The request was prompted by the death of a former employee who initially became ill after working with diphenylmethane diisocyanate (MDI) at the plant. This individual had a respiratory illness which his physician felt was consistent with isocyanate-induced hypersensitivity pneumonitis. The facility produces artificial plant and tree arrangements and uses a MDI-based polyurethane foam to provide a rigid support for the arrangements.NIOSH investigators conducted an initial site visit and walk-through inspection on October 7, 1991. Work on this project was delayed by the lack of an analytical method for measuring airborne MDI and by the departure of the initial medical project officer from NIOSH. On September 29, 1992, a second walk-through inspection was made by the new project team. An in-depth medical survey was conducted March 11-22, 1993, and an industrial hygiene survey was completed March 23-24, 1993.Detectable concentrations of monomeric MDI were found in two of the five full-shift area air samples collected in impingers; however, these concentrations were below the limit of quantitation. The minimum detectable concentration was 0.6 ug/m 3 , and the minimum quantifiable concentration was 1.6 ug/m 3 for the samples. The six impingers used for shortterm personal sampling did not indicate detectable concentrations of monomeric MDI. The detection limit for these samples was about 20 ug/m 3 .Vapors/aerosols were observed rising into the faces of workers working with the foam. This observation and a chemical smoke tube test indicated that the ventilation systems in the foaming areas were not adequate for preventing worker exposure to MDI. Skin contact with the curing was also noted during the survey.The medical portion of the survey consisted of a medical questionnaire, occupational and exposure histories, spirometry, and serial peak flow measurements. Of 93 current employees, 80 (86%) participated in some aspect of the survey. Individuals who reported high exposure to the polyurethane foaming process were more likely to report work-related nasal and eye irritation than were individuals in the other exposure categories. Selfreported exposure to the foaming process was not associated with any other symptoms, nor was it related to pulmonary function, as measured by spirometry and serial peak flow monitoring.This Health Hazard Evaluation (HHE) report and any recommendations made herein are for the specific facility evaluated and may not be universally applicable. Any recommendations made are not to be considered as final statements of NIOSH policy or of any agency or individual involved. This Health Hazard Evaluation (HHE) report and any recommendations made herein are for the specific facility evaluated and may not be universally applicable. Any recommendations made are not to be considered as final statements of NIOSH policy or of any agency or individual involved. applicable. Any recommendations made are not to be considered as final statements of NIOSH policy or of any agency or individual involved.Additional H...