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 uses
0

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 Communications
10

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, 2009
11

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 Processes
12

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 sealant
13

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 usage
15

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 gaps
17

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 Agency
19

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, cleanup, 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/collisionrepair
24

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 reenter 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.gov

Janet 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 Consulting
77

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 level 
80

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 HomeSingleFamily HomeTown 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)

Airborne MDI Concentrations - Applicator and Helpers

0

50

100

150

200

250

300

350

400

450

500

1 2 3 4 5

Survey No.

Concentration (ug/m3)

Applicator Helper 1 Helper 2

OEL 51 ug/m3
Spray Foam Worker 

MDI Exposures (con’t)

Short-Term Airborne MDI Concentrations - Applicator

0

100

200

300

400

500

600

700

800

900

1000

1 2 3 4 5

Survey No.

Concentration (ug/m3)

OEL 200 ug/m3
Spray Foam Worker 

MDI Exposures (con’t)

Airborne MDI Concentrations with Distance from Applicator

0

10

20

30

40

50

60

70

80

90

1 2 3 4 5

Survey No.

Concentration (ug/m3)

10 feet 20 feet 30 feet

OEL 51 ug/m3
Spray Foam Worker 

MDI Exposures (con’t)

0

50

100

150

200

250

300

1 2 3 4 5 Concentration (ug/m3)

Survey No.

Short-Term Airborne MDI Concentrations with 

Distance from Applicator

10 feet 20 feet

OEL 200 
Spray Foam Worker 

MDI Exposures (con’t)

Migration of 

Airborne MDI

MDI

Slight Migration to Lower 

Floors.

<5% of concentration on floor 

sprayed

Slight Migration to Lower 

Floors.

<20% of concentration on 

floor sprayed

3 None

4 None

Survey 

No.

Degree of Migration Observed

MDI Oligomers

Moderate Migration to Lower 

Floors.

5 None None

1

2

<45% of concentration on 

floor sprayed

None

None

None

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/m3(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 nontoxic” 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!