Industrial hygiene surveys were conducted at urea formaldehyde and polyurethane foam thermal insulation manufacturing and application facilities as part of a NIOSH industrywide study of foam insulation materials. In all, eight sites were surveyed--two sets of manufacturers and applicators for each of the two types of foams. Personal and area monitoring were conducted to determine exposure levels to chemical substances and physical agents.Within the urea formaldehyde industries surveyed formaldehyde exposures at the manufacturing facilities ranged from a TWA value of 0.18 ppm to peak values of 5-10 ppm; exposures at the application sites ranged from <0.08 to 2.4 ppm. The NIOSH and ACGIH recommended limits were exceeded and the potential for an excursion to the OSHA standard for formaldehyde was shown to exist. In addition ammonia, furfuryl alcohol, acetaldehyde, phenol, nitrosamines, and respirable dust were measured. Ammonia sample results were less than established workplace limits, except during ammonia drum pump stem removal when the measured concentration of 300 ppm exceeded the ACGIH STEL of 35 ppm. All other chemical contaminant levels were below the lower limits of detection. Noise levels in excess of established limits were measured at one of the manufacturing facilities.Within the polyurethane industries surveyed MDI exposures ranged from <0.0008 to peaks of 0.002-0.005 ppm at the manufacturiD9 facilities and <0.001 to peaks of 0.002-0.068 ppm at the application sites. The NIOSH, ACGIH and OSHA limits for MDI were exceeded at one of the application sites. In addition, exposure levels for TOI (not a component of polyurethane thermal insulation systems) were exceeded at a manufacturing facility. Measurements for fluorotrichloromethane, alpha-methyl stryene, tertiary amine compounds, organotin compounds, 2-ethoxyethanolj carbon monoxide and methylene chloride were taken; these compounds were not detected at levels which exceeded either the NIOSH and AGGIH recommended limits or the OSHA standards. Exposure to noise in excess of established limits would not occur under routine conditions.