Industrial hygiene evaluations were performed in three facilities manufacturing flexible toluene-diisocyanate (TDI) based foam. This report concerned nonisocyanate exposures inherent in those operations. The concentrations of several air contaminants were monitored including aliphatic amines, nitrosamines, nitrogen-dioxide (10102440), thermal degradation products, organic solvents, polyurethane (9009545) dust, and flame retardants. In each facility workers had respiratory and probably dermal exposure to methylene- chloride (75092). Traces of nitrogen-dioxide and some aliphatic amines were found. Exposure to thermal degradation products, polyurethane dust, and flame retardants was not a problem under reasonable hygienic conditions. Evidence was found for acrolein (107028) and acrylonitrile (107131) exposure at one facility due to the thermal degradation of finished foam. Mutagenic activity was highest when the total isocyanate group air concentrations were also high.