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 low density (1/2-pound), 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

 Flame 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 

emissions during SPF application 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 rates measured as Air Changes per Hour (ACH), equipment pressures, spray tips, and material 

temperatures. 

General descriptions 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

Low Density (1/2 pound) High 

Pressure SPF Formulation

Medium Density (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 Polyol 

(33.61%)

Polyester Polyol (23%)

Polyether Polyol (23%)

NPE Emulsifier (11.9%)

Blowing agent Water (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%)

Fire 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,NTrimethylaminoethylethanolamine

(4.0%)

Catalyst 

Bis (2-Dimethylaminoethyl) ether 

BDMAEE (0.7%)

Bis (dimethylaminopropyl) 

methylamine (2.59%)

N,N,NTrimethylaminoethylethanolamine

(0.3%)

Catalyst (5%)

Pentamethyldiethylene 

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. Applicators will spray 

selected formulations of 1⁄2-pound, 2-pound, and low pressure kits under the following conditions:

1. Ambient air 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 while 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. The amount of foam used (lbs) and the densities of the foams sprayed will be recorded.

2.2 Phase II

During Phase II, personal and area air monitoring will be conducted while three (3) SPF formulations are 

applied to test panels inside a spray room. The 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. Make-up air is 

supplied to the room and it is exhausted though an 8ft x 8ft filter bank on the opposite wall 

of the room. 

2. A ventilation plenum downstream from the filter bank ensures an even distribution of air 

through the room. 

3. 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.

An SPF applicator will spray the selected SPF 1⁄2 pound and 2.0 pound formulations using a Graco Fusion 

Air Purge 01 round tip spray gun. Low pressure kit formulations will be sprayed using manufacturer 

supplied spray equipment. SPF will be applied under the following conditions:

1. Ambient air temperature of 75°F with 50% relative humidity.

2. Samples will be sprayed using manufacturer 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 approximately 12 to 24 inch distance from 

the substrate 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 density (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 applicable sampling and 

analysis protocols:

1. Three (3) to four (4) sessions 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 substrate.

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 approximately 15 minutes for each air sampling test, 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

Flow 

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 Nos: 

1.20.0 and 1.7.7

1.0 Lpm Midget impinger with 

15 mL toluene / 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 Polymeric MDI (pMDI)

(3-ring and larger oligomers of 

MDI)

460-73-1 1,1,1,3,3-Pentafluoropropane 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 

acetone and 

analyzed by 

GC/NPD

0.40 Lpm XAD-2 tubes 

67-48-4 Tetramethyliminobispropylamine

2212-32-0 N,N,NTrimethylaminoethylethanolamine

3855-32-1 Bis (dimethylaminopropyl) 

methylamine

3030-47-5 Pentamethyldiethylenetriamine

Workers will 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 Material Science Laboratory will 

analyze all samples according to the methods listed in Table 2 above.

2.3 Phase III

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 concentrations of 

SPF chemicals. 
CPI Draft SPF Ventilation Research Proposal

April, 2011

The 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 opposite 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 exchange 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 previously 

described to provide documented air exchange rates. 

Air 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 test. Similar spray equipment and work techniques established for Phase 

II will be used for each SPF application during Phase III. 

Pre-fabricated, multiple wall units will be similar in design to those used during Phase II; however,

additional spray cavities 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 research 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 incorporate 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 monitoring 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 including 

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 the 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 ventilation 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 justification 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 period 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 (include 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 maintenance 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 amount

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 provided by equipment manufacturer if appropriate)