Occupational Exposure to Volatile Organic Compounds in Polyurethane Foam Production-Concentration, Variability and Health Risk Assessment.

Volatile organic compounds (VOCs) are a major occupational concern in polyurethane foam production, where exposure may impact worker health. This study identified key VOCs and evaluated their concentrations across different sections of a polyurethane manufacturing facility. Area (n = 5) air samples were collected during routine full-load production using short-duration active sampling and analyzed by thermal desorption gas chromatography-mass spectrometry (TD-GC-MS). The results revealed marked spatial variability in VOC concentrations, with the curing section showing the highest totals. Dichloromethane (DCM) constituted the dominant VOC in high-emission zones. All measured concentrations of DCM and other regulated substances remained well below European and Polish short-term exposure limits. Quantitative health risk assessment demonstrated that lifetime cancer risk values for DCM and benzene were in the 10-6 range, far below the regulatory threshold of concern (10-4). Non-carcinogenic risk indices (HQ) were generally low; however, a markedly elevated HQ was identified for 1-hexanol, 2-ethyl- in the cutting area (HQ = 5.7), indicating a potential localized non-cancer health concern. Overall, existing protective measures appear effective, but additional targeted precautions are warranted in zones with elevated emissions. Enhanced ventilation, strengthened personal protective equipment, and routine air monitoring are recommended to minimize potential health risks. Regular updates of occupational safety standards should reflect evolving toxicological evidence to ensure sustainable protection of workers in polyurethane foam production.