The Polyurethane Foam Book

Chapter Seven: Foam and Safety 

by David B. South

Urethane foam is both safe and dangerous.  

Foam comes as two major components. The "A component" is isocyanate, manufactured by only a few chemical companies in the world because it is so dangerous and complex. A few years ago, a plant in Bahpoul, India had a major spill, and many people died. Generically, isocyanate is made from chemicals, much like those in Phosgene -- the gas used on troops in World War I. 

A chemist in charge of making isocyanate described its complexity. He said that each time a new batch is made approximately 50 new chemicals, never identified or seen before, are created.  
Safety: The process of making isocyanate turns volatile raw chemicals into a stable chemical. Its stability allows us to use it everywhere. Probably the most pervasive use is in "foam rubber," which today is not rubber but flexible urethane foam. Most Americans sleep on urethane mattresses, sit on urethane cushions, use urethane varnishes, etc. 

The B component is called a Polyol. It is a mixture of catalysts, foaming agents, blowing agents, surfactants and secret additives. The Polyol formulas are what separate the foam suppliers. The B component is made by many companies. A drum of the A component and a drum of the B component are called a set.  

The stability of the finished chemicals also allows them to be shipped without red labels. They are organic and will burn. The products of combustion can kill you, but while burning they are no more dangerous than wood. Note: Organic smoke will kill, so burning urethane must be treated with respect. It burns dark and stinky. Consequently, urethane should be disposed of by following the manufacturer's instructions instead of burning. Our sky is polluted enough already.  

Note: Fire properties of sprayed urethane foam are discussed in Chapter Five.

Download the whole book as a PDF

Table of Contents:

• Introduction: by David B. South
• Chapter One: What Is Polyurethane Foam?
• Chapter Two: Spray-in-place Polyurethane Foam
• Chapter Three: Foam Roofing
• Chapter Four: R-value Fairy Tale
• Chapter Five: Fire and Foam
• Chapter Six: Application -- Substrates, Water and Blisters
• Chapter Seven: Foam and Safety
• Chapter Eight: Foam Equipment
• Chapter Nine: Starting a Urethane Foam Business
• Chapter Ten: Selling Polyurethane Foam for Use in Homes
• Addendum: A History of Polyurethane by Nick Clark

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