Envelope Applications of spray foam insulation in the building envelope • 101 - I - Fundamentals of Spray Polyurethane Foam and Covering Systems for the Independent Inspector Like Course 101 - R but directed towards the architect, roof inspector, specifier etc. • 201 - Project Management Provides tested and proven techniques for bringing a project in on -time and within budget. • 301 - Selling and Marketing Principles Sales strategy and modern selling, understanding buyer behavior, listening skills, identifying customer needs, and closing techniques. • R- 1 - Roofing Prerequisites for the SPF Industry Roofing practices and theory for ALL roofing systems other than SPF.

# Closing Remarks Bill Hansen, EPA Neeva - Gayle Candelori, CPI

# Fore more information, visit www.spraypolyurethane.com

Thank You!