Formaldehyde: Health Facts And Regulatory Requirements

More than 24 billion pounds of formaldehyde are produced worldwide each year. Approximately half of this formaldehyde is used to make synthetic resins (e.g., urea- and phenol-formaldehyde resins). These resins are used primarily as adhesives when making particleboard, fiberboard, and plywood. Formaldehyde is also used as a textile finisher (permanent press), a preservative in medical laboratories, an embalming fluid, a sterilizer, an additive in dyes, a fertilizer, a hardening agent, and a rust inhibitor. Formaldehyde may be listed under a variety of synonyms, and the Occupational Safety and Health Administration (OSHA) estimates that approximately 2.1 million employees are exposed to formaldehyde in United States workplaces.

What Are The Health Effects?

Acute Effects: The most common routes of industrial formaldehyde exposure are through inhalation and skin absorption. Formaldehyde is highly irritating to the eyes and upper respiratory tract, with effects typically occurring at airborne concentrations above 1 part per million (ppm). Irritation to the eyes and upper respiratory airways can occur in some employees at concentrations as low as 0.1 ppm. Other potential acute effects of formaldehyde exposure include pulmonary edema, pneumonia, and bronchial irritation, which can result in death.

Chronic Effects: The American Conference of Governmental Industrial Hygienists (ACGIH) suspects long-term formaldehyde exposure increases the risk of nasal and lung cancer in humans.

Skin Contact: Skin contact with formaldehyde solutions can cause irritation of the skin and allergic contact dermatitis. Symptoms include erythema, edema, and hives. Inhalation exposure can provoke skin reactions in sensitized employees even when airborne concentrations of formaldehyde are below 1 ppm.

What Are The Occupational Exposure Limits?

Occupational exposure limits have been established by the ACGIH, the Occupational Safety and Health Administration (OSHA), and the National Institute for Occupational Safety and Health (NIOSH). ACGIH established a ceiling limit threshold limit value (TLV-C) of 0.3 ppm (2002), which is the concentration that should not be exceeded during any part of the workday. NIOSH established a recommended exposure limit (REL) of 0.016 ppm measured as a 10-hour time-weighted average, which represents the lowest concentration that can be reliably quantified with current analytical methods.

OSHA’s current permissible exposure limit (PEL) is 0.75 ppm measured as an 8-hour time-weighted average. OSHA also has a short-term exposure limit [i.e., maximum exposure allowed during a 15-minute period (STEL)] of 2 ppm and has assigned an “action level” of 0.5 ppm, which triggers OSHA-mandated controls.

What Does The OSHA Standard Require?

OSHA’s formaldehyde standard (29 CFR 1910.1048) applies to all general industry, construction and maritime workplaces and pertains to formaldehyde gas, its solutions, and materials that release formaldehyde. OSHA’s formaldehyde standard requires exposure monitoring, medical surveillance, engineering and work practice controls, labeling, and training.

Exposure Monitoring: Initial exposure monitoring must be conducted for those employees who may be potentially exposed to airborne concentrations at or above the action level or the STEL. Exposure monitoring should be periodically conducted if initial monitoring indicates airborne concentrations at or above either the action level or STEL. Air monitoring may be discontinued if the exposure level is maintained below the action level and STEL unless there is a process change that could affect exposure levels. Employee exposure must also be monitored promptly if employees show signs or symptoms of respiratory or dermal conditions associated with formaldehyde exposure.

Medical Surveillance: A medical surveillance program must be provided if air-sampling results indicate formaldehyde concentrations at or above the action level or STEL, or for any employees who develop signs and symptoms of formaldehyde exposure. A licensed physician must administer the medical surveillance program by evaluating completed medical disease questionnaires for each affected employee on an annual basis. The physician subsequently determines, based on evaluation of the medical disease questionnaire, whether a medical examination is necessary. The employer is required to obtain a physician’s written opinion containing the results of each medical examination.

Engineering and Work Practice Controls: Feasible engineering and work practice controls must be implemented to maintain employee exposures below the PEL and STEL. Respiratory protection must be worn if feasible engineering and work practice controls cannot reduce employee exposure below the PEL and STEL, and during the time necessary to implement engineering and work practice controls.

Labeling: Specific hazard labeling requirements are needed for all forms of formaldehyde, including mixtures and solutions, containing 0.1 percent or greater formaldehyde, and for materials capable of releasing formaldehyde (outgassing) in excess of 0.1 ppm. Hazard labeling, including a warning that formaldehyde presents a potential cancer hazard, is required where the airborne formaldehyde levels may exceed 0.5 ppm.

Training: Training is required for all employees exposed to formaldehyde concentrations of 0.1 ppm or greater. The training must be conducted prior to the affected employee’s initial assignment and annually thereafter. The content of the training should include the health hazards of formaldehyde exposure, the control measures in place to minimize exposures, and the contents of the medical surveillance program.

XL Environmental • Risk Control Division • 520 Eagleview Boulevard, PO Box 636, Exton, PA 19341 • Phone: 800-327-1414 • Fax: 610-458-7285 • xlenvironmental.com

XL Environmental is a division of XL Specialty Insurance Company.