SPF safety update

The spray polyurethane foam (SPF) industry continues to grow and develop new uses and applications for SPF. During the SPF industry's pioneering phase of the late 1960s, SPF's commercial uses were for insulation and roofing applications. As the industry's use of SPF grew, roofing industry trade associations began developing and writing application guidelines.

SPF's growth was not without problems. The Federal Trade Commission (FTC) led investigations into flammability issues during the early 1970s, which led to extensive fire testing, research, and the issuance of a widespread communications program to inform those involved with SPF or plastic-based products about the products' potential flammability issues.

However, the SPF industry continued to evolve, and in the 1980s, NRCA formed an SPF committee to begin drafting documents for SPF roof system applications. The Spray Polyurethane Foam Alliance (SPFA), as well as its predecessor, the Urethane Foam Contractors Association, also introduced several documents and training programs for SPF applications.

During the late 1990s, the residential market for SPF insulation grew dramatically. And during the past five years, the housing segment has shown a 60 percent increase in SPF use according to the Center for the Polyurethanes Industry's 2008 End-Use Market Survey on The Polyurethane Industries in the U.S., Canada, and Mexico. To meet demand, more applicators are becoming educated about and involved with SPF applications.

Rapid expansion

Industry growth brings more participants, which can cause problems. In the past, SPF applicators typically have been individuals with entrepreneurial business skills who may have learned the trade and wanted to form their own businesses. But now, electronic commerce makes it easier to penetrate an industry and introduce products to many more prospects than conventional marketing techniques previously allowed.

The SPF industry's recent rapid growth has been further aided by the emergence of several large companies such as BASF Corp., Wyandotte, Mich.; BaySystems North America LLC, Spring, Texas; The Dow Chemical Co., Midland, Mich.; Huntsman, The Woodlands, Texas; Honeywell International Inc., Morristown, N.J.; CertainTeed Corp., Valley Forge, Pa.; Johns Manville, Denver; and Graco Inc., Minneapolis, to name a few. Similar growth of the SPF industry has occurred as a result of many roofing contractors entering the SPF business.

The SPF industry has been involved with the cool roofing movement since the early 1970s. Companies such as The Upjohn Co., Kalamazoo, Mich.; Witco Corp., New Castle, Del.; and PPG Industries, Pittsburgh, recognized dark asphalt-based coatings work well on top of SPF roof systems. During the mid- to late 1970s, manufacturers of white and light-colored elastomeric coatings joined in selling to and expanding the SPF industry.

But with all this rapid growth, it is worth asking: Are the documents, research, training and necessary controls in place to ensure SPF workers are trained for safe SPF applications? Are available SPF products fully researched so we know they are safe for use and understand where and where not to use them?

Observations and concerns

Relatively recently, several government agencies began noticing SPF products' increased use in schools, government buildings, military applications and residential applications because of more stringent thermal efficiency mandates. They noted some industry participants use professional SPF application equipment and some work with do-it-yourself products, such as disposable applicators and refillable pressure vessels.

SPF safety practices were observed through reviewing marketing pieces, videos posted on YouTube and trade show practices. The reviewed safety practices caused concern among several regulatory agencies. Their research showed many differences among safety practices used within the SPF industry. Discussions began between government groups, and a plan of action was crafted to work with the industry to increase efforts to ensure the safety of all its participants.

The regulatory agencies' primary concern was ensuring workers follow proper safety practices during SPF application. This means making sure all safety materials in the industry are accurate and complete and communicated to those who work with or around the products.

Previous government interagency coordination group activities have proved effective for issue management and program development. As a result, the American Chemical Council's Center for the Polyurethanes Industry (CPI) and SPFA gathered SPF industry representatives and met with several regulatory agencies—including the Environmental Protection Agency (EPA), Occupational Safety and Health Administration (OSHA), National Institute of Occupational Safety and Health, and Consumer Safety and Products Commission—to discuss SPF safety issues. Coordination meetings were held during 2009, and an action plan was developed and implemented.

In addition to existing construction regulatory requirements, the government agencies wanted to ensure proper applicator protection was understood and practiced by all those handling and installing SPF products.

Consolidating information

During the past 40 years, a lot of SPF safety information has been provided. This information has been produced by industry trade associations, government regulatory agencies, and the private sector that produces and applies SPF materials. CPI, SPFA, Insulation Contractors Association of America and NRCA have provided specific safety information in videos, printed documents and training programs. This information, as well as industry proprietary safety information, was reviewed and consolidated by the interagency group to produce materials to explain the possible risks associated with SPF application.

The goal was to put the information into a format that could be easily used and accessible to all in the industry. It became apparent many of the interagency group's requests would have to be broken down into what are referred to as Tier 1 and Tier 2 projects. Tier 1 projects were those that could be done quickly and put to immediate use. Tier 2 projects would take more time or research to develop before establishing industry best practices.

Safety documents

The first materials produced by the interagency group were task-related safety posters showing the necessary personal protective equipment (PPE) suggested for various tasks such as opening drums of compounds, spraying foam, equipment cleaning and maintenance, etc.

The next items produced were industry guidance documents, question-and-answer documents, and step-by-step guidelines; these were created using all of the industry groups' information and past experiences. Air monitoring during sample applications and government agency input also were included.

The documents were created so an SPF applicator or user could read and understand possible risks and the PPE or actions required for protection. The documents can be accessed at www.spraypolyurethane.com.

The information was released for use and distribution in August 2009, and a panel of industry and government representatives presented the information during CPI's Polyurethanes 2009 Technical Conference in Washington, D.C., as well as at Greenbuild 2009 in Phoenix.

The information is intended to be reviewed and improved upon as the SPF industry continues to receive feedback and new information about SPF's health and safety issues. Webinars providing outreach and communications about safety concerns also have been conducted.

Work groups

The initial production of safety materials was geared toward professional SPF applicators because they seem to comprise the main SPF industry segment and are easier to define and reach compared with the large number of applicators making up the do-it-yourself market.

Some questions asked of SPF industry participants remain unanswered, such as: "How long does it take for SPF to fully cure?" and "How soon can workers be around SPF without PPE?" It was determined that work groups need to be created to address specific tasks such as research, hazard communications, and communication and marketing programs.

A request to SPF industry participants brought a second wave of volunteers who will be coordinated by CPI and SPFA and move forward with guidance and feedback from the government interagency group previously established.

Challenges

These new developments likely will help rewrite more detailed SPF application and industry guidelines regarding worker and product safety. As the industry continues to grow, the documents and practices will continue to evolve.

Make no mistake: Safety costs money. In the construction industry, there often are differences in safety practices. One of the interagency group's objectives is to establish a standard set of practices for safe SPF applications to be followed by all in the SPF industry.

The interagency group's SPF safe use communications and marketing are a huge challenge. As the interagency group continues to gather research results, increased information from outreach programs and updates, the documents need to be refreshed, distributed and put to use.

Education and training are key parts of SPF safety. Advancements must be made so educated applicators are the ones performing SPF applications and practicing what they have learned.

The SPF industry's makeup is complex, and when you consider the do-it-yourself market, the task of educating and training that segment becomes a big job. Increased knowledge about the SPF industry and its available products will ensure safe and successful SPF applications.

The future

Professional SPF roofing contractors and SPF applicator companies—from large companies to single-person companies—need to review and update their safety programs; www.spraypolyurethane.com regularly provides updated information.

The SPF industry and government agencies will continue to provide new information as it becomes available, and I am sure trade associations will update their SPF-related documents as they move forward.

Jim Andersen is manager of applications and training for BASF Polyurethane Foam Enterprises LLC, Minneapolis.