high pressure applications of spray polyurethane foam (spf)

High Pressure Applications of

Spray Polyurethane Foam (SPF)

Health and Safety

Product Stewardship Workbook

ACC Center for the Polyurethanes Industry

March 26, 2010

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• 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.