Worker exposure to MDI (methylenediphenyl isocyanate) in the sprayed-on truck bed lining industry was assessed by examining Washington State OSHA inspection files and industrial insurance records. The industry uses MDI to form a protective urethane coating on pick-up truck beds. The lining is applied by a worker using a handheld spray gun with application equipment at temperatures and pressures specified by the urethane supplier. Inspections with MDI sampling were initially identified by searching the agency's laboratory database and were further screened for the targeted process. Data for 13 employers was found and extracted from the inspection records. All were small companies with only 1 to 2 workers exposed to MDI; 10 of the 13 employers had started the bed lining service within the last 4 years. The process was found in truck bed lining specialty shops as well as in other truck-related businesses. Six different urethane products were used with reported MDI monomer concentrations of up to 75 percent along with varying concentrations of MDI pre-polymers and other reactants and solvents. Sampling for MDI by inspectors found 7 worksites with worker exposure in excess of the state and OSHA ceiling limit of 0.200 mg/M(3). Deficiencies in respirator programs and engineering controls for MDI were cited. A review of the industrial insurance records found a total of five MDI-related claims at 4 inspected worksites, two for new-onset asthma. It was concluded that workers in the urethane sprayed-on truck bed lining industry are at an increased risk of developing illnesses associated with isocyanate exposure. Interventions are needed to further assess the hazard as well as motivate and assist franchisers, distributors, and retailers to implement effective engineering controls and respiratory protection programs in this nationally emerging small employer industry.