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High Pressure Applications of
Spray Polyurethane Foam (SPF)
Health and Safety
Product Stewardship Workbook
ACC Center for the Polyurethanes Industry
March 26, 2010
Legal
• This slide presentation is part of, and is intended for use as a training aid for, the American
Chemistry Council’s (ACC’s) Health and Safety Product Stewardship Workbook for High-
Pressure Application of Spray Polyurethane Foam (SPF), issued March 15, 2010.
• This work is protected by copyright. The American Chemistry Council, which is the owner of
the copyright, hereby grants a nonexclusive royalty-free license to reproduce and distribute this
work, subject to the following limitations: (1) the work must be reproduced in its entirety, without
alterations; (2) the work may be used only as a training aid for the American Chemistry
Council’s (ACC’s) Health and Safety Product Stewardship Workbook for High-Pressure
Application of Spray Polyurethane Foam (SPF) issued March 15, 2010; (3) all copies of the
work must bear this notice, including the copyright notice; and (4) copies of the work may not be
sold.
Copyright © 2010 American Chemistry Council.
March 26, 2010
Diisocyanate + Polyol Polyurethane Polymer + Heat
SPF Chemicals
• The two basic chemical ingredients in SPF
systems are:
– A-side: MDI (polymeric MDI or modified MDI)
– B-side: Polyol resins
A-side: Methylene diphenyl diisocyanate (MDI)
• Commonly referred to as MDI.
• A-side is reactive and may undergo
chemical reaction with various
chemicals, including water.
• May cause skin and respiratory
sensitization or both.
B-side: Polyol Resin System
Typical Composition of a Polyol Resin in SPF Systems
Component Low Density
Open Cell
Medium Density
Closed Cell
Polyol 35-60% 40-65%
Blowing Agent 18-24% 7-15%
Catalyst 3-8% 3-10%
Flame Retardant 15-25% 15-25%
Surfactant and Glycerin 0.5-8% 1-8%
A Worker May be Exposed to Chemicals by:
• Breathing chemical mists or vapors
• Skin or eye contact
• Ingestion
Types of SPF Products
One-component
foam (OCF)
Two-component
kits
Refillable systems
Two-component
high-pressure
systems
Hazard and PPE varies widely among products.
Potential for Exposure
By Task: Potential for Breathing Chemical Vapors
or Dusts, Skin Contact, and Eye Contact
Task A-side B-side Solvents
SPF application
Trimming and cutting
Coating and priming
Cleanup
Spill response
A-side: Potential Heath Effects
• Possible effects of overexposure to A-side chemicals: – Respiratory irritation and/or respiratory sensitization
– Skin irritation and/or skin sensitization
– Eye contact may cause irritation
• May be immediate or delayed
• Most people cannot smell MDI at the levels regulators consider “safe”
A-side: Respiratory Effects
• Respiratory effects may include:
– Coughing
– chest-tightness/discomfort
– shortness of breath
– reduced lung function
If you experience any of these symptoms, seek medical
attention and notify your supervisor immediately!
A-side: Sensitization
• Sensitization is a reaction much like an allergic reaction – Symptoms tend to disappear even after contact with the A-side stops
– Symptoms may be delayed up to 8 hours after exposure
– Sensitization can get progressively worse and may be permanent
– Once sensitized, consult with a physician since you may be instructed to no longer come in contact isocyanates.
• In animals studies, skin contact has led to respiratory sensitization.
Respiratory sensitization can result in asthma; a severe asthmatic attack could lead to death.
A-side: Skin and Eye Contact
• Skin contact with A-side chemicals may cause skin discoloration or irritation.
• Eye contact with A-side chemicals may cause tearing and burning or stinging in the eyes.
B-side: Potential Health Effects
• Inhalation overexposure may result
in respiratory irritation.
• Skin or eye contact may cause
irritation at the site.
• In eyes, foggy vision or “blue haze”,
also called “halovision” may occur.
(Vision restored within a few hours
after exposure ceases)
• Amine catalysts can be associated
with a fishy odor.
Solvents: Potential Health Effects
• Used in surface preparation, coatings, and cleanup
• Potential effects of overexposure include: • Headaches
• Slurred speech
• Nausea and/or vomiting
• For solvents, important routes of exposure include breathing chemical vapors and skin contact.
First Aid
The following slides include general first-aid advice
applicable to most chemicals at a construction site.
For specific instructions on any chemical, refer to the
Material Safety Data Sheet (MSDS).
First Aid: Inhalation Overexposure
• Always consult the MSDS for
instructions specific to
particular chemical use.
• Move to an area with fresh air.
• Seek medical attention
immediately.
First Aid: Skin Contact
• Always refer to the MSDS for
specific information.
• Remove contaminated clothing.
• Wash skin thoroughly with soap
and/or water.
• Do not use solvents!
• Seek medical attention if irritation
develops.
First Aid: Eye Contact
• Refer to MSDS for
specific information.
• Wash immediately with
water, preferably from
an eyewash fountain,
for 15 minutes or more.
Review
1. The A-side of a spray polyurethane
foam contains ____: A. Water
B. Polyurethane foam dust
C. A chemical commonly referred to as MDI
D. Alcohol
Answer
1. The A-side of a spray polyurethane
foam contains:
A. Water
B. Polyurethane foam dust
C. A chemical commonly referred to as MDI
D. Alcohol
Review
2. Skin contact with A-side chemicals
may lead to ____:
A. Skin sensitization
B. Respiratory sensitization
C. Skin irritation
D. All of the above
Answer
2. Skin contact with A-side chemicals
may lead to:
A. Skin sensitization
B. Respiratory sensitization
C. Skin irritation
D. All of the above
Review 3. For individuals who become sensitized to
isocyanates, which of the following is the
appropriate course of action ____?
A. Let them continue working in their present job
because the sensitization will go away.
B. Assign them to jobs in which there is no
possibility of exposure to isocyanates.
C. Have them get plenty of exercise.
D. Have them wear a respirator.
Answer 3. For individuals who become sensitized to
isocyanates, which of the following is the
appropriate course of action?
A. Let them continue working in their present job
because the sensitization will go away.
B. Assign them to jobs in which there is no
possibility of exposure to isocyanates.
C. Have them get plenty of exercise.
D. Have them wear a respirator.
Safety Information
• Safety information regarding the hazards
related to your job include:
– Material Safety Data Sheets (MSDSs)
– Chemical labels
Material Safety Data Sheet (MSDS)
• Per OSHA Standard Hazard Communication,
employers must have MSDS readily accessible for
each chemical used.
• MSDS contain important information about chemical
products, including chemical constituents,
appropriate PPE, handling, storage, spill response,
transportation, and disposal.
• Be familiar with the MSDS for the
chemicals you are working with. Know
where the MSDS is in your work area!
Chemical Labels
• Per the OSHA Hazard Communication
Standard, chemical containers must be labeled
with the trade name and/or the full chemical
name.
• Examples of recognizable, easily understood
systems for identifying specific hazards include
HMIS and NFPA.
Hazardous Materials Identification System
(HMIS)
HMIS® Ratings
O – Minimal hazard
4 – Severe hazard
PHYSICAL HAZARD
National Fire Protection Association (NFPA®)
Label
• Indicates hazards under fire conditions for fire fighters.
: Health
: Fire
: Instability
: Special/specific hazards
O – lowest degree of hazard
4 – highest degree of hazard
Occupational Exposure Limits
• Levels intended to protect healthy workers from chemical
exposure.
– Short-term -average concentration over 15 minutes
– Shift - average concentration over 8 hours, based on 40-hour workweek
– Ceiling limits - not to be exceeded for any amount of time
– Examples: OSHA PEL and STEL, NIOSH REL, and ACGIH TLV
• May not be protective of all workers, such as sensitized
persons.
Review
4. Before beginning work, you should be
familiar with _____:
A. Material Safety Data Sheet (MSDS) for each
chemical used
B. Chemical labels
C. Worksite-specific procedures
D. All of the above
Answer
4. Before beginning work, you should be
familiar with:
A. Material Safety Data Sheet (MSDS) for each
chemical used
B. Chemical labels
C. Worksite-specific procedures
D. All of the above
Review
5. The HMIS system ranks hazards from
“minimal hazard” to “severe hazard” from
___ to ___.
A. 0 to 4
B. 4 to 0
C. D to A
D. A to D
Answer
5. The HMIS system ranks hazards from
“minimal hazard” to “severe hazard” from
___ to ___.
A. 0 to 4
B. 4 to 0
C. D to A
D. A to D
Safety Controls
• Engineering Controls - the first safety control
used to change the design of the job to
minimize the hazard.
– e.g., Ventilation
• Work Practices
– e.g., No-smoking policy
• Personal Protective Equipment (PPE)
– e.g., Gloves
Safety Equipment
• Prior to beginning work, know
the location of the following:
– MSDS for all chemicals present at
the job site
– Fire extinguisher
– Eye wash station or personal eye
wash
– First-aid kit
Job Factors to Consider
• High pressure vs. low pressure
• Amount of foam applied
• Temperature of SPF chemicals
• Air temperature and humidity
• Indoor vs. outdoor (wind
direction?)
• Occupied building vs.
vacant building
• Other tradeworkers
present
• Size of the work area
• Ventilation rate
• Attics and crawlspaces
Occupant Outreach
• Appendix D of the workbook provides a
sample checklist of information to discuss
with owners, designees, or occupants.
– Hazards associated with SPF application.
– Discuss re-occupancy time with occupants.
Specific time varies based on product formulation.
Consult with manufacturer for specific information.
– Any person with potential exposure during
application needs appropriate PPE.
Site Preparation:
Exterior Applications
• Shut down HVAC system
• Seal air intakes with plastic sheeting and tape
• Remain sealed for the duration of work and several hours after
application (typically 24 hours or more). Contact supplier for more
information.
• A longer period may be needed for coating applications.
• Establish perimeter around work area
• Permit access only to those wearing appropriate PPE
• Protect surfaces that could be damaged by overspray
• Shut down HVAC system
• Seal vents with plastic sheeting and tape
• Ventilate and prohibit access to the spray area for a period of
time following installation. Contact your SPF supplier for
guidance
• Permit access only to those wearing appropriate PPE
• Protect surfaces that could be damaged by overspray
Site Preparation:
Interior Applications
Engineering Controls
• Some engineering controls can be
used to reduce the risk of
overexposure, particularly in attics
and crawlspaces and buildings that
have not been vacated.
– Worksite containment
– Ventilation
• Locate discharge points away from air intakes
SPF Chemical Storage and Handling
• Secure chemicals in a well-ventilated
area away from direct sunlight or extreme
temperatures.
• A-side chemicals are reactive, even with
water. Seal tightly to prevent entry of
moisture or water contact.
• Keep B-side containers cool to help
prevent bulging or rupture. Contact
supplier for suggested storage
temperature (typically 45 – 75⁰F).
SPF Application Work Practices
• Read and understand the MSDS
for all the chemicals you are
working with
• Use appropriate PPE
• To help prevent ingestion
exposure, don’t eat, drink, or
smoke in the work area
• Promptly clean surfaces that
contact SPF chemicals
After Application of SPF Chemicals
• There may be potential for inhalation
overexposure or skin or eye contact with SPF
chemicals during:
– Trimming and cutting foam
– Coating and priming
– Cleanup and equipment maintenance
Use appropriate PPE during these tasks too!
SPF Application in
Attics and Crawlspaces
• Hazardous atmospheres may be generated in these
spaces
• Depending on characteristics, may be considered a
confined space
– OSHA Permit-Required Confined Space Standard (29 CFR
1910.146) may apply
– OSHA is currently developing Confined Space in
Construction Standard
– ANSI Standard Z117.1 Safety Requirements for Confined
Spaces provides additional information
Personal Protective Equipment (PPE)
• In addition to engineering controls and work practices, PPE is needed to prevent:
• Skin and eye contact
• Inhalation overexposure
• Refer to the MSDS for specific information related to the chemicals you work with.
Personal Protective Equipment (PPE)
• Protective Clothing
• Gloves
• Eye Protection
• Respiratory protection
PPE Guidance
PPE Guidance for Applicators and Helpers in the Spray Area –
Interior and Exterior Applications
Personal Protective Equipment (PPE) Interior
Applications
Exterior
Applications
Protective Clothing
Gloves
Full-face or hood Supplied Air Respirator (SAR)
Full-face Air-Purifying Respirator (APR) or full-face or
hood Powered APR (PAPR)
Additional materials available at:
www.spraypolyurethane.com
Protective Clothing
Disposable Coveralls Disposable Overboots (when
their use does not pose a slip /
trip hazard)
To prevent skin contact and protect clothing:
Gloves
• Refer to MSDS for specific information
• Fabric gloves fully coated with nitrile, neoprene, butyl rubber, or
PVC can provide protection for applicators
• For helpers and during liquid chemical handling, consider
nitrile, neoprene, butyl rubber, or PVC gloves
Eye and Face Protection
For liquid chemical handling, use
chemical safety goggles or safety
glasses with side shields
Eye protection may be
provided through the use of
a full face or hood respirator
Respiratory Protection
• Regulated by OSHA Respiratory Protection Standard,
29 CFR 1910.134
– When respiratory protection is needed to protect health of
employees, OSHA regulations require employers to provide
respirator.
• OSHA requires that the respirator selected must be
certified by NIOSH.
– To maintain NIOSH certification, respirator facepiece must
be of the same brand as accessories (e.g. cartridges,
compressor).
Respiratory Protection Program
OSHA requires employers to have a written respiratory
protection program when respirators are necessary to
protect employee health.
Model Respiratory Protection Program
Developed by CPI to help assist
companies in compliance with OSHA’s
Respiratory Protection Program Standard
29 CFR §1910.134
Available on CPI’s website,
www.americanchemistry.com/polyurethane
Supplied Air Respirators
• Supplies the respirator user with breathing air via air line
• Locate supplied air source outside spray area
• May be a tight-fitting facepiece or a hood
Procedures for maintaining
quality of breathing air
are specified in 29 CFR 1910.134.
Air-Purifying Respirators
• Primarily for exterior applications
• Protection provided is dependent on: – Type of respirator and cartridge used
– Condition of respirator and cartridge
• Different cartridges are certified by NIOSH to protect against different chemicals
• Particulate filters protect against mists and dusts
Powered Air-Purifying Respirators
(PAPR)
• Primarily for exterior applications.
• Similar to APR, but air is pulled through the filters via a battery-
operated blower unit. This creates positive pressure at the
facepiece.
• Provides higher degree of protection than APR due to positive
pressure.
• In many cases, cooling effect due to airflow at facepiece.
• May be used with a full-face mask or a hood.
APR Cartridges
• In most cases, when applying SPF or coatings combination organic vapor cartridge with a particulate pre-filter is appropriate.
• NIOSH color coding of respirator cartridges and filters: – Black for Organic vapor (OV)
– Yellow for Organic vapor/ Acid gas (OV/AG)
– Magenta for P100 filters
– Filters designated N95, N99, R95, R99, or P100
• If you have any doubt about which cartridge to use, contact the respirator supplier for advice.
APR Cartridge Change out
• To prevent breakthrough, respirator cartridges are changed out:
– Per employer’s cartridge changeout schedule • API Model Respiratory Protection Program provides
guidance for changing cartridges after 8 hours of use for most applications when working with MDI
– More frequently if: • Cartridge becomes damaged
• Detection of chemical odor
• Experience breathing resistance
User Seal Check
• Prior to entering work area
• Conduct each time the respirator is worn
• Follow manufacturer’s instructions for the
respirator you are using
Medical Evaluations
• Conducted by a Physician or Licensed Healthcare
Provider (PLHCP)
• Per OSHA, employees may not wear a respirator until
determined that they are medically able to do so
• Medical evaluations include, at a minimum, medical
questionnaires per 29 CFR 1910.134, Appendix C
Complete prior to fit testing
or issuance of respirator.
Fit Testing
• Needed for tight-fitting facepieces
• To determine whether a seal can be obtained
between user’s face and respirator facepiece
• Fit test with the same make, model, style, and
size of respirator that will be used on the job
• Complete prior to issuance and repeat annually
Hood vs. Full Face
Respirators
Full-face
• Medical evaluation required
• Annual fit testing is required
• Facial hair cannot interfere with face-
to-facepiece seal
• Available with APR, PAPR, and SAR
• Cartridge change-out schedule is
needed for APR
Hood
• Medical evaluation required
• Annual fit testing not required
• No facial hair limitations
• May provide cooling
• Only available with PAPR and SAR
• May decrease range of vision
Review
6. ____ are the first safety control used to
change the design of the job to minimize
the hazard.
A. Engineering controls
B. Work practices
C. Personal Protective Equipment (PPE)
D. Gloves
Answer
6. ____ are the first safety control used to
change the design of the job to minimize
the hazard.
A. Engineering controls
B. Work practices
C. Personal Protective Equipment (PPE)
D. Gloves
Review
7. In addition to engineering controls and
work practices, PPE is needed to prevent:
A. Skin contact
B. Eye contact
C. Inhalation overexposure
D. All of the above
Answer
7. In addition to engineering controls and
work practices, PPE is needed to prevent:
A. Skin contact
B. Eye contact
C. Inhalation overexposure
D. All of the above
Review
8. Gloves made of ____ provide protection
from SPF chemicals.
A. Cotton
B. Latex
C. Nitrile
D. None of the above
Answer
8. Gloves made of ____ provide protection
from SPF chemicals.
A. Cotton
B. Latex
C. Nitrile
D. None of the above
Review
9. True or False? OSHA standards require
that a written respiratory protection
program be in place for all companies that
use respirators.
A. True
B. False
Answer
9. True or False? OSHA standards require
that a written respiratory protection
program be in place for all companies that
use respirators.
A. True
B. False
Review
10.Respirator user seal check is completed:
A. Monthly
B. Each time the respirator is worn
C. Weekly
D. Twice a year
Answer
10.Respirator user seal check is completed:
A. Monthly
B. Each time the respirator is worn
C. Weekly
D. Twice a year
Other Safety Considerations
Thermal Degradation
• When overheated, polyurethanes and other polymers may breakdown.
– Some toxic chemicals may be
emitted. This may or may not be seen as smoke.
– These chemicals may include carbon dioxide, carbon monoxide, nitrogen oxides, hydrogen cyanide, isocyanates and amines.
Hot Work Includes:
• Welding
• Heating polyurethane foam
while working on pipes
• Soldering
• Treatment with a heat gun
• Cutting with torches or hot wire
• Grinding
Other Safety Considerations
Fire Hazards
• Improper application of SPF can be a fire hazard
because of the high temperatures that can be
generated.
• Properly applied SPF reaches approximately 160°F to
200°F during the curing process.
• SPF applied too thickly can reach curing temperatures
of about 300°F. In some cases, this can ignite the
spray foam.
Other Safety Considerations
Energized Equipment
• Be extremely cautious when working near energized electrical equipment and lines. Never let equipment touch or come too close to electric lines or equipment.
• Equipping electric equipment that is used in SPF applications with Ground Fault Circuit Interrupters (GFI) helps prevent electrical shock or electrocution if a short develops in the equipment.
Waste Disposal
Dispose of waste according to
applicable federal, state, and
local regulations.
Disposal of Empty Containers
• Depending on the circumstances, three options
are typically used for disposing decontaminated
steel containers that have contained MDI (A-
side):
– A container reconditioner
– A scrap metal dealer
– An approved landfill
Empty Containers
• Storing other materials in containers that previously held A-side could lead to a chemical reaction and potential safety issues.
• The use of hot torches can result in thermal decomposition or a dangerous fire or explosion. If a used A-side container must be cut, use cool tools.
• Properly decontaminated containers that have held A-side may be punctured or crushed to prevent reuse.
Spill Handling
• Protect employees – Restrict access to spill area
– PPE for personnel involved in cleanup
• Protect Environment – Contain the spill
– Absorb the spill • A-side may need to be neutralized
• An example of an appropriate solution is a 5-10% sodium carbonate and water mixture
– Decontaminate surfaces
• Dispose of waste per applicable regulations
References
ACC Center for the Polyurethanes Industry
www.americanchemistry.com/polyurethane
SPF Health and Safety
www.spraypolyurethane.com
Spray Polyurethane Foam Alliance
www.sprayfoam.org
Occupational Safety & Health Administration
www.osha.gov
National Institute of Occupational Safety & Health
www.cdc.gov/niosh
Review 11.Which of the following materials may be
generated in a fire involving SPF materials
____?
A. Cyanide compounds
B. Isocyanates
C. Oxides of carbon and nitrogen
D. All of the above
Answer 11.Which of the following materials may be
generated in a fire involving SPF materials?
A. Cyanide compounds
B. Isocyanates
C. Oxides of carbon and nitrogen
D. All of the above
Review
12.Dispose of waste ____:
A. In the dumpster
B. Leave it at the jobsite
C. According to applicable federal, state, and local
regulations
D. None of the above
Answer
12.Dispose of waste:
A. In the dumpster
B. Leave it at the jobsite
C. According to applicable federal, state, and
local regulations
D. None of the above
Review 13.True or False. Storing other materials in
containers that previously held MDI could
lead to a chemical reaction and potential
safety issues.
A. True
B. False
Answer
13.True or False. Storing other materials in
containers that previously held MDI could
lead to a chemical reaction and potential
safety issues.
A. True
B. False
Review
14.Which of the following is NOT TRUE regarding
spill cleanup ____:
A. Personnel cleaning up the spill should wear appropriate
PPE.
B. A-side may need to be neutralized before cleaning the spill
C. B-side may need to be neutralized before cleaning the spill
D. Dispose of waste per applicable regulations.
Answer 14.Which of the following is NOT TRUE regarding
spill cleanup:
A. Personnel cleaning up the spill should wear appropriate
PPE.
B. A-side may need to be neutralized before cleaning the
spill.
C. B-side may need to be neutralized before cleaning the
spill.
D. Dispose of waste per applicable regulations.