Evaluation of Disposable Protective Garments against Isocyanate Permeation and Penetration from Polyurethane Anticorrosion Coatings.

Background Polyurethanes are a class of isocyanate-based organic coatings commonly used to control corrosion on high-value metallic structures. Despite their widespread use, dermal exposure to these isocyanate-containing coatings presents a significant occupational health risk to workers, including the development of allergic and irritant contact dermatitis and systemic sensitization. At present, little is known about the effectiveness of the protective garments commonly used to prevent dermal exposure to polyurethane coatings in construction trades. Objectives The primary objective of this study was to measure the permeation and penetration of isocyanates from polyurethane anticorrosion coatings though a selection of protective garments. In addition, a standardized spray procedure using a fixed-position spraying technique was evaluated as an option to minimize variability in coating application. Methods Five disposable garment materials were evaluated for resistance to isocyanates during this study: latex gloves (0.076 mm), nitrile gloves (0.078 mm), Tyvek coveralls (0.105 mm), polypropylene/polyethylene (PP/PE) coveralls (0.116 mm), and a cotton t-shirt (0.382 mm). A permeation test cell system was used to evaluate each garment material against two products: a polyurethane zinc-rich primer based on 4,4'-methylene diphenyl diisocyanate and an aliphatic finish coating based on prepolymers of 1,6-hexamethylene diisocyanate. Glass fiber filters pretreated with 1-(9-anthracenylmethyl)piperazine were used to collect penetrating isocyanates during the 120-min test period, which were analyzed by liquid chromatography-tandem mass spectrometry. Polytetrafluoroethylene loading filters were sprayed in series with permeation test cells and analyzed gravimetrically to assess the homogeneity of coating application. Results The latex gloves demonstrated the highest rate of isocyanate permeation of all evaluated garments during testing with both coatings (primer: 27.38 ng cm-2 min-1; finish coating: 7.39 ng cm-2 min-1). Nitrile gloves were much more resistant than latex gloves (primer: 1.89 ng cm-2 min-1; finish coating: 1.26 ng cm-2 min-1) and were not permeated by the finish coating until after 15 min. The PP/PE coverall provided the most consistent resistance to both coatings (primer: 0.08 ng cm-2 min-1; finish coating: 1.27 ng cm-2 min-1), whereas the Tyvek coverall was readily permeated by the primer (primer: 3.47 ng cm-2 min-1; finish coating: 0.87 ng cm-2 min-1). The cotton t-shirt was rapidly permeated by the primer during the first 5 min of exposure (primer: 146.65 ng cm-2 min-1; finish coating: 4.64 ng cm-2 min-1). In addition, the fixed-position spraying technique used during this study demonstrated a significant reduction in loading variability within each batch of test cells when compared to manual spray application. Conclusion Nitrile gloves demonstrated superior resistance to both isocyanate-containing coatings in comparison to latex gloves. Although both coverall materials were resistant to permeating isocyanate within the established thresholds, the PP/PE coverall provided more consistent resistance to both coatings. Owing to the cotton t-shirt's high rate of penetration with both coatings, it is recommended only as a secondary barrier. Study results showed that the use of fixed-position spray techniques provided consistent and reproducible results within each batch of test cells. Additional test design modifications are necessary to further reduce variability between batches and ensure more consistent coating thickness.