Expanding Foam (PU Foam) COSHH assessment
Expanding polyurethane foam contains isocyanates while uncured. It is a respiratory sensitiser and skin irritant, and needs ventilation and skin protection - especially with larger spray-applied jobs.
The hazards
- Uncured foam contains isocyanates - respiratory sensitisers
- Sticks aggressively to skin and is hard to remove
- Spray-applied foam creates a fine mist
- Propellant makes the can pressurised and flammable
Who is at risk
Exposure routes
- Inhalation of vapour or mist
- Skin and eye contact
Health effects
- Occupational asthma (sensitisation)
- Skin and eye irritation
- Chest tightness with heavy exposure
Control measures (hierarchy of control)
Controls should be applied in order — eliminate or substitute first, then engineering controls, then PPE as the last line.
- Ventilate the work area; extra care in enclosed spaces
- Avoid skin contact - foam is very hard to remove once on skin
- For large spray-foam jobs, use RPE and treat it like isocyanate spraying
- Keep cans away from heat and ignition sources
- Let foam cure fully before trimming; control dust when cutting cured foam
PPE & RPE
- Chemical-resistant gloves
- Eye protection
- RPE for spray application or poor ventilation
- Coveralls
First aid
- Skin: do not use solvents; remove with a proprietary foam remover or let it wear off, and wash
- Eyes: irrigate with clean water and seek medical advice
- Breathing symptoms: move to fresh air and get medical help
Workplace exposure limit (WEL)
Relevant legislation & guidance
Expanding Foam (PU Foam) COSHH FAQs
Yes - uncured foam contains isocyanates, which are the leading cause of occupational asthma. For occasional gap-filling the risk is lower with ventilation and gloves, but larger spray-foam work needs the same care as isocyanate spraying.
Do not use solvents, which drive it in. Use a proprietary foam remover on skin while still wet, or let it wear off, and wash with soap and water. Better still, prevent contact with gloves.
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