(Adopted March 6, 1987)(Amended April 3, 1987)(Amended August 3, 1990) 

(Amended December 7, 1990) (Amended August 2, 1991)(Amended July 10, 1992) 

(Amended May 13, 1994)(Amended November 17, 2000)(Amended November 9, 2001) 

(Amended July 11, 2003)(Amended July 9, 2004)(Amended July 8, 2005) 

RULE 1162 POLYESTER RESIN OPERATIONS 

(a) Applicability 

This rule shall apply to all polyester resin operations that fabricate, rework, repair, 

or touch-up products for commercial, military, or industrial use including, but not 

limited to, boats, tubs, pools, shower enclosures, spas, bathroom fixtures, jigs, 

tools, molds, building panels, air pollution control equipment, sewage treatment 

equipment, storage tanks, transportation parts, automotive, aircraft, and aerospace 

components, and other industrial and consumer products. 

(b) Definitions 

For the purpose of this rule, the following definitions shall apply: 

(1) AIR-ASSISTED AIRLESS SPRAY is a coating application system in 

which the coating fluid is supplied to the gun under fluid pressure and air 

is combined at the spray cap. 

(2) CLOSED MOLDING SYSTEM is a method of fabricating composite 

parts by placing composite materials in a confining mold cavity and 

applying pressure and/or heat. 

(3) CORROSION-RESISTANT MATERIALS are polyester resin materials 

used to make products for corrosion resistant applications such as tooling, 

fuel or chemical tanks, boat hulls, pools and outdoor spas. 

(4) ELECTROSTATIC APPLICATION is charging of atomized coating 

droplets for deposition to a grounded substrate by electrostatic attraction. 

(5) EXEMPT COMPOUND is as defined in Rule 102. 

(6) FIBER REINFORCEMENT MATERIALS are multifilament of glass or 

other fibrous materials such as, carbon, boron, metal and amid polymers, 

which are used to reinforce plastic. 

(7) FIBER REINFORCED PLASTIC OR COMPOSITE (FRP/C) 

MATERIALS is a mixture of polyester resin and fiber reinforcement 

materials. 

(8) FILLER is a finely divided inert (non-VOC) material, which may be 

added to the resin to enhance its mechanical properties and extend its 
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volume. Resin fillers include, but are not limited to, silica, carbon black, 

talc, mica and calcium carbonate. 

(9) FILLED POLYESTER RESIN MATERIAL is a material formulated by 

adding compatible filler(s) to polyester resin material(s). 

(10) FIRE RETARDANT MATERIALS are polyester resin materials used to 

make products that are resistant to flame or fire. 

(11) FLOWCOATER is a nonatomizing application technique of applying 

resins and gel coats to an open mold with a fluid nozzle in a fan pattern 

with no air supplied to the nozzle. 

(12) GEL COAT is a thermosetting polyester resin surface coating, either 

pigmented or clear, that provides a cosmetic enhancement and improves 

resistance to degradation from exposure to the elements. 

(13) GENERAL PURPOSE POLYESTER RESINS are resin materials that are 

not corrosion resistant, fire retardant, high strength, or gel coats. 

(14) HAND LAY-UP is a hand application technique of composite materials 

using a bucket and a paint brush or a paint roller, or other hand held 

method of application. 

(15) HIGH-VOLUME, LOW-PRESSURE (HVLP) SPRAY is a coating 

application system which is operated at air pressures between 0.1 and 10 

pounds per square inch gauge (psig) measured dynamically at the center of 

the air cap and at the air horns. 

(16) HIGH-STRENGTH MATERIALS are polyester resins which have casting 

tensile strength of 10,000 psi or more and which are used for 

manufacturing of high performance boats and skis. 

(17) LAMINATION RESINS are orthophthalate, isophthalate and 

dicyclopentadiene (DCPD) resins which are used in composite system 

made of layers of reinforcement fibers and resins, such as in boat 

fabrication. 

(18) MARBLE OR CULTURED RESINS are orthophthalate and modified 

acrylic isophthalate resins, which are designed for the fabrication of cast 

products, such as vanities. 

(19) MONOMER is a volatile organic compound that partially combines with 

itself, or other similar compounds, by a cross-linking reaction to become a 

part of the cured resin. Monomers include, but are not limited to, styrene 

and methyl methacrylate. 
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(20) MONOMER PERCENT BY WEIGHT OF A RESIN is the weight of the 

monomer, divided by the weight of the polymer. 

(21) MONOMER PERCENT BY WEIGHT OF A FILLED RESIN AS 

APPLIED is the weight of the monomer, divided by the weight of the 

polymer and filler(s). 

(22) NONATOMIZING SPRAY APPLICATION is any application technique 

in which resin flows from the applicator, in a steady and observable 

coherent flow, without droplets, for a minimum distance of three (3) 

inches from the applicator orifices. 

(23) OPEN MOLDING SYSTEM is a method of fabricating composite parts by 

applying gel coats, resins, fibers, and other composite materials on an 

open mold using either hand lay-up or spray-up applications. 

(24) PIN STRIPING is a spray application technique used to apply one or more 

narrow bands, marks, or streaks of gel coat onto the surface of an open 

mold of a composite product. 

(25) POLYESTER is a polymer of ester molecules, which are formulated by 

the reaction of an acid and an alcohol and linked together by the ester 

linkages. 

(26) POLYESTER RESIN MATERIALS are 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 material containing VOC used in polyester resin 

operations. 

(27) POLYESTER RESIN OPERATIONS fabricate, rework, repair, or touchup products for commercial, military, or industrial use by mixing, pouring, 

hand laying-up, impregnating, injecting, forming, winding, spraying, 

and/or curing by using polyester resin materials. 

(28) POLYMER is a chemical compound, such as polystyrene, comprised of a 

large number of chemical units (monomer) composed of identical crosslinking groups, such as styrene. 

(29) PRESSURE-FED ROLLER is a fabric roller that is fed with continuous 

supply of catalyzed resins from a mechanical fluid pump. 

(30) PRIMER GEL COAT is gel coat which is used to coat the surface of 

composite parts, prior to top-coat painting, for automotive, aerospace, 

marine and home building industries. 
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(31) PULTRUSION is a process where continuous roving strands are moved 

through a strand-tensioning device into a resin bath for impregnation and 

then passed through a heated die for curing. 

(32) REPAIR is that portion of the fabrication process that requires the addition 

of polyester resin materials to portions of a previously fabricated product 

in order to mend damage. 

(33) RESIN is any thermosetting polyester resin, which is used to encapsulate 

and bind together reinforcement fibers and/or fillers in the formulation of 

composite materials. 

(34) RESIN IMPREGNATOR is a mechanical nonatomizing composite 

materials application technique in which fiber reinforcement is saturated 

with resins in a controlled ratio for each specific composite product. 

(35) SOLID SURFACE RESINS are resins, which are used without gel coats 

to fabricate homogenous solid surface products. 

(36) SPECIALITY GEL COATS are gel coats which are used in conjunction 

with fire retardant, corrosion resistant or high-strength materials. 

(37) THERMOSET POLYESTER RESIN is a resin material that undergoes a 

chemical reaction during curing and can not be reshaped. 

(38) TOUCH-UP is that portion of the process that is necessary to cover minor 

imperfections. 

(39) TUB/SHOWER RESINS are dicyclopentadiene (DCPD) resins, along 

with orthophthalate and isophthalate resins, which are used to fabricate 

bathware products. 

(40) VAPOR SUPPRESSANT is a wax substance added to resin for the 

purpose of forming a layer on the surface of the resin while it is curing and 

minimize the outward diffusion of monomer vapor into the atmosphere. 

(41) VAPOR SUPPRESSED RESIN (VSR) is a polyester resin material which 

contains additives to reduce VOC evaporation loss to less than fifty (50) 

grams per square meter of surface area as determined and certified by 

resin manufacturers. 

(42) VOLATILE ORGANIC COMPOUND (VOC) is as defined in Rule 102. 

(c) Requirements 

(1) Application Techniques 

 (A) Except for gel coats, effective July 1, 2002, a person shall not 

apply any resin materials to an open mold surface unless one of the 
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following nonatomizing application techniques is used and 

operated according to the operating procedure specified by the 

equipment manufacturer: 

(i) Nonatomizing Spray Application Technique, as defined in 

paragraph (b)(22); 

(ii) Flowcoaters; 

(iii) Pressure-Fed Rollers; 

(iv) Resin Impregnators; 

(v) Hand Lay-up Applications; or 

(vi) Other nonatomizing application techniques which are 

approved in writing by the Executive Officer, CARB, and 

U.S. EPA, as having similar emission reduction 

efficiencies. 

(B) Effective July 1, 2005, an operator shall not apply gel coat 

materials to an open molding surface unless one of the following 

application techniques is used and operated according to the 

operating procedure specified by the equipment manufacturer: 

(i) Any nonatomizing application technique listed under 

subparagraph (c)(1)(A); 

(ii) Air-Assisted Airless Spray; 

(iii) Electrostatic Attraction; or 

(iv) High-Volume, Low-Pressure (HVLP) 

(2) Material Requirements 

(A) A person shall not use polyester resin material in an open molding 

system, which has a monomer content in excess of the limits 

specified in the following Table. 
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Polyester Resin Materials Monomer Percentage by Weight as Applied 

Prior to 11-09-2001 Current Limits 

Clear Gel Coat 

 For Marble Resins 

 For Other Resins 

50 

- 

- 

- 

40 

44 

Pigmented Gel Coat 

 White and Off White 

 Non-White 

 Primer 

Specialty Gel Coats 

45 

- 

- 

- 

- 

- 

30 

37 

28 

48 

General Purpose Resin 

 Marble Resins 

 Solid Surface Resins 

Tub/Shower Resins 

 Lamination Resins 

Others 

35 

- 

- 

- 

- 

- 

- 

10 or 

(32 % as supplied, no fillers) 

17 

24 or 

(35 % as supplied, no fillers) 

31 or 

(35 % as supplied, no fillers) 

35 

Fire Retardant Resin 

Corrosion Resistant Resin 

High Strength Resin 

42 

48 

48 

38 

48 

40 

(B) Composite operations that are also subject to Rule 1132 and have 

elected to comply under the alternative compliance option 

specified in paragraph (d)(1) of Rule 1132, shall comply with the 

July 1, 2002, monomer content requirements of subparagraph 

(c)(2)(A) on January 1, 2002. 

(C) Effective July 1, 2002, a person shall not apply to an open molding 

system any tub/shower polyester resin material unless all the 

applied resin material is vapor suppressed. 

(3) Process Requirements 

(A) A person shall not operate a closed molding system, unless the 

weight loss of polyester resin materials during polymerization is 

less than four (4) percent. 
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(B) Until July 1, 2002, in lieu of using resins that comply with the 

monomer content requirements of subparagraph (c)(2)(A), a person 

may use a vapor suppressed resin, provided the weight loss from 

VOC emissions does not exceed fifty (50) gram per square meter 

of exposed surface area during resin polymerization. 

(C) A person shall not perform a pultrusion operation, unless wet-out 

baths are covered except for 18 inches from the exit of the bath to 

the die. The weight loss of polyester resin materials during 

polymerization shall be less than three (3) percent in a pultrusion 

operation. 

(4) Notwithstanding the requirements specified in paragraph (c)(1), a person 

may perform touch-up and repair using a hand-held spray gun which has 

a container for gel coat or resin as part of the gun. 

(5) Any person processing polyester resin materials and any other VOCcontaining materials shall keep these materials in closed containers except 

when filling or emptying the container. 

(6) Solvent cleaning of application equipment, parts, products, tools, 

machinery, equipment, general working areas, and the storage and 

disposal of VOC-containing materials used in cleaning operations shall 

comply with Rule 1171 - Solvent Cleaning Operations. 

(d) Control Equipment 

In lieu of complying with the requirements of subdivision (c), a person may install 

and operate an emission control system which has an overall capture and control 

efficiency of 90 percent or more on a mass basis, as approved by the Executive 

Officer. 

(e) Recordkeeping Requirements 

(1) A person subject to the provisions of this rule shall maintain daily records. 

Alternatively, records may be kept on a monthly basis provided the 

polyester resin process or equipment is not subject to a daily production 

limit or daily VOC limit in any applicable District rule(s) or permit(s). 

Such records shall be made available to the Executive Officer's designee 

upon request and shall be kept for not less than two years. The records 

shall contain: 
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(A) The type of the nonatomizing, or other in the case of gel coat, 

application technique(s) used, manufacturer’s name, and the 

records of the fluid tip pressure calibration as specified by the 

manufacturer; 

(B) The manufacturer's name, the type and amount of each of the 

polyester resin materials used; and the weight (in percent) of 

monomer for all polyester resin materials and filler(s). If 

VOC-containing materials are added to the polyester resin, the 

amount of VOC-containing materials, in grams, and the VOC 

content in grams per liter, of VOC-containing materials; 

(C) Certification of Analysis from the resin manufacture(s) to verify 

that all the applied tub/shower resin materials are vapor 

suppressed; and 

(D) For closed-mold and pultrusion systems, the weight loss (in 

percent) of polyester resins materials for each application. 

(2) Records for cleaning solvents subject to Rule 1171 - Solvent Cleaning 

Operations shall be maintained pursuant to Rule 109. 

(3) Any person using an emissions control system as a means of complying 

with this rule shall maintain daily records of all key system parameters, 

including hours of operation, temperatures, pressures and flow rates, that 

are necessary to ensure control efficiency requirements. 

(f) Test Methods and Procedures 

The following test methods and procedures shall be used to determine compliance 

with this rule. Other applicable test methods may be used if they are determined 

to be equivalent and approved in writing by the Executive Officer, the California 

Air Resources Board and the U.S. Environmental Protection Agency. 

(1) Determination of VOC Content of VOC- Containing Materials 

(A) U.S. EPA Method 24 - Determination of Volatile Matter Content, 

Water Content, Density Volume Solids, and Weight Solids of 

Surface Coating. 

(B) District Methods 302 and 303–Determination of Exempt 

Compounds. 

(C) District Method 304-Determination of Volatile Organic 

Compounds (VOCs) in Various Materials, or any other applicable 
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method approved by the US Environmental Protection Agency, 

California Air Resources Board, and the SCAQMD. 

(D) District Method 309 – Determination of the Weight Loss of 

Polyester Resin Materials. 

(E) District Method 312 – Determination of the monomer content of 

Polyester Resin Materials. 

(F) District Method 313 – Determination of Volatile Organic 

Compounds by Gas Chromatography/Mass Spectrometry. 

(2) Determination of Efficiency of Emission Control System 

(A) The capture efficiency of an emission control system shall be 

determined by verifying the use of a Permanent Total Enclosure 

(PTE) and 100% capture efficiency as defined by U.S. EPA 

Method 204 “Criteria for and Verification of a Permanent or 

Temporary Total Enclosure.” Alternatively, if a U.S. EPA Method 

204 defined PTE is not employed, capture efficiency shall be 

determined using a minimum of three sampling runs subject to data 

quality criteria presented in U.S. EPA technical guidance 

document “Guidelines for Determination Capture Efficiency, 

January 9, 1995.” Individual capture efficiency test runs subject to 

the U.S. EPA technical guidelines shall be determined by: 

(i) The Temporary Total Enclosure (TTE) approach of U.S. 

EPA Method 204 through 204F; or 

(ii) The District “Protocol for Determination of Volatile 

organic Compounds (VOCs) Capture efficiency.” 

(B) The efficiency of the control device and the VOC content 

measured and calculated as carbon in the control device exhaust 

gases shall be determined by U.S. EPA's Test Method 18, or Air 

Resources Board (ARB) Method 422 for the determination of 

emissions of Exempt Compounds and U.S. EPA's Test Methods 

25, 25A, District Method 25.1 for the determination of Total 

Gaseous Non-Methane Organic Emissions as Carbon, or District 

Method 25.3 for the determination of Low Concentration NonMethane Non-Ethane Organic Compound Emissions from Clean 

Fueled Combustion Sources, as applicable. 

 (C) The overall efficiency of an emission control system shall be 

determined using the following equation: 
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Overall Efficiency 

 = (Capture Efficiency) x (Control Equipment Efficiency)/100 

(g) Alternative Compliance Option 

A person may use alternative application processes and materials to those listed in 

paragraphs (c)(1) and (c)(2) provided they result in equivalent VOC emissions 

and are approved in writing by the Executive Officer, CARB and U.S. EPA. 

(h) Exemption 

The requirement of subparagraph (c)(1)(B) shall not apply to pin striping 

provided that the total amount of gel coat materials sprayed does not exceed one 

(1) gallon per day per facility.