PPG Protective and Marine Coatings: Protective Coatings

Application

Environmental

© Copyright 2016 Fitz-Coatings Ltd

 Volatile Organic Compounds

Objective:
The objective of this training until is to review volatile organic compounds and their impact on the
Coatings Industry.

Volatile Organic Compounds – Introduction

The solvents used in coatings are known as volatile organic
compounds (VOC’s) and such compounds can promote the
production of ozone in the lower atmosphere (troposphere).

When present at elevated concentrations for prolonged periods,

ozone can damage the health of humans, animals and vegetation.

Ozone is formed by the reaction of the Sun's UV radiation on air

containing hydrocarbons and nitrogen oxides emitted from vehicle
exhausts and from combustion processes, such as power
generation plants and domestic boilers.

The presence of VOC’s accelerates the rate of ozone production.

Solvent Content
Most liquid paints contain volatile organic solvents.

These solvents modify the viscosity of the paint and are designed to
assist wetting and film formation before evaporation, leaving a film
of non-volatile resin and pigments.

VOC’s will be released during the coating application process.

It is estimated that indoor VOC levels are routinely 10 times higher

than outdoor levels and up to 1000 times higher immediately after
coating application.

Correct PPE and RPE are essential for the coating applicator.

Volatile Organic Compounds

VOC’s are linked to a wide range of health problems, including
some very serious diseases.

Health effects such as cancer, kidney change, liver damage,

damage to the central nervous system (including the brain), can be
caused by volatile organic compounds.

Minor complaints like headaches and eye, throat and nose irritation
can be caused by volatile organic compounds.

There is no doubt that a reduction in the amount of volatile organic

compounds is in the best interest of the end user as well as the
general ozone levels.

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 Coatings and Volatile Organic Compounds
Paints and coatings fall into the following groups.

Solvent evaporation only – where there is no further

chemical reaction. These usually have a high VOC content.
One pack - typically air drying coatings which chemically
react, often with oxygen in the air - once applied, the film of
paint will dry without further action.
Two pack coatings - these coatings use the reaction
between two chemical species to create a cured film in-situ.
These are generally superior performing coatings compared to
one pack products.
Stoved finishes – such coatings require a minimum
temperature to initiate the curing process and a prescribed
curing schedule, in terms of dwell time and temperature, to
achieve full cure.

General Regulations and Directives

There are no global regulations or directives on VOC’s and
Regulations vary around the globe.

Specifiers have to be aware which regulations are being used prior

to the development of a coating system.

The maximum VOC is usually specified as gm/litre or 1b/gal.

Typical maximum VOC content for protective coatings listed in this

table, however this is an example only. Check specific regulations.

On certain coatings WB is water based and the SB is solvent

based.

Effect of Regulations
A reduction scheme is the preferred method of preventing and
minimising emission of VOC, using non abatement techniques
such as:

Water borne coatings (low organic solvent carrier)

High solids content coatings
Powder coatings
Organic solvent free liquid coatings
Radiation cured coatings (for example, ultra violet and electron
beam)

In the Protective Coatings Industry, the higher solids coatings and

water borne coatings are the most commonly used coatings that
meet VOC Regulations.

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 Coating Suppliers
The challenge to the coating suppliers is to reformulate coatings to
meet the current and potential VOC regulations on coating systems.

Existing coatings have been formulated and tested over a number

of years. New formulated products with lower VOC’s are now
available, however it will be many years before a successful track
record can be provided.

There are also existing high solid VOC compliant coatings which
have gained a tremendous track record such as hi build epoxy and
polyurethane coatings. While water borne coatings can meet the
VOC Regulations they do not offer the same performance as hi-
solid epoxy coatings.

Coating Application
The use of VOC compliant coatings will have an affect on the type
of application and post cure etc.

High solid coatings may require specialist equipment such as

plural spray equipment.

Some products may have to be heated to achieve the correct

viscosity and consistency for spray application.

Water based or borne coatings may require specialist extraction

equipment and air movement to allow all the water (solvent) to
evaporate correctly and ensure the correct cure of the coating.

Product Data Sheets

The paint supplier product data sheets will detail the extent of the
VOC content.

The Specific Solvent Emissions Directive or Regulation should be

referenced also as this can vary from country to country.

Ensure the latest revision of the product data sheets are used which
detail the correct level of VOC content.

Environmental Protection
Legislation is in force in many parts of the globe, to ensure
protection of the environment from industrial activities. This includes
paint/coating works both in shop and on site.

Sometimes linked to Health and Safety it is clear that Environmental

Protection is technically a separate activity.

Environmental Protection means the prevention, or sometimes the

minimisation, of environmental damage or pollution of:

Air
Land
Water

There is risk of pollution to all three of the above from painting

operations if they are not effectively managed and controlled.

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 In the UK the controlling legislation is The Environmental Protection
Act. Part of this states that:

Pollution of the environment means pollution of the environment

due to the release (into any environmental medium) from any
process of substances which are capable of causing harm to man
or any other living organisms supported by the environment.

Many countries have their own enforcing authorities.

Solvents
Painting operations, both in shop and on site, will normally involve
the release of solvents (or VOCs) into the air.

Many VOCs are harmful to health.

They can also undergo chemical reactions causing the formation of

ground-level ozone, an air pollutant. High concentrations of ozone
can be detrimental to human and animal health. They can also
cause damage to building materials, forests, vegetation and crops.

Management plans should be developed to reduce solvent

emissions and both a Solvent Reduction Scheme as well as a
Solvent Management Plan must be put in place, and
maintained, by the Contractor.

In practice the increasing use of high solids coatings together with

some solvent-free and water based coatings means contractors are
able to comply with the regulations.

Water and Land Pollution

Site painting works requires carefully control of all aspects of the
works to ensure there is no pollution of the land and especially
water, both fresh water and seawater.

The use of containment systems to encapsulate painting works is

now common and effective in preventing pollution.

Working over water will normally require consent from the

appropriate environment agency and they may accept that some
minor escape of perhaps blasting dust is possible, provided that
the best practical means of pollution prevention are employed.

The containment of water used for pressure washing is often of

concern. The discharge of wastewater without approval from the
appropriate environment agency is an offence.

Waste
The control of waste from painting activities is a major responsibility
for all contractors. They have a Duty of Care under regulations to
ensure that all waste is recovered and disposed of correctly in
accordance with the appropriate regulations.

A waste carrier and the operator of the disposal site must be

licensed and registered with the appropriate environment agency
for the specific country.

Certain waste resulting from painting activities may be classified as

Special Waste.

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 This may include blasting debris contaminated by lead and other
heavy metals, empty paint cans and waste paint.

Particular precautions are required when handling and disposing of

Special Waste.

Monitoring the Works

Monitoring painting works for good practice with regard to
environmental protection may well be an activity a Coating
Supervisor or inspector will be expected to undertake.

The volumes of paints and solvents used must be carefully

monitored.

This may include checking paperwork and even arranging for

testing of waste.

However environmental issues can often be complex and involve

compliance with legislation, hence the input of an expert in this field
should be sought if required.

Summary
Within this training unit we have reviewed Volatile Organic
Compounds or VOC's as they are commonly known.

We reviewed what constitutes a VOC and how it can create health

hazards.

We also reviewed the regulations and impact to land and water.

We discussed the requirement for correct waste control and

monitoring.

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 Hazardous Waste

Objective:
The objective of this training unit is to review waste disposal in the Protective Coating Industry.

Waste in the Coatings Industry

Waste is created in the surface preparation and coating application
in a number of ways:

Spent abrasives from the abrasive blast cleaning process

Waste water used for water washing, water jetting, wet
abrasive blast cleaning or general cleaning
Cured and uncured paints
Used paint drums
Liquids such as solvents, grease, oil, cleaning agents etc.
General rubbish and debris

Spent Abrasives
Expendable abrasives are still used in large volumes as the
preferred media for abrasive blast cleaning, especially for non-
factory locations.

Although the exact volume of expendable per square metre (per

sq.ft) varies depending upon the type of surface, specified
standard, existing coating, configuration etc. it can vary between
25-75 Kilograms/m² (55-165 lbs/m²).

On this basis, a typical site structure of say 10,000m² (101,000

ft2) could generate 250,000Kg (250 ton) of waste.

This weight of spent abrasive excludes the coating or rust that is

removed by the abrasive blast cleaning, which may account for
another 5-10% of the total weight.

Spent Abrasives
The spent abrasive will have to be analysed before it can be safely
disposed of.

The analysis will look for various hazardous materials in the spent
abrasive including heavy metal etc.

Some aged coatings may contain lead or chromium which are

classified as hazardous and special collection and disposal is
required.

Some expendable abrasives are now classified as hazardous

before even being used.

It is important to understand that the regulations on hazardous waste

vary from location to location, with some countries having very
stringent regulations, to other countries having virtually no
regulations.

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 Waste Water
Water is frequently used on structures, especially if maintenance
painting is to be conducted.

Fresh waster washing is usually used on old painted structures to

remove grime, dusts, salts etc.

Note: The washing may be proceeded by a detergent wash.

As water is used in water jetting and wet abrasive blast cleaning,

collection of this water may be necessary depending upon the
process and location.

Water analysis may also have to be conducted to establish if the

waste water is then a hazardous product.

It is now possible to site clean the waste water and dispose of the
material as non hazardous.

Cured and Uncured Paints

Any cured or uncured paints that have been removed from the site
will be classified as hazardous material.

Paint spillages and wrongly mixed materials fall into the above
categories.

The cured material may be collected safely into suitable bags,

however the liquid material may have to be collected into bigger
drums or mechanically removed in liquid form.

It is essential that the product is identified and documented.

Used Paint Drums

Unless there is a fixed location or a large volume type contract most
paints are delivered in 5 to 25 litre (1.3 to 6.6 US Gallon) tins
(pails).

Paint residue within the walls of the paint tins will always remain
after mixing (boxing).

The residue must be allowed to dry (single part) or cure (two part)
before the paint tins are safely disposed of.

The paint tins can be crushed to reduce the volume, however in

most cases the contents will be classified as hazardous.

Under no circumstances will the residue material be allowed to

enter drains or waterways etc.

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 Used Paint Can
Even when all the paint is used from the paint can or drum there
will still be residual material around the side walls of the can and
there will always be some products at the bottom of the base.

Any liquids must be removed into larger liquid drums and the
remainder must then cure before the paints can be disposed of
properly by licensed waste disposal organizations.

It is in the interest of all parties to get as much paint out the

container during mixing and application.

Hazardous Liquid
On a typical Industrial Painting Contract the use of solvents,
detergents, alkali and emulsifying agents is common.

All the above and associated items such as rags etc. may be
classified as hazardous and must be removed safely from the site.

The company must have COSHH and risk assessments (or

similar) when using such products.

The Material Safety Data Sheets (MSDS) must also be available to

the site management.

Disposal information should also be contained within the Material

Safety Data Sheets.

General Waste
General Waste can usually be disposed of as non hazardous.

Guidance from the waste carrier may be a requirement.

You should ensure that no hazardous waste such as spent

abrasives, used paint tins etc. do not get into the non hazardous
disposal units.

Heavy fines can be given out to users and contractors who abuse
the system and local regulations.

Burning waste (either hazardous or non hazardous) is prohibited in

most locations. The process is also very hazardous.

Management
It is essential that an Environmental Plan is developed for a
coatings project and this will include hazardous waste disposal.

The environmental plan will also include details of local

Regulations, names of local waste disposal licensed organisations,
documentation, training of site personnel and emergency plans for
spillages etc.

Regular audits should be conducted on the environmental plan to

ensure that the agreed procedures and processes are being
adhered to.

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 Environmental Plan

The environmental plan should be developed in line with any local

or national legislation and contractual requirements prior to
commencement of the works.

The environmental plan will review the both atmosphere and earth
which may include local wild life etc.

The investigation or environmental review is usually conducted by

environmental experts and its objective is to ensure that any works
do not damage the environment which maybe ground works, rivers
etc. Also to ensure there is no long term impact such as damage to
ground created by works access.

The contractor will have to review the findings of the environmental

investigation and develop the environmental plan for the execution
of the works.

Never underestimate the requirement for a environmental review

and plan.

Environmental Plan - Audits

Regular audits should be conducted on the contract to ensure the

enviromental plan is being adhered too.

The auditor should be suitably qualified, experienced and have the

authority to stop the works if they do not comply with the approved
environmental plan.

Summary
This training unit reviewed hazardous waste and management of
hazardous materials used such as abrasive, paints, solvents etc.

We reviewed the requirement to collect waste, cure or dispose of

paints and liquids correctly and how to have an environmental
management plan in place.

© Copyright 2016 Fitz-Coatings Ltd Page 9