p.1 

OAR Box 1384 

Prepped by Charmelle Mathews 

Document Number: 

ll-E-191 

Docket Number: 

A-94-52 

Printed 7/2/2008 8:42:11 AM Sheet 231 of 264 
P.2 

j " CCP GEL COAT RESEARCH 

V 

_^816 391 6026 10/08/98 14:15 O :02/10 NO:121 

Contact Report 

From: 

Date: 

Contact: 

Madeleine Strum, U.S. Environmental Protection Agency 

Melanie Proctor and Shawn McKee, Pacific Environmental Services, Inc. 

October 7,1998 

Mr. Mark Hollenbeck 

Company: Cook Composites and Polymers (CCP) 

Telephone Number: (816) 391 -6000 ext. 6044 

Fas Number: (816) 391 -6026 

Contact Summary: 

Mr. Hollenbeck was contacted in order to gather information about the distribution and 

availability of CCP gel coats and request information on tooling resins. Ms. Proctor explained that 

this information is being gathered to address these issues being raised during the September 11,1998 

Small Business Open Molding Outreach Meeting for the Reinforced Plastics MACT Standard. In 

response to Ms. Proctor ond Ms. Strum's questions, Mr. Hollenbeck answered the following; 

CCP has a number of distributors. CMI and PlooTeeh are two of their larger distributors. 

Most manufacturing facilities would be within range of a distributor, but in the event that ihey are 

out of range, they could order a gel coat directly from the CCP service center in Kansas City. CCP 

does not charge any special fees for orders from outside the range of a distributor. [Mr. Hollenbeck 

agreed to provide a list of CCH distributors in order to help detennine their geographic distribution.] 

Fluctuations in price for a product depend mostly on the quantity ofthe product being purchased and 

the location ofthe customer. Larger quantities will usually cost less per gallon of gel coat purchased 

than smaller quantities. Those customers that are out of range of a distributor and order directly 

from Kansas City may huve to pay for the freight costs incurred due to making a special shipment 

depending on the size of the shipment. However, these freight costs would not differ for the 

purchase of a low HAP gel coat versus a high HAP gel cont. If a customer working with a 

distributor of CCP wanted to purchase a gel coat that had not been previously carried by that 

distributor, the distributor would be uble to obtain the new gel coat from CCP 

"\Y\. \o ^.voon-v or \ar«^€r W\cA *» -^c 

Customers that purchase mwre ihan appfonimatoly 10 druma »vory two wecltj to-four w—kg 

have the option of working with CCP to tailor the gel coat to their specific needs. Customers 

purchasing smaller quantities are generally limited lo buying the standard formula ofthe purchased 

gelcoat. 0J\"\\s Wv\^o r (**i,\ ^ Ce^t^ S SVJ_CVN CVS Vj\SCO«\*V' 

Gor*A CAX^C Ca»\ * % A 

< ^ 0^5 COSILY 

INFORMATION IS ACCURATE ffl/n/ ^JLJ^ . J 
P.3 

CCP GEL COAT RESEARCH S 816 391 6026 10/08/98 14:15 0:03/1 0 N0:121 

. in/ UA..' HA i.t:it 'ut I:IIIMH" HI_.» T rt a ntr INL i_)i»».» 

Cook Composites and Polymers- Mark Hollenbeck 

October 7,1998 

Page 2 

Ms. Strum explained that Mr. Jonathan Spaulding of North End Composites pointed out 

during the September 11,1998 Small Business Open Molding Outreach Meeting for the Reinforced 

Plastics MACT Standard lhat his CCP representative did not recommend CCP's low HAP gel coat 

for his operation. Ms. Strum asked Mr. Hollenbeck if he could comment on tliis issue. Mr. 

Hollenbeck replied that he could not comment on this specific issue without specific information 

about the context in which tliis remark WJU* made, and without knowing which representative made 

the recommendation. Ms. Proctor promised to contact Mr. Spaulding to collect more specific 

infonnation ou this issue. Mr. Hollenbeck made a generul comment that CCP makes a low HAP 

version of their marine grade and sanitary grade gel coats. He added that several customers are 

trying the low VOC marine gel Coat at this time. Mr. Hollenbeck did not know of an applicable 

application for which CCP would not recommend either of these gel coats, however due to 

difficulties with the composition, the gel coats art not yet available in some ofthe brighter colors. 

Ms. Proctor explained that the EPA was currently investigating the usage of low IIAP tooling 

resins. She added that the liPA collected resin specification sheets for two tooling resins wilh less 

than 35% HAP from Ashland Chemical Company (See attached sheets). Ms. Proctor asked if Mr. 

Hollenbeck could provide resin technical data sheets for their isophthalic tooling resins, so that the 

resin properties ofthe low HAP Ashland tooling resins could be compared to the isophthalic tooling 

resin supplied by CCP. Mr. Hollenbeck agreed to provide a resin technical duta sheet for their most 

frequently sold isophthalic tooling resin, f Mr. Hollenbeck, could you ;dso please provide the pages 

ofthe MSDS for this tooling resin that pertain to the composition and properties?! 

INFORMATION IS ACCURATE •MJmJd. 

V 

-2-
^PA^ 

. 'SEP-?8t-\3?Q 16:81 fiSHLAND CPD 

AshlandChemical 

ASHLAND CHEMICAL COMPANY • DIVISION OF ASHLAND INC. 

BOX 2219, COLUMBUS, OHIO 43216 • (614) 790-3333 

614 vya fa<iii r.^'mM. 

TECHNICAL DATA 

AROTOOL® 2001 

Modified Epoxy Tooling 

Resin 

NOVEMBER 1997 

Heat Resistant, Modified Epoxy Tooling Resin For Extended Life Of FRF Tools 

DESCRIPTION: 

PERFORMANCE: 

SUGGESTED USES: 

AROTOOL 2001 resin is a high solids, thixotropic, promoted resin containing styrene. 

This resin system contains less than 35% styrene monomer. AROTOOL 2001 resin 

displays excellent wet-out and handling; characteristics. It exhibits improved impact 

properties to resist cracking and crazing; AROTOOL 2001 resin has excellent 

resistance to heat degradation and styrene attack of the FRP molds. 

• Less than 35% monomer 

• Low shrink 

a Excellent handling characteristics 

a Extended tool life-more cycles per tool 

• Excellent strength retention at elevated temperatures 

• High heat distortion temperature (HDT) 

• Excellent resistance to styrene attack 

• Reduced fiber pattern transfer 

AROTOOL 2001 resin can be used in the fabrication of FRP tooling and molds that are 

used for the production of FRP molded products by hand lay-up, spray-up, cold 

molding and RTM process techniques. AROTOOL 2001 resin is suited for marine, 

casting, automotive and electrical tooling applications where long life, good profile 

and excellent appearance of finished parts are required. 

TYPICAL* LIQUID PROPERTIES AT77,F(25°Q 

Percent Solids 

Monomer 

Viscosity - Brookfield, cps 

#2 Spindle at 60 rpm 

#2 Spindle at 6 rpm 

Ihixotropic Index 

Pounds per Gallon 

Flash Point Range, °F 

66 

styrene 

375 

790 

2.1 

9.0 

73-100 

* Typical Values: Based on material tested in our laboratories but varies from sample to sample. Typical values 

should not be construed as a guaranteed analysis of any specific lot or as specification items. 

STANDARD PACKAGE: 

DOT LABEL REQUIRED: 

CODE: 

55-gallon drum, Non-Retumable, Net WL 500 lbs. 

Flammable Liquid 

562-412 

OCopyright 1997, Ashland Inc. 

®Registered trademark of Ashland Inc 

NOTCE; The laboratory data and resuhaprasaraad herein were r^ 

duprtcaBon of SUCH result* by third partes. All dau presentod It provided gratuitously and. although h Is Intended to bo accurate In regard to the subjao maner 

involved. D Is provided without warranty of any Kind, and any and al warranties, either express or Implied, are disclaimed. AB recommendations or suggestions 

contained herein or baaed hereon must be waiuated by you to detennine thehappficsbflityof sul«H*iy for your panleuler use. 

Ad precautionary labels snd notices should be read and understood by a l supervisory personnal and employees betore using. Consult Aaniand Chemical 

Company and OSHA regulations tor addWonal safety and health Iniotmeson. Purchaser lo responsible (or complying whfi a* applicable brteral* ame or local lawa 

and regulations covering use of the product Special attention should be given to consumer appUcations. freedom to use any patent unwed tiy AeMand or others Is 
._ i P.5 

AROTOOL® 2001 Resin (continued) 

TYPICAL * PERFORMANCE DATA V 

(for guidance only) 

TYPICAL CURING CHARACTERISTICS AT 77°F (25°Q: 

1.5% LUPERSOL1 DDM-9 Catalyst 

Gel Time, minutes 

Total Time, minutes 

Peak Exotherm, °F 

TYPICAL* MECHANICAL PROPERTIES 

CAL PHYSICAL PROPERTIES OF CURED CASTINGS AT 77°F (25°Q: 

-TES-T VALUE 

Tensile Strength, psi 10,560 

Tensile Modulus, psi x VP M 

Tensile Elongation, % 2.66 

Flexural Strength, psi 16/400 

Flexural Modulus, psi x 10s .60 

Heat Deflection Temperature °C(°F) 127(261) 

30 

36 

360 

TEST METHOD 

ASTMD-S38 

ASTMD-638 

ASTMD-638 

ASTMD-790 

ASTMD-790 

ASTMD-648 

HANDLING: AROTOOL 2001 resin contains ingrediento which could be harmful if mishandled. Contact with 

skin and eyes should be avoided and necessary protective equipment and clothing should be worn. 

Ashland Chemical Company maintains Material Safety Data Sheets on all of its products. Material Safety Data 

Sheets contain health and safety information for your development of appropriate product handling procedures to 

protect your employees and customers. 

Our Material Safety Data Sheets should be read and understood by all of your supervisory personnel and 

employees before using Ashland Chemical Company's products in your facilities. 

RECOMMENDED STORAGEDrums-Store at temperatures below 80°F. Storage life decreases with increasing storage temperature. Avoid 

exposure to heat sources such as direct sunlight or steam pipes. Mild agitation is recommended to address 

thbcotrope settling after prolonged storage. Keep sealed to prevent moisture pick»up and monomer loss. Rotate 

stock. 

Bulk • See Ashland Chemical's Bulk Storage and Handling Manual for Polyesters and Vinyl Esters. A copy of this 

may be obtained hom Ashland Chemical's Composite Polymers Division at (614) 790-3333. 

SHELF LIFE: This product has a limited shelf life. When stored in accordance with the above conditions, this 

product has a minimum shelf life of three months. 

Registered trademark of FJfAtochem America, Ine, e 

4 

TOTfiL P.03 
P.6 

EASTERN RESERRCH 6RUUP IU :9iy-4b8-t'«Ul U U U3^B o iUZ INO .uui r .UD 

AME5000 LOW VOC MARINE RESIN 

Helps Meet Air Quality Emission Standards 

AME 5000 is a high-solids, thixotropic, 

modified epoxy resin developed by 

Ashland Chemical exclusively for marine 

applications. 

This resin system contains less than 35 percent styrene monomer. AME 5000 marine 

resin meets requirements of the Southern 

California Air Quality Management District 

Rule 1162 for low VOC resins. 

AME 5000 resin can be specified for the construction of marine laminates where low 

shrink, improved strength, impact resistance, 

blister resistance, and profile are required. 

The physical properties of cured laminates 

made with AME 5000 marine resin out perform conventional polyester resins systems. 

AME 5000 displays excellent wet-out and 

handling characteristics under a variety of 

shop conditions. 

Ashland Chemical recommends that each 

end-user evaluate the performance of 

AME 5000 marine resin under conditions; 

which simulate both production procedures 

(including laminate design and sequence) 

and anticipated field exposures. For more 

technical information on the performance 

of AME 5000 resin, contact your 

Ashland Chemical marine resin sales 

representative. 

AME 5000 LOW VOC MARINE RESIN 

• Meets Rule 11621 Specification 

• Low VOC 

• High-Solids Content 

• Low Shrink 

• Improved Profile 

• Fast Wet-Out 

• Excellent Handling Conditions 

1

 Snuthorn California Air Quality Manaoomonl District »Trademark, Organic Peroxide Oi-ricion, Aiochem North America. Inc. 

5" 
P.7 

EASTERN RESEARCH GROUP lD:919-4b8-f8U l . U U Ub*y« »:ua NO.UU1 K.uo f 

Ashland Chemical 

INTERLAMINATE 

ADHESION 

It Is recommended that all 

laminates which have been 

heat cured, exposed to direct 

sunlight, or which have been 

allowed to cure for more than 

72 hours at room temperature, 

be sanded before the next 

laminate is applied. 

RECOMMENDED STORAGE 

Store in a cool dry area at temperature below 80° F. 

Avoid exposure to heat sources such as direct sunlight 

or steam. 

Drums — Keep containers sealed to prevent moisture 

pickup and monomer loss. Rotate stock. Some 

thixotrope settling may occur. Mild agitation is required 

to redlsperse the thixotrope. 

BLISTER 

RESISTANCE 

Each end-user should evaluate 

the performance of AME 5000 

marine resin in conjunction with 

their respective gel coat under 

conditions which simulate both 

production procedures (including laminate design 

and sequence) and anticipated field exposure. For 

best results, it is recommended that the skin coat 

be applied once the gel coat reaches a Shore A 

hardness of between 60 and 80. Blister resistance 

may be affected if the gel coat has been allowed to 

cure overnight or longer. 

SAFETY & HANDLING 

AME 5000 marine resin contains ingredients which 

could be harmful if mishandled. Contact with skin and 

eyes should be avoided and necessary protective 

equipment and clothing should be worn. 

For Important health, safety and handling 

Information, consult Ashland's Material 

Safety Oata Sheet before using this product. 

SHELF LIFE 

This product has a limited shelf life. When stored In 

accordance with the above conditions, this product has 

an average shelf life of three months. 

Bulk Storage — Tanks should comply 

with the SPI documents outlining storage 

conditions recommended for polyester 

and vinyl ester resin. Only stainless steel 

or epoxy lined mild carbon steel tanks 

are recommended. Periodic agitation is 

required to keep the thixotrope properly dispersed. 

STANDARD PACKAGING 

Nonreturnable 55 gallon drums, 475 lb net. 

DOT LABEL REQUIRED 

Flammable Uquid. 

0? 
P.8 

CCP GEL COAT RESEARCH 

7 CCP 

Cook Comooaltea and Polvmera Co. 

^ 816 391 6026 

FAX 

COMMUNICATION 

10/08/98 14:15 0 :01/10 N0:121 

POBox 419389 

Kansas City. MO 64141-6389 

816/391-6044 

TO: 

COMPANY: 

FAX NBR: 

DATE: 

Shawn, 

Shawn McKee 

Pacific Environmental 

919-941-0234 

10/8/98 

FROM: Mark Hollenbeck 

DEPARTMENT: Research 

FAX NBR: 816/391-6026 

NBR PAGES: 10 

1 would like to modify ihe notes somewhat. 

• I checked the sales records and find that CMl and GLS are the top two distributors for CCP. 

Plas-Tex is actually fourth. 

• I have changed the thought a bit on minimum batch size. CCP will provide customer specific 

formulas in 10 drum batch size or larger. (Tiiese customers typically will reorder about every 

two to four weeks.) Minor modifications to viscosity or cure rates can be made lo smaller 

batches, but we will typically work from a basic or standard formula. 

• Certain bright colors in low HAPS bases may not be achievable. 

Please see attached pencil changes. 

I have attached a current distributor list. 

1 am in the process of obtaining literature for CCP counterparts for Ashland's AROTOOL® 

2001 and AME® 5000. 

Thank you. 

7