Appendix A - UFC 4-211-02 Aircraft Corrosion Control and Paint Facilities.pdf

UFC 4-211-02

1 December 2012

UNIFIED FACILITIES CRITERIA (UFC)

AIRCRAFT CORROSION CONTROL

AND PAINT FACILITIES

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED

AIRCRAFT CORROSION CONTROL AND PAINT FACILITIES

Any copyrighted material included in this UFC is identified at its point of use.

Use of the copyrighted material apart from this UFC must have the permission of the copyright holder.

U.S. ARMY CORPS OF ENGINEERS

NAVAL FACILITIES ENGINEERING COMMAND (Preparing Activity)

AIR FORCE CIVIL ENGINEER CENTER

Record of Changes (changes are indicated by \1\ ... /1/)

Change No. Date Location

This UFC supersedes UFC 4-211-02NF, dated 10 January 2005, with Changes 1-4.

FOREWORD

The Unified Facilities Criteria (UFC) system is prescribed by MIL-STD 3007 and provides planning, design, construction, sustainment, restoration, and modernization criteria, and applies to the Military Departments, the Defense Agencies, and the DoD Field Activities in accordance with USD (AT&L) Memorandum dated 29 May 2002. UFC will be used for all DoD projects and work for other customers where appropriate. All construction outside of the United States is also governed by Status of Forces Agreements (SOFA), Host Nation Funded Construction Agreements (HNFA), and in some instances, Bilateral Infrastructure Agreements (BIA.)

Therefore, the acquisition team must ensure compliance with the most stringent of the UFC, the SOFA, the HNFA, and the BIA, as applicable.

UFC are living documents and will be periodically reviewed, updated, and made available to users as part of the Services’ responsibility for providing technical criteria for military construction. Headquarters, U.S. Army Corps of Engineers (HQUSACE), Naval Facilities Engineering Command (NAVFAC), and Air Force Civil Engineer Center (AFCEC) are responsible for administration of the UFC system. Defense agencies should contact the preparing service for document interpretation and improvements. Technical content of UFC is the responsibility of the cognizant DoD working group. Recommended changes with supporting rationale should be sent to the respective service proponent office by the following electronic form: Criteria Change Request. The form is also accessible from the Internet sites listed below.

UFC are effective upon issuance and are distributed only in electronic media from the following source:

• Whole Building Design Guide web site http://dod.wbdg.org/.

Hard copies of UFC printed from electronic media should be checked against the current electronic version prior to use to ensure that they are current.

JAMES C. DALTON, P.E. JOSEPH E. GOTT, P.E.

Chief, Engineering and Construction Chief Engineer U.S. Army Corps of Engineers Naval Facilities Engineering Command

SCOTT HARTFORD, Colonel, USAF, P.E. MICHAEL McANDREW Acting Director Director, Facilities Investment and Management Facilities Engineering Center of Excellence AF Civil Engineer Center

Office of the Deputy Under Secretary of Defense (Installations and Environment) http://www.wbdg.org/pdfs/ufc_implementation.pdf http://www.wbdg.org/ccb/browse_cat.php?o=29&c=4 http://dod.wbdg.org/

NEW DOCUMENT SUMMARY SHEET

Document: UFC 4-211-02, Aircraft Corrosion Control and Paint Facilities

Superseding: UFC 4-211-02NF, Corrosion Control and Paint Finishing Hangars, dated 10 January 2005, with Changes 1-4

Description: This UFC provides criteria for the planning and design of Aircraft Corrosion Control and Paint Finishing (ACCPF) Facilities for the aircraft of the combined DoD United States Armed Forces.

Reasons for Document: This is a new Joint Service document. This new document represents another step in the Joint Services effort to bring uniformity to the planning, design and construction of military facilities. This UFC was developed to provide design requirements to accomplish the following:

• Assist planners in understanding the facility requirements to ensure accurate space programs and budgets.

• Provide architects, engineers, and construction surveillance personnel with the essential, minimum requirements for the design and construction of Aircraft Corrosion Control or Paint Finishing Facilities.

• Clarify the operational intent of the facility design.

Impact: The following will result from the publication of this UFC:

• This UFC creates a single source for common DoD ACCPF criteria and an accurate reference to individual Service-specific documents.

• This UFC facilitates updates and revisions and promotes agreement and uniformity of design and construction between the Services.

Unification Issues: The following are issues that remain non-unified and the reasoning for each:

• Section 2-1 identifies Service-specific documents for corrosion control requirements. The documents detail Service-specific aircraft corrosion control maintenance procedures and practices that may affect the facility design and are noted for reference.

• Section 2-5.3 identifies different minimum clearances and working space allowances. The exception is based on Service operational requirements for aircraft movement near fixed objects. The exception has little impact on Corrosion Control hangar size, since operational clearances control the size of the hangar bay.

• Sections 3-2.2.1, 3-4.3 and 3-6 identify different Service-specific Fire Protection requirements. These requirements are not currently unified by Fire Protection Working Group. These issues will be discussed in developing unified requirements for General Maintenance Hangars in the near future.

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TABLE OF CONTENTS

CHAPTER 1 INTRODUCTION

1-2 SCOPE OF DOCUMENT

1-3 APPLICABILITY

1-3.1 General Building Requirements

1-4 SCOPE OF FACILITY

1-5 FACILITY PROJECT TEAM

1-6 PROGRAM AUTHORITIES

CHAPTER 2 PLANNING AND LAYOUT

2-1 FACILITY FUNCTION

2-1.2 Depot Level Facilities

2-1.3 Corrosion Control Facilities

2-1.4 Wash Racks

2-1.5 Multi-Use Facilities

2-1.6 Technical Complexity of Ventilation Systems

2-1.7 Equipment Planning Issues

2-2 LOCATION DETERMINANTS

2-2.1 Geographical Location

2-2.2 Site Orientation

2-2.3 Site Organization

2-3 HVAC SYSTEM PLANNING & SELECTION

2-4 LAYOUT AND ADJACENCIES

2-4.1 General Building Layout and Adjacencies

2-4.2 Combining Corrosion Control Functions

2-5 FACILITY STUDY

2-5.1 Space Criteria

2-5.2 Facility Space Criteria Study

2-5.3 Minimum Clearances and Working Space

2-5.4 Ancillary Spaces

2-6 HEALTH, SAFETY AND THE ENVIRONMENT

CHAPTER 3 GENERAL DESIGN CRITERIA

3-1 GENERAL

ii

3-2 ARCHITECTURE

3-2.1 Exterior Design

3-2.2 Interior Design

3-2.3 Acoustics

3-3 CONVEYING SYSTEMS

3-3.1 Weight Handling Equipment

3-4 PLUMBING

3-4.1 Water and Sewer

3-4.2 Industrial Waste

3-4.3 Control of Hazardous Effluents

3-4.4 Compressed Air

3-4.5 Process Systems

3-5 HEATING, VENTILATING & AIR CONDITIONING (HVAC)

3-5.1 Hangar Bay HVAC Process Requirements

3-5.2 Ventilation for Control of Air Contaminants and Flammable Vapors

3-5.3 HVAC for Ancillary Spaces

3-5.4 Noise and Vibration Control

3-6 FIRE PROTECTION AND LIFE SAFETY

3-7 ELECTRICAL

3-7.1 Electrical Installations

3-7.2 Electrical Hazardous Classifications

3-7.3 Grounding

3-7.4 Lighting

3-8 EQUIPMENT

3-8.1 Work Platforms

3-8.2 Fall Protection

3-8.3 Rigid Rail Lifeline Systems

3-8.4 Blast and Paint Booths

3-9 SITE WORK

3-9.1 Aircraft Pavement Design

3-9.2 Site Lighting

3-10 HEALTH SAFETY AND ENVIRONMENTAL CONTROLS

3-10.1 Health and Safety iii

3-10.2 Environmental Controls

CHAPTER 4 MEDIA BLAST HANGAR DESIGN CRITERIA

4-1 FUNCTION

4-2 DMB MATERIAL

4-2.1 DMB Material Combustibility

4-2.2 DMB Recovery

4-2.3 DMB Recycling

4-2.4 PMB Hangar Cautions

4-3 WASH RACKS FOR DMB OPERATIONS

4-4 ARCHITECTURAL AND STRUCTURAL REQUIREMENTS

4-4.1 Interior Surfaces

4-4.2 Use Group Classifications

4-4.3 Other Architectural Requirements

4-5 MECHANICAL REQUIREMENTS

4-5.1 Plumbing

4-5.2 Ventilation for Control of Air Contaminants

4-5.3 Noise and Vibration Control

4-6 ELECTRICAL REQUIREMENTS

4-6.1 Hazardous Classification

4-6.2 Grounding

4-7 FIRE PROTECTION

CHAPTER 5 CHEMICAL DEPAINT DESIGN CRITERIA

5-1 GENERAL DESIGN REQUIREMENTS

5-2 CHEMICAL DEPAINT (ONLY) FACILITIES

5-3 DRAINAGE SYSTEMS FOR CHEMICAL DEPAINT

CHAPTER 6 AIRCRAFT WASH RACKS

6-1 INTRODUCTION

6-2 DESIGN CRITERIA

CHAPTER 7 SPECIFIC DESIGN CRITERIA

7-1 INTRODUCTION

7-2 BUILDING DESIGN CRITERIA

APPENDIX A References

APPENDIX B Best Practices iv

B-1 Introduction

B-2 RECOMMENDED DESIGN GUIDANCE

B-2.1 Process Ventilation Systems

B-2.2 Program Planning for Determination of Areas for a New ACCPF

B-3 PERSONNEL SAFETY ISSUES

B-3.1 Respiratory Protection

B-4 MAINTENANCE CONTRACTS

B-4.1 Service Contracts

B-5 LESSONS LEARNED

B-5.1 Dimensions of Booth/Bay

B-5.2 Incorporating Fall Protection Control Measures

B-5.3 Proper Sizing of Air Compressors

B-5.4 Equipment Designation

B-5.5 Airflow Requirements

B-5.6 Air Exhaust

B-5.7 Electrical Equipment in Spraying Area

B-5.8 Pressure Differential Devices

APPENDIX C Applicable Environmental Standards

C-1 Federal

C-1.1 Clean Air Act

C-1.2 Clean Water Act

C-1.3 Resource Conservation and Recovery Act

C-2 State

C-3 Local

APPENDIX D OSHA INTERPRETATIONS AND REFERENCES FOR REDUCED

AIRFLOW AND RECIRCULATING AIRFLOW

APPENDIX E Glossary v

FIGURES

FIGURE 1-1. ACCPF FACILITIES

FIGURE 2-1. HVAC SYSTEM SELECTION STEP 1

FIGURE 2-2. HVAC SYSTEM SELECTION STEP 2 TEMPLATE

FIGURE 2-3A. DF PAINT & CHEMICAL DEPAINT BUBBLE DIAGRAM

FIGURE 2-3B. DF DRY MEDIA DEPAINT BUBBLE DIAGRAM

FIGURE 2-4. CCF BUBBLE DIAGRAM

FIGURE 2-5. CLEAN-DIRTY SCHEMATIC

FIGURE 3-1. SAMPLE HORIZONTAL FLOW HANGAR CONFIGURATION

FIGURE 3-2. SUPPLY AND EXHAUST PLENUM AIRFLOW CONTROL DETAILS .. 37

FIGURE C-1 APPLICATION OF AEROSPACE NESHAP TO VARIOUS OPERATIONS

FIGURE D-1. NFESC MEMORANDUM TO OSHA

FIGURE D-2. OSHA INTERPRETATION

TABLES

TABLE 1-1. ACCPF FUNCTIONAL PROGRAM AREAS

TABLE 2-1. ACCPF PLANNING ISSUES

TABLE 7-1. AIRCRAFT HANGAR BAY(PAINT/WASH/CHEM. DEPAINT)

TABLE 7-2. AIRCRAFT HANGAR BAY (DMB DEPAINT)

TABLE 7-3. PAINT MIX ROOM

TABLE 7-4. PAINT STORAGE ROOM

TABLE 7-5. TOOL CRIB

TABLE 7-6. EQUIPMENT STORAGE

TABLE 7-7. EQUIPMENT CLEANING

TABLE 7-8. SOLVENT STORAGE

TABLE 7-9. CENTRAL ACID STORAGE

TABLE 7-10. CENTRAL CHEMICAL STORAGE

TABLE 7-11. MATERIAL STORAGE

TABLE 7-12. PPE STORAGE

TABLE 7-13. PPE CLEANING

TABLE 7-14. PAINT BOOTH

TABLE 7-15. STENCIL ROOM

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TABLE 7-16. COMPOSITE ROOM

TABLE 7-17. WASH RACK

TABLE 7-18. SUPERVISOR’S OFFICE

TABLE 7-19. OFFICES GENERAL

TABLE 7-20. CONFERENCE ROOM

TABLE 7-21. FAX/COPY

TABLE 7-22. BREAK ROOM

TABLE 7-23. LOCKER ROOMS(CLEAN)

TABLE 7-24. LOCKER ROOMS(DIRTY)

TABLE 7-25. TECHNICAL LIBRARY

TABLE 7-26. MAINTENANCE SHOPS

TABLE 7-27. MECHANICAL ROOM(S)

TABLE 7-28. COMPRESSOR ROOM

TABLE 7-29. CENTRAL PLANT

TABLE 7-30. ELECTRICAL ROOM(S)

TABLE 7-31. FIRE PROTECTION ROOM

TABLE 7-32. COMMUNICATION ROOM

TABLE 7-33. DRY MEDIA EQUIPMENT ROOM

TABLE 7-34. DRY MEDIA STORAGE ROOM

TABLE 7-35. DRY MEDIA BLAST BOOTH

CHAPTER 1 INTRODUCTION

1-2 SCOPE OF DOCUMENT.

This UFC provides requirements for evaluating, planning, programming, and designing Aircraft Corrosion Control and Paint Facilities (ACCPFs). The information in this UFC applies to the design of all new construction projects, to include additions, alterations, and renovation projects in the continental Unites States (CONUS) and outside the continental US (OCONUS). The requirements contained in this UFC apply to Army, Navy, Marine Corps and Air Force facilities unless specifically referenced to a single service. This UFC is not intended as a substitution for thorough review during design by individual Program Managers and Operations Staff in the appropriate Service.

1-3 APPLICABILITY.

This UFC provides planning and design criteria applicable to new construction as well as sustainment, restoration and modernization projects on all Department of Defense (DoD) facilities in the continental United States, (CONUS), and outside the continental United States (OCONUS).

1-3.1 General Building Requirements.

Comply with UFC 1-200-01, General Building Requirements. UFC 1-200-01 provides applicability of model building codes and government-unique criteria for typical design disciplines and building systems, as well as for accessibility, antiterrorism, security, sustainability, and safety. The design requirements in this UFC are to be used in addition to UFC 1-200-01 and referenced UFC’s and criteria.

1-4 SCOPE OF FACILITY.

ACCPFs provide space, infrastructure and support facilities to conduct de-paint, paint, and corrosion control activities for DoD aircraft. There are three categories of facilities:

• Depot Facilities (DF) support comprehensive de-paint and paint programs.

These facilities may operate almost continuously in support of the corrosion control program.

• Corrosion Control Facilities (CCF) support periodic activities on an as-needed basis. In the past, these facilities have also been called operational/intermediate level facilities, squadron level, field level, and patch and paint facilities.

• Wash Racks fulfill the requirement of periodic corrosion control on aircraft not requiring remedial corrosion maintenance. Wash Racks may be open, covered, enclosed, or integrated into the hangar bay, but the functions performed and the utilities provided at the Wash Rack are limited to the washing and rinsing of aircraft.

The ACCPFs described in this document are indicated in Figure 1-1. A comprehensive list of functional program spaces are listed and described briefly in Table 1-1 and described in greater detail in Chapters 2 and 4 through 7

FIGURE 1-1. ACCPF FACILITIES

May perform function

Aircraft Corrosion Control and Paint Facilities (ACCPF)

Depot Facilities (DF)

Chemical Paint Finish Removal

PMB Dry Media Paint Removal

Paint Finishing Facility

Corrosion Control Facility (CCF)

Depaint Finishing Facility

Washracks

TABLE 1-1. ACCPF FUNCTIONAL PROGRAM AREAS

Functional Program Area Description

Operational Spaces

Aircraft Hangar Bay (Paint/Wash/Chemical Depaint)

Houses aircraft and equipment anticipated for the mission of Facility.

The bay must be sized for the largest aircraft with additional space for anticipated maintenance platforms and equipment. The bay should also include utility connections required for the mission.

Utilities will vary for paint application, and chemical depaint versus dry depaint.

Aircraft Hangar Bay (Dry Media Depaint)

Houses aircraft and equipment anticipated for the mission of Facility.

The bay must be sized for the largest aircraft with additional space for anticipated maintenance platforms and equipment. The bay must be designed for a dusty environment and include strategically placed outlets for Dry Media Blast (DMB) distribution and spent DMB pick up /delivery system for DMB reclamation; with additional utilities specific for the mission.

Paint Mix Room Coating mix and paint pot staging; should be adjacent to paint storage with easy access to paint bay.

Paint Storage Room Aircraft coating container storage; adjacent to paint mix, with curbed storage area drained to I.W.; should also have access for deliveries.

Tool Crib Special use equipment tools such as pallet jacks, ladders, facility maintenance items.

Equipment Storage Paint application equipment storage; typically combined with paint equipment cleaning room.

Equipment Cleaning Paint application equipment cleaning; room generally contains small paint booth or other solvent cleaning apparatus for use with paint spray guns and paint pots.

Solvent Storage Large container (typ. 55 gal) paint solvent storage; requires pallet storage with door openings and aisles suitable for deliveries.

Central Acid Storage Central storage for acid cleaner and conversion coating; may include central chemical mix and storage tanks with pumps and piping for distribution to the hangar bay.

Central Chemical Storage Central storage/distribution for hot soap/water mix and hot and cold water; typically includes bulk storage of concentrated soap, central hot water heater/tank, soap/HW mix tank and associated distribution pumps.

Material Storage Secure storage of non-hazardous paint prep materials; typically includes a window for distribution of materials to paint personnel;

may also include storage of paint process equipment and parts.

PPE Storage Room/area designated for secure storage of PPE; storage of PPE is typically combined with PPE cleaning.

PPE Cleaning Cleaning of personnel protective equipment; typically includes divided sinks; central washer and drier (optional).

Paint Booth Individual paint spray booth for small parts (may be located inside hangar bay or exterior to building).

TABLE 1-1. ACCPF FUNCTIONAL PROGRAM AREAS

Functional Program Area Description Operational Spaces (cont’d)

Stencil Room Houses aircraft stencil equipment; room size should consider size of aircraft stencils as well as equipment.

Composite Room Composite/fiberglass layup/repair room will typically contain work benches with ventilation hoods, and curing ovens for repair of composite parts.

Dry Media Equipment Room Centralized dry blast media retrieval, processing and distribution equipment

Dry Media Storage Room Bulk dry media storage (palletized) Dry Media Blast Booth Fully enclosed self -contained room specifically designed with the equipment and utilities for the removal of coatings by the DMB method, generally manually performed by a DMB nozzle operator stationed inside the booth.

Wash Rack Accommodates aircraft cleaning and can be open, covered, enclosed, or integrated into the hangar bay.

Administrative Spaces

Supervisor’s Office Private office located with view of hangar bay Offices Private offices and/or workstations determined by mission requirements Conference Room Small assembly with conference table and chairs Fax/Copy Centralized fax/copy room Break Room Personnel break and assembly room Locker Rooms (clean) Male and female locker/shower/toilet facilities Locker Rooms (dirty) Male and female lockers used for disposition contaminated clothing worn by operators during the performance of their corrosion control duties

Technical Library Storage of aircraft technical documents Maintenance Shops (option) Optional mission-specific maintenance spaces

Support Spaces

Mechanical Room(s) HVAC and miscellaneous mechanical systems Compressor Room Plant air and breathing air compressor systems .Note specific requirements for Breathing Air vs. Plant Air Central Plant Centralized chilled water and heating hot water supply Electrical Room(s) Switchboards, motor control centers, distribution transformers, circuit breaker and lighting panels, VFD equipment Fire Protection Room Fire water riser, distribution manifold, AFFF or HEF storage tanks Communication Room(s) Telephone switchboard and misc communications equipment

Note: All spaces listed above in Table 1-1 are examples of spaces common to DFs and CCFs. Actual spaces included in the planning phase must be based on the specific mission of the facility.

1-5 FACILITY PROJECT TEAM.

The planning and design team for ACCPF must include the following specialists in addition to the standard architecture and engineering disciplines:

• Aircraft Corrosion Control and Prevention Operations

• Aircraft Maintenance Operations

• Industrial Hygiene

• Environmental Quality and Protection

• Safety

• Fire Marshall

• Facility Maintenance

• Energy Manager

• Flight line and AT/FP Security

1-6 PROGRAM AUTHORITIES.

Prior to project development, confirm the acquisition methodology and coordinate facility requirements with the following contacts for the appropriate Service:

• Army. Aviation and Missile Command Corrosion Program Office

• Air Force. AF Corrosion Prevention and Control Office (AFCPCO)

This Page Intentionally Left Blank

CHAPTER 2 PLANNING AND LAYOUT

2-1 FACILITY FUNCTION.

Design the corrosion control hangar to provide space and equipment for the specific corrosion control functions required by the project mission. These corrosion control functions can be performed at either a DF or CCF.

In general, base facilities designed for DF perform de-paint/re-paint maintenance on the entire aircraft. Base facilities designed for CCF perform de-paint/re-paint maintenance on repaired or replaced components only. Service-specific corrosion control requirements are defined in the following documents:

• Army and Navy. NAVAIR Technical Manual NAVAIR 01-1A-509-1, Cleaning and Corrosion Control

• Air Force. Air Force Corrosion Control Facility Reference Guide Aircraft Corrosion Control Facilities, as a whole, encompass the following functions:

• Aircraft washing

• Repair and Touchup Painting

• Full Aircraft Repainting

• Finish Curing and Drying

• Depaint (Chemical and Dry Media)

• Component painting

• Paint mixing

• Chemical/paint storage 2-1.2 Depot Level Facilities.

The primary function of a Depot Level Paint or De-paint Facility is to provide the necessary space and services to perform complete corrosion control activities on aircraft undergoing scheduled major maintenance checks or a scheduled complete corrosion control repaint. Depot level facilities must be capable of providing complete services required for all operations involved with the total paint, or de-paint of an entire aircraft. While chemical de-paint operations are often performed in a depot level Paint Facility, Dry Media Blast operations must be performed only in facilities specifically designed and built for the DMB de-paint function.

2-1.3 Corrosion Control Facilities.

The primary function of a Corrosion Control Facility is the performance of minor corrosion control activities in support of an active squadron as part of non-scheduled maintenance completed on an as needed basis. Corrosion Control Facilities, in general, must be able to perform all the functions listed above with the exception of the DMB De-paint. As noted above in 2-1.1, the DMB De-paint function should be reserved for a Depot Level Facility. The planner should also be aware that if the mission of the CCF includes the requirement to repaint an entire aircraft or any part of the aircraft, airflow requirements in the CCF paint bay will be the same as the Paint Finishing (Depot Level) Hangar.

In some cases, the mission of the CCF may require special functions such as composite or sheet metal repair. Extra shops will be needed for the completion of these tasks.

The primary difference then between the DF and the CCF is the projected aircraft throughput versus the necessity for operational flexibility.

Table 2-1 ACCPF PLANNING ISSUES, below provides the different functional issues which must be considered when planning a CCF or DF which must fulfill the mission requirements, and also be safe, cost effective, energy efficient, and environmentally compatible.

TABLE 2-1. ACCPF PLANNING ISSUES

Planning Issue CCF DF

GENERAL *Low Aircraft Throughput

*Greater Process Variety *Shorter Process durations *Increased Downtime *Limited Number of Personnel *Fueled aircraft

*High Aircraft Throughput *Limited Processes required *Longer Process durations *Minimum Downtime *More Personnel Involved *Defueled and purged Aircraft

SPACE PLANNING Consider number of hangar bays

WRT aircraft throughput & operation specialization. Lower personnel = lower area required for amenities. Higher number of processes = higher number of specialty spaces (Back shops)

Consider number of hangar bays WRT aircraft throughput and processes performed. High personnel reqs = large area needed for amenities. Minimum specialized processes = fewer number of Back Shops.

HVAC DESIGN

PLANNING

Increased downtime allows for use of prevailing weather to provide window of opportunity for correct Temp/ humidity conditions. Heating only systems typical. Horizontal air flow offers flexible, economic Supply Air design.

24/7 type operations with minimum downtime call for full temp./ humid.

HVAC Systems. Exhaust Recirc + add'l energy recovery systems should be considered. Downflow Air Supply an option; offers high quality "Auto" finish; with fast production for hangars designed for single aircraft.

FACILITY

ENVIRONMENTAL

Air: Consider air emissions WRT overall Base Permit.

Air: Consider air emissions WRT overall Base Permit.

TABLE 2-1. ACCPF PLANNING ISSUES

Planning Issue CCF DF IMPACT Water: Consider Industrial Waste

(IW) treatment requirements wrt existing base capabilities and capacity

Water: Consider increased and special CCF Waste treatment reqs.

with respect to existing base capacity, and possible need for a new WT system required for pretreatment of IW effluent

MECHANICAL

EQUIPMENT

REPAIR &

REDUNDANCY

Increased available hangar downtime allows for less critical timing for repair/replacement of failed systems.

Longer processes, low available downtime mandate an increased level of redundant equipment.

FIRE PROTECTION AFFF, HEF and/or DELUGE FP systems required for facilities housing aircraft with any fuel on board.

Typical installation for defueled and purged aircraft requires a closed head sprinkler FP system

WORKER

ACCESS/SAFETY

Fewer personnel, shorter processes call for minimal number of Ceiling supported man lifts, high use of ground supported man lifts and maintenance stands

Higher number of personnel with longer processes call for higher density of Ceiling & ground supported man aboard systems

Fall Protection required.

Fall Protection required.

Change Rooms, Lockers, Showers and Contamination Control required.

Change Rooms, Lockers, Showers and Contamination Control required.

2-1.4 Wash Racks.

The variety of wash racks are as follows and are discussed in greater detail in UFC 3- 260-01, Airfield and Heliport Planning and Design:

a. Open (uncovered) Wash Rack – an open air paved area specifically designed for the manual washing of aircraft. This facility should include wash utilities, drainage capability for both storm water and wash water waste, and may include lighting and power outlets for night operations, depending on the mission.

b. The Covered Wash Rack – The Covered facility will provide the same capabilities as noted above in Item A. with the added benefit of a non-climate controlled roof structure, typically with open sides. The covered facilities are used primarily to keep aircraft out of direct sun to reduce the skin temperature and improve wash conditions.

c. Interior Wash Racks –Interior Wash Racks for the purpose of this document will be considered fully enclosed environmentally controlled facilities with all utilities required for the washing of aircraft. The DF (Paint) and CCF as described in this document are required to provide all services for the Interior Wash Rack. Please refer to the appropriate DF and CCF sections for those requirements.

d. Birdbaths (Aircraft Rinse Facility) – An Aircraft Rinse Facility referred to as a ”Birdbath” provides an unattended taxi-through treadle-operated freshwater deluge system to rinse aircraft typically subjected to accelerated corrosion due to low-level over water operations or a corrosive atmosphere at the installation.

2-1.5 Multi-Use Facilities.

Multi-use facilities, for the purpose of this document, refer to ACCPF that include functions outside the family of corrosion control, such as Fuel Cell or Maintenance activities. This document does not address those functions outside the corrosion control capability nor the special requirements those functions may impose on an ACCPF facility.

2-1.6 Technical Complexity of Ventilation Systems

Corrosion control facilities normally require complex, and expensive ventilation systems in order to comply with applicable environmental, fire protection, and occupational health requirements. It is essential that the system requirements and costs are identified during the project development and are included on the DD Form 1391.

The DD Form 1391 should also note that the facility requirements include the mandatory need for mechanical ventilation to remove paint particulates and solvent vapors. The inclusion of this statement, as well as including the costs for the system (including the acceptance test and associated report), as a separate line item in the facility cost estimate will help ensure that adequate funds are allocated for this extremely costly requirement. An example of a statement that might be included on the DD Form 1391 is shown below:

“Mechanical Ventilation is required to remove paint particulate and solvent vapors from the Corrosion Control Facility. Upon facility completion, an independent ventilation expert must evaluate the effectiveness of the mechanical ventilation system. The ventilation expert must provide a detailed evaluation report with recommendations regarding system acceptance and corrective action for discrepancies”.

2-1.7 Equipment Planning Issues.

It is imperative that all operational equipment anticipated for use in the new facility be identified and programmed early in the planning process in order to ensure the provision of adequate space and utilities in the facility design.

2-2 LOCATION DETERMINANTS.

2-2.1 Geographical Location

The location of a Depot Level and Corrosion Control Facility is generally predetermined by mission requirements, and climate is typically not a determining factor in location selection. Climate, however, has a significant effect on the design, energy usage and operational constraints of the facility. As part of the statement(s) which will go into DD Form 1391 regarding the mechanical ventilation system (ref. paragraph 2-1.5, above), the steps outlined in Section 2-3 HVAC System Selection must first be followed to determine the level, complexity and estimated cost of the proposed hangar bay HVAC system required to meet the mission of the facility.

2-2.2 Site Orientation.

Consider the prevailing wind in orienting the building in relation to aprons, taxiways, and parking, to avoid exhaust air dispersal over areas affected by solvent vapors and to avoid recirculation into the ventilation system intakes.

Orient hangar such that it complies with all geometric requirements of UFC 3-260-01.

2-2.3 Site Organization.

Locate the corrosion control hangar in close proximity to the maintenance hangars and as close as possible to an aircraft wash rack. Access between the corrosion control hangar, the maintenance hangar, and the aircraft wash rack is required. Locate the paint-finishing hangar with due regard to the requirement for aircraft and vehicle access.

2-3 HVAC SYSTEM PLANNING & SELECTION.

Non-process areas of hangars must meet all energy efficiency goals. Process areas must meet energy goals as much as practical. Systems also must conform to the latest service-specific policies for energy efficiency. See Chapter 3 for design applications and requirements for specific HVAC systems. For the initial facility planning phase, use the following steps in selecting the HVAC system for the Hangar Bay which will house the aircraft spray painting operations.

STEP 1. Define the facility mission to determine facility type (CCF vs. DF) and process requirements to establish HVAC objectives per Figure 2-1.

FIGURE 2-1. HVAC SYSTEM SELECTION STEP 1

1. CCF Baseline is 100% OA. See UFC 3-400-02 for dry bulb & humidity parameters: MEL, MEH@2%, MEH@97.5%, HR@2%. Evaluate need for heating for operations (~75 deg F [23.9 C]) and freeze protection based on ambient conditions. Also evaluate need for heat recovery.

2. Evaluate the operational requirements for temp and humidity and compare to the ambient conditions.

3. Establish the effect of 1. & 2 on the Mission Performance and Throughput

Evaluate Facility Mission:

CCF or DF

DF CCF

Go to Step 2 Evaluate: (See Guidelines below):

1. Ambient Conditions

2. Operational Requirements

If Mission Throughput can be maintained from the results of Evaluation Item 3., below, further HVAC system review is not required.

If the Mission cannot be performed as required, go to Step 2

STEP 2. Identify requirements for interior conditions of the process hangar bay per Figure 2-2.

FIGURE 2-2. HVAC SYSTEM SELECTION STEP 2 TEMPLATE

Process Mode

Interior Conditions % Usage Per Year

TEMP (F)* RH*

Air Flow Requirements Max Min Max Min

Unoccupied Paint Prep Paint Removal Pre-treatment Paint Cure Min-Occupancy

* Interior Conditions must be based on the more stringent of 1) coating manufacturer’s temperature and relative humidity requirements or 2) personnel heat stress limitations per Chapter 3, Mechanical.

STEP 3. Establish a baseline HVAC System which represents the lowest perceived capital first cost that fulfills the requirements of Step 2. Based on the baseline system, develop an energy budget for each process. Service specific guidelines and the minimum guidelines of ASHRAE 90.1 must also be followed for auxiliary spaces.

Note that during the development of the energy budget, consideration should be given to utilization of the ambient conditions as much as possible during processes which require large amounts of outside air.

STEP 4. Analyze alternative HVAC systems and/or energy conserving methods as determined appropriate for the application as potential additions or alternatives to the baseline system. Examples of alternative systems or methods include recirculation, heat recovery, and ice storage.

With the emphasis on energy conservation along with recent improvements in mechanical system technology, recirculation of ventilation air is now being recognized as an accepted alternative to improving energy efficiency in a spray paint environment.

The effectiveness of recirculation in reducing energy usage can vary widely depending upon climate. In locations where much energy is expended to keep the temperature and humidity of the facility within operational parameters, recirculation may be easily justified from an economic perspective. In very temperate climates, the mechanical complexity and additional equipment required for a recirculated ventilation system may negate the climate control savings advantage. It is important to evaluate the economic impact of recirculation over time based on anticipated energy savings. Also included in the evaluation for determination of exhaust air recirculation are the OSHA regulatory issues related to personnel safety and the required monitoring of the ventilation air and operations personnel.

STEP 5. Establish the potential Life Cycle Cost Analysis (LCCA) benefit to the project and select system with the lowest Life Cycle Cost (LCC) which fulfills current occupational safety, health, energy efficiency, and other related standards for the facility’s process spaces.

2-4 LAYOUT AND ADJACENCIES.

2-4.1 General Building Layout and Adjacencies.

The appropriate building layout and adjacencies are illustrated in Figures 2-3 and 2-4.

These diagrams do not convey a building shape. Figures 2-3a and 2-3b represents the DF and Figure 2-4 represents the CCF. Figure 2-5 provides a schematic representation of the personnel flow from the “dirty” or “hot” hangar bay areas and the “clean” or “cold” areas. This is to prevent any contamination from the cleaning, depainting or painting agents used in the hangar bay reaching the clean areas where protective equipment is not required.

Arrange work-bays so that each has ready access to the outside and to equipment and storage spaces of the hangar. Isolate work-bays in which cleaning and stripping are done from work-bays in which painting and curing are done. Administrative spaces such as work control offices may be accommodated in mezzanines. Provide mechanical equipment rooms with outside access. “Break” rooms must be on “clean” side, but areas can be included on “dirty” side for brief breaks without eating.

FIGURE 2-3a. DF PAINT & CHEMICAL DEPAINT BUBBLE DIAGRAM

FIGURE 2-3b. DF DRY MEDIA DEPAINT BUBBLE DIAGRAM

FIGURE 2-4. CCF BUBBLE DIAGRAM

FIGURE 2-5. CLEAN-DIRTY SCHEMATIC

2-4.2 Combining Corrosion Control Functions.

Combining functions within the family of corrosion control tasks may only be considered as follows:

• Paint facilities may include both paint and chemical depaint functions with special care taken to address the industrial waste issues of chemical de-paint operations.

• All CCFs and DFs should have a wash function inside the hangar as described in this document as well as paint spray and/or chemical depaint capability (exception: dry depaint facilities will not have a wash function within the hangar bay, but will coordinate with near or adjacent wash racks).

• Performing Paint or Chemical De-paint functions in a facility where Dry Media Blast stripping operations take place is not allowed due to the critical nature of maintaining a dry environment for the Dry Media and the de-paint equipment. Dry Media Stripping and Painting/Chemical De-paint must always be accomplished in separate areas. If grinding operations (scuff sanding) are performed in a Paint Facility, vacuum pickup equipment must be utilized to minimize the spread of dust in the hangar bay. Every effort must be made to maintain a dust free environment where painting is performed.

2-5 FACILITY STUDY.

Due to the complexity and unique characteristics of Aircraft Corrosion Control & Paint Facilities, a facility study must be performed on all proposed CCF and DF projects to determine space and process system requirements.

2-5.1 Space Criteria.

ACCPF space needs are site and mission specific and must be individually programmed based on a facility study. Space program development guidance is provided in UFC 3-260-01, Airfield and Heliport Planning and Design and the following documents:

• Army TM 5-803-5, Installation Design

• Navy UFC 2-000-05N (P-80), Facility Planning Criteria for Navy and Marine Corps Shore Installations.

• Air Force AFH 32-1084, Facility Requirements

• Department of Defense Unified Facilities Criteria UFC 3-101-01, Architecture

Certain spaces are not defined specifically in space programming criteria. These spaces include air recirculation rooms, fan rooms, and filter plenums for example. These spaces should be considered and added to the space criteria if anticipated.

2-5.2 Facility Space Criteria Study.

Prepare a facility study with input from Chapter 1, Program Authorities, and Chapter 1, Facility Project Team. Also see Appendix B Section 2.2 for design guidance on programming an accurate estimate of the gross area for a new ACCPF. Ensure that the clearance factors in 2-5.3 are addressed in the facility space study to accurately determine the total square footage for the new facility.

2-5.3 Minimum Clearances and Working Space.

For minimum safety clearances based on aircraft type, reference the following documents:

• Army & Air Force: UFC 3-260-01, Airfield and Heliport Planning and Design

• Navy: UFC 2-000-05N, (P-80), Facility Planning Criteria for Navy and Marine Corps Shore Installations

The size of the various aircraft scheduled to use the facility will determine the hangar bay dimensions. Determine the interior dimensions of the Corrosion Control facility, by using the dimensions of the largest aircraft that will occupy the facility, and adding the minimum clearances indicated below. Include additional space as required for tow vehicles and turning radii. Size the bay to accommodate fixed-wing aircraft with wings unfolded, and helicopters and V-22 with rotors in place and unfolded unless it has been determined that aircraft surfaces are accessible with the wings/rotors folded. Verify the configuration of rotors on rotary aircraft undergoing corrosion control when sizing the process (hangar) bay.

The following minimum operational clearances are required to allow proper access for work platforms and to minimize paint overspray on hangar walls and ceilings:

• Top of aircraft (vertical fin, radome, rotor head, tail rotor) to underside of ceiling - 10 ft (3.0 m); For hangar bays required to have draft curtains, clearance must be to lowest point of draft curtains.

• Nose of aircraft to hangar door - 10 ft (3.0 m);

• Tail of aircraft or tail rotor to exhaust target wall - 10 ft (3.0 m); and

• Horizontal and vertical clearance from aircraft to inside face of open front door - 5 ft (1.5 m). In addition to these clearances, an approximate thickness of the supply and exhaust plenum (T) is required to properly size the gross area of the hangar bay. The equation T = 1/5H defines this approximate depth where H is the height of the aircraft at its highest point plus 5 ft (1.5 m). Note that the depth (T) does not include the thickness of the structure of the door or the filter media. The actual plenum thicknesses are dependent on the airflow required to ensure laminar flow in the hangar and as appropriate for the corrosion control and painting activities.

• Additional clearance between the work platforms and the hangar walls should be considered with respect to circulation space around the aircraft and avoiding pinch points, particularly at the wing tips. Consider tug and cart travel including turning radiuses in developing the required circulation clearances.

Base the number of hangar bays for each site on an analysis of aircraft types, production schedules, hours required for each corrosion control operation, and number of work shifts. Moveable partitions to subdivide the bay are discouraged, as they introduce complications to exiting, fire protection, air flow and balance. Separate spaces where painting is being done from bays in which dry stripping, blasting, or grinding are done.

2-5.4 Ancillary Spaces.

Provide the following Ancillary spaces as a minimum for the Facility

• Ancillary space requirements will vary based on facility requirements.

Provide spaces for paint mixing, paint storage, waste paint area, bead blast rooms, gear equipment and tools, office, nondestructive inspection, strip/rinse, paint spray, and dry storage. Base the size of the rooms on the workload. Provide exit doors to the outside for rooms designated for storing or mixing chemicals or paints. Provide a depressed floor slab or doorsills with ramps to contain spills. Separate spaces where sanding, blasting, or grinding are done from spaces where painting is done.

• Provide storage space for dry filters. Provide stairs for personnel and a jib crane for materials transport to the roof or upper floors.

• Provide a loading dock with a manual dock leveler.

• Provide space for work on composite parts including helicopter rotor blades if applicable.

• Locate utilities on the side walls. Use of utility pits in hangar floors is prohibited.

• Decontamination Facilities (See Figure 2-5 for a schematic showing separation of clean and dirty areas):

• For operations where employees may be exposed to harmful contaminants, provide the following:

a. An Initial Decontamination Area inside, or adjacent to the hangar bay.

Provide HEPA vacuum for removing accumulations of contaminants from PPE. When located in the Hangar Bay, this area must be on the “clean side”, i.e. close to the supply air side and away from the exhaust air side.

b. A walk-through vestibule with air shower (Air Lock) to capture contaminants between the Initial Decontamination Area and the Initial Accumulation Point.

c. An Initial Accumulation Point with space for drums for disposable PPE.

d. Provide an area with a sink for cleaning, drying and storing respirators.

e. Shower facilities with hot and cold water.

f. Change rooms with separate lockers for protective clothing and street clothes.

g. Toilet facilities must be located on the clean side of the locker rooms.

• Paint Mixing Rooms:

All dispensing or transfer of flammable liquids from containers, mixing of flammable liquids, and filling of containers, including paint guns and pressure pots must be done only in an approved spray booth or mixing room. A separate paint mixing room will significantly reduce the amount of clutter in the paint booth. A properly designed and located paint mixing room must accommodate all equipment, cabinets, and tables associated with paint mixing and daily-use storage of paints and thinners, which otherwise, would be housed within the confines of the paint booth.

Installing prefabricated mixing booth is a simple method to incorporate a separate mixing area into a new or existing facility.

The design requirements in Chapter 3 are generally applicable to Paint Mixing Rooms. Additional requirements are listed below:

a. The size of the mixing room must not exceed 150 ft2 (14 m2).

b. Must have continuous mechanical ventilation as specified in NFPA 30.

c. Mixing rooms should be provided with a floor drain to make it possible to wash down spills. However, local installations must ensure that collection sumps are installed in the floor drain system and (or) that the wastewater treatment plant can process the spillage. If this is not the case, local installations must develop an alternate means of cleaning up the spillage.

d. Agitators must be driven by compressed air, water, low-pressure steam, or electricity. If powered by an electric motor agitator must meet all electrical codes and standards.

e. An EyeWash/Safety Shower must be located inside or adjacent to a Paint Mixing Room.

• Flammable and Combustible Liquid Storage

Storage of flammable or combustible storage, in cabinets, specially designed room within the facility or in a detached structure is required.

Design must comply with UFC 3-600-01, NFPA 80, and 29 CFR 1910.106.

AFOSHSTD 91-17 also applies for Air Force Projects.

2-6 HEALTH, SAFETY AND THE ENVIRONMENT.

Planning activities for an ACCPF must address all requirements for worker health and safety, and environmental permitting. Compliance with all health, safety, and environmental regulations is required and is achievable without significantly disrupting the operations if adequate advanced planning and coordination is performed. These issues must be incorporated into the selection of HVAC Systems per this Chapter and Chapter 3. Appendix C provides an overview of the applicable environmental standards.

http://www.nfpa.org/

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CHAPTER 3 GENERAL DESIGN CRITERIA

3-1 GENERAL.

UFC 1-200-01 provides applicability of model building codes and government-unique criteria for typical design disciplines and building systems, as well as for accessibility, antiterrorism, security, sustainability, and safety. Use this UFC in addition to UFC 1-200-01 and the UFCs and government criteria referenced therein.

3-2 ARCHITECTURE.

3-2.1 Exterior Design.

3-2.1.1 Specular Reflectance.

To prevent mirror-like reflections from building surfaces to aircraft in flight, roofs and other external surfaces must have a specular reflectance compatible with the location of the building on the airfield.

3-2.1.2 Operational Hazard Glare.

If the building is located so that glare may be an operational hazard, the critical surfaces of the building must have a light reflectance of not more than 10, measured at an angle of 85 degrees in accordance with ASTM D523, Standard Test Method for Specular Gloss.

3-2.1.3 Roof.

The roof must be a smooth surface type or metal standing seam system. Exposed fastener (“Screw Down”) metal roofs must not be specified. If a membrane roof is chosen, gravel or any other material which could become loose and carried off the roof in high winds will not be permitted. The membrane must be specified as being capable of flexing in both directions independent of the roof structure.

Provide exterior access to the high roof the through a secured access panel or hatch, to prohibit unauthorized passage.

Roofs must slope only to the rear or sides of the hangar and not towards the flightline.

3-2.1.4 Exterior Walls.

Exterior walls must be impact resistant material coated with a weather resistant baked on PVDF finish or similar product.

Provide seals at doors, wall penetrations, and building joints in the hangar bays and ancillary spaces to ensure airtight performance to maintain pressure differentials and prevent contamination of the air in the hangar bay.

3-2.1.5 Doors.

3-2.1.5.1 Hangar Doors.

Hangar doors defined in this section are a specialized, insulated, hangar Supply Air type with swinging or sliding leaves. These doors are designed to serve as insulated supply air plenums when closed. Eighteen (18) gauge galvanized steel perforated plates are to be placed on the inside face of in the supply air plenums with a means to allow for balancing air of distribution to achieve evenly distributed laminar flow in the hangar bay.

The hangar door acts as a plenum, thus see Section 3-5.2.8 Ventilation System Configurations for additional design criteria to construct Supply and Exhaust Plenums for horizontal laminar air flow. Other arrangements may be used if the required calculations are performed or if alternative successful designs can be proven. A Computational Fluid Dynamics study is required or other means of verification of the air delivery method if the proposed system is unproven.

The hangar doors must be electric motor operated. Each leaf must operate independently from its’ own drive unit. Each drive unit must have a release mechanism, and the doors must be provided with a means of mechanical attachment for movement in the event of power failure. The minimum speed of door travel must be 60 feet (18.29 meters) per minute. Thresholds must be designed to minimize dirt accumulation and ice buildup.

Control of the doors must be by momentary contact type push buttons located near the leading edge on both sides of the door with limit switches on each door leaf to stop door movement. Safety devices must be installed to prevent injury to personnel and damage to equipment by moving door sections. If personnel access doors are provided in the hangar door leaves, an interlock must be installed at each access door to prevent operation of the hangar door leaves when the personnel access doors are open and halt the hangar door leaves in the event a personnel access door is opened while the hangar door leaves are in operation. An alarm must sound in conjunction with safety warning beacons when doors are in motion. Sliding steel hangar doors must be in accordance with UFGS 08 34 16, Corrosion Control Hangar Doors.

Configure horizontal sliding hangar doors such that they are operable during power outages, by both manual and electrical means (electrical means via emergency power).

3-2.1.5.2 Other Doors.

No hold-open devices are permitted. Take special precautions to seal doors between hangar areas and exterior or adjacent spaces.

Exterior doors with closers must be Level 4, physical performance Level A doors complying with ANSI/SDI A250.8. Frames must match door level. Exterior door frames must be welded type.

Provide Grade 1 hardware typical.