# PROPOSED August 18, 2011

   	
 
 RULE 4684 POLYESTER RESIN OPERATIONS (Adopted May 1 9, 1994; Amended

December 20, 2001; Amended September 20, 2007; Amen ded September 17, 2009; Amended [ rule adoption date ])

1.0 Purpose

The purpose of this rule is to reduce emissions of volatile organic compounds (VOC) from polyester resin operations, fiberglass boat ma nufacturing operations and the organic solvent cleaning, and the storage and dispo sal of solvents and waste solvent materials associated with such operations.

2.0 Applicability

The provisions of this rule apply to commercial and industrial polyester resin operations, fiberglass boat manufacturing operation s, and to the organic solvent cleaning, and the storage and disposal of all solve nts and waste solvent materials associated with such operations.

3.0 Definitions

The following definitions apply for the purpose of this rule.

3.1 Air Pollution Control Officer (APCO): as defin ed in Rule 1020 (Definitions).

3.2 Application Equipment: a device, including, bu t not limited to, a spray gun, brush, and roller, used to apply adhesives, coating s, or inks.

3.3 ARB: California Air Resources Board.

3.4 Assembly Adhesive: any chemical material used in joining fiberglass, metal, foam, or wood parts to another to form a temporary or permanently bonded assembly. Assembly adhesives include, but are not limited to, methacrylate adhesives and putties made from polyester or vinyle ster resin mixed with inert

filler or fibers.

3.5 ASTM: American Society of Testing and Material s International.

3.6 Atomized Resin Application: a resin applicatio n technology in which the resin leaves the application equipment and breaks into dr oplets or an aerosol as it travels from the application equipment to the surfa ce of the part. Atomized resin application includes, but is not limited to, resin spray guns and resin chopper spray guns.

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 3.7 Bench Scale Project: a project (other than at a research and development facility) that is operated on a small scale, such a s one capable of being located on a laboratory bench top.

3.8 Catalyst: a substance that is added to resin t o initiate or promote polymerization.

3.9 CFR: Code of Federal Regulations.

3.10 Cleaning Materials: materials including, but not limited to, materials used for cleaning hands, tools, molds, application equipment , and work areas.

3.11 Clear Gel Coat: a gel coat that is clear or t ranslucent so that underlying colors are visible. Clear gel coat is used to manufacture parts for sale. Clear gel coat do not include tooling gel coat used to build or re pair molds.

3.12 Closed Molding Process: any molding process i n which pressure is used to distribute the resin through the reinforcing fabric placed between two mold

surfaces to either saturate the fabric or fill the mold cavity. The pressure may be clamping pressure, fluid pressure, atmospheric p ressure, or vacuum pressure used either alone or in combination. The mold surf aces may be rigid or flexible. Closed molding includes, but is not limi ted to, compression molding with sheet molding compound, infusion molding, resi n injection molding (RIM), vacuum-assisted resin transfer molding (VARTM), res in transfer molding (RTM), and vacuum-assisted compression molding. Pr ocesses in which a closed mold is used only to compact saturated fabric or re move air or excess resin from the fabric (such as in vacuum bagging) are not cons idered closed molding. Open molding steps, such as application of gel coat or skin coat layer by conventional open molding prior to a closed molding process are not closed molding.

3.13 Coating: a material applied onto or impregnat ed into a substrate for protective, decorative, or functional purposes. Such materials include, but are not limited to, paints, varnishes, sealers, and stains.

3.14 Corrosion–Resistant Material: a polyester res in material used to make products for corrosion resistant applications such as toolin g, fuel or chemical tanks, boat hulls, pools and outdoor spas.

3.145 Cure: to polymerize, i.e., to transform from a liquid to a solid state or semisolid state to achieve desired physical properties for the product, including

hardness.

3.156 Cured Coating: a coating that is dry to the touch.

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 3.167 Degreaser: a tank, tray, drum or other conta iner in which objects to be cleaned are exposed to a solvent or solvent vapor in order to remove contaminants. The objects to be cleaned include, but are not limited to, parts, products, tools, machinery, and equipment. An enclosed spray applic ation equipment cleaning system is not a degreaser.

3.178 Dissolver: an organic solvent that is added to an adhesive, coating, or ink in order to melt or to liquefy solid particles.

3.189 EPA: United States Environmental Protection Agency.

3.1920 Fiberglass Boat: a vessel in which either t he hull or deck is built from a composite material consisting of thermosetting resi n matrix reinforced with fibers of glass, carbon, or other material.

3.201 Fiberglass Boat Manufacturing: facilities th at manufacture hulls or decks of boats from fiberglass, or build molds to make fiber glass boat hulls or decks. Facilities that manufacture solely parts of boats ( such as hatches, seats, or lockers), or boat trailers, but do not manufacture boat hulls or decks from fiberglass or build molds to make fiberglass boats or hulls are not considered fiberglass boat manufacturing. A facility that man ufactures hulls or decks, or molds for hulls or decks, and other fiberglass boat parts, including small parts such as hatches, seats, and lockers, is considered fiberglass boat manufacturing. Fiberglass boat manufacturing operation include ope n molding resin and gel coat operations (these include pigmented gel coat, clear gel coat, production resin, tooling gel coat, and tooling resin), resin and gel coat mixing operations, and resin and gel coat application equipment cleaning o perations.

3.22 Filament Application: a method of applying re sin to an open mold that involves feeding reinforcement fibers through a resin bath a nd winding the resinimpregnated fibers on a rotating mandrel.

3.23 Filled Polyester Resin Material: a material f ormulated by adding compatible filler(s) to polyester resin material(s).

3.24 Filler: a finely divided inert (non-VOC) mate rial, which may be added to the resin to enhance its mechanical properties and exte nd its volume. Resin fillers include, but are not limited to, silica, carbon bla ck, talc, mica and calcium

carbonate.

3.25 Fire Retardant Material: a polyester resin ma terial used to make products that

are resistant to flame or fire.

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 3.26 Fluid Impingement Technology: a spray gun that produces an expanding nonmisting curtain of liquid by the impingement of low -pressure uninterrupted liquid streams.

3.217 Gel Coat: a polyester resin topcoat that pro vides a cosmetic enhancement and improves resistance to degradation from environment al exposure.

3.228 Grams of VOC per liter of material: grams VO C per liter of material is

determined as follows: Grams VOC per liter of material = (W
s - W w - W es ) / V
m

Where:

W s = weight of all volatile compounds, in grams

W w = weight of water, in grams

W es = weight of exempt solvents, in grams

V m = volume of the material, in liters

3.29 High-Strength Material: a polyester resins wh ich have a casting tensile strength of 10,000 psi or more and which are used primarily for manufacturing high performance boats and skis.

3.2330 High-Volume, Low-Pressure (HVLP) Spray Equip ment: equipment used to apply materials by means of a spray gun which is designed and intended to be operated, and which is operated, between 0.1 and 10.0 psig of air atomizing pressure, measured dynamically at the center of the air cap a nd the air horns.

3.31 Lamination Resin: an orthophthalate, isophtha late and dicyclopentadiene (DCPD) resin which is used in composite system made of layers of reinforcement fibers and resins, such as in boat fa brication.

3.2432 Liquid Leak: a visible solvent leak from a container at a rate of more than three drops per minute, or a visible liquid mist.

3.2533 Maintenance Cleaning: the cleaning of tools , forms, molds, jigs, machinery, and equipment (except coating application equipment , ink application equipment, or adhesive application equipment), and the cleaning of work areas where maintenance or manufacturing occurs.

3.34 Manual Application: the application of resin to an open mold using a hand layup technique. Components of successive plies of re sin-impregnated reinforcement fibers are applied using hand tools s uch as brushes and rollers.

# PROPOSED August 18, 2011

  	
 
 3.2635 Manufacturing Process: the process of makin g goods or articles by hand or by

machine.

3.36 Marble Resin: an orthophthalate and modified acrylic isophthalate resin, which is designed for the fabrication of cast products, s uch as vanities.

3.2737 Mold: the cavity or surface into or on whic h gel coat, resin, and fibers are placed and from which finished fiberglass parts tak e their form.

3.2838 Monomer: an organic compound, such as styre ne, that reacts with unsaturated polyester resins to form a cured polyester resin.

3.2939 Month: a calendar month.

3.3040 Neat Resin: a resin to which no filler has been added.

3.3141 Non-Absorbent Container: a container made o f non-porous material that does not allow the migration of solvents through it.

3.3242 Non-Atomized Resin Application: any applica tion technology in which the resin is not broken into droplets or an aerosol as it tra vels from the application equipment to the surface of the part. Non-atomized resin application technology includes, but are not limited to, non-atomizing spr ay guns, flowcoaters, chopper flowcoaters, pressure fed resin rollers, resin impr egnators, or fluid impingement technology., and hand application (for example, pai nt brush or paint roller).

3.3343 Non-Atomized Solvent Flow: solvents in the form of a liquid stream without the introduction of any propellant.

3.44 Non-Atomizing Spray Gun: a spray gun from whi ch the resin flows in a steady and observable coherent flow, with no droplets form ed in the area that is within the first three (3) inches of the applicator orific e. Droplets may form in the area greater than three (3) inches from the applicator o rifice.

3.345 Non-Leaking Container: a container without a liquid leak.

3.3546 Normal Business Hours: Monday through Frida y, 8:00 am to 5:00 pm.

3.3647 Open Molding Resin and Gel Coat Process: an y process in which the reinforcing fibers and resin are placed in the mold and are open to the surrounding air while the reinforcing fibers are sa turated with resin. For the purpose of this rule, open molding includes operati ons in which a vacuum bag or similar cover is used to compress the uncured la minate to remove bubbles or excess resin, or to achieve a bond between core mat erial and a laminate.

# PROPOSED August 18, 2011

   	
 
 3.3748 Organic Solvent: the same as “Solvent.”

3.3849 Organic Solvent Cleaning: as defined in Rul e 4663 (Organic Solvent Cleaning, Storage, and Disposal).

3.3950 Pigmented Gel Coat: opaque gel coat used to manufacture parts for sale. Pigmented gel coat does not include tooling gel coa t used to build or repair

molds.

3.4051 Polyester Resin Materials: materials includ ing, but not limited to: unsaturated polyester resins such as isophthalic, orthophthalic , halogenated, Bisphenol-A, vinyl-ester, or furan resins; cross-linking agents; catalysts, gel coats, inhibitors, accelerators, promoters, and any other materials us ed in polyester resin operations.

3.4152 Polyester Resin Operations: methods used fo r the production or rework of products by mixing, pouring, hand layup, impregnati ng, injecting, forming, winding, spraying, and/or curing with fiberglass, f illers, or any other reinforcement materials and associated cleanup.

3.4253 Polymer: a chemical compound comprised of a large number of chemical units and which is formed by chemical linking of monomers

.

3.54 Production Resin: a general purpose resin mat erial that is not especially corrosion resistant, fire retardant, high strength, or gel coats.

3.4355 Propellant: any gas, including air, in a pr essure container for expelling the contents when the pressure is released.

3.4456 Repair Cleaning: a solvent cleaning operati on or activity carried out during a repair process.

3.4557 Repair Process: the process of returning a damaged object or an object not operating properly to good condition.

3.4658 Research and Development: a facility or por tion thereof used to further the development of useful materials, devices, systems, or methods, including, but not limited to, design, development, and improvemen t of prototypes and processes. Research and development does not inclu de the manufacturing process itself.

# PROPOSED August 18, 2011

  	
 
 3.4759 Resin: any of a class of organic polymers o f natural or synthetic origin used in reinforced products to surround and hold fibers or filler particles, and is solid or

semisolid in the cured state.

3.4860 Resin and Gel Coat Operation: any operation in which resin or gel coat, including the mixing of putties or polyputties, is combined with additives that include, but are not limited to, fillers, promoters , or catalysts.

3.4961 SCAQMD: South Coast Air Quality Management District.

3.5062 Skin Coat: a layer of resin and fibers appl ied over gel coat to protect the gel coat from being deformed by the next laminate layer s.

3.63 Small Job: minor resin or gel coat applicatio n project which requires only a very limited amount of materials. Total material u se for all small jobs at a facility shall not exceed two (2) gallons a day.

3.64 Solid Surface Resin: a resin, which is used, without gel coats, to fabricate homogenous solid surface products.

3.5165 Solvent: as defined in Rule 4663 (Organic S olvent Cleaning, Storage, and Disposal).

3.66 Specialty Gel Coat: a gel coat which is used in conjunction with fire retardant, corrosion resistant or high-strength materials.

3.5267 Specialty Resin: any halogenated, furan, bi sphenol A, vinyl-ester, or isophthalic resin used to make products for exposur e to one or more of the following extreme environmental conditions: acute o r chronic exposure to corrosive agents, caustic agents, acidic agents, or flame.

3. 5368Stationary Source: as defined in Rule 2201 (New and Modified Stationary Source Review Rule).

3. 5469Tooling Resin: the resins used to build or repair molds (also known as tools) or prototypes (also know as plugs) from which the mold s will be made.

3. 5570Tooling Gel Coat: the gel coat used to buil d or repair molds (also known as tools) or prototypes (also known as plugs) from whi ch the molds will be made.

3.71 Touch-up: The application of resin or gel coat to correct minor cosmetic imperfections that occur during fabrication or fiel d installations.

# PROPOSED August 18, 2011

   	
 
 3.72 Tub/Shower Resin: a dicyclopentadiene (DCPD) resin, along with orthophthalate and isophthalate resins, which are u sed to fabricate bathware products.

3.5673 Vapor Suppressant: a substance added to res in to minimize the transfer of monomer vapor into the atmosphere.

3.574 Vinylester Resin: a thermosetting resin cont aining esters of acrylic or methacrylic acids having a double-bond and ester li nkage sites at the end of the

resin molecules.

3.5875 Volatile Organic Compound (VOC): as defined in Rule 1020 (Definitions).

3.5976 Waste Materials: materials including but no t limited to paper or cloth used for cleaning operations, waste resins, or spent cleanin g materials.

4.0 Exemptions

4.1 Except for fiberglass boat manufacturing operat ions, the provisions of this rule, other than the recordkeeping requirements of Sectio n 6.1, shall not apply to any polyester resin operation provided the volume of po lyester resin materials used is less than 20 gallons per month.

4.2 For fiberglass boat manufacturing, production r esins (including skin coats) that must meet the specifications for use in military ve ssels or must be approved by

the U.S. Coast Guard for use in construction of lif eboats, rescue boats, and other life-saving appliances approved under 40 CFR subchapter Q, or to the construction of small passenger vessels regulated b y 46 CFR subchapter T are exempt from the requirements of Section 5.2.2. Pro duction resins that meet these criteria shall be applied with nonatomizing r esin application equipment.

4.3 The solvent cleaning provisions of Section 5.3 Table 34 shall not apply to the following applications:

4.3.1 Cleaning of solar cells, laser hardware, scie ntific instruments, or high precision optics.

4.3.2 Cleaning in laboratory tests and analyses, or bench scale or research and development projects.

5.0 Requirements

5.1 Polyester Resin Operation, Except for Fibergla ss Boat Manufacturing Subject to

Section 5.2.21

# PROPOSED August 18, 2011

  	
 
 5.1.1 An operator of a polyester resin operation sh all comply with one of the following process or control requirements:

5.1.1.1 Prior to January 1, 2013, Uuse low-VOC poly ester resins with the following monomer content: Low VOC resins, exc ept for specialty resins and gel coats, containing no more than 35% monomer by weight. Low VOC pigmented gel coats con taining no more than 45% monomer by weight. Low VOC specia lty resins and clear gel coats containing no more than 50% monomer by weight; or comply with Section 5.1.1.3; 5.1.1.4,

or 5.1.1.5.

5.1.1.2 On and after January 1, 2013, use materials in an open molding process that comply with the weighted average monom er VOC content limits in Table 1. In addition to complyin g with Table 1 limits, the non-monomer VOC content of each resin and gel coat shall not contain more than 5 percent by weigh t of the resin or gel coat; or comply with Section 5.1.1.3; 5.1.1.4, or

5.1.1.5.

Table 1: Compliant Materials Weighted Average Monom er VOC Content

for Open Molding Resin and Gel Coat

Material Weight Percent Limit on and after January 1, 2013 a. General Purpose Resin

- Marble Resin 10% or 32%, as supplied, with no fillers

- Solid Surface Resin 17%

- Tub/Shower Resin 24% or 35%, as supplied, with no fillers

- Lamination Resin 31% or 35%, as supplied, with no fillers b. Tooling Resin - Atomized (spray) 30%

- Non-atomized 39% c. Specialty Resin

- Fire Retardant Resin 38% - High Strength Materials 40%

- Corrosion Resistant Resin 48%

d. All Other Resin 35%

# PROPOSED August 18, 2011

   	
 
 Table 1: Compliant Materials Weighted Average Monom er VOC Content

for Open Molding Resin and Gel Coat (continued)

Material Weight Percent Limit on and after January 1, 2013 e. Tooling Gel Coat 40% f. Pigmented Gel Coat

- White and Off White 30%

- Non-White 37%

- Primer 28% g. Clear Gel Coat

- Marble Resin 40%

- Other Resin 44% h. Specialty Gel Coat 48%

5.1.1.23 Use resin containing a vapor suppressant, such that the weight loss from the VOC emissions does not exceed 50 60 g rams per square meter of exposed surface during resin polyme rization; or

5.1.1.34 Use a closed-mold system; or

5.1.1.45 Install and operate a VOC emissions contro l system which meets all of the requirements of Sections 5.1.1.45. 1 through 5.1.1.45.3 during periods of emission producing act ivities.

5.1.1. 45.1 The VOC emission control system shall b e

approved, in writing, by the APCO.

5.1.1. 45.2 During continuous operation, not to exc eed 24

hours, the The VOC emission control system shall have an overall capture and control efficiency of a t least 85 90 percent by weight, demonstrated using the applicable test method(s) in Section 6.2.

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 5.1.1.45.3 The VOC emission control system shall re duce VOC

emissions, at all times, to a level that is not gre ater
than the emission which would have been achieved through the use of compliant materials, compliant equipment, or compliant work practices, as applicable. The following equation shall be used t o determine if the minimum required overall capture and control efficiency of an emission control syste m is at an equivalent or greater level of VOC reducti on as would be achieved using compliant materials, equipment, or work practices:



## ( ) ( ) 100

x D / VOC c -1 D

/ VOC -1

x VOC VOC -1 = CE

c LW Max

n, Max LWn,

Max LWn, LWc    

           

Where:

CE = Minimum Required Control Efficiency

specified in Section 5.1.1.45.2 in percent.

VOC LWc = VOC content of applicable resin, gel coat, or

solvent of Rule 4684, less water and less exempt compounds.

VOC LWn,Max = Maximum VOC content of resin, gel coat, or

solvent, used in conjunction with a control device, less water and less exempt compounds.

D n,Max = Density of the noncompliant resin, gel coat, o r

solvent, containing the maximum VOC content of the multi-component material.

D c = Density of corresponding resin, gel coat or

solvent, used in the compliant resin, gel coat,

or solvent.

5.1.1.6 Resins and gel coats used for touch up, rep air, or small jobs, may have a monomer content limit up to 10% more tha n the applicable limit set forth in Table 1. Such resins or gel coats shall only be applied by a hand-held atomized spray gun which has a container for the resin or gel coat as part o f the gun. Resins or gels applied by another method shall comp ly with the applicable limit in Table 1. Total material use for all small jobs at a facility shall not exceed two (2) gallons a da y.

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 5.1.2 Spray application of polyester resin shall on ly be performed using airless, air assisted airless, high-volume, low-pre ssure (HVLP) spray equipment, or electrostatic spray equipment.

5.1.2.1 High-Volume, Low-Pressure (HVLP) spray equi pment shall be operated in accordance with the manufacturer's

recommendations.

5.1.2.2 For HVLP spray guns manufactured prior to J anuary 1, 1996, the end user shall demonstrate that the gun meets H VLP spray equipment standards. Satisfactory proof will be ei ther in the form of manufacturer's published technical material or by a demonstration using a certified air pressure tip ga uge, measuring the air atomizing pressure dynamically at the center of the air cap and at the air horns.

5.1.2.3 A person shall not sell or offer for sale f or use within the District any HVLP spray gun without a permanent mar king denoting the maximum inlet air pressure in psig at which the gun will operate within the parameters specified in Section 3.0.

5.1.3 In lieu of complying with the applicable requ irements of 5.1.2, an operator may install and maintain a VOC emission co ntrol system that meets the requirements of Section 5.1.1.45 around t he coating application operation.

5.2 Fiberglass Boat Manufacturing Operation

5.2.1 Requirements for Closed Molding Process

Effective on or after January 1, 2011, aAn opera tor of a fiberglass boat

manufacturing facility who uses a closed molding pr ocess, as defined in Section 3.0, shall comply with the applicable requi rements of Sections 5.1, 5.3, 5.4, and 6.0.

5.2.2 Requirements for Open Molding Process

5.2.2.1 Effective on and after January 1, 2011, aAn operator of a fiberglass boat manufacturing facility who uses an open molding process, as defined in Section 3.0, and who se total actual VOC emissions from all fiberglass boat manuf acturing operations, including related solvent cleaning acti vities, at a stationary source are equal to or greater than 2.7 tons of VOC per 12-month rolling period, before consideration o f controls,

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 shall comply with at least one of the Compliance Op tions in Section 5.2.2.4 through 5.2.2.6, and the applicable requirements of Sections 5.3, 5.4, and 6.0.

5.2.2.2 An operator subject to Section 5.2.2.1 shall comply with the applicable recordkeeping requirements of Section 6. 1 and calculate the fiberglass boat manufacturing facilit y emissions to demonstrate if the VOC emissions from all fiberglas s boat manufacturing operations, including related solvent cleaning activities, at a stationary source are equal to or greater than 2.7 tons of VOC per 12-month rolling period, before

consideration of controls.

5.2.2.3 An operator of an open molding process whos e total actual

VOC emissions from all fiberglass boat manufacturin g operations, including related solvent cleaning acti vities, at a stationary source are less than 2.7 tons of VOC pe r 12-month rolling period, before consideration of controls, s hall comply with the applicable requirements of Sections 5.1, 5 .3, 5.4, and 6.0. The operator shall comply with the applic able recordkeeping requirements of Section 6.1 and calcu late the fiberglass boat manufacturing facility emissions to demonstrate if the VOC emissions from all open molding fibergla ss boat manufacturing operations, including related cleanin g activities are less than 2.7 tons of VOC per 12-month rolling period.

5.2.2.4 Requirements for Compliant Materials

5.2.2.4.1 An operator subject to Sections 5.2. 2.1 shall not use materials in any open molding process that exceed the weighted average monomer VOC

content limits in Table 12. In addition to complying with Table 12 limits, the non-monomer VOC content of each resin and gel coat shall not contain more than 5 percent by weight of the resin or gel coat.

# PROPOSED August 18, 2011

  	
 
 Table 12: Compliant Materials Monomer VOC Content for Open Molding Resin and Gel Coat for Fiberglass Boat Manufacturing Operation

Material Application Method Weighted Average Monomer

VOC content (weight percent) limit Production Resin Atomized (spray) 28%

Production Resin Non-atomized 35% Pigmented Gel Coat Any method 33% Clear Gel Coat Any method 48% Tooling Resin Atomized 30% Tooling Resin Non-atomized 39% Tooling Gel Coat Any method 40%

5.2.2.4.2 The weighted average monomer VOC conten t shall be determined based on a 12-month rolling average. The operator shall use Equation 1 to determine weighted average monomer content for a particular open molding resin or gel coat material.

Equation 1:

Weighted Average Monomer VOC Content = 

## ∑ ∑

= =

n

1 i )i( n

1 i )i(

)i(

) M ( ) VOC M (

Where:

M (i) = mass of open molding resin or gel coat i used in the past 12 months in an operation, megagrams.

VOC (i) = Monomer VOC content, by weight percent, of open molding resin or

gel coat i used in the past 12 months in an operati on.

n = number of different open molding resins or gel coats used in the past

12 months in an operation.

5.2.2.5 Requirements for Emissions Averaging Opt ion

5.2.2.5.1 In lieu of complying with the requirem ents of

Section 5.2.2.4, an operator that is subject toSection 5.2.2.1 may comply by meeting a facilityspecific monomer VOC mass emission limit (12- month rolling average) that is determined using

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 Equation 2, provided all resins and gel coats included in this option do not exceed 5 percent by weight non-monomer VOC content.

5.2.2.5.2 At the end of the first 12-month avera ging period and at the end of every subsequent month, the operator shall use Equation 3 to show that the monomer VOC emissions from the operations included in the average do not exceed the emission limit calculated using Equation 2 for the same 12- month period. The operator shall include in Equation 2 and Equation 3 the terms for only those operations and materials included in the average.

5.2.2.5.3 For those materials that are not inclu ded in the emissions average, the facility would resort to one of the other two options for limiting monomer and non-monomer VOC emissions from resin and gel

coats.

Equation 2:

Monomer VOC Limit = 46(M R ) + 159 (M PG ) + 291(M CG ) + 54(M TR ) + 214(M TG )

Where:

Monomer VOC Limit = Total allowable monomer VOC tha t can be emitted from open molding operations included in the average, ki lograms per 12-month period.

M R = Mass of production resin used in the past 12 mont hs,

excluding any materials that are exempt pursuant to Section 4.2, in megagrams.

M PG = Mass of pigmented gel coat used in the past 12 mo nths,

excluding any materials that are exempt pursuant to Section 4.2, in megagrams.

M CG = mass of clear gel coat used in the past 12 months , excluding any materials that are exempt, in megagrams.

M TR = mass of tooling resin used in the past 12 months, e xcluding any materials that are exempt pursuant to Section 4 .2, in

megagrams.

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 M TG = mass of tooling gel coat used in the past 12 months

, excluding any materials that are exempt pursuant to Section 4.2, in megagrams.

Equation 3:

Monomer VOC Emissions = (PV R )(M R )+(PV PG )(M PG )+(PV CG )(M CG )+(PV TR )(M TR )+ (PV TG )(M TG )

Where:

Monomer VOC Emissions = Monomer VOC emissions calcu lated using the monomer VOC emission equations for each operation included in the average, in kilograms.

PV R = Weighted-average monomer VOC emission rate for production resin used in the past 12 months, in kilograms per megagrams.

M R = Mass of production resin used in the past 12 mon ths, in

megagrams.

PV PG = Weighted-average monomer VOC emission rate for pigmented gel coat used in the past 12 months, in kilograms per megagrams.

M PG = Mass of pigmented gel coat used in the past 12 mo nths, in megagrams.

PV CG = Weighted-average monomer VOC emission rate for clear gel coat used in the past 12 months, in kilog rams

per megagrams.

M CG = Mass of clear gel coat used in the past 12 months , in

megagrams

PV TR = Weighted-average monomer VOC emission rate for tooling resin used in the past 12 months, in kilogr ams

per megagrams.

M TR = Mass of tooling resin used in the past 12 months, in

megagrams.

# PROPOSED August 18, 2011

   	
 
 PV TG = Weighted-average monomer VOC emission rate for tooling gel coat used in the past 12 months, in kil ograms

per megagrams.

M TG = Mass of tooling gel coat used in the past 12 mont hs, in

megagrams.

5.2.2.5.4 For purposes of Equation 3, the operato r shall use Equation 4 to compute the weighted-average monomer VOC emission rate for the previous 12 months for each open molding resin and gel coat operation included in the average.

Equation 4:

PV OP = 

## ∑

∑

= =

n

1 i n

1 i

) Mi ( ) PVi Mi (

Where:

PV OP = Weighted-average monomer VOC emission rate for ea ch open

molding operation (PV R , PV PG , PV CG , PV TR , and PV TG ) included in the average, kilograms of monomer VOC per megagram of material applied.

Mi = Mass of resin or gel coat i used within an op eration in the past 12

months, in megagrams.

n = Number of different open molding resins and ge l coats used with

the operation in the past 12 months.

PVi = The monomer VOC emission rate for resin and gel coat i used

within an operation in the past 12 months, in kilog rams of monomer VOC per megagram of material applied. Use T able 23 to compute PVi.

# PROPOSED August 18, 2011

   	
 
 Table 23 Monomer VOC Emission Rate Formulas for Ope n Molding

for Fiberglass Boat Manufacturing Operation Material Application Method Formula to calculate mo nomer VOC emission rate*

Production resin, Tooling resin Atomized 0.014 x (Resin VOC%) 2.425
Atomized, plus vacuum bagging with roll-out 0.01185 x (Resin VOC%) 2.425
Atomized, plus vacuum bagging without roll-out 0.009454 x (Resin VOC%) 2.425
Non-atomized 0.014 x (Resin VOC%) 2.275
Non-atomized, plus vacuum bagging with roll-out 0.0110 x (Resin VOC%) 2.275
Non-atomized, plus vacuum bagging without roll-out 0.0076 x (Resin VOC%) 2.275
Pigmented gel coat, clear gel coat, tooling gel coat All methods 0.445 x (Gel coat VOC%) 1.675

* The formulas in Table 23 calculate monomer VOC em issions in kilograms of monomer per megagram of resin or gel coat applied. The formula s for vacuum bagging with roll-out are applicable when a facility rolls out the applied re sin and fabric prior to applying the vacuum bagging materials. The formulas for vacuum bagging without roll-out are applicable when a facility applies the vacuum bagging materials immed iately after resin application without rolling the resin and fabric. VOC% = monomer VOC c ontent as supplied, expressed as a weight-percent value between 0 and 100%.

5.2.2.6 Requirements for Add-on VOC Control System Option

5.2.2.6.1 In lieu of complying with the requiremen ts of

Compliant Materials Option in Section 5.2.2.4 or the requirements of Emissions Averaging Option in Section 5.2.2.5, an operator may choose to use an APCO-approved add-on control equipment to meet the emission limit determined by Equation 2 above. However, instead of using the mass of each material used over the past 12 months in Equation 2, the operator shall use the mass of each material used during control device performance source testing in Equation 2 to determine the emission limit (in kilograms of monomer VOC) that is applicable during the source testing. If t he

measured emissions at the outlet of the control device (in kilogram of monomer VOC) are less

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 than the emission limit, then the control device

shall be considered to have achieved the emission limit, and provided the control device also meets the requirements of Sections 5.1.1.45.1 through

5.1.1.45.3.

5.2.2.6.2 All resins and gel coats used during add -on VOC

controlled operations shall not exceed 5 percent by weight non-monomer VOC content limit.

5.2.2.6.3 The operator shall monitor and record re levant

control device and capture system operating parameters such as temperature, pressure, and flow rate, and use the recorded values to establish operating limits for the emission control device an d capture system, and maintain such parameters within the established operating limits.

5.2.2.7 Requirements for Filled Resins

5.2.2.7.1 An operator who uses resins to which fil lers are

added shall use Equation 5 to adjust the emission rate for filled resins under all three options specified in Section 5.2.2.4 through Section 5.2.2.6. If an operator uses a filled production resin or filled tooling resin, the operator shall

calculate the emission rate for filled material on an as-applied basis using Equation 5.

5.2.2.7.2 All filled resins used shall not exceed 5 percent by

weight non-monomer VOC content limit.

5.2.2.7.3 If the filled resin is used as a product ion resin, the

value of PVF calculated by Equation 5 shall not exceed 46 kilograms of monomer VOC per megagram of filled resin applied.

5.2.2.7.4 If the filled resin is used as a tooling resin, the

value of PVF calculated by Equation 5 shall not exceed 54 kilograms of monomer VOC per megagram of filled resin applied.

5.2.2.7.5 If the operator is including a filled re sin in the

emissions averaging option procedure, the operator

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 shall use the value of PV F calculated using Equation 5 for the value of PVi in Equation 4 of

this rule.

Equation 5:

PV F = PV U x [ 100 ) Filler % 100 (

− ]

Where:

PV F = The as-applied monomer VOC emission rate for the filled production resin or tooling resin, in kilograms mon omer VOC per megagram of filled material.

PV U = The monomer VOC emission rate for the neat (unfi lled)

resin, before filler is added, as calculated using the

formulas in Table 23 of this rule.

% Filler = The weight percent of filler in the as-a pplied filled resin

system.

5.2.2.8 Work Practice Standards for Resins and Gel Coat

Effective on or after January 1, 2011, aAn operato r shall ensure

that all containers with a capacity equal to or gre ater than 208 liters (55 gallons), including those used for on-si te mixing of putties and polyputties, have a cover with no visib le gaps in place at all times, except when material is being m anually added or removed from a container, or when mixing o r pumping equipment is being placed in or removed fro m a container.

5.3 Organic Solvent Cleaning Requirements

5.3.1 An operator shall not use organic solvents fo r cleaning operations that exceed the VOC content limits specified in Table 34 , in accordance with the corresponding effective date.

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 Table 34 VOC Content Limits for Organic Solvents Us ed in Cleaning Operations
Type of Solvent Cleaning Operation VOC Content Limit Grams of VOC/liter of material (lb/gal)

A. Product Cleaning During Manufacturing Process or Surface Preparation for Coating Application 25 (0.21)

B. Repair and Maintenance Cleaning 25 (0.21)

C. Cleaning of Polyester Resin Application Equipment 25 (0.21)

5.3.2 In lieu of complying with the VOC content lim its in Table 34, an operator may control VOC emissions from cleaning op erations with an APCO-approved VOC emission control system that meet s the requirements of Section 5.1.1.45 for the solvent cl eaning operations.

5.4 Solvent Storage and Disposal

An owner or operator shall store or dispose of all uncured polyester resin materials, fresh or spent solvents, waste solvent c leaning materials such as cloth, paper, etc., coatings, adhesives, catalysts, and thinners in self-closing, non-absorbent and non-leaking containers. The cont ainers shall remain closed at all times except when depositing or removing the co ntents of the containers or when the container is empty.

6.0 Administrative Requirements

6.1 Recordkeeping

An operator subject to this rule shall maintain the following records:

6.1.1 Daily records of the type and quantity of all resins, gel coats, fillers, catalysts, and cleaning materials (including cleani ng solvents) used in each operation. Records shall also indicate the am ount used and VOC content, in weight percent, of all polyester resin and gel coat materials used for touch up, repair, and small jobs.

6.1.2 Records of the VOC content, in weight percent , of all polyester resin and gel coat, filler materials, including the weight pe rcent of non-monomer VOC content of the resin and gel coat, used or stor ed at the stationary

source.

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 6.1.3 Records of the VOC content of all cleaning ma terials used and stored at the stationary source as specified in Section 5.3.

6.1.4 Records showing the weight loss per square me ter during resin polymerization for each vapor-suppressed resin.

6.1.5 VOC Emission Control System Records

An operator using a VOC emission control system pur suant to Section 5.1.1.45 to comply with this rule shall maintain da ily records of key system operating parameters to demonstrate continuo us operation and compliance of the VOC emission control system durin g periods of emission-producing activities. Key system operatin g parameters are those parameters necessary to ensure compliance, in cluding, but not limited to, temperature, pressure drop, and air flo w rate.

6.1.6 An operator claiming exemption under Section 4.1 shall maintain records of polyester materials usage to support the claim o f exemption.

6.1.7 The operator shall retain the records specifi ed in Sections 6.1.1 through 6.1.6, as applicable, on site for a period of five years, make the records available on site during normal business hours to t he APCO, ARB, or EPA, and submit the records to the APCO, ARB, or EP A upon request.

6.2 Test Methods

The analysis of cleaning materials, polyester resin materials and control efficiency shall be determined by the following met hods:

6.2.1 The emission rate per square meter of exposed surface during polymerization of Polyester Resins is to be determi ned using: SCAQMD Method 309 (Static Method for Determination of Volatile Emissions from Polyester and Vinyl Resins Operation s), Attachment A, 1/8/91.

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 6.2.2 Determination of Overall Capture and Control Efficiency of VOC Emission Control Systems

6.2.2.1 The capture efficiency of a VOC emission co ntrol system’s collection device(s) shall be determined according to EPA’s “Guidelines for Determining Capture Efficiency,” Ja nuary 9, 1995 and 40 CFR 51, Appendix M, Test Methods 204-20 4F, as applicable, or any other method approved by EPA, AR B, and

the APCO.

6.2.2.2 The control efficiency of a VOC emission co ntrol system’s VOC control device(s) shall be determined using EPA Test Methods 2, 2A, or 2D for measuring flow rates and E PA Test Methods 25, 25A, or 25B for measuring total gaseous organic

concentrations at the inlet and outlet of the contr ol device(s).

EPA Method 18 or ARB Method 422 shall be used to de termine the emissions of exempt compounds.

6.2.2.3 For VOC emission control systems that consi st of a single VOC emission collection device connected to a single VO C emission control device, the overall capture and control eff iciency shall be calculated by using the following equation:

CE Capture and Control = [ CE Capture x CE Control ] / 100

Where:

CE Capture and Control = Overall Capture and Control Efficiency, in

percent
CE Capture = Capture Efficiency of the collection device,

in percent, as determined in Section 6.2.2.1.

CE Control = Control Efficiency of the control device, in

percent, as determined in Section 6.2.2.2.

6.2.3 The monomer content of uncatalyzed resin mate rials is to be determined using ASTM D2369-87 (Standard Test Method for Volat ile Content of Coatings) or SCAQMD Test Method 312.

6.2.4 The VOC content of cleaning materials shall b e determined using EPA Method 24 (40 CFR Part 60, Appendix A).

6.2.5 Determination of emissions of VOC from spray gun cleaning systems shall be made using SCAQMD "General Test Method for Deter mining Solvent Losses from Spray Gun Cleaning Systems," October 3, 1989.

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 6.2.6 The transfer efficiency of alternative coatin g application methods shall be determined in accordance with the SCAQMD method “Sp ray Equipment Transfer Efficiency Test Procedure for Equipment Us er,” May 24, 1989.

6.3 Multiple Test Methods

When more than one test method or set of test metho ds is specified for any testing, a violation of any requirement of this rule established by any one of the specified test methods or set of test me thods shall constitute a

violation of this rule.