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# OAR Box 

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Number: 

# t-E-15 3 Docket Number: 

# A-94-5 2

Printed 7/2/2008 8:42:10 AM

Sheet 194 of 264P. 2

-- -" 05/19/9 8 11:3 0 FA X 71 5 23 4 625 9 t 05/19/9 8 12:0 2 ©1919941023 4 F/ G PRODUCT S IN C PE S RT P N C 1^00 2
B I 002/00 4

From : Date : Contact : Company : Contac t Repor t Rober t Jemison , Pacifi c Environmenta l Services , Inc
. (PES ) May 13,199 8 Mr
. Chadwic k

Nelso n F G Products , Inc
. Telephon e Number : (715)234-233 4 Fa x Number : (715)234-625 9 Contac t Summary : Mr
. Chadwic k

Nelso n wa s contacte d o

n behal f o f th e U.S
. EPA t o clarif

y informatio n relate d t o th e manufactur e o f

plasti c composite s at

th e F G Products , Inc
. facilit y locate d i n Ric e Lake , Wisconsin
. Th e infonnalio n wa s provide d t o th e EP A i n aMay 4,199 8 lette r fro mMr
. Nelso n o f F G Products
. Th e infonnatio n wa s submitte d i n respons e t o areques t fo r informatio n fro mMr
. Jemiso n viatelephon e o n Apri l 4,1998
. I n respons e t o m y question s Mr
. Nelso n indicate d th e following : Th e facilit y produce s movabl e insulatio n panel s fo r tracto r traile r trucks
. Thes e panels ar

e ofte n custo mmad e t o differen

t size s an d shape s i n orde

r t o meet th e need s o f

aparticula

r customer
. Th e compan y employ s 50-5 5 peopl e wit h approximatel y 1 5 peopl e bein g involve d i n th e actua l spra y lay-u p operations
. The compan y i s primaril

y involve d i n th e manufactur e and sal e o f

product s compose d a t

leas t partiall y o f

thermoset plastic s (the product s ma

y or ma y no t b e plasti c composites , dependin g th e product)
. Th e facilit y use s atomize d spra

y lay-up to appl

y a n unfille d polyester

resi n i n th e fabricatio n o f th e movabl e insulatio n panel s describe d above
. Th e polyeste r resi n applie d usin g spray lay-u p contain s approximatel y 35.0 % HA P b y weigh t

Th e facility' s permi t

prohibit s th e us e o f

an y productio n (non-tooling ) resi n tha t contain s mor

e than 35.0 % styren e b y weight
. Th e facility may purchas e th e same typ e o r

simila r resin s fro mdifferen t supplier s when convenient fo r th e facilit y but th e resins neve r

contai n more than 35 % styren e b y weight
. Th e tw o MSD S sheet s provide d b y th e facilit y (marke d genera

l purpos e resi n # 1 an d genera l purpos e resi n #2 ) ar e simpl y genera l purpos e MSD S sheet s provide d b y tw o differen t manufacturers o f

th e typ e o f

resi n use d b y F G Products , Inc
. an d th e stvren e content s show n ar e no t th e actua

l styren e content s a s receive d fro mth e manufacturer s o f

th e resins
. A s indicate d i n th e spreadshee t provide d b y F G Products , Inc. , th e unfille d polyeste r

resi n use d t o produc e th e movabl e insulatio n panel s accounte d fo r 98.4 % o f th e total resi n use d b y th e facilit y durin g th e calende

r y&fy\991.
INFORMATIO N I S ACCURAT E1 05/19/9 8 11:3 0 FA X 71 5 23 4 625 9 F/ G PRODUCT S INC 05/19/9 6 12:0 3 81919941023 4 PE S RT P N C 1^)00 3 2)003/00 4 P. 3

1
A / 4

ContactRepor t F G Products , Inc . - Mr

. Chadwic k Nelso n Ma y 13,199 8 Pag e Two . Th e onl y HA P initiall y presen ti n th e unfille d polyeste r resin s used t o fabricat e th e movabl e insulatio n panel s i s styrene . N o additiona l HA P i s adde d to the resin s durin

g o r prio r t

o th e fabrication proces s wit

h th e exception o f

smal l amount s o f HA P tha tma y (o r may not) b e presen

t i n iniriatois , promoters , and/o r catalyst s adde d t o th e resins . Non e o f

th e unfille d polyeste r resin s currentl y contai n a vapo

r suppressan

tTh e facilit y di d us e vapo

r suppressant

s wit h thei r unfille d polyeste r resin s a

ton e time , bu tdiscontinue

d th e us e o f vapo r suppressant

s du e t o possibl e negativ e effect s th e vapor suppressant

s wer e havin g o n othe r material s presen tin thei r products .

, Th e facilir

y use s atomi2e

d spra y lay-u p t o appl y one pigmente

d (white ) production ge l coat i n th e fabricatio

n o f the movabl

e storag e panel s discusse d above. Thi

s ge l coa tcontain s 3 7.0 % HA P b y weigh t(32.0 % styren

e an d 5.0 % methy

l methacrylate) . Th

e facility' s permi

tprohibit s th e us e o f a pigmente d productio

n ge l coa tcontainin

g mor e tha n 32.0 % styren

e b y weigh t Th e facilir y applie s a pigmente

d (black ) toolin g ge l coa

tusing atomize

d spra y lay-u p i n the fabricatio n o f th e custo m mold s use d t o creat e the movabl

e insulatio n panels describe

d above . Thi s gel coa tcontain s 47.39 % HA

P b y weigh

t(43 % styren

e an d 4.39 % methy

l methacrylate) . Afte r th e applicatio n o f

th e pigmente

d (black ) toolin g ge l coat

, the facilit

y applie s a combinatio n o f a n unfilled , isophthali c "ski n coat " tooling resi

n an d glas s fibers t

o the mol d i n a thi n laye r (approximatel

y 0.125 t o 0.25 0 inches) . This "ski

n coat " toolin g resin i s heal resistan tan d act s a s a hea ttransfe r buffe r t o protec tthe mol d fro m the hea tgiven of f durin g th e exothermi

c reactio n tha

t occur s whe n th e unfilled polyeste r resin applie d t o th e mol d (durin

g norma l production) begin s t o cure . Thi s hea

ttransfe r buffe r i s necessar

y because th

e transfe r o f a n exces s amoun

to f heatma y caus e th e mol d t

o war p t o a n unacceptabl

e degree. Th

e "ski n coat " tooling resi

n contain s 43 % HA

P b y weigh tan

d doe s no tcontai

n a vapo r suppressan

tAfte r th e applicatio

n an d curing o f

th e "ski n coat " toolin g resin , th e facilit y uses atomize

d spra y lay-u p t o appl y polyeste r toolin g resi n a s th e fina l step i n th e fabricatio

n o f th e custo m molds . Th

e facilit y add s aluminu m trihydrat

e t o th e toolin g resi n t

o preven tshrinkag e an d warpin g durin g curin g o f th e mold . Thi s polyeste r toolin g resi n contain

s 50 % HA

P b y weight(no

tincluding filler) an

d doe s notcontain a vapo r suppressan t Th e onl y HA

P initially presen

ti n eithe r the filled tooling resi

n o r the unfille d "ski

n coat " toolin g resi n i s styrene . N o additiona l HA P i s adde d t o these resin

s durin g o r prio r t o the fabrication proces s with th e exception o f smal l amount s o f HA P tha tma y (o r ma y not ) b e presenti n initiators , promoters , and/or catalyst s adde d t o the resins . N o additiona

l HA P i s adde d to eithe r th e pigmente

d productio

n o r pigmente d toolin g ge l coat s durin g o r prio r t o th e fabricatio

n process wit

h the exceptio

n o f smal l amount s o f HA P tha tma y (or ma y not ) b e presen

tin initialois , promoters, and/or^catalyst s adde d t o the ge l coats . Non e o f

th e ge l coats contain a vapo

r suppressan

t INFORMATION I S ACCURAT E

- >P. 4
1 * • 05/19/9 8 11:3 0 FA X 71 5 23 4 625 9 F/ G PRODUCT S IN C ©00 4

_05/19/9 8 12:0 4 ©1919941.023 4 FE S RT P N C ©004/00 4

ContactReport FG Products , Inc . - Mr

. Chadwic k Nelso n Ma y 13,199 8 Pag e Thre e Al l o f th e resi n mixin g conducte d a tthis facilit

y i s don e fo r th e purpos e o f mixin g filler int

o the toolin g resi n discussed above . Th e mixing i s conducte

d insid e 5 5 gallo n drum

s b y inserting a drill shaf tthroug h a hol e i n a woode

n cover place

d on to p o f the 55 gallo n drum

. The 5 5 gallo n dru m wa s opene

d a tth e to p (i-e . the to

p o f the dru m wa s removed ) prio r t o th e star

to f th e mixin g operation. Approximatel

y 90 % o f th e ope n dru m surfac e i s covere d b y thi s woode n cover . Th e dril l shaf ti s drive n b y a dril l powere d •with compresse

d air . Th e facilit y heat s th e 5 5 gallo n dru

m usin g a hea tstri p placed aroun

d the botto

m o f th e drum . Th e hea tkeep s th e filled resi n a

ta lo w enoug

h viscosit y t o b e transferre

d throug h close d line s from th

e 5 5 gallo n dru

m to th e spra

y guns . Th

e facilit y doe s no tactively (force) ven temissions from th

e 55 gallo n dru

m b y applyin g a vacuu

m t o th e drum .

INFORMATIO

N I S ACCURAT

E ^^Z<^^/^'/yU^pT 

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