Centro Para Prevenção da Poluição (C3P) Engineering and Technical
Services

Potential Alternatives Report

C3P.Proj.CS.Port.001

For the Replacement of a Chromate and High-VOC Coating System in
Aircraft Painting Process

[January, 2006]{.mark}

Centro Para Prevenção da Poluição (C3P) Engineering and Technical
Services

Potential Alternatives Report

C3P.Proj.CCC.Port.001

For the Replacement of a Chromate and High-VOC Coating System in
Aircraft Painting Process

[January, 2006]{.mark}

Distribution Statement \"A\" applies

Approved for Public Release; Distribution is unlimited

Prepared by:

Centro Para Prevenção da Poluição (C3P)\
Casa do Ambiente e do Cidadão

Rua S. Domingos à Lapa nº 26, 1200-835 Lisboa

Reviewed by

NASA Acquisition Pollution Prevention Office (NASA AP2)

**PREFACE**[]{#__RefHeading___Toc74972599 .anchor}

This report was prepared by the Centro Para Prevenção da Poluição (C3P)
under the guidance of the NASA Acquisition Pollution Prevention Office.
This report was prepared in accordance with the tenants of the *Joint
Statement (JS) between NASA and the Portuguese Ministry of the
Environment Regarding Cooperation in the Field of Environmental
Pollution Prevention*, signed by the American Ambassador and the
Ministério das Cidades, Ordenamento do Território e Ambiente Portugal,
and the subsequent *Terms of Reference (TOR)*, signed by the NASA
Director of Environmental Management, Portuguese President of the
Institute of Environment, and the C3P Director General on September 18,
2002. The structure, format, and depth of technical content of the
report was determined by a joint project team comprised of
representatives from C3P, Instituto de Soldadura e Qualidade (Institute
of Welding and Quality) (ISQ), International Trade Bridge, Inc. (ITB),
Instituto de Engenharia Mecânica e Gestão Industrial (Institute of
Mechanical Engineering and Industrial Management) (INEGI), TAP Portugal,
and OGMA -- Indústria Aeronáutica de Portugal, S.A..

> **TABLE OF CONTENTS**[]{#__RefHeading___Toc74972600 .anchor}

Page

[**PREFACE** I](#__RefHeading___Toc74972599)

[**TABLE OF CONTENTS** II](#__RefHeading___Toc74972600)

[**LIST OF FIGURES** IV](#__RefHeading___Toc74972601)

[**LIST OF TABLES** IV](#__RefHeading___Toc74972602)

[**EXECUTIVE SUMMARY** V](#__RefHeading___Toc74972603)

[**INTRODUCTION** 1](#__RefHeading___Toc74972604)

[**1.** **BASELINE PROCESS** 4](#__RefHeading___Toc74972605)

[1.1. [Baseline Process Flow]{.smallcaps}
5](#__RefHeading___Toc74972606)

[1.2. [Baseline Process Description]{.smallcaps}
5](#__RefHeading___Toc74972606)

[1.3. [Baseline Process Equipment]{.smallcaps}
5](#__RefHeading___Toc74972606)

[1.4. [Baseline Material and Energy Usage]{.smallcaps}
5](#__RefHeading___Toc74972606)

[1.5. [Baseline Waste and Emissions Summary]{.smallcaps}
5](#__RefHeading___Toc74972606)

[1.6. [Environmental, Safety and Occupational Health (ESOH) Status for
the Baseline Process]{.smallcaps} 5](#__RefHeading___Toc74972606)

[*1.6.1* *Environmental Issues, Health and Safety
Issues*](#__RefHeading___Toc74972607) *5*

[1.7. [Baseline Capital and Operation Costs]{.smallcaps}
5](#__RefHeading___Toc74972606)

[**2.** **identified alternatives and preliminary screening**
4](#__RefHeading___Toc74972605)

[2.1. [High Solids Painting Scheme -- Akzo Nobel]{.smallcaps}
5](#__RefHeading___Toc74972606)

[*2.1.1* *Process Description*](#__RefHeading___Toc74972607) *5*

[*2.1.2* Technical Considerations](#__RefHeading___Toc74972607) *5*

[*2.1.3* *Environmental Issues*](#__RefHeading___Toc74972607) *5*

[*2.1.4* *Health and Safety Issues*](#__RefHeading___Toc74972607) *5*

[*2.1.5* Additional Supporting Literature](#__RefHeading___Toc74972607)
*5*

[2.2. [PreKote Surface Pretreatment -- Pantheon Chemical]{.smallcaps}
5](#__RefHeading___Toc74972606)

[*2.2.1* *Process Description*](#__RefHeading___Toc74972607) *5*

[*2.2.2* Technical Considerations](#__RefHeading___Toc74972607) *5*

[*2.2.3* *Environmental Issues*](#__RefHeading___Toc74972607) *5*

[*2.2.4* *Health and Safety Issues*](#__RefHeading___Toc74972607) *5*

[*2.2.5* Additional Supporting Literature](#__RefHeading___Toc74972607)
*5*

**LIST OF FIGURES**[]{#__RefHeading___Toc74972601 .anchor}

> **Page**

[[Figure 1. Steps for Painting Preparation]{.smallcaps}
5](#__RefHeading___Toc74972973)

[[Figure 2. Steps for Baseline Painting Process]{.smallcaps}
6](#__RefHeading___Toc74972974)

[[Figure 3. Aerial Photograph of TAP Maintenance and Engineering.
Location of Hangar 4, 5 and 6]{.smallcaps}
16](#__RefHeading___Toc74972975)

> **LIST OF TABLES**[]{#__RefHeading___Toc74972602 .anchor}
>
> **Page**

[[Table 1. Target HazMat Summary -- TAP]{.smallcaps}
3](#__RefHeading___Toc74972743)

[[Table 2. Spray Guns and Pumps used in the Baseline Painting
Process]{.smallcaps} 8](#__RefHeading___Toc74972745)

[[Table 3. Specifications of the Baseline Painting System
Products]{.smallcaps} 8](#__RefHeading___Toc74972746)

[[Table 4. Composotion and Information on Ingredients of Painting
Products (Metaflex FCR Primer, Aerodur CF Primer 37047, Aerodur Finish
C21/100 UVR)]{.smallcaps} 9](#__RefHeading___Toc74972747)

[[Table 5. Wastes Produced in TAP Painting Area with respective ELR
Code]{.smallcaps} 10](#__RefHeading___Toc74972747)

[[Table 6. Wastes Quantities Produced in TAP Painting Area between 1998
and 2002 TAP]{.smallcaps} 10](#__RefHeading___Toc74972748)

[[Table 7. Level of VOC Emissions from the Baseline Painting
Products]{.smallcaps} 11](#__RefHeading___Toc74972749)

[[Table 8. Safety Equipment Used at TAP Painting Area (ME/MA/MB) --
Painting -- Painting Shop (Hangar 4, Hangar 5, Hangar 6)]{.smallcaps}
13](#__RefHeading___Toc74972750)

[[Table 9. IPE's Acessories List Used in the Painting Areas]{.smallcaps}
14](#__RefHeading___Toc74972751)

[[Table 10. Chemicals -- Worker Exposure Limits]{.smallcaps}
14](#__RefHeading___Toc74972752)

[[Table 11. Material Costs (Painting Preparation and Painting
Operation)]{.smallcaps} 16](#__RefHeading___Toc74972753)

[[Table 12. Power Costs -- Hangar 6]{.smallcaps}
17](#__RefHeading___Toc74972754)

[[Table 13. Power Costs -- Hangar 5]{.smallcaps}
17](#__RefHeading___Toc74972754)

[[Table 14. Manpower Costs for Several Aircraft Models]{.smallcaps}
17](#__RefHeading___Toc74972754)

[[Table 15. Costs of Sanding and Stripping Processes in na Airbus A310
Aircraft]{.smallcaps} 18](#__RefHeading___Toc74972754)

[[Table 16. Most Viable Alternatives to Chromate and High-VOC Coating
System]{.smallcaps} 19](#__RefHeading___Toc74972754)

[[Table 17. Products for Aircraft Painting and Mixing
Ratios]{.smallcaps} 21](#__RefHeading___Toc74972754)

[[Table 18. CAS Numbers for Cleaner M790 E]{.smallcaps}
21](#__RefHeading___Toc74972754)

[[Table 19. CAS Numbers for Aviox CF Primer (TC) and Hardener
93231]{.smallcaps} 21](#__RefHeading___Toc74972754)

[[Table 20. CAS Numbers for Aviox Finish 77702, White BAC 7067, Hardener
90150 and Activator 99321]{.smallcaps} 22](#__RefHeading___Toc74972754)

[[Table 21. Chemicals -- Worker Exposure Limits]{.smallcaps}
23](#__RefHeading___Toc74972754)

[[Table 22. General Requirement Tests for Group 2 Coatings]{.smallcaps}
26](#__RefHeading___Toc74972754)

[[Table 23. Adhesion Requirement Tests for Group 2 Coatings]{.smallcaps}
26](#__RefHeading___Toc74972754)

[[Table 24. Corrosion Resistance Requirement Tests for Group 2
Coatings]{.smallcaps} 27](#__RefHeading___Toc74972754)

[[Table 25. Fluids Resistance Requirement Tests for Group 2
Coatings]{.smallcaps} 27](#__RefHeading___Toc74972754)

[[Table 26. Marine Atmospheric Test on Scribed Painting Substrates
Requirement Tests for Group 2 Coatings]{.smallcaps}
28](#__RefHeading___Toc74972754)

[[Table 27. Rain Erosion Requirement Tests for Group 2
Coatings]{.smallcaps} 28](#__RefHeading___Toc74972754)

> **EXECUTIVE SUMMARY**[]{#__RefHeading___Toc74972603 .anchor}

A common coating system on aluminum substrates consists of a chromate
conversion coating, a primer and a topcoat.

> Chrome conversion coating involves the treatment of a metal substrate
> with a chrome solution to produce an adherent coating. The metal
> substrate is changed to a layer of chromium salts to produce the
> desired decorative or functional properties. Chrome conversion
> coatings are used for three general purposes:

-   Increase corrosion resistance

-   Improve paint (primer) adhesion

-   Minimize electrical resistance.

Chrome primers are commonly applied to surfaces as a protective coating
offer significant corrosion protection.

> Although chrome conversion coating and primer coatings offers many
> advantageous coating properties, its use of hexavalent chromium is
> strictly regulated due to the compound\'s toxicity and suspected
> carcinogenicity. For this reason, manufacturers have begun to
> identify, evaluate, and implement acceptable alternatives for chrome
> conversion coating and primer coating where feasible. These
> alternative technologies commonly generate less pollution than chrome
> conversion coatings and chrome primers, and have fewer associated
> health and safety risks.
>
> Also traditional coatings are paints containing high amounts of
> volatile organic compounds (VOC), such as methyl ethyl ketone,
> toluene, and xylene, and some percentage of solid components.
> Alternative coatings seek to reduce the amount of VOCs, and yet retain
> or improve the ability of the coating to protect metallic or composite
> surfaces.
>
> At TAP Portugal, and OGMA -- *Indústria Aeronáutica de Portugal,
> S.A.*, chrome in chemical conversion coatings and primers coatings, as
> well as VOC found in paints, were identified as a hazardous material
> of concern, and targeted for elimination or reduction.

This Potential Alternatives Report (PAR) provides an analysis of
identified alternatives to chromate and high-VOC coating systems and
recommended alternatives for testing and possible implementation at TAP
and OGMA.

Two viable alternatives have been identified. These viable alternatives
are *High Solids Painting Scheme* from Akzo Nobel; and *PreKote Surface
Pretreatment*, from Pantheon Chemical, plus the *High Solids Painting
Scheme*, from Akzo Nobel. The environmental, safety, and occupational
health characteristics of these viable alternatives were evaluated. In
addition, the key process characteristics of these alternatives were
compared to those of the existing process. As a result of the analyses,
both of the alternatives were classified as potential alternatives and
chosen for testing/performance comparison in accordance with the
approved Joint Test Protocol (JTP), *Joint Test Protocol for the
Replacement of a Chromate and High-VOC Coating System in Aircraft
Painting Process,* dated November, 2004. A Joint Test Report (JTR) will
document the data and results of the testing/performance comparison to
minimize duplication of effort.

> **INTRODUCTION**[]{#__RefHeading___Toc74972604 .anchor}

The National Aeronautics and Space Administration (NASA) and the
Portuguese Ministry of Urban Affairs, Spatial Planning and the
Environment, in their concern for the quality of the natural environment
have agreed jointly to explore ways to prevent environmental pollution.

The following outlines specific areas of pollution prevention (P2)
interests in the joint cooperation between NASA and the Portuguese
Ministry of Environment:

-   Integrating environmental, safety, and occupational health
    considerations in acquisition, manufacturing, and maintenance
    processes/procedures;

-   Information sharing on integrating environment, safety, and
    occupational health considerations into life cycle analysis;

-   Use of existing information networks for environmental purposes;

-   Information sharing programs on United States and European
    regulations and their potential impact on manufacturing and
    maintenance processes and their impacts on operational
    capability/supportability; and

-   Integrating safety and occupational health considerations into
    environmental programs.

The NASA Acquisition Pollution Prevention (AP2) Program Office, operated
under the Spaceport Technology Directorate (YA) at Kennedy Space Center,
Florida, will act as facilitator while the Center for Pollution
Prevention (C3P), in Lisbon, Portugal, will establish the infrastructure
and develop strategic plans - The C3P Mission is to identify and
validate pollution prevention technologies through joint activities that
enhance environmental stewardship and reduce risk while minimizing
duplication of effort and associated costs.

To reduce HazMats, the C3P process first identifies the HazMat, related
process, and affected substrates or parts. Details identified include
equipment requirements; material and energy usage; waste and emission
generation; environmental, safety, and occupational health (ESOH)
issues; and capital and operating costs.

Identifying and selecting alternative processes that have the potential
to reduce the identified HazMats can be a complicated task due to the
fast pace at which new technologies emerge and the ever-increasing
volume of published and unpublished documentation. Under the C3P
process, a technology survey is performed to identify commercially
available or near commercially available alternative technologies. The
alternatives are identified through literature searches, electronic
database searches, Internet searches, customized surveys, and/or
personal and professional contacts.

After reviewing technical and ESOH information in the technology survey,
technical representatives select a shortened list of viable alternative
technologies. The selection rationale and conclusions are documented in
the PAR, and vendors of the selected technologies are contacted
concerning their specific products.

The identified vendor products then undergo a more in-depth technical
and preliminary ESOH analysis. The technical analysis includes
determining how well the alternatives match the current operations and
future needs. Examples of evaluation criteria may include expected
additional equipment, material and energy usage, waste and emission
generation, and capital and operating costs.

After reviewing the technical and ESOH analyses, technical
representatives select potential alternatives for testing in accordance
with the *C3P Joint Test Protocol for the Replacement of a Chromate and
High-VOC Coating System in Aircraft Painting Scheme,* dated November,
2004. Test results will be reported in the JTR.

Table 1 summarizes the target HazMat, process and material and affected
programs at TAP Portugal.

+----------------------+-----------------------+-----------------------+
| **Table 1. Target    |                       |                       |
| HazMat Summary --    |                       |                       |
| TAP**                |                       |                       |
+----------------------+-----------------------+-----------------------+
| **Target HazMats**   | **Process/Material**  | **Affected Programs** |
+----------------------+-----------------------+-----------------------+
| Hexavalent Chrome    | Chemical Conversion   | [Airbus]{.underline}: |
|                      | Coatings              | A310, A320 family and |
| Volatile Organic     |                       | A340                  |
| Compounds            | Primers               |                       |
|                      |                       | [Boeing]{.underline}: |
|                      | Topcoats              |                       |
|                      |                       | B727, B737            |
|                      |                       |                       |
|                      |                       | [L                    |
|                      |                       | ockheed]{.underline}: |
|                      |                       |                       |
|                      |                       | L1011                 |
+----------------------+-----------------------+-----------------------+

**1. BASELINE PROCESS**[]{#__RefHeading___Toc74972605 .anchor}

The following baseline information was provided by TAP.

The painting systems should comply with the Aerospace Material
Specification AMS 3095 Paint, Gloss, Airline Exterior System of SEA
International [(Annex A)]{.mark}.

Airbus Industries defines two procedures of product application related
with exterior painting process. These documents are designated by
*Process and Material Specifications* (PMS), and are PMS 01-02-29 and
PMS 01-02-27.

PMS 01-02-29 defines the tests that should be performed after the
painting process is completed, for both primers and topcoats. These
tests are adhesion and thickness. For thickness tests the proper
equipment to be used is the Isometer or Permascope for light alloys and
Microtest equipment for steels. For the adhesion tests it should be used
scotch tape 250 from 3M (adhesive tape) in different points of the
painted surface. In the test coupons the thickness measurement should be
done before the adhesion test. If necessary these coupons can be used
for verification of the decoration paint colour. In this procedure, is
also defined as a criterion of aircraft exterior painting approval, the
evaluation of painting conditions, based on technical and aesthetics
aspects. Concerning the technical aspects, it should be considered the
protection factor of the painting system, while the aesthetics aspects
are related with the manufacturer and operator image.

The PMS 01-02-27 defines primer application. The point 3.2.4 of the PMS
01-02-27 document specifies thickness and weight (by surface unit) range
values, which epoxy and polyurethane based dry films should have. The
values of thickness and weight, by surface unit, are respectively, 17 ±
3µm and 30g/m^2^. In the quality requirements it is specified that
visual inspections should be done at 100%, for search of irregularities.
After drying the thickness measurements should be done using
non-destructive methods. The equipment to be used should be Microtest,
Isometer, Permascope, or Elcometer. The adhesion test should be
conducted, as follows:

-   Degrease the test area.

-   Apply adhesive tape on the clean area. Use Scotch tape Nº250 with 1
    inch of width, with no longer than 12 months after manufacture date.
    It should be assured that there is a perfect contact between the
    adhesive tape and the coating avoiding air bubble imprisonment.

-   Remove the tape in an abrupt movement keeping an angle of
    approximately 90º.

If the adhesion test fails the piece should be rejected.

**1.1. Baseline Process Flow**[]{#__RefHeading___Toc74972606 .anchor}

The sequence of steps for painting preparation is shown in Figure 1.

**Figure 1. Steps for painting preparation**

Figure 2 shows the sequence of steps for TAP baseline painting process.

**Figure 2. Steps for baseline painting process**

**1.2. Baseline Process Description**

Previous to the painting process it's required a preparation of all
aircraft surfaces. Initially, all surfaces are washed with cold water,
followed by an inspection. If the surface is not in perfect conditions
it's necessary to mask, followed by a stripping process and wash with
cold water. If the surface is in perfect conditions is conducted
masking, followed by sanding, washing with cold water and masking again.
After masking, all aircraft surfaces are cleaned with *Oplosser*.

The following describes each step of TAP's painting process:

1.  *Application of Metaflex FCR Primer*: Metaflex FCR Primer is a
    3-component filiform corrosion resistance washprimer and is spray
    gun applied in the areas with bare metal.

2.  *Application of Aerodur CF Primer 37047*: Aerodur CF Primer 37047 is
    a 3-component chromate cured modified epoxy primer for exterior use
    and is spray gun applied in all aircraft surfaces.

3.  *Masking*: fuselage lower half.

4.  *White with Aerodur Finish C21/100 UVR*: Aerodur Finish C21/100 UVR
    is an universal 3-component, high gloss very durable polyurethane
    finish for interior and exterior use, and is spray gun applied in
    the fuselage upper half.

5.  *Masking*: fuselage upper half.

6.  *Grey with Aerodur Finish C21/100 UVR*: spray gun application in
    fuselage lower half.

7.  *Marking*

8.  *Masking*

9.  *Decoration with Aerodur Finish C21/100 UVR:* spray gun application
    in accordance with TAP's painting draw.

10. *Technical Marking*

**1.3. Baseline Process Equipment**

The baseline equipment for the painting process is listed below:

-   Thermohygrometer

-   Flow cup

-   Chronometer

-   Mechanical Shaker

-   Thickness gauge

-   Gloss gauge

-   Spray guns and pumps (See Table 2).

  ------------------------------ ----------------------------------------
  **Table 2. Spray Guns and      
  Pumps used in the Baseline     
  Painting Process**             

  **Product**                    **Equipment**

  *Metaflex FCR Primer*          High pressure electrostatic spray guns
                                 model 4000 with Monarch pumps

  *Aerodur CF Primer 37047*      High pressure electrostatic spray guns
                                 model 4000 with Monarch pumps

  *Aerodur Finish C21/100 UVR*   High pressure electrostatic spray guns
                                 model 4500 with Monarch pumps
  ------------------------------ ----------------------------------------

**1.4 Baseline Material and Energy Usage**

The painting system products used at TAP are *Metaflex FCR Primer*,
*Aerodur CF Primer 37047* and *Aerodur Finish C21/100 UVR,* all from
Akzo Nobel.

*Metaflex FCR Primer* is a 3-component filiform corrosion resistance
washprimer which has been designed as an alternative pre-treatment to
chemical conversion coatings; for reactivation of aged anodized or
chromated alloys and sealed anodized surfaces; for stippability of
polyurethane systems with alkaline paint removers; and to provide
adhesion of subsequent polyurethane or epoxy/isocyanate primers.

*Aerodur CF Primer 37047* is a 3-component chromate free isocyanate
cured modified epoxy primer for exterior use.

*Aerodur Finish C21/100 UVR* is a universal 3-component, high gloss very
durable polyurethane finish for interior and exterior use.

The specifications respected by the painting system products are shown
in Table 3.

+-----------------------------------+-----------------------------------+
| **Table 3. Specifications of the  |                                   |
| Baseline Painting System          |                                   |
| Products**                        |                                   |
+-----------------------------------+-----------------------------------+
| **Products**                      | **Specifications**                |
+-----------------------------------+-----------------------------------+
| Metaflex FCR Primer               | AIMS 04.04.012 (TN 10.113)        |
|                                   |                                   |
|                                   | BMS 10-72 Type V                  |
|                                   |                                   |
|                                   | FSD 7065                          |
|                                   |                                   |
|                                   | Airbus CML No. 16-020 A           |
+-----------------------------------+-----------------------------------+
| Aerodur CF Primer 37047           | SMI 70043                         |
|                                   |                                   |
|                                   | STD 175437                        |
+-----------------------------------+-----------------------------------+
| Aerodur Finish C21/100 UVR        | AIMS 04.04.012                    |
|                                   |                                   |
|                                   | BAEP 3545                         |
|                                   |                                   |
|                                   | BMS 10-72 Type V                  |
|                                   |                                   |
|                                   | DOL 256                           |
|                                   |                                   |
|                                   | MEP 10-61                         |
|                                   |                                   |
|                                   | SMI 70089-1                       |
|                                   |                                   |
|                                   | Airbus CML No. 07-017             |
|                                   |                                   |
|                                   | Airbus CML No. 16-016             |
+-----------------------------------+-----------------------------------+

Note: Specification Codes: AIMS-Airbus Industrie Material Specification,
BMS-Boeing Material Specification, Airbus CML-Airbus Consumable Material
List, BAMS Bombardier Aerospace Material Specification, MEP-Embraer
Specification, FSD Swedish Defense Specification, SMI-Air France
Specification, STD-Saab Specification, BAEP-BAE Systems Specification
and DOL-Fairchild Dornier Specification.

The composition and information on ingredients of the baseline painting
products are described in the following Table.

  --------------------------------------- ----------------------- -----------------------
  **Table 4. Composition and information                          
  on ingredients of Painting Products**                           
  (Metaflex FCR Primer, Aerodur CF Primer                         
  37047, Aerodur Finish C 21/100 UVR)                             

  **Chemical**                            **CAS No.**             **Percentage (%)**

  **Metaflex FCR Primer**                                         

  Propan2-ol                              67-63-0                 50-75

  Zinc chromates                          11103-86-9              10-25

  Toluene                                 108-88-3                1-2.5

  Isobutyl acetate                        110-19-0                1-2.5

  Butan-1-ol                              71-36-3                 1-2.5

  Phenol                                  108-95-2                0-1

  **Aerodur CF Primer 37047**                                     

  2-Methoxy-1-methylethyl acetate         108-65-6                10-25

  n-butyl acetate                         123-86-4                10-25

  Phosphoric acid, zinc salt (2:3)        7779-90-0               10-25

  Butan-2-ol                              78-92-2                 2.5-10

  Solvent naphtha (petroleum), heavy      64742-94-5              0-1
  arom.                                                           

  Zinc oxide                              1314-13-2               0-1

  2-Methoxypropyl acetate                 70657-70-4              0-1

  **Aerodur Finish C 21/100 UVR**                                 

  2-Methoxy-1-methylethyl acetate         108-65-6                25-50

  n-butyl acetate                         123-86-4                1-2.5

  Decanedioic acid, bis                   41556-26-7              0-1
  (1,2,2,6,6-pentamethyl-4-piperidinyl)                           
  ester                                                           

  2-Methoxypropyl acetate                 70657-70-4              0-1

  Decanedioic acid, methyl                82919-37-7              0-1
  1,2,2,6,6,-pentamethyl-4-piperidinyl                            
  ester                                                           
  --------------------------------------- ----------------------- -----------------------

No data available on the energy usage.

**1.5. Baseline Waste and Emissions Summary**

The wastes produced in TAP Painting Area are described in Table 5 with
the respective European Waste Catalogue and Hazardous Waste List (ELR)
Code.

  ----------------------------------- -----------------------------------
  **Table 5. Wastes produced in TAP   
  Painting Area with respective ELR   
  code**                              

  **Residue Type**                    **ELR Code**

  Epoxy and polyurethane based paints 080111
  and painting chamber sludge         

  Non-halogenated solvents            140603

  Painting residues with stripper     160302
  ----------------------------------- -----------------------------------

The non-halogenated solvents are recycled by Ecosocer Company. The
paints, sludge, and painting residues with stripper are sent to a
specific dirt fill of Industrial Hazardous Wastes.

Siemens-Efacec is contracted by TAP services to collect wastes to be
delivered to Quimitécnica, a waste management entity. Table 6 shows the
description and wastes quantities produced by TAP Painting Area. The
values refer to the quantities produced between 1998 and 2002.

+---------+---------------------+-------+------+------+------+------+
| **Table |                     |       |      |      |      |      |
| 6.      |                     |       |      |      |      |      |
| Wastes  |                     |       |      |      |      |      |
| qua     |                     |       |      |      |      |      |
| ntities |                     |       |      |      |      |      |
| p       |                     |       |      |      |      |      |
| roduced |                     |       |      |      |      |      |
| in TAP  |                     |       |      |      |      |      |
| p       |                     |       |      |      |      |      |
| ainting |                     |       |      |      |      |      |
| area    |                     |       |      |      |      |      |
| between |                     |       |      |      |      |      |
| 1998    |                     |       |      |      |      |      |
| and     |                     |       |      |      |      |      |
| 2002**  |                     |       |      |      |      |      |
+---------+---------------------+-------+------+------+------+------+
| **ELR   | **Description**     | **1   | **19 | **20 | **20 | **20 |
| Code**  |                     | 998** | 99** | 00** | 01** | 02** |
+---------+---------------------+-------+------+------+------+------+
| 080111  | Epoxy and           | 1     | 1.5  | 0    | 3.6  | 0    |
|         | polyurethane based  |       |      |      |      |      |
|         | paints and painting |       |      |      |      |      |
|         | chamber sludge      |       |      |      |      |      |
|         |                     |       |      |      |      |      |
|         | (in tons)           |       |      |      |      |      |
+---------+---------------------+-------+------+------+------+------+
| 140603  | Non-halogenated     | 11.8  | 21.8 | 14   | 16.6 | 10.6 |
|         | solvents            |       |      |      |      |      |
|         |                     |       |      |      |      |      |
|         | (in cubic meters)   |       |      |      |      |      |
+---------+---------------------+-------+------+------+------+------+
| 160302  | Painting residues   | \-    | \-   | \-   | 11   | 16   |
|         | with stripper (in   |       |      |      |      |      |
|         | tons)               |       |      |      |      |      |
+---------+---------------------+-------+------+------+------+------+

During 2003 and 2004 the recovery, separation and classification of the
wastes has been transferred from TAP-Maintenance & Engineering to TAP
Services / Siemens-Efacec. These data were not included in this report
due to the changes of the wastes classification.

The levels of VOC's emissions from the products of the baseline painting
system were provided by the manufacturer. The data is shown on Table 7.

  ----------------------------------------- -----------------------------
  **Table 7. Level of VOC emissions from    
  the Baseline Painting Products**          

  **Products**                              **VOC (grams/liter)**

  **Preparation for painting**              

  Solvent Oplosser                          826

  **Painting**                              

  **Wash-primer**                           

  Metaflex FCR Primer                       656

  Metaflex FCR Hardener                     799

  **Intermediate Primer**                   

  Aerodur CF Primer 37047                   606

  Hardener S66/14                           562

  **Topcoat**                               

  Aerodur Finish C21/100 UVR BAC 7067       447

  Aerodur Finish C21/100 UVR BAC 707        458

  Aerodur Finish C21/100 UVR BAC 701        561

  Aerodur Finish C21/100 UVR BAC 1247       394

  Aerodur Finish C21/100 UVR BAC 4213       512

  Aerodur Finish C21/100 UVR PMS 012C       498

  Aerodur Finish C21/100 UVR PMS Reflex     483
  Blue                                      

  **Other painting products**               

  Hardener S66/22R                          640

  Thinner 98056                             908

  Thinner 96184                             908

  Thinner 98064                             900

  Thinner C25/90S                           849
  ----------------------------------------- -----------------------------

**1.6 Environmental, Safety, and Occupational Health (ESOH) Status for
the Baseline Process**

Although chrome conversion coating offers many advantages, the use of
hexavalent chromium is facing increasing regulation in both the United
States and Europe due to the compound\'s toxicity and suspected
carcinogenicity. The U.S. Environmental Protection Agency (EPA) lists
chromium as one of the 17 materials that are targeted for strict
regulation.

Continued use of the chrome process carries a growing risk of workplace
and environmental liability, along with increased costs for trucking
inventories, monitoring emissions, and reporting usage of chromium
compounds and resulting wastes. These regulatory driving forces are
increasing manufacturing costs and hazardous material liability, leading
industry to identify, evaluate, and implement acceptable alternatives
for the chrome conversion coating and chrome primers.

Coatings containing VOC are toxic to human health. In the European Union
VOC emissions are regulated by EU Directive 1999/13/CE, March 11, 1999,
that has the objective to reduce both the direct and indirect effects of
the VOC emissions to the environment, as well as reduce the potential
risks to human health in consequence of a series of procedures
applicable to the industrial activities described in the Directive.

**1.6.1. Environmental Issues, Health and Safety Issues**

TAP Maintenance and Engineering complies with the Portuguese National
Legislation related to Hygiene and Safety issues, namely:

-   Law-decree no. 441/91, November 14, altered by Law-decree no.
    133/99, April 21 -- Establishes the juridical regime within the
    scope of Safety, Hygiene and Health.

-   Law-decree no. 488/99, November 17 -- Defining the application forms
    of the juridical regime of Safety Hygiene and Health for Public
    Administration and revokes the Law-decree no. 191/95, July 28.

-   Law-decree no. 26/94 February 1, altered by Law-decree no. 7/95,
    March 9, and Law-decree no. 109/2000 June 30, that republishes it,
    with all the modifications - Establishing the regime of organization
    and operation of the activities for the Safety, Hygiene and Health.

The workers in TAP Painting area are exposed to mechanical and chemical
risks. Thereby TAP Maintenance and Engineering supply the workers with
Individual Protection Equipment (IPE). These are intended to eyes,
airways, torso and upper and lower limb protection. The equipments
respect the Portuguese national legislation or in their absence, the
international legislation. The legislation that regulates the IPE's is
the following:

-   Law-decree no. 128/93, April 22, altered by Law-decree no. 139/95
    June 14, and Law-decree no. 374/98, November 24 (First article of
    Law-decree 374/98 revoked by Law-decree no. 320/2001). --
    Establishing the essential technical demands of safety that the
    individual protection equipment should comply, with the objective of
    preserving the health and the safety of its users.

-   Law-decree no. 348/93, October 1, - Minimal prescriptions in terms
    of workers health and safety, using IPE.

-   Government Directive no. 988/93, October 6 - Minimal prescriptions
    in terms of workers health and safety, using IPE (Regulates the
    Law-decree no. 348/93, October 1).

-   Government Directive no. 1131/93, November 4, altered by the
    Government Directive no. 109/96, April 10, and by Government
    Directive no. 695/97, August 19 -- Establishing the essential
    technical demands of safety that the IPE must respect, with the
    objective of preserving health and safety of its users.

Table 8 shows all the IPE's used by Maintenance and Engineering/Aircraft
Maintenance/Base Maintenance (ME/MA/MB) -- Painting -- Painting Shop
(Hangar 4, Hangar 5, Hangar 6).

+---------------------------+-------------------------+---------------+
| **Table 8. Safety         |                         |               |
| equipment used in TAP     |                         |               |
| painting area (ME/MA/MB)  |                         |               |
| -- Painting -- Painting   |                         |               |
| Shop (Hangar 4, Hangar 5, |                         |               |
| Hangar 6)**               |                         |               |
+---------------------------+-------------------------+---------------+
| **IPE**                   | **Type**                | **Ce          |
|                           |                         | rtification** |
+---------------------------+-------------------------+---------------+
| Ultravision Glasses       | Eye protection          | DIN EN ISO    |
|                           |                         | 9001          |
|                           | (risk factor of         |               |
|                           | chemical nature)        |               |
+---------------------------+-------------------------+---------------+
| Half-mask 3M 7500 series  | Respiratory protection  | EN 140:1999   |
|                           |                         |               |
|                           | (risk factor of         | CE 0086       |
|                           | chemical nature)        |               |
+---------------------------+-------------------------+---------------+
| Filter for gas and        | Respiratory protection  | EN 141:2000   |
| vapours ref. 6057 ABE1    |                         |               |
| for half-mask 3M series   | (risk factor of         | CE 0086       |
| 7500 and mask 3M-6800S    | chemical nature)        |               |
+---------------------------+-------------------------+---------------+
| Anti-particle pre-filter  | Respiratory protection  | EN 143        |
| ref. 5911 P1 for half     |                         |               |
| mask 3M 7500 series       | (risk factor of         | CE 0086       |
|                           | chemical nature)        |               |
+---------------------------+-------------------------+---------------+
| Full Face breathing mask  | Respiratory protection  | EN 136 CL     |
|                           |                         | 1-1996        |
| 3M-6800S                  | (risk factor of         |               |
|                           | chemical nature)        | CE 0086       |
+---------------------------+-------------------------+---------------+
| Anti-particle pre-filter  | Respiratory protection  |               |
| ref. 5911 P3 for mask     |                         |               |
| 3M-6800S                  | (risk factor of         |               |
|                           | chemical nature)        |               |
+---------------------------+-------------------------+---------------+
| Breathing mask 3M 9310    | Respiratory protection  | EN 149:2001   |
|                           |                         |               |
|                           | (risk factor of         | CE 0086       |
|                           | mechanical nature -     |               |
|                           | dusts)                  |               |
+---------------------------+-------------------------+---------------+
| Breathing mask 3M 9312    | Respiratory protection  | EN 149:2001   |
|                           |                         |               |
|                           | (risk factor of         | CE 0086       |
|                           | mechanical nature -     |               |
|                           | dusts)                  |               |
+---------------------------+-------------------------+---------------+
| Plastic arm protection    | Arm protection          |               |
|                           |                         |               |
|                           | (risk factor of         |               |
|                           | chemical nature)        |               |
+---------------------------+-------------------------+---------------+
| Policloroprene glove Mapa | Hand protection         |               |
| Baltex TECHNIC 420        |                         |               |
|                           | (risk factor of         |               |
|                           | chemical nature)        |               |
+---------------------------+-------------------------+---------------+
| Nitrilo glove Ansell      | Hand protection         | 3111          |
| Edmonton HYNIT            |                         |               |
|                           | (risk factor of         | EN 388        |
|                           | mechanical nature)      |               |
+---------------------------+-------------------------+---------------+
| Nitrilo glove Ansell      | Hand protection         | 4331 EN 388   |
| Edmonton NITRASAFE        |                         |               |
|                           | (risk factor of         | X1XX4X EN 407 |
|                           | mechanical nature)      |               |
|                           |                         | CE 0493       |
+---------------------------+-------------------------+---------------+
| PVC apron                 | Torso protection        |               |
|                           |                         |               |
|                           | (risk factor of         |               |
|                           | chemical nature)        |               |
+---------------------------+-------------------------+---------------+
| Protection suite          | Body protection         | CE 0120       |
|                           |                         |               |
| Tyvek - PRO/SHIELD 2      | (risk factor of         |               |
|                           | chemical nature --      |               |
|                           | painting operation)     |               |
+---------------------------+-------------------------+---------------+
| Protection suite          | Body protection         | EN 340 CE     |
|                           |                         | 0120          |
| KLEENGUARD reference IPP  | (risk factor of         |               |
|                           | chemical nature)        |               |
+---------------------------+-------------------------+---------------+
| Protection shoes with     | Feet protection         | EN 345-1      |
| steel toecap TRUENO-LUIBA |                         |               |
| model                     | (risk factor of         | EN 347-1      |
|                           | mechanical nature)      |               |
+---------------------------+-------------------------+---------------+
| Protection boots with     | Feet protection         | EN 345-1      |
| steel toecap TRUENO AGUBA |                         |               |
| model                     | (risk factor of         | EN 347-1      |
|                           | mechanical nature)      |               |
+---------------------------+-------------------------+---------------+

The IPE' accessories equipment is shown in Table 9.

+-----------------------------------+-----------------------------------+
| **Table 9. IPE's accessories list |                                   |
| used in Painting areas**          |                                   |
+-----------------------------------+-----------------------------------+
| **IPE**                           | **Type**                          |
+-----------------------------------+-----------------------------------+
| Replacement lenses for            | Eye protection                    |
| Ultravision glasses               |                                   |
|                                   | (risk factor of chemical nature)  |
+-----------------------------------+-----------------------------------+
| Small hand towel for mask         | Respiratory protection            |
| cleaning reference 3M 105         |                                   |
|                                   | (risk factor of chemical nature)  |
+-----------------------------------+-----------------------------------+
| Protection pellicle for mask      | Respiratory protection            |
| 3M-6800S                          |                                   |
|                                   | (risk factor of chemical nature)  |
+-----------------------------------+-----------------------------------+

The Threshold Limit Values (TLV) of the painting materials were
collected from the Portuguese Norm NP 1796:2004 and from the publication
Threshold Values for Chemical Substances and Physical Agents of the
American Conference of Governmental Industrial Hygienists (ACGIH) (See
Table 10).

+----------------+----------------+----------------+-----------------+
| **Table 10.    |                |                |                 |
| Chemicals --   |                |                |                 |
| Worker         |                |                |                 |
| Exposure       |                |                |                 |
| Limits**       |                |                |                 |
+----------------+----------------+----------------+-----------------+
| **Chemical**   | **CAS No.**    | **TVL/ACGIH**  | **TWA/PEL^1^**  |
|                |                |                |                 |
|                |                | **(ppm)**      | **(mg/m^3^)**   |
+----------------+----------------+----------------+-----------------+
| **Metaflex FCR |                |                |                 |
| Primer**       |                |                |                 |
+----------------+----------------+----------------+-----------------+
| Propan-2-ol    | 67-63-0        | 400            | 999             |
+----------------+----------------+----------------+-----------------+
| Zinc chromates | 11103-86-9     | 0.01 mg/m^3^   | 0.05            |
+----------------+----------------+----------------+-----------------+
| Toluene        | 108-88-3       | 50             | 191             |
+----------------+----------------+----------------+-----------------+
| Isobutyl       | 110-19-0       | 150            | 724             |
| acetate        |                |                |                 |
+----------------+----------------+----------------+-----------------+
| Butan-1-ol     | 71-36-3        | 20             | STEL^2^: 154    |
|                |                |                | mg/m^3^         |
+----------------+----------------+----------------+-----------------+
| Phenol         | 108-95-2       | 5              | 7.7 (2 ppm)     |
+----------------+----------------+----------------+-----------------+
| **Aerodur CF   |                |                |                 |
| Primer 37047** |                |                |                 |
+----------------+----------------+----------------+-----------------+
| 2-Methoxy      | 108-65-6       | \-\--          | 274             |
| -1-methylethyl |                |                |                 |
| acetate        |                |                |                 |
+----------------+----------------+----------------+-----------------+
| n-butyl        | 123-86-4       | 150            | 724             |
| acetate        |                |                |                 |
+----------------+----------------+----------------+-----------------+
| Butan-2-ol     | 78-92-2        | 100            | 308             |
+----------------+----------------+----------------+-----------------+
| **Aerodur      |                |                |                 |
| Finish C21/100 |                |                |                 |
| UVR**          |                |                |                 |
+----------------+----------------+----------------+-----------------+
| 2-Methoxy      | 108-65-6       | \-\--          | 274             |
| -1-methylethyl |                |                |                 |
| acetate        |                |                |                 |
+----------------+----------------+----------------+-----------------+
| n-butyl        | 123-86-4       | 150            | 724             |
| acetate        |                |                |                 |
+----------------+----------------+----------------+-----------------+

^1^ TWA/PEL -- Time Weighted Average / Permissible Exposure Limits (8
hours)

^2^ STEL -- Short Term Exposure Limit (15 minutes)

Ventilation is required to maintain airborne contaminants below the TLVs
and PELs. In addition, personal protective equipment is required, such
as eye goggles or face shields, neoprene or polyvinyl gloves,
appropriate protective clothing, and a dust filter mask or respirator.

**1.7. Baseline Capital and Operating Costs**

Costs with painting materials are shown in Table 11. The values include
costs with painting preparation materials and painting materials
(primers and topcoats). The consumption of the cleaning agent Solvent
Oplosser was not recorded.

+---------------------------+------------------------------------------+
| **Table 11. Material      |                                          |
| Costs**                   |                                          |
|                           |                                          |
| **(Painting preparation   |                                          |
| and painting operation)** |                                          |
+---------------------------+------------------------------------------+
| **Aircraft Model**        | **Cost (in Euros)**                      |
+---------------------------+------------------------------------------+
| Airbus A310               | \*                                       |
+---------------------------+------------------------------------------+
| Airbus A319               | 6500                                     |
+---------------------------+------------------------------------------+
| Airbus A340               | 7500                                     |
+---------------------------+------------------------------------------+

\* Data not available

There is no data available for the Airbus models A321 and A340.

As to auxiliary painting materials the data available refers to an A310
aircraft, and the cost is approximately 2000 Euros. The auxiliary
painting materials are, for example, plastic foils used in masking,
tapes, window protectors, gloves, etc.

![](media/image1.wmf){width="5.5in" height="3.8645669291338582in"}TAP
Maintenance and Engineering conducts the aircraft maintenance work in
three Hangars. Figure 3 shows Hangars 4, 5 and 6 with a total covered
surface of 26380 m^2^.

**Figure 3.** Aerial photograph of TAP Maintenance and Engineering.
Location of Hangars 4, 5 and 6.

Concerning power costs TAP-ME conducted a study for the painting costs
in Hangar 5 and 6. These Hangars are not exclusively dedicated to
aircraft painting and the data collected is affected with some
inaccuracy. Regarding Hangar 6 the power consumption includes the
following:

-   Diesel oil for air heaters;

-   Natural gas consumed at the central for hangar heating, which also
    serves other building (Component Shop);

-   Electrical energy for electric outlets, equipment, illumination
    lines and compressed air.

Power consumptions within Hangar 6 (Airbus A310 aircraft painting case)
are shown in Table 12.

+-----------------+-----------------+-----------------+-----------------+
| **Table 12.     |                 |                 |                 |
| Power costs --  |                 |                 |                 |
| Hangar 6**      |                 |                 |                 |
+-----------------+-----------------+-----------------+-----------------+
| **Situation**   | **Day of the    | **Season**      | **Cost**        |
|                 | week**          |                 |                 |
|                 |                 |                 | **(Euros/day)** |
+-----------------+-----------------+-----------------+-----------------+
| Painting        | Weekend         | Winter          | 2950            |
+-----------------+-----------------+-----------------+-----------------+
| Without work    | Weekend         | Winter          | 1750            |
+-----------------+-----------------+-----------------+-----------------+
| Maintenance     | Monday to       | Winter          | 4450            |
|                 | Friday          |                 |                 |
+-----------------+-----------------+-----------------+-----------------+
| Maintenance     | Monday to       | Summer          | 3900            |
|                 | Friday          |                 |                 |
+-----------------+-----------------+-----------------+-----------------+

Table 13 presents the Hangar 5 power costs (Boeing 737 aircraft painting
case).

+-----------------+-----------------+-----------------+-----------------+
| **Table 13.     |                 |                 |                 |
| Power costs --  |                 |                 |                 |
| Hangar 5**      |                 |                 |                 |
+-----------------+-----------------+-----------------+-----------------+
| **Situation**   | **Day of the    | **Season**      | **Cost**        |
|                 | week**          |                 |                 |
|                 |                 |                 | **(Euros/day)** |
+-----------------+-----------------+-----------------+-----------------+
| Painting        | Weekend         | Winter          | 2375            |
+-----------------+-----------------+-----------------+-----------------+

The manpower costs are indicated in Table 14. The values are based on
Heavy Maintenance manpower costs (values of the year 2005).

+----------------+----------------------------+-----------+-----------+
| **Table 14.    |                            |           |           |
| Manpower Costs |                            |           |           |
| for several    |                            |           |           |
| aircraft       |                            |           |           |
| models**       |                            |           |           |
+----------------+----------------------------+-----------+-----------+
| **Model**      | **Description**            | **Direct  | **Total   |
|                |                            | Cost**    | Cost**    |
|                |                            |           |           |
|                |                            | **        | **        |
|                |                            | (Euros)** | (Euros)** |
+----------------+----------------------------+-----------+-----------+
| Airbus A310    | Stripping, Sanding and     | 113500    | 193000    |
|                | Painting the entire        |           |           |
|                | aircraft                   |           |           |
+----------------+----------------------------+-----------+-----------+
| Airbus A319    | Sanding and Painting the   | 43000     | 73000     |
|                | entire aircraft            |           |           |
+----------------+----------------------------+-----------+-----------+
| Airbus A320    | Sanding and Painting the   | 47000     | 80000     |
|                | entire aircraft without    |           |           |
|                | decoration                 |           |           |
+----------------+----------------------------+-----------+-----------+
| Airbus A320    | Stripping, Sanding and     | 59000     | 101000    |
|                | Painting the entire        |           |           |
|                | aircraft                   |           |           |
+----------------+----------------------------+-----------+-----------+
| Airbus A320    | Stripping, Sanding and     | 73000     | 125000    |
|                | Painting the entire        |           |           |
|                | aircraft (\*)              |           |           |
+----------------+----------------------------+-----------+-----------+
| Airbus A321    | Stripping, Sanding and     | 62000     | 106000    |
|                | Painting the entire        |           |           |
|                | aircraft                   |           |           |
+----------------+----------------------------+-----------+-----------+

(\*) In this case the value of manxhour was higher because the stripper
application method was different. Currently the stripper is spray
applied.

The direct cost is the number of hours spent with direct coordination,
painters and the auxiliary personnel. The total costs include all the
described costs and other TAP Maintenance and Engineering costs, namely,
equipment maintenance, power costs, cleaning, security, etc.

Table 15 expresses the costs of stripping and sanding process in an A310
aircraft (includes process auxiliary material). There is no data
available for other aircraft models.

  ----------------------- ----------------------- -----------------------
  **Table 15. Costs of                            
  sanding and stripping                           
  processes in an Airbus                          
  A310 aircraft**                                 

  **Operation**           **Description**         **Costs (Euros)**

  Sanding                 \-                      9500

  Stripping and Sanding   With Turco 6776LO       18500

  Stripping and Sanding   With Ardrox 2526        10500
  ----------------------- ----------------------- -----------------------

The Ardrox 2526 stripper has been progressively replaced by Turco 6776LO
because this product is less harmful for the Environment and Human
Health.

**2. IDENTIFIED ALTERNATIVES AND PRELIMINARY SCREENING**

Table 16 presents the most viable alternatives to chromate and high-VOC
coating systems, which are indicated that generate less pollution, and
have less health and safety risks associated with them.

  --------------------------------------- -------------------------------
  Table 16. Most Viable Alternatives to   
  Chromate and High-VOC Coating System    

  **Product**                             Company

  *High Solids Painting Scheme*           **Akzo Nobel**

  ***PreKote SP***                        **Pantheon Chemical**
  --------------------------------------- -------------------------------

**2.1. High Solids Painting Scheme -- Akzo Nobel**

Conventional solvent borne paints typically contain 8 to 30 percent
solids. High solids paints contain an increased amount of non-volatiles,
resulting in formulations that range from 40 to nearly 100 percent
solids. These paint formulations use low-molecular-weight resins (500 to
2,000 as compared to 20,000 for conventional resins), which require less
solvent to attain the desired application viscosity. These resins have
highly reactive sites to aid in coating polymerization.

High-solids paints may be one-component or two-component systems based
on acrylic, alkyd, epoxy, polyester, or urethane resins. High-solids
coatings can be cured in conditions ranging from ambient air dry to a
high temperature bake (above 180°C \[350°F\]).

The reduced solvent content in high-solids coatings presents some
potential difficulties. Surface preparation is more critical because
oils, greases, and other surface contaminants normally dissolved by
solvents in conventional formulations may affect paint adhesion.
Although some high-solids paints may be applied by conventional
application techniques (e.g., air spraying, curtain coating, dip
coating, electrostatic spraying, or flow coating), special equipment may
be required for others, especially those approaching 100 percent solids.
For high viscosity materials, it may be necessary to heat the paint to
maintain a workable paint consistency, increase the pressure in spray
applications, or use two component formulations and plural component
equipment that meters and mixes the materials at the spray gun. Since
thicker coatings do not blend as well as thinner coatings, color
matching may be more complicated. In addition, the reduced solvent
content may make clean-up more difficult.

Akzo Nobel High Solids Painting Scheme selected by TAP was *Aviox
Advanced Series*:

1.  *M790E*: for surface preparation is a water based detergent that
    gives improved adhesion properties, and the content of organic
    solvents is less than 10%.

2.  *Axiox CF Primer (Tropical Conditions)*: is a two pack coating for
    aircraft exterior surfaces, and is a corrosion inhibitor, don't
    contain leads or chromates, resistant to aircraft fluids and
    chemicals, high solids content, and is compatible with *Aviox
    Finish*.

3.  *Aviox Finish 77702*: is a polyurethane topcoat and a 3 component
    durable high gloss finish for exterior use. *Aviox Finish 77702*
    have extended durability and UV resistance, high solids content,
    resistance to aircraft hydraulic fluids and chemicals, and have a
    wide application window due to various activators, also have a wide
    range of colors available.

**2.1.1. Process Description**

The *High Solids Painting Scheme* is for aircraft exterior surfaces.

*M790E,* for surface preparation, shall be applied via the following
procedure on fully stripped aircrafts or bare/stripped aluminum skins:

> 1\. Remove heavy contamination of the surface with a solvent wash.
>
> 2\. Rub the surface thoroughly with clean rags soaked with M790E.
>
> 3\. Wipe off with a clean cloth after 10 to 20 seconds (No further
> rinsing or surface preparation is required).
>
> 4\. Allow the surface to dry for a minimum of 4 hours to prevent water
> enclosure under rivets and overlaps.
>
> 5\. Apply primer coating (the surface should be fully dry).

The *Aviox CF Primer* (Tropical Conditions) shall be spray applied to
pretreated aluminum, after being thoroughly cleaned with Cleaner *M790E*
or other.

The *Aviox Finish 77702* is compatible with the most commonly used
primers, and shall be spray applied on clean primer.

**2.1.2. Technical Considerations**

**2.1.3. Environmental Issues**

Table 17 shows the list of products for aircraft painting and the
respective mixing ratios.

[]{.mark}

+-----------------------------------+-----------------------------------+
| **Table 17. Products for aircraft |                                   |
| painting and mixing ratios**      |                                   |
+-----------------------------------+-----------------------------------+
| **Product**                       | **Mixing ratio (in volume)**      |
+-----------------------------------+-----------------------------------+
| Cleaner M790E                     | \-                                |
+-----------------------------------+-----------------------------------+
| Aviox CF Primer (Tropical         | 100 parts of Aviox CF Primer      |
| conditions)                       |                                   |
|                                   | 55 parts of Hardener 93231        |
+-----------------------------------+-----------------------------------+
| Aviox Finish 77702 White BAC 7067 | 100 parts of Aviox Finish 77702   |
|                                   |                                   |
|                                   | 50 parts of Hardener 90150        |
|                                   |                                   |
|                                   | 50 parts of Activator 99321       |
+-----------------------------------+-----------------------------------+

[]{.mark}

[]{.mark}

Table 18 describes the chemicals in Cleaner M 790E and the respective
Chemical Abstracts Service registry numbers (CAS numbers).

  ----------------------------------- -----------------------------------
  **Table 18. CAS Numbers for Cleaner 
  M 790E**                            

  **Chemical**                        **CAS Number**

  Propan-2-ol; isopropanol            67-63-0

  Butan-1-ol; n-butanol               71-36-3
  ----------------------------------- -----------------------------------

According with the *Aviox CF Primer* Material Safety Data Sheet (MSDS),
*Aviox CF Primer* is highly flammable; reactive with oxidizing agents,
strong alkalis and strong acids conducting to strong exothermic
reactions; stable formulation, under recommended storage and handling
conditions, with a basic pH; and partially soluble in cold water.

*Aviox CF Primer* shouldn't enter drains and watercourses, and the
disposal is performed in accordance with the applicable regulations.

*Aviox CF Primer* contains substances presenting a health or
environmental hazard within the meaning of the Dangerous Substances
Directive 67/584/EEC, which are described in Table 19 with the
respective CAS numbers.

  ------------------------------------------- -----------------------------------
  **Table 19. CAS numbers for Aviox CF Primer 
  (TC) and Hardener 93231**                   

  **Chemical**                                **CAS Number**

  **Aviox CF Primer (TC)**                    

  Acetoacetate resin                          \-\--

  4-Methylpentan-2-one                        108-10-1

  Xylene                                      1330-20-7

  Zinc Oxide                                  1314-13-2

  Ethylbenzene                                100-41-4

  **Hardener 93231 for Aviox CF Primer (TC)** 

  Ketimine resin                              \-\--

  Amine-ketone-condensate                     \-\--

  Xylene                                      1330-20-7

  Silane,                                     2530-83-8
  trimethyoxy\[3-(oxiranyl-methoxy)propyl\]   

  Ethylbenzene                                100-41-4

  5-Methylheptane-3-one                       541-85-5
  ------------------------------------------- -----------------------------------

According with the *Aviox Finish 77702, white BAC 7067* Material Safety
Data Sheet (MSDS), *Aviox Finish 77702* is flammable; reactive with
oxidizing agents, strong alkalis and strong acids conducting to strong
exothermic reactions; stable formulation, under recommended storage and
handling conditions, with a neutral pH; and partially soluble in cold
water.

*Aviox Finish 77702* shouldn't enter drains and watercourses, and the
disposal is performed in accordance with the applicable regulations.

*Aviox Finish 77702* contains substances presenting a health or
environmental hazard within the meaning of the Dangerous Substances
Directive 67/584/EEC, which are described in Table 20 with the
respective CAS numbers.

  --------------------------------------- -----------------------------------
  **Table 20. CAS numbers for Aviox       
  Finish 77702, white BAC 7067, Hardener  
  90150 and Activator 99321**             

  **Chemical**                            **CAS Number**

  **Aviox Finish 77702, white BAC 7067**  

  n-butyl acetate                         123-86-4

  Polyester polyol                        \-\--

  Cyclohexanone                           108-94-1

  Xylene                                  1330-20-7

  Decanedioic acid, bis                   41556-26-7
  (1,2,2,6,6-pentamethyl-4-piperidinyl)   
  ester                                   

  Acrylates/metacrylates                  \-\--

  Decanedioic acid, methyl                82919-37-7
  (1,2,2,6,6-pentamethyl-4-piperidinyl)   
  ester                                   

  **Hardener 90150**                      

  Hexane, 1,6-diisocyanato-, homopolymer  28182-81-2

  4-methylpentan-2-one                    108-10-1

  Hexamethylene-di-isocyanate             822-06-0

  **Activator 99321**                     

  4-methylpenran-2-one                    108-10-1

  Pentane-2,4-dione                       123-54-6

  Propanoic acid, 3-ethoxy-, ethyl ester  763-69-9

  Dibutyltin dilaurate                    77-58-7
  --------------------------------------- -----------------------------------

**2.1.4. Health and Safety Issues**

The Threshold Limit Values (TLV) of the chemicals of the Aviox Painting
Scheme were collected from the Portuguese Norm NP 1796:2004 and from the
publication Threshold Values for Chemical Substances and Physical Agents
of the American Conference of Governmental Industrial Hygienists (ACGIH)
(See Table 21).

+----------------+----------------+----------------+-----------------+
| **Table 21.    |                |                |                 |
| Chemicals --   |                |                |                 |
| Worker         |                |                |                 |
| Exposure       |                |                |                 |
| Limits**       |                |                |                 |
+----------------+----------------+----------------+-----------------+
| **Chemical**   | **CAS No.**    | **TVL/ACGIH**  | **TWA/PEL^1^**  |
|                |                |                |                 |
|                |                | **(ppm)**      | **(mg/m^3^)**   |
+----------------+----------------+----------------+-----------------+
| **Cleaner M    |                |                |                 |
| 790E**         |                |                |                 |
+----------------+----------------+----------------+-----------------+
| Propan-2-ol    | 67-63-0        | 400            | 999             |
+----------------+----------------+----------------+-----------------+
| Butan-1-ol;    | 71-36-3        | 20             | STEL^2^: 154    |
|                |                |                | mg/m^3^         |
+----------------+----------------+----------------+-----------------+
| **Aviox CF     |                |                |                 |
| Primer (TC)**  |                |                |                 |
+----------------+----------------+----------------+-----------------+
| 4-Meth         | 108-10-1       | 50             | 208             |
| ylpentan-2-one |                |                |                 |
+----------------+----------------+----------------+-----------------+
| Xylene         | 1330-20-7      | 100            | 220             |
+----------------+----------------+----------------+-----------------+
| Ethylbenzene   | 100-41-4       | 100            | 441             |
+----------------+----------------+----------------+-----------------+
| **Aviox Finish |                |                |                 |
| 77702**        |                |                |                 |
+----------------+----------------+----------------+-----------------+
| n-butyl        | 123-86-4       | 150            | 724             |
| acetate        |                |                |                 |
+----------------+----------------+----------------+-----------------+
| Cyclohexanone  | 108-94-1       | 25             | 10 ppm          |
+----------------+----------------+----------------+-----------------+
| Xylene         | 1330-20-7      | 100            | 220             |
+----------------+----------------+----------------+-----------------+

^1^ TWA/PEL -- Time Weighted Average / Permissible Exposure Limits (8
hours)

^2^ STEL -- Short Term Exposure Limit (15 minutes)

Ventilation is required to maintain airborne contaminants below the TLVs
and PELs. In addition, personal protective equipment is required, such
as eye goggles or face shields, neoprene or polyvinyl gloves,
appropriate protective clothing, and a dust filter mask or respirator.
Chemicals are harmful by inhalation and in contact with skin, irritating
to eyes, respiratory system and skin, toxic to aquatic organisms, and
the vapors may cause drowsiness and dizziness.

**2.1.5. Additional Supporting Literature**

**2.2. PreKote Surface Pretreatment -- Pantheon Chemical**

PreKote SP, from Pantheon Chemical, is a non-chromated pre-treatment for
use on metal and composite substrates to enhance the bond between
coatings and various surfaces. PreKote SP can be used on aluminium,
steel, magnesium, titanium, CRES, galvanized surfaces, composite and
plastic surfaces.

According with Pantheon Chemical PreKote SP cleans the surface to be
painted while enhancing the adhesion of the coatings and improves
corrosion protection. This process deposits a molecular layer that bonds
to the surface of metal or composite material. This layer allows the
coating, when applied, to get closer to the substrate surface creating a
bond with the surface.

PreKote SP is not a conversion coating, does not permanently change the
surface of the substrate, and is designed to be an integral part of the
coating system.

**2.2.1. Process Description**

PreKote SP can be applied using different methods: manual, spray, power
wash or immersion.

[Immersion Process for Aluminum]{.underline}:

1.  *Clean:* the used product is X-IT Platinum (Pantheon Chemical) at a
    temperature of 110º-130ºF (43-54ºC) and between 2 to 5 minutes.

2.  *Rinse in Cold Water or De-ionized Water:* rinse during 2-5 minutes
    at a temperature of 110º-130ºF (43-54ºC).

3.  *Deoxidize:* can be used any deoxidizer product and the application
    must be as per manufacturer recommendation.

4.  *Rinse in Cold Water or De-ionized Water:* rinse during 2-5 minutes
    at maximum temperature of 110ºF (43ºC).

5.  *PreKote SP:* application of PreKote SP at maximum temperature of
    110ºF (43ºC) during 2-5 minutes without any circulation.

6.  *Rinse in De-ionized Water:* rinse during 2-5 minutes at a
    temperature of 110º-130ºF (43-54ºC).

7.  *Dry:* As required.

[Spray Process for Aluminum]{.underline}:

1.  *Clean:* the used product is X-IT Platinum (Pantheon Chemical) at a
    temperature of 110º-130ºF (43-54ºC) and 20-30 psi pressure during 60
    sec.

2.  *Rinse in Cold Water or De-ionized Water:* rinse during 60 sec at a
    temperature of 110º-130ºF (43-54ºC).

3.  *Deoxidize:* can be used any deoxidizer product and the application
    must be at a temperature of 110º-130ºF (43-54ºC) and 20-30 psi
    pressure during 60 sec.

4.  *Rinse in Cold Water or De-ionized Water:* rinse during 60 sec at
    room temperature.

5.  *PreKote SP:* application of PreKote SP at maximum temperature of
    110ºF (43ºC), at a pressure of 15-20 psi during 90 sec.

6.  *Rinse in De-ionized Water:* rinse during 60 sec at a temperature of
    110º-130ºF (43-54ºC) and 15-20 psi pressure.

7.  *Dry:* As required.

[Aircraft Application Process]{.underline}:

1.  *PreKote First Application:* application of PreKote SP to the
    surface being prepared, creating a "flood type coating". The
    application must start from the top and work down. The surface must
    be completely scrubbed with a 180-240 grit alumina oxide pad to
    generate a rich lather. Start from top and work down. A pneumatic
    power buffer or pole scrubber may be used. Pay particular attention
    to leading edges and other high-erosion areas. Let PreKote dwell for
    approximately 2 minutes and then proceed to step 2.

2.  *PreKote Second Application:* flood surface again with PreKote. The
    surface must be again completely scrubbed with a 180-240 grit
    alumina oxide pad to generate a rich lather. Start from top and work
    down.

3.  *Water Rinsing:* rinse the aircraft thoroughly and allow drying. The
    aircraft is ready for primer and paint application.^1^

^1^Note: If the aircraft is exposed to significant airborne
contamination prior to priming/painting, all surfaces should be wiped
down with a clean, PreKote moistened, lint-free cloth.

**2.2.2. Technical Considerations**

PreKote SP has been subject to laboratory tests over the last eight
years.

PreKote was approved for use on the F-16, of USAF, in 1998. In 2003, use
of PreKote was mandated by the Air Education and Training Command (AETC)
of the USAF.

The next tables present tests that verify acceptable performance of
chemical conversion coatings as Group 2 coatings. This group represents
painted surfaces requiring maximum paint to substrate adhesion. Group 2
chemical conversion coatings increase adhesion on parts requiring paint
or primer for end use that normally exhibit poor adhesion on the bare
substrate.

[General Requirements]{.underline}

+----------+------+----------------------------------------------------+
| **Table  |      |                                                    |
| 22.      |      |                                                    |
| General  |      |                                                    |
| Requ     |      |                                                    |
| irements |      |                                                    |
| Tests    |      |                                                    |
| for      |      |                                                    |
| Group 2  |      |                                                    |
| Co       |      |                                                    |
| atings** |      |                                                    |
+----------+------+----------------------------------------------------+
| **Test** | **R  | **Reference**                                      |
|          | esul |                                                    |
|          | ts** |                                                    |
+----------+------+----------------------------------------------------+
| Repar    | Pass | Boeing Seattle, Paint Softening, D6-17487/ASTM     |
| ability/ |      | F502                                               |
| Compa    |      |                                                    |
| tibility |      |                                                    |
+----------+------+----------------------------------------------------+
| Humidity | Pass | Boeing Seattle BMS10-11, Test 24. 8.2.16 HUMIDITY  |
| Re       |      |                                                    |
| sistance |      | Use three or more Class C panels. The panels shall |
|          |      | be suspended in a humidity cabinet in accordance   |
|          |      | with BSS7250. The cabinet shall operate at 120° ±  |
|          |      | 1.8 °F with condensing humidity conditions \[for   |
|          |      | 32 days\]. Panel evaluation after exposure shall   |
|          |      | include adhesion in accordance with Section 8.2.8. |
|          |      |                                                    |
|          |      | Class C panels = 4 by 6 by 0.020 inch **bare**     |
|          |      | 2024--T3 aluminum alloy in accordance with         |
|          |      | QQ--A--250/4 with conversion coating in accordance |
|          |      | with BAC5719, Type I, Class A. These are the only  |
|          |      | panels that should be non-clad aluminum.           |
|          |      |                                                    |
|          |      | \*\*Note\*\* -- Clad panels were substituted in    |
|          |      | lieu of bare panels to account for the difference  |
|          |      | between the interior and exterior fuselage skins   |
|          |      | (the condensing humidity test is currently called  |
|          |      | out in BMS10-11)                                   |
+----------+------+----------------------------------------------------+

[Adhesion Requirements]{.underline}

+----------+------+----------------------------------------------------+
| **Table  |      |                                                    |
| 23.      |      |                                                    |
| Adhesion |      |                                                    |
| Requ     |      |                                                    |
| irements |      |                                                    |
| Tests    |      |                                                    |
| for      |      |                                                    |
| Group 2  |      |                                                    |
| Co       |      |                                                    |
| atings** |      |                                                    |
+----------+------+----------------------------------------------------+
| **Test** | **R  | **Reference**                                      |
|          | esul |                                                    |
|          | ts** |                                                    |
+----------+------+----------------------------------------------------+
| Wet Tape | Pass | Boeing Seattle BMS10-72, Test 16. Scribe Adhesion  |
| Adhesion |      | (Wet and Dry)                                      |
|          | Pass |                                                    |
|          |      | 8.2.10.2 Cross--Hatch Test                         |
|          | Pass |                                                    |
|          |      | (3 panels 2024-T3/PreKote™, 3 panels               |
|          |      | 2024-T3/Alodine 1000L, 3 panels 7075-T6/PreKote™,  |
|          |      | 3 panels 7075-T6/Alodine 1000L)                    |
|          |      |                                                    |
|          |      | Prepare test panels in accordance with Section 8.1 |
|          |      | and cure for 7 days minimum.                       |
|          |      |                                                    |
|          |      | 1.  Subject the panels to fluid immersion, when    |
|          |      |     required. Wipe panels dry with clean dry       |
|          |      |     cheesecloth after tests.                       |
|          |      |                                                    |
|          |      | Procedure:                                         |
|          |      |                                                    |
|          |      | \(1\) Test in accordance with BSS7225, Type I,     |
|          |      | Class 5 and Type III, Class 5.                     |
|          |      |                                                    |
|          |      | \(2\) Examine panel for film failures. Check tape  |
|          |      | for film removal.                                  |
|          |      |                                                    |
|          |      | \(3\) A retest is required if a primer adhesion    |
|          |      | failure occurs.                                    |
|          |      |                                                    |
|          |      | ESCTP Phase 1 Report, [Nonchromated Aluminum       |
|          |      | Pretreatments]{.underline}, Project #PP025, Pgs    |
|          |      | 29-39                                              |
|          |      |                                                    |
|          |      | [Non-Chromate Pre-treatments vs. Non-Chromate      |
|          |      | Primers Final Report]{.underline}                  |
|          |      |                                                    |
|          |      | Contract No. F42620-00-D-0039-0001, UDRI Tracking  |
|          |      | No. UDRI-2187-F2-02. Pg 7, 8                       |
+----------+------+----------------------------------------------------+
| Fle      | Pass | [Non-Chromate Pre-treatments vs. Non-Chromate      |
| xibility |      | Primers Final Report]{.underline}                  |
|          |      |                                                    |
| (Ambient |      | Contract No. F42620-00-D-0039-0001, UDRI Tracking  |
| Impact;  |      | No. UDRI-2187-F2-02. Pg 14, 15 Ambient             |
|          |      | Temperatures                                       |
| Low      |      |                                                    |
| Temp     |      |                                                    |
| erature) |      |                                                    |
+----------+------+----------------------------------------------------+

[Corrosion Resistance Requirements]{.underline}

+----------+------+----------------------------------------------------+
| # **     |      |                                                    |
| Table 24 |      |                                                    |
| . Corros |      |                                                    |
| ion Resi |      |                                                    |
| stance R |      |                                                    |
| equireme |      |                                                    |
| nts Test |      |                                                    |
| s for Gr |      |                                                    |
| oup 2 Co |      |                                                    |
| atings** |      |                                                    |
+----------+------+----------------------------------------------------+
| **Test** | **R  | # **Reference**                                    |
|          | esul |                                                    |
|          | ts** |                                                    |
+----------+------+----------------------------------------------------+
| Salt     | Pass | # Boeing Seatt                                     |
| Spray    |      | le BMS10-72, Test \# 20 a. -- 3000 hour Salt Spray |
|          | Pass |                                                    |
|          |      | (3 panels 2024-T3/PreKote™, 3 panels               |
|          | Pass | 2024-T3/Alodine 1000L, 3 panels 7075-T6/PreKote™,  |
|          |      | 3 panels 7075-T6/Alodine 1000L)                    |
|          |      |                                                    |
|          |      | 8.2.14.1 Salt Spray                                |
|          |      |                                                    |
|          |      | 1.  Prepare test panels in accordance with Section |
|          |      |     8.1 and cure for 7 days minimum.               |
|          |      |                                                    |
|          |      | 2.  \[Machine\] Scribe two diagonal marks from     |
|          |      |     corner to corner through the coating down to   |
|          |      |     the base metal.                                |
|          |      |                                                    |
|          |      | 3.  Expose test panels to 3000 hours minimum of 5  |
|          |      |     percent salt spray fog in accordance with      |
|          |      |     BSS7249, except place panels on an incline of  |
|          |      |     6 degrees from vertical (painted side up).     |
|          |      |                                                    |
|          |      | 4.  Examine the test panel for corrosion. Conduct  |
|          |      |     adhesion test in accordance with 8.2.10.1.     |
|          |      |                                                    |
|          |      | ESCTP Phase 1 Report, [Nonchromated Aluminum       |
|          |      | Pretreatments]{.underline}, Project #PP025, Pgs    |
|          |      | 54, 3000 hrs, ASTM B117, Navair, Patuxent River,   |
|          |      | MD, AL2024 w/Mil-PRF-23377or 85582Cl2 primer.      |
|          |      |                                                    |
|          |      | [Non-Chromate Pre-treatments vs. Non-Chromate      |
|          |      | Primers Final Report]{.underline}                  |
|          |      |                                                    |
|          |      | Contract No. F42620-00-D-0039-0001, UDRI Tracking  |
|          |      | No. UDRI-2187-F2-02. Pg 9, 10                      |
+----------+------+----------------------------------------------------+
| SO       | Pass | ESCTP Phase 1 Report, [Nonchromated Aluminum       |
| ~2~/Salt |      | Pretreatments]{.underline}, Project #PP025, Pgs    |
|          |      | 59-61, ASTM G85 Annex 4, Navair, Patuxent River,   |
|          |      | MD, AL2024 w/Mil-PRF-23377or 85582Cl2 primer       |
+----------+------+----------------------------------------------------+
| Filiform | Pass | [Non-Chromate Pre-treatments vs. Non-Chromate      |
|          |      | Primers Final Report]{.underline}                  |
|          | Pass |                                                    |
|          |      | Contract No. F42620-00-D-0039-0001, UDRI Tracking  |
|          |      | No. UDRI-2187-F2-02. Pg 13                         |
|          |      |                                                    |
|          |      | # Boeing Seattle BMS10-72, Test \# 20 b. Fili      |
|          |      | form Corrosion, Machined Scribe (3 panels 2024-T3/ |
|          |      | PreKote™, 3 panels 2024-T3/Alodine 1000L, 3 panels |
|          |      |  7075-T6/PreKote™, 3 panels 7075-T6/Alodine 1000L) |
|          |      |                                                    |
|          |      | 8.2.14.2 Filiform Corrosion                        |
|          |      |                                                    |
|          |      | 1.  Prepare test panels in accordance with Section |
|          |      |     8.1, except dry film thickness of enamel shall |
|          |      |     be 4.0 ± 0.5 mils.                             |
|          |      |                                                    |
|          |      | > 8.2.14.2 Filiform Corrosion 2024--T3 Clad        |
|          |      | > Aluminum 4 × 6 × 0.040 inch                      |
|          |      |                                                    |
|          |      | 2.  Machine two diagonal lines to the base metal   |
|          |      |     in accordance with BSS7258, Type I.            |
|          |      |                                                    |
|          |      | 3.  Expose panels in accordance with BSS7258 for   |
|          |      |     30 days minimum.                               |
|          |      |                                                    |
|          |      | 4.  Examine panels for corrosion, blisters, and    |
|          |      |     other film failures.                           |
+----------+------+----------------------------------------------------+

[Fluids Resistance Requirements]{.underline}

+----------+------+----------------------------------------------------+
| **Table  |      |                                                    |
| 25.      |      |                                                    |
| Fluids   |      |                                                    |
| Re       |      |                                                    |
| sistance |      |                                                    |
| Requ     |      |                                                    |
| irements |      |                                                    |
| Tests    |      |                                                    |
| for      |      |                                                    |
| Group 2  |      |                                                    |
| Co       |      |                                                    |
| atings** |      |                                                    |
+----------+------+----------------------------------------------------+
| **Test** | **R  | **Reference**                                      |
|          | esul |                                                    |
|          | ts** |                                                    |
+----------+------+----------------------------------------------------+
| Fluid    | Pass | [Non-Chromate Pre-treatments vs. Non-Chromate      |
| Re       |      | Primers Final Report]{.underline}                  |
| sistance |      |                                                    |
|          |      | Contract No. F42620-00-D-0039-0001, UDRI Tracking  |
|          |      | No. UDRI-2187-F2-02. Pg 7                          |
+----------+------+----------------------------------------------------+
| Fuels    | Pass | [Non-Chromate Pre-treatments vs. Non-Chromate      |
| Re       |      | Primers Final Report]{.underline}                  |
| sistance |      |                                                    |
|          |      | Contract No. F42620-00-D-0039-0001, UDRI Tracking  |
|          |      | No. UDRI-2187-F2-02. Pg 7                          |
+----------+------+----------------------------------------------------+

[Marine Atmospheric Test on Scribed Painted Substrates
Requirement]{.underline}

  ------------- ------------- ----------------------------------------------------
  **Table 26.                 
  Marine                      
  Atmospheric                 
  Test on                     
  Scribed                     
  Painted                     
  Substrates                  
  Requirement                 
  Tests for                   
  Group 2                     
  Coatings**                  

  **Test**      **Results**   **Reference**

  Beach Test,   Pass          ESCTP Phase 1 Report, [Nonchromated Aluminum
  NASA, Kennedy               Pretreatments]{.underline}, Project #PP025, Pgs 84,
  Space Center,               12 months Exposure AL2024 w/Mil-PRF-23377or 85582Cl2
  FL                          primer.
  ------------- ------------- ----------------------------------------------------

[Rain Erosion Requirement]{.underline}

+---------+-------+---------------------------------------------------+
| # *     |       |                                                   |
| *Table  |       |                                                   |
| 27. Rai |       |                                                   |
| n Erosi |       |                                                   |
| on Requ |       |                                                   |
| irement |       |                                                   |
|  Test f |       |                                                   |
| or Grou |       |                                                   |
| p 2 Coa |       |                                                   |
| tings** |       |                                                   |
+---------+-------+---------------------------------------------------+
| *       | *     | # **Reference**                                   |
| *Test** | *Resu |                                                   |
|         | lts** |                                                   |
+---------+-------+---------------------------------------------------+
| Boeing  | Pass  | # BMS10-72, Test #23 - Rain Erosion               |
| Seattle |       |                                                   |
|         |       | Use all 8 rain erosion foils, 4 foils have        |
|         |       | PreKote™ and 4 foils have Alodine 1000L.          |
|         |       |                                                   |
|         |       | 1.  Immerse foils in water at 75 ±5 F for 16 to   |
|         |       |     24 hours just prior to test. Start test       |
|         |       |     within 1 hour maximum after removal from      |
|         |       |     water.                                        |
|         |       |                                                   |
|         |       | 2.  Expose specimens to 385 miles per hour (at    |
|         |       |     specimen midpoint) with 3 to 4 inches per     |
|         |       |     hour water spray (1 to 4 mm drop size) for 30 |
|         |       |     minutes set time.                             |
|         |       |                                                   |
|         |       | Check and measure erosion peeling from paint      |
|         |       | leading edges                                     |
+---------+-------+---------------------------------------------------+

**2.2.3. Environmental Issues**

According with the PreKote Material Safety Data Sheet (MSDS), PreKote is
water-based, biodegradable, non-toxic, non-hazardous, non-flammable,
non-corrosive and stable formulation with a pH range from 10.0 to 11.5.
The MSDS also lists the health hazardous from exposure to PreKote as
slight and the flammability, reactivity and contact hazards as
insignificant.

The ingredients Diethylene Glycol Monobutyl Ether, \<3%, CAS No.
112-35-5 and N-Methylpyrrolidone (NMP), \<3%, CAS No. 872-50-4; are
contained in the formulation and is subject to reporting requirements
under SARA Title III Section 313 Part 372. All other ingredients are on
the TSCA Inventory.

**2.2.4. Health and Safety Issues**

Personal protective goggles must be utilized. It is not necessary to
have respiratory and ventilation control measures.

Nevertheless, avoid prolonged contact with skin and wash after handling.

**2.2.5. Additional Supporting Literature**

-   Air Education and Training Command, July 1999, *AETC Test Project:
    Surface Conversion Coating -- Qualification Operational Test and
    Evaluation Final Report*, Randolph Air Force Base, Texas.

-   Buchi, Richard H.; Patterson, Ken; Gowers, Clyde J.; *Non-Chromate
    Conversion Coating -- Final Report*; Ogden Air Logistics Center
    Science and Engineering Laboratory, 3 April, 1998.

-   Air Force Corrosion Prevention and Control Office (AFCPCO),
    *Position on PreKote*, February 2004.

-   United States Environmental Protection Agency (EPA); *Regulatory
    Determination for the PreKote Surface Preparation Process*;
    Washington, D.C., 1 April, 2003.

-   Roberts, Laura; Galanis, Anthony; *Proven Non-Chromated Technology*;
    Pantheon Chemical.

-   Palermo, David; *Environmentally Sustainable Business in Aerospace
    Trough Innovative Technology*; Pantheon Chemical, Phoenix.

-   Christopher A. Joseph; *Non-Chromate Pre-Treatments vs. Non-Chromate
    Primers -- Final Report*; University of Dayton Research Institute
    (UDRI), 17 March, 2003, Dayton, OH.

-   Material Safety Data Sheet (MSDS) on PreKote Surface Treatment,
    Pantheon Chemical, May 2004.

-   Boeing Commercial Airline Approval Letter on PreKote Surface
    Treatment, 22 April, 2004.

-   PreKote SP Immersion and Spray Application Process for Aluminum,
    Pantheon Chemical.