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: ThreePronged 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 highpressure 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 InProgress

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 twocomponent, 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 InProgress

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

 Proposed 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 test 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 VaporPhase 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, μg Observed, μg % 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 μg 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, μg

Measured in Chamber, μg

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, μg

Measured in 

Chamber, μg

% 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

MultiSorbent 

Tube 

Breakthrough 

Volume, L

Safe 

Sampling 

Volume, L

Minimum 

Concentration 

Level, μg/m3

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 μg/cm2 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 Symposiumon 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.