Polyurethane (PU) is everywhere. It cushions your sofa, forms the core of many mattresses, bounces in your trainers, seals and protects floors, and hides in wall and appliance insulation. Because it’s synthetic, it’s natural to wonder: can it cause cancer – and is this something you should avoid at home? I recently chose natural mattresses for our new place, but I still wanted a clear, balanced answer before writing off PU altogether.
This guide keeps things simple and practical. We’ll separate real risks from scary headlines, explain any jargon in plain English, and cover what matters in everyday life: off-gassing (those “new” smells), flame retardants, and what actually happens in a fire. You’ll also get straightforward steps to reduce exposure if you already have PU furniture, plus smarter shopping tips – relevant whether you live in the UK, Europe, North America or elsewhere.
Quick answer: Polyurethane itself (once fully cured) isn’t classed as a cancer risk in normal home use. Most worries are about: (1) the chemicals used to make it – isocyanates (a worker-safety issue), (2) some flame retardants sometimes added to foam, which can end up in house dust, and (3) the very toxic smoke if polyurethane burns in a fire.
Now, let’s get into all the details.
What is polyurethane, in simple terms?
Polyurethane (PU) is a type of plastic made by combining two main ingredients: isocyanates and polyols. When these react, they “snap” together to form a solid, durable material. Depending on how it’s made, PU can be soft and flexible (like foam in mattresses and sofas) or rigid and tough (like insulation boards or coatings).
Quick jargon helper: Isocyanates are highly reactive chemicals used to make PU. They’re mostly a concern for workers who handle them during manufacturing, not for people using finished products at home
Where you’ll come across polyurethane
Polyurethane is everywhere, even if you don’t notice it. At home, it’s commonly used in mattresses, sofas, cushions, carpet underlay, and shoe soles or insoles. You’ll also find it in appliance insulation (like fridges and freezers), spray foam insulation in walls, wood floor finishes, sports floors, and many sealants and adhesives.
Outside the home, PU shows up in car seats and interiors, rollers and wheels, spandex/elastane fabrics, and protective coatings on wood, metal, and other surfaces.
Are the chemicals used to make polyurethane a cancer risk?
Some of the chemicals used to make polyurethane have raised health concerns, but this mostly affects workers in manufacturing, not people using finished products at home.
For example, toluene diisocyanate (TDI), commonly used to produce flexible PU foam for things like mattresses and sofas, is classed as “possibly carcinogenic to humans” by the International Agency for Research on Cancer (IARC) source.
Another chemical, methylene bis(2-chloroaniline) (MBOCA), used in certain heavy-duty PU products like industrial rollers, has been linked to bladder cancer in workers with high exposure.
The key thing to understand is that these chemicals are reactive ingredients – they’re used to create polyurethane but don’t stay active once the material is fully cured (when the chemical reaction is complete). In products like mattresses, sofas, shoes, or flooring, little to none of these chemicals remain.
Takeaway: the cancer risks linked to these substances mainly apply to making and processing polyurethane, not to using everyday PU products at home.
What about flame retardants in foam?
Some polyurethane foams are treated with flame retardants (FRs) to meet fire safety standards. The concern is that certain chlorinated or organophosphate flame retardants don’t stay locked inside the foam and can slowly migrate into household dust or air. Over time, this dust can be inhaled or ingested, which is why researchers have studied potential health risks.
Health concerns linked to some FRs:
Several older flame retardants once widely used in foam – like TDCPP (chlorinated tris), TCEP, and some PBDEs (polybrominated diphenyl ethers) – have been associated with potential cancer risks. For example:
- TDCPP and TCEP are both listed under California’s Proposition 65 as chemicals known to cause cancer.
- Studies have shown that some FRs can also affect lung health, particularly when inhaled through household dust.
It’s worth noting that many manufacturers have phased out the most problematic FRs in places like the US and EU, but some products, especially older sofas, mattresses, or imported goods, may still contain them.
What’s changing globally:
Regulations around flame retardants are shifting, but rules vary by country. In many regions, safety standards have moved away from open-flame testing, reducing the need for chemical treatments in furniture and mattresses.
- United States: In California, the updated TB117-2013 rule now uses a smolder test instead of an open-flame test. A smolder test checks how fabric and foam react to a small burning source, like a cigarette, rather than a large open flame. Because of this, many sofas and chairs can now meet safety standards without added flame retardants. The SB 1019 law also requires labels stating whether flame retardants were used.
- EU and UK: The EU (and UK retained law) restricts some flame retardants like TCEP, TCPP, and TDCP in certain products, especially toys and items for young children . However, furniture rules can still differ between countries.
- Canada: Health Canada has flagged several flame retardants, including TCPP and TDCPP, as potential health concerns and is taking steps to manage risks.
What this means for your home:
When shopping, look for labels that say “NO added flame retardant chemicals” or ask the retailer directly. Many brands now meet fire safety standards using barrier fabrics or safer design methods instead of chemical treatments.
Off-gassing from polyurethane: should you be concerned?
Aside from flame retardants, another concern with polyurethane foam products is off-gassing – the release of VOCs (volatile organic compounds). These are tiny gases that come from leftover chemicals, adhesives, or finishes used during manufacturing. They’re what give that typical “new mattress” or “new furniture” smell.
Are VOCs from polyurethane dangerous?
For most people, VOCs are more likely to cause short-term irritation — things like headaches, dizziness, or throat discomfort. However, some VOCs used in manufacturing furniture and foam, such as formaldehyde (from certain adhesives), are classified as potential or known carcinogens.
Common VOCs that may come from polyurethane foam include:
- Toluene – can cause headaches or dizziness at high levels.
- Formaldehyde – a known human carcinogen, though modern levels are usually low.
- Acetone and other solvents – mostly cause short-term irritation, not cancer.
The good news is that in modern products, VOC levels are usually much lower than they used to be, and emissions drop significantly within days to weeks.
How to reduce exposure at home:
- Unwrap and air out new foam products as soon as possible.
- Keep the room well ventilated for the first few days or weeks.
- Choose products with low-VOC certifications like UL GREENGUARD Gold or CertiPUR-US.
Polyurethane and fire: when it’s most dangerous
Polyurethane foam isn’t considered a cancer risk in normal use, but in a house fire it can release very toxic gases, including carbon monoxide (CO) and hydrogen cyanide (HCN) . These are an immediate danger, not a long-term cancer concern. Flame retardants may slow ignition slightly but don’t stop polyurethane from eventually burning and producing toxic fumes.
How to Reduce Chemical Exposure from Polyurethane Products
If you have polyurethane foam products at home or are buying new ones, there are simple steps you can take to minimise potential exposure to VOCs, flame retardants, and dust particles – without having to avoid polyurethane entirely.
When Buying New Furniture or Mattresses
- Look for labels stating “NO added flame retardants”, or check with the retailer directly.
- Choose products with recognised low-emission certifications, such as:
- GREENGUARD Gold — sets strict limits on VOCs and is widely used in furniture for homes and schools.
- CertiPUR-US / CertiPUR-EU — tests flexible foam for banned substances, low VOC emissions, and carcinogenic risks.
- EU Ecolabel for Furniture — applies European VOC limits across foam components, aligning closely with CertiPUR criteria.
- Retailers and designers targeting European markets may use FEMB Level, Indoor Advantage (SCS), or BIFMA LEVEL®, which monitor broader sustainability and indoor air quality.
At home
- Ventilate new items: Unwrap them as soon as possible and air them out in a well-ventilated room.
- Keep dust under control: Use a HEPA vacuum regularly and wipe surfaces with a damp cloth to capture particles where flame retardants can settle.
- Wash your hands often: Especially before eating, as FRs and VOC residues can accumulate in dust.
- Replace very old foam products: Older foam products (for example, many pre-2013 US sofas) may still contain older, more concerning flame retardants.
During renovations or installations
- Stay away during floor finishing: Oil-based polyurethane finishes and adhesives can release high levels of VOCs while curing.
- Avoid exposure to spray foam insulation during installation: Isocyanates are released at this stage — ensure professional-grade ventilation and only re-enter once it’s fully cured.
- If you’re hiring professionals, confirm they follow local safety guidelines and wear protective gear.
Do air purifiers help?
Air purifiers can be useful, but you need the right type:
- For dust particles (including those where some FRs end up): Choose a purifier with a HEPA filter.
- For gases and VOCs: Pick a purifier with an activated carbon filter — HEPA alone won’t capture these.
- Ventilation still does most of the work, so always air out rooms when possible.
Alternatives If You’d Rather Avoid Polyurethane
If you’d prefer to limit PU in your home, there are other options — but each comes with trade-offs:
- Natural latex — durable and supportive, but usually pricier; also check for latex allergies.
- Wool — naturally flame-resistant and breathable, though softer products can feel less supportive.
- Cotton — often used in futons or toppers; comfortable but less common in full mattresses and can compress over time.
When shopping, ask sellers about:
- A full materials list (especially for mattresses and sofas).
- Their flame-retardant approach — some use barrier fabrics instead of chemicals.
- Any VOC or emission testing they’ve done.
- The return policy, since natural materials can feel different from what you’re used to.
Key Takeaways
- PU itself isn’t classed as a human carcinogen during normal home use.
- The bigger concerns come from chemicals used to make PU (like isocyanates and MBOCA) — but those mainly affect workers in manufacturing, not consumers.
- Some flame retardants used in PU foam have been linked to health risks, including potential cancer concerns, and can migrate into household dust.
- Off-gassing from new PU products can cause short-term irritation (odour, headaches), but at typical home levels from modern items, evidence for increased cancer risk is limited; VOCs are mainly a comfort/irritation issue, while household dust concerns relate more to certain flame retardants.
- If you’re worried, you can reduce your exposure by choosing products with “no added flame retardants”, looking for low-emission certifications, ventilating new items, and replacing very old, crumbling foam.
- Alternatives like natural latex, wool, and cotton exist but can be more expensive or harder to find.
