CPI-SPFA

Enhanced Spray Polyurethane Foam

Product Stewardship Program

Neeva-Gayle Candelori, Director

ACC Center for the Polyurethanes Industry

February 17, 2010
Overview

• Who is CPI?

• 2009 - Enhanced Product Stewardship Program

• 2010 - Next Stage of Spray Polyurethane Foam 

Product Stewardship Program

• Summary
ACC Center for the 

Polyurethanes Industry

CPI - largest group

servicing the polyurethanes 

industry. 

ACC’s Plastics Division - lead 

organization for 

plastics resin producers. 
Center for the Polyurethanes Industry

CPI Mission

 CPI is the voice of the PU industry in North America

 CPI promotes the sustainable growth of the PU 

industry in cooperation with user groups.

 CPI coordinates on key industry activities with PU 

trade associations across the globe.
Broad Product 

Stewardship Programs 

• Guidance 

documents / videos

• Training programs

• RCAP

• Truck Bed Liners

5
Setting the Stage...

 Rapidly growing SPF market

 Driven by energy use reduction 0

30

60

90

120

150

180

Res. Wall Comm. Wall Res. Roof Comm. Roof

P

o

u

n

d

s

( M

L

)B

NAFTA Spray Polyurethane Foam Market

2006 2008

62%

170%

73%

14%
CPI-SPFA Enhanced 

Product Stewardship Program

• Launched in 2009 by both SPFA and CPI, 

together

• Has both a worker focus and a consumer / 

building occupant focus

• Initial worker focus (2009) – improve 

understanding with high pressure workers: 

hazard communications; good workplace 

practices
SPF Posters
SPF Guidance Documents
Video: Safe Handing of MDI

www.spraypolyurethane.com
SPF Health and Safety Website

www.spraypolyurethane.com
CPI-SPFA 

Spray Polyurethane Foam 

Technical Discussion

Jim Chapman

Bayer MaterialScience LLC
Overview

• SPF Systems

• Cure and Re-Entry Times

• Existing Product Testing Capabilities

• Ventilation
SPF System Characteristics

• Basic Categories:

– High-Pressure SPF systems

• 2-component systems

– Low-Pressure SPF systems

• 2-component kits

• 1-component foam products
SPF Delivery Systems

• Containers

– Refillable Cylinders:

• 2-component, Low-P only

– Single-use Drums / Cylinders:

• 2-component only, High- & Low-P 

– Pressurized Cans / Single-use cylinders:

• 1-component only
SPF Delivery Modes

• Spray

– 2-component only, high & low 

pressure

– Product application: insulation, 

coating

• Stream / Bead

– 1-component & 2-component, 

low pressure only 

– Product application: adhesive, 

sealant 
0 System sprayed- temp 130 F

Cream time exothermic reaction beginning 

– physical blowing agent volatilizing

0.5

2 Gel time polymerization beginning

4 Tack free time surface of polymer solidified

Time, sec Observation

360 Peak reaction exotherm achieved

14400 Reported cure time

900 Lesage et al., 2007- detects no MDI on 

foam surface

Approximate

SPF Cure Timeline

(High Pressure 2-component)
Re–Entry Times

• Re-occupancy time dependent on numerous factors, 

such as:

– SPF formulations

– Amount of foam applied per volume of space

– Degree of ventilation

• Certain components can be liberated from some 

newly-installed high pressure SPF products for a short 

period following installation

• Evaluation reports for specific SPF products often 

include the product manufacturer’ recommended 

re-occupancy time, which is variable.
Existing Product Testing Capabilities

• SPF products have been tested using the Canadian 

Standard Laboratory Guide for the Determination of 

Volatile Organic Compounds from Polyurethane Foam 

(CAN/ULC S774-06).

• Information is publicly available in some cases from 

The Canadian Construction Materials Centre which 

has a searchable database.

– www.nrc-cnrc.gc.ca/eng/services/irc/ccmc/registry-productevaluations.html

• Greenguard Environmental Institute testing program 

and Product Guide.

– www.greenguard.org/Default.aspx?tabid=12
Ventilation Considerations

• Spray Polyurethane Foam Insulation – Understanding the Hazards

– MDI hazards

– Other Emissions

• Potential Exposure Risks for Other Workers and Building Occupants

• Reducing Risks

– During Application

• Jobsite Communication

• Safety Zone – Clearance from Applicator

– After Application

• Post-Application Ventilation

• Re-Occupancy Time

• Odor Disclosure

• Occupant Communication

– Ventilation Methods
Next Stage of

CPI-SPFA Spray Polyurethane Foam 

Product Stewardship Program

Neeva-Gayle Candelori, Director

ACC Center for the Polyurethanes Industry
Next Stage of 

SPF Product Stewardship Program

• Worker Performance

• D-I-Y, Consumer, Building and 

Construction Sector Knowledge

• Research
Next Stage of 

SPF Product Stewardship Program

• Worker Performance

– Enhanced EH&S content.

– New mechanism for broader availability, and more 

rapid availability, of EH&S training to the high 

pressure community.

– Programs designed to supplement, not replace, 

existing contractor training.

– Programs will be monitored to track participation 

and other features (e.g., understandability). 
Next Stage of 

SPF Product Stewardship Program

• DIY, Consumer, Building & Construction 

Sector

– Broaden communication on EH&S issues to wider 

audiences, including building occupants and 

specifiers

• Guidance for homeowners on different products, 

with focus on health and safety issues (e.g., 

ventilation, re-occupancy, understanding green 

marketing claims) 
Next Stage of 

SPF Product Stewardship Program

• Research

–Additional areas under consideration

–Focus on ventilation methods, exposure 

issues
Summary

• Work will continue in 2010 and beyond.

• We need your engagement to make this 

program a success. 

• We are continuing to update materials and 

programs regularly, visit our website. 

www.spraypolyurethane.com
Thank You

Contact Information:

Neeva-Gayle Candelori, Director

ACC Center for the Polyurethanes Industry

1300 Wilson Blvd., Arlington, VA 22209

Tel: 703-741-5103

www.spraypolyurethane.com

www.americanchemistry.com/polyurethane

www.americanchemistry.com/tbl
28

Spray Polyurethane Foam (SPF)

- EPA Considerations -

Mary Cushmac

Office of Pollution Prevention and Toxics 

U.S. Environmental Protection Agency

Washington, DC 20460
29

Why is this Issue Important? 

 SPF is one of the fastest growing products in 

building and construction. (Reuters 2009).

 SPF is an very effective insulator and sealant, 

with widespread use to retrofit schools, 

residences, and buildings to conserve energy.

 Government is investing billions of dollars to 

promote energy efficiency and green jobs.
30

Why is this Issue Important? - 2

 Many applicators, helpers, do-it-yourselfers, 

consumers, homeowners, and decision makers are 

unaware of the potential hazards from inhalation, 

skin and eye exposures.

 Some marketing information is misleading –

focuses on “green” aspects and does not address 

potential hazards. 

 Often, material safety data sheets (MSDS) do not 

contain consistent health and safety information.
31

Why is this Issue Important? -3

 SPF application presents the same hazards as 

spray-on truck bed liner operations (NIOSH ALERT)

and requires the same level of protection. 

 Product composition, applicator technique, accurate 

proportioning of SPF components, temperature, and 

humidity are important factors that impact quality of 

foam, curing time and potential exposures to SPF 

chemicals.

 Often persons not wearing prescribed personal 

protective equipment are in or near the work site.

 It is difficult to find reliable guidance on re-entry 

times.
32

SPF Chemical Composition

 Side A – Isocyanates

 Methylene diphenyl diisocyanate (MDI) and pMDI

 MDI – based isocyanates (varying species)

 Side B – Polyol Blend (variable/proprietary)

 Polyols (certain % bio-based)

 Flame retardants

 Blowing agents

 Amine or metal catalysts

 Surfactants

A + B  POLYURETHANE FOAM
33

Side A - Concerns

 Health concerns with isocyanates:

 Lung and skin sensitizer (causes an allergic reaction).

 Leading attributable cause of work-related asthma.

 Can trigger severe or fatal asthma attacks in sensitized 

persons upon further exposure, even at very low levels.

 MDI is a hazardous air pollutant. (Clean Air Act)

 NIOSH issued Alerts in 1996 and 2006 to prevent 

asthma and death in workers exposed to isocyanates. 

http://www.cdc.gov/niosh/topics/isocyanates/

 The European Union has issued new regulations to 

prevent exposures to MDI in consumer products. 

http://www.isopa.org/isopa/uploads/Documents/documents/2009-02-

16_MDI_EU_legal_Marketing_and_Use_Restr.pdf
34

What is a sensitizer?

 OSHA definition, for purposes of the Hazard Communication 

Standard: 

 “A chemical that causes a substantial proportion of exposed people or 

animals to develop an allergic reaction in normal tissue after 

repeated exposure to the chemical.“

 “A sensitizer (allergen) causes little or no reaction in man or test 

animals on first exposure. The problem arises on subsequent 

exposures when a marked immunological response occurs.

http://www.osha.gov/dsg/hazcom/ghd053107.html#a

 The Michigan OSHA has prepared a fact sheet on 

sensitization and employer’s responsibilities to protect 

workers. http://www.michigan.gov/documents/dleg/reactions_292569_7.pdf
35

Links to Health Effects Information on Isocyanates

 EPA

 Integrated Risk Information System (IRIS) for MDI and pMDI: 

http://www.epa.gov/iris/subst/0529.htm

 EPA Isocyanates Profile: http://www.epa.gov/dfe/pubs/auto/profile/

 EPA New Chemicals Program – Chemical Category: 

http://www.epa.gov/oppt/newchems/pubs/cat02.htm#Isocyanates

 TSCA section 8(e) Notifications of Substantial Risk, available at: 

http://www.epa.gov/oppt/tsca8e/

 NIOSH

 Isocyanates Page: http://www.cdc.gov/niosh/topics/isocyanates

 Preventing Asthma and Death from Diisocyanate Exposure, NIOSH 

ALERT, DHHS Publication No. 96-111: 

http://www.cdc.gov/niosh/asthma.html

 OSHA

 Isocyanates Page: http://www.osha.gov/SLTC/isocyanates/index.htm
36

Side B – Concerns

 Often chemical identities are claimed 

confidential so it is difficult to evaluate toxicity.

 Amines (catalysts) may be irritants; can cause 

blurry vision (halo effect).

 Some flame retardants may be persistent, 

bioaccumulative, and/or toxic.

 Some blowing agents may contribute to global 

warming or have health effects.
37

Other Considerations

 Long term stability of polyurethane foam:

Fully cured polyurethane foam is not considered a 

problem unless disturbed.

Heating, welding, or grinding generates free 

isocyanates and other hazards.

Fires and thermal degradation can generate and 

release isocyanates, hydrogen cyanide, carbon 

monoxide, and amines.
38

Exposure Assessment

 We need data that accurately assesses exposures 

with variable applications and product formulations:

Measuring total isocyanates and other chemicals.

Answering the question – When can occupants, 

residents, school children, and others re-enter 

the premises after SPF application?
39

Typical Exposures - Spray Application

 Generates vapor, mist, and particulates 

exceeding occupational exposure limits.

 Isocyanates & amines can migrate to other 

rooms or floors.
40

Typical Exposures – Trimming Foam

 Cutting, scraping foam that is not fully cured 

generates dust, particles that may contain isocyanates 

and other unreacted chemicals.
41

Typical Exposures - Consumer & 

Do-It-Yourself Projects

 Consumers, a growing market of Do-it-Yourself applicators, 

are using one-component cans or two-component kits for 

sealing cracks, as insulation, or creative arts.

 Users are often unaware of the hazards and the need to 

prevent skin, eye and inhalation exposures, and the proper 

type of protections to use.
42

Best Practices

 When safer alternatives are not 

available, best practices need 

to be developed, shared, and 

implemented to minimize 

exposures. 

 As an example, EPA’s Design 

for the Environment (DfE) 

Program works in partnership 

with the industry to identify and 

promote best practices to 

reduce exposures to 

isocyanates and other 

chemicals of concern in the 

workplace and community.

http://www.epa.gov/dfe/pubs/projects/auto

http://www.ccar-greenlink.org/cshops

http://www.epa.gov/collisionrepair
43

Alternative Technologies

 A new class of hybrid non-isocyanate 

polyurethanes (HNIPU) is being marketed.

 The Department of Energy provides 

information on insulation options: 

http://www.ornl.gov/sci/roofs+walls/insulation/ins_01.html
44

Marketing Claims

 Some claims are misleading:

 “no off-gassing,” “non-toxic” and “safe”

 “green” and “environmentally friendly”

 “plant-based” and “made from soy beans”

 May not provide information on toxic 

chemicals in the product.

 May cause important important safety 

information to be overlooked.
45

Marketing Claims

 Federal law prohibits deceptive acts or practices, 

including deceptive representations in advertising, 

labeling, product inserts, catalogs, and sales 

presentations - Federal Trade Commission (FTC)

 FTC Green Guide provides specific guidance on the 

use of environmental claims. 

http://www.ftc.gov/bcp/grnrule/guides980427.htm

 All products should be properly labeled by 

manufacturers/distributors - Federal Hazardous Substances 

Act/Consumer Product Safety Commission (CPSC)
46

Government & Industry Involvement

 Federal Advisory Group

 Environmental Protection Agency (EPA)

 National Institute for Occupational Safety & Health (NIOSH)

 Occupational Safety & Health Administration (OSHA)

 Consumer Product Safety Commission (CPSC)

 Industry

 American Chemistry Council’s Center for the Polyurethanes 

Industries (CPI)

 Spray Polyurethane Foam Association (SPFA)

 Diisocyanates and SPF Manufacturers
47

Goals

 Improve availability of accurate and 

comprehensive hazard & risk information.

 Develop and communicate “Best Practices” to 

prevent exposures.

 Ensure accurate marketing claims.

 Address exposure assessment and data gaps.
48

Achieving these Goals

 Manufacturers need to ensure their products can be applied 

safely and are properly labeled.

 Hazards, as well as benefits, need to be clearly communicated 

throughout the product value chain. 

 Ensure premises are restricted to workers wearing appropriate 

personal protective equipment.

 Provide guidance on re-entry time that is based on accurate 

monitoring data of total isocyanates and other SPF chemicals.

Communication, training, and best practices are key to safe use and 

handling of SPF, and to prevent misleading marketing claims.
49

Contact Information

Mary Cushmac

(202) 564-8803

cushmac.mary@epa.gov
Daniel Almaguer, M.S.

National Institute for Occupational Safety and Health (NIOSH)

Disclaimer: The findings and conclusions in this presentation are those of the author(s) and do not 

necessarily represent the views of the National Institute for Occupational Safety and Health (NIOSH). 

Mention of company names or products does not constitute endorsement by the Centers for Disease 

Control and Prevention (CDC) or NIOSH.

Spray Polyurethane Processes 
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
Division of Applied Research & Technology

Engineering & Physical Hazards Branch

 Engineers, Industrial Hygienists, Physicists, 

other disciplines 

 Identify and evaluate occupational exposures

 Develop and evaluate engineering controls 

for preventing or reducing exposures

 Disseminate information on hazards, 

exposures, and control solutions to industry 

and professionals 
NIOSH Alert on Truck Bed-Liners 

Applicable to all SPF Operations

Contains Recommendations for:

 Workers

 Employers

 Future Research

 Engineering controls

 Exposure monitoring

 Respiratory protection

 Medical monitoring

 Surveillance

 Decontamination 
Why NIOSH issued Alert

 Reports of occupational asthma – detailed in 

NIOSH Alert.

 Isocyanates – cause occupational asthma.

 Workers with asthmatic symptoms from 

isocyanate exposure often continue to have 

symptoms even after exposures have ended

 Affected workers often have to leave their jobs to 

prevent progression of respiratory symptoms
NIOSH Assessment of Spray 

Polyurethane Products Industries

 Comprehensive study of the spray polyurethane truck 

bed-liner (TBL) process (2003-2006)

 Preliminary assessment of the Spray Polyurethane 

Foam (SPF) insulation process - 4 sites (Aug. 2009)

 Review of industry information on the SPF process

 Concluded that based on the similarities --these two 

spray polyurethane processes (TBL and SPF) are 

essentially the same (i.e. same chemicals and 

equipment)
Importance of worker issues

 Worker exposures not always considered in 

developing “green” products and practices

 Workers/applicators generally have higher 

exposures compared to homeowners or 

consumers

 Controls and training to reduce worker 

exposures generally likely to reduce 

exposures for homeowners

 A truly comprehensive approach to 

sustainability and green practices needs to 

include occupational safety and health 

aspects. 
Industrial Hygiene

Hierarchy of controls

 Elimination

 Substitution – replace high hazard with low 

hazard

 Engineering – ventilation, enclosure

 Administrative – training, job rotation, 

procedures, policy

 Protective Clothing and Equipment –

respirators, ear plugs, gloves
SPF Recommendations

 Hazard Communication

 Wear Personal Protective Equipment (PPE)- sprayer and helper.

 Full-Face Supplied-Air Respirator (SAR) 

 chemical protective clothing (i.e. disposable coveralls and 

gloves).

 Limit access to spray area.

 Only trained workers with proper PPE.

 Isolate process to prevent chemical migration to other areas to 

ensure others are not exposed.

 Provide adequate ventilation to remove chemicals.

 Filter and exhaust to unoccupied area. 

 Prevent access to exhaust area.

 Do not re-enter spray area without appropriate PPE.

 Need to determine appropriate time period. 
Use of PPE at SPF sites

Implementation Gap

 Gap between what we know and what workers do.

 Studies – worker exposures exceed the occupational 

exposure limits (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.
Initial Assessment of SPF

 The industry has a wealth of information on spray 

polyurethane products.

 Published studies indicate that the information is 

not consistently reaching the worker.

 We need to work collaboratively to protect the health 

of the SPF workforce and the consumer/occupant.

 Ensure that correct information gets to the workers.
Challenges for SPP industries

 Develop engineering control strategies to protect all workers during 

all phases of the operations.

 Preparation

 Spraying

 Trimming

 Clean-up.

 Controls need to be adaptable to a wide variety of applications and 

foam densities.

 Indoor and outdoor

 New construction and retrofits

 Residential (attic retrofits)

 Commercial

 1⁄2-pound (low density), 2-lb. (medium), and 3-lb. (high) foams
Challenges for SPP industries

 Develop strategies to isolate (enclose) process.

 Contain and control chemicals generated.

 Prevent migration of chemicals to other areas.

 Develop ventilation system for enclosures.

 Reduce airborne chemicals including MDI.

 Air supply and exhaust needed.

 Exhaust to unoccupied location.

 Determine appropriate time(s) period to re-enter 

areas without PPE.

 Dependent on ventilation rate and SPF curing time.
Potential Controls used at SPF sites

 Explore ways to isolate (enclose) process.

 Used plastic sheeting to cover wall studs.

 Used metal grating to control expansion of foam.

 Potential advantages – reduced chemical usage; 

chemical vapors and aerosols likely trapped behind 

plastic film resulting in lower airborne chemical 

concentrations.

Panel system
Controls used at SPF sites

 Use air movers to exchange air in the spray 

zone.

 Reduce airborne chemical concentrations.

 Air supply and exhaust needed.

 Filter and exhaust to unoccupied location.
General Guidelines

 Enclose the spray zone 

as much as possible

 Supply air (active or 

passive) at one end of 

spray zone

 Direct airflow past spray 

zone 

 Filter and exhaust air at 

opposite end of spray 

zone

 Create negative pressure 

within the enclosure
One Proposed Enclosure

(There is no one-size fits all solution)

Note: the above proposed enclosure has not been tested and is not 

intended to be applicable to every SPF insulation worksite.

Temporary Wall – isolates (encloses) 

spray-zone

Air Exhaust SPF Sprayer Air Supply

Air Supply Fan – located 

in window or door 

Air Exhaust Fan –with 

filter, located in window 

or door

Spray-zone

Spray zone – must be under negative pressure to prevent 

chemical migration to adjacent work areas
Moving forward

 Government/industry partners must continue 

working together toward comprehensive 

solutions to address worker, homeowner, and 

consumer exposures associated with SPF

 Practitioners need to be aware of potential 

hazards and solutions -- even for “green” 

products and technologies
Contact Information

Daniel Almaguer, M.S.

NIOSH, Division of Applied Research and 

Technology, Engineering and Physical Hazards 

Branch

4676 Columbia Parkway, Mail Stop R-5

Cincinnati, OH 45226

Phone: 513-841-4232

Fax: 513-841-4506

Email: dla3@cdc.gov

Janet Carter

Health Scientist

Directorate of Standards and Guidance

Considerations for Safe Use of 

Spray Polyurethane Foam (SPF): 

An OSHA Perspective
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
OSHA’s Concern with SPF

 Linked to Work-related asthma (WRA)

Asthma serious condition

Can worsen with each exposure

May be life threatening 

 Hazard information not reaching all users

Inconsistent worker protection
OSHA Applicable Standards

 3 PELS for isocyanates

29 CFR 1910 subpart Z (Air contaminants)

 General duty clause
OSHA Applicable Standards

• 29 CFR 1910.1200; 1915.1200; 1917.28; 

1918.90; and 1926.59 (Hazard 

Communication)

• 29 CFR 1910.134 (Respiratory Protection)

• 29 CFR 1910 Part I, 1926.95 (Personal 

Protective Equipment)

• 29 CFR 1910.94; 1915.51; 1918.94; 1926.57 

(Ventilation)
Employer Responsibilities

 Full Hazard Communication

 Provide worker training

 Appropriate Exposure Control System

PPE for ALL exposed workers

Adequate and appropriate containment and/or 

ventilation

Develop best practices for handling these and 

ALL hazardous materials
Hazard Communication

 Communicate all hazards via:

MSDS 

Labeling of all hazardous substances

Warning signs of hazards

 Employee training
Hazard Communication - MSDS

 Material Safety Data Sheets

Integral part of communication strategy

Must be readily available to all affected 

workers

Must be comprehensive

 Issues with accuracy, consistency and 

completeness
Hazard Communication - MSDS

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 Communication - MSDS

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 containment and 

ventilation

 Includes use of filters (bed-liner guidance)

 May also include generation of dust – may contain 

isocyanates
Hazard Communication

 MSDS from manufacturers 

Information should not be deleted down the 

supply chain

User accepts liability if change information

 What if a worker or adjacent person is 

harmed because of inadequate or altered 

information?
Hazard Communication –

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 

and SPF

Proper control measures 

Proper use of PPE

Protecting those in adjacent areas

Appropriate ventilation
Training

 Training should be available to all

appropriate workers 

 Training material is available on web:

OSHA

NIOSH

ACC/Polyurethane Industry
Appropriate Exposure Control

 Exposures should be controlled whenever 

possible

 PPE should be last resort

 Problems with compliance

 Need for education and training

 Consider all phases of operation

 Start to finish, including clean-up

 Consider use of PPE for clean-up crew

 Same as operator/helper

 Develop best practices for work activities

 Enclosures or partitions

 Dust control measures

 Proper air circulation and ventilation
Exposure Control - Proper Use of PPE

 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

 Adjacent workers

 Train ALL workers - training is essential

 Consider developing checklist to ensure compliance
Ventilation Considerations

 Ventilation crucial for worker safety

 Only vent to outside using approved filter

 Protect workers or passer-by’s outside

 Similar methods can be adapted from measures used in truck 

bed-liner industry, see OSHA issued publications in alliance with 

CPI for Truck Bed-liners (developed for employers, the 

documents includes information on how to recognize 

MDI-related hazards and reduce employees' exposure 

to MDI)

“Spray on Truck Bed Liner Applications Using MDI/PMDI; 

Seven Important Points” and

“Considerations for the Application of Spray-On Truck Bed 

Liners” 

 Similar hazards

 Similar remedies
Additional Information

 OSHA assistance

 OSHA has free consultation program

 Small and medium sized businesses

 All 50 states participate & Regions have been alerted

 “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

 DOL and OSHA are working to include safety and health as key 

message in “Green” jobs training programs

 Promote safe use of these materials in the workplace
SPF Contractor Perspective

Bob Duke

Carolina Comfort Foam
Current Activity

• 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 

U.S. Housing Market