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# A ${(JA$) ll-E-20 5 Docket Number: 

# A-94-5 2

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Sheet 245 of 264P. 2 

# E9it Incorporated. Environmental Consulting and

Research Reinforced Plasti c Composite s Pollutio n Preventio n Focu s Grou p Meetin g Septembe r 13 , 199 3 Organized by : Organic s Contro l Branc

h Ai r & Energ y Engineerin g Research Laborator y U.S . Environmenta

l Protectio n Agenc

y Research Triangl e Park , Nort h Carolin a 

# ®@a/F F

Participant s Rober t Lacovara , Composite s Fabricator s Associatio n Nanc y Dehmlow , Grea

t Lake s Termina

l & Transpor

t Corporatio n Rober t L . Cottrell , ARJA

Y Technologies , Inc . Bill Seemann , Seeman

n Composite s Inc . G . Maur y Shepherd , Fil mTechnology , Inc . Rober t McCullough , Binks Manufacturing Compan y Case y Herbert , W.E.T. , Inc . Mar k Livesay , Sunre z Corporatio n Donald E . Cope , Byk-Chemi e US A Willia mA . Schramm , Reichhol d Chemicals , Inc . Kennet h Kensington , Viate c Recover y Systems , Inc . Fre d Dierks , Aqu aGlas s Corporatio n Gar y Multanen , Fiberglas s Systems , Inc . Bruc e Pfund , Professiona

l BoatBuilde

r Magazine Carlo s Nunez , U.S . EP

A Davi d Ocamb , TR

C Environmenta

l Corporatio n Rebecc aBattye , EC/

R Incorporate d Jeann e LaPlaca , EC/

R Incorporate d Stev e Fudge , EC/

R Incorporate d Jame s H . Jones , Nationa

l Institute fo

r Occupationa

l Safet y & Healt h Am y Beasle y Spencer , Nationa

l Institute fo

r Occupationa

l Safet y & Healt h Georg e M . Fullbright , Owens/Cornin g Fibergla s Karsten H . Moritz , Ne

w Jersey Institute of

Technology Rober t J . Cavalier , Cavalie

r Enterprises , Inc . Gregor y A . L aFlam , Pacifi c Environmenta l Services , Inc . Dea n A . Carroll , Pacifi c Environmenta l Services , Inc .

Universit y TOWCT

, Suit e 40 4 • 310 1 Pett

y Road , Bo

x 3 7 • Durham , Nort

h Carolin a2770 7 Telephone : (919 ) 493-609 9 • Fax : (919 ) 493-639 3P. 3

I . Introductio n Th e purpos e o

f thi s projec t

wa s to suppor

t th e U.S . Environmenta

l Protectio n Agency' s (EPA ) effort s to develop Maximu mAchievabl e Contro l Technolog y (MACT) regulation s fo

r th e Reinforced Plastic s Composit e Productio n sourc e category . Th e ope n mol d proces s ha s bee

n preliminaril y identified a s th e larges t potentia l subcategor

y o f emission s within th e Reinforced Plasti c Composite s Productio n sourc e category . Boa t Manufacturin g als o utilize s th e ope n mol d process , an

d man y opportunitie s tha

t wer e identifie d prio r

to th e meeting were first

teste d an d utilize d i

n th e boa t manufacturing industry . Therefor

e participant s i n th e meeting represente d th e ope n mold segmen

t of th e Reinforced Plastic s Composite s sourc e categor y a s wel l a s th e Boa

t Manufacturing sourc e category . Th e deadlin e establishe d fo r th e developmen

t o f MAC T standard s fo

r Reinforce d Plastic s i s 1997 , an

d i t i s th e yea r 200 0 fo r Boa t Manufacturing . Boa

t manufacturing i s liste d a s aseparat

e categor y in section 112(c)(8 ) o

f th e 199 0 Clea

n Ai r Ac t amendments . Th e precedent

fo r regulatin g boa

t manufacturing a s aseparat e categor y wa s se t whe n th e Occupationa

l Safet y an d Healt h Administratio n (OSHA

) exempted boa

t manufacturing i

n their regulation s o

f worke r exposur e to styrene . Preliminar y investigation s into thes e sourc e categorie s identifie d sourc e reductio n technique s tha

t hav e alread

y bee n developed bu t

hav e no t full y penetrate d th e industry . A s such , th e meeting wa s oriente d mor e toward s th e discussio n o f specifi c product s an

d researc h effort s i n aforu

mwher e industr y could as k

question s an

d discus s th e advantage s an d limitation s o

f th e technology . Eac

h participant

briefl y introduce d themselves , an d provide d som e insigh t a s to wh y the y wer e participatin g i

n th e meeting . A copy o

f eac h participant s busines s car

d i s attache d (Attachmen

t 1) . Fou r genera l group s o f participant s wer

e present a t th e meeting . Th e group s represente d resi n manufacturers , resi n applicatio n equipmen t manufactures , fabricators , an d "other. " Th e resi n manufacturer s included majo r polyeste r resi n manufacturers , a s well a s manufacturer s o

f styren e suppressan

t resi n additives , photo initiato r additives , an

d wate r emulsified resins . Th e equipmen t manufacturer s include d th e larges t distributor s o

f spra y guns , a s well a s alternativ e les s pollutin g applicatio n equipmen t includin g pressurize d rollers , fabri c impregnators , an

d vacuu mba g molders . Th e fabricator s include d representative s fro m th e tu b an d showe r industry , filament

winding , an

d boa t manufacturing . "Other " include d th e U.S . EPA , Nationa

l Institute o

f Occupationa

l Safet y an d Healt h (NIOSH) , trad e associations , academia , an d EP A contractors . A flowchar t tha t illustrate s th e function s o

f th e differen t EP A office s an

d th e relationship of

thes e office s to th e variou s contractor s wa s requeste d an

d i s attache d (Attachmen

t 2) . I t wa s noted durin g th e meeting tha t anothe r secto r o f th e industry , reinforcemen t manufacturers , were no t

represente d a

t th e meeting . Th e meeting bega

n wit h a n introductio n on th e purpos e o f th e meeting , stressin g th e need fo r participant s to "brainstorm " an d no t t o focu s on issue s relate d t o th e limitation s ofP. 4

idea s (economic , mechanical , etc.) . Th e mai n goal s o f th e focu s group wer

e to identif

y a ful l rang e o f pollutio n preventio n options , includin g technica l change s and/o r

proces s modifications , an

d to discus s th e possibilit

y of overcomin g th e limitation s of suc h technologie s withi n th e industry . I n addition , th e meeting wa s intende d t o i n aprioritize d lis t o f potentia l sourc e reductio n researc h project s wit h atime fram

e fo r thei r implementation , if possible . Statu s o f MAC T Standard s Developmen t Th e first topi c o f discussio n wa s th e statu s of th e MAC T standard s developmen t effor t fo r Reinforce d Plasti c Composite s Production . Thi s standar d i s in th e first

stag e o f development , which i s th e informatio n gatherin g phase . Informatio n gatherin g include s literature searches , plant

visits , discussion s wit

h manufacturer s an

d trad e association s an

d th e development , distributio n an d analysi s o

f a n Informatio n Collectio n Reques t (ICR) o r surve y o f th e industry . Th e IC R wil l yiel d informatio n o n wha t technolog y i s currentl y bein g use d an d will provid e th e necessar y informatio n fo

r determinin g th e MAC T floor , which i s th e bes t performin g 1 2 percent

o f th e industry . Question s wer

e raise d o n th e criteri afo

r determinin g th e bes t

performin g 1 2 percent o f th e industry . If

atechnolog y ha s bee

n demonstrate d t o b e effectiv e i n on e secto r o f th e industry , industr

y representative s questione d whethe r i t would b e forced ont

o anothe r sector o f th e industry . One concer n wa s whethe

r amanufacture

r buildin g epox

y boat s wit

h vacuu m ba g technolog y (an

d virtuall y n o emissions ) would b e classified wit h afabricator

using polyeste r resin s i n ope

n molds . Industr

y representative s pointe d ou t tha t man y boa t manufacturer s hav e used sourc e reductio n technique s an d hav e gon e out

o f business , an

d there wa s concer

n tha t th e economic s o

f thes e alternativ e technologie s would no t b e studied . Assuranc e wa s give

n tha t EP A i s ver y sensitiv e to th e differen

t processe s an

d products , an

d their limitation s t

o adoptin g ne

w technologies . Question s wer

e als o raise d regardin g th e siz e cutof f fo r potentia l regulations . Industr y representative s asked whethe r th e larger manufacturer s would b e require d to instal l contro l equipment , thereb y penalizin g the man d givin g th e smalle

r facilitie s (tha

t ma y b e unde r a n emission s threshold ) a

n unfai r advantage . Conversely , i f asmall manufacture

r (buildin g on e dingh

y aweek ) use s a n exemplar

y process , could the

y stil l qualif

y in th e bes t 1 2 percent . Woul d amanufacture r wit h onl y on e spra y gu n b e considere d amajo

r sourc e becaus e th e 1 0 to n pe r

yea r cutof f i s simpl y theoretica

l an d i s based on th e potentia

l t o emit rather tha n th e actua

l emissions ? EP

A indicate d tha

t th e applicabilit

y of th e regulatio n ha s no t ye t bee n determined . Durin g th e informatio n gatherin g phase , al l manufacturer s ar e bein g considered , eve

n shop s wit

h a s fe w a s fou r employees . Question s were als o raise d a s to how muc h of th e budget

would b e geare d towar

d fugitiv e emission s tha

t coul d b e addresse d wit

h housekeeping change s (fo r example , loos e lid s o r uncovere d drums) .P. 5

A genera l discussio n o f

regulation s affectin

g th e sourc e categor

y an d styren e a s a pollutant wa s held . Styren e ha s historically been regulate d b y EP A unde r Titl e I (a s a precurso r to photochemica

l ozone ) along wit

h other volatil e organi c compound (VOC ) emissions . OSH

A ha s regulate d styren e fro mahealt h effects an

d worke r exposur e perspective . Stat

e regulations , zonin g an

d fire law s ar e als o constraints , an d the y ar e sometime s inconsisten

t wit h federa l environmenta

l regulations . I t

wa s pointe d out

tha t conflicting regulation s en

d up costin g manufacturer s significan t amount s o f

mone y on unnecessar

y change s tha

t hav e bee n require d mor

e fo r politica l tha n environmenta

l reasons . Fo r example , th e us e o f

abotto mdum

p dru mi s environmentally asuperio r wa y to handl e resi n bu t th e zonin g department , th e fire department , th e Stat e an d th e U.S . EP

A al l hav e thei r ow n rule s an d the y ar e ofte n contradictor

y in thei r objectives . OSH

A requirement s hav e ofte n le d t o increase d ventilatio n whic h i s no t th e sam e a s reduce d emissions . Th e lo w capita

l intensivenes s o

f thi s industr

y wa s discussed , a s well a s th e futur e inabilit y fo r ne w manufacturer s to get

starte d based o

n th e complexit

y an d requirement s o

f regulations . Historically , ther e wa s n o barrier

preventin g anyone wit

h " apicku

p truc k an d a garage " fro

menterin g thi s industry . Th e European s ar e believe d to b e a t agrea t disadvantag e to th e U.S . in th e small boa t market , du e to th e stric t

regulation s there . There wa s agenera

l discussio n o

f technolog y transfe

r an d th e suitabilit

y o f transferrin g sourc e reductio n technique s fro mon e industr

y segmen t t o another . There i s concer n tha t filamen t winding processe s an

d corrosio n an

d chemica l resistant product s coul d b e require d to enac t

th e sam e type s o f contro l measure s a s thos e use d b y th e les s restricte d tu b an d showe r manufacturers . Th e uniquenes s o f th e corrosio n resistant

resin s i n filament winding wa s brough

t up , an d severa l o f th e boa t manufacturer s state d tha

t man y o f thes e sam e concern s ar e applicabl e t o their industry . Fo r

example , som

e boat s ar e no

w buil t wit h abarrie r coa t o f 3 0 t o 7 5 millimeter s o

f corrosio n resistant

resi n behind th e ge l coat . I t wa s generally agree d tha

t man y o f th e opportunitie s would hav e asegmen t o f applicabilit

y an d tha t n o on e sourc e reductio n measur e would b e applicabl e t

o al l produc t

type s an d al l processes . I t

wa s als o acknowledged tha t man y in th e industr

y shar e th e sam e type s o f problem s an

d tha t i n som e areas , technology transfe r i s appropriate . Th e Composite s Fabricator s Associatio n (CFA ) prepare d adocumen t title d Policy Statement on Reducing Air

Emissions from Open Molding Composites Fabricators (Attachmen

t 3) . Thi s documen

t include s achar

t whic h break s dow

n processe s into their smalles t steps . Th e char

t take s th e finit

e numbe r o f step s i n th e productio n proces s an d look s a t eac h individua

l ste p a s asourc e o

f emissions , increasin g th e feasibilit y o f takin g simpl e step s to reduc e emissions . I t wa s agree d tha

t there wil l no t

b e on e "magi c bullet " technolog y tha t wil l solv e al l emission s problems . A n "option s list " fro

mwhich manufacturer s would b e abl e to choos e th e bes t

option s amongs t

pollutio n preventio n technique s on asituation-by

situatio n basis , would b e preferabl e fo r th e ne w standards . Th e assumptio n within th e industr y member s o

f th e grou p appeare d to b e tha

t th e standar d would b e aquantified standar d wit h arequire d percent

reduction . Fo r

thi s industry ,P. 6

tha t approac h i s no t

necessarily valid . Th e Sout h Coas t Air Qualit y Managemen

t Distric t (SCAQMD ) Rul e 1162 doe s no t hav e suc h apercent

reductio n an

d th e Rul e 116

2 approac h i s stil l a n option . Th e questio n a s to whethe r emission s a s estimate d usin g th e AP-4 2 emissio n factor s would b e use

d a s th e baselin e fo

r standard s wa s raised . I t

wa s pointe d out

tha t man y manufacturer s hav e alread

y changed processe s o r

incorporate d procedure s tha t reduc e emission s belo w wha

t AP-4 2 would estimate . Th e questio n of ho w thes e manufacturer s would b e credite d fo

r thes e change s wa s raised . Without a n understandin g of

how th e baselin e i s determined , there i s n o incentiv e fo r industr y to continu e changin g an

d improvin g thei r emissio n rates ; i n fact , they ma y benefit fro mdelayin g th e implementatio n o f emissio n reductio n change s unti l th e standard s ar e promulgated . Th e questio n of how thes e reduction s would b e quantifie d wa s raised . Equipmen t

Modification s I n atypica l spra y u p o r chop operation , half

o f th e styren e emission s ar e believe d t o occu r during , an

d a s aresul t

of , th e spraying , an

d half ar e believe d to occu

r durin g th e curin g process . Ther e i s no w suc h awide rang e of

applicatio n equipmen

t tha t th e fraction fro mapplicatio n ca

n rang e fro

mapproximately 8 0 percent fro ma n older high pressure airles s gu n to perhap s 2 0 percent

wit h ahigh volum

e lo w pressure (HPLV ) gun . Eliminatin g th e us e o f sprayin g wher

e i t i s no t necessary could b e ahel

p ir i reducin g emissions . Wit h th e exceptio n o f

applyin g ge l coa

t (wher e sprayin g i s necessar

y fo r acceptabl e cosmetics ) an

d chop (wher

e sprayin g i s a

n inherent par t of th e process) , sprayin g i s use d to transfe r th e resi n fro mth e dru mo r tan k ont o th e mold . I

n man y cases , usin g equipmen

t tha t doe s no t atomiz e th e resin , suc

h a s pressure-fe d roller

equipmen t o r flow-coater s wit

h pour heads , dramatically increase s transfe r efficiency an

d reduce s emissions . Pre-impregnate d fiberglass o r pre-preg s coul d b e aviabl e optio n i n certai n circumstances . Us e o f thes e technologie s nee d no t b e extremely expensive , becaus e th e spra y equipmen

t manufacturer s ar e currentl y producin g equipmen

t which i s either

adaptabl e t o o r

focuse d o n thes e type s o f

applications . Spray Guns Ther e wa s adiscussio n o f

change s i n spra

y gun technology , which ha s advance d dramatically sinc e 1985 . One equipmen t vendo r believe s fifty percent

o f th e field i s using 3 0 t o 4 0 yea r ol d spra y technolog y (i.e . th e airles s high pressure spra y gun) . Usin g newl

y advanced spra

y gun s significantl

y reduce s spra

y gu n emissions . I t

i s believe d tha

t tw o percent o f th e resi n weigh

t i s los t a s ai r emission s durin g spraying . Spra y gun s ar e require d fo

r ge l coa t operations , an

d typically higher

pressure s ar e used to atomiz e th e ge l coat . However , on e equipmen t vendo r believe s tha

t ge l coa t operation s only accoun

t fo r 8 t o 12 , o r

mayb e 15 , percent

of th e tota l emissions . Th e emissio n rat e fo

r ge l coa t operation s i s highe

r tha n durin g resi n application , bu t th e quantit

y o f ge l coa t use d i s asmall percent

o f th e tota l resi n use . Th e us e o f

roller s an d brushe s t

oP. 7

appl y ge l coa t i n England wa s brough

t up , bu t th e industr

y representative s were quic k to point ou t tha t th e Unite d Kingdom' s ge l coat s ar e of alowe r qualit y tha n America n ge l coats . Changing t o ales s cosmetically perfec t proces s would b e impossibl e fo r man y industr y segments . Nevertheless , lo w pressure , lo w volume ge l coa t sprayin g ca

n reduc e emission s significantly . B y usin g apressure of 3 5 (a s opposed t o 65 ) psi , asmalle r nozzl e orifice , an

d alowe r viscosit y gel , alo t

les s ge l coa

t i s use d t o cove

r asurface , an

d th e only economi c • los s i s i n increase d labo r

demands , du e to th e comparativ e slownes s of th e process . Usin g recommendation s suc

h a s these , a4 5 percent

reductio n in ge l coa

t spending ca

n b e achieved . Operato r trainin g wa s liste d a s th e ke y to making thes e change s effective . I t wa s pointe d ou t

tha t regulation s prohibitin g th e us e o f spra y gun s migh

t no t reduc e emissions . Industr

y emphasize d th e importanc e o f creatin g incentive s fo

r producer s to d o thing s mor

e efficiently , rather

tha n forcing the

mto mee t regulator y requirements . Th e issu e o

f "equipmen

t loyalty " an

d agenera l reluctanc e on th e par

t o f manufacturer s to chang e equipmen t brand s wa s raised . I t

wa s pointe d out

tha t MAC T standard s wil l be phased

i n ove r aperio d o f

year s an d tha t studie s hav e show

n tha t replacin g equipmen t i s profitabl e to manufacturers , wit h payback time bein g les s tha

n on e yea r i n som e cases , du e to th e amoun

t o f resi n saved . Pressure Fed

Rollers Th e us e o f pressure fe

d roller s a s awa

y to reduc e emission s wa s discussed . Certainly fo r man y applications , aspra

y gun i s no t

necessar y an d apressure fe

d rolle r tha t meter s resi n wil l resul t

in a n eve n distributio n o f

th e resi n witii significantl

y les s wast

e an d les s emissions . Ofte

n mold s ar e designe d to b e used wit h spra y gu n technolog y an

d b y rethinkin g th e manufacturing process , roller s ca n b e used instea

d o f spra y guns . Th e pressure fe

d roller technolog y should eventually penetrate th e fabricatio n industr y becaus e i t

ca n b e show n tha t there i s a n economi c incentiv e fo

r usin g thi s technology . Governmen t should no t

forc e adoptio n o f

thi s technology , b y bannin g th e us e of th e spra y gun ; rather , industr

y should b e educate d tha

t ahighe r quality , lowe

r cos t produc t ca n b e produce d usin g thi s technology , which i s als o les s polluting . Vacuum Bag Molding Vacuu mbag moldin g i s atechnolog y tha t ha s bee n in existenc e sinc e 1948 . Th e MARC O vacuu

mba g method , dr

y fabri c wa s place d on th e mold , there wa s aresi n trough aroun d th e part , and th e vacuu mpulle d th e resi n up an

d through th e fabric . Sometime s th e resi n woul d hav e t o infus e up si x feet . Ne

w advance s in vacuu

mba g moldin g hav e occurred , primaril y in th e resi n deliver y technique . I n vacuu

massiste d resi n transfe

r an d in th e vacuuminfusion process , th e resi n goe s over th e fabri c an

d under th e vacuu mbag . Th e resi n only ha s t o infus e throug h th e thicknes s o f th e part . 

## fP. 8

Vacuu mba g molding i s rather

simple ; th e fabri c i s lai d o n th e mol d dry , aresi n distributio n syste

mi s pu t o n to p o f th e fabric , th e vacuu

mba g i s pu t ove r th e mold , an

d a vacuu mi s drawn which pull s th e resi n ove r th e fabric . Part s mad

e usin g thi s proces s hav e bee n around fo

r awhil e an

d hav e undergon e extensiv e testing . Vacuu mba g moldin g work s wit h flat , female , an

d mal e molded parts . Th e qualit y of th e finished part s i s simila r to tha t i n th e aerospac e industry , wit h glas s content s of

7 0 percent

and avirtuall y porosit

y free product . Smal l part s ca

n b e made , an

d currentl y availabl e materials , includin g epoxies , phenolics , polyesters , an

d viny l esters , wor

k wit h th e system . Thi s syste

mwet s out

fiber underneat h acore . One compan

y ha s bee n workin g wit

h vacuu mba g molding unde

r contrac t to th e Nava l Researc h lab , focusing o n th e abilit y t o produc e ver

y large , high qualit

y parts . Th e Nav y ha s require d th e developmen t o f thi s technolog y usin g material s alread y o n th e market . OSH A ha s been unabl e to detec t emission s in thi s sho

p whil e usin g th e vacuu

mba g technology , despit

e th e fac t tha t th e buildin g i s ai r

conditione d an

d there i s n o specia

l ventilatio n a

t work . I n addition , th e worker s ar e happie r wit h aclean , comfortabl e environment . Recently Tilli s & Pearso n (boa t manufacturer s i n Rhode Island ) hav e begu n usin g thi s ne w technolog y wit

h existin g molds . The

y hav e buil t

a t leas t sixt y Ja y 80' s an d the y ar e gearin g u p to buil d other

boa t models . The

y ar e saving mone

y an d labo r wit h thi s technology , buildin g half

o f a6 4 foo t hull in les s tha

n a n hour . I n som e application s wher

e cosmetic s ar e no t

aprimar y concern , th e surfac e i s neithe r ski n coate d no r

ge l coated . Th e cure d resi n i s translucen t an d an y problem s i

n th e final produc t ar e clearl y visible . Becaus e th e product s ar e produce d i n on e step , however , there i s aproblemwit

h prin t through . Reichhol d i s currentl y assistin g in providin g idea s and/o r researc h in solvin g thi s prin t through problem . Productio n shop s d o typically includ e age l coa t step . Improvement s in th e cosmeti c qualit y produce d b y th e vacuu

mbagging , non-ge l coa t proces s ar e bein g investigate d i n order to allo w fo

r th e us e o f

thi s technolog y among mor e manufacturers . Warpag e i s no t aproblemwit

h thi s technology . A collectiv e problem solving effor

t coul d b e mad

e i n thi s field. I t

wa s pointe d out

tha t free exchang e of informatio n an

d cooperatio n would b e invaluabl e to solving alo t o f th e problem s bein g discussed . Vacuu mba g molding technology i s acos t effectiv e sourc e reductio n optio n fo r larg e boa t manufacturing . There ar e secondar y benefits , t o thi s proces s a s well , includin g a reductio n i n soli d waste , th e need fo r littl e re-trainin g o f

employees , a

n increas e i

n competitiveness , n o need fo r chemica l re-formulation , an

d areductio n in OSH

A concerns . Thi s i s a"ne

w ol d process, " becaus e i t i s awa y to us e old technique s wit h ne w innovations . Vacuu mba g molding i s slowl

y penetratin g som

e segment s of

th e reinforce d plastic s composit e productio n an

d boa t manufacturing industry ; however , there ar e concern s in pushin g th e technolog y to o fast . Thi s technolog y doe s no t eliminat e al l emissions . Han

d la yP. 9

up , secondar

y bonding , an

d ge l coatin g application s ar e stil l used in shop s tha t us e vacuu

m ba g molding technology . Vacuu mba g moldin g ma

y b e a n idea l system , bu t

i t i s no t currentl y viabl e fo

r hig h volume productio n applications , includin g tub s an d shower s an

d entr y leve l boat s (1 7 to 1 8 fee t i n length) . I n th e 1 7 an

d 1 8 foo t segmen t o f th e marin e industry , cosmetic s ar e incredibly important

an d wil l mak

e adoptio n of

thi s technolog y difficult . There i s n o economi c advantag e to buildin g small boat s wit h thi s technology ; th e current boa t weight s ar e acceptable . I t i s believe d tha

t thi s technology i s advantageou s fo r som e boa t manufacturer s an

d th e aerospac e industry , wher e vacuu massiste d resi n transfe

r technolog y provide s a

n economi c advantag e ove

r th e us e o f

pre-pregs . Side panel s fo r Clas s A motor

home s ar e currentl y buil t

usin g vacuu

mba g molding technology , although the y ar e believe d to us e wet laminate . Thi s technolog y wa s believe d to b e easily transferrabl e t o tha t industr y segment , although there were n o clas s A motor hom e fabricator s present

a t th e meeting . There i s a

n emission s reductio n in usin g dr y laminate , becaus e th e us e of we t laminate s ha s emission s unti l th e vacuu

mi s drawn . Thi s proces s als o work s wit h phot o initiate d resins . Laminating or

Fabric Impregnator

machines Th e proces s o f

impregnatin g laminat

e usin g afabri c impregnato r wa s described . Th e proces s i s t o squeez e th e resi n int o th e fabri c usin g roller s tha t resembl e "grandma' s wash wringer. " Thi s technolog y ca n accurately wet

ou t 10 0 squar e fee t o f laminat e per minute , versu s th e 1 0 squar

e fee t tha t askille d operato r

coul d accomplish . Thi s technolog y allow s th e us e o f lowe r viscosit y resins , which allow s reduction s i n th e monome

r conten t o f th e resin . I n addition , 4 8 to 5 0 ounc e rovin g ca n b e used . I

n th e past , th e weigh

t o f th e rovin g wa s restricte d b y how lon g i t took to properl y wet

out th e rovin g b y hand . Thi s ca

n resul t in using fewe

r laminatin g step s t

o buil d th e product , whic

h result s in fewe

r emissions . Proces s change s ofte

n require othe

r change s to mak

e th e technolog y work . Fo r example , worker s nee d t o b e re-traine d an d there ar e other

change s tha

t facilitat e th e us e o

f fabri c impregnators , includin g tiltin g molds , customconfigured resins , alternativ e catalysts , and/o r initiators . On e problemwit

h th e fabri c impregnator

i s tha t th e boa t industr y tend s t o ru n ver y shor t ge l times . Thi s mean s tha t th e projec t

need s t o run through th e machine in twent y minute s an

d the n th e proces s mus t

shu t dow n whil e i t i s cleaned . I

n a n elegan t combinatio n o f man y technologies , photo initiate d resin s ca n b e used wit

h th e fabri c impregnator . I n thi s combination , th e fabricatin g ca n b e interrupte d b y throwin g atar p ove r th e projec t

whil e a lunch brea k i s take n an d the n th e wor k ca n resum e without cleanin g th e machines . 8P.1 0

Resin s an d Resi n Additive s A second wa

y t o reduc e emission s i s throug h th e resi n formulation . On e optio n fo r complyin g wit

h SCAQM

D Rul e 1162 i s t o reduc e th e styren e conten t o f th e resi n t o 3 5 percent . Resin s o f

thi s typ e ar e terme d lo w styren e resin s an d hav e differen

t physica l propertie s whic h ma

y resul t i n fabricator s increasin g th e numbe r of laminatin g layers . Th e possibilit y tha t th e SCAQM

D Rul e 1162 ma

y hav e increase d emission s b y requirin g mor e laminatin g step s wa s raised . Th e lac k of analysi s towar

d actua l emissio n reduction s achieve d through rul e 116 2 wa s discussed . Fabricator s hav e arang e o f additives , ofte

n calle d micr

o ingredient s an

d processin g aids , which ca

n b e adde d to abas e resin . Th e additive s on th e market hav e man y functions . Th e mos t common additive s ar e catalyst s an d mol d releas e agents . Differen t catalyst s ca

n affec t th e cure time o

f th e resi n an

d consequentl

y th e emissio n rate . Th e next mos t commo n additive s ar e use d t o increas e ai r releas e an

d facilitat e wettin g of

th e laminate . Th e lo w styren e resin s hav e sacrificed som e properties , and processin g agent s ar e used t o enhanc e th e propertie s o f

ai r releas e and fiber

wetting . I n th e marin e industry , th e us e o f lo w styren e resin s ca

n resul t i n aproduc t

tha t i s mor e pron e t o cracking . Rathe r tha n dealin g wit

h thi s problemb y addin g more glas s (an d consequently mor

e resin , creatin g mor

e emissions ) additive s pa

n b e used to increas e flexibilit y an d decreas e cracking . Styrene Suppressants Additive s tha

t suppres s styren e emission s wor k b y crystallizin g a

t th e surfac e o f

th e laminate . Evaporatio n o f

styren e cool s th e surface , which crystallize s th e additive . Th e functioning o f

th e additiv e i s ver

y dependen

t upon it s solubilit

y in th e resin , which in tur n i s dependen t upon th e temperatur

e an d th e exother

mof th e resin . High ai r

flow s acros s th e surfac e wil l resul t

in rapi d reactio n of

th e additives , du e to th e increase d evaporatio n of styrene . Styren e suppressan t additive s ca

n reduc e curin g emission s by 8 0 percent whe n use d wit h astandar

d orthophthali c resi n wit

h afifteen minut

e ge l time , usin g methy l ethy l keton e peroxid e (MEKP) initiato r an d cobalt . Thes e reduction s do no t apply to emission s fro

m sprayin g operations . Th e us e o f thes e additive s wil l hav e a n emissio n reductio n effec t i n handlin g operation s suc

h a s fugitiv e emission s froma n uncovere d drum . Ther e wa s adiscussio n o f

th e suitabilit

y o f usin g styren e suppressan

t resin s i n corrosio n resistant

an d fire retardant

applications , du e to problem s of secondar y bonding . There ar e resi n additive s in existenc e whic h reduc e styren e emission s without introducin g secondar y bondin g problems , an

d manufacturer s hav e supportin g data . However , there ar e limit s t o th e us e o f

additive s i

n reducin g emissions .P.1 1

Benzoyl Peroxide (BPO) Benzoyl peroxid e (BPO ) ca n b e used instea

d o f methyl ethy l keton e peroxid e (MEKP ) a s a n initiator . One fabricator bega n a n analysi s of

BPO whe n th e Occupationa

l Safet y an d Healt h Administratio n (OSHA

) wa s considerin g lowerin g th e acceptabl e worke r exposur e limi t fo r styren e to 5 0 ppm . Knowin g tha t the y exceeded th e 5 0 pp mthreshold , on e fabricator wanted t o find awa

y to reduc e th e concentratio n without spending alo t

o f mone y on a n engineerin g solution . TTie y bega n usin g BP

O and notice d significan

t reduction s i

n th e concentration s o f

styren e in th e spra

y booths . A tes t wa s conducte d to determin e how muc h th e emission s were reduce d usin g th e BPO . Th e sam

e amoun t o f materia l wa s sprayed on tw o molds , usin g th e sam e spra y booth , usin g th e sam

e leve l o f initiator . Ga s tex sensidyne tube s were place d a n inc h abov e th e laminat e i n anumbe

r o f differen t intervals . Th e styren e coming of f th e laminat

e cure d using BP O wa s determine d to b e tw o third s les s tha n th e styren e coming of

f th e laminat

e cure d wit h MEKP . Th e BP O decrease s th e ge l time dramatically , allowin g th e product s to reac h th e require d Barco l hardnes s in a n hour , a s opposed t o th e 4 8 hour s require d wit h th e us e o f MEKP . Th e cos t o f using BP O i s ove r twic e a s hig

h a s MEKP , bu t

ther e ar e saving s tha

t offse t thes e costs . Respirator s ar e no longe r require d fo

r th e wor k force , du e to th e lo w readin g o f styren e emission s in th e spra y booths , an

d th e employee s ar e happier . Th e BPO enhance s th e propertie s o f

th e product s bein g built , whic h includ e hors e trailer

tops , tub s an

d showers , an

d small ope

n molde d tanks . I t

i s recognize d tha

t man y factor s affec

t th e fractur

e rate , bu t i t i s believe d th e BPO ha s reduce d fractur e rates . Th e chemica

l limitation s o

f using BP O in achemica

l resi n were mentioned . Difference s between th e tub/showe r industr y segmen t and th e filament

winder s wa s discussed , includin g th e lac k o f fillers in filament

windin g an

d th e differen

t type s of resin s tha t ar e used . Th e filament

winder s hav e trie d BP

O an d dimethy l anilin e (DMA

) bu t were unabl e t o achiev e th e desire d Barco l hardnes s readings . Th e chemistr y fo r th e viny l ester resin s i s differen

t an d a s suc h th e desire d Barco l hardnes s canno t b e achieve d usin g BPO/DMA initiators . Fo r th e filament

winders , th e productio n of aflims y par

t i s unacceptabl e and they need to us e pos t curin g to achiev e th e desire d Barco l hardness . There wa s areques t

fo r amor e scientifi c an

d defensibl e tes t

to quantif y thes e findings. Photocuring Resin Additives Light-cure d o r

photocure d resi n i s anothe r ne w technolog y tha

t i s penetratin g th e industry . I

n thi s process , aphotocurin g additiv e i s mixed wit h th e resin , th e resi n i s applied , 1 0P.1 2

th e produc t

i s exposed to light , an

d th e produc t

cure s usually within 1 0 seconds . Barco l hardnes s ca

n b e reache d in 1 0 minutes , a t which point

th e par t i s remove d fro

mth e mold . Within 1 0 second s o f

th e light application , th e styren e i s locke d insid e th e par t an d emission s cease . Th e photocurin g additive s hav e n o effec t on reducin g emission s durin g sprayin g o r other application s methods , th e emissio n reductio n i s achieve d in th e curin g phase .

Advantage s o f

photocurin g resi n include : N o mixin g an d dosin g i s necessary ; mixin g an d meterin g system s for curin g agent s ar e no t needed . N o mixin g an

d meterin g errors . N o limit s on th e processin g time (th e "po t life" ) by th e additio n o f

th e catalys t

an d th e accelerator . Fas t gellin g an

d shor t curin g times . Curin g wit

h les s stress . Reduce d evaporatio n o f

styrene . Re-us e o f resi n waste . Lo w cleanin g costs . Les s cleanin g agent s required . Disadvantage s include : Canno t b e pigmented . Onl y limite d quantitie s o

f transparen

t fillers ca n b e added . Light cure d resi n i s mor

e expensiv e tha

n standar d resin , bu t

ther e ar e saving s associate d wit

h it . Fo r example , there i s les s waste , sinc e th e resi n ca n b e gathere d u

p an d reused . I n addition , bot

h labo r an d solven t cost s fo r clea n u p ar e reduce d becaus e th e resi n doe s no t cure unti l th e light

i s activated . Cost s associate d wit h thi s syste

minclud e th e cos t o f th e resi n an

d th e lamps . Th e cos t

i s dependen

t upon th e application , an

d th e quantit

y an d reactivit y o f th e resin . Th e photocurin g additiv e cost s 2 0 to 2 5 cent s apound . Fluorescent lamp s wor k well and ar e les s expensiv e tha n mercur y vapo r lamps . Thi s proces s ca

n increas e th e productio n schedul e an d cost s should b e analyze d on acas e b y cas e basi s to determin e i f

th e increase d cost s o

f th e resi n wil l resul t

in saving s in other

productio n costs . Hea t i s no t require d fo

r photocurin g resi n an

d i t work s well in col d weather . However , th e applicatio n metho d (spraying , rolling , etc. ) doe s requir e awar mresi n tha

t will flow . Thi s typ e o f

resi n allow s wid e variation s in bot h th e temperatur

e an d viscosit y o f th e resi n formulation . I t

ca n b e held a

t atemperatur

e o f 13 0 ° F fo

r awhil e an

d ca n mov e ver

y quickly throug h th e resi n transfe r molding system . Photocurin g additive s ar e BAS F technology . Thi s curin g syste mresult s i

n complet e cross-linking ; th e product s hav e n o styren e smell , even i f they ar e broken . Laminate s up 5/8 " thic k ca n b e mad e i n on e step . Thi s resi n ha s bee n used wit h 2 4 ounc e roving s an

d a 1 1P.1 3

fabri c impregnator , an

d th e laminat

e wa s cure d in on e step . Ful l curin g ca n b e achieved , eve n i n corners , wit

h th e us e o f

han d hel d lights . Thi s proces s i s i n commercia l production . Th e Arm

y i s currentl y usin g patche s create d b y thi s process . Th e patche s ar e preimpregnate d repai r kits . The

y ca n b e used to patc h aluminum , steel , o r

fiberglass. A small boa

t manufacturing facilit

y in Florid ai s als o usin g thi s process . I n addition , afirmi n Texa s i s usin g thi s technolog y t o buil d 5 2 inc h coupling s fo

r sewag e pipes . A s par

t of ateachin g program , thi s resi n i s used to buil d a coupl e o f boat s ayear . One advantag e of thi s syste mi s tha t th e brushe s and roller s ca n b e wrappe d i n foi l overnigh

t and used agai n th e next

day , thereb y reducin g th e amoun t o f solvent s an

d th e time used i n clean-up . Thi s resi n wil l no t

wor k well i n th e tub/showe

r industr y becaus e th e fillers used , primaril y calciumcarbonate , ar e opaqu e an d interfer e wit h th e curing . Thi s resi n can , however , b e used wit

h polypropylen e core materials , becaus e the y allo w th e penetratio n of light . Currently , ther e i s ajoin t effor t t o integrate th e technologie s o f vacuumassiste d resi n transfe r an d photocurin g resins . I

n th e vacuu

mprocess , th e fibers ar e washed ou t whe n th e resi n i s pulle d through . Th e photocurin g resi n ca n b e use d to stapl e th e reinforcemen t i n plac e b y selectively curin g smal l area s o f resin . Onc e th e reinforcemen t i s securely in plac e th e vacuu mwil l b e drawn an

d th e resi n wil l b e pulle d through . Water Emulsified

Resin I n th e past , wate

r emulsified resin s hav e ha

d alo t of problems ; th e resi n shrank , there were problem s gettin g al l o f th e wate r out , th e laminate s ha

d crackin g problems , an

d th e cure d produc t

tende d to giv e up it s physica l an d mechanica

l properties , resultin g in aproduc t tha t wa s unsatisfactor

y in structura

l applications . A ne

w wate r emulsified resi n ha s recently bee n develope d tha

t doe s no t hav e thes e problem s and limitation s an d i s believe d to hav e lowe r styren e emissions . Th e pea k exother m(18 5 °F ) an

d vapo r pressure ar e lowe

r tha n fo r nea t resin . Therefore , th e styren e i s les s volatil e an d emission s ar e reduced . Th e ne w wate r emulsified resi n i s produce d b y addin g a n agen t to th e wate

r an d anothe r agen t to th e resin , an

d amachine i s used t o emulsif y th e resi n an

d water . Thi s result s in a

n emulsified resi n tha

t contain s fort

y percent les s styren e tha

n nea t resin . Thi s reduce s overal l cos t

o f th e resi n b y eigh

t t o te n cent s apound . Th e emulsified resi n i s stable ; i t ca n b e manufactured a

t aresi n manufacturing facilit y an d shipped . Th e intent

i s to licens e th e technology , sell th e machine an d hav e th e fabricator s emulsif y th e resi n o

n site . Thi s woul d avoi d th e cos t

o f shipping th e water . Th e wate r come s ou t

o f th e resi n durin g th e curin g process , an d ahigh densit

y cellula r structur e i s produced . N o pos t

curin g i s required . Secondar y bondin g i s believe d to b e enhance d du e t

o th e propertie s o

f th e agent s tha

t ar e added to emulsif

y th e resin . There 1 2P. M

hav e no t been an y test s o n thi s resi n fo

r chemica l resistance . Th e initia

l marke t wa s see n a s th e marin e and tub/showe

r segment s of

th e industry . An

y fire retardant

an d temperatur

e resistent propertie s tha

t ar e i n th e bas e resi n wil l b e maintaine d i n th e emulsified resin . Th e cure d resi n ha s equa

l physica l an d mechanica

l propertie s to thos e o f

anea t resin . Th e cure d resi n i s thicke

r an d stiffe r pe r dolla r o f resi n applied . There hav e bee

n n o forma

l emissio n rat e tests . Som e test s were conducte d wit h draegge r tubes . Emission s ar e believe d to b e lowe r becaus e of

th e lowe r styren e content , th e lower exother mand th e lower

vapo r pressure . I t

wa s generally agree d tha

t a4 0 percent reductio n i n th e styren e conten t o f th e resi n wil l no t

necessarily translate int o a4 0 percent reductio n in th e emissions ; th e reductio n coul d b e higher . Humidit y i s know n t o effec t emissio n rate s an

d th e evaporatio n o f

wate r would probably als o effec t th e emission s fro

m thi s resin . Thi s proces s ha s bee

n teste d b y buildin g acommercia l fishing boa

t which i s stil l i

n th e wate r an d show s n o sign s o

f problems . Durin g th e constructio n o f th e boa t there wa s no nee d to periodicall y ope

n u p th e buildin g to ai r

ou t th e styren e emissions . I

n addition , tes t panel s were prepare d and sen t to laboratorie s fo

r tensile , flexibility , an

d impac t tests . One tes t pane l wa s mad

e wit h thre e layer s o

f 1. 5 ounc e chop strand ma t an d th e othe r tes t pane l wa s mad e wit h thre e layer s o

f 1. 5 ounc e chop strand ma t an d thre e layer s o

f continuou s roving . Th e highe

r glas s conten

t pane l did hav e highe

r number s tha

n th e nea t resi n bu t statistically n o differenc e i n th e structura l test s wer e observed . Th e thickes t

laminat e produce d wa s 3/ 8 inch , an d n o cracking , steaming , o r boilin g u p o f th e resi n wa s observed . Th e emulsified resi n i s white , which require s tha t worker s in th e marin e industry , who ar e accustomed to clea r resins , becom

e comfortabl e wit

h rollin g out

awhit e resi n wher

e th e existenc e o

f ai r bubble s would no t

b e visible . Thi s resi n i s ver y eas y to rol l out . Thi s resi n i s no t

yet in commercia

l use . Th e wate r emulsified resi n ca

n b e used wit

h MEK P o r BP O an d standar d spra y equipment . There i s th e possibilit y tha t th e tip s of

th e spra y gun s ma

y corrod e du e t

o th e water . A venu s choppe

r gu n wa s used durin g th e buildin g o f th e commercia

l fishing boat . Th e resi n ha s goo d structura l propertie s becaus e i t

i s thicke r an d stiffe r tha n nea t resin . There wa s areques t

t o includ e thi s wate

r emulsified resi n in th e CF A emissio n tes t program . Research to Determine a Non-volatile Cross Linking Agent Th e Emissio n Reductio n Research Cente r i s acooperativ e organizatio n composed of academi aan

d industria

l representatives . Th e consortiumi s composed of New Jersey Institute o f Technolog y (NJTT) , th e Massachusett s Institute o f Technolog y (MIT) , Ohi o Stat e Universit y an d Pennsylvani aStat

e University . Thei r

current fundin g i s fro mth e Nationa

l Scienc e Foundation . The

y ar e currentl y researchin g ane w resi n formulatio n tha

t utilize s a 1 3P.1 5

non-volatil e cros s linkin g agent . The y ar e jus t beginnin g thi s researc h effor t an d do not hav e anythin g t o pu t

on th e tabl e a

t thi s time . Fabricator s Severa l concern s were voice d b y th e fabricators . Th e IC R and th e difficult y o f estimatin g baselin e emission s wit h th e current

tool s availabl e wa s discussed . I n addition , th e lac k o f definitio n o f

th e targe t fo r th e regulatio n wa s o f

concern . Specifically , i t

wa s questione d whethe

r a n 8 0 percent

emissio n reductio n o f

emission s froma

n ope n mol d proces s usin g aspra

y gun would b e enough . Inquirie s wer e als o mad

e a s to whethe

r reduction s tha

t ca n b e achieve d b y switching from aspra y gu n t o apressure fe

d rolle r would b e enoug h o r would th e fabricator

nee d to g o al l th e wa

y to vacuu mbag molding ? Afte

r th e emission s fro

msprayin g resi n ar e reduced , th e emission s fro msprayin g ge l coa

t wil l b e th e nex t singl e larges t

chun k o f emission s an

d th e next logica l target fo r reductions . A discussio n o f

plant visit s wa s held . N o applicatio n contro l equipmen t (fo r example , incinerators ) ha s bee

n observe d in thi s industry , b y EP A representatives , although som e i s know n to exist . On e fabricator

mentioned tha

t durin g aplant

visi t to hi s facility , h e held bac k nothin g an

d showe d th e contractor s everythin g the y wished to see , in order

t o ensur e tha t there wa s agoo d understandin g o f hi s industr

y an d th e problem s which misguided regulatio n coul d hav e on hi s business . Filament windin g use s historica

l dat afo r corrosio n an

d chemica l resistant properties . Filamen t windin g typically use s astandar d MEK P initiator ; there ar e n o fillers, th e curin g i s typically don e a

t roo mtemperature , the

y ofte n buil d ver

y larg e vessels , an

d secondar

y bondin g i s a

n importan

t issu e becaus e o

f th e liabilit

y i f on e o f thes e vessel s wer

e to fail . Withi n th e shop , te

n differen t resin s ca n b e in us e a

t on e time . Ofte

n th e structure s ar e buil t in th e field. There ar e fort y year s of dat aon som

e of thes e resins , which allo w fo r agrea t dea l o f confidenc e in th e us e o f

thes e material s to buil d vessel s tha t wil l hous e acid s an

d othe r substance s tha

t wil l caus e grea

t environmenta

l damag e in th e event

o f a n accident . Th e us e o f

specialt y resin s wit

h chemica l an d corrosio n resistant

propertie s i s no t limite d to th e filament

windin g segmen

t o f th e industry . Th e marin e industr y ofte n use s a corrosio n resistant

viny l ester

barrie r coa t to reduc e blistering . I

n addition , product s buil t

fo r th e governmen

t (specificall

y th e defens e department

) ofte n require thes e highe

r properties . Th e plasti c composite s industr y ha s bee n hi t wit h anumbe

r of regulation s an

d investment s t o compl

y wit h thes e regulatio n ar e ofte

n counterproductive . Fo r

example , automati c handlin g equipmen t tha t would pum

p resi n throughout

th e plant coul d b e installe d i n afacilit y fo r approximately $20,000 . Thi s typ e o f equipmen t significantly reduce s "housekeeping " emissions , suc h a s fugitiv e emission s fromuncovere d drum s an d reduce s labo r costs . Installatio n o f

automati c handlin g equipmen t i n som e State s an

d localities , however , conflict s wit

h cit y plannin g ordinance s ari

d fire departmen

t regulation s (th e fire departmen t prefer s tha

t resi n b e poure d int o buckets) . T o compl y wit h thes e other 1 4P.1 6

regulation s a

n additiona

l $60,00 0 woul d b e require d t o instal l acontainmen t are ato hol d th e liqui d bins , asprinkle

r syste move r th e containmen

t areas , sum

p pump s t o pum

p rai n wate

r out o f th e bin , etc . Cost s associate d wit h ne w operatin g permit s were mentioned , a s well a s th e cos t o f havin g aful

l time employe e who onl

y deal s wit

h regulations . Also , th e uncertaint y o f th e regulation s tha

t ar e bein g develope d wa s voice d a s aproblem . One tu b and showe

r fabricator state d tha t i n asmall (roughly 13 0 unit s aday ) shop , h e reduce d ge l coa

t usag e b y on e third . Thi s wa s accomplishe d whe n th e pum p pressure wa s reduce d from6 5 ps i dow

n t o 3 5 psi , on a2 0 t o 1 pump , th e orific e siz e o f th e spra y ti p wa s reduce d from21,00 0 t o 18,00 0 an d th e viscosit

y o f th e ge l coa

t wa s lowered . Measuremen t o f ge l coa t usag e showe

d tha t previously th e manufacture r used 16 4 ounce s o f

ge l coa t to cove r atub/shower

and usin g th e ne

w lo w pressure gun reduce d th e ge l coa t usag e to 12

4 ounce s o f materia l to cove r atub/showe

r a t th e sam e thickness . Labor

cost s increased , bu t th e actua l ge l coa t cost s hav e bee

n reduce d b y 4 0 percent . Additiona l reduction s fo

r thi s fabricator

coul d b e achieve d b y hi s usin g alowe r fluid pressure ; fo

r example , 35 0 ps i instea

d of 70 0 psi . Bu

t th e high pressure i s used becaus e thi s fabricator stil l choose s to us e a

n externa l mi x gun . Operator

trainin g i s ver

y important

to reduc e ge l coa

t usage . Anothe r tub/showe

r manufacture

r state d tha t h e i s locke d int o usin g th e spra y booth s tha t hi s compan

y uses . The

y ar e currentl y abl e to produc e 8 0 t o 9 0 tub/shower s pe r

ge l coa t operato r (a s opposed to th e 2 5 to 3 0 tha t ar e produce d using th e lowe r pressure s mentione d above) . Du e t o th e conveyor lin e nature o

f th e wa y thi s sho p i s se t up , i t would b e impractica l to hav e th e tub/shower s held up to apply th e ge l coa t wit h lowe r pressure . A discussio n o f

reducin g emission s through reduction s in th e numbe r o f laminatin g step s wa s raised . I t

wa s pointe d ou t

tha t in Californi athere coul d b e anegativ e impac t (increase d emissions) , becaus e usin g lo w styren e resin s ma y resul t in afabricator

usin g five laminatin g layer s instea

d o f fou r t o compensat

e fo r th e los s o

f structura l propertie s o f

th e low styren e resins . I t

wa s pointe d ou t

tha t emission s coul d b e reduce d b y reducin g th e numbe r o f laminatin g layers . Som

e boa t manufacturer s ar e beginnin g to us e 6 0 ounc e glas s an d puttin g dow n on e layer . Fabricator s mus t

compet e no t onl y wit h other composite s fabrication s bu t wit h other materials , suc

h a s steel stamped tub s an

d tiles . Thi s plant

ha s 3 0 model s a

t on e plant an d 4 0 model s a t anothe r plant . Tyin g up th e mold s to us e lo w pressure gun s would b e impractical . High volume seria

l productio n i s no t

limite d t o th e tub/shower s sector of th e industry . Th e transportatio n segment , which include s truc k hoods , truc k

cabs , va n tops , etc. , would hav e th e sam

e problem s wit

h technolog y transfe

r a s th e tub/showe

r segment . Purchasin g ne

w equipmen

t a s aresul t

o f MAC T regulation s coul d hav e aprofitabl e impac t o n man y manufacturers . Old , airless , high pressure equipmen t ca n b e replace d wit

h 1 5P.1 7

ne w equipmen

t wit h apa y back perio d o f les s tha n on e year . Replacemen

t of ol d equipmen

t ca n b e amone

y maker . Thi s i s aver

y lo w capita

l intensiv e industry . I t

wa s mentione d tha

t asid e effec

t o f regulatio n could b e th e developmen t an d expansio n of

ne w technologies , wit

h a n overal l lowerin g o

f costs . Tes t Program s A discussio n o f

th e upcoming CF

A tes t progra mfo r ope n mol d processe s wa s held . Th e purpos e o f

th e tes t progra mi s t o get

datato suppor

t th e regulator

y developmen

t effort . Th e test s wil l b e conducte d a t th e DO W Chemica

l facilit y i n Freeport , Texas . DOW i s a majo r manufacture

r o f styrene , an

d thi s facilit

y ha s th e analytica

l equipmen

t an d peopl e to suppor t th e testing . Th e test s wil l b e conducte d ove r a3 0 to 4 5 da

y time perio d in a controlle d environment . Th e dat awil l b e publi c an d wil l hopefull

y b e used in th e developmen

t o f revise d emissio n factors . Th e testin g i s currentl y scheduled to begi n in 3 0 t o 4 0 days . Th e test s wil l b e used to establis h baselin e emissio n rates . Seve n variable s wil l b e analyzed , includin g percent styrene , airflow , ambien

t temperature , ge l time , surfac e area , an d deliver y rat e (th e sevent

h variabl e wa s no t

remembere d a

t th e time o f

th e meeting) . Each variabl e wil l b e teste d a t tw o point s wit

h other factor s held constant , an

d th e datawil l b e analyze d usin g th e Taguch i scientifi c method . Th e result s o f th e tes t coul d b e use

d in th e developmen

t o f apredictiv e tool . Th e CF A i s contributin g $30,00 0 t o addres s direc t cost s fo r th e on-site testing . They ar e als o contributin g indirec t cost s fo r non direc t

bille d expenses , suc

h a s professiona

l time . Th e tota l cos t o f th e progra

mi s probably close

r to $50,00 0 to $60,000 . Lac k o f resource s wil l exclud e additiona

l tes t scenarios . Th e tes t

wil l measur

e percent styren e lost . They wil l run aspra y applicatio n o f

resi n an d aspra y applicatio n o f

ge l coat , an

d the n han d batc h it . Ideally , they woul d lik e t o analyz e seve n resin s an

d about 2 0 variables , an d al l o f

th e currentl y availabl e applicatio n equipment . Th e resource s ar e simpl y no t availabl e fo

r this . A recent pultrusio n emissio n rat e stud y showe d tha t temperatur

e i s aleve l on e factor i n emissio n rate . Question s wer e raise d concernin g th e regulatio n of shop temperature , if temperatur

e i s foun d t o b e ver y important . Regulatio n o f sho p temperatur

e wa s no t rule d out . Transfe

r efficiency wil l not

b e teste d directl y i n th e CF A program . Mas s balanc e wil l b e take n int o account , bu t

only alimite d amoun

t o f applicatio n equipmen

t wil l b e analyzed . Industr y representative s state d tha t the y hav e performe d man

y test s on thei r

ow n an d would lik e t o se e aprotoco l establishe d tha t ca n b e used i n ashop environment . Th e more complex CF A result s ca

n b e use d a s acalibratio n method . A lis t o f twenty-on e variable s tha

t ca n effec t transfe r rat e were mentioned . Thes e variable s includ e temperature , airflow , viscosity , ge l time , VO C content , volume o f resi n versu s surfac e area , interna l versu s externa

l mi x 1 6P.1 8

guns , fluid pressure , ti p geometry , sprayin g versu s non spraying , distanc e fromth e gu n to th e part , th e angl e th e operato r spray s at , vertica

l versu s horizonta

l spray , an

d th e spra y patter n use d b y th e operator . DO W i s amanufacture

r o f viny l este r resins , bu t

their resin s wil l no t

b e apar t o f thi s tes t program . Corrosio n an

d chemica l resistant resin s ar e no t

par t of thi s program . Additive s wil l no t

b e teste d i n th e initial program . There i s suc

h tremendou s variabilit

y in emissio n rate s tha

t i t i s unclea r how thi s industr y wil l b e regulate d an

d ho w th e MAC T floo

r (bes t performin g 1 2 percent

o f th e industry ) wil l b e chosen . Th e seasona l performanc e of

resin s an d resi n formulation s wa s discussed . Th e questio n wa s raise d a s t o how wil l thi s variabilit y b e take n into account . Th e difficult

y o f testin g in real worl d application s wa s discussed . Som e fabricator s wor

k wit h a1 2 foo t diamete r mandrel which i s 3 0 fee

t lon g an d ca n pu t on 1,00 0 pound s of

resi n i n a n hour . Fabricator s wanted to know how emission s ar e to b e measured . A meeting between th e CF

A and th e Stationar

y Sourc e Complianc e Divisio n (SSCD ) i s schedule d t o discus s th e difficult

y o f complianc e testin g fo

r thi s industry . A commitmen

t to expand th e tes t

progra mi f additiona l resource s were mad

e availabl e could no t b e mad e durin g th e meeting (DO

W wa s no t

represente d a

t th e meeting) . Onc e th e tes t equipmen t i s se t up , i t would b e relatively eas y t o run additiona l tests . Question s o

n additiona l resourc e requirement s fo r specifi c test s (i.e . how muc h would i t cos t to tes t light cure d resin? ) an

d ho w soo n funds would b e needed were raised . EP A committe d to lookin g into thei r current testin g plans , coordinatin g wit h OPPT , an

d OAQPS t o determin e th e viabilit y o f supplementing th e tes t

program . CF

A i s anxiou s fo

r thi s no t to b e viewed a s a

n industr y tes t in asupplier s facility ; th e result s wil l b e publi c an d CF A i s anxiou s fo

r an y input EP A ma y hav e to mak

e th e tes t progra musefu l fo r thei r regulator y developmen

t effort . A n inquir y a s to whethe

r EP A ha s a n availabl e an

d suitabl e laborator

y wa s made . Th e amoun

t o f floor spac e require d i s rather

small , bu t

th e airflo w an

d temperature mus t

b e carefull y controlled . Onc e th e CF A test s ar e completed , i t

i s hoped tha

t additiona l testin g ca n b e don e in actua

l fabricatio n shop s an

d th e datacompare d wit

h th e CF A tes t results . Th e CF A test s wil l establis h baselin e emission s under standar d conditions . I t wa s pointe d out

tha t th e pultrusio n segmen

t of th e industr

y ha d complete d ates t progra min th e DO

W facilit y an d wa s plannin g asecon

d progra mto refin e th e dat acollecte d through th e firs t

program . Airflo w an

d resi n temperatur

e wer e foun d to b e th e tw o mos t importan t variable s tha

t cam e ou t o f th e pultrusio n study . I t

wa s als o mentione d tha

t DO W i s currentl y testin g filament windin g an

d corrosio n resistant

resins . Bot

h o f thes e tw o tes t program s utilize d th e sam

e tes t protocols . I t

i s hoped tha

t th e Taguch

i scientifi c metho d ca

n b e use d t o integrate thes e datasets . Th e issu e o f

th e variabilit

y o f th e styren e itsel f

wa s raised . A questio n wa s raise d abou t alph amethy l styrene . I t

wa s explaine d tha

t alph amethyl styren e i s used to lower th e 1 7exother

mo f th e resi n an

d improv e workability . Typically , i t i s adde d to aresi n formulatio n in aconcentratio n o f

approximately thre e percent , base d o n th e tota l weigh t o f th e resin . Th e CF A test s wil l utiliz e tw o generi c orthophthali c resins , on e wit h ahigh styren e conten

t an d th e other

wit h alo w styren e content . Th e resin s wil l b e cooked in th e sam e batc h an d th e styren e wil l b e fro

mth e sam

e batch . Conclusio n Styren e i s amonome

r used i n bot

h th e Reinforce d Plastic s Composit e Productio n an

d Boa t Manufacturin g sourc e categories . Styren e i s present in th e resi n an

d evaporate s durin g materia l handling , th e applicatio n process , and th e curin g process . Becaus e styren e i s par t o f th e polymerizatio n process , evaporatio n o f styren e i s undesirabl e an

d represent s a

n economi c los s to th e fabricators . A s suc h industria

l representative s frombot

h o f th e subject

sourc e categorie s hav e continuously sough t way s to reduc e styren e losse s to th e atmosphere . Sourc e reductio n technique s wer e identifie d in thre e genera l areas , applicatio n equipment , resi n formulation , an d fabricatin g practices . I

n th e are aof

applicatio n equipment , emission s ar e reduce d through th e increas e o f transfe r efficiency of

th e resi n to th e mold . Thi s include s th e us e o f hig h volume lo w pressure spra y guns , pressurize d rollers , vacuu minfusion molding , and fabri c impregnators . Resin formulation s includ e styren e suppressan t additives , alternativ e initiator s tha t affec t ge l time, an

d lo w styren e resin s includin g wate

r emulsified resins . Finally , th e fabricator s ca n reduc e emission s through better housekeepin g and b y analyzin g thei r processe s t o determin e area s where existin g sourc e reductio n measure s ca n b e implemented . Th e CF A i s currentl y plannin g a

n emission s testin g progra

mto quantif

y th e variable s tha t effect emissio n rate s fo

r th e ope n mol d process . Th e consensu s o f th e meetin g wa s tha

t th e sourc e reductio n technique s tha t hav e alread

y bee n identifie d an

d develope d b y industry , would benefit

fro madditiona

l emission s testin g tha

t quantified th e emissio n reductions . Thi s i s importan

t i n orde r t o rank th e differen

t technique s i n term s of

thei r emissio n reductio n effectivenes s an

d in order to utiliz e sourc e reductio n technique s i n aregulator y effort . I t

wa s agree d tha t aforma l tes t progra mi s needed an

d tha t th e current

progra msponsore d b y CF

A wil l only addres s th e baselin e an d du e to fundin

g constraint s wil l no t

addres s th e sourc e reductio n method s discusse d durin g th e meeting . Th e result s of th e tes t progra mshoul d b e utilize d to develop asimple r emissio n tes t

protoco l tha

t ca n b e used b y industr

y to quantif

y emissio n losse s durin g manufacturing .

1 8