Diisocyanates – Level 3 Training
Safe Handling of Chemicals Based on Diisocyanates According to the Restriction Under REACH (Level 3)
This TÜV SÜD Level 3 training course provides the knowledge required to safely handle diisocyanates in applications with a high exposure potential, including spraying outside spray booths, handling heated formulations above 113°F (45°C), maintenance activities with elevated exposure risks, and other operations involving significant skin contact or inhalation exposure. Participants will learn how to identify hazards, assess exposure risks, implement effective control measures, select appropriate personal protective equipment (PPE), and respond to emergency situations while meeting the REACH training requirements for Level 3 applications. Successful completion helps organizations comply with mandatory training obligations for the industrial and commercial use of diisocyanates.
Upon completion of this course, participants will be able to:
- Explain the REACH restriction requirements applicable to diisocyanates.
- Describe the chemical and physical properties of commonly used diisocyanates.
- Recognize health hazards associated with inhalation and skin exposure.
- Interpret product labels and Safety Data Sheets (SDS).
- Understand occupational exposure limits and workplace exposure assessment principles.
- Identify high-risk processing conditions such as spraying and hot processing.
- Conduct exposure and hazard evaluations for high-risk activities.
- Apply the STOP principle to reduce workplace risk.
- Select and use suitable respiratory protection equipment.
- Select appropriate chemical protective clothing, gloves, and eye protection.
- Respond effectively to spills, leaks, and emergency incidents.
- Implement correct cleaning, decontamination, and disposal procedures.
- Safely perform maintenance and repair activities involving diisocyanates.
- Support workplace compliance through operational controls and change management procedures.
This training is intended for commercial and industrial users of diisocyanates whose work involves a high exposure potential.
Typical activities requiring Level 3 training include:
- Handling incompletely dried or still-warm products.
- Foundry applications.
- Maintenance and repair work requiring access to process equipment.
- Open handling of warm or hot formulations (>113°F (45°C)).
- Spraying outside a spray booth.
- Spraying in open-air environments or large industrial work areas with limited ventilation.
- High-energy spraying processes such as foam and elastomer applications.
- Any other activity resulting in comparable exposure through skin contact and/or inhalation.
Module 1: Regulatory Framework
- REACH restriction requirements
- Training obligations
- Exposure categories and training levels
Module 2: Fundamentals of Diisocyanates
- Chemical and physical properties
- Applications and uses
- Product labels and Safety Data Sheets
Module 3: Health Hazards and Exposure
- Exposure routes
- Occupational exposure limits
- Health effects and sensitization
- Hazard classifications
Module 4: Risk Assessment and Exposure Control
- Exposure assessment
- Skin and inhalation risks
- Risk determination methods
- STOP principle
Module 5: Protective Measures
- Engineering controls
- Ventilation systems
- Organizational measures
- Workplace hygiene
Module 6: Personal Protective Equipment
- Respiratory protection
- Eye and face protection
- Chemical protective gloves
- Protective clothing and footwear
- PPE inspection and maintenance
Module 7: High-Risk Level 3 Applications
- Open handling of warm or hot formulations (>45°C)
- Risks associated with heated products
- Exposure during container changes
- Spraying outside spray booths
- Aerosol exposure hazards
- Respiratory protection requirements for spraying operations
Module 8: Emergency Measures
- Spill and leak response
- First aid procedures
- Incident management
Module 9: Cleaning and Waste Management
- Cleaning contaminated equipment
- Neutralization procedures
- Waste handling and disposal
- Packaging disposal
Module 10: Storage, Maintenance and Change Management
- Safe storage of diisocyanates
- Maintenance and repair activities
- Operating instructions
- Change management procedures
Training for High-Exposure Diisocyanate Applications: Spraying, Hot Processing, Maintenance, and Advanced Exposure Control.
Are you a commercial or industrial user of diisocyanates? Have you fulfilled your legal training obligations? Diisocyanates are key raw materials used in the production of polyurethane products including rigid and flexible foams, insulation products, construction foams, adhesives, coatings, paints, and sealants. Because exposure to diisocyanates can lead to serious health effects, including respiratory sensitization, occupational asthma, and allergic skin reactions, the European Union introduced restrictions under REACH requiring mandatory training for professional users.
This TÜV SÜD Level 3 training course has been developed specifically for workers and supervisors involved in activities with the highest exposure potential. The course addresses challenging work environments where elevated temperatures, aerosol formation, open spraying, maintenance interventions, and extensive skin contact significantly increase the risk of worker exposure. Participants will gain a deep understanding of how diisocyanates behave, how exposure occurs, and how these risks can be effectively controlled.
The training covers the chemical and physical properties of diisocyanates, health hazards, occupational exposure limits, product labeling requirements, and hazard communication through Safety Data Sheets. Special emphasis is placed on recognizing high-risk situations such as hot-processing operations above 113°F (45°C), spraying outside spray booths, maintenance activities, and large-scale applications that may generate aerosols or vapors.
Participants will learn how to apply the hierarchy of controls, including engineering controls, workplace ventilation, containment methods, organizational controls, and advanced personal protective equipment. The course also provides practical guidance on respiratory protection, chemical protective clothing, spill response, emergency procedures, first aid, cleaning processes, waste handling, maintenance activities, and change management.
Upon completion, participants will have the knowledge necessary to work safely with diisocyanates in high-exposure applications and will have fulfilled the REACH training requirements applicable to Level 3 uses. The training supports safer workplaces while helping organizations demonstrate compliance with regulatory obligations.
Participants will learn:
- How to safely handle diisocyanates in high-exposure industrial and commercial applications.
- How to identify and control exposure through inhalation and skin contact.
- How elevated temperatures and aerosol generation increase exposure risks.
- How to implement technical, organizational, and personal protective measures using the STOP principle.
- How to select and use suitable respiratory protection and chemical protective equipment.
- How to manage emergencies, spills, maintenance activities, and waste disposal safely.
- How to fulfill the REACH training obligation applicable to diisocyanate use with high exposure potential.
Important Regulatory Note
IMPORTANT NOTE:
This training does not release participants or employers from the obligation to provide information, instruction, and workplace-specific training in accordance with § 14 of the German Hazardous Substances Ordinance (GefStoffV)
This course is delivered as a live instructor-led virtual classroom training.
Participants benefit from:
- Live presentations by TÜV SÜD experts
- Practical case studies
- Industry examples
- Interactive discussions
- Knowledge checks and exercises
- Question-and-answer sessions
The virtual classroom environment allows participants to interact directly with instructors and peers while learning practical approaches to managing high-risk diisocyanate applications.
Participants who attend at least 90% of the total training duration will receive a Certificate of Attendance from TÜV SÜD Academy.
This training is appropriate for personnel working in applications involving high exposure potential to diisocyanates.
Participants should have:
- Responsibilities involving diisocyanate-containing materials
- Access to a computer with webcam and microphone
- Stable internet access
- A valid personal email address
Important
There are three training levels available: Level 1, Level 2, and Level 3. The correct level is determined by the workplace exposure potential.
If you are uncertain which level applies to your activities, it is generally preferable to attend the higher level, as the content significantly overlaps and attending a lower level may not satisfy your training requirements.
Is Level 3 the highest level of Diisocyanate training?
Yes. Level 3 is designed for activities with the highest exposure potential and includes specialized content on spraying operations, hot processing, respiratory protection, and high-risk maintenance activities.
Do I need Level 3 if I already completed Level 1 or Level 2?
Not necessarily. The required level depends on your workplace activities and exposure potential. Users involved in high-exposure scenarios require Level 3 training.
What is considered a high-exposure activity?
Examples include spraying outside spray booths, working with heated formulations above 113°F (45°C), extensive skin contact, maintenance work involving open systems, and operations generating aerosols or vapors.
Is respiratory protection covered in this course?
Yes. The course includes detailed guidance on respiratory hazards and the selection and use of suitable respiratory protective equipment.
How often must this training be repeated?
Every five years.
Does this course include emergency response procedures?
Yes. It covers spill response, first aid, leak management, and incident response measures.
Does this course satisfy REACH training obligations?
Yes. The course is designed to fulfill the REACH training requirement for Level 3 applications involving high exposure potential.
Specialist lecturers from the TÜV SÜD Academy