Download a free Gap Filling Foam COSHH assessment for documenting the safe use, handling and storage of expanding foam and gap filling foam products in the workplace. This editable COSHH assessment template is designed for builders, joiners, maintenance teams, facilities departments, insulation installers, contractors, school site teams, housing providers, workshops and commercial premises where gap filling foam is used for sealing, filling, insulating or bonding around gaps, joints, pipe penetrations, frames, walls, cavities and construction openings.
Gap Filling Foam is commonly supplied as an expanding polyurethane foam used to fill voids, reduce draughts, seal around service penetrations and support general building, repair and maintenance tasks. Because many expanding foam products are supplied in pressurised aerosol canisters and may contain polyurethane ingredients, propellants or isocyanates, they should be assessed carefully under COSHH, particularly where they are used indoors, in enclosed spaces, during repeated application tasks or by workers who may handle uncured foam.
This Gap Filling Foam COSHH assessment template helps employers and responsible persons record key product details, intended use, application method, surface preparation, storage arrangements, ventilation controls, exposure controls, first aid information, spill response, emergency procedures, disposal arrangements, PPE requirements, user instructions and review dates. It provides a practical starting point for workplaces needing a expanding foam COSHH assessment, PU foam COSHH template, insulation foam COSHH document or free health and safety document template for construction foam products used at work.
Employers have a legal responsibility to assess substances used during work activities and make sure employees, contractors, trainees, building users and others are not exposed to unnecessary health risks. Under the Control of Substances Hazardous to Health Regulations 2002, employers must identify hazardous substances, assess how exposure could occur, prevent or adequately control exposure where required, and provide suitable information, instruction and training. Where gap filling foam contains flammable propellants or creates fire and explosion risks, employers should also consider the Dangerous Substances and Explosive Atmospheres Regulations 2002. These duties sit alongside the wider requirements of the Health and Safety at Work etc. Act 1974 and the Management of Health and Safety at Work Regulations 1999.
For products such as Gap Filling Foam, the COSHH assessment should reflect the actual task being carried out, including shaking and preparing the canister, attaching the applicator, applying foam into gaps or voids, controlling overspill and expansion, allowing curing time, trimming cured foam, preventing skin and eye contact, ensuring suitable ventilation and storing pressurised containers away from heat or ignition sources. Where the product contains isocyanates, the assessment should also consider UK REACH training duties, respiratory sensitisation risks, glove selection and the manufacturer’s safety data sheet.
A clear Gap Filling Foam COSHH assessment helps demonstrate that expanding foam products, aerosol canisters and potential isocyanate exposure have been properly considered as part of your workplace health and safety arrangements. This is particularly useful for builders, maintenance operatives, joiners, insulation workers, facilities managers, school caretakers, housing maintenance teams, supervisors and duty holders responsible for chemical storage, contractor control, refurbishment work, staff training and workplace safety documentation.
The document can be customised with your company details, site location, product brand, storage area, task description, application method, areas of use, ventilation arrangements, responsible person, PPE requirements, control measures and review date. Once completed, the assessment can be downloaded as a PDF, stored in your compliance records or shared with employees, contractors, maintenance teams, site managers, supervisors and health and safety representatives.
Relevant compliance includes the Control of Substances Hazardous to Health Regulations 2002, Dangerous Substances and Explosive Atmospheres Regulations 2002, Health and Safety at Work etc. Act 1974, Management of Health and Safety at Work Regulations 1999, Provision and Use of Work Equipment Regulations 1998, Workplace (Health, Safety and Welfare) Regulations 1992, UK CLP requirements, UK REACH duties where applicable, HSE COSHH guidance, HSE isocyanates guidance, HSE occupational asthma guidance and the requirement to use the manufacturer’s safety data sheet when completing a suitable and sufficient assessment.