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Coatings Removal from Delicate Substrates and Application Process Improvements for DoD Industrial Facilities (Task N.308)

Statement of Need

Federal, state, and local environment, health and safety (EHS) laws and regulations have placed stringent requirements on Department of Defense (DoD) industrial operations. As a result, the prevailing manufacturing, repair, and rework practices have become increasingly difficult, less efficient, and more costly. DoD industrial facilities have therefore been tasked to reduce or eliminate emissions and waste that are associated with these industrial operations. The Trident Refit Facility (TRF) at Kings Bay provides maintenance and repair services for Trident submarines and has several coatings application and removal processes with the potential for operation and performance improvements. Three areas with potential process improvement at TRF Kings Bay include a paint/mixing delivery center, coatings removal processes, and powder coating. Other operations with the potential for reducing or eliminating emissions and waste include coatings removal and selective stripping of special hull treatment (SHT), passive countermeasure system (PCMS), radomes, and antennas from submarines and surface ships. Current technologies involve use of chemicals, hand sanders, abrasive media, and saws. These can damage substrates, are labor-intensive, and can adversely affect the environment. To address this, the National Defense Center for Environmental Excellence (NDCEE) will provide technical support to Naval Surface Warfare Center, Carderock Division (NSWC-CD) in identifying alternative technologies to remove coatings from delicate substrates without damaging the surface, and reduce labor and waste streams. by Pressure Island®, Government POCs and MM-818 corrosion Thomas Judy, NSWC-CD inhibitor, manufactured Gregory Walsh, TRF Kings Bay by Nutraceutical Albert Walker, ODASA(ESOH) Clinical Laboratories International, Inc. (now Status Preservation Sciences Completed Inc.)--to current baseline processes. In addition to the objective, specific acceptance criteria were developed prior to the initiation of the testing in order to indicate whether to implement one of the evaluated pretreatment processes. TRF Kings Bay developed the acceptance criterion that in order for one of the selected pretreatments to be implemented, it must provide significant coating performance improvement over the baseline processes. The results of the testing indicated that there was not significant coating performance improvement between the baseline processes and pretreatments that were evaluated under the specific testing conditions that were defined in the Final Pretreatment Test Plan, dated June 13, 2003. Therefore, based on the test results and acceptance criteria, neither pretreatments was recommended for implementation under the existing blasting and powder coatings conditions at TRF Kings Bay. However, if process changes occur, further evaluation is recommended. A complete description of the completed testing can be found in the Subtask 1 - Coatings Removal and Application Process Improvement at Trident Refit Facility Kings Bay Technology Demonstration Final Report, dated July 2, 2004.

Identified Alternatives

Process improvement recommendations have been identified for TRF Kings Bay. The needs that were identified include recommendations for a paint dispensing center, process flow for a paint/blast facility, and an evaluation of the effect that pretreatments have on coating performance in a shipyard environment prior to powder coating. Technologies that were identified under previous efforts (e.g., NDCEE Tasks N.022, N.087, N.122, and N.227 subtask 022) and under this effort, as potential alternatives for coatings removal from delicate substrates include fiber media, lasers, high-pressure water, and corn hybrid polymer blasting.

Implementation

Demonstration and Justification

The NSWC-CD and the NDCEE initiated a conceptual design for the paint distribution center and process flow for the paint/blast facility at TRF Kings Bay. While in the process of providing recommendations for both, the NDCEE was notified by TRF Kings Bay that support was no longer required due to contractual changes. The specific objective for the pretreatment testing was to compare the effectiveness of selected pretreatments--EZ Treat, a spray-applied product

Executive Agent Office of the Assistant Secretary of the Army (Installations and Environment)

The NDCEE is working closely with representatives from Portsmouth Naval Shipyard (PNSY) to implement highpressure water blasting into the next availability at PNSY. To assist with this implementation, the NDCEE has provided a revised cost-benefit analysis for the implementation of high-pressure water blasting for select applications into an upcoming availability. The NDCEE will continue to follow-up with representatives from PNSY. The results of this effort will be reported in the Subtask II - Coatings Removal from Delicate Substrates Final Report.

Follow-Up

If a technology is implemented, the NDCEE will provide support services as necessary, including periodic implementation review, measured progress, and as appropriate, corrective action implementation.

NDCEE

Rev. 4-08

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