overcoating of lead-based paint on steel structures

7/30/2019 Overcoating of Lead-Based Paint on Steel Structures

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I'llusArmyCorpsofEngineers EngineerResearchandDevelopmentCenter

Overcoating ofLead-BasedPainton SteelStructures CostandPerformanceReportTimothyD .Race,AshokKumar,Robert A.Weber,andL.D.Stephenson I V I a r c h 2003

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Overcoating ofLead-BasedPainton SteelStructures C o s tan dPerformanceRepor tTimothyD.Race,AshokKumar,RobertA.Weber,andL.D.Stephenson

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March2003

Approved forpublicrelease;distribut ionisunlimited.


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ERDC/CERLTR-03-5

ExecutiveSummary Inthepast,hazardouslead-basedpaint(LBP)hasbeenusedextensivelyonalltypesof DepartmentofDefense(DoD)steelstructuresandsteelcomponentsinclud-ingroadandrailbridges,ransmissiontowers,antennae,storagetanks,metalbuildings,andaircrafthangars.Theremovalof LBPis generallyperformedbyabrasiveblastingor by waterjetting.Containmentanddisposalofsurfacepreparationdebris,workerprotection,andotherregulatorycompliancecostscombinetomakeremovalofLBPveryexpensive.According toarecentFederalHighwayAdministrationreport(FHWA1995),bridgemaintenancepaintingcosts have nearlydoubledoverthepast5 years.Theaddedcostsfo rworkerhealth,environmentalmonitoring,wastedisposal, andcontainmentaresignificant.ThisEnvironmentalSecurityTechnologyCertificationProgram(ESTCP)projectdemonstratedtheovercoatingprocess,whichmaybedefinedasthepracticeofpaintingover existing coatingsasa meansofextending serviceHfe.Maintenancepaintingof this typedoes notrequireextensivesurface preparationandminimizesworkerexposuresandhazardouswastegeneration.Demonstrationof theovercoatprocesswas performedduring2000 on awatertankatFortCampbell,K Y andarailroadbridgeatHolstonArmy AmmunitionPlant(HAAP),Kingsport,TN.hedemonstrationsmettheperformancerequirements,whichwereto:(1)cleanandovercoattheexistingLBP,(2)complywithenviron-mentalstandards,(3 )complywithworkerhealthandoccupationalsafetyrequire-ments,(4 )collectdataandestimateinstalledcosts,and(5)determinetheperform-anceoftheovercoatprocess.Theinstalledcostofovercoatingonasimplestructure(Fort Campbellwatertank)wasestimated at$1.55/sqft .Theinstalledcostfo rovercoatingon acomplex struc-ture(HAAP railroadbridge)wasestimatedat$2.83/sq ft.By comparison,thecostofdeleadingandinstaUinganewpaintsystemis$5 to$18/sqftwithanaveragecostof$8/sqft.Thehazardouswastesgeneratedduringpreparationfo rovercoatingof thesimpleandcomplexstructures were0.18kg perand6.87kg per1,000sqft ,respectively.


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ERDC/CERL TR-03-5

By comparison,completecoatingremovalby abrasiveblastingwithexpendablecoalslagabrasivewouldproduceapproximately6,800kgof hazardouswasteper10 0sqft.Overcoatingoffersthebenefitof maximizingtheeconomic lifeof existingLBPcoat-ingswhileminimizingpresentexpendituresandreducingworkerexposureandhazardouswastegeneration.


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Preface Thistechnologydemonstrationwasconductedfor Headquarters,Departmentof theArmyunderProgramElement(PE)063728A,"EnvironmentalTechnology Demon-stration";Project002,"EnvironmentalComplianceTechnology";WorkUnitCF-M BlOl,CostEffectiveTechnologiesoReduce,Characterize,Dispose,orReuseSourcesofLeadHazards."Partofthisworkwas accomplishedwithfundsprovidedby U.S.ArmyForcesCommandunderMiUtaiyInterdepartmentalPurchaseRe-questsMIPR0BJECCEN04andMIPR0DJ7CDEN35.hetechnicalmonitor wasBryanNix(ACSIM-FSF).TheworkwasperformedbytheMaterialsandStructuresBranch (CF-M)oftheFa-ciUtiesDivision (CF), ConstructionEngineeringResearchLaboratory (CERL).TheCERL PrincipalInvestigatorwasDr.AshokKumar.Partof thisworkwasdonebyTimRace,CorrosionControlConsultantsandLaboratories,undercontractno .DACA42-002-P-0274 andDACA42-00-D-0002.hetechnicaleditor wasLindaL.Wheatley,InformationTechnology Laboratory-Champaign.MartinJ.SavoieisChief,CF-M,andL.MichaelGohshisChief,CF.TheTechnical DirectoroftheIn-stallationOperationsBusinessAreaisGaryW.Schanche(CV-T),andthe DirectorofCERL isD r.Alan W.Moore.Theauthorswishtoexpressappreciationto KarenKopp,UtilitiesBranchChief,andAudieHardinof theUtilitiesBranch,bothof FortCampbell,KY,andMichaelBMills(Chief)andScottShelton,bothof theProductionEngineeringDivision atHol-stonArmyAmmunitionPlant,TN.CERL isanelementoftheEngineerResearchandDevelopmentCenter(ERDC),U.S.ArmyCorpsof Engineers.TheCommanderandExecutiveDirectorofERDC is COLJohnW.MorrisIII,EN,andtheDirector isD r.JamesR.Houston.

DISCLA IMER :Thecontentsof thisreport arenottobe usedforadvertising,publication,or promotionalpurposes.Citation of trade namesdoesnotconstituteanofficialendorsementor approvaloftheus eofsuchcommercialproducts.Allproductnamesandtrademarkscitedarethepropertyof theirrespectiveowners.Thefindingsof thisreport arenotto be construedasanofficialDepartment of the Armypositionunlessso designatedby other authorizeddocuments.DESTROYTHIS RE P O RTWH E NITIS NO L O N G E RN E E D E D .O NO TRETURNIT TO TH E ORIGINATOR.


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Contents ExecutiveS u m m a r yPreface1ntroduction

BackgroundObjectivesApproachM o d eof TechnologyTransferUnitsof Weightand Measure

2echnologyDescript ionTechnology Application an dProcessDescriptionAdvantagesan dLimitationsofth eTechnology 0

3emonstration Design 1Performance Objectives 1Selectionof TestSites 1TestSiteCharacteristics 1PhysicalSetupand Operation 4Fort ,Campbel lWaterTank 4

HAAP Railroad Bridge 4MonitoringProcedures 6AnalyticalProcedures 6

4erformanceAssessmen t 7Performance Data 7

FortCampbe l lWater Tank 7HAAP Railroad Bridge 8

Data Assessment 0 FortCampbe l lWater Tank 0HAAP Railroad Bridge 1

TechnologyCompar ison 2 5ostAssessmen t 3

CostReportingan d Analysis 3FortCampbe l lWaterTank 3 HAAP Railroad Bridge 24

CostComparison 4


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6 Implementation Issues 6CostObservations 6OtherSignificantObservations 6

References 0PointsofContact 3Listo fAcronyms 4Appendix: Overcoat System MaterialSafety DataSheets 5ReportDocumentation Page 0


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1 Introduction Background

Inthepast,hazardouslead-basedpaint(LBP)hasbeenusedextensivelyonalltypesof DepartmentofDefense(DoD)steelstructuresandsteelcomponentsinclud-ingroadandrailbridges,ransmissiontowers,antennae,storagetanks,metalbuildings,andaircrafthangars.heremovalofLBPisgenerallyperformedbyabrasiveblastingor bywaterjetting.Containmentanddisposalof surfaceprepara-tiondebris,workerprotection,andotherregulatorycompliancecostscombineto make removal of LBPveryexpensive.Accordingto arecentFederal HighwayAd- ministrationreport(FHWA 1995),bridgemaintenancepaintingcostshavenearlydoubledoverthepast5years.headdedcostsforworker health,environmentalmonitoring,wastedisposal,andcontainmentaresignificant.Asanalternativeto removingtheLBP,overcoatingisthepracticeof paintingoverexistingcoatings as ameansof extendingservicelife.Maintenancepaintingof thistypedoesnotrequireextensivesurfacepreparationandminimizesworkerexpo-suresandhazardouswastegeneration.heEnvironmentalSecurityTechnologyCertificationProgram(ESTCP)projectreportedheredemonstratedtheovercoatingprocess.

Object ives Theobjectiveof thesedemonstrationswereto:1)cleanandovercoatthe existingLBP,(2)comply withenvironmentalstandards,(3 )complywithworkerhealthandoccupational safetyrequirements,(4 )collectdata andestimateinstalledcosts,and(5)determinetheperformanceoftheovercoatprocess.

ApproachDemonstrationof theovercoatprocesswasperformedduring2000 on awatertankatFortCampbell,KY,andarailroadbridgeatHolston Army AmmunitionPlant(HAAP),Kingsport,TN.


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ModeofTechnologyTransferTechnologytransferisbeingaccomplishedby:1)TechnologyTransferImple-mentationPlanthroughtheU.S.ArmyEnvironmentalCenter(AEC);(2)PWTB 420-70-2 "InstallationLeadHazardManagement;" (3) participationinUserGroupsandCommitteessuch astheArmyLeadandAsbestosHazardManagementTeam,FederalLead-basedPaintCommitteeMeetingsatEPAorHUD,andASTM D01.46(IndustrialandProtectiveCoatings)Committee;(4 )websitesmaintainedbytheArmyAssistantChiefof Stafffo rInstallationManagement(ACSIM)[http://www.hqda.army.mil/acsimweb/fd/policy/facengcur.htm],AEC[http://aec.army.nii]/usaec/l,andtheU.S.ArmyEngineerResearchandDevelopmentCenter/ConstructionEngi-neeringResearchLaboratory(ERDC/CERL)[http://www.cecer.army.mil],as wellastheHands-on-Skills-Training(HOST) website athttp://www.hqda.army.mil/acsimweb/fd/policy/host/index.htm;(5) demonstration/vaUdationof emergingtechnologiesthroughArmydemonstrationfunding(6.3) starting inFiscalYear2000(FYOO)andcontinuinghroughY03,ndost/performanceeportsesultingro mhosedemonstrations.

UnitsofWeightandMeasureU.S.standardunitsof measureare usedthroughoutthis report.A tableofconver-sion factorsfo rStandardInternational(SI)unitsisprovidedbelow.

SIconversionfactors1n. = 2.54cm 1ft = 0 . 305m

1 sqft = 0.093 m^ Igal = 3.78L

1b = 0.453 kg F = (Cx1.8)+32


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2 TechnologyDescriptionTechnologyApplicationandProcessDescription

Overcoatingdoesnotrequireextensivesurfacepreparation.urfacesto beover-coated maybelow-pressurepowerwashedorhandwashed using a milddetergentandwatersolution.Washwatershouldbe collectedandtested,however,to ensurethatitdoesnotmeetthehazardouscriteriafo rlead,whichtypicallyitwillnot.Thewashedsurfaces arethenfurtherpreparedby spotcleaningrustedareaswithpowerorhandtools.Vacuum-assistedpowertoolscanbe usedtocollectthedebrisandreduce workerexposure.Groundtarpaulins(tarps)shouldalsobeusedtocollectanyfallingdebris.Thecleanedsurfaces shouldreceiveafinalcleaningusingeithersolventorwatertoremoveanyadherentdust.hecleandrysurfacesarethenovercoatedusinganappropriatecoating.Overcoatmaterialsareusuallyappliedassystemsof tw otothreecoats.Healthandsafetyrequirementsarethesameasforotherindustrialmaintenancepaintingprojects,includingfallprotection,flammableliquids,hearingconservation,eyeprotection,andrespiratoryprotection.Additionalrequirements maybeneces-sarydependingonwhetherworkersareexposedtoleadabovetheactionlevelduringsurface preparationactivities.Half-facerespiratorswithanAssignedPro-tection Factor(APF)of 10 arerecommendedforuse duringcleaningwithvacuum-assistedpowertools.A greaterdegree of respiratoryprotectionmaybe requiredifvacuumassistisnot used.Personalairmonitoring (PAM)should beconductedattheoutsetofanyprojectinvolvingtheremovalof LBPto ensurethatworkersareadequately protected.The purpose of overcoatingistomaximizetheeconomiclifeof theexistingLBPbydeferringdeleading,whichis veryexpensive.TheovercoatedLBP doesnotlast aslongasanewhighperformancecoatingsystemappliedtoawell-preparedblastcleanedsurface.owever,theinstalledcostofovercoatingislowcomparedto deleading,andlifecyclecostanalysesgenerallyshow overcoatingtobemorecosteffectivefo ratmosphericexposuresinmildandmoderatelycorrosive atmospheres.Thetechnologyisapplicabletoalltypesof D oD steelstructuresandsteelcompo-nentsincludingpedestrian,vehicular,andrailbridges;exteriorsof watertanksand


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^RDC/CERLTR-03-5tanksstoringpetroleum,oils,andlubricants(POL),metalbuildings,transmissiontowers,antennae,aircrafthangars,andmaintenancefacilities.

AdvantagesandLimitationsofth e TechnologyTheremovalofhazardouscoatingsis generallyperformedby abrasiveblastingor bywaterjetting,butcontainmentanddisposalof surfacepreparationdebris,workerprotection,andotherregulatorycompliance costsmakeremovalof hazardouspaintsveryexpensive.ridgemaintenancepaintingcostshavenearlydoubledoverthepast5years(FHWA1995).Typical bridge maintenancepaintingcontractsinvolv-ingcompletecoatingremovalandrepaintingaveraged$5.05/sq ftfo rnonhazardouscoatingsand$10.60/sqftforhazardouspaintremoval.Theadded costsfo rworkerhealth,environmentalmonitoring,wastedisposal,andcontainmentaresignificant.TheF HWAstudyconcludedthat,fo rmildserviceenvironments,overcoatingismorecosteffectivethan othermaintenanceoptionson alifecyclecostbasis.Theyreportanaverageequivalentannualcostof$1.04/sqftfo rovercoatingusinga3-coat alkyd systemversus$1.99/sqftfortotalremovalandrepaintingwithanin -organiczinc/epoxy/polyurethanesystem.Overcoatingisperformedwithasignificantdegreeofrisk,whichreferstothechancethattheovercoatedsystem may eitherfailcatastrophicallyorwillnot pro-videthedesiredperiodofprotection.Theapplicabilityof overcoatingishmitedbytheconditionoftheexistingcoatingandunderlyingsubstrateandtheseverityoftheexposureenvironment.fthe existingcoatingistoothick, brittle,orpoorlyad -herent,thenovercoatingshouldnotbeperformed.fthedegreeof substratecorro-sion issignificant, thenthelevelofeffortneededtopreparethesubstratemayindi-catethatovercoatingisnoteconomically viable.Overcoatingsystemsgenerallyarenotrecommendedformoresevereexposureenvironmentsbecausedeleadingandpaintreplacementlastssignificantlylongerthanovercoatingandis morecosteffec-tive.


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3 Demonstrat ionDesign Per formance Object ives

Theperformanceobjectivesfo rthesedemonstrationswereto:leanandovercoattheexisting LBP,omplywithenvironmentalstandards,omplywithworkerhealthandoccupationalsafetyrequirements,ollectdataandestimateinstalledcosts,andeterminetheperformanceof theovercoatprocess.

Select ionofTestSites Twotest siteswereselected.hedelugewatertank atFortCampbellwaschosenbecauseitis representativeofa simplestructure.Thetankisweldedanddoesnothaveanyirregularsurfacesorcomplicatedgeometry.heHAAPrailroadbridgewasselectedas arepresentativecomplex steelstructure.Thedesigncontainscom-pUcatedshapessuchasback-to-backanglesandrivetheads.othsiteswerese-lectedbecauseoftheirnorthernclimeswithwinterandsummertemperatureex-tremes,whichcaninfluencetheperformanceofovercoating.vercoatsurfaceswereselectedto presentarangeof solarorientations,whichmayalso influencetheperformanceof theovercoatsystem.

TestSite Cliaracter ist icsDelugetanknumber 7151isnearthecorners of BlacksheepRun andCAvenuead -jacentto HangarComplex4,FortCampbell,KY.he tankisapproximately 22 fttall.Chicago BridgeandIronCompanyconstructedthetankin1960.TheexistingLBPsystemwasTT-P-86Type I,Red LeadLinseed Oil PrimerandTT-P-38 Alumi-numPigmentedTungOil PhenolicCoating.Figure1 showsthetankpriorto clean-ingandovercoating.


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A visualinspection andphysicaltestswereperformed on theexistingagedcoating.Dryfilm thicknesses(DFTs)weremeasuredateightlocations.Theaveragethick-nessrangedfrom 2.0to 4.1mils.heoverallaveragethicknessisapproximately3.0 mils.Threeadhesionmeasurementsweretaken,tw o withasouthsolarorienta-tionandonewithanorthsolarorientation.Crosscutadhesionvalues(ASTM D 3359MethodA)were3Aand5A (southfacing)and3A(northfacing),indicatingslightlydegradedintercoatadhesion.Rustingrangedfrom 3to5percentof thetanksurface.Corrosionwasprimarilygeneral spotcorrosionwithassociatedstaining.Thenorthside and lowerportionsofthetankweresomewhatmoredegraded thantheupperportionsandsouth side.However,therustdistribution wasfairlyuniformoverall.BasedonthegenerallylowD FTandoverallappearance,thetankhasprobablyneverbeenmaintainedorrecoated.

Figure 1.ortCampbe l lwater tankpr ior to cleaning an dovercoat ing


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Bridge29atHAAP isanactiverailroadbridge.hebridgewasoriginallyfabri-catedinthe1890sandmoved toHAAP inabout1943 duringtheconstructionof theplant.Thebridgeisamulti-spanthroughtruss-typesteelbridgewithrivetedcon-nections andbuilt-upbeams.Thepiers areconcrete.Welded pipehangerssupportpipesconveying wastewaterandchemicals.hebridgetraversesabranchof theHolstonRiverandisalmostentirelyoverwater.Figure2showstherailroadbridgewithovercoatedtestareas.Avisualinspectionandphysicaltestswereperformedontheagedcoating.hebridgeappearstohavebeentouchedupandrepaintedon numerousoccasions.tis doubtfulthatthe bridgehas beenabrasiveblastedandpainted inatleastthelast30 yearsandpossiblynotsinceitwaserectedatHAAP in1943.Thepaintsystemiscomprisedof anorangeprimerandaluminumtopcoat,whichareprobablyTT-P-86 , Type I, redleadinlinseedoil andTT-P-38,aluminumphenolic finishcoat.Mostof the touchuppaintingwasdonewithanaluminumfinishcoat.aintfilm thick-nessesaregenerally8to15milsonflatverticalsurfacesand20 to25 milsonup- wardfacinghorizontalsurfaces.Theamountof visiblerustislessthan1 percentofthetotaltestarea.Mostof therustwasonthe topsof flanges.omerustedareasontheflangeswerepreviously coatedoverand wereliftingandcurled.Adhesiontests wereperformedinaccordancewithASTM D3359MethodA X-cuttapetest.Adhesionrangedfrom4A to 5A .nsomecases,a thinlayerofaluminum pigmentwasliftedwiththetape.This nonadherentmaterialistheequivalentof chalkin astandardpigmented coating.A gooddealof dirthadalsoaccumulatedon manyofthebridgecomponents.

Figure 2.ailroad bridge atHAAP,TN ,withovercoated testareas.


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J! f ERDC/CERLTR-03-5PhysicalSetup an dOperat ion

Fort Campbel lWaterTankThestructurewasaccessedusingstepladders,paintingpoles,andplatformscaf-folds.Ground surfaces adjacenttothetankwerecoveredwithwaterimpermeabletarpaulins.he tarps weretapedtothebaseofthetank.Cleaningwasperformedwithan aqueousmixtureof soap (100to 1 dilution,Kleenz-BriteExtra,manufacturedbyLadChemicals,Inc.,fo r JamesA.Lytle,Inc.).Clean-ing solution wasappUedbysponge,andthesurface wasscrubbedwithnonwoven abrasivepads attachedto wood backupholders.Washedsurfaceswererinsedwithcleanwaterusingsponges anddriedwithcleanclothes.Washandrinsewaterwerecollectedongroundtarps.LoosepaintandrustwereremovedinaccordancewithSSPC-SP3PowerToolCleaningusingtw orotarycleaningtools equippedwith3M brandCleanandStrippads.WastewascollectedinaHighEfficiencyParticulate Air(HEPA)filtervac-uumcanister.olventwipingwithcleanagsandvarnishmakersandpaint(VM&P)naphtha wasperformedto removeresidualdustandcontaminants.WasserM io Aluminumprimer,Ferromasticintermediate,andFerroxA topcoatwereappliedby brush androllerto thefirsttestarea.Sherwin-WilliamsCorothaneI Masticprimer,CorothaneIIronoxA intermediate,and Corothane IIronoxA top-coatwereappliedby brushandrollertothesecondtestarea.igure3showsthedeluge tankafterovercoatingwith test patchesof moisturecurepolyurethane.Allequipment,groundtarps,anddebriswereremovedfi-omthesite.Washandrinsewatercollectedonthe tarps wasvacuumedandcontainerized.HAAP Railroad Bridge Thestructurewasriggedusingacombinationofscaffolding,picks,andhangingstages.ccessto thescaffoldtowerandstaging wasbyladder.lacementofthescaffoldtowerandstagingwasfacilitatedby useofasingle-personliftbucket.Theliftbucketwasalsousedtoaccessportionsoftheworksurface.Groundsurfacesbelowthebridgewerecoveredwithwater-impermeabletarpaulins.


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Figure3.e lugetankatFortCampbe l lA r m y Airfield.Orig inalcoat ingwithlead-basedpaintpr imervisibleatto p Is deter ioratedan dstee lunderneath isrusted.he tank was overcoated withtestpatcheso fmoisturecurepolyurethane in October2000.)

Cleaningwasperformedwithanaqueousmixtureofhouseholdbleach (100 to1di-lution) andsoap(1000 to 1 dilution, Kleenz-BriteExtra).Cleaningsolutionwasap -pliedbyspongeandthesurfacewas scrubbedwith 3-M ScotchBritepads.Washedsurfaceswererinsedwithclean waterusingspongesanddried withcleancloths.Washandrinsewaterwerecollectedonthegroundtarps.LoosepaintandrustwereremovedinaccordancewithSSPC-SP3PowerToolCleaningusingavacuum-shroudedneedlegunwith2-mm diameterneedles.WastewascollectedinaHEPAvacuumcanister.olventwipingwithcleanragsandV M & P naphtha wasperformedto removeresidualdustandcontaminants.PowertoolcleanedareaswereprimedwithSSPCPaint 25 usinganaturalbristlebrushfollowed bytwocoatsofTT-P-38Eapphedbybrushandrollerovertheentiretestarea.hesecondtestareawascoatedwithtw ofullcoatsof WasserM C-Aluminumapplied bybrushandroller.All riggingwasremovedatthecompletionof painting.Groundtarpsandalldebriswereremovedfromthesite.


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MonitoringProceduresAmbientandsurfacetemperaturesas wellas relativehumidity weremonitoreddur-ingcoatingapplication.Drytimeand degree ofdrynesspriortorecoatingwereas-sessed.Wetanddryfilm thicknesses(WFTs/DFTs) weremeasured.heappear-anceoftheappliedcoatingswasnoted.otalsurfaceareathat wascleanedwithpowertoolsandcoatedwereestimated.ersonalairmonitoring(PAM)wascon-ductedonthepowertooloperatortodetermineleadexposure.TotalleadandToxic-ityCharacteristicLeachingProcedure(TCLP) leadweredeterminedonMquidandsolidwastes.Wastequantitiesweremeasured.ninspectionwasperformed6months afterapplicationto assesstheperformanceoftheovercoatsystems.Corro-sionandadhesionwereevaluated.

AnalyticalProcedures Thepersonal airsampleswere analyzedfo rlead accordingtoNationalInstituteforOccupationalSafety andHealth(NIOSH)Method7300.TherespirabledustlevelwasmeasuredbyNIOSHMethod600.CLPwasperformedinaccordancewithU.S.EnvironmentalProtection Agency(EPA)Method1311.


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4 Performance Assessmen tPer formance Data

FortCampbel lWaterTankApproximately5percentof thetotaltestareawaspower-toolcleaned.TheaverageWFTof theWasserM io Aluminumprimerwas3.3 mils.TheaverageDFTwas2.0 mils.Theairtemperatureatthetimeof applicationwas73 F andthesurfacetemperature was67.5F .heFerromasticintermediatecoatwasappliedafteradryingperiodof19 hours.The averageW FT was4.3 mils.TheaverageD FTwas 2.6mils.Theairtemperature atthetimeof applicationwas70 F andthesur-facetemperaturewas68.5F .TheFerroxA topcoatwasappliedafteradryingpe-riodof22 hours.heaverage WFTwas4 .6 mils.heaverageDFTwas2.8mils.The airtemperature atthetimeof appUcationwas65 Fandthesurface tempera-ture was65F .heaverageDFTfo rthecompleteovercoatsystem was7.4mils.TheCorothaneI Mastic primerforthesecondtestareawasapphedtoanaverageWFTof 3.6 mils.TheaverageDFTwas2.2 mils.Theairtemperatiu-eatthetimeofapplicationwas73 Fandthesurfacetemperaturewas67.5F .heCorothaneIIronoxA intermediatecoatwas appUed afteradryingperiodof 19 hours.Theaver-ag eW FT was3.6 mils.TheaverageDFTwas2.0mils.Theairtemperatureatthetimeofapplicationwas70Fandhesurfaceemperaturewas68.5F.heCorothaneIIronoxA topcoatwasapphedafteradryingperiodof28 hours.The av-erageWFTwas3.6 mils.heaverageDFTwas2.0mils.heairtemperatureatthetimeof apphcationwas65 F andthe surfacetemperaturewas65 F .Theaver-ag eDFTfo rthecompleteovercoatsystemwas6.2mils.Wasteminimizationwas accompHshed by handwashingratherthanpower washingtheexistingcoating.Wastewaterwascollectedfromthetarps,weighed,andtestedfo rtotalleadandTCLP.Thetotalliquidwastecollected fromthetarpswas 20 gal-lons(73kg).CLPleadwas0.41ppm.hewastewaterwasbelowtheEPAUmitfo r leadand wasconsiderednonhazardous waste.


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Thepowertoolcleaningwastewasweighedandtestedfo rtotalandTCLPlead.Thetotalweightofpowertoolcleaningdebriscollectedwas0.22kg .otalandTCLPleadwere83,000 ppmand270ppm,respectively.hepower-toolcleaningdebriswas abovetheEPAlimitfo rleachablelead(>5ppm lead)andwasdisposedofashazardous waste.Theworkeroperatingavacuum-shroudedrotarypowertoolwore a PAM devicefo rthe120-minutedurationofthepower-toolcleaning.heworker exposure was81 lig/m3.Averagedoveran8-hourworkday,theexposurewas20 pg/m^.heactionlevelforleadexposureis30 pg/m^ foran8-hourworkday.f theworkdurationhadbeen8hours,thentheleadactionlevelwouldhavebeenexceeded.

Thetwoovercoatsystemson thedelugetankwere inspectedinMarch2001.DFT,corrosion,appearance,andadhesionwere evaluated.Table1 presentstheinspec-tionresultsfo rboth testareas.Table1.Watertankovercoatper formance .

TestArea Appearance Rust(% )DF TR an g e

(mils) Avg.DF T(mils) Adhes ion (D 3359)1 ruststain 0 7.1-12.7 9.6 5A 2 ruststain 0 6.9-13.2 9.7 5A

HAAP RailroadBridge Approximately 3to 4sq ft ,or lessthan1 percentofthetotaltestarea waspower-toolcleaned(SP 3).Approximately25 sqftofsurfacewasprimedwithSSPC Paint25usinganaturalbristlebrush.heapproximateWFToftheprimer was3to5mils.Theairtemperatureatthetimeof appUcation was 55 F andthesurfacetem-peraturewas56F .Afteradryingperiodof21hours,thefirstcoatof TT-P-38Ewasappliedby brushand roller.TheapproximateW FT was2to 2.5mils.Theairtemperatureatthetime ofapplicationwas74 F and the surface temperaturewas55to62F .hesecondcoatofTT-P-38Ewasappliedafteradryingperiodof16hours.TheapproximateW FT was 2 to2.5mils.Theairtemperatureatthetimeofapplication was59 F .TheSSPC Paint25 primerwasjustbarelyset-to-touchafter21 hourswhenthefirsttopcoatwasapplied.ContrastinappearancebetweencoatsofTT-P-38 wassuffi-cienttoallow easyrecoat.T-P-38containsleafingaluminumpigment.Duringapplication thepigment doesnot immediatelyleafandthe coatinghasa dullgraycolor.hedullgraycontrastednicelywiththedriedfirstcoatofTT-P-38,whichhadgonethroughtheleafingprocesstodevelopthecharacteristicshinysilverappearanceofaleafingaluminumtopcoat.


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ERDC/CERLTR-03-5 Thesecond testareawasprimedwithWasserMC-AluminumappHed bybrushandroller.TheapproximateWFTwas 2.5to 3.5mils.TheairtemperatureatthetimeofappUcationwas 54 F andthe surfacetemperaturewas 52 to54 F .Therelativehumiditywas98 percent.A secondcoatofMC-Aluminumwasapplied afteradry-ingperiodof 4 to 5 hours.TheapproximateW FT was2.5to 3.5mils.Theairtem-peratureatthetimeofappUcationwas74 F ,andthesurfacetemperaturewas55 to62 F .Wasteminimizationwasaccomplished byhandwashingratherthanpower washingtheexistingcoating.Washandrinsewaterwere evaporatedfromthetarpstofur-therreducetheamountofwaste.Debriswas collected from thetarps,weighed, andtestedfortotalleadandTCLP.hetotalwastecollectedfrom thetarps was6.49kg.TotalandTCLPleadwere25,000 ppm and6ppm,respectively.Thetarpdebrisexhibitedthehazardouscharacteristicfo rlead(>5ppmleachablelead).Thepower-toolcleaningwastewasweighedandtestedfortotalandTCLPlead.Thetotalweightofpowertoolcleaningdebriscollectedwas0.38kg .otalandTCLPleadwere70,000ppmand22 0ppm,respectively.hepower-toolcleaningdebriswasabove theEPAUmitfo rleachablelead(>5ppmlead) andwasdisposedofashazardous waste.Theworkeroperatingthevacuumshrouded needlegunworeaPAM device forthe85-minute durationofpower-toolcleaning.Noairborne leadwasdetected.Basedon the sample results,therewas no leadexposure.Based on thecalculatedreport-inglimit,however,theleadexposurewas12 pg/m^.Averagedoveran8-hourwork-day,the exposure basedon thecalculated reportingHmitwouldbe2.1pg/m^.TheOccupationalSafetyandHealthAdministration (OSHA) requiresthatairmonitor-ingdataandexposurelevelsbe reportedbasedon theoperatingdetectionlimitifnoleadisdetected.heactionlevelfo rleadexposureis30pg/m^fo ran8-hourworkday.A half-maskrespiratorwithanAPFof10waswornbythepowertoolopera-tor.hevacuumshroudaloneprovidedanadequatedegreeof worker protection.Anevaluationof theovercoatsystemswasperformedafter6 monthsof service.Theperiodofserviceincludedthewintermonthswithseveralperiodsoffreeze-thaw.Theovercoatedsurfaces wereinspectedforcoatingDFT,corrosion,andadhesion.TheresultsarepresentedinTable2.


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Table2.ailroadbridge overcoa tper formance .Pain tSystem Area Average Pain tThickness(mils) Adhes ion (D 3359) Rust(% )

TestArea 1 Southstringer,northside 15.2 5A 0Southstringer,southside 12.5 4A 0

Northstringer,northside 16.0 5A 0Southtruss,northside 10.2 5A 0Southtruss,south side 14.0 4A 0Northtruss,northside 15.2 5A 0Northtruss,south side 13.2 5A 0

TestArea 2 Southstringer,north side 16.3 5A 0Southstringer,south side 13.8 4A 0Northstringer,northside 14.9 5A 0

Southtmss,northside 11.2 5A 0Southtruss,south side 15.2 5A 0Northtruss,northside 13.9 5A 0Northtruss,southside 17.6 3A 0

DataA s s e s s m e n tFort Campbel lWaterTankAreasofthedriedprimer,Mio Aluminum,wereobservedto havenumeroustinybubblesoverthepreparedrustspots.Theseareasappearslightlyrough.Thebub-blesarecharacteristicallyformedinpolyurethanefilmsascarbon dioxide is evolved.Theproblemoccurswhenthecurereactionoccurstoorapidlyorthecoatingisap -pliedtoo thickly.Wasserrecommends thatM io AluminumbeappliedataW FT of2.5to3.0mils.heachievedW FTwasslightlyabovetherecommendedrange.Highhumidityalsopromotesrapidcure.Paintingconditionswerenearlyidealandhumiditywas nothighduringapplication.ThebubblingmayhavebeencausedbyacombinationofrelativelyhighW FTandmoistureretainedintherust.Bothovercoatsystemswereperformingwellafter5monthsof service.Thewintermonthswererelativelyharshwithnumerousfreeze-thawcycles.ntercoatadhe-sion betweentheovercoatsystems andtheoriginalpaintsystemwasexcellent.Theadhesion of theoriginalcoatingtothesubstratewasunaffected byeitherovercoatsystem.Theriskthatacatastrophicdelaminationfailurewilloccurinthefutureisnegligible.othsystemsweredevoidof anysignofearlycorrosion.omeruststainingoftheovercoatedareashadoccurredasaresultofwashdownfromcor-rodedsurfacesabovetherepairedareas.


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ERDC/CERLTR-03-5 2 1

After evaluationofthetwo coating systems,thecoating system composedof Sher-win-WiUiamsCorothaneIMastic primer,CorothaneIIronoxA intermediate,andCorothaneIIronoxA topcoatwaschosenforcompletionofthetankcoating job,asshowninFigure4.Theprojectedlifeof theovercoatrepairon thistankis15 to 25 years.hisprojectionisbasedonthepre-overcoatconditionoftheoriginalpaintsystem,thedurabilityoftheovercoatmaterials,andtheseverityof theexposureenvironment.tshouldalsobenotedthatthewatertankcanprobablybeover-coatedtwomoretimesprovideditsconditionisnot allowed to deterioratepastthatwhichissuitablefo rovercoating.HAAPRailroad Bridge Areasof driedMC-Aluminumcoatingwereobserved to havenumeroustinybubbles.Theseareasappearedslightlyrough.The formationof theses bubbles isa charac-teristicflawof polyurethanecoatings andoccurswhencarbondioxideformsandes-capesfromthepartiallycuredfilm.Theproblemis exacerbatedwhenthecurereac-tionoccurstoo rapidlyorthecoatingisappliedattoo greatathickness.ThecoatingmanufacturerrecommendsthatMC-AluminumnotbeappUedat aWFTof greaterthan8mils.herecommendedmaximumthickness wasnotexceeded.Highhu-midityalsopromotesrapidcure.Humiditywashighduringpaintapphcationbutwaswithinthemanufacturer'srecommendedrange.hebubbhngwasprobablycausedbyacombinationofrelativelyhighWFTandhighhumidity.Manufacturerdatasheetsdo not necessarilyaddressintermediateconditionsormultipleeffects.

^*:: = "^h ii'

:t: .- *

-'t ;.- ysst-

Figure 4.e luge tank atFortCampbe l lA r m y Airfieldatterovercoat ing comple tedin August2001.


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22 ERDC/CERLTR-03-5

Bothovercoatsystemswereperformingwellafter6monthsof service.Thewintermonthswererelativelyharshwithnumerousfreeze-thawcycles.ntercoatadhe-sionbetweentheovercoatsystemsandtheoriginalpaintsystemwasexcellent.Theadhesionof theoriginalcoatingto thesubstratewasunaffected byeitherovercoatsystem.oatingadhesiontothesubstratewasslightlylessforsurfaceswithasouthsolarorientation.Thisis typicalof alkyd-typepaintsystemsastheytendtoembrittleandloseadhesion withprolonged exposure to ultravioletradiation.Theriskthat a catastrophicdelaminationfailurewilloccurinthefutureisvery small.Bothsystemsaredevoidofanysignof earlycorrosion.Theprojectedlifeof anovercoatrepairis12 to 18 years.Thisprojectionis based on thepre-overcoatconditionoftheoriginalpaintsystem,thedurabilityof theovercoatmaterials,andtheseverityof theexposureenvironment.

Technology Compar ison Complete coatingremovalbyabrasiveblastingwithcoalslagabrasivewouldhaveproduced approximately 15,000 lb (6800kg )ofhazardouswasteper 1,000sqft.Thequantityofhazardouswastegeneratedwas lessthan0.1percentof whatwouldbeproducedusing expendablecoalslagabrasive.Completecoatingremovalbyabrasiveblastinginsideofaproperlydesignedandventilatedcontainmentstructurewould have exposed workersto alead concentra-tion upto58,700 pg/m3witha presumedexposureof over2,500pg/m^.Coatingre -movalusingnonvacuum-assisted powertoolswouldhaveexposed workersto aleadconcentrationof upto20,000 pg/m^ withapresumedexposureof upto 2,500pg/m^.Theuseofvacuum-assistedpower-toolcleaninggreatlyreducedpotentialleadexpo-suresduring surfacepreparation.Completecoating removalby abrasiveblastingwithcontainmenthashighriskofenvironmentalexposure.ower-toolcleaninghasa lowto moderateriskand vac-uum-assistedpower-toolcleaning hasonlyalowriskofenvironmentalexposure.OvercoatedLBPwillnotlastaslong asanew highperformancecoatingsystemap -pliedtoawell-preparedblastcleanedsurface.heprojectedovercoatlifeforthewater tank is15to25 years.heoriginalcoatingsystemlasted40yearswithno maintenance.


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5 Cost Assessmen tCostRepor t ingan dAnalys is

CostwasmeasuredusingtheBureauofLaborStatistics1998NationalOccupa-tional EmploymentWageEstimatesfo rlabor category87402PaintersandPaper-hangers,ConstructionandMaintenance.he9 0 * 1 ^ percentilewage($21.40/h)ad -justedforinflation(2percentperannum)wasused.50-percentburdenwasaddedtocoverinsurance,pension,annuity,vacation,andprofit.helaborcostusedfo rthecostestimatewas $33.40/h.Laborandcostdetailsaretabulatedbelow.Fort Campbel lWater Tank Theestimatedunitareacostforovercoatingthetankwas$1.55/sqft(seeTable3).Workwasperformedon portionsofthetankthat weregenerallymoreaccessible.Theestimatedunitareacostrangefo rovercoatingsimilartanksandother simplestructuresis$1.40/sq ft to $1.86/sqft .Table 3.Watertankcos treport.

WorkPhase Hours Mobil ization 6. 0 W asli ing 8.75PowerToolCleaning 4. 0 SolventW i pe 1. 0 PaintingSystem1 4. 5PaintingSystem 2 4. 5Demobil ization 4. 0 C o s t ($/sqft )M obilization/Demob ilization 0.167SurfacePreparation 0.383 PaintApplication 0.251Paintan dExpendables (est.) 0.750W asteDisposal 0 . 0 0 0 TotalCost 1.551


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HAAP Railroad Bridge Theestimatedunitareacostfo rovercoatingthebridge is$2.83/sqft(seeTable4).Workwasperformedon portions ofthebridgethatweregenerallymoreaccessible.Theestimatedunitareacostfo rovercoatingthebridgeandothercomplexstruc-turesis$2.55/sqftto $3.39/sq ft. Table 4.ailroadbridge cos trepor t .

WorkPhase Hours Mobil ization 18.0 Washing 12 .5PowerToolCleaning 1 .5 SolventW i pe 5. 5PaintingSystem1 15.0 PaintingSystem 2 14.5Demobil ization 6. 0 C o s t ($/sqft )Mobilization/Demobilization 0.802 SurfacePreparation 0.651 PaintApplication 0.985Paintan dExpendables(est.) 0.395WasteDisposal 0 . 003 TotalCost 2 . 836

C o s tCompar ison Cost-effectiveremovalof hazardousLBPisgenerallyperformedby abrasiveblast-ingorby waterjetting.Containmentanddisposalofsurfacepreparationdebris,workerprotection,andotherregulatorycompliancecostscombinetomakeremovalofLBPveryexpensive.heFHWA exampleshowedthattypicalbridgemainte-nancepaintingcontractsinvolvingcompletecoatingremovalandrepaintingaver-aged$5.05/sqftfo rnonhazardouscoatingsand $10.60/sqftfo rhazardouspaintre -moval.headdedcostsorworkerhealth,environmentalmonitoring,wastedisposal,andcontainmentaresignificant(FHWA1995).Theinstalledcostofovercoating on asimplestructure (Fort Campbellwatertank)was estimatedat$1.55/sqft.Theinstalledcostforovercoatingon acomplexstruc-ture (HAAP railroadbridge)wasestimatedat$2.83/sqft.Bycomparison,thecostofdeleadingandinstalhnganew paintsystemis$5 to$18/sqftwithanaveragecostof$8/sqft.


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ERDC/CERLTR-03-5

Case-specificeconomicanalysisisrecommendedfo rmeasuringthelife-cycle costofrepaintingversusovercoating.Themaintenancepaintingoption,overcoatingor re -painting,withthelowesttotalnetpresentvalueshould be implemented.Overcoatinginamildexposureenvironmentis alwayscheaperthanrepainting,butitisnoteconomically viableinasevereexposureenvironment.Overcoatingmayormaynotbemoreeconomicalina moderateexposureenvironment.


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26 RDC/CERLTR.03-5

6 Implementat ionIssues C o s tObservat ions

Overcoatingsimplestructuresis significantlylessexpensive thanovercoating morecomplex structures.Thelesscomplexastructureis,thelessexpensiveovercoatingwillbeandlifecyclecostswillbemorefavorable.

OtherSigni f icantObservat ions Inmanycases,overcoatinghasbeenusedinappropriatelyby theindustry.Becauseofthepotentiallylargeinitialcostsavingsassociatedwithovercoating,asopposedto containmentandremoval,thetemptationtoovercoatisgreat.The large initialcostdifferencebetweenthesemaintenanceoptionshasmeantthatownersaremoretolerantoftherisksinvolvedinovercoating.Ownersshouldfirstproperlyassesstherisks,andifovercoatingrisksaredeemedacceptable,thenthefaciHtyownershouldtakeadditionalstepstomitigatetheriskofovercoating.Theprimaryriskassociatedwithovercoatingisthatthecoatingsystemwillde -laminate.fadelaminationfailureoccurs,thentheovercoatinginvestmentislost.Delaminationofalead-containingcoatingmayalsorepresentanenvironmentalhazard.nthiscase,the possibilityfo rlitigationis veryreal.Theremedialcostofanunintentionalintroductionof leadintotheenvironmentmaybesignificant.D e-laminationisdifficultto predict.nunderstandingoftheunderlyingprinciples,however,shouldhelp the coatings engineerpreventorreduce thechanceofsuffer-ingadelaminationfailure.Delaminationisprimarilytheresultofinternalstressesintheovercoatmaterialthatcannotbe supportedby theunderlyingagedcoating.nternalstressoccursastheappliedovercoatcontracts,eitherfrom solvent evaporationorcuring.everalfactorsaffectthedegreeofinternalstressintheovercoat material,includingtypeofcoating,formulation,andfilm formingconditions.Ascoatingsage,film stressgen-erally increases.Agingmayresultinadditionalcross-linkingandfilm shrinkage.Agoodexampleofage-relatedstressincreaseistheoxidativecuringofalkyds.Temperaturefluctuationsmayalsoaffectthelevelof internalstress,withhigher


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ERDC/CERLTR-03-5 7

temperaturesfavoringlowerstressandcoldertemperaturescausinghigherstress.Thehigherstressassociatedwithcoldtemperaturesis themajorcause of overcoatsystemfailureby delamination.Plasticizermigrationmayleadto reducedelasticityorembrittlementof bothagedcoatingsandovercoats.Brittlecoatings aremoreaptto crackduringtemperature cycles.Theapphcationof theovercoatmayalsoaffecttheinternalstressoftheagedcoating.olventmigration mayinitiallyreduce thestress in theexistingcoating,butsubsequent solvent evaporationwillresultinanincreaseinthefilm stress.Resin intheovercoatmaterial maypenetratetheagedpainttoformastresszonewithintheoldcoating.hestresspresent intheover-coatisimportant becauseitistransmittedtothebasecoating.Theinternalstressof theovercoatiscounteractedby itsadhesionto theagedcoat-ing. lossofadhesionof theagedcoatingmayresult incrackingoftheovercoatbecausetheunderlyingcoatingnolongersupportsinternalstress.hisistruewhentheinternalstressof theovercoatexceeds itstearstrength.Whenthetensilestressintheovercoatexceedsthatintheagedcoatingandtheovercoatcracks,thenpeelinganddelaminationarelikelyto occur.Goodovercoat^asecoatsystems, likeallmulti-coatsystems, shouldhavehighertensilestrengthandrigidityinthebase-coat thaninthetopcoat.ew coating systemsarespecificallydesignedthisway.Overcoat/basecoatsystemsshould be designedthis wayas well.npractice,how-ever,itisdifficultto assurethatthestressoftheovercoatwillnotoverwhelmtheadhesionof theold existingcoating.Theotherprimaryriskassociatedwithovercoatingisthattheovercoatsystemwillnotprovidea long enoughperiodof serviceto beconsideredcosteffective.nthiscase,theovercoatsystemmaynotexperienceacatastrophicfailuresuchasdelami-nation,butmayfailprematurelybecauseof theseverityof theserviceenvironmentand/orthedegreeof protectionaffordedby theovercoatmaterial.Suchfailuresaretypifiedbyearly onsetorexcessiverust-through.Thickeragedcoatingstendtobemorehighlystressed.Largepeelingforces canbegeneratedduringcuringand agingof theovercoat.Whenovercoated,thickermorehighlystressedcoatingsaremorelikelytodelaminatethan thinnercoatingswithlowerinternalstress.Delamination may also becausedby thermalcycling, whichmaydisrupthentegrityofthickagedcoatingshathavebeenovercoated.Thicker,morehighlystressedcoatingsarealso morelikelyto sustainblastmediaorothermechanically induceddamagewithasubsequentlossofadhesionthatmayaffecttheperformanceof theovercoatsystem.Themechanicalpropertiesofcoatingsmaychangeas theyage.Age-relatedchangesaredueprimarilytochangeswithinthecoatingthatincreasetheglasstransition


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^ RDC/CERLTR-03-5

temperature.sacoating'sglasstransitiontemperatureincreases,itsinternalstressincreases,adhesiondecreases, andbrittlenessincreases.Theglasstransitiontemperatureincreaseis generallytheresultof thermalandphotoradiationeffects.Foracryliclatexcoatings,ithasbeenshownthatthetemperatureincreaseisdueentirelytophotoradiation.Foroil painttheeffectismainlyduetophotoradiation;fo ralkyd,itisduetoboththermal and photo radiation,withthermaleffectsplayingagreaterrole.ongoilcoatingsgenerallytakelongertoembrittlethanshortoilcoatings.

Epoxyand alkydcoatingsmaychalkanderode withprolongedexposure.Generally,thisdoesnotpresentaproblemfo rovercoatingaslongastheloosechalkisremovedbeforeovercoating.Evenseverelyerodedcoatingswithexposedprimermaybe goodcandidatesforovercoating,providedtheremainingcoatinghasgoodadhesionandtotalrustingisnominal.Thedegreeofadhesionoftheagedcoatingto thesubstratesis one of themostcriti-calfactorsaffectingtheovercoatingprocess.oorlyadherentcoatingsaremorelikely to delaminatewhenovercoatedthanareagedcoatingswithgoodadhesion.Poorintercoatadhesioninagedmulti-coatsystems mayalso resultin overcoatde-laminationfailures.enerallytheagedcoatingsystemwillfailatitsweakestpoint.Coatingtype,age,thickness,andsurface preparation may allaffectthead -hesionof theagedcoatingsystem.The conditionof thesubstratemayalsoaffectthe performanceoftheovercoatsys-tem.ngeneral,ifmorecorrosionispresent,moresurfacepreparationwillbe needed.Mechanicalcleaning,especiallyabrasiveblasting,maydisrupttheadhe-sionof theagedcoatingadjacenttotheremovalareas.Additionally,overcoatingmaynotbe costeffectiveifextensivesurface preparationisrequired.Theoriginalsurfacepreparationmayalsoplayaroleintheperformanceoftheovercoatto theextentthatitaffectscoatingadhesionon millscaleandotherpoorlycleanedsur-faces.ThiseffectmaycauselocaUzedproblems on structuresthatwerenotcleaneduniformlybeforereceivingtheoriginalcoating.Theproblemsassociated withsurfacecontaminantsarenot necessarily specificto overcoating;however,contaminantsarelesslikely to be removedduringovercoatingbecausemuchlesssurfacepreparationis typicallydone.Lesssurfacepreparationis performedto lowercostsandtoreduceenvironmentalandworkerexposuresto haz-ardousdusts.Rigoroussurfacepreparationisalso morelikelytocausemechanicaldamage to anoldmarginallyadherentembrittledcoatingthatmaylatermanifestitselfasadelaminationfailure.


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ERDC/CERLTR-03-5 9

Asnoted above,thermal-andphotoradiation-inducedincreasesto theglasstransi-tiontemperaturemayleadtoembrittlementandreduced adhesionoftheaged coat-ing.Oil andoil-modifiedalkydson structuralcomponentsexposedtothermalandphotoradiation,willbe moreproneto theseage-relatedeffects.Similarcoatingsinprotectedareasnotdirectlyexposedtothesunmaybe moresuitablefo rovercoat-ing.hermalcycUngisanotherweather-relatedeffect.nternalcoatingstressesmayincreaseto unsupportablelevelsatlowtemperatures,explaining whymanyovercoatdelaminationfailuresoccurduringoraftercoldspells.Structuresinmildclimatesareless likelyto beexposedto lowtemperaturesthatmayprecipitatede-laminationfailures.Conversely,oilandalkydcoatingsexposedinsunnyclimatesmayagefasterthaninotherlocales.Severeexposureenvironments,ncludingreshandsaltwatermmersionandchemicalandmarineatmospheres,areusuallynotsuitableforovercoating.FH WA andArmyresearchhasshownthat,forsevereserviceenvironments, totalremovalandreplacementoftheagedcoatingwithahighperformancecoatingsystemis morecosteffectivethanovercoating.


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J2 RDC/CERLTR-03-5

References CitedAmericanSocietyfo rTestingandMaterials(ASTM)D 3359, StandardTestMethodsforMeasuring

Adhesionby TapeTest.FederalHighwayAdministration(FimA), Lead-ContainingPaintRemoval,Containment,andDisposal,FHWA-RD-94-100,February1995.NationalInstitutefo rOccupationalSafety andHealth(NIOSH)Method600,Nuisance Dust,Respirable.NIOSH Method1311,Toxicity CharacteristicLeachingProcedure.NIOSHMethod7300, Elements(ICP)Societyfo rProtectiveCoatings(SSPC)SP3, Power ToolCleaning.U.S.EnvironmentalProtectionAgencyMethod1311,ToxicityCharacteristicLeachingProcedure.UncitedASTM D 610, StandardTestMethodforEvaluatingDegree of Rusting on PaintedSteelSurfaces.ASTM D5064,Practicefor Conducting aPatchTestto AssessCoatingCompatibility.ASTM D5065, PracticeforAssessingtheCondition ofAgedCoatingson SteelSurfaces.SSPCPA-2,Measurementof Dry PaintThicknesswithMagneticGages.

SSPC-VIS2,StandardMethodof EvaluatingDegreeof Rustingon PaintedSteelSurfaces. SSPC-VIS 3,VisualStandardforPower-andHand-ToolCleaned Steel.SSPC-Technology UpdateNo .3,Overcoating,SSPCPublicationNo .97-17.Angelhofif, C,"Overcoating BridgesContainingLeadBasedPaints: An Economical Alternativeto TotalRemovalandcontainment,"SSPCProceedings,Achieving QualityinCoatingWork,November1992.Appleman,B.R.,"Overcoating vs RemovingLeadPaint:AComparativeAnalysis,"JournalofProtectiveCoatingsandLinings,November1993.


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ERDC/CERLTR-03-5 L

Appleman,BernardA.,Guidelinefor Cost-Effective LeadPaintRemoval,FinalReport,Societyfo rProtectiveCoatings,FederalHighway Administration, SSPC96-06,1996.

Byrnes,G.,"Delaminationby Design.," MaterialsPerformance,February1993.DaSilva,R.,"An Alternative toRemovingLad-BasedPaint:Overcoating,"SSPCProceedings,

BalancingEconomicsandCompliance forMaintainingProtectiveCoatings,November1995.

Farschon,C.L.,andAult,J.P.,"FieldTestingofOvercoatingSystemsfo rBridges,"SSPCProceedings,BalancingEconomicsandCompliance forMaintainingProtective Coatings,November1995.

Farschon,C.L.,andKogler,R.A.,"FieldMaintenanceOvercoating SystemsforBridges,"JournalofProtective CoatingsandLinings, January1997.

FHWA,BridgeCoatingsTechnicalNote,"Overcoating(MaintenancePainting),"January1997.FHWA,EnvironmentallyAcceptableMaterialsfo rtheCorrosionProtectionof SteelBridges,FHWA-RD-96-058, January1997.Hare,C.H., "PreventingOvercoatingFailures,"JbumaZof ProtectiveCoatings andLinings,

November1997.Hopwood,T.,Evaluationof KentuckyOvercoatingProjects,"SSPCProceedings,ManagingCosts

andRisksforEffective Protection,November1994.Hopwood,T,"Overcoating on Minimally PreparedBridgeSurfaces," SSPCProceedings,EvaluatingCoatingsfo r EnvironmentalCompliance,June1994.Journal of Protective CoatingsandLinings,ProblemSolving Forum,"WhenAreCoatingsToo Thick

ToRepair," September1997.Kline,E.S.,"Economicsof Overcoating,"SSPC Proceedings,ManagingCostsandRisksforEffective

Protection,November1994.Kline,E.S.,andCorbett,W.D.,"BeneficialProcrastination,"Journalof Protective Coatingsand

Linings,March1992.Kogler,R.A.,Ault,J.P.,andFarschon,C.L.,"Environmentally Acceptable Materialsfo rtheCorrosion ProtectionofSteelBridges,"FederalHighway AdministrationTechnicalReport,

FHWA-RD-06-058,January1997.Lenhart,C.F.,andEl-Naggar,K.S., "Evaluating Lead-BasedPaintfo rOvercoating," Journal of

Protective Coatingsand Linings, July1995.Melewski,P.M.,Kline,E.S.,andMeLampy,M.F.,"ProtectiveCoatingAnalysisandBridge

Maintenance,"SSPC Proceedings,Expanding Coatings KnowledgeWorldwide,November1997.


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O'Toole,D.E., "Overcoating: AnEffectiveandEconomical SolutionforWaterTankExteriors,"SSPCProceedings,BalancingEconomicsandCompliance forMaintainingProtectiveCoatings,November1995.

Race, TimothyD.,DevelopingOvercoating Criteria for the Army,preparedby CorrosionControlConsultantsandLabsfor theUS ArmyConstructionEngineering ResearchLaboratory(CERL),October1998.Race, TimothyD.,Summary Report:Demonstrationof OvercoatingPracticesandMaterialsatFt.Campbell,preparedby CorrosionControlConsultantsandLabsfo rCERL,October2000.Race, TimothyD., SummaryReport:Demonstrationof OvercoatingPracticesandMaterialsatHolstonArmyAmmunitionPlant,prepared by CorrosionControlConsultantsandLabsfo rCERL,October2000.Race, TimothyD.,Guidefo rOvercoatingCivilWorksStructures, preparedby Corrosion Control

ConsultantsandLabsfortheCERL,December2000.Race,TimothyD.,Decision Treefo rLead-BasedPaintHazardControlandAbatementfo rSteel

Structures,preparedby CorrosionControlConsultantsandLabsfo rCERL,April2002.Trimber,K.A.,andNeal,T.W., "NewProcedurefo rFieldClassificationofPaintCondition," SSPC

Proceedings,Improving theFieldReliability of ProtectiveCoatings,November1987.Vincent,L.D.,"MaintenanceAlternativesfo rLeadPaintedBridges,"SSPC Proceedings,Achieving

QualityinCoating Work,November1992.

Voigt,N.R.,"Evaluationof OvercoatOptionsforaBridgeCoatingsProject,"SSPC Proceedings,Expanding Coatings KnowledgeWorldwide,November1997.


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PointsofContactOrganizat ion

ERDC-CERL PO Bo x90 0 5Champaign,IL 61826-9005A F Z B -P W -M-UBIdg.86 8FortCampbell ,K Y 4 2223- 5 1 30AFZB-PW-E-C86 513*S tFortCampbell ,K Y4 2223- 5 1 30A F Z B -P W -M-UBIdg.86 8FortCampbell ,K Y 42223-5130 CorrosionControlConsultants&Labs .

Phone/Fax/emai lTel:217-373-7235 Fax:217-373-7222

Phione:270-798-5082 Fax:270-798-6075

Phone:270-798-9597Fax:270-798-9606

Phone:70-798-7213 Fax:270-798-6075

Phone:630-834-3811 CorrosionControlConsultants&Labs .

Phone:616-940-3112

Rolein ProjectPrincipalInvestigator AssistantInvestigatorContractMonitor

Ft.CampbellP W B C UtilitiesBr.Chief

FortCampbel lT S C A *Man ag e r

FortCampbellPW C

PrincipalContractorPrincipalContractor

* ToxicSubstancesControlAc t


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34 ERDC/CERLTR-03-5

ListofAcronyms APFssignedProtectionFactorASTMmericanSocietyfo r TestingandMaterialsDFTryfilm thicknessD oDepartmentofDefenseEPAnvironmentalProtection AgencyESTCPnvironmentalSecurity TechnologyCertificationProgramFHWAederalHighwayAdministrationHAAPolstonArmyAmmunitionPlantHEPAighEfficiency ParticulateAirLBPead-basedpaintNIOSHationalInstituteforOccupationalSafetyandHealthOSHAccupationalSafetyandHealthAdministrationPAMersonalair monitoringPOLetroleum,oils,andlubricantsPPMartpermillionSSPCheSocietyfo rProtectiveCoatingsTCLPoxicCharacteristicLeachingProcedureW FTetfilm thickness


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ERDC/CERLTR-03-5 5

Appendix: OvercoatSystemMaterialSafetyDataSheets


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36 ERDC/CERLTR-03-5

B ndustr ialand Marine Coa t i ng 5.03 C O R O T H A N E MASTICB65R13PRODUCTNFORMATION R e v i s e d 7 / o 2PROOOCTESCRIPTION REC0IMIEM3E0UsBCOROTHANE1-M A S T I Cs singlecomponent,moisturecuringurethanewithmicaceousro noxide,designedasprimerorintermediatecoatforpreviouslypaintedsteelsur-faces,includingleadovercoating.tis highsolidsan d VO C compliant.Productisdesignedtobotopcoaled.utperformsepoxymasticswhenovercoatingoldred leadcoalingsowtemperatureapplication-downo20Fanbeappliedinhumidiliesupto99%xcellentreooatabilityuperiortoepoxymaslicsforflexibility.corrosion resistance,blisterresistancean d InDadresistance

sauniversalprimerorintermediatecoalforpreviouslypaintedsurfaces,steel,an d weatheredgalvanized steel

orapplicationduringoold,damp,ard/orhighhumidityconditionslimiting theus e ofoonventionalcoatings

PRODUCTHARACTERISTICS PERFORMAIIJCEHARACTERISTICSFinish: MaU eColor: ReddishGrayVolumeSolids: 60 % 2% VO Ccalculated): 93F,PM C C Reducer/CleanUp : Reducori15,R7K1S

SystemTested:unlessolherwiseindicated)Substra te: steelSurfacePreparation: SSPC-SP6Id. [email protected]. Corothane -Mastic30milsdftAbrasionResistance:Method : A S T M D4060 .C S 1 7 wheel,1000cydes.1 kg loadResult: 17mglossAdhesion:Method: A ST M D4541 Result : 1000psiCon-oslonWeatherlng:(ZincPrimer/Mastic/AliphaUc Finish)Method: A S T M D5894.3024hours. 9cydesResult : Ftating10perASTMD714forblister1ngFtating9per A S T M D610 formstingDirectmpactResistance: Method: A S T M D2794Result: 60n,lb sDryHeatResistance:Method: A S T M D248S Result : SOOT Flexibility:Method: ASTM0522.180 bend . 3/8-mandrelResult: PassesMoistureCondensationResistance:Method: A ST M D4S85,lOOT, 00 hoursResult: PassesPencilHardness:Method: A ST M 03363Result: 2B SaltFo gResistance:ZincPrimerMasUc/AliphaticFinish)Method: A S T M B117. 0 00 hoursResult: Rating10 per A ST M D714ftxblisteringRating9per A ST M D610formstingWetHeatResistance: Method: Non-immersionResult: 180"F

Polyurelhane 5.03 2004744 continuedon bade


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ERDC/CERLTR-03-5 37

Industrialand MarineCoatings

5.03COROTHANEMASTIC

B65R13P RODU C TINFORMATION

RECOMHENDHJSYSTEMSsteel:Id.1t. 1t.

CorothaneI-GalvaPacZincPrimer@ 3.0-4.0nilsd ftCorothane I -Mastic @ 2. 5-3. 5milsdf tCorothane I -Aliphatic@ 2.0 -3. 0milsdt tCorothane IHS @ 2. 0 - 3. 0milsd flSteel: 1ct.orothaneI -PrePrlme@ 1.5-2.0 milsdft 1ct.orothane -MIO-Aluminum 2.0 -3. 0milsdft [email protected] ds .CorothaneI -Aliphatic@ 2.0 -3. 0milsdft/dSteel: 1d. CorothaneI-Mastic@ 2. 5 -3. 5milsdf t1-2 d s.Corothane -Aliphatic@ 2.0 - 3.0milsdfl/dPreviouslyPaintedSurfaces:Spotprimebaresteelwith1coatof Corothane -GalvaPacZincPrimerId. [email protected] d. Corothane I -Aliphatic@ 2.0 -3.0 ntilsdft

SURFACEPREPARATI6N

Th esystemslistedaboveare representativeof the produd's us e Othersystemsma y be appropriate

Surfacemustbeclean,dry,and insound condition.Removealloil,dust,grease,dirt, loosemst.and otherforeign materialto ensure adequateadhesion.Referto product ApplicationBulletinfor detailedsurfaceprepa-rationinformation.Minimum recommended surfacepreparation:Iron&Steel:SPC-SP2.SP3 Previously Painted: SSPC-SP2.SP 3

TINTING[J onottint.

APPLICATIONcaDiTioNsTemperature:air and surf ace:material:Relativehumidity:

20Fminimum,100F maximum 45FminimumDo not apply oversurfaceice Can beappliedatrelativehumidi-tiesu p to 99%.Referto produdApplicationBulletinfor detailedapplicationinfomiation.

O RDERINGNFORMWrioN:Packaging:Weight pergallon:

1 and5galloncontainers18.0 0. 2ib

SAFETYPREC AU TIO NS Refer to the MSDSsheetbeforeuse.Published technicaldata and instmctionsaresubjed to changewithout notice.Contadyour Sherwin-Williamsrepresentativefor additionaltechnicaldataand instrudions.


39/51


IndustrialandMarineCoating

5.03A COROTHANEMASTIC

B65R13APPLICATIONBULLETIN Revisod7/02

SURFACEPISPARATIONSurfacemustbe dean.dry.an dinsoundcondit ione mov e alloil.dust.groase.dirt.looserusl.andotherfofeignmater ia lto ensureadequateadhesion.Iron St e e lM in imu msurlace preparat ionisHa nd Tool Clean pe rSSPC-SP 2emove all oil an d grease f romsur facobySolvontClean- in g pe rSSPC-SP1.Fo r bettorpor formanco.us eCommercia l BlastCleaning pe rSSPC-SP6.blastclean all surfaces using a stiarp.angularabrasive fo r opt imum surface profile(2 mils)Pr ime an ybaret ee lwithin8hoursor beforeflashrusling occursPrev iouslyPaintedurfaces If n sound condit ion, deanthe surface o( all foreign matenal .Sniooh,hard ,orglossy coaljngs an d surfaces should be dulledby abradingth esurface.Applyatestarea,albwingpaintto dr y on e week before testing adhesion.Itadhesionispoor,or ifthisprodud attacksthe previous f inish,removal o fthe previ-ou s coatingma y be necessary.Itpaint is peeling or bady weath-ered ,deansurfaceto soundubstratend t reatas n ew surfaceas above .

APPLICATIONC otem oNsTerrperature: ai ran d surface:material:Relativehumidity:

20Fmin imu m.100Fma x imu m 45 Fminimum Do no tapplyoversurfaceic e C an be appl iedatrelativohumidi -liesupto99%.

APPLICAHONQUIPMENTThefoltowingisaguide .Cha nge s in pressuresan d tipsizesm ay be needed tor properspraycharadenst ics.Always purgespray equipment before us e with listed reducer.An y reduction must be compatible with th e exist ing environmenta lan d appli-cation condi t ions.Reducer /Cleanpeducer#15.R?K15Air lesspray P u m p0:1 Pressure800-2000ps iHose/4'IDTip15"-.019-FillerO m e s hRedudKinsne e d e dup to 10 % by volume C o nven t io na lS p rayUnitraooinksGu n 005

FluidNozzle706/65 Ai rrsteezle476P R Atomizatlon Pressure ...60-70ps i0-70ps iFlu idPressure5-20si5-20psiReducttonsne e d e dup to 10 %by volumeBrushB m s haturalBrisUe Redudionsne e d e dup to10 %by vo\umaRol le rCover8" naturalor synthetic withphenol iccore Reductionsne e d e dup to10%by volumeIfspedf icapplicationquipment islistedabove ,equiva lente qu ipme ntm ay be substituted.

Polyurethane 5.03A 2004744A cont inued on back


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ERDC/CERLTR-03-5 39

Industrialand MarineCoatings

5.03A COROTHANEMASTIC

B65R13APPLICATIONBULLETIN

APPLICATIONP ROCED URES Surfacepreparationmust eoorrpletedas indicated.Stirpaintthoroughlypriortous ewithapoweragtator.ilterslowlythnDugha55 meshscreen.Applypaintattherecommendedfilmthicknessan d spreadingrateas indicatedbelow:RecommendedSpreadingRatepercoat:Wetmils:.0-55Drymils:.5-3.5Coverage:75 -3 85 sq ft/galapproximate.DryingSchedule@ 5.0 milswet@ 50 %RH ;55T @77F @100FTotouch: 40 minutes 30 minutes 15 minutesToreooatminimum: 7 hours 4 hours 4hoursmaximum: 60 d a y s 60 days 60 daysTohandle: 2 4 hours 18 hours 5hoursTo cure: 7 days 3 days 3 daysDryingtimeistemperature,humidily.andfilmthicknessdependent.

ApplicatHDhofcoatingabovemaximumor belowminimumreo-ommendedspreadingratemayadverselyaffectcoatingper-formance.

CLEANPNST FI ICT IONS Cleanspillsan dspattersmmediatelywithReducer#15.R7K15.CleantoolsimmediatelyafterusewithReducer#15.R7K15.Foltawmanufacturer safetyrecommendationswhenus inganysolvent.

PERFORMANCE; TIPSstripecoatall crevices,welds,an dsharpanglestopreventeariyfailure in theseareas.Whenusingsprayapplication,usea50 %overtapwitheach passofthegu n toavoid holidays,bare areas, an d pinholes.If necessary,crosssprayat aright angleSpreadingratesare calculatedonvolumesolidsan d donotincludean applicationloss factordue tosurface profile,rough-ness orporosityofth esurface,skillan d techniqueof theap-plicator,methodofappllcatton.varbussurfaceirregularities,material lostduring mixing .spillage,overthi nning.climaticcon-ditions . andexcessivefilmbuikJ .Excessivereductionof materialca naffectfilmbuild,appear-ance,an d adhesion.Inordertoavoidblockageofsprayequipment,cleanequip-mentbefore useorbeforeperiodsofextended downtimewithReducer#15,R7K15.PourasmallamountofReducer#15.R7K15overthetopof thepaintinth ecantopreventsl^inning orgelling.Placea temporarycoverover th e pailtokeepexcessivemois-ture,condensation,fog.orrainfromcontaminatingth ecoat-ing.CorothaneKAAcceleratorisacceptableforuse.eedatapage 5.98fordetails.It is recommendedthatpartiallyused cansno t be sealed/dosedforus eatalaterdate.Productis designedtobe topcoated.RefertoProductInformation sheetforadditionalperformancecharacteristics an d properties.

SAFETYP R E C M J T I O N SRefertotheM S D S sheetbeforeuse.Publishedtechnicaldata an d instmctionsare subject tochangewithoutnotice.ContactyourShenwin-Williams representativeforadditbnaltechnicaldataan d instructions.


41/51


Industrialand MarineCoalings

5.08COROTHANEIRONOXA

GFMY B65A10PRODUCTINFORMATION RavisGd 1/2002

PROD UC TEScRiprroN COROTHANE IRONOXAisas inglec ompone nt .VOCc x D m -pBanl.moisturecuring ure lhanefinishcoalwithnnicaceous iran oxide ,designed for lo w temperatureor highhumidity ap -plications, providingUV resistancean d chemicalresistance equivalent totwoparture lhane coat ings.ow temperatureappl icat ion-down to 2DFrovidesresistance to yollowtng,chalking ,or degradat ionbysunl ightxcellent adhesionto mostsurfaces uperiorabrasion res is tance Outstandingchemicalresistance uitabletor us e in US D A inspectedfacilit ies

PROD UC THARACTERISTICS Finish:Color:Vo lum eSol ids:Weightol ids:VO Ccalculated) :

LowGloss Gray55%12%747%2%93F.P M CC Reducer#15.R7K15

RECOMMEM)EDse solortopcoatfor previousiy paintedsurlacos wheremaxi-m um colorretention an dchemicalresistance are required hemicalres is tantooat ingformetal feedsurfaces, oontain-m e n lponds,an d tanltsuperiorcoverage on edges an d bridging over hairtine cradts du e to nnicaceous iron oxide e c omme nd e d topcoatfor leadovercoatsystem

PERFORMANCECHARACTERISTICSSystem Tested:unless olherwseindcaled) SubslraleSteelSufacePrepaaljon:SPC-SP51 cl CorotianeI GalvaPao ZincPrimer @ 30 milsdft 1cl CorotianeI-Mastic25-3 5milsdd lot. CorotianeI-IronOxA @ 30 milsdfl AbrasionReslstance:Metiod /\STMD


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ERDC/CERLTR-03-5 41

Industrialand MarineCoatings GtKf

5.08 COROTHANEIRONOXAB65A10

PRODUCTINFORMATIONR E C 0 M M E N D H 3S Y S T E M S

Steel: 1 t. Corothane -GalvaPacZincPrimer@ 3.0-4.0milsdft1- 2cts.orothane -IronOx A@ 2. 5 -3. 5milsdfl/ctSteel:1 t. Corothane -GalvaPacZincPrimer@ 3.0-4.0milsdft1 t. Corothane -Mastic@ 2.5-3.5milsdft1ct Corothane -IronOx A@ 2. 5-3 .5 milsdftSteel:1 t.orothane -PrePrime@ 15-2. 0milsdft1 t.orothane -MIO-Aluminum@ 2.0-3.0mils dft1 t.orothane -Mastic@ 2.5-3.5milsdft1 t.orothaneI -IronOx A@ 2. 5-3 .5 milsdftConcrete,smootli:1 t. Corothane -PrePrime@ 1.5 -2. 0 milsdft1 t. Corothane -IronOx A@ 2. 5-3. 5milsdftPreviouslyPaintedSurfaces:Spotprinnebaresteelwith coatofCorothane -GalvaPacZincPrimer2cts.orothane -IronOx A@ 2. 5-3. 5milsdftor1 t.orothane -Mastic@ 2. 5 -3. 5mils dft/d1 t.orothane -IronOx A@ 2. 5-3. 5mils dft(Check compatibility)Thesystemsl istedabovear erepresentativeoftheproduct'suse.Othersystemsmayb eappropriate.

?SURFACEPREPARATfON Surfacemustbe clean, dry ,an d In sound condition.Remove alloil,dust,grease.dirt, loosemst,an d otherforeignmaterialtoensureadequateadhesion.RefertoproductAppllcationBulletinfordetailed surfaceprepa-rationinformation.Minimumrecommendedsurfacepreparation:*ronsSteel:SP C - SP 6Concrete&Masonry SSPC-SP13/NACE 6Previously Painted Clean, dry,sound *rimerrequired

COLCRAvAiLABlLlty/TlNTINGColor: GrayDo no ttint.

APPLICATIONCdnoT i oNsTenperature:airan d surface:material:

Relativehumidily:

20Fminimum.100Fmaximum45F minimumDo not apply oversurfaceice Canbe appliedat relativehumidi-tiesupto99%.

RefertoproductApplicationBulletinfordetailedapplicationinformation.

ORDEFUNGNFO RMATIO N Packagng:Weightpergallon:

1 and5galloncontainers13.40.2lbdependingon color

SAFETYPREC AU TIO NSRefertotheM S D S sheetbeforeuse.Publ ished technicaldata and instructionsare subjec t tochange withoutnotice.ContactyourSherwin-Williamsrepresentativeforaddittonaltechnicaldataan d instructions.


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42 ERDC/CERLTR-03-5

Industrialand MarineCoating

5.08ACOROTHANEIRONOXA

GnuY B65A10APPLICATIONBULLETIN R9vised 1/2002

SURFACEPISIARATION Surfacemustbe dean.dry.an dinsound condit ione mov eaiioil.dusl.groase.dirt.loosenjst.an d oUier tore ignmaterial to ensure adequateadhesion.Iran St e e lR e mov e all oi lan d gr e a sefrom surface by SolventCleaning pe r SSPC-SP1.Minimum surfacepreparaUon is Comme r c ia lBlastCleaningpe rSSPC-SP6.Fo rbetterper formance ,us e NearWhite Meta lBlastCleaning perSSPC-SPIOlastdeanall surfaces us ingasharp,angularabrasive for opt imum sur-face profile(2 mils) r ime an y bare steel the sa me da y as t is deaned PouredConcrete Ne w Fo rsurfacereparation,referto SSPC-SP13/NACE .ur -face mustbeean.dry.sound,an doffersutf identprofi leto achieve adequateadhesion.i n imu m substratecure s 28 daysat75F.t omov eall form re leaseagents,curing com-pounds,salts.efflorescence, laitance.an d otherforeign mat-lerbysandblast ing. shotblasting.mechanica lscarification.or suitable chemical me a nseferto ASTMD4260.Rinsethor- oughlyto achieveafinalpH between 60an d10.0.llowlo dry thonx ighlypriorlo coating.O ld Surface preparation is donoin muchthe sa me ma nne r as ne wconcrete:hcwever . fthe concrete s oontaminaledwithoils,gr e a se ,chemicals,etc..they mustboemo vedbyd e a n ing witha strong detergenteferto ASTMD4258.Formrelease agents ,hardeners ,et cmustbe removed by sandblasting, shot-blasting,mechanical scarification.or suitable chemicalmean sIf surface deteriorationpresentsan unacceptably roughsur-face.Ke m Cal i -CoatHSEpox yFil ler/Sealerisr e c omme nd e d to patch an dresurface dam agedconcreteFill all aacks.voids andbugholeswithArmorSealCrackFil ler .Alwaysfollow th eAS T Mmett iodsl istedbelow:AS T MD4258 Standard Pradice for CleaningConcrete.ASTM D4259Standard Pradice for Abrading Concrete ASTM 04260Standard PracUce for Etching Concrete. AS T MD4263PlasUcShe e tMethodfor Checking fitoislure inConcxele .S S PC -S P 13/Nace 6SurfacePreparation of Concrete Prev iouslyPaintedurfaces Ifinsound condit ion,deantliesurface of all fore ignmaterial SmocU).hard or glossy coatings an dsurfaces shouldbe dulledby abrading the surface.Applyatestarea ,altowingpaintto dry on e we e kbefore tesUngadhesionfadhesionispoor,or if thisprodud attacksthe previous finish,removal of the previ-ou scoatingma ybe necessaryf paint is peeling or baclyweath-ered ,cleansurfacelo soundubstratean dt reats ew surface as aboveAPPLICATIONONDITIONS Temperature:ai r an dsurface:material:RelativehumWity: 20Fminimum.100F ma x imu m45Fmin imumDo no tapply oversurfaceice Ca n be appl iedatrelativehumidi -liesupto99%.APPLICATIONQUIPMENT Th e folfciwing isaguide .Cha nge sinpressuresan dlip si?esm ay be needed fo r properspray diarader isUcs. Always purgespray equipment before us e with listed reducer.An yreductionmustbe compatible withth e exist ing environmenta lan d appii-calion condi t ions.Reducer /Cleanpeduc8r#15.R7K15Air lesspray Pum p0:1 Pressure800-2000ps iHose/4 "ID Tip1 r-.015-FilteromeshRedudionsne e d e dup to 10% by volumeC o nven t io na lS p rayUnitraooinks Gu n005FluidNozzle706/65Ai rNcezle476P R AtontzationPressure...60-70 ps i0-70ps iFlukJPressure5-20si5-20ps iRedudfcmsne e d e dup to10 %by volumeBrush B m s haturalBristle Redudfonsne e d e dup to 10 %by volume Rol le rCo ve r/4"natural or synthetic vnlliphenol iccore Redudfonsne e d e dup lo10% by volumeIf spedf icapplicationquipmentislistedabove,equivalent e qu ipme ntm ay be substituted

Polyurolt iane S.08A 2004751A continued on back


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ERDC/CERLTR-03-5 43

Industrialand MarineCoating

5.08A COROTHANEIRONOXAGm v B65A10

APPLICATIONBULLETINAPPLICATIONPraacHJURts

Surfacepreparationmust ecorrpletedas indicated.StirpaintIhorouglilypriortou se withapoweragtator.ilterslowlythrougha 55 meshscreen.Applypalntattherecommendedfilmthicloiessan dspreadingrate asindicatedbelow:RecommendedSpreadingRatepercoat:Wetmils:.0-7.0Drymils:.5-3.5Coverage:20 -29 0 sqft/galapproximateDryingSchedule(g5.0 milswet@ 50 %RH :@55F77 F100FTotouch: 1-1/2hours 1hour0minutesTorecoat: 24 hours 4hourshourTo cure:daysd a y sd a y sDryinglime is temperature, humidiiy, and f i lm thicknessdependentApplica tion ofcoating abovemaximumorbelowminimumrec-ommendedspreadingratemayadverselyaffectcoatingper-

formance.

PERFORMANCETipsstripecoatallcrevices,welds,andsharpanglestopreventearlyfailure intheseareas.Whenusingsprayapplication,us ea50 % overlapwitheachpass of thegu n to avoidholidays.bareareas, an d pinholes.If necessary,crosssprayat arightangleSpreadingratesare calculated onvolumesolidsan d donotincludean applicationlossfaotorduetosurfaceprofile,rough-ness orporosityofthe surface,sidllan d techniqueof theap -plicator,methodofapplication,varioussurfaceirregularities,materialtost during mixing, spillage,overthinning.climatic con-ditions, an d excessivefilmbuild.Excessivereductionof materialcan affectfilmbuild,appear-ance, an d adhesion.Inordertoavoidblockageof sprayequipment,cleanequip-mentbeforeus e orbeforeperiodsofextendeddowntimewithReducer#16.R7K15.PourasmallamountofReducer#15.R 7 K 1 5 overthetopofthepaint inth ecan topreventskinning orgelling.Place a temporarycoveroverth e pailtokeepexcessive mois-ture,condensation,fog.or rain fromcontaminatingth ecoat-ing.CorothaneKAAcceleratorisacceptableforuse.ee data pag65.98fordetails. WhenapplyingWhiteorlightcolors ofCorothane 1 -Aliphaticoverdarkcolorsorporoussurfaces.aminimumof2 coatsisrequired for ad equatehide.It is recommendthatpartiallyused cans notbe sealed/dosedforus eatalaterdate.RefertoProductInformattonsheet foradditionalperformancecharacteristics an d properties.

CLEANPNSTRUCTIONS SAFETYRECAiJTioNS Cleanspillsan dspattersmmediatelywithReducer#15.R7K15.Clean toolsimmediatelyafterusewithReducer#15.R7K15.Foltow manufacturer'ssafetyrecommendationswhenus ingan y solvent

RefertotheM S D S sheetbeforeuse.Publishedtechnicaldata an d instructkxtsare subject tochangewithoutnotice.ContactyourSherwin-Williamsrepresentativeforaddittonaltechnicaldata an d instrudtons.


45/51


D A TEOFPREPARATION: DATEOFLASTREVISION:MANUFACTURER'S CODE:SECTIONI:GENERALMATER IAL SAFETY DATA SHEET09/27/97 09/17/01MC -ALUM INUM 2. 8

MANUFACTURER'SN/iiMEAN D ADDRESS:INFORMATIONPHONEN UM B ER :EMERGENCY PHONE NUMBER:CHEMICALFAMILY:TR A D ENAME:HMISRATINGS:aESTTOfy ;HAMM"?PSmCTmimTS

WASSERmOH-TECHCOATTNGS,INC.1004WESTJAMESSTREET,SUITE100,KENT,WA 8032233-850-2967CHEMTREC 800-424-9300 MOISTURE-CURE,PO L YURETHANE PAINTWASSERMC-ALUMDTOMH-2,F-3,R-1PO L YURETHANE PREPOLYMER535HIGHFLASHNAPTHA5-15XYLENE5-15MaAS^rUBFPPropneUry64742-95-6 1330-20-7ETHYLBENZENEALUMINUMPOWDER 01-03 100-41-4 15-25 7429-90-5 0.02ppm ocihogOSHA PEL50ppm-MaDufachirer100ppm-TW8,OSHAISOppmOSHASTEL 100ppm-TW8,ACGIHISOppmACGIHSTEL100ppm-TW8,OSHA125ppmOSHASTEL100ppm-TW8,ACaiH125ppmACGIHSTEL5mg/m'-TWA,RespinblcSH A15mg/m-DustOSHA

1 Omg/m'-TWADualACGIH260F;127''C 9.5LBS,.lg/cm'SLOWERTHAN ETHERPEAVIERTHAN AIR 38(APPRX)LESSTHAN 2,8 LBS/GAL;340g/LSILVERCOLORED LIQUID WITH/SOMATICSOLVENT ODORNONE

SECTIONm;HYSICALDATABOILINGPOINT APPROX,WEIGHTPE RGALLON EVAPORATIONRATE.VAPORDENSITY v.VOLATILE(VOLUME)V OC APPEARANCEAN D ODORSOLUBILITYIN WATERFLASHPOINT:3%;28C,CLOSED CU P SSJ^f 'SJSS *S2I*'^ C H E M I C A L ,F O A M , C A R B O N D I O X I D E , W A T E R S P R A Y SPECIALIREFIGHTINGPROCEDURES:W=ardf-corUinrireakingpparahi,SCBA),ith ull-facei=ctoperatedinthe positive-pressuremode.Fullprotectiveclothingsuchasrubbergloves,boots,etc.shouldbewmbyfirefirfiters'NoStanshouldbeexposed.learfireareaofunprotectedpersonnel.aterfixjmfognozzlesmaybe scfiiloool losedcontainerstopreventpressurebuild-up. prosUALIITREANDEXPLOSldNHAZARDS:Vaporisheavierthanir.nderconditionsofstagnant ir,vaporscan buildpandtravelaconsiderabledistancealongthegroundtoanignitionource,vAichmay resultinaflashbacktothesourceotthe vaporsranexplosion.Dono tuse or storenearopen flame,heat,sparks,electricalequipmentor ho tsurfacesseonlyJJ.,;^""^""';?''"losedontainersmay explodewhenexposedoextrem:heator burstvtencontaminatedwithMter(C02volved).uring ire,socyanateaporsndthernritaHng,ighlyoxicaaes aybeeneratedyherrraldec omposihonor combustion. INGESTION: Gastro-intestinalistress. Inheunlikelyeventofingestion,all hysicianmmediatelywith listofthe ingredients.JN:emoveheavilycontaninaledclothing.Washaffectedskinthoroughlywithsoapandvmler.ETC:Flushwithwaterfor atleast15minutesan dconsult aphysician.firritationcontinues,consultaphysicianINHALATION: Thissnndustrial aint. Th eprimaryhazaris rganicolvent. InhalationofreacHvepolyurethancsunlikelyunlessspraying,henhehazardspraydust. AnnhalationboveTL Vcan ccurwhenprayingorpaintinginconfinedspacewithoutrespiratory protection.Removeexposedpersontofreshair.reatforexposuretoorganicsolvent Givemouttiomouththenoxwenfbreathing has slopped.ontactaphysician. AslhmaHctypesymptomsmaydevelopandpenistlSi-1,iil'?,"fl'.Si"tcMsiyespray dustorfumeswithoutrespiratoryprotection.reatmentissymptomatic. HEALTHHAZARDINFORMATION:SYMPTOMSOFOVEREXPOSURE:INHALED;asalandrespiratorytractirritation.reathingsolventvaporsatconcentrationsinair thatexceedSOppm cancausenarcosis and centralnervoussj^temeffectsincludingdizziness,lossofcoordination, rowsiness, eadaches,onfusion,aHgue,ausea,ossfappetiteand/orossfconsciousness. Sensitimd individuals ma y expenencechesttightness,wheezing, coughingand/orshortnessofbreath.hese symptomsimvnot aooearfor hoursandmay peraislfor4-24hours. ffCONTACTWTTHSKIN:Dyereiposure maycausesevererritation. Skinrritationoisocyanatesandorganicsolventsmay ^ dermatitismindividualswithpnorsensitiation.Exposuretodriedpaintor dustisno thazardousCONTACTWITHEYES:M ay causesevereirritation.SWALLOWED:Anyingestionisharmfulresultinginburning sensationnthemouthandstomachaccompanied byabdominalHEALTHEFFECTSORRISKSFROMUNPROTECTEDEXPOSURE:ACUTE;rolongedunprotectedbreathingofsolventvaporor spraymaycauseeye,nose,respiratory tractand/or skinirritation Allergickin respiiatotyeactionma y ccurnom endividuals. Nareoticnigh oncentrations. Headache nausea con^sion,reversibleeyedamag:,abdominalpain,fatigueandloss ofconsciousness ma y occur.CHRONIC:onglerrnunprotectedexposurema yleadtomuscularweakness,confusion,mpairedoordinationiverdamagekidney damage,demialitis,mucousirembranedamage,pulmonaryedema,anorexiaand/or blooddisoHers Largedecreasesinlungfunctionmay occurwithchronicovercxposuretoisocyanates.Reportshaveassociatedrepeatedandprolongedoccupationalovercxposure tosolventswithpermanentbrainandnervoussystem Ol-MC-AIuminum2.8 2001-09-17 Page of 2


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ERDC/CERLTR-03-5

SECTIONV,conl.As esultofpreviousunprotected vcrexposure,certainndividualsmaydevelopisocyanateensitizationchemicalsthma)whichw i l lausehem toeacto aterxposureosocyanateswellbelowheTLV. Sensitizedndividualsmayshowsymptomssimilartoindividualswho showsensitizationtospecificdusts,animal furs,and otherirritants ifre-exposedtothisproduct. Thisungsensitivitycaneappearin ensitizedndividualfre-exposed. Skinensitizationanlsoesultfromovercxposure.Laboratorystudieswithatshavehownhatpetroleum distillatesausekidneydamageand bdneyorlivertumors, Severalstudiesevaluating petroleumworkershavenotshownsignificant increases ofkidneydamagenor kidneyor livertumors.Prolongedand repeatedunprotected breathingofspray mistsand/ordustsover aperiodofyearsmay causelungdisease.Thiflproduct containano cancer agentfoundonan y listSECT ION VI ;REACnVITYDATACOND IT IONS TO AVOID :Avoidheat,sparks,open flamesand othersourcesofignition.INCOMPATrBILlTY(MATER I A L S TO AVOID ) :Mixingwithwater, lcohol,mines,trongacidsndbases, xidizing agentsand surfaceactivemateriaisma y causereactionor gelling.HAZA R DOU S DECOMPOSITIONPRODUCTS :Toxicgasesand vaporsincluding carbonmonoxide,carbondioxide,oxidesofnitrogen,tracesofHCN,isocyanatesand otherunidentifi(5organiccompounds.COND IT IONS TO AVOID :Combiningor mixing withwater or othermaterialsthatreachwithisocyanatesma y causegellationorprematurereactioninthe container.SECTIONVU; S P I L L . LEAK.ANDDISPOSALI NFORMAT ION ; STEP S TOBETAKENIN C A S E MATE 3 i I A LIS R E L E A S E D O R S P I L LED :Thismaterialispaint.Minorspillsor leaksinwell-ventilatedareacauseno hazard.Majorspillsinconfinedareasshouldbetreatedwithcare.voidall sourcesofignitionifolventvapors rcxcessive rhepillsonfinedo losedvanronfinedpace. Persons otwearingprotectiveequipmentshouldvoidheareauntilolventvaporshavesubsided. Avoid llowingspilledmaterialoleakintony flowing watersource. Materialspilledonhegroundcanbeontainedndcollectedwithbsorbent, Theres odangerofmaterialpenetratingnto roundwaterifitiscontained. Solventvaporationwilloccurinpilledmaterial^ifleftin pen ventilation leavingasolidtable on-hazardousesidue. Driedmaterialanbe isposedofinandfill. Semi-dryandiquidhouldbe collectedand placedinsealedsalvagecontainers or allowedtodrybyevaporationinawell-ventilatedarea.WASTEDISPOSALP R OC E D U R E S ;pilledproductthatis otathinfilmdriedpaintmustbedisposedofasahazardoussolidwasteaccording to ResourceConservation and RecoveryActregulations.referredmethod ofdisposalisincineration.SECT ION Vm;EMPLOYEEPROTECTIONI NFORMAT ION : Precautionsmustbetakensothosepersons handlingthismaterialdo no tbreathethe vaporsabovetheTLV,or haveitcontacttiieskinor eyes.nspray operations,protectionmustbeaffordedagainsterqjosuretobothvaporand spray mist,EYEPROTECT ION :LiquidhemicaJgoggles.aporresistantgoggleshouldbewornwhencontactlensesarc inuse.nasplashhazard environment:gobiesor afullface-shieldshouldbeused.SKINPROTECT ION :eniKationesistantglovesbutylubber,itrilcubber, olyvinyl lcohol).oversmuchofthe exposedkin reas ossiblewithppropriate lothing. Ifskinreams reused,keephe reaoveredbyhecreamtominimum.R E S P I R A TOR : Thisproductcontainspolymericreactivepolyurethane prepolymers. D uetothe highmolecularweightand lowvaporpressureitisextremelyunlikely thatmeasurablereactivepolymercanget intothe vaporphaseduringnormalmixing,stirring,brushing, rollingapplications;however,duringprayingnonfinedpaceshepraymistparticlesmayeachhazardouslevel,venfthevaporphasedoes ot containhazardouslevels.SincehisroductcontainsorganicolvcnttisrequiredtowearanorganicvaporcartridgeAlterduring stirring,brushing,rolling or inspectionofdrying paint .uringsprayingorapplication inonfinedpacestisequiredtowearaullreshairuppliedespirator. Thisroductwillgenerallyotho weactivesocyanatetevelsboveheTLVnheaporhase,venuringprayperations;however, duringsprayoperationssprayparticleswillcontaineactiveprepolymerataazardouslevel. Thesearticles ma ypenetrate canisterrespiratorifImproper iyfit or if not equippedwithaHEPA prefll ter.hereforealwayswearafull freshairsuppliedrespiratorduring spray operationswhenairbornespraydust ispresent inhazardouslevels.GLOVE S :kin contactshouldbeminimizedbywearingsolventimpermeableglovesmadeofneoprene or nitrilerubber,OTHE R PROTECTIVECLOTH INGANDEQUIPMEINT:ppropriate protectiveclothingnecessary topreventrepeatedor prolongedkinontactshouldbeworn. Solventresistantbootsshouldbewornwherespill rsplashingcan ccur. Ifbamercreamsare used,keepthearea,vAichisprotectedonlyby the cream,toaminimum,HYGIENIC WORKP R A C T I C E S ;Washhandsthoroughlywithoap and waterafterhandlingthisproduct,and beforeeatingormoking. Washontaminatedclothingthoroughlybeforeeuse. Safetyshowersndyetationshould evailableoemployees,OTHE RTOR AGE ND HANDLING EQU IR EMENTS :bserveabel recautions. Storen ool,well-ventilatcdliquidstoragearea,eep away frommoisture, heat,sparks,and openflames.Usenon-sparking tools.seonlywithadequate ventilation.voidcontactwithyes,kin and clothes. Avoidbreathingvapor. Atstoragetemperaturesbove00degreesF, thisproductmay slowlypolymerize,PROTECTIVEM E A S U R E S UR INGMAINTENANCE F ONTAM INATEDQU I PMENT :Do otweld,heat rdrill nornearcontainers. Wearappropriatepersonalprotectiveequipmentwhenworkingonontaminated equipmentif the ingredients exceed the TLV,Dono tsand,flamecut,brazeor welddry coatingwithoutaNIOSH/MSHSapprovedrespirator,asweldingfumesmaybeharmful.Th einformationcontainedhereinIs believedto beaccurateandrepresentshebestinfonnationcurrentlyavailableto us. However, emakeoarrantyfmerchantabilityrnytherwarranty,xpressrmplied, ithespectouc h information,and we assumenoiabilityresultingrom it suse.sershouldmaketheirownnvestigationstodetermineth esuitability ofth einformationfortheir particular purposes.

01-MC-Aluminum 2.8 2001-09-17 age 2of2


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DATEOFPREPARATION: DATEOFLAST REVISION: MANUFACTURER'SCODE:SECTIONl!EN E R A L MAmgAC T U R B k '5 H A M E A to A D D R E S S :

MATER IAL SAFETYDATA SHEET09/27/97 09/17/01MC - FERROMAST IC2. 8INFORMATIONPHONENUMBER: EMERGENCY PHONE N UM B ER :CHEMICALFAMILY:TRADE NAME:HMISRATINGS: SECT ION II: HAZA R DOU SI NGRED I ENTS

WASSER HIGH-TECHCOATINGS,INC.1004W.JAMESSTREET,SUITE 00, K EN T,W A 8032253-850-2967CHEMTREC 800-424-9300 MOISTURE-CURE,POLYURETHANEPAINTWASSERMC-FERROMASTICH-2,F-3J*-1

HIGHFLASHNAPTHA5-15 M ETH Y Ln-AMYLK ETO N E-10 METHYLISOBUTYLKETONE-10 CASNTJMBEP. EypOSUBFT.nfJffTiy' Propnelary.02ppmcsihngOSHAPELpnctary.02ppmceilingC 64742-95-6Oppm-Manufichirer110-43-00ppm-TW8ACGIHlOOppm-TWSOSHA 108-10-10ppm TW AOSHA75ppmOSHASTEL 50ppm-TWAACGIHr 5ppm ACGIH STEL '"^ENE-10 1330-20-7OOppm-TWAOSHAtSOppmOSHA STELlOOppm-TWAACGIHSECnONIH:HYS I CAL DATA SOppm ACGIH STEL BOILINGPOINT60''F- 27CAPPROX.WHGHTPE RGALLON: 12LBS.; .4 g/cm'EVAPORATIONRATE.LOWERTHANETHERV A P O RDENSITYEAVIERTHAN AIR % VOLATE-E(VOLUME)8(APPRX)V OCESSTHAN 2.8 LBS/GAL;340g/LAPPEARANCEAN D O D O RROWNCOLORED LIQUID -MTHAROMATICSOLVENT ODORSOLUBILITY INWATERON E F L A SH POINT:5*F;29'C,CLOSED CU PEXTINGUISHING MEDl^:RY CHEMICAL,FOAM,CARBON DIOXIDE,WATERSPRAY S P EC I A LIREFIGHTINGROCEDURES:W c rdf-conlainaircatWngppirahisSCBA),ith ull-faceieceoperatedinticpositive-prcMuremode.Fullprotectiveclothingmetasnilbergloves,boots,etc.stiouiabeucrabyfirefigbten'Nokinshouldbeexposed.learfireareaofunprotectedpersonnel.aterfromfognozzlesnay be sefiilooo l losedcontainerstopre ventpressurebuild-up.proSUALFIREAND EXPLOSIONHAZA R D S :Vaporisheavierthan ir.ndercondition,of stagnantair,vaporscan build pand travelaconsiderabledistancealongthegroundtoanignitionource,v*ichmay resultinaflashback tothe source ofthe vaporsranexplosion.Dono tuse or slot^nearopenflame,heat,sparks,electricalequipmentor hoi surfaces.se only|5,,!S""^?''j!'"'"'"' Closedonlaineramay explode\Aenexposedoextrem:heator burstwhencontaminatedwithWer (C02volved).uring ire,socyanateaporsndtherrritating,ighlyoxicases aybeeneratedvhermaldecompositionor corribustion. .onSSJcr !j?. "^"^"^ H A Z A R D I N F O R M A T I O N :

INGESnON: Gastro-intcjtinalistress. Inheunlifalyeventofingestion,all hysicianmmediatelywith istofthe ingredients.SKIN :emoveheavilyconUminatedclothing.Washaffectedskinthoroughlywithsoapand valer.ETC :Flushwithwaterforat least15minutesandconsultaphysician.firritation continues, consultaphysicianI NHALAT ION : Thissnndustrialpaint. Th eprimaryhazards rganicolvent. Inhalationofreactivepolyurethanesunlikely nlessspraying,henhehazardspraydust. AnnhalationboveTL Vcanoccurwhenprayingorpaintingnconfinedspacewithoutrespiratory protection.Removeexposedpersontofreshair.reatforexposuretoorganicsol-wnt Give5"",?1rao""','"':"O'tyvenfbreathing hasstopped.ontactaphysician. Asthmatictypesymptomsnuydevelopandpersist""_'""'if exposedtoexcessivespraydustor fumeswithoutrespiratoryprotection.reatmentissymptomatic HEALTHHAZARDI NFORMAT ION :SYMPTOMSO F OV ER EXPOSURE ; I NHALED :asaland respiratory tractirritation.reathingsolventvaporsat concentrationsinairthatexceed80ppmcancausenarcosis and centralnervoussystem effectsincludingdizziness,lossofcoorfinatjon, rowsiness,eadaches,onfusion,atigue,ausea,ossfappetiteand/orossfconsciousness Sensitiadindividualsmay expenencechesttightness,wheezing, coughingand/orshortness ofbreath.hesesymptomsimyno tappearforhouuandmaypersistfor4-24hours. rrCONTACTWIIHSKIN :Overexpojuremay causesevererritation. Skinrritationoisocyanatesand rganicsolventsmay causeallergicdermatitisinindividuals withpnorsensitimtion.Exposuretodriedpaintordustisno thazardousCONTACTWITH EYES:Maycausesevereirritation.SWA L LOWED :nyingestionisharmfulresultinginburningsensationnthemouthand stomachaccompanied byabdominal HE A L TH EFFECTSORR I SKS F R OM UNPROTECTEDEXPOSURE:ACUTE :rolongedunprotectedbreathing ofsolvent vaporor spraymay causeeye,nose,respiratorytractand/orskinirritationAllergickin respiratoryeaction ay ccurnom endividuals. Narcoticnhighoncentrations. Headache auseacontusion,reversibleeyedamage,abdominal pain,fatigueandoss ofconsciousness may occur.CHRON I C :ongterm unprotectedexposuremay leadtomuscular weakness,confusion,nyairedoordinationiverdamagekidniydamage,dermatitis,mucousmembrane amage,pulmonaiyedema,anorexiaand/orblooddisorders Largedecreasesinlungfunctionrrayoccurwithchronicoverexposuretoisocyanatcs.Reportshaveassociatedrepeatedandprolongedoccupational overexposure tosolventswithpermanentbrainandnervous system 01 -Feiromastic2.82001-09-17 Page of2


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ERDC/CERL TR-03-5 7

SECTIONV.cont.Asaresultofpreviousunprotected vcrexposure,certainndividualsmaydevelopisocyanatcensitizationchemicalsthma)

whichillausehe mtoeacto ater.exposureosocyaJiatcswellbelowheTLV. Sensitizedndividualsma yhowsyirrotomssimilartoindividualswho showsensitizationtospecificdusts,animalfurs,andother irritantsifre-ejcposed tothisproduct, Thisungsensitivitycaneappearin ensitizedndividualfre-cxposed. Skinensitizationanlsoesultfromovcrexposure, iLabora,torystudieswithatshavehownhatpetroleumdistillatesausebdncydamagean dbdneyorlivertumors, Severalstudiesevaluating petroleumworkershavenotshownsignificantincreasesofkidney^ damageno rkidneyor livertumors.Prolongedand repeatedunprotected breathingofspray mistsand/ordustsover aperiodofyearsmay causelungdisease.Thiaproductcontainsno canceragent fonndonanylist.SECTIONV l!REACnVrTY DATACONDTTIONSTOAVOID:Avoidheat,sparks,open flamesandothersourcesofignition.INCOMPATIBILITY(MATERIALSTOAVOID)!Mixingwithwater, lcohol,mines,trongacidsndbases, xidizing agentsan dsurfaceactivematerialsma y causereactionor gelling.HAZARDOUSDECOMPOSITIONPRODUCTS IToxicgasesand vaporsincluding carbon monoxide,carbon dioxide, oxidesofnitrogen,traces ofHCN,isocyanatesandotherunidentifiedorganiccompounds.CONDITIONSTOAVOID:Combiningor mixingwithwateror othermaterialsthatnsachwithisocyanates ma y causegellationorpremature reactioninthe container.SECTIONVn:SPILL.LEAK.AN D DISPOSALINFORMATION;STEPSTOBETAKENINCASEMATERL4LIS RELEASEDORSPILLED:Thisrnatenal ispaint.Minorspillsor leaksinvll-ventilatedareascauseno hazard.Majorspillsinconfinedareasshould betreatedwithcare.voidallsourcesofignitionifolventvapors rexcessive rhepillsonfinedo losedvan ronfinedpace. Persons otwearingprotectiveequipmentshouldvoidhe reauntilsolventvaporshavesubsided. Avoid llowingspilledmaterialoeak intony flowing watersource. Materialspilled nhegroundanbeontainedndollectedwithbsorbent. Theresodangerofrmtcrialpenetratingntogroundwaterifitisontained, Solventevaporationwilloccurinpilledmaterialfleftin penventilationleavingasolidtable on-hazardousesidue. Driedmaterialan e isposedofinandfill. Semi-dryandiquidhouldbecollectedand placed insealedsalvagecontainersorallowedtodry by evaporationinawell-ventilalcdarea.WA5TEDISPOSALPROCEDURES;Spilledproductthatis ot athinfilmdriedpaintmustbedisposedof as hazardoussolidwasteaccordingtoResourceConservationand RecoveryActregulations.referredmethodofdisposalisincineration.SECTIONVni!EMPLOYEE PROTECTION INFORMATION; Precautionsmustbetakensothosepersonshandlingtiaismaterialdo no tbreathethe vaporsabovethe TL V ,or haveitcontactth

overcoating of lead-based paint on steel structures

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