# Industry Update: Spray 

# Polyurethane Foam Product Stewardship April 24, 2014

# Industry

- Led Product Stewardship

Primary Goal 

# To enhance understanding of safe installation practices regarding 

# use, handling and disposal of spray polyurethane foam (SPF).

# Industry

- Led Product Stewardship: Three



# Pronged Approach

Program focuses on practices and communications that can help to minimize potential for exposure of workers and building occupants to SPF chemicals.

• Worker Performance and Training

– develop and deploy health and safety 

### training programs for professional SPF applicators.

• Outreach

- Educate DIY’ers , consumers and the building/construction sector about best practices on key issues including the selection of a contractor; different types of SPF products; health and safety 

### considerations for DIY’ers and consumers during and after SPF product installation.

• Research

- Develop research and support testing programs to improve understanding of potential exposure to chemical components for workers 

### applying SPF and potential consumer/occupant exposure to SPF emissions.

# CPI SPF Health and Safety 

# Training and Outreach Update

# High

- pressure product training launched in Dec. 2010.

The program provides free online health and safety information for SPF contractors, applicators or 

# helpers who work with two

- component high

pressure SPF systems.

More than 11,000 users have accessed the training 

# program either online or in an instructor

- led capacity.

This program was recently upgraded and translated 

# into Spanish (Dec 2012). 

# CPI SPF Health and Safety Training Programs: 

# High

- Pressure

# ACC CPI High

- pressure Safety & Health Training Through 

# March 2014

Test Scores through February 2014 100% 90

- 99% 70

- 89%

Percent achieving test scores: English 43% 51% 6%

Percent achieving test scores: Spanish 39% 7% 54% February 2014 English February 2014

Spanish March 2014

English March 2014

Spanish Total Through

March 2014

Job Description Fully Complete Fully Complete Fully Complete Fully Complete Fully Complete In Progress

Instructor Online Instructor Online Instructor Online Instructor Online Instructor Online Started, not finished

Applicator 30 139 0 16 12 155 0 9 450 3245 1081

Helper 0 25 0 3 2 23 0 2 68 523 201

Other 29 38 0 0 7 30 0 1 335 2214 815

Supervisor 11 67 0 2 10 64 0 0 474 1649 729

Total 70 269 0 21 31 272 0 12 1323 7631 2826

Total # of Students Fully Completed Through March 2014 Total # of Students Started or Finished Through March 2014

8954 11780

# Low

- pressure product training launched in Dec. 2012 in English and Spanish.



# This training was supported by grant funding from OSHA.

The Low

- Pressure Training provides information for weatherization professionals, applicators or helpers, who work with one

- component SPF or two



# component, low

- pressure SPF kits for sealing and insulating. CPI SPF Health and Safety Training Programs: 

# Low

- Pressure

# ACC CPI Low

- pressure Safety & Health Training Through 

# March 2014

Test Scores through March 2014 100% 90

- 99% 70

- 89%

Percent achieving test scores: English 20% 63% 17%

Percent achieving test scores: Spanish 0% 0% 100% Total # of Students Fully Completed Through March 2014 Total # of Students Started or Finished Through March 2014

1065 1697 February 2014 English February 2014

Spanish March 2014

English March 2014

Spanish Total Through

March 2014

Job Description Fully Complete Fully Complete Fully Complete Fully Complete Fully Complete In Progress

Instructor Online Instructor Online Instructor Online Instructor Online Instructor Online Started, not finished

Applicator 0 27 0 7 0 26 0 0 1 385 286

Helper 0 3 0 2 0 3 0 3 0 72 37

Other 0 7 0 1 0 7 0 0 0 392 167

Supervisor 0 16 0 1 0 9 0 0 0 215 142

Total 0 53 0 11 0 45 0 3 1 1064 632

## Trainees have the option of taking one or both training courses.

Each training program takes between 1.5 to 2.5 hours to complete.

Those who pass with a 70% or higher receive a “recognition of completion” form and wallet

- size card, which is valid for 2 years.

Completion of the high

- pressure training program is a prerequisite 

## for any level of the certification in SPFA’s Professional Certification Program.

For convenience, both programs are available online 24/7 or in a 

## classroom setting when organized by a registered instructor. 

# CPI SPF Health and Safety Training Programs

## This video provides general guidance for professionals on how to apply low

- pressure spray polyurethane foam. It is intended as a 

## supplement to available job safety information such as specialized training, Safety Data Sheets (SDS), product label information and other

materials

. 

# Working Safely with Low

- Pressure Spray Polyurethane Foam Insulation

(Online DVD)

The video is available to view or download at

www.spraypolyurethane.org.

The video has over 3,400 downloads.

# Website 

# www.spraypolyurethane.com

# Website 

# www.spraypolyurethane.com

 Recently completed: Guidance for Developing a Written Respiratory Protection Program; Ventilation Considerations for 

## SPF; Polyurethane and Thermal Degradation Guidance

 Continue to promote available 

## health and safety information at industry events

# 2014 Outreach

Outreach for CPI SPF Worker Training Programs:

• Fliers promoting training for events e.g. SPFA Conference (Jan. 2014)

• In January, the use of the high

- pressure training program increased 31 percent over last January’s high, setting a new record of 446 training completions (in English and Spanish) for the month of January.

• Hosted a training room at the 2014 SPFA Conference

• Participate in industry events (i.e. booth at SPFA Conference)

• Spanish flyers created to promote the translated training programs (Jan. 2014)

# CPI SPF VENTILATION RESEARCH TASK FORCE 

# RE

- ENTRY STUDY

RICK WOOD, AIR PRODUCTS

# Project Status

Phase 1

– Complete

 Develop and test generic high pressure low density, high pressure medium density, and low pressure kit formulations.

 Evaluate commercial spray equipment using the formulations.



## Phase 2a

– Complete

 Conduct air monitoring in a fabricated spray room and spray booth to measure chemical emissions during application of the generic formulations under controlled environmental conditions.



## Phase 2b

– In Progress

 Document the decay rate of specific chemical vapors following SPF application. The purpose is to estimate the time required to restrict unprotected adult trade workers from the work area in order to minimize exposure.



## Phase 3

– Not started

 Conduct air monitoring in the field, such as in a medium

- sized residential building, to measure chemical emissions during SPF application.

# Phase 1

 Three generic formulations were developed:

 Low density open cell formulation

 Medium density closed cell formulation

 Low pressure 2

- component kit formulation



##  The formulations represent typical commercial systems; however, they do not reveal confidential information of actual formulations on the market/in use.

 Generic formulations used for the CPI Ventilation and Emissions studies.

# Phase 2a Test Protocol for Ventilated Spray 

# Room

 Initial Proposal

– Spray three (3) generic formulations at four (4) ventilation rates

 P roposed rates

- 0.3, 2, 5, and 10 Air Changes per Hour (ACH)



##  Testing completed for 10 ACH ventilation rate

 Four (4) sessions of personal and area sampling were completed for each formulation.

 Each session included post

- spray sampling beginning 30 min after the completion of the spray session.



##  Two (2) hour ventilation purge between sessions.



##  Testing completed for 233 ACH and 598 ACH ventilation rates

 Four (4) sessions of personal and area sampling were completed for the 2 lb generic formulation.

# Ventilated Spray Room

 Approximately 8 ft x 8ft x 8ft.

 Adjustable air flow rates range between 1 ACH and 13 ACH.

 Ventilation rate of 85 cfm or 10 ACH selected for testing. Low exchange rate equivalent to 1 air change every 6 min.

 Make

- up air introduced on one side of the room and exhausted though a filter bank on the opposite wall of the room.



###  Spray equipment and chemicals located outside the room.

# Ventilated Spray Room

Courtesy of Air Products and Chemicals, Inc.

# Phase 2a: Work Process

 Applicator sprayed 2 inserts, removed the inserts, stacked them in the work area, placed new inserts in the substrate, and repeated the process.

 Twelve (12) inserts sprayed for low and medium density formulations. Six (6) inserts for the kit formulation. The amount of foam sprayed (lbs) and foam densities were recorded.

 Spray time limited to 15 minutes during SPF application.

 Post spray area samples collected 30 min after SPF application completed.

 Sprayed inserts remained in the room

 Ventilation continued to operate at 10 ACH

# Phase 2a: Air Sampling

Area samples located behind the applicator. Collected during SPF application and post

- spray session

Personal samples positioned on spray applicator

# Phase 2a: 

# Conclusions

– 10 ACH Research

 CPI Ventilation Research Task Force reviewed findings.

 Concentrations of chemicals monitored exceeded occupational exposure limits during application at the 10 ACH ventilation rate.

 A

- side MDI not detected in post spray samples.



###  B

- side components lower concentrations in post spray samples



##  Recommended future studies be conducted at higher air exchange rates.

# Spray Booth Study

 Testing conducted in a spray booth capable of higher ventilation rates. Experimental protocol unchanged

 High pressure medium density formulation evaluated at air exchange
rates of 233 and 598 ACH.

# Phase 2a: 

# Conclusions 233 ACH / 598 ACH

 SPF particulate emissions from high pressure systems are difficult to control even at ventilation rates as high as 598 ACH

.

 SPF applicator and others working in close proximity to application continue to follow safe work practices and wear protective clothing, gloves and air

- supplied respiratory protection to prevent chemical exposure as recommended.

# Phase 2b: 

# CPI Re

- Entry Test Protocol

 The purpose of the study is to evaluate emissions during 12 hour period following the application of the 3 generic formulations.

 Recommended best practice is to continue mechanical exhaust ventilation for 24 hours following application. Sometimes, fans and 

### blowers are removed at the end of the shift. Phase 2b t est protocol was designed to simulate field conditions with ventilation removed.

 Air Exchange Rates: 10 ACH for initial measurements and 1 ACH beginning 3 hours after application

 The higher ventilation rate of 10 ACH was selected for the first segment of air monitoring since it would representative minimal mechanical air ventilation and open windows.

 The 1 ACH rate would be considered passive ventilation representative of a sprayed building space without mechanical ventilation.

# Phase 2b: 

# CPI Re

- Entry Test Protocol

 12 inserts sprayed for a 15 min period at 10 ACH. After spraying ventilation to continue at a rate of 10 ACH for 1 hour with inserts remaining in the room. Air sampling to begin at Hour 1 and continue for 12 hours in accordance with the following schedule:

 Hour 1

– Air samples collected for 20 minutes 1 hour after application. Ventilation to operate at 10 ACH.

 Hour 2

- Air samples collected for 20 minutes 2 hours after application. Ventilation to operate at 10 ACH.

 Hour 3

- At the completion of second hour sampling, ventilation to be reduced from 10 ACH to 1 ACH. The ventilation to operate at 1 ACH for 1 hour. No air sampling to be conducted during Hour 3.

 Hour 4

– Air samples collected for 20 minutes 4 hours after application. Ventilation to operate at 1 ACH

 Hour 8

– Air samples collected for 20 minutes 8 hours after application. Ventilation to operate at 1 ACH

 Hour 12

- Air samples collected for 20 minutes 12 hours after application. Ventilation to operate at 1 ACH

# Phase 2b: 

# Air Sampling/Analytical Methods

 Air sampling duration 20 minutes for each sample with the sample time bracketing the hour; 10 min before the hour and 10 min after the hour.

 A

- Side: 2,4 and 4,4

- MDI collected during Hour 1 (10 ACH), 2 (10 ACH), 

### and 4 (1ACH)

 OSHA Method 47

– Glass fiber filter treated with 2PP

– HPLC/UV



###  B

- Side: Amine catalyst, Blowing agent, Fire retardant collected at each scheduled test hour

 Draft ASTM standard test method for “ Sampling and Determination of Vapor

Phase Organic Compounds Emitted from Spray Polyurethane Foam (SPF) Insulation in Micro

- Scale Chambers using Sorbent Tubes Analyzed by Thermal Desorption Gas Chromatography and Mass Spectrometry.”

# Thermal Desorption Tubes 

# B

- Side Components

 Stationary/area air samples collected in the center of the spray room , suspended at a height of approximately 6 feet with inserts in the

room.

# Treated glass fiber filter 

# A

- Side MDI Vapor

# Blowing Agent

– HFC 245fa Medium Density High Pressure SPF Formulation 

## November 19

- 20, 2013

0.1 1 10 100

1 2 4 8 12 Concentration – (ppm)

Hours Post Application 11/19/2013
11/20/2013 Air Exchange Rate
Hours 0

– 3 = 9.2 ACH Air Exchange Rate
Hours 3

– 12 = 1.7 ACH Occupational Exposure Limit =300 ppm

# DAPA and BDMAEE Medium Density High Pressure SPF Formulation 

## November 19

- 20, 2013

0 0.01 0.02 0.03 0.04 0.05 0.06

1 2 4 8 12 Concentration - (ppm)

Hours Post Spray DAPA 11/19/13
DAPA 11/20/13
BDMAEE 11/19/13
BDMAEE 11/20/13 Occupational Exposure Limit BDMAEE = 0.05 ppm

Air Exchange Rate
Hours 0

– 3 = 9.2 ACH Air Exchange Rate
Hours 3

– 12 = 1.7 ACH

# TCPP Medium Density High Pressure SPF Formulation 

## November 19

- 20, 2013

0 0.001 0.002 0.003 0.004 0.005

1 2 4 8 12 Concentration - (ppm)

Hours Post Spray TCPP 11/19/2013
TCPP 11/20/2013

# 2,4 and 4,4

- MDI Medium Density High Pressure SPF Formulation

0 0.005 0.01 0.015 0.02 0.025 0.03

0 0.5 1 2 4 Concentration - (ppm)

Hours Post Spray 2,4-MDI

4,4-MDI SPF Application

# DAPA and BDMAEE Medium Density High Pressure SPF Formulation

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5

0 0.5 1 2 4 8 12 Concentration - (ppm)

Hours Post Spray DAPA 11/20/13
BDMAEE 11/20/13 SPF Application

# TCPP Medium Density High Pressure SPF Formulation

0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4

0 0.5 1 2 4 8 12 Concentration - (ppm)

Hours Post Spray TCPP

SPF Application

# Blowing Agent

– HFC 245fa Medium Density High Pressure SPF Formulation

0.1 1 10 100

0 0.5 1 2 4 8 12 Concentration – (ppm)

Hours Post Application HFC-245fa

SPF Application

# CPI Re

- entry Study 

# Preliminary Conclusions

A

- Side

 Airborne concentrations of 2,4 and 4,4

- MDI below detection limits (<0.0015 ppm) 30 min after application.

B

- Side

 10 ACH

- Blowing agent, fire retardant, and amine catalysts well within exposure limits at Hour 1

. Concentrations continued to drop at Hour 2.

 1 ACH

- B

- side components generally increased at Hour 4 as ventilation was reduced. Gradually declined form Hour 4 to Hour 12.

 Testing for the generic low density open cell formulation completed Feb 2014. Awaiting report review.

 Testing for the generic low pressure kit formulation scheduled for May 2014.

 Results for all three formulations to be presented at 2014 CPI Conference.

# John Sebroski, Bayer MaterialScience LLC Center for the Polyurethanes Industry (CPI) Spray Polyurethane Foam Emissions Task Force

# ASTM Standards and Work Items

ASTM D7859

- 13e1

• Standard Practice for Spraying, Sampling, Packaging, and Test Specimen Preparation of Spray Polyurethane Foam (SPF) Insulation for Testing of Emissions Using Environmental Chambers



### WK40292

• To be withdrawn (thermal desorption GC/MS combined with WK40293)



### WK40293

• Test Method for Determination of Vapor

- Phase Organic Compounds Emitted from Spray Polyurethane Foam (SPF) using Micro

- Scale Environmental Test Chambers



### WK43872

• Test Method for Determination of Emissions of Methylene diphenyl diisocyanate (MDI) from Spray Polyurethane Foam (SPF) Insulation using Emission Cells or Micro

- Scale Environmental Test Chambers



### Proposed

• Standard Practice for Determination of SPF Emissions in Spray Booth

# Recovery of SVOCs Spiked into 36 Liter 

# Electropolished Chamber

Compound Spike, μ g Observed, μ g % Recovery

BDMAEE 85.0 16.4 19.3

PMDTA 74.4 2.50 3.36

DAPA 70.3 <2 <3

TCPP 9.49 5.42 57.1

Carrier = Air, RH=55% Air Exchange Rate = ~1/hr. Sampling Time = 20 hours with XAD

- 2 Analyzed with GC/MS

Surrogate spike = 40 μ g bromofluorobenzene Recovery = 97.7 %

Mixing fan did not improve SVOC recoveries. New chamber required conditioning.

# Micro

- Scale Chamber System for SPF

# Measuring Relative Humidity

# Recovery of SVOCs in Micro Chamber

Spike Recovery of SVOCs Captured with XAD

- 2 Tubes, GC/MS

Compound Relative

Humidity, % Determined Spike

Amount, μ g Measured in Chamber, μ g Mean % Recovery Precision,

RPD Run 1 Run 2

BDMAEE 50.0 118 113 116 97.0 2.62
<1 111 115 117 105 1.72

PMDTA 50.0 125 102 119 88.4 15.4
<1 120 117 121 99.2 3.36

DAPA 50.0 143 84.2 115 69.7 30.9
<1 136 116 125 88.6 7.47

TCPP* 50.0 17.3 1.90 1.90 11.0

- <1 22.9 2.30 2.10 9.61 9.09

Flow rate = 100 cc/minute; sampling time = 20 minutes

.

*Previous data show 100% recovery of TCPP at 16 hours.

# Recovery of SVOCs in Micro Chambers

# Recovery of SVOCs in Micro Chamber

Spike Recovery of SVOCs in Micro Chamber with Thermal Desorption GC/MS

Compound Determined Spike Amount, μ g Measured in

Chamber, μ g % Recovery

BDMAEE 1.63 1.77 109

PMDTA 1.91 1.97 103

DAPA 2.47 1.93 78.1

TCPP 2.76 0.34 12.4

Flow rate = 100 cc/minute; sampling time = 20 minutes; carrier is ultra zero air , RH <1 %.

# Thermal Desorption Safe Sampling 

# Volumes and Method Detection Limits

Compound Method
Detection
Limit on TD Tube, ng Multi

Sorbent Tube Breakthrough

Volume, L Safe

Sampling Volume, L Minimum

Concentration Level, μg/m 3

HFC

- 245fa 49.4 B >12 8 6.2

TMAEEA 479 A >12 8 59.9

BDMAEE 32.2 A >12 8 4.0

DAPA 222 A >12 8 27.8

PMDTA 74.0 A >12 8 9.3

TMIBPA 654 A >12 8 81.8

TCPP 26.0 A >12 8 3.2



### Tube A contains Tenax TA and graphitized carbon black Tube B contains Tenax TA, graphitized carbon black and carbonized molecular sieves

# III Research for MDI Emissions

Evaluation of Modified FLEC Cell and Micro Chamber Prototype for Monitoring MDI Emissions

FLEC Emissions Cell Micro Chamber Prototype

# Glass Fiber Filter Spiked with MDI

500 μ g/cm 2 

### polymeric MDI added to glass fiber filter to simulate sample surface

# 1,2

- PP Coated FLEC

Surface coated with 10 mg 1,2

- PP on 150 mm diameter FLEC surface. Carrier = Dry air and humidified air (50% RH) at 100cc/min for 2 hours. Outlet = 13mm 1,2

- PP filter to measure breakthrough

# Modified FLEC Evaluation

Sample placed on stainless steel plate, which was heated to approximately 32 ° C Carrier = UHP nitrogen at 100cc/min for 2.5 hours and 18 hours. 1,2

- PP filter desorbed with 90:10 Acetonitrile, DMSO; Test Method US EPA CTM

- 036.

# FLEC with Sample Holder

Polyurethane foam placed in sample holder to minimize distance from FLEC

# Evaluation of 1,2

- PP Coated FLEC

Sample Conditions Distribution of MDI 2,4

- MDI 4,4

- MDI Polymeric MDI

FLEC

- 1 Dry Ultra Zero Air at 100

cc/min for 2 hours Coated Walls 99.3% 99.7%

-

13mm Filter 0.68% 0.34%

-

FLEC

- 2 Dry Ultra Zero Air at 100

cc/min for 2 hours Coated Walls 99.6% 99.7% Not Analyzed 13mm Filter 0.42% 0.26%

FLEC

- 3 Humidified Air, 50% RH,

at 100 cc/min for 2 hours Coated Walls 99.7% 99.8% Not Analyzed 13mm Filter 0.33% 0.20%

# Micro Chamber Prototype

Wall height = 6 mm Filter diameter = 57 mm Inner diameter = 45 mm 

### Sample surface temperature = 32 ° C

Carrier = Dry air and humidified air (50% RH) at 100

- cc/min for 2 hours

.

# Micro Chamber Lid Assembly

Lid with glass fiber residue after test

Micro Chamber Apparatus for MDI Evaluation

# Evaluation of Micro Chamber Prototype for Measuring MDI Emissions

Sample Conditions Distribution of MDI 2,4

- MDI 4,4

- MDI Polymeric MDI

MC

- 1 Dry Ultra Zero Air at

100 cc/min for 2 hours Filter 89.4% 89.8%

-
Walls 10.6% 10.2%

-

MC

- 2 Dry Ultra Zero Air at

100 cc/min for 2 hours Filter 85.1% 84.7%

-
Walls 14.9% 15.3%

-

MC

- 3 Dry Ultra Zero Air at

100 cc/min for 2 hours Filter 87.2% 86.6% 100%

Walls 12.8% 13.4%

-

MC

- 4 Humidified Air, 50%

RH, at 100 cc/min for 2 hours Filter 86.8% 86.1%

-

Walls 13.2% 13.9%

-

MC

- 5 Humidified Air, 50%

RH, at 100 cc/min for 2 hours Filter 90.0% 89.9%

-

Walls 10.0% 10.1%

-

# 1,2

- PP Diffusion to Sample

Sample Description Mass of 1,2

- PP,
μg Diffused 1,2

- PP

onto Sample, % Sample Time, hours

FLEC Sample Filter 787 6.84 2 1,2

- PP Coated on interior of FLEC 11500

Micro Chamber Sample Filter 289 0.49 19 1,2

- PP on 57mm Filter 59214



### There were known amounts of 1,2

- PP on the coated FLEC and on the 57mm filter used in the micro chamber

.

The 1,2

- PP was measured on the sample filter by desorbing with 90:10 acetonitrile and DMSO followed by LC analysis with UV detection.

# Next Steps

Micro

- Scale Chamber and TD/GC/MS

 Combine WK40292 and WK40293 into single document

 Continue research, method development and validation

 Ballot the combined document at ASTM D22.05 , August 2014



# MDI Emissions

 

## Work with vendor to develop micro chamber for MDI emissions

 Write draft ASTM standard

# ASTM Symposium on SPF Emissions

Call for Papers for the Symposium on Development Consensus Standards for Measuring Chemical Emissions from Spray Polyurethane Foam (SPF) Insulation

 Abstract Submissions Due Date

- April 30, 2014



###  Symposium on April 30 and May 1, 2015 in Anaheim , CA

Objective

 Provide a forum for the exchange of ideas from SPF manufacturers, regulatory agencies, indoor air quality professionals, testing labs, air quality consultants, instrument vendors, and other stakeholders. Following the presentations on the current status of measuring emissions 

### from SPF insulation, participants will discuss paths forward for research, method development, and development of standards.