Attachment 2 - USAF TechOrder TO 1-1-8.pdf

TO 1-1-8

TECHNICAL MANUAL

APPLICATION AND REMOVAL OF

ORGANIC COATINGS,

AEROSPACE AND NON-AEROSPACE

EQUIPMENT

F09603-87-D-2264

FA8501-05-D-0002

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited (WR-ALC/PA Public Affairs Certificate Number PA05-0758). Other requests for this document shall be referred to 584 CBSS/GBHDE, Robins AFB, GA 31098. Questions concerning technical content shall be referred to AFRL/MLS-OLR.

Published Under Authority of the Secretary of the Air Force

15 FEBRUARY 2006 CHANGE 3 - 30 JANUARY 2008

BASIC AND ALL CHANGES HAVE BEEN MERGED

TO MAKE THIS A COMPLETE PUBLICATION

Dates of issue for original and changed pages are:

Original . . . . . .0 . . . . . .15 February 2006 Change . . . . . . 1 . . . . . . 14 February 2007

Change. . . . . . . . 2 . . . . . . . 14 July 2007 Change. . . . . . . . .3. . . . .30 January 2008

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 170 CONSISTING OF THE FOLLOWING:

Page *Change No. No.

Page *Change No. No.

Page *Change No. No.

Title A i - iii iv - vi vii - ix x - xi xii Blank 1-1 1-2 2-1 - 2-4 2-5 - 2-7 2-8 2-9 - 2-10 2-11 2-12 2-13 2-14 - 2-17 2-18 2-19 - 2-20 2-21 - 2-22 2-23 2-24 - 2-28 3-1 - 3-3 3-4 3-5 - 3-7 3-8 - 3-15 3-16 - 3-17 3-18 Blank 4-1 4-2 - 4-12 4-13 - 4-15 4-16 - 4-23 4-24 Blank 5-1 - 5-2 5-3 5-4 - 5-7 5-8 - 5-9 5-10 - 5-11 5-12 5-13 - 5-14 5-15 - 5-17 5-18 Blank 6-1 - 6-6 6-7 - 6-8 6-9

6-10 6-11 - 6-12 6-13 - 6-14 6-15 - 6-23 6-24 - 6-26 7-1 - 7-3 7-4 - 7-5 7-6 Blank 8-1 8-2 8-3 8-4 8-5 8-6 8-7 - 8-8 A-1 - A-2 A-3 A-4 Blank B-1 - B-10 B-11 - B-12 C-1 - C-4 Glossary 1 Glossary 2 - Glossary 4 Glossary 5 Glossary 6 Blank

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LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

NOTE The portion of the text affected by the changes is indicated by a vertical line in the outer margin of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands.

* Zero in this column indicates an original page.

USAFA Change 3

TABLE OF CONTENTS

Chapter Page Chapter Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . vi

LIST OF TABLES . . . . . . . . . . . . . . . . . . vi

FOREWORD . . . . . . . . . . . . . . . . . . . . . vii

SAFETY SUMMARY . . . . . . . . . . . . . . . xi

1 INTRODUCTION AND GENERAL DIS-

CUSSION OF COATING MATERIALS

AND TERMS . . . . . . . . . . . . . . . . . . . 1-1

1.1 INTRODUCTION . . . . . . . . . . . . 1-1

1.2 GENERAL DISCUSSION OF OR-

GANIC COATINGS . . . . . . . . . 1-1

1.2.1 Coatings Systems For Metal Sur-

faces . . . . . . . . . . . . . . . . . . . 1-1

1.2.2 Aircraft Protective Finish Systems . 1-1

1.3 ORGANIC COATING . . . . . . . . . 1-1

2 ORGANIC FINISH SYSTEM REMOVAL . . 2-1

2.1 INTRODUCTION . . . . . . . . . . . . 2-1

2.2 GENERAL . . . . . . . . . . . . . . . . . 2-1

2.3 PREPARATION FOR PAINT RE-

MOVAL . . . . . . . . . . . . . . . . . 2-2

2.3.1 Application . . . . . . . . . . . . . . . . . 2-3

2.3.2 Procedures . . . . . . . . . . . . . . . . . 2-3

2.4 ORGANIC FINISH SYSTEM RE-

MOVAL . . . . . . . . . . . . . . . . . 2-4

2.5 CHEMICAL REMOVAL OF OR-

GANIC FINISH SYSTEMS

FROM METAL SUBRATES . . . 2-4

2.6 CHEMICAL REMOVERS . . . . . . 2-4

2.6.1 Deleted . . . . . . . . . . . . . . . . . . . . 2-5

2.6.2 Remover For Epoxy and Polyure-

thane Primers and Epoxy and Polyurethane Top-Coats Over Ep-oxy or Polyurethane Primers . . . 2-5

2.6.3 Remover For Polysulfide Primer

With A Polyurethane Topcoat . . . 2-6

2.6.4 Removers For Environmental Com-

pliance . . . . . . . . . . . . . . . . . . 2-6

2.6.5 Chemical Remover Selection For

Depot Removal Operations . . . . 2-7

2.7 GENERAL OVERALL CHEMICAL

REMOVAL PROCEDURES . . . 2-8

2.8 CHEMICAL REMOVAL PROCE-

DURES FOR CONFINED LO-

CATIONS . . . . . . . . . . . . . . . . 2-11

2.9 MECHANICAL REMOVAL OF

ORGANIC FINISH SYSTEMS . 2-12

2.10 MECHANICAL REMOVAL METH-

ODS OTHER THAN PLASTIC

MEDIA OR MEDIUM PRES-

SURE WATER BLASTING FOR

METAL SUBSTRATES . . . . . . 2-13

2.10.1 Abrasive Blasting . . . . . . . . . . . . . 2-13

2.10.2 Hand or Motor-Driven Abrasive Re-

moval . . . . . . . . . . . . . . . . . . . 2-13

2.10.3 Hand Held Abrasive Removal . . . . 2-14

2.10.4 Motor Driven Abrasive Removal . . 2-14

2.10.5 Stainless Steel (CRES) and Nickel

Based Alloys . . . . . . . . . . . . . . 2-14

2.10.6 Dust Removal . . . . . . . . . . . . . . . 2-14

2.11 PMB REMOVAL METHOD . . . . . 2-19

2.11.1 Media Type . . . . . . . . . . . . . . . . . 2-19

2.11.2 Media Authorized for Air Force

Use . . . . . . . . . . . . . . . . . . . . 2-19

2.11.3 Operational Parameters for Metallic

Surfaces . . . . . . . . . . . . . . . . . 2-19

2.11.4 Usage Restrictions . . . . . . . . . . . . 2-20

2.11.5 Operational Parameters for Non-

Metallic (Composite) Surfaces . . 2-20

2.11.6 Operation Safety Requirements . . . 2-22

2.11.7 Personnel Qualifications . . . . . . . . 2-22

2.11.8 Pre-blast Preparation . . . . . . . . . . . 2-22

2.11.9 Postblast Cleaning . . . . . . . . . . . . 2-23

2.11.10 Specific Technical Data and Work

Directives . . . . . . . . . . . . . . . . 2-23

2.11.11 Disposal of Plastic Media Used in

Paint Removal Operations . . . . . 2-23

2.11.12 Contamination Testing of Plastic

Media . . . . . . . . . . . . . . . . . . 2-23

2.12 MPW REMOVAL METHOD . . . . . 2-25

2.12.1 Preparation . . . . . . . . . . . . . . . . . 2-25

2.12.2 Paint Removal Operations . . . . . . . 2-26

2.12.3 Post-Paint Removal Cleaning . . . . . 2-26

2.12.4 Operational Safety Requirements . . 2-26

2.12.5 Personnel Qualification . . . . . . . . . 2-27

2.13 REMOVAL OF THERMOPLASTIC

POWDER COATING . . . . . . . . 2-27

2.13.1 Removal Procedures . . . . . . . . . . . 2-27

2.14 PAINT REMOVAL ON NON-

METALLICS . . . . . . . . . . . . . . 2-27

2.14.1 Removal Requirements . . . . . . . . . 2-27

2.14.2 Mechanical Paint Removal on Fiber

Glass, Arranged Fiber (Kevlar)/ Epoxy, and Graphite or Boron Fiber/Epoxy Composite Sur-faces . . . . . . . . . . . . . . . . . . . 2-28

Change 3 i

3 SURFACE PREPARATION AND CHEMI-

CAL PREPAINT SURFACE TREAT-

MENT . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 SURFACE PREPARATION FOR

PAINTING AND CHEMICAL

PREPAINT SURFACE TREAT-

MENT . . . . . . . . . . . . . . . . . . 3-1

3.1.1 Surface Preparation For Painting . . 3-1

3.1.2 Surface Preparation For Repair or

Over Coating of Damaged Or-ganic Coating . . . . . . . . . . . . . 3-1

3.1.3 Scuff Sanding For Overspraying Ex-

isting Coating Systems On Air-craft . . . . . . . . . . . . . . . . . . . . 3-2

3.1.4 Solvent Wiping For Surface Prepara-

tion . . . . . . . . . . . . . . . . . . . . 3-3

3.1.5 Surface Preparation For MIL-C-

27725/SAE AMS-C-27725 Inte-gral Fuel Cell Coating . . . . . . . 3-5

3.1.6 Reactivation of Newly Applied

Primer or Tiecoat . . . . . . . . . . . 3-7

3.1.7 Surface Preparation, Unpainted Sur-

faces . . . . . . . . . . . . . . . . . . . 3-7

3.1.8 Corrosion Removal, Chemical and

Mechanical . . . . . . . . . . . . . . . 3-7

3.1.9 Preparation for Prepaint Treatment, Unpainted Surfaces . . . . . . . . . . 3-7

3.1.10 Water Break Inspection . . . . . . . . . 3-7

3.1.11 Evidence of Inadequate Cleaning . . 3-8

3.1.12 Corrosion Removal Prepaint Com-

pound, Aluminum . . . . . . . . . . 3-8

3.1.13 Prepaint Chemical Corrosion Re-

moval Materials . . . . . . . . . . . . 3-8

3.1.14 Application of MIL-C-38334/SAE

AMS-1640 Solution/Not LOX Compatible . . . . . . . . . . . . . . . 3-8

3.1.15 Surface Treatment Materials For

Aluminum . . . . . . . . . . . . . . . . 3-8

3.1.16 Touch-Up of Damaged Aluminum

Surface Treatment MIL-DTL- 5541 . . . . . . . . . . . . . . . . . . . 3-9

3.1.17 No-Rinse Process For Surface Treat-

ment of Aluminum . . . . . . . . . . 3-9

3.1.18 Mixing MIL-C-81706/MIL-DTL-

81706 Solution . . . . . . . . . . . . 3-11

3.1.19 Application of MIL-C-81706/MIL-

DTL-81706 Solutions . . . . . . . . 3-11

3.1.20 Alternate Surface Preparations For

Aluminum Surfaces (PreKote

SP) . . . . . . . . . . . . . . . . . . . . 3-13

3.1.21 Application of PreKote SP . . . . . . . 3-13

3.1.22 Use of PreKote SP on Exterior Sur-

faces Where Paint and Primer Have Been Removed During Scuff Sand, Touch-up or Repair . 3-14

3.1.23 Corrosion Removal Solution For

Magnesium . . . . . . . . . . . . . . . 3-15

3.1.24 Surface Treatment Process For Mag-

nesium . . . . . . . . . . . . . . . . . . 3-15

3.1.25 Surface Preparation For Steel . . . . . 3-16

3.1.26 Masking . . . . . . . . . . . . . . . . . . . 3-16

3.1.27 Tack Ragging . . . . . . . . . . . . . . . 3-17

4 PAINTING APPLICATION METHODS . . . 4-1

4.1 GENERAL . . . . . . . . . . . . . . . . . 4-1

4.2 SPRAY METHODS . . . . . . . . . . . 4-1

4.2.1 HVLP Spray . . . . . . . . . . . . . . . . 4-1

4.2.2 Hot Spray . . . . . . . . . . . . . . . . . . 4-1

4.2.3 Airless Spray . . . . . . . . . . . . . . . . 4-2

4.2.4 Air-Assisted Airless Spray . . . . . . . 4-2

4.2.5 Electrostatic Spray . . . . . . . . . . . . 4-2

4.3 SPRAY PAINTING EQUIPMENT,

GENERAL . . . . . . . . . . . . . . . 4-2

4.3.1 HVLP Spraying Systems . . . . . . . . 4-2

4.3.2 Spray Gun, General . . . . . . . . . . . 4-2

4.3.3 Classes of Spray Guns . . . . . . . . . 4-2

4.3.4 Material Containers . . . . . . . . . . . 4-3

4.3.5 Air Compressors . . . . . . . . . . . . . 4-5

4.3.6 Air Regulators or Transformers . . . 4-5

4.3.7 Air Condensers . . . . . . . . . . . . . . 4-5

4.3.8 Air Supply . . . . . . . . . . . . . . . . . 4-5

4.3.9 Hose . . . . . . . . . . . . . . . . . . . . . 4-5

4.4 SPRAY PAINTING . . . . . . . . . . . 4-5

4.4.1 Gun Techniques . . . . . . . . . . . . . . 4-5

4.4.2 Gun Adjustments . . . . . . . . . . . . . 4-11

4.4.3 Painting Difficulties and Remedies . 4-12

4.5 CLEANING AND MAINTE-

NANCE . . . . . . . . . . . . . . . . . 4-22

4.6 MECHANICAL PAINT GUN

WASHER . . . . . . . . . . . . . . . . 4-23

5 PAINTING OPERATIONS FOR AIRCRAFT

AND EQUIPMENT . . . . . . . . . . . . . . . 5-1

5.1 GENERAL . . . . . . . . . . . . . . . . . 5-1

5.2 SAFETY AND HEALTH ASPECTS

OF PAINTING . . . . . . . . . . . . 5-1

5.2.1 Respiratory Protection . . . . . . . . . . 5-3

5.3 SPRAY BOOTHS AND PAINTING

AREAS, GENERAL . . . . . . . . . 5-3

5.4 PAINT BOOTH TYPES . . . . . . . . 5-3

5.4.1 Dry-Type Booth . . . . . . . . . . . . . . 5-3

5.4.2 Air-Water Wash Type Booth . . . . . 5-3

5.4.3 Cleaning and Maintenance . . . . . . . 5-4

5.4.4 Part and Equipment Painting Opera-

tions . . . . . . . . . . . . . . . . . . . . 5-4

5.5 AIRCRAFT PAINTING OPERA-

TIONS . . . . . . . . . . . . . . . . . . 5-4

5.5.1 Depot Level Aircraft Painting Opera-

tions . . . . . . . . . . . . . . . . . . . . 5-4

5.5.2 Field Level Aircraft Painting Opera-

tions . . . . . . . . . . . . . . . . . . . . 5-5

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ii Change 3

5.5.3 Electrostatic Aircraft Painting . . . . . 5-5

5.5.4 Atmospheric Conditions For Paint-

ing . . . . . . . . . . . . . . . . . . . . . 5-6

5.5.5 Test Panels . . . . . . . . . . . . . . . . . 5-7

5.5.6 Material Requirements, General . . . 5-7

5.6 THE AIRCRAFT PAINTING PRO-

CESS SEQUENCE OF

EVENTS . . . . . . . . . . . . . . . . 5-7

5.6.1 Aircraft Paint Application Se-

quence . . . . . . . . . . . . . . . . . . 5-8

5.6.2 Overspraying Existing Coating Sys-

tems On Aircraft and Aerospace Equipment . . . . . . . . . . . . . . . 5-9

5.6.3 Curing of Finishes . . . . . . . . . . . . 5-10

5.6.4 Coating Thickness Measurements . . 5-10

5.6.5 Allowable Coating Thickness . . . . . 5-10

5.6.6 Inspection Control . . . . . . . . . . . . 5-11

5.6.7 Soil Barrier Coating . . . . . . . . . . . 5-13

5.7 INTERIOR FINISHING PROCE-

DURES AND OPERATIONS . . 5-13

5.7.1 Preparation For Coating . . . . . . . . 5-13

5.7.2 Coating Application . . . . . . . . . . . 5-13

5.7.3 Refinishing of Fiber Glass Compo-

nents . . . . . . . . . . . . . . . . . . . 5-13

5.8 MAINTENANCE PAINTING . . . . 5-13

5.8.1 Epoxy or Polyurethane Primer/Poly-

urethane Topcoat . . . . . . . . . . . 5-13

5.8.2 Primer and Polyurethane Touch Up . 5-13

5.8.3 Aerosol Touchup . . . . . . . . . . . . . 5-14

5.8.4 Brush/Roller Touchup . . . . . . . . . . 5-15

5.8.5 Brush Application . . . . . . . . . . . . 5-15

5.8.6 Roller Application . . . . . . . . . . . . 5-16

5.8.7 Temporary Protection . . . . . . . . . . 5-16

5.8.8 Powder Coating . . . . . . . . . . . . . . 5-16

6 USAF STANDARD COATING SYSTEMS

FOR AIRCRAFT AND EQUIPMENT . . . 6-1

6.1 CLASSIFICATION OF ORGANIC

COATINGS . . . . . . . . . . . . . . . 6-1

6.2 CONSTITUENTS OF ORGANIC

COATINGS . . . . . . . . . . . . . . . 6-1

6.3 PIGMENTS . . . . . . . . . . . . . . . . 6-1

6.4 VEHICLE . . . . . . . . . . . . . . . . . . 6-1

6.5 PREPARATION OF COATING MA-

TERIALS FOR USE, GEN-

ERAL . . . . . . . . . . . . . . . . . . 6-1

6.6 MIXING AND THINNING OF

COATING MATERIALS, GEN-

ERAL . . . . . . . . . . . . . . . . . . 6-2

6.6.1 Method of Mixing . . . . . . . . . . . . 6-2

6.6.2 Mixing Test . . . . . . . . . . . . . . . . . 6-2

6.7 SOLVENTS, DILUENTS AND

THINNERS . . . . . . . . . . . . . . . 6-3

6.7.1 Volatility . . . . . . . . . . . . . . . . . . . 6-3

6.7.2 Thinners . . . . . . . . . . . . . . . . . . . 6-4

6.7.3 Viscosity . . . . . . . . . . . . . . . . . . . 6-4

6.8 BLUSHING . . . . . . . . . . . . . . . . 6-5

6.9 RESINS . . . . . . . . . . . . . . . . . . . 6-5

6.9.1 Alkyds . . . . . . . . . . . . . . . . . . . . 6-5

6.9.2 Acrylics . . . . . . . . . . . . . . . . . . . 6-5

6.9.3 Vinyls . . . . . . . . . . . . . . . . . . . . 6-5

6.9.4 Phenolics . . . . . . . . . . . . . . . . . . 6-5

6.9.5 Silicones . . . . . . . . . . . . . . . . . . . 6-5

6.9.6 Epoxies . . . . . . . . . . . . . . . . . . . 6-5

6.9.7 Polyurethane . . . . . . . . . . . . . . . . 6-6

6.10 ADHESION . . . . . . . . . . . . . . . . 6-6

6.11 PRIMERS . . . . . . . . . . . . . . . . . . 6-6

6.12 COATINGS AND COATING SYS-

TEMS . . . . . . . . . . . . . . . . . . 6-6

6.12.1 USAF Standard Polyurethane Air-

craft Coating System . . . . . . . . 6-6

6.12.2 Primer Coating, Epoxy, For Aircraft

Application, Specification MIL-

PRF-23377 . . . . . . . . . . . . . . . 6-6

6.12.3 Primer Coating, Epoxy, VOC Com-

plaint, Chemical and Solvent Re-sistant, MIL-PRF-85582 . . . . . . 6-7

6.12.4 Primer Coating, Polyurethane, TT-P-

2760 . . . . . . . . . . . . . . . . . . . 6-8

6.12.5 Primer Coating, Elastomeric, Polysulfide Corrosion Inhibiting, PR-1432GV . . . . . . . . . . . . . . 6-9

6.12.6 Tiecoat, Non-Chromated . . . . . . . . 6-10

6.12.7 Polyurethane Topcoat, High Solids

(MIL-PRF-85285, Type I) . . . . . 6-11

6.12.8 Curing of Complete Polyurethane

System . . . . . . . . . . . . . . . . . . 6-13

6.12.9 Coating Compound (Wash Primer), Metal Pretreatment, Resin-Acid, Specification MIL-C-8514 . . . . . 6-13

6.12.10 Primer, Coating, Inorganic, Zinc

Dust Pigmented, Self-Curing, For Steel Surfaces, Specification MIL-

P-38336/SAE AMS-P-38336 . . . 6-16

6.12.11 Primer Coating For Steel Surfaces, Specification MIL-PRF-26915 . . 6-17

6.12.12 Paint, Aluminum, Heat Resisting

(1200° F) TT-P-28 . . . . . . . . . . 6-18

6.12.13 Enamel, Alkyd, Gloss, Low VOC

Content, TT-E-489 . . . . . . . . . . 6-18

6.12.14 Enamel, Heat Resistant (204° C or

400° F), A-A-3054 . . . . . . . . . . 6-18

6.12.15 Coating, Sprayable, Strippable, Pro-

tective, MIL-PRF-6799 . . . . . . . 6-18

6.12.16 Resin Coating, Unpigmented, For

Engine Components and Metal Parts, MIL-PRF-3043 . . . . . . . . 6-19

6.12.17 Coating Kit, Epoxy, For Interior of

Steel Fuel Tanks, MIL-PRF- 4556 . . . . . . . . . . . . . . . . . . . 6-19

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TABLE OF CONTENTS - CONTINUED

Change 3 iii

6.12.18 Coating, Corrosion Preventive, For

Aircraft Integral Tanks, MIL-C-

27725/SAE AMS-C-27725 . . . . . 6-20

6.12.19 Coating Compound, Nonslip (For

Walkways), A-A-59166 . . . . . . . 6-22

6.12.20 Coatings, Polyurethane, Rain Ero-

sion Resistant For Exterior Air-craft and Missile Parts, MIL-C-

83231/SAE AMS-C-83231 . . . . . 6-23

6.12.21 Coating System, Polyurethane, Non-

Yellowing White, Rain Erosion Resistant, Thermally Reflective, MIL-C-83445/SAE AMS-C-

83445 . . . . . . . . . . . . . . . . . . . 6-23

6.12.22 Leading Edge Polyurethane Rain

Erosion Resistant Tape . . . . . . . 6-23

7 APPLICATION AND REMOVAL OF DE-

CALS AND SILK SCREENING . . . . . . 7-1

7.1 DECALS - GENERAL . . . . . . . . . 7-1

7.1.1 Surface Preparation . . . . . . . . . . . 7-1

7.1.2 Application Procedures For Decals

and Colored Marking Stripes . . . 7-1

7.2 SMALL DECALS AND MARKING

STRIPES . . . . . . . . . . . . . . . . 7-1

7.2.1 Decals Up To 12 inches x 2 inches . 7-1

7.2.2 Film For Striping . . . . . . . . . . . . . 7-1

7.3 LARGE EMBLEMS AND LET-

TERS USING HINGE APPLICA-

TION METHOD . . . . . . . . . . . 7-2

7.4 DECALS APPLIED USING APPLI-

CATION TAPE . . . . . . . . . . . . 7-3

7.5 EDGE SEALING . . . . . . . . . . . . . 7-3

7.6 APPLICATION OF PREMASKED

DECALS . . . . . . . . . . . . . . . . 7-4

7.7 DECAL REMOVAL . . . . . . . . . . . 7-4

7.7.1 Mechanical Removal . . . . . . . . . . 7-4

7.8 APPLICATION OF MARKINGS

WITH SILKSCREEN . . . . . . . . 7-5

7.8.1 Materials and Equipment for Silk-

screening . . . . . . . . . . . . . . . . 7-5

7.9 SURFACE PREPARATION . . . . . . 7-5

7.9.1 Application . . . . . . . . . . . . . . . . . 7-5

7.9.2 Topcoat Application . . . . . . . . . . . 7-5

7.10 APPLICATION OF MARKINGS

USING STENCILS . . . . . . . . . 7-5

7.10.1 Surface Preparation . . . . . . . . . . . 7-5

7.10.2 Mounting Stencil . . . . . . . . . . . . . 7-5

7.10.3 Painting of Stencils . . . . . . . . . . . 7-5

8 EXTERIOR FINISHES, INSIGNIA AND

MARKINGS, APPLICABLE TO USAF

AIRCRAFT . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 GENERAL . . . . . . . . . . . . . . . . . 8-1

8.1.1 Purpose . . . . . . . . . . . . . . . . . . . 8-1

8.1.2 Responsibilities . . . . . . . . . . . . . . 8-1

8.1.3 Maintenance and Application . . . . . 8-1

8.1.4 Major Command Instructions . . . . . 8-1

8.1.5 Authorized Deviations . . . . . . . . . 8-1

8.1.6 Paint Scheme and Marking Approval

Process . . . . . . . . . . . . . . . . . . 8-1

8.1.7 89th AW, 201AS, and the 1st Heli-copter Squadron . . . . . . . . . . . . 8-1

8.1.8 U.S. Air Force Aerial Demonstration

Squadron The Thunderbirds . . . . 8-1

8.1.9 76TH Airlift Squadron . . . . . . . . . 8-1

8.1.10 Low Observable Aircraft . . . . . . . . 8-1

8.1.11 Aircraft Received From Other Ser-

vices . . . . . . . . . . . . . . . . . . . 8-1

8.1.12 Service Tests . . . . . . . . . . . . . . . . 8-2

8.1.13 Decals . . . . . . . . . . . . . . . . . . . . 8-2

8.1.14 Applicable References . . . . . . . . . 8-2

8.2 STANDARD EXTERIOR FIN-

ISHES MARKINGS AND IN-

SIGNIA FOR USAF AIR-

CRAFT . . . . . . . . . . . . . . . . . 8-2

8.2.1 Metal Exterior Finishes . . . . . . . . . 8-2

8.2.2 Titanium and Corrosion Resistant

Steel . . . . . . . . . . . . . . . . . . . 8-2

8.2.3 Treatment of Metal Exteriors . . . . . 8-2

8.2.4 Policy Guidance . . . . . . . . . . . . . . 8-2

8.2.5 Camouflage . . . . . . . . . . . . . . . . . 8-3

8.2.6 Special Purpose Exterior Solar Re-

sistant Finishes . . . . . . . . . . . . 8-3

8.2.7 Paint Facility/Finish Identification

Block . . . . . . . . . . . . . . . . . . . 8-3

8.3 Markings and Insignia for USAF

Aircraft . . . . . . . . . . . . . . . . . 8-3

8.3.1 General . . . . . . . . . . . . . . . . . . . 8-3

8.3.2 USAF Marking . . . . . . . . . . . . . . 8-3

8.3.3 American Flag Marking . . . . . . . . 8-3

8.3.4 United States of America Marking . 8-4

8.3.5 Aircraft Radio Call Numbers . . . . . 8-4

8.3.6 AMC Standard Radio Call Num-

bers . . . . . . . . . . . . . . . . . . . . 8-4

8.3.7 ACC Standard Radio Call Num-

bers . . . . . . . . . . . . . . . . . . . . 8-5

8.4 Organization Insignia or Emblems . 8-5

8.4.1 Outstanding Unit Award Marking . . 8-5

8.4.2 Crew Names . . . . . . . . . . . . . . . . 8-5

8.4.3 Aircraft Names . . . . . . . . . . . . . . 8-5

8.4.4 Local Station Numbers and Mark-

ings . . . . . . . . . . . . . . . . . . . . 8-5

8.4.5 Propeller Markings . . . . . . . . . . . . 8-5

8.4.6 Helicopter Main Rotor Blade Mark-

ings . . . . . . . . . . . . . . . . . . . . 8-6

8.4.7 Helicopter Tail Rotor Blade Mark-

ings . . . . . . . . . . . . . . . . . . . . 8-6

8.4.8 Identification Markings of Jettison-

able Aircraft Components . . . . . 8-6

TO 1-1-8

TABLE OF CONTENTS - CONTINUED

iv Change 1

8.4.9 Markings for Servicing, Ground

Handling and Hazard Warning . . 8-6

8.4.10 Markings for Engine Compartment

Fire Access Panel . . . . . . . . . . . 8-6

8.4.11 Ejection Seats . . . . . . . . . . . . . . . 8-6

8.4.12 Identification of Ballistic Hose As-

semblies . . . . . . . . . . . . . . . . . 8-6

8.4.13 Markings for Tank Filler Areas . . . . 8-7

8.4.14 Marking of Emergency Lighting

(Flashlight) for Cargo &Transport Aircraft . . . . . . . . . . . . . . . . . 8-7

8.4.15 Markings for Walkways and Steps . 8-7

8.4.16 Markings for Composite/Honeycomb

Panels . . . . . . . . . . . . . . . . . . 8-7

8.4.17 Removable Escape Panels . . . . . . . 8-7

8.4.18 Markings for Unmanned aerial Ve-

hicles . . . . . . . . . . . . . . . . . . . 8-7

8.4.19 Conspicuity Markings . . . . . . . . . . 8-7

8.4.20 Arctic Markings . . . . . . . . . . . . . . 8-7

8.5 Establishing Requirements for Mis-

sion Activity, Crew Accomplish-ment, and Esprit de Corps Insig-nia and Markings . . . . . . . . . . . 8-8

APPENDIX A SHELF-LIFE EXTENSION

PROCEDURES . . . . . . . . . . . . . . . . . . A-1

APPENDIX B STANDARD AIR FORCE

AIRCRAFT MARKINGS . . . . . . . . . . . B-1

APPENDIX C RESPIRATOR PROTEC-

TION EQUIPMENT . . . . . . . . . . . . . . . C-1

GLOSSARY . . . . . . . . . . . . . . . . . . . . . .Glossary-1

TO 1-1-8

TABLE OF CONTENTS - CONTINUED

Change 1 v

LIST OF ILLUSTRATIONS

Figure Title Page Figure Title Page

4-1 Nozzle Pressure Gauge . . . . . . . . . . . 4-1 4-2 Simple Spray System Setup . . . . . . . . 4-4 4-3 Airless Spray System . . . . . . . . . . . . . 4-5 4-4 Complete Spray System . . . . . . . . . . . 4-6 4-5 Sectional View of Spray Gun . . . . . . . 4-7 4-6 Proper Installation of Air Compressor, Piping . . . . . . . . . . . . . . . . . . . . . 4-8 4-7 Right and Wrong Methods of Spraying . 4-9 4-8 Fifty Percent Overlap . . . . . . . . . . . . . 4-10 4-9 Cross Coating . . . . . . . . . . . . . . . . . . 4-10 4-10 Spray Gun Adjustments . . . . . . . . . . . 4-11 4-11 Excessive Spray Fog . . . . . . . . . . . . . 4-12 4-12 Paint Leaks From Spray Gun . . . . . . . 4-12 4-13 Gun Sputters Constantly . . . . . . . . . . . 4-13 4-14 Orange Peel . . . . . . . . . . . . . . . . . . . 4-19 4-15 Sandpaper Finish . . . . . . . . . . . . . . . 4-19 4-16 Wrinkling . . . . . . . . . . . . . . . . . . . . 4-20 4-17 Crazing . . . . . . . . . . . . . . . . . . . . . . 4-20 4-18 Cracking . . . . . . . . . . . . . . . . . . . . . 4-20 4-19 Blistering . . . . . . . . . . . . . . . . . . . . . 4-21 4-20 Fish Eyes . . . . . . . . . . . . . . . . . . . . . 4-21 4-21 Lifting . . . . . . . . . . . . . . . . . . . . . . . 4-21 4-22 Pitting or Cupping . . . . . . . . . . . . . . . 4-21 5-1 Sempen . . . . . . . . . . . . . . . . . . . . . . 5-14 5-2 Sempen Mixing . . . . . . . . . . . . . . . . 5-14 5-3 Sempen Application . . . . . . . . . . . . . . 5-14 5-4 Spray Tool . . . . . . . . . . . . . . . . . . . . 5-15 6-1 Zahn Cup . . . . . . . . . . . . . . . . . . . . 6-4 7-1 Applying Small Decal. . . . . . . . . . . . . 7-1

7-2 Applying Marking Stripe . . . . . . . . . . 7-2 7-3 Applying Large Emblems (Step 1) . . . . 7-2 7-4 Applying Large Emblems (Step 2) . . . . 7-2 7-5 Applying Large Emblems (Step 3) . . . . 7-2 7-6 Applying Large Emblems (Step 4) . . . . 7-2 7-7 Use of Application Tape (Step 1) . . . . . 7-3 7-8 Use of Application Tape (Step 2) . . . . . 7-3 7-9 Use of Application Tape (Step 3) . . . . . 7-3 7-10 Use of Application Tape (Step 4) . . . . . 7-3 7-11 Edge Sealing . . . . . . . . . . . . . . . . . . 7-4 B-1 Edge Sealing . . . . . . . . . . . . . . . . . . B-2 B-2 National Star Insignia on Swept Wings . B-3 B-3 Form of Letters and Numerals . . . . . . . B-4 B-4 Typical Marking For Paint

Facility/Finish Identification Block . . B-5

B-5 “UNITED STATES OF AMERICA”

AND AMC Standard Marking Sample . . . . . . . . . . . . . . . . . . . . B-6

B-6 Distinctive Unit, Serial Number and ACC Standard Sample . . . . . . . . . . B-7

B-7 Aircraft Markings, Servicing and Precautioning . . . . . . . . . . . . . . . . B-8

B-8 Ground Here, International Symbol . . . B-10 B-9 Markings For Fire Access Panel . . . . . B-10 B-10 Helicopter Tail Boom Markings . . . . . . B-11 B-11 Typical Emergency Instruction

Markings . . . . . . . . . . . . . . . . . . . B-11 B-12 Typical Emergency Entry Markings . . . B-12

LIST OF TABLES

Table Title Page Table Title Page

2-1 Hand Held Abrasives . . . . . . . . . . . . . . 2-15 2-2 Motor Driven Abrasives . . . . . . . . . . . . 2-16 2-3 Abrasive Materials . . . . . . . . . . . . . . . . 2-17 2-4 Recommended Controls and PPE for

Abrasive Blasting Operationsa . . . . . . 2-18 3-1 Recommended Controls and PPE for

Surface Preparation Operationsa . . . . . 3-4 3-2 Wipe Solvents . . . . . . . . . . . . . . . . . . . 3-5 4-1 Spray Coating Troubles, Possible Causes, and Remedies . . . . . . . . . . . . . . . . . 4-13 5-1 Minimum Recommended Controls and

PPE for Priming and Painting Operationsa . . . . . . . . . . . . . . . . . . . 5-2

5-2 Allowable Coating Thickness for Production Level Finishing (Depot, Original Manufacture, Field) . . . . . . . 5-11

5-3 Gloss Requirements . . . . . . . . . . . . . . . 5-12 6-1 Thinning Ratio (Volume) for Wash Primer

MIL-C-8514 . . . . . . . . . . . . . . . . . . 6-15

6-2 Leading Edge Tape Materials/Tools . . . . . 6-24 8-1 Standard Markings . . . . . . . . . . . . . . . . 8-4 8-2 Aircraft Authorized American Flag

Markings . . . . . . . . . . . . . . . . . . . . 8-4 8-3 Aircraft Authorized United States of

America Markings . . . . . . . . . . . . . . 8-4 8-4 Aircraft Authorized Multi-Colored Blade

Tip Markings . . . . . . . . . . . . . . . . . . 8-6 A-1 Viscosity and Pot Life . . . . . . . . . . . . . A-3 C-1 Respirator Protection Equipment . . . . . . . C-2 vi Change 1

FOREWORD

1 PURPOSE.

The purpose of this technical order is to prescribe standard procedures for the removal, application, and maintenance of coating systems on Air Force systems and equipment. Its applicability is generally imposed by reference in system or item technical data. It also should be used where there is an absence of paint process requirements in system or item technical data. System and item (SM/IM) management ac-tivities have an obligation to require the use of this technical order to the maximum practical extent. It reflects the use of standard materials and procedures that meet Defense Stan-dardization Program, AF Corrosion Prevention and Control Program, and Air Force policy (AFI 21-105) requirements.

SM/IM offices should modify standard requirements or specify alternate requirements only as needed to support the specific requirements of their systems and equipment as stated in TO 00-5-1. Where there is a conflict between this general TO and the weapon system specific TO, the weapon system specific TO will take precedence. Such departures from standard should also be coordinated with all applicable Office of Coordinating Responsibilities (OCRs) (e.g., Corro-sion Control, Ground Safety, Bioenvironmental Engineering, Environmental Management).

2 SCOPE.

This technical manual specifies procedures, materials, and equipment for preparing surfaces and correctly applying effective finishes to interiors and exteriors of Air Force aircraft, missiles, and associated equipment. Painting tech-niques are suggested and common difficulties discussed.

Procedures for applying complete coating systems are given.

Some basic discussion of paint technology is included and a glossary of painting terms appended.

3 ABBREVIATIONS AND ACRONYMS.

The following nonstandard abbreviations are used in this manual. For definition of standard abbreviations and acro-nyms, refer to ASME 14.38.

ACGIH American Conference of Govern-ment Industrial Hygienists

ALC Air Logistic Center BCE Base Civil Engineer BES Base Environmental Services CFM Cubic Feet per Minute CID Commercial Item Description CRES Corrosion Resistant Steel DR Drum EAID Equipment Authorization Inventory

Data

EPA Environmental Protection Agency FSC Federal Stock Classes GL Gallon gm Grams HAZMAT Hazardous Materials HDI Hexamethylene Diisocyanate HVLP High Volume Low Pressure ID Inside Diameter IPB Illustrated Parts Breakdown IPI In-Process Inspection LEL Lower Explosive Limit LOX Liquid Oxygen MEK Methyl-Ethyl-Ketone ml milliliter moh Measure of Hardness MPW Medium Pressure Water MSDS Material Safety Data Sheets NATO North Atlantic Treaty Organization NDI Non-Destructive Inspection No. Number NSN National Stock Number OCR Office of Coordinating Responsi-bilities OSHA Occupational Safety and Health Act

PAPR Powered Air-Purifying Respirator PCBTF Parachlorobenzotrifluoride PD Purchase Description PMB Plastic Media Blasting PN Part Number PPE Personal Protective Equipment PPM Parts per Million PSI Pound-force per square inch PSIG Pounds Per Square Inch Gauge PVC Polyvinyl Chloride QPL Qualified Products List SG Specific Gravity SLED Shelf-Life Extension Data SM/IM System Manager/Item Manager SPD Systems Program Director SPO System Program Office TNP Touch-N-Prep UAV Unmanned aerial Vehicle UV Ultra Violet

Change 3 vii

VOC Volatile Organic Compound

4 LIST OF RELATED PUBLICATIONS.

The following publications are to be used for reference.

Maintain only those publications required to perform as-signed mission. This list is not all inclusive. This list also includes general information TOs pertaining to inspection, maintenance, storage, and use of personal flying and survival equipment.

List of Related Publications

Number Title ASTM D 1153 Methyl-Isobutyl-Ketone

(Repl. TT-M-268) ASTM D 13 Spirits of Turpentine (Repl.

TT-T-801)

ASTM D 304 n-Butyl Alcohol (Butanol)

(Repl. TT-B-846) ASTM D 329 Acetone, Technical (Repl.

O-A-51) ASTM D 330 Ethylene Glycol Monobutyl

Ether (2-Butoxyethanol) (Repl. TT-E-776)

ASTM D 740 Methyl-Ethyl-Ketone (Repl.

TT-M-261)

CCC-C-440 Cloth, Cheese, Cotton, Bleached and Unbleached

CID A-A- 857 Thinner, Dope and Lacquer (Cellulose Nitrate) (Repl.

MIL-T-19544)

CID A-A-1043 Wool, Steel (Repl. FF-W- 1825 steel type)

CID A-A-1044 Wool, Metallic (Copper and Aluminum) (Repl. FF-W- 1825 aluminum type)

CID A-A-1047 Paper, Abrasive, Silicon Carbide, Waterproof (Repl. by ANSI B74.18)

CID A-A-1800 Varnish, Oil, Spar (Repl.

TT-V-119)

CID A-A-2522 Rags, Wiping (Cotton and Cotton Synthetic)

CID A-A-3003 Lacquer, Spraying, Clear and Pigmented, for Inte-rior Use (Repl. TT-L-58)

CID A-A-3007 Thinner for Phenol- Formaldehyde and Me-dium Oil and Styrenated Alkyd Paints and Var-nishes (Repl. TT-T-306)

List of Related Publications - Continued

Number Title CID A-A-3054 Paint, Heat Resisting (204°

C) (Repl. TT-E-496) CID A-A-3118 Brush, Plater’s, Hand

(Curved Handle Type) (Repl. H-B-178)

CID A-A-3164 Synthetic Lacquer, Camou-flage, Exterior, VOC Compliant (Repl. TT-L- 20)

CID A-A-341 Pigment, Aluminum, Pow-der and Paste (Repl. TT- P-320)

CID A-A-55827 Chromium Trioxide, Tech-nical (Repl. O-C-303)

CID A-A-58054 Abrasive Mats, Non- Woven, Non-Metallic (Repl. MIL-A-9962)

CID A-A-58060 Fluorocarbons and Other Refrigerants

CID A-A-59105 Nitric Acid, Technical CID A-A-59106 Ethylene Glycol Monoethyl

Ether, Technical (Repl.

TT-E-781)

CID A-A-59107 Toluene, Technical (Repl.

TT-T-548)

CID A-A-59124 Deck Covering, Light-weight, Non-Slip (Repl.

MIL-W-5044)

CID A-A-59133 Cleaning Compound, High Pressure (Steam) Clean-ing (Repl. MIL-C-5543)

CID A-A-59146 Cleaning Compound, Al-kali, Boiling Vat (Soak) or Hydrosteam (Repl.

P-C-436)

CID A-A-59166 Coating Compound, Non- Slip, for Walkways (Repl.

MIL-W-5044)

CID A-A-59281 Cleaning Compound, Sol-vent Mixtures (Repl.

MIL-C-38736)

CID A-A-59282 Alcohol, Ethyl (Repl. O-E- 760)

CID A-A-59485 Plastic Material, Pressure Sensitive, for Aerospace Identification and Mark-ing (Repl. MIL-P-38477)

DOD-P-15328 Primer (Wash), Pretreat-ment, (Formula No. 117 for Metals) viii Change 3

List of Related Publications - Continued

Number Title GGG-C-520 Cloth and Disks, Abrasive, Open-Mesh, Waterproof (Repl. by ANSI B74.18)

MIL-A-8625 Anodic Coatings for Alumi-num and Aluminum Al-loys

MIL-B-23958 Brush, Cleaning, Aircraft, Metal Brightening

MIL-C-16555 Coating Compound, Strip-pable, Sprayable

MIL-DTL-5541 Chemical Conversion Coat-ings for Aluminum and Aluminum Alloys

MIL-C-81706/MIL-DTL-

81706

Chemical Conversion Mate-rials, for Coating Alumi-num and Aluminum Al-loys

MIL-DTL-85054 Corrosion Preventive Com-pound, Water Displacing, Clear (AMLGUARD)

MIL-C-8514 Coating Compound, Metal Pretreatment, Resin-Acid

MIL-C-8779 Color, Interior, Aircraft, Requirements for

MIL-DTL-24441 Paint, Epoxy-Polyamide, General Specification for

MIL-P-15930 Primer Coating, Shipboard, Vinyl-Zinc Chromate

MIL-PRF-23377 Primer Coatings, Epoxy, High Solids

MIL-P-38336/SAE AMS-P-

38336

Primer Coating, Inorganic Zinc Dust Pigmented, Self Curing, for Steel Surfaces

MIL-P-85891 Plastic Media for Removal of Organic Coatings

MIL-PRF-121 Barrier Material, Grease Proof, Water Proof, Flex-ible

MIL-PRF-131 Barrier Material, Water Va-por Proof, Grease Proof, Flexible

MIL-PRF-22750 Coating, Epoxy, High Sol-ids

List of Related Publications - Continued

Number Title MIL-PRF-26915 Primer Coating for Steel

Surfaces MIL-PRF-3043 Resin Coating, Permanent, for Engine Components and Metal Parts

MIL-PRF-4556 Coating Kit, Epoxy, for Interior of Steel Fuel Tanks

MIL-PRF-6799 Coating, Sprayable, Strip-pable, Protective, Water Emulsion

MIL-PRF-680 Degreasing Solvent (Repl.

P-D-680)

MIL-PRF-83936 Remover, Paint, Tank type;

for Aircraft Wheels, Landing Gear Compo-nents, and Other Aircraft and Support Equipment

MIL-PRF-85285 Coating, Polyurethane, High-Solids

MIL-PRF-85570 Cleaning Compound, Air-craft Exterior

MIL-PRF-85582 Primer Coatings, Epoxy, Waterborne

MIL-PRF-87937 Cleaning Compound, Aero-space Equipment

MIL-PRF-87978 Remover, Paint, Epoxy and Polyurethane Systems, Tank Type, Ambient tem-perature, for Aircraft Wheels and Landing Gear Components

MIL-STD-7179 Finishes, Coatings, and Sealants for Protection of Aerospace Weapon Sys-tems (Repl. MIL-F-7179)

MIL-T-81772 Thinner, Aircraft Coating SAE AMS-1640 Corrosion Removing Com-pound, for Aircraft Sur-faces (Repl. MIL-C- 38334)

SAE AMS-3002 Alcohol, Ethyl, Specially Denatured (Repl. MIL-A- 6091)

Change 3 ix

List of Related Publications - Continued

Number Title SAE AMS-3819 Cloths, Cleaning SAE AMS-C-27725 Coating, Corrosion Preven-tive, Polyurethane, for Aircraft Integral Fuel Tanks (to 250° F) (Repl.

MIL-C-27725)

SAE AMS-C-83231 Coating, Polyurethane, Rain Erosion Resistant, for Exterior Aircraft and Missile Plastic Parts (Repl. MIL-C-83231)

SAE AMS-C-83445 Coating System, Polyure-thane, Non-Yellowing White, Rain Erosion Re-sistant, Thermally Reflec-tive (Repl. MIL-C-83445)

SAE AMS-M-3171 Magnesium Alloy, Pro-cesses for Corrosion Pro-tection (Repl. MIL-M- 3171)

SAE AMS-T-21595 Tapes, Pressure-Sensitive Adhesive, Masking, Non- Staining-for Aircraft Painting Applications (Repl. MIL-T-21595)

SAE AMS-T-23397 Tapes, Pressure Sensitive Adhesive, for Masking During Paint Removal Operations (Repl. MIL-T- 23397)

SAE AS-22805 Spray Kit, Self Pressurized (Repl. MIL-S-22805)

TT-E-751 Ethyl Acetate, Technical TT-I-735 Isopropyl Alcohol TT-N-95 Naphtha, Aliphatic TT-P-1757 Primer Coating, Alkyd

Base, One Component TT-P-2760 Primer Coating, Polyure-thane, Elastomeric, High Solids

TT-P-28 Paint, Aluminum, Heat Re-sisting (1200° F)

VV-P-236 Petrolatum, Technical TO 00-25-172 Ground Servicing of Air-craft and Static Ground-ing/Bonding

List of Related Publications - Continued

Number Title TO 00-25-4 Depot Maintenance of

Aerospace Vehicles and Training Equipment

TO 00-5-1 Air Force Technical Sys-tems

TO 1-1-24 Maintenance, Repair, and Electrical Requirements for Fiberglass Airborne Radomes

TO 1-1-24-1 Supplementary Manual -- Maintenance, Repair, and Electrical Requirements for Fiberglass Airborne Radomes

TO 1-1-689 Volumes I, III, and V

Cleaning and Corrosion Control, Avionics and Electronics

TO 1-1-690 General Advanced Compos-ite Repair Manual

TO 1-1-691 Aircraft Weapon Systems Cleaning and Corrosion Control

TO 31-1-221 Field Instructions for Paint-ing and Preserving Elec-tronics Command Equip-ment

TO 35-1-3 Corrosion Prevention, Painting, and Marking of USAF Support Equip-ment (SE)

TO 42B1-1-15 Cross Reference - NATO/ ASCC Interchangeability of Aviation Fuels, Lubri-cants and Allied Products

TO 42C2-1-7 Process Instructions-Metal Treatments, Electro depo-sition of Metals, and Metal Surface Treatments Meet Air Force Mainte-nance Requirements x

SAFETY SUMMARY

1 GENERAL SAFETY INSTRUCTIONS.

This manual describes physical and chemical processes, which may cause injury or death to personnel, or damage to equipment if not properly followed. This safety summary includes general safety precautions and instructions that must be understood and applied during operation and maintenance to ensure personnel safety and protection of equipment. Prior to performing any task, the WARNINGs, CAUTIONs, and NOTEs included in the task shall be reviewed and under-stood.

2 WARNINGS, CAUTIONS, AND NOTES.

WARNING, CAUTION, and NOTE statements have been strategically placed throughout this text prior to operating or maintenance procedures, practices or conditions considered essential to the protection of personnel (WARNING) or equipment and property (CAUTION), or when essential to highlight a practice (NOTE). A WARNING, CAUTION or NOTE will apply each time the step to which it refers is repeated. Prior to starting any task, the WARNINGS, CAU- TIONS, and NOTES for that task will be reviewed and understood. Refer to the materials list table at the beginning of the appropriate work package for material used during maintenance of this equipment. The detailed warnings for hazardous materials are listed separately in the safety sum-mary in the Hazardous Materials paragraph. Other warnings, cautions, and notes which appear in this manual are not listed separately in this safety summary, and are defined as follows:

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed, could result in injury to, or death of, personnel or long term health hazards.

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc.

which if not strictly observed, could result in damage to, or destruction of, equipment or loss of mission effectiveness.

NOTE

Highlights an essential operating or maintenance procedure, condition, or statement.

3 HAZARDOUS MATERIALS WARNINGS.

Hazardous Material Warnings are provided through use of Hazard Symbols listed below. Consult the HAZARDOUS MATERIALS DESCRIPTION below or MSDS OSHA Form 20 or equivalent for specific information on hazards, effects and protective equipment requirements. If you do not have an MSDS for the material involved, contact your supervisor, or base Safety or Bioenvironmental Engineering Offices.

xi/(xii blank)

CHAPTER 1

INTRODUCTION AND GENERAL DISCUSSION OF COATING

MATERIALS AND TERMS

1.1 INTRODUCTION.

NOTE

See Chapter 8 for Air Force policy on determin-ing when individual aircraft are to be repainted or touched up.

The surfaces of aircraft, missiles, and associated equipment are subjected to hostile environments both natural and man-made. Inadequate control or prevention of metal corrosion or other forms of surface deterioration is costly and can shorten weapon or equipment life, hinder mission accomplishment, or endanger personnel or equipment. To add to their ability to resist detrimental environments, surfaces are coated in vari-ous ways with a variety of materials. Coatings are divided into two main groups: inorganic and organic. The principal and most versatile means of protection is organic coating, or “paint”. In general, a suitable organic coating system, prop-erly applied, offers greater protection against corrosion on metals than an inorganic finish (such as a metallic plating) alone and is more easily maintained. This technical manual also covers some inorganic materials, insofar as they are applied in surface preparation for painting by personnel involved with paint removal and painting operations.

1.2 GENERAL DISCUSSION OF ORGANIC COAT-

INGS.

NOTE

Precautionary measures shall be taken to prevent paint and paint removal waste from contaminat-ing air, water, or soil. Some of the chemicals utilized for painting and paint removal require treatment or other special control prior to dis-posal. Disposal of materials shall be accom-plished under the direction of the Base Safety Office, Base Civil Engineer, Bioenvironmental Engineer, and Environmental Management in accordance with applicable directives and in a manner that will not result in violation of local, state, or federal pollution criteria. Detailed infor-mation for disposal is cited in AFI 32-1067, AFI

32-7041, AFI 32-7042, AFPAM 32-7043, AFI

32-7045, AFI 32-7080, AFI 32-7086, and

AFOSH STD 91-501.

To provide optimum protection from deterioration and cor-rosion, the proper coating systems (combination of pretreat-ment, primer, and topcoat) must be selected for a specific application. The selection of the proper coating system depends on the material to be coated, the environment to which the item will be subjected, and the service life requirement of the coating. No single coating or coating system can perform adequately on all types of surfaces under all conditions to which Air Force equipment is subjected. For example, a coating paint conforming to Specification MIL- C-27725/SAE AMS-C-27725 is good for fuel immersion service, but is inadequate for exposure to an industrial atmosphere or high humidity conditions. Many primers and topcoats can be used in various combinations; however, some primers are specifically formulated for a particular type topcoat. One Component, Alkyd Base Primers are for use under enamels. Use of this primer under epoxy or polyure-thane coatings will result in premature failure of the coating system.

1.2.1 Coatings Systems For Metal Surfaces. Unless

protected, metals surfaces (with the exception of stainless steel, titanium and some of the more exotic metals) react with oxygen and various contaminants in the atmosphere, particu-larly in the presence of moisture, to form rust or other corrosion products. The most common method of preserving metals is by applying organic coatings.

1.2.1.1 Polishing, buffing, and waxing of aircraft and parts

is prohibited unless authorized and directed by the MAJCOM Senior Logistics Official.

1.2.2 Aircraft Protective Finish Systems. MIL-STD-

7179 covers the general requirements for protective finishes and coatings on aerospace weapon system structures and parts. (It does not necessarily govern coatings on aeronautical equipment such as propellers or power plants, nor those on accessories such as motors, generators, instruments, etc.) The level of coating protection is specified depending on the environment to which the weapon system is to be subjected.

1.3 ORGANIC COATING.

An organic coating or paint may be defined as a carbon based liquid or semi-liquid material which is applied to a surface by some mechanical means and which, when dried or cured, will provide an adherent film of certain desired characteristics.

Organic coatings are variously classed as paints, enamels, varnishes and lacquers. As these classifications are not always practical, due to modern formulations, and because the coating materials dealt with in this technical manual are almost exclusively organic in chemical structure, the pre-ferred term “organic coating” is used to designate finishing materials in general. For the purposes of this technical manual the term is extended to include some heavy elasto-

Change 3 1-1 meric materials which are not truly “paints,” and also certain chemical surface-treating materials which are not truly or-ganic. These materials may or may not be applied by painters, but are closely associated with painting operations. Also, the term “to paint” will continue to be used to signify the application of organic coatings by painters.

1-2

CHAPTER 2

ORGANIC FINISH SYSTEM REMOVAL

2.1 INTRODUCTION.

The most important factor in removal of organic finish systems (coatings/paints) is complete removal without dam-aging surfaces on which they are applied. A variety of materials and either chemical or mechanical methods can remove finish systems. In choosing a material and a method, a compromise between maximum removal power and maxi-mum protection for the equipment being stripped must be made. Accessibility of areas to be stripped can dictate the types of materials and methods to be used. For these reasons, only those materials and methods described in this chapter, subject to noted restrictions, are authorized for general use in organic finish system removal from Air Force equipment.

Adherence to removal procedures and their sequence of performance in this chapter is mandatory. Other removal materials and methods can be authorized for limited and specific applications, but only when specifically approved and defined in system peculiar aircraft and/or equipment technical orders. The term “Depot Level” in this chapter refers to organizations and facilities which are involved in complete aircraft stripping operations on a routine, if not daily basis. This includes the Air Logistic Centers (ALCs) and contract stripping operations. It does not include field-level maintenance facilities.

NOTE

National Stock Numbers (NSNs), if assigned, for chemical removers, abrasives, and other materi-als and equipment authorized in this chapter are in Federal Stock Classes (FSC) 5345/50, 6850, and 8135 and FSC 7500, 7900, and 8000. Consult the current FED LOG and GSA Catalog and/or the D043 System to convert specification and part numbers to NSNs and for ordering and pricing information and shelf life codes.

2.2 GENERAL.

NOTE

Each time an aircraft is completely depainted, the following information shall be documented in the aircraft historical record, AFTO Form 95: 1. Type of paint removal process used, 2. Where accom-plished, and 3. Date accomplished.

Organic finish systems shall be removed from Air Force aircraft and equipment only when the condition of deteriora-tion of the system indicates the need for removal or when required in a system peculiar technical order to perform a specified inspection of the underlying structure. This applies to stripping of components and small areas of aircraft and equipment as well as to the entire surface of aircraft or equipment. Removal of the entire exterior organic finish system from aircraft shall be accomplished in accordance with the criteria specified in Chapter 8 of this manual and the Aircraft System Program Manager’s Service Life Paint Plan.

Prior to any organic finish system removal, the following steps shall be taken in all cases:

a. Ensure that the facility to be used for finish system removal operations meets all the safety, fire precaution, health promotion, and environmental requirements in applicable AFOSH and NFPA standards. Precautionary measures shall be taken to prevent paint and paint removal waste from contaminating air, water, or soil.

Prior to performance of finish system removal opera-tions, all personnel must be trained on Personal Protec-tive Equipment (PPE) as required in AFOSH STD 48-137 and 91-501. Personnel who are not wearing appropriate PPE shall not perform finish system removal operations.

b. Ensure that the facility to be used for finish system removal operations provides the proper precautionary measures for disposal of finish system removal waste products as required by AFI 32-7041, AFI 32-7080, and AFI 32-7086 to prevent contamination of lakes, rivers, and streams. Many chemicals used in finish system removal operations and finish system residues require special treatment and control prior to disposal. Disposal shall be accomplished under the direction of the Base Safety Office, the Base Civil and Bioenvironmental Engineers, and the Environmental Management Office in a manner which will not violate local, state, and federal pollution regulations. Consult AFI 32-1067, AFI

32-7041, AFI 32-7042, AF PAM 32-7043, AFI 32-7045,

AFI 32-7080, AFI 32-7086, and AFOSH STD 91-501 for detailed information on disposal of finish system removal waste.

c. Determine the type of organic finish system to be removed so that the proper material and method for removal can be chosen from those listed in this chapter.

Consult aircraft and/or equipment system peculiar tech-nical orders and drawings, component drawings, aircraft historical records (AFTO Form 95), and/or the aircraft exterior finish identification marking on the aircraft (reference Chapter 8) to help in this determination. If the finish system cannot be determined from these docu-ments or they are not available, determine the finish system as follows:

(1) Rub a small area on the surface from which the finish system is to be removed vigorously with a cotton rag wet with ASTM D 329 acetone. If the finish system

2-1 is removed, it is a lacquer or alkyd enamel coating. If it is not removed, or very little is removed, it is a polyurethane or an epoxy coating.

(2) For polyurethane and epoxy coatings, scrape off the topcoat from a small area down to the primer coating with a knife blade or razor blade. If the primer is rubbery and a tan-gray color, it is a polysulfide primer. If the primer is hard and either a yellow, light brown, or dark green (olive drab) color, it is either an epoxy or a polyurethane primer.

d. As a last step, study the removal operation to be performed and determine the most logical and efficient process for the job. If confined areas are involved, they shall be protected during a general overall removal operation, and shall be stripped using the special proce-dures in this chapter for these areas. If fiberglass, kevlar, or other composites are involved, they shall be stripped using the special procedures outlined later in this tech-nical order. For extensive removal operations, such as removal of the entire exterior finish system on aircraft and large pieces of equipment, a detailed sequential step-by-step process specification confirming to all of the requirements in this chapter shall be prepared and followed. All personnel involved with finish system removal shall be trained in and thoroughly familiar with all requirements of this chapter.

2.3 PREPARATION FOR PAINT REMOVAL.

All aircraft will be de-energized per AFOSH STD 91-17, support equipment or components must be properly prepared for paint removal operations.