What You Need to Know About 

the Safe Use of Spray 

Polyurethane Foam

EPA Spray Polyurethane Foam Workshop

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EPA Spray Polyurethane Foam Workshop

Hyatt Regency, Phoenix, AZ

November 12, 2009, 3:30 – 5:30 pm

Presented by: Federal SPF Workgroup

ACC-CPI and SPFA
Today’s Objectives:

 Communicate hazards associated 

with SPF installation. 

 Communicate SPF safe practices for 

applicators, other trade workers and 

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consumers. 

 What you can do to help assure 

consistent use of best practices 

throughout industry. 
The Federal SPF Workgroup:

 EPA

 NIOSH

 OSHA

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 CPSC

 FTC
The Industry Workgroup:

 American Chemistry Council (ACC) –

Center For Polyurethane Industries 

(CPI)

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 Spray Polyurethane Foam Alliance 

(SPFA)
Today’s Presenters

 Bill Hanson, Environmental Protection Agency

 Introduction and Background

 Mary Cushmac, Environmental Protection Agency

 Hazards and Potential Exposures

 Daniel Almaguer, National Institute for Occupational Safety 

and Health

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 Spray Polyurethane Processes and Best Practices

 Janet Carter, Occupations Safety & Health Administration

 An OSHA Perspective on Employer Responsibilities

 Neeva-Gayle Candelori, American Chemistry Council-CPI

 Industry’s new stewardship program

 Kurt Reisenburg, Spray Polyurethane Foam Alliance

 Worker best practices
Federal SPF Project Goals:

1. Improve availability of accurate and 

comprehensive hazard & risk information

2. Develop and communicate improved “Best 

Practices” to prevent exposures

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3. Accurately market SPF benefits and 

communicate need for safe practices

4. Conduct research to address exposure 

assessment and data gaps
Chemical Right-to-Know

 Promote stewardship throughout the supply

chain

 Protect workers & consumers – informed of 

hazards 

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 Consumer / homeowner is well-informed

 Promotes Green Chemistry / Safer 

alternatives and practices
Effective Green Building Practices

EPA Green Building Goal- “To facilitate the mainstream 

adoption of effective green building practices”

 Why Spray Polyurethane Foam is valuable:

 An important tool to help achieve energy efficiency

 Numerous performance attributes

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 3-6x R-value of other insulation

 Vapor barrier

 Moisture barrier (closed cell)

 Structural strengthener (closed cell) 

 Fills all gaps and crevices 

-- thermal break

 Stops air infiltration

 Reduces noise

 Can be made, in part, from sustainable resources 

(e.g. soy polyols) 
Alternative Insulation Technologies

 Fiberglass, cotton, and mineral wool 

 Fiberglass and cellulose mixed with an adhesive 

can be wet sprayed into wall cavities and have an 

R-value per inch similar to low density SPF. 

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 Rigid foam board products that can be used for 

some applications.

 Cementations and tripolymer foam products can 

also be poured into walls or behind special netting. 
Advertising and Marketing Claims

Examples:

 “No off-gassing”, “non-toxic”, “safe”...foam

 “green” and “environmentally friendly”

 ...”plant-based”

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Principles of Sound Marketing:

 FTC Act // FTC “Green Guides”

 Substantiate “Green” claims 

 Deception is the representation, omission, 

or practice that could mislead the 

consumer
Spray Polyurethane Foam (SPF) -

Hazards and Potential Exposures

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Mary Cushmac

Office of Pollution Prevention and Toxics

U.S. Environmental Protection Agency
Outline

 Important Considerations

 Chemical Composition of SPF

 Health Effects

 Exposures

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 Hazard Communication
Why is this Issue Important?

 American Resource and Recovery Act (ARRA) 

of 2009 is investing billions of dollars to 

promote green jobs & energy efficiency.

 Use of SPF has increased 60% in the last five 

years.

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 With widespread use of SPF to retrofit buildings 

to conserve energy, the entire industry needs to 

ensure that SPF installation is carried out in a 

safe manner to protect workers, helpers, 

building occupants, and consumers.
Chemical Composition of SPF

 Side A – Isocyanates

Methylene diphenyl diisocyanate (MDI)

pMDI (50% MDI)

 Side B – Polyol Blend (variable/proprietary)

Polyols (certain % biobased)

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

 Flame retardants

 Blowing agents 

 Amine or metal catalysts

 Surfactants

A + B  POLYURETHANE FOAM
Health Effects - Isocyanates (Side A)

 Isocyanates cause asthma and are the leading 

attributable cause of work-related asthma.

 Isocyanates are potent lung and skin sensitizers 

(allergens) and irritants.

Isocyanates can trigger severe or fatal asthma attacks 

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

in sensitized persons at low levels.

 MDI is a hazardous air pollutant – Clean Air Act

 NIOSH issued an Alert in 2006 to prevent MDI 

exposures for a similar spray application.

 The European Union has issued new regulations for 

consumer products containing MDI.
Potential Health Effects - Polyol Blend 

(Side B)

Proprietary Chemical Ingredients:

 Amines (catalysts) – sensitizers; irritants; 

can cause blurry vision (halo effect).

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 Flame retardants – some are persistent, 

bioaccumulative, and toxic

 Blowing agents – global warming potential 

and other considerations
Exposures – Spray Application

 Vapor, mist, particulates (isocyanates, amines) 

can migrate to other rooms or floors.

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Exposures – Trimming Foam

 Cutting, scraping foam that is not fully cured 

generates dust that may contain isocyanates.

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Exposures – Do-It-Yourself Projects

 Do-it-yourselfers are often unaware of the hazards, 

the need to prevent skin, eye, and inhalation 

exposure, and the proper type of protections to use.

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Exposures – Consumer Use

 Consumers using spray foam canisters for 

insulation, sealing cracks, or creative arts 

are often unaware of the hazards and the 

need to prevent skin, eye and inhalation 

exposures.

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Photos Courtesy Dow Chemical
Types of SPF Insulation/Sealants

 Two-Component: > over 80 million lbs. sold in a year*

 Professional – 55 gal. drums

 Do-It-Yourself – large quantities also

 Retail, hardware, internet purchase

 One Component: > Over 50 mil. lbs. sold in a year* (or 

over 60 mil. cans) – fills, seals, and insulates gaps

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 One Component: > Over 50 mil. lbs. sold in a year* (or 

over 60 mil. cans) – fills, seals, and insulates gaps

 Consumer 

 12 oz. can (market leader); also 16 oz., 20 oz.

 Plastic straw applicator included

 Professional & Do-It-Yourself 

 20 oz., 24 oz., 26 oz., 30 oz., 33 oz.

 Typically gun delivery or applicator tool for precise control, 

sold separately

* Data Courtesy CPI
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 

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isocyanates and other hazards.

Fires and thermal degradation can generate and 

release hydrogen cyanide, carbon monoxide, 

amines, and isocyanates.
Assessing Exposures

 Data are needed to accurately assess the 

potential for exposures with variable 

applications & product formulations:

Measuring total isocyanates.

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Other substances.

Answering the question – When can 

occupants, residents, and school children reenter the premises after SPF application?
Hazard Communication and

Right-to-Know

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

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 

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hazards. 

 EPA has compared Material Safety Data Sheets and 

found that the health and safety information for MDIbased isocyanates (Side A) is not consistent among 

distributers of SPF insulation.

 All products should be properly labeled by 

manufacturers/distributors (FHSA requirement).
Hazard Communication and

Right-to-Know

 The SPF industry needs to ensure:

There is clear hazard communication for all SPF 

users – applicators, helpers, do-it-yourselfers, 

consumers, and decision makers.

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 Consumers are not usually familiar with MSDS and need 

clear hazard warnings.

The work site is restricted to only those wearing 

appropriate personal protective equipment.

Guidance is provided on re-entry time. 

Marketing claims are accurate and balanced.
Federal Panel 

Concluding Remarks

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Re-Cap

 SPF industry needs to ensure that operations 

are carried out in a safe and healthful manner.

 SPF application presents the same hazards as 

spray-on truck bed liner operations and requires 

the same level of protection (NIOSH ALERT).

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 Product formulation/composition, applicator 

technique, temperature, humidity, and product 

disturbance over time are important factors that 

impact curing time and potential exposures.

 Challenge: Guidance is needed on ventilation, 

exposure controls, clean-up, and re-entry time.
Re-Cap

 Manufacturers need to ensure their products can 

be applied safely and are properly labeled.

 Employers need to communicate hazards, train 

workers, control exposures, and ensure all 

workers are adequately protected.

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 Training needs to be widely available, integrate 

health and safety with performance, and 

repeated.

 Challenge: Best practices need to be 

developed, shared, and implemented to reduce 

exposures.
Re-Cap

 Challenge: Provide data that accurately assesses 

exposures with variable applications and product 

formulations:

Measuring total isocyanates.

How formulation, product composition, 

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temperature, humidity, and technique impact 

curing (understanding tack-free versus fully cured 

exposure potentials).

Answering the question – When can occupants, 

residents, school children, and others re-enter the 

premises after SPF application?
Federal Outreach Activities

 Inform stakeholders

 SPF Workshop, Phoenix, AZ

 Webinar – Dec 2, 2009

 Engage key stakeholders, seeking assistance with:

Communication to spray applicators, customers, and others

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

 Consistent use of best practices

 Promote informed marketing

 Exposure monitoring and other data gaps

 Communicate with specific audiences

 Website information

 Print and Media -- e.g. articles in the building trade press 

 Conference and trade show presentations
Key Actions Going Forward

 Quickly communicate hazard / safety information to 

workers and customers

 Federal agency websites 

 ACC-CPI and SPFA’s “Tier 1” guidance ready adoption

 Augment health and safety training

 Enhance training, specialize training, and expand offerings 

 Spray foam applicators

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 Weatherization programs

 Emphasize sound marketing

 Employ enhanced practices to improve protection

 SPF worksite management plans 

 Role of engineering controls, including ventilation

 Safety procedures for DIY low pressure two-part SPF

 Occupant re-entry considerations.

 Conduct analysis and research on exposure 

monitoring and other needs
Sources of Information on SPF:

 EPA: www.

 OSHA Website: www.osha.gov

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

 NIOSH Website: www.cdc.gov/NIOSH

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

 NIOSH 800 Number: 1-800-CDC-INFO

 EPA: http://www.epa.gov/dfe/pubs/auto/profile/

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 CPSC Website: www.cpsc.gov

 CPSC Chronic Hazard Guidelines:

http://cpsc.gov/BUSINFO/chronic.pdf

 ACC-CPI (Center for the Polyurethanes Industry) website–

www.polyurethane.org – many publications on MDI and other 

isocyanates.

 http://www.americanchemistry.com/s_api/SF_index.asp

 SPFA -http://www.sprayfoam.org/

 ACC-CPI -- SPF Health and Safety Protection –

summary of safe use practices

http://www.americanchemistry.com/s_api/SF_index.asp
Questions and Answers

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Workshop Wrap Up Slides

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Contact Information:

EPA Office of Prevention, Pesticides and Toxic Substances:

 Mary Cushmac- cushmac.mary@epa.gov

 Carol Hetfield- hetfield.carol@epa.gov

EPA Green Building:

 Bill Hanson- hanson.bill@epa.gov

 Bill Swietlik- swietlik.william@epa.gov

NIOSH:

 Dan Almaguer- dla3@cdc.gov

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 Dan Almaguer- dla3@cdc.gov

OSHA-

 Janet Carter- carter.janet@dol.gov

CPSC 

 Trey Thomas – tthomas@cpsc.gov

ACC-CPI 

 Neeva-Gayle Candilori -

Neeva_Candelori@americanchemistry.com

SPFA 

 Kurt Reisenberg- kurtriesenberg@sprayfoam.org 
Upcoming Webinar: 

“What You Need to Know About the Safe Use of 

Spray Polyurethane Foam"

Panelists: EPA, NIOSH, OSHA, CPSC

ACC-CPI and SPFA

Wednesday, December 2, 2009 

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1:00 – 3:00 pm EST 

To register for the Webinar, please visit

https://www1.gotomeeting.com/register/800171944

For Slides of this SPF Workshop (Phoenix),

contact: hetfield.carol@epa.gov