**CPI Draft**  **SPF Ventilation Research Proposal** 

**April ,**  **2011**



### 1 **Introduction** The purpose of this research is to evaluate the impact of changes in ventilation rates on the concentration of spray polyurethane foam ( SPF ) chemical vapor and particulates emitted during SPF application. Emissions from l ow density (1/2

- po und) , medium - density (2 - pound) high pressure SPF, and a low pressure, 2 component kit formulations will be evaluated. Chemical ingredients selected for evaluation represent those typically present in SPF formulations. Substances to be evaluated include:  Methylene diphenyl diisocyanate (MDI ),  Amine catalysts,  Blowing agents other than water  F lame retardants 

### 2 **Research Framework** The investigation will include 3 phases.  **Phase I:**  Spray foam equipment and experimental formulations will be evaluated at 4 industry laboratories .  **Phase II:** Air monitoring will be conducted in a fabricated spray room to measure chemical emission s during SPF applicatio n under controlled environmental conditions .  **Phase III:** Air monitoring will be conducted in the field, such as a medium -sized residential building, to measure chemical during SPF application . The investigations will be conducted under controlled conditions which include predetermined air exchange rate s measured as Air Changes per Hour (ACH), equipment pressure s, spray tips, and material temperature s . G eneral description s of the generic SPF formulations selected for this research project are included in Table 1:**CPI Draft**  **SPF Ventilation Research Proposal** 

**April ,**  **2011 Table 1 : Generic SPF Formulations**  **L ow**  **D ensity**  **(1/2 pound) High Pressure SPF Formulation**  **Medium D** **ens ity**  **(2 pound) High Pressure SPF Formulation**  **Low Pressure (**  **2 Component**  **) Kit**  **Formulation** A-side 100% MDI 100% MDI 92.5% MDI Blowing Agent 134a (7.5% ) B -side Polyether Polyol (34%) Aromatic Polyester Polyol (36. 39 %) Aromatic Amino Polyether P olyol (3 3.61 %) Polyester Polyol ( 23% ) Polyether Polyol ( 23% ) NPE Emulsifier (11.9%) Blowing agent W ater (20%) Blowing agent HFC- 245a (6 .97 %) Water (2.55 %) Blowing Agent 134a ( 17% ) Fire Retardant Tris- (1 - chloro - 2 - propyl) phosphate (TCPP) (25.2%) F ire Retardant Tris- (1 - chloro - 2 - propyl) phosphate TCPP (15.91 %) Fire Retardant Tris- (1 - chloro - 2 - propyl) phosphate TCPP ( 30% ) Silicone Surfactant (1.0) Silicone Surfactant (1.0) Silicone Surfactant ( 2% ) Catalyst Bis (2 - Dimethylaminoethyl) ether BDMAEE ( 0 . 9 %) Tetramethyliminobispropylamine (3.0%) N,N,N Trimethylaminoethylethanolamine (4 .0%) Catalyst Bis (2 - Dimethylaminoethyl) ether BDMAEE (0.7 %) Bis (dimethylaminopropyl) methylamine (2. 59 %) N,N,N Trimethylaminoethylethanolamine (0 . 3 %) Catalyst (5%) Pe ntamethyldiethylene triamine (ethylhexanoic, 2 -, potassium salt/ Oxybisethanol, 2,2’)**CPI Draft**  **SPF Ventilation Research Proposal** 

**April ,**  **2011** 

### 2.1 **Phase I** During Phase I, spray equipment and formulations will be tested to verify the consistency of results achieved with different formulations and equipment. Three member companies equipped with similar spray equipment will verify SPF formulations are suitable for spray application . A pplicators will spray selected formulations of 1⁄2 - pound , 2 - pound , and low pressure kits under the following conditions:

1. Ambient a ir temperature and relative humidity . 2. Samples will be applied using spray equipment suggested by the system manufacturer.  Manufacturer recommended pressure during spraying  System heated to the manufacturer recommended temperature 3. Samples will be sprayed w hile maintaining a 12 to 24 inch distance from the substraight being sprayed. 4. The spray substrate will consist of five (5) 2x6 inch studs, 7 feet in height, spaced 16 inches apart, providing 4 cavities lined with cardboard for SPF application. The total size of the spray structure will be approximately 5 ft x 7 ft. 5. The 4 cavities will be sprayed in one pass at a nominal thickness of:  2 in for medium density (2 lb) SPF  4 in for low density (1/2 pound) SPF.  4 in for low pressure kit SPF 5. T he amount of foa m used (lbs) and the densities of the foams sprayed will be recorded . 

### 2.2 **Phase II** During Phase II, p ersonal and area a ir monitoring will be conducted while three (3) SPF formulations are applied to test panels inside a spray room. T he spray room will be designed to meet the following specifications: 1. The dimensions of the spray room to be approximately 8 ft x 8ft x 8ft . M ake - up air is supplied to the room and it is exhausted though a n 8ft x 8ft filter bank on the opposite wall of the room . 2. A ventilation plenum downstream from the filter bank e nsure s an even distribution of air through the room. 3. The spray s ubstrate will consist of five (5) 2x6 inch studs, 7 feet in height, spa ced 16 inches apart, providing 4 cavities lined with cardboard for SPF app lica tion. The t otal size of the spray structure will be approximately 5 ft x 7 ft. An SPF applicator will spray the selected SPF 1⁄2 pound and 2.0 pound formulations using a Graco F usion Air Purge 01 round tip spray gun . Low pressure kit formulations will be s prayed using manufacturer supplied spray equipment. SPF will be applied under the following conditions:

1. Ambient air temperature of 75°F with 50% relative humid i ty. 2. Samples will be sprayed using m a nufacturer recommended pressure. 3. The system will be heated to the manufacturer recommended temperature.**CPI Draft**  **SPF Ventilation Research Proposal** 

**April ,**  **2011** 4. Samples will be sprayed while maintaining an approxi mately 12 to 24 inch distance from

the substra te being sprayed. 5. A 5 ft by 7 ft area will be sprayed in one pass at a nominal thickness of:  2 in for medium d ensity (2 lb) SPF  4 in for low density (1/2 pound) SPF.  4 in for low pressure kit SPF. 6. The amount of foam used (lbs) and the densities of the foams sprayed will be recorded. Air monitoring will be conducted by a third - party contractor according to applica ble sampling and analysis protocols : 1. Three (3) to four (4) se ssions of personal an area samples will be collected as each SPF formulation ( low density high pressure SPF, medium density high pressure SPF, and low pressure kit SPF ) is applied to the spray s u bstrate . 2. One suite of personal samples will be collected and 2 suites of area samples will be collected during each test. 3. SPF formulations will be applied at ventilation rates of 0.3, 2, 5, and 10 ACH . 4. SPF formulations will be applied for approximatel y 15 minutes for each air sampling t est, with at least 2 hours between sessions. The sampling methodology is summarized below in Table 2.

**Table 2: Air Sampling and Analytical Methodology for Select SPF Constituents.**  CAS # Analyte Analytical Method Flo w

Rate Sampling media 101 - 68 -8 Methylene bisphenyl isocyanate

(MDI) Urea derivatives analyzed by HPLC with UV Detection according to Bayer Material Science Industrial Hygiene Laboratory Method No s : 1.20.0 and 1.7.7 1.0 Lpm Midget impinger with 15 mL tolue ne / 1

- (2 - pyridyl)piperazine; followed by: 13 mm glass fiber filter treated with 1 - (2 - pyridyl)piperazine and diethyl phthalate housed in a Swinnex cassette. 9016 -87 -9 Polyme ric MDI (pMDI)

(3 - ring and larger oligomers of MDI)

460- 73 - 1 1,1,1,3,3 - Penta fluoropropane Modified OSHA 7 (diffusive sampler), Or Bayer Method No. 0.01 Lpm

for Charcoal tubes Diffusive sampler –

Assay Technology Sampler No.548, or 2 charcoal tubes in series. 811 -97 - 2 1,1,1,2 -Tetrafluoroethane**CPI Draft**  **SPF Ventilation Research Proposal** 

**April ,**  **2011** 3.53.0 Desorption with carbon disulfide (or methylene chloride (3.53.0)) and analyzed by GC/FID 13674-84- 5 Tris- ( 1 - chloro - 2 - propyl) phosphate

(TCPP) ( Proposed Method) GC/NPD 0.40 Lpm XAD - 2 tubes

3033 -62 -3 Bis (2 - Dimethylaminoethyl) ether Bayer Method No. 2.10.3 Desorption with a cetone and analyzed by GC/NPD 0.40 Lpm XAD - 2 tubes 67 -48 -4 Tetramethyliminobispropylamine 2212 -32 -0 N,N,N Trimethylaminoethylethanolamine 3855 -32 - 1 Bis (dimethylaminopropyl)

methylamine 3030-47 -5 Pentamethyldiethylenetriamine

W orkers wi ll wear portable sampling pumps with the sampling media placed in the vicinity of the workers’ breathing zone . Area samples will be located to approximate a worker’s breathing zone, in an area where the highest concentrations are anticipated . The Bayer M aterial Science Laboratory will analyze all samples according to the methods listed in Table 2 above. 

### 2. **3 Phase II**  **I** During Phase III, personal and area air monitoring will be conducted while applying SPF that is representative of conditions found during field work in a medium -sized residential building. The purpose of the field study will be to verify findings obtained in Phase II and to determine if similar exhaust ventilation rates can be used effectively in the work area to reduce airborne concentrati ons of SPF chemicals.**CPI Draft**  **SPF Ventilation Research Proposal** 

**April ,**  **2011** T he preferred room for the high pressure SPF applications will have dimensions with a minimum floor area of 12 ft x 12 ft and a ceiling height of 8 feet. The room must have at least one window and one door opening (preferably oppos ite of each other). An exhaust ventilation unit (e.g. negative air machine or similar fan system with variable speed capability) will be used to create air flow through the room. Air exhaust rates (e.g. cfm) will be determined to calculate room air excha nge rates. A work area will be chosen that is representative of a typical retrofit/weatherization application for the low pressure 2 component kit formulation . An exhaust ventilation unit will be used as previous ly described to provide documented air exchange rates. A ir monitoring will be conducted three to four times with varying room air exchange rates (0.3 ACH, 2 ACH, 5 ACH, and 10 ACH) for each SPF formulation. Spraying will last for approximately 30 minutes with at least 2 hours between each te st. Similar spray equipment and work techniques established for Phase II will be used for each SPF application during Phase III. P re -fabricated , multiple wall units will be similar in design to th ose used during Phase II ; however, additional spray cavi ties will be available to permit a longer spray time . Units will be oriented in the same manner as Phase II such that air flow will be perpendicular (parallel?) to the spray substrate. Although temperature and humidity will be recorded, there will be no attempt to control these parameters . Air monitoring will be conducted by a third party contractor. The sampling and analytical methods used will be the same as those established during Phase II.**CPI Draft**  **SPF Ventilation Research Proposal** 

**April ,**  **2011**



### 3 **Interpretation** Laboratory analytical results will be compared with applicable occupational exposure levels (see Table 3). **Table 3: Occupational Exposure Limits for Select SPF Constituents.** CAS Analyte Occupational Exposure Limit Type of OEL (e.g.

OSHA Ceiling, ACGIH TLV, NIOSH REL) OEL (units)

101 - 68 -8 Methylene bisphenyl

isocyanate (MDI) 0.02

0.005 OSHA Ceiling

ACGIH TLV-TWA ppm

ppm 9016 -87 -9 Polymethylene

polybisphenyl isocyanate (pMDI) 0.02

0.005 OSHA Ceiling

ACGIH TLV-TWA ppm

ppm 460- 73 - 1 1,1,1,3,3 -

Pentafluoropropane 300 AIHA WEEL ppm 811 -97 - 2 1,1 ,1,2 -

Tetrafluoroethane 1000 AIHA WEEL ppm 3033 -62 -3 Bis (2 -

Dimethylaminoethyl) ether (BDMAEE) 0.05

0.15 ACGIH TLV-TWA

ACGIH TLV-STEL ppm

ppm



### 4 **Timeline** Phase I:  Create formulations = 3 weeks,  Test formulations = 1 week Total project time estimate = 4 weeks Phase II:

 Total sampling time = 6 weeks  Report writing = 2 weeks Total project time estimate = 8 weeks**CPI Draft**  **SPF Ventilation Research Proposal** 

**April ,**  **2011** Phase III:  1 week per formulation = 6 weeks  Report writing = 2 weeks Total project time estimate = 8 weeks



### 5 **Reporting** Upon completion of the re search proposal, it will be shared with the federal agencies to seek their input (allow 2 weeks for feedback). Consideration will be given to the agencies feedback and adjustments will be made to the research proposal as needed (allow 4 weeks to incorpora te feedback). Upon completion of final research proposal, the final proposal will be shared with the agencies. Following Phase I, CPI will prepare a written report summarizing the findings and selected test conditions and equipment. Following air monito ring of Phases II and III, the industrial hygiene contractor will provide a written report containing a summary of procedures, field observations, and results. As an appendix to the report, the industrial hygiene contractor will provide field notes includ ing the information described in Appendix A of this research proposal as well as the analytical data from the laboratory . CPI will evaluate the preliminary results following each phase of research and determine whether further study is needed. If further study is needed, a preliminary explanation of further research will be shared with the agencies. Following completion of the research, a final report will be written and the final report will be shared with the agencies. CPI will consider publishing th e final study report in a journal.**CPI Draft**  **SPF Ventilation Research Proposal** 

**April ,**  **2011 Appendix**  **A : Elements to consider including in the final report**  1) Product characteristics a. Manufacturer, name of product, batch # b. Type of product (OCF, 2CLP, 2CHP) c. Product composition 2) Equipment characteristics a. Nozzle type b. Nozzle diameter c. Application pressure d. Application temperature 3) Test area characteristics a. Type of space (residence, spray booth, mine, etc) b. Dimensions of test area c. Temperature d. Humidity e. Ventilation (ACH or cfm for local exhaust). Description of any ventilatio n such as open windows, fans, etc should also be included. 4) Task description a. Task duration b. Task frequency 5) Sampling and analytical method (such as OSHA 47) 6) Sampling Characteristics a. Correlate sample time start/stop to SPF application start/stop. Provide just ification for sampling duration. b. Sampling media (include type, lot#, expiration date) c. Sample pump (include manufacturer, model, serial #) d. Flow rate (Report average flow rate of 3 measurements at start and end of sampling). Flow rate for entire sampling pe riod is average of these 2. e. Confirm pump operation throughout sample duration (use of sound or blinking red light for visual) f. Sample start time, sample stop time g. Derivatizing agent (include name of derivatizing agent, lot #, expiration date, volume used, and time derivatizing agent was used typically within a few minutes of completing sampling) h. Use of sample blanks and duplicates to verify analytical lab accuracy 7) Analysis a. Include raw data provided by the laboratory as an appendix b. Name of analytical lab (in clude whether IHLAP accredited) c. Date/time of analysis (to determine whether holding times have been exceeded) d. Detection limit**CPI Draft**  **SPF Ventilation Research Proposal** 

**April ,**  **2011** e. Analytical technique/equipment used, to verify equipment was operating properly.

Include relevant certificates/equipment maintena nce or calibration history. f. Any solutions used in the analysis and their volume, lot #/expiration date g. Any deviations from the analytical method (OSHA 47) and justification for deviation h. QA/QC techniques used such as lab blanks i. LOD and/or LOQ j. Detected amou nt k. Estimated concentration (mass identified in sample divided by the sample volume) l. Show any conversions to ppm or ug/m3 m. Comparison to applicable OEL. Provide justification for appropriateness of OEL used. 8) Conclusions and executive summary. Confirm that the values reported in exec summary, data tables, and conclusions are consistent with those reported in the raw data appended to the report. 9) Include copies of relevant certificates such as the lab accreditation certificate and equipment certificates (as p rovided by equipment manufacturer if appropriate)