Air Force Technical Manual 1-1-8.pdf

TO 1-1-8

TECHNICAL MANUAL

APPLICATION AND REMOVAL OF

ORGANIC COATINGS,

AEROSPACE AND NON-AEROSPACE

EQUIPMENT

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited. PA Case Number 05-0758. Other requests for this document shall be referred to 406 SCMS/GUEE, Robins AFB, GA 31098. Questions concerning technical content shall be referred to

AFLCMC/EZPT-CPCO.

Published Under Authority of the Secretary of the Air Force

12 JANUARY 2010 CHANGE 26 - 25 OCTOBER 2019

BASIC AND ALL UPDATES HAVE BEEN MERGED TO MAKE THIS A COMPLETE PUBLICATION.

Dates of issue for original and changed pages are:

Original. . . . . . . .0. . . . .12 January 2010 Change . . . . . . . . 1 . . . . .28 January 2011 Change . . . . . . . . 2 . . . . . . . 18 May 2011 Change . . . . . . . . 3. . . . .16 October 2012 Change . . . . . . . . 4 . . . . . . . 12 June 2013 Change . . . . . . . . 5 . . . . . . . 26 July 2013 Change . . . . . . . . 6. . . .8 November 2013 Change . . . . . . . . 7. . . . . .30 March 2014 Change . . . . . . . . 8 . . . . . . . 29 May 2014 Change . . . . . . . . 9 . . . . . . . 11 July 2014 Change . . . . . . . 10 . . . . . 30 August 2014 Change . . . . . . . 11. . . . .11 October 2014 Change . . . . . . . 12 . . . 25 December 2014 Change . . . . . . . 13. . . . . . .29 April 2015

Change . . . . . . . 14 . . . . . . . 14 May 2015 Change . . . . . . . 15 . . . . . . . . 4 July 2015 Change . . . . . . . 16 . . . . . . 9 August 2015 Change . . . . . . . 17 . . . . . . 9 March 2016 Change . . . . . . . 18. . . . . . . .4 May 2016 Change . . . . . . . 19 . . . . . . . 24 June 2016 Change . . . . . . . 20 . . . . . 12 August 2016 Change . . . . . . . 21 . . . . . 24 August 2017 Change . . . . . . . 22 . . . . 22 February 2018 Change . . . . . . . 23 . . . . . 10 August 2018 Change . . . . . . . 24 . . . . 16 February 2019 Change . . . . . . . 25 . . . . . 28 August 2019 Change . . . . . . . 26. . . . .25 October 2019

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 182, CONSISTING OF THE FOLLOWING:

Page *Change No. No.

Page *Change No. No.

Page *Change No. No.

Title A i ii - v vi - vii viii - ix x Blank xi - xiv xv Added xvi Blank 1-1 1-2 2-1 2-2 2-2.1 - 2-2.2 Deleted 2-3 - 2-4 2-4.1 Added 2-4.2 Blank 2-5 2-6 - 2-7 2-8 Blank 2-9 - 2-10 2-11 2-12 2-12.1 Added 2-12.2 Blank 2-13 - 2-14 2-14.1 Added 2-14.2 Blank 2-15 - 2-17 2-18 - 2-19 2-20 2-20.1 Added

2-20.2 Blank 2-21 2-22 2-23 - 2-24 2-25 2-26 3-1 - 3-4 3-4.1 Added 3-4.2 Blank 3-5 - 3-8 3-8.1 Added 3-8.2 Blank 3-9 - 3-12 3-13 3-14 3-15 3-16 3-17 3-18 4-1 - 4-8 4-9 4-10 - 4-22 5-1 5-2 5-3 5-4 - 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12

5-13 - 5-14 5-15 5-16 - 5-17 5-18 Blank 6-1 - 6-4 6-5 - 6-6 6-7 6-8 6-9 6-10 6-11 6-12 6-13 6-14 6-15 - 6-20 6-21 - 6-23 6-24 Blank 7-1 7-2 - 7-5 7-6 8-1 8-2 - 8-4 8-4.1 Added 8-4.2 Blank 8-5 - 8-8 A-1 - A-3 A-4 Blank B-1 - B-4 B-5 B-6 - B-12 C-1 - C-4 Glossary 1 - Glossary 4 Glossary 5 - Glossary 6

TO 1-1-8

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 margins 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.

A Change 26 USAF

TABLE OF CONTENTS

Chapter Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . viii

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . viii

INTRODUCTION . . . . . . . . . . . . . . . . . . . . xi

SAFETY SUMMARY . . . . . . . . . . . . . . . . . xv

1 INTRODUCTION AND GENERAL DISCUS-

SION 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

Surfaces . . . . . . . . . . . . . . . . . 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

REMOVAL . . . . . . . . . . . . . . . 2-2

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

2.3.2 Procedures . . . . . . . . . . . . . . . . . 2-4

2.4 ORGANIC FINISH SYSTEM

REMOVAL . . . . . . . . . . . . . . . 2-4.1

2.5 CHEMICAL REMOVAL OF OR-

GANIC FINISH SYSTEMS

FROM METAL

SUBSTRATES. . . . . . . . . . . . . 2-4.1

2.6 CHEMICAL REMOVERS. . . . . . . 2-4.1

2.6.1 Remover for Epoxy and Polyure-

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

2.6.2 Remover for Polysulfide Primer with

a Polyurethane Topcoat . . . . . . . 2-5

2.6.3 Removers for Environmental

Compliance . . . . . . . . . . . . . . . 2-5

2.6.4 Chemical Depaint Materials Autho-

rized for Air Force Use . . . . . . . 2-6

2.7 GENERAL OVERALL CHEMICAL

REMOVAL PROCEDURES . . . 2-6

2.8 CHEMICAL REMOVAL PROCE-

DURES FOR CONFINED

LOCATIONS. . . . . . . . . . . . . . 2-10

Chapter Page

2.8A CHEMICAL DIP TANK MATERI-

ALS AND PROCEDURES . . . . 2-11

2.8A.1 MIL-PRF-83936, Heated Tank Type for Aircraft Wheels, Landing Gear Components, and Other Air-craft and Support Equipment. . . . . . . . . . . . . . . . 2-11

2.8A.2 Deleted. . . . . . . . . . . . . . . . . . . . 2-11 2.8A.3 Chemical Dip Tank Procedures. . . . 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 . . . . . . 2-12.1

2.10.1 Abrasive Blasting . . . . . . . . . . . . . 2-12.1

2.10.2 Hand or Motor-Driven Abrasive

Removal . . . . . . . . . . . . . . . . . 2-12.1

2.10.3 Hand Held Abrasive Removal . . . . 2-13

2.10.4 Motor Driven Abrasive

Removal . . . . . . . . . . . . . . . . . 2-13

2.10.5 Stainless Steel (CRES) and Nickel

Based Alloys . . . . . . . . . . . . . . 2-13 2.10.5A Cold Spray Repairs. . . . . . . . . . . . 2-13

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

2.11 PMB REMOVAL METHOD . . . . . 2-18

2.11.1 Media Type . . . . . . . . . . . . . . . . . 2-18

2.11.1.1 Type I . . . . . . . . . . . . . . . . . . . . 2-18

2.11.1.2 Type II . . . . . . . . . . . . . . . . . . . . 2-18

2.11.1.3 Type III . . . . . . . . . . . . . . . . . . . 2-18

2.11.1.4 Type IV . . . . . . . . . . . . . . . . . . . 2-18

2.11.1.5 Type V . . . . . . . . . . . . . . . . . . . . 2-18

2.11.1.6 Type VII . . . . . . . . . . . . . . . . . . . 2-18

2.11.1.7 Type VIII . . . . . . . . . . . . . . . . . . 2-18

2.11.2 Media Authorized for Air Force

Use . . . . . . . . . . . . . . . . . . . . 2-18

2.11.3 Operational Parameters for Metallic

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

2.11.4 Usage Restrictions . . . . . . . . . . . . 2-19

2.11.5 Operational Parameters for Non-

Metallic (Composite) Surfaces . . . . . . . . . . . . . . . . . 2-19

2.11.6 Operation Safety Requirements. . . . 2-19

2.11.6.1 Walk-In Blast Booth . . . . . . . . . . . 2-19

2.11.6.2 PMB Blasting Cabinets . . . . . . . . . 2-20

2.11.7 Personnel Qualifications . . . . . . . . 2-20

2.11.8 Pre-blast Preparation. . . . . . . . . . . 2-20

2.11.9 Postblast Cleaning . . . . . . . . . . . . 2-20

Change 26 i

2.11.10 Specific Technical Data and Work

Directives . . . . . . . . . . . . . . . . 2-20.1

2.11.11 Disposal of Plastic Media Used in

Paint Removal Operations . . . . . 2-21

2.11.12 Contamination Testing of Plastic

Media. . . . . . . . . . . . . . . . . . . 2-21

2.11.12.1 Equipment and Materials

Recommended . . . . . . . . . . . . . 2-21

2.11.12.2 Sampling Procedure . . . . . . . . . . . 2-21

2.11.12.3 Contamination Test Procedure . . . . 2-21

2.12 MPW REMOVAL METHOD. . . . . 2-23

2.12.1 Preparation . . . . . . . . . . . . . . . . . 2-23

2.12.2 Paint Removal Operations . . . . . . . 2-23

2.12.3 Post-Paint Removal Cleaning . . . . . 2-24

2.12.4 Operational Safety

Requirements. . . . . . . . . . . . . . 2-24

2.12.5 Personnel Qualification . . . . . . . . . 2-24

2.12.5.1 Equipment Manufacturer’s

Training . . . . . . . . . . . . . . . . . 2-25

2.12.5.2 Air Force Supplied Local

Training . . . . . . . . . . . . . . . . . 2-25

2.13 REMOVAL OF THERMOPLASTIC

POWDER COATING . . . . . . . . 2-25

2.13.1 Removal Procedures . . . . . . . . . . . 2-25

2.14 PAINT REMOVAL ON

NON-METALLICS . . . . . . . . . 2-25

2.14.1 Removal Requirements . . . . . . . . . 2-25

2.14.2 Mechanical Paint Removal on Fiber

Glass, Arranged Fiber (“Kevlar”)/ Epoxy, and Graphite or Boron Fiber/Epoxy Composite Surfaces . . . . . . . . . . . . . . . . . 2-25

3 SURFACE PREPARATION AND CHEMICAL

PREPAINT SURFACE TREATMENT . . . . 3-1

3.1 SURFACE PREPARATION FOR

PAINTING AND CHEMICAL

PREPAINT SURFACE

TREATMENT . . . . . . . . . . . . . 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 Aircraft. . . . . . . . . . . . . . . . . . 3-2

3.1.4 Solvent Wiping for Surface

Preparation . . . . . . . . . . . . . . . 3-3

3.1.4.1 Solvent-Wipe, Aircraft Prepaint for

Environmental Compliance . . . . 3-5

3.1.5 Surface Preparation for MIL-C-

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

Chapter Page

3.1.6 Reactivation of Newly Applied

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

3.1.7 Surface Preparation, Unpainted

Surfaces . . . . . . . . . . . . . . . . . 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 Treatment 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 . . . . . . . . 3-12

3.1.20 Alternate Surface Preparations for

Aluminum Surfaces (PreKote

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

3.1.20.1 Surface Preparation. . . . . . . . . . . . 3-13

3.1.21 Application of PreKote SP. . . . . . . 3-14

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

Magnesium . . . . . . . . . . . . . . . 3-16

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

3.1.26 Masking . . . . . . . . . . . . . . . . . . . 3-17

3.1.27 Tack Ragging . . . . . . . . . . . . . . . 3-18

4 PAINTING APPLICATION METHODS . . . . 4-1

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

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

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

4.2.1.1 HVLP Touch-Up Spray Gun . . . . . 4-1

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

4.2.3 Airless Spray. . . . . . . . . . . . . . . . 4-1

TO 1-1-8

TABLE OF CONTENTS - CONTINUED

ii Change 21

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 . . . . . . . . . . . 4-3

4.3.3 Classes of Spray Guns . . . . . . . . . 4-3

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

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

4.3.6 Air Regulators or Transformers . . . 4-4

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

4.3.8 Air Supply . . . . . . . . . . . . . . . . . 4-7

4.3.9 Hose . . . . . . . . . . . . . . . . . . . . . 4-7

4.4 SPRAY PAINTING . . . . . . . . . . . 4-8

4.4.1 Gun Techniques . . . . . . . . . . . . . . 4-8

4.4.1.1 Distance . . . . . . . . . . . . . . . . . . . 4-8

4.4.1.2 Stroking . . . . . . . . . . . . . . . . . . . 4-8

4.4.1.3 Triggering . . . . . . . . . . . . . . . . . . 4-8

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

4.4.3 Painting Difficulties and

Remedies . . . . . . . . . . . . . . . . 4-12

4.5 CLEANING AND

MAINTENANCE. . . . . . . . . . . 4-21

4.6 MECHANICAL PAINT GUN

WASHER . . . . . . . . . . . . . . . . 4-22

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 . . . . . . . 5-3

5.4.4 Part and Equipment Painting

Operations. . . . . . . . . . . . . . . . 5-4

5.5 AIRCRAFT PAINTING

OPERATIONS. . . . . . . . . . . . . 5-4

5.5.1 Depot Level Aircraft Painting

Operations. . . . . . . . . . . . . . . . 5-4

5.5.2 Field Level Aircraft Painting

Operations. . . . . . . . . . . . . . . . 5-5

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

5.5.4 Atmospheric Conditions for

Painting . . . . . . . . . . . . . . . . . 5-6

5.5.5 Test Panels . . . . . . . . . . . . . . . . . 5-6

5.5.6 Material Requirements, General. . . . . . . . . . . . . . . . . . 5-7

Chapter Page

5.6 THE AIRCRAFT PAINTING PRO-

CESS SEQUENCE OF

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

5.6.1 Aircraft Paint Application

Sequence . . . . . . . . . . . . . . . . 5-7

5.6.1.1 Small Aircraft-Tail Toward Hanger/

Insert Exhaust . . . . . . . . . . . . . 5-7

5.6.1.2 Large Aircraft-Nose Toward Hanger

Exhaust . . . . . . . . . . . . . . . . . 5-9

5.6.1.3 Walkway Coatings . . . . . . . . . . . . 5-9

5.6.2 Overspraying Existing Coating Sys-

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

5.6.3 Curing of Finishes . . . . . . . . . . . . 5-9

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 . . . . . . . . . . . 5-12

5.7 INTERIOR FINISHING PROCE-

DURES AND

OPERATIONS. . . . . . . . . . . . . 5-12

5.7.1 Preparation for Coating . . . . . . . . . 5-12

5.7.2 Coating Application . . . . . . . . . . . 5-12

5.7.3 Refinishing of Fiber Glass

Components . . . . . . . . . . . . . . 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

5.8.2.1 Brush or Spray . . . . . . . . . . . . . . 5-13

5.8.2.2 Touch-Up Pen . . . . . . . . . . . . . . . 5-13

5.8.3 Aerosol Touch-Up . . . . . . . . . . . . 5-14

5.8.4 Brush/Roller Touch-Up . . . . . . . . . 5-15

5.8.5 Brush Application. . . . . . . . . . . . . 5-16

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

5.8.7 Temporary Protection . . . . . . . . . . 5-17

5.8.8 Powder Coating . . . . . . . . . . . . . . 5-17

5.8.8.1 Surface Preparation. . . . . . . . . . . . 5-17

5.8.8.2 Maintenance Painting . . . . . . . . . . 5-17

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

TO 1-1-8

Change 21 iii

6.5 PREPARATION OF COATING

MATERIALS FOR USE,

GENERAL . . . . . . . . . . . . . . . 6-1

6.6 MIXING AND THINNING OF

COATING MATERIALS,

GENERAL . . . . . . . . . . . . . . . 6-2

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

6.6.2 Mixing Test. . . . . . . . . . . . . . . . . 6-3

6.7 SOLVENTS, DILUENTS, AND

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

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

6.7.2 Thinners . . . . . . . . . . . . . . . . . . . 6-3

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

6.7.3.1 No. 2 Zahn Cup. . . . . . . . . . . . . . 6-4

6.7.3.2 No. 4 Ford Cup . . . . . . . . . . . . . . 6-4

6.7.3.3 Adjustments . . . . . . . . . . . . . . . . 6-4

6.8 BLUSHING . . . . . . . . . . . . . . . . 6-4

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

6.10 ADHESION . . . . . . . . . . . . . . . . 6-5

6.11 PRIMERS. . . . . . . . . . . . . . . . . . 6-5

6.12 COATINGS AND COATING

SYSTEMS . . . . . . . . . . . . . . . 6-5

6.12.1 USAF Standard Polyurethane Air-

craft Coating System . . . . . . . . 6-5

6.12.2 Primer Coating, Epoxy, For Aircraft

Application, Specification

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

6.12.2.1 Characteristics . . . . . . . . . . . . . . . 6-6

6.12.2.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-6

6.12.2.3 Mixing . . . . . . . . . . . . . . . . . . . . 6-6

6.12.2.4 Thinning . . . . . . . . . . . . . . . . . . . 6-7

6.12.2.5 Application . . . . . . . . . . . . . . . . . 6-7

6.12.2.6 Drying Time . . . . . . . . . . . . . . . . 6-7

6.12.3 Primer Coating, Epoxy, VOC Com-

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

6.12.3.1 Characteristics . . . . . . . . . . . . . . . 6-7

6.12.3.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-7

6.12.3.3 Mixing . . . . . . . . . . . . . . . . . . . . 6-7

6.12.3.4 Thinning . . . . . . . . . . . . . . . . . . . 6-7

6.12.3.5 Application . . . . . . . . . . . . . . . . . 6-8

6.12.3.6 Drying Time . . . . . . . . . . . . . . . . 6-8

6.12.4 Primer Coating, Polyurethane, TT-P-2760. . . . . . . . . . . . . . . . 6-8

6.12.4.1 Characteristics . . . . . . . . . . . . . . . 6-8

6.12.4.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-8

6.12.4.3 Mixing . . . . . . . . . . . . . . . . . . . . 6-8

6.12.4.4 Thinning . . . . . . . . . . . . . . . . . . . 6-9

Chapter Page

6.12.4.5 Application . . . . . . . . . . . . . . . . . 6-9

6.12.4.6 Drying Time . . . . . . . . . . . . . . . . 6-9

6.12.5 Primer Coating, Elastomeric, Poly-

sulfide Corrosion Inhibiting, PR-1432GV. . . . . . . . . . . . . . . 6-9

6.12.5.1 Characteristics . . . . . . . . . . . . . . . 6-9

6.12.5.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-9

6.12.5.3 Mixing . . . . . . . . . . . . . . . . . . . . 6-9

6.12.5.4 Thinning . . . . . . . . . . . . . . . . . . . 6-10

6.12.5.5 Application . . . . . . . . . . . . . . . . . 6-10

6.12.5.6 Drying Time . . . . . . . . . . . . . . . . 6-10

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

6.12.6.1 Characteristics . . . . . . . . . . . . . . . 6-10

6.12.6.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-10

6.12.6.3 Mixing . . . . . . . . . . . . . . . . . . . . 6-10

6.12.6.4 Thinning . . . . . . . . . . . . . . . . . . . 6-11

6.12.6.5 Application . . . . . . . . . . . . . . . . . 6-11

6.12.6.6 Drying Time . . . . . . . . . . . . . . . . 6-11

6.12.7 Polyurethane Topcoat

(MIL-PRF-85285) . . . . . . . . . . 6-11

6.12.7.1 Coating Classifications . . . . . . . . . 6-11

6.12.7.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-12

6.12.7.3 Advanced Performance Coating

(APC) . . . . . . . . . . . . . . . . . . 6-12

6.12.7.4 Mixing . . . . . . . . . . . . . . . . . . . . 6-12

6.12.7.5 APC Mixing . . . . . . . . . . . . . . . . 6-12

6.12.7.6 Thinning . . . . . . . . . . . . . . . . . . . 6-13

6.12.7.7 Application . . . . . . . . . . . . . . . . . 6-13

6.12.8 Curing of Complete Polyurethane

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

6.12.9 Primer, Coating, Inorganic, Zinc

Dust Pigmented, Self-Curing, for Steel Surfaces, Specification

MIL-P-38336/SAE

AMS-P-38336 . . . . . . . . . . . . . 6-14

6.12.9.1 Characteristics . . . . . . . . . . . . . . . 6-14

6.12.9.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-14

6.12.9.3 Mixing . . . . . . . . . . . . . . . . . . . . 6-14

6.12.9.4 Thinning . . . . . . . . . . . . . . . . . . . 6-14

6.12.9.5 Application . . . . . . . . . . . . . . . . . 6-15

6.12.9.6 Drying Time . . . . . . . . . . . . . . . . 6-15

6.12.10 Primer Coating for Steel Surfaces, Specification

MIL-PRF-26915. . . . . . . . . . . . 6-15

6.12.10.1 Characteristics . . . . . . . . . . . . . . . 6-15

6.12.10.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-15

6.12.10.3 Mixing . . . . . . . . . . . . . . . . . . . . 6-15

6.12.10.4 Thinning . . . . . . . . . . . . . . . . . . . 6-15

6.12.10.5 Application . . . . . . . . . . . . . . . . . 6-15

6.12.10.6 Drying Time . . . . . . . . . . . . . . . . 6-15

6.12.11 Paint, Aluminum, Heat Resisting

(1200 °F) TT-P-28 . . . . . . . . . . 6-15

6.12.11.1 Characteristics . . . . . . . . . . . . . . . 6-15

6.12.11.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-16

6.12.11.3 Thinning . . . . . . . . . . . . . . . . . . . 6-16

TO 1-1-8

iv Change 21

6.12.11.4 Mixing and Application. . . . . . . . . 6-16

6.12.11.5 Drying Time . . . . . . . . . . . . . . . . 6-16

6.12.12 Enamel, Alkyd, Gloss, Low VOC

Content, TT-E-489 . . . . . . . . . . 6-16

6.12.12.1 Characteristics . . . . . . . . . . . . . . . 6-16

6.12.12.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-16

6.12.12.3 Thinning . . . . . . . . . . . . . . . . . . . 6-16

6.12.12.4 Application . . . . . . . . . . . . . . . . . 6-16

6.12.12.5 Drying Time . . . . . . . . . . . . . . . . 6-16

6.12.13 Enamel, Heat Resistant (204 °C or

400 °F), CID A-A-3054 . . . . . . 6-16

6.12.13.1 Characteristics . . . . . . . . . . . . . . . 6-16

6.12.13.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-16

6.12.13.3 Thinning . . . . . . . . . . . . . . . . . . . 6-16

6.12.13.4 Application . . . . . . . . . . . . . . . . . 6-16

6.12.13.5 Drying Time . . . . . . . . . . . . . . . . 6-16

6.12.14 Coating, Sprayable, Strippable, Pro-

tective, MIL-PRF-6799 . . . . . . . 6-16

6.12.14.1 Characteristics . . . . . . . . . . . . . . . 6-16

6.12.14.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-16

6.12.14.3 Thinning . . . . . . . . . . . . . . . . . . . 6-17

6.12.14.4 Application . . . . . . . . . . . . . . . . . 6-17

6.12.14.5 Drying Time . . . . . . . . . . . . . . . . 6-17

6.12.15 Resin Coating, Unpigmented, for

Engine Components and Metal Parts, MIL-PRF-3043 . . . . . . . . 6-17

6.12.15.1 Characteristics . . . . . . . . . . . . . . . 6-17

6.12.15.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-17

6.12.15.3 Thinning . . . . . . . . . . . . . . . . . . . 6-17

6.12.15.4 Application . . . . . . . . . . . . . . . . . 6-17

6.12.15.5 Drying Time . . . . . . . . . . . . . . . . 6-17

6.12.16 Coating Kit, Epoxy, for Interior of

Steel Fuel Tanks, MIL-PRF-4556 . . . . . . . . . . . . 6-17

6.12.16.1 Characteristics . . . . . . . . . . . . . . . 6-17

6.12.16.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-17

6.12.16.3 Mixing . . . . . . . . . . . . . . . . . . . . 6-17

6.12.16.4 Thinning . . . . . . . . . . . . . . . . . . . 6-17

6.12.16.5 Application . . . . . . . . . . . . . . . . . 6-17

6.12.16.6 Drying Time . . . . . . . . . . . . . . . . 6-17

6.12.17 Coating, Corrosion Preventive, for

Aircraft Integral Tanks, MIL-C-

27725/SAE AMS-C-27725. . . . . 6-17

6.12.17.1 Characteristics . . . . . . . . . . . . . . . 6-17

6.12.17.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-17

6.12.17.3 Mixing . . . . . . . . . . . . . . . . . . . . 6-18

6.12.17.4 Application . . . . . . . . . . . . . . . . . 6-18

6.12.17.5 Drying Time . . . . . . . . . . . . . . . . 6-19

6.12.18 Coating Compound, Nonslip (for

Walkways), CID A-A-59166 . . . 6-19

6.12.18.1 Characteristics . . . . . . . . . . . . . . . 6-19

6.12.18.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-19

6.12.18.3 Thinning . . . . . . . . . . . . . . . . . . . 6-19

Chapter Page

6.12.18.4 Mixing and Application. . . . . . . . . 6-19

6.12.18.5 Drying Time . . . . . . . . . . . . . . . . 6-19

6.12.19 Coatings, Polyurethane, Rain Ero-

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

83231/SAE AMS-C-83231. . . . . 6-19

6.12.19.1 Characteristics . . . . . . . . . . . . . . . 6-19

6.12.19.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-19

6.12.19.3 Thinning . . . . . . . . . . . . . . . . . . . 6-20

6.12.19.4 Application . . . . . . . . . . . . . . . . . 6-20

6.12.19.5 Drying Times . . . . . . . . . . . . . . . 6-20

6.12.20 Coating System, Polyurethane, Non-

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

AMS-C-83445 . . . . . . . . . . . . . 6-20

6.12.20.1 Characteristics . . . . . . . . . . . . . . 6-20

6.12.20.2 Uses. . . . . . . . . . . . . . . . . . . . . . 6-20

6.12.20.3 Thinning . . . . . . . . . . . . . . . . . . . 6-20

6.12.20.4 Application . . . . . . . . . . . . . . . . . 6-20

6.12.20.5 Drying Times . . . . . . . . . . . . . . . 6-20

6.12.21 Leading Edge Polyurethane Rain

Erosion Resistant Tape . . . . . . . 6-20

6.12.21.1 Description and Use . . . . . . . . . . . 6-20

6.12.21.2 Installation . . . . . . . . . . . . . . . . . 6-20

6.12.21.3 Application of Edge Sealer . . . . . . 6-22

6.12.21.4 Repair of Damaged Area . . . . . . . . 6-22

6.12.21.5 Tape Removal . . . . . . . . . . . . . . . 6-22

6.12.21.6 Painting Instructions . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . 7-2

7.2.1 Decals Up to 12 Inches x 2

Inches . . . . . . . . . . . . . . . . . . 7-2

7.2.2 Film for Striping . . . . . . . . . . . . . 7-2

7.3 LARGE EMBLEMS AND LET-

TERS USING HINGE APPLI-

CATION METHOD . . . . . . . . . 7-2

7.4 DECALS APPLIED USING APPLI-

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

7.5 EDGE SEALING. . . . . . . . . . . . . 7-4

7.6 APPLICATION OF PREMASKED

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

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

TO 1-1-8

Change 21 v

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

7.8 APPLICATION OF MARKINGS

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

7.8.1 Materials and Equipment for

Silkscreening . . . . . . . . . . . . . . 7-5

7.8.2 Surface Preparation. . . . . . . . . . . . 7-5

7.8.3 Application . . . . . . . . . . . . . . . . . 7-5

7.8.4 Topcoat Application . . . . . . . . . . . 7-5

7.9 APPLICATION OF MARKINGS

USING STENCILS . . . . . . . . . 7-6

7.9.1 Surface Preparation. . . . . . . . . . . . 7-6

7.9.2 Mounting Stencil . . . . . . . . . . . . . 7-6

7.9.3 Painting of Stencils. . . . . . . . . . . . 7-6

7.9.4 Adhesion Promoters . . . . . . . . . . . 7-6

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

8.1.6.1 89th AW, 201AS, and the 1st Heli-copter Squadron . . . . . . . . . . . . 8-1

8.1.6.2 U.S. Air Force Aerial Demonstration

Squadron “The Thunderbirds” . . . . . . . . . . . . . 8-1

8.1.6.3 76th Airlift Squadron . . . . . . . . . . 8-1

8.1.6.4 Low Observable Aircraft . . . . . . . . 8-1

8.1.6.5 Aircraft Received from Other

Services . . . . . . . . . . . . . . . . . 8-1

8.1.7 Service Tests . . . . . . . . . . . . . . . . 8-1

8.1.8 Decals . . . . . . . . . . . . . . . . . . . . 8-2

8.1.9 Applicable References. . . . . . . . . . 8-2

8.2 STANDARD EXTERIOR FIN-

ISHES, MARKINGS, AND IN-

SIGNIA FOR USAF

AIRCRAFT. . . . . . . . . . . . . . . 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

Chapter Page

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

8.3.1.1 National Star Insignia . . . . . . . . . . 8-3

8.3.1.2 The National Star Insignia on Air-

craft Fuselage . . . . . . . . . . . . . 8-3

8.3.1.3 The National Star Insignia on Air-

craft Wings . . . . . . . . . . . . . . . 8-3

8.3.1.4 The National Star Insignia on

Helicopters . . . . . . . . . . . . . . . 8-3

8.3.2 “USAF” Wing 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

Numbers . . . . . . . . . . . . . . . . . 8-4.1

8.3.7 ACC Standard Radio Call

Numbers . . . . . . . . . . . . . . . . . 8-4.1

8.3.7.1 Distinctive Unit Identifiers . . . . . . . 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

8.4.2.1 Combat Deployment

Requirements. . . . . . . . . . . . . . 8-5

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

8.4.4 Local Station Numbers and

Markings . . . . . . . . . . . . . . . . 8-5

8.4.4.1 Station Numbers . . . . . . . . . . . . . 8-5

8.4.4.2 Tail Stripe . . . . . . . . . . . . . . . . . . 8-5

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

8.4.6 Helicopter Main Rotor Blade

Markings . . . . . . . . . . . . . . . . 8-6

8.4.7 Helicopter Tail Rotor Blade

Markings . . . . . . . . . . . . . . . . 8-6

8.4.8 Identification Markings of Jettison-

able Aircraft Components . . . . . 8-6

8.4.8.1 Canopies. . . . . . . . . . . . . . . . . . . 8-6

8.4.8.2 Ejection Seats . . . . . . . . . . . . . . . 8-6

8.4.8.3 Jettisonable Components . . . . . . . . 8-6

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

Assemblies . . . . . . . . . . . . . . . 8-7

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

8.4.14 Marking of Emergency Lighting

(Flashlight) for Cargo and Trans-port Aircraft . . . . . . . . . . . . . . 8-7

8.4.15 Markings for Walkways and

Steps . . . . . . . . . . . . . . . . . . . 8-7

TO 1-1-8

vi Change 26

8.4.16 Markings for Composite/Honeycomb

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

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

8.4.17.1 Internal Markings . . . . . . . . . . . . . 8-7

8.4.17.2 External Markings . . . . . . . . . . . . 8-7

8.4.18 Markings for Unmanned Aerial

Vehicles . . . . . . . . . . . . . . . . . 8-7

8.4.18.1 Target Drones . . . . . . . . . . . . . . . 8-7

8.4.18.2 Other Unmanned Aerial

Vehicles . . . . . . . . . . . . . . . . . 8-7

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

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

8.5 ESTABLISHING REQUIREMENTS

FOR MISSION ACTIVITY,

CREW ACCOMPLISHMENT,

AND ESPRIT DE CORPS IN-

SIGNIA AND MARKINGS . . . . 8-8

APPENDIX A SHELF-LIFE EXTENSION

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

A.1 GENERAL TESTING

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

A.2 MIL-PRF-23377 EPOXY

PRIMER. . . . . . . . . . . . . . . . . A-1

A.2.1 Condition in the Container. . . . . . . A-1 A.2.2 Viscosity and Pot Life. . . . . . . . . . A-1 A.2.3 Drying Time . . . . . . . . . . . . . . . . A-2 A.2.4 Surface Appearance . . . . . . . . . . . A-2

A.3 MIL-PRF-85582 WATERBORNE

EPOXY PRIMER. . . . . . . . . . . A-2

Chapter Page

A.3.1 Condition in the Container. . . . . . . A-2 A.3.2 Viscosity and Pot Life. . . . . . . . . . A-2 A.3.3 Drying Time . . . . . . . . . . . . . . . . A-2 A.3.4 Surface Appearance . . . . . . . . . . . A-2

A.4 TT-P-2760 POLYURETHANE

PRIMER. . . . . . . . . . . . . . . . . A-2

A.4.1 Condition in the Container. . . . . . . A-2 A.4.2 Viscosity and Pot Life. . . . . . . . . . A-2 A.4.3 Drying Time . . . . . . . . . . . . . . . . A-2 A.4.4 Surface Appearance . . . . . . . . . . . A-2

A.5 MIL-PRF-85285 HIGH SOLIDS

POLYURETHANE. . . . . . . . . . A-2

A.5.1 Condition in the Container. . . . . . . A-2 A.5.2 Viscosity and Pot Life. . . . . . . . . . A-3 A.5.3 Drying Time . . . . . . . . . . . . . . . . A-3 A.5.4 Surface Appearance . . . . . . . . . . . A-3

APPENDIX B STANDARD AIR FORCE

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

B.1 NATIONAL STAR INSIGNIA . . . . B-1

B.2 U.S. AIR FORCE MARKING . . . . B-1

APPENDIX C RESPIRATOR PROTECTION

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

C.1 INTRODUCTION . . . . . . . . . . . . C-1

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

TO 1-1-8

Change 26 vii

LIST OF ILLUSTRATIONS

Number PageTitle

4-1 Nozzle Pressure Gauge . . . . . . . . . . . . . 4-1 4-2 Simple Spray System Setup . . . . . . . . . . 4-3 4-3 Airless Spray System . . . . . . . . . . . . . . 4-4 4-4 Complete Spray System. . . . . . . . . . . . . 4-5 4-5 Sectional View of Spray Gun . . . . . . . . . 4-6 4-6 Proper Installation of Air Compressor, Piping. . . . . . . . . . . . . . . . . . . . . . . 4-7 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 . . . . . . . . . . . . . . . 4-16 4-12 Paint Leaks From Spray Gun . . . . . . . . . 4-16 4-13 Gun Sputters Constantly . . . . . . . . . . . . 4-17 4-14 Orange Peel . . . . . . . . . . . . . . . . . . . . . 4-18 4-15 Sandpaper Finish . . . . . . . . . . . . . . . . . 4-18 4-16 Wrinkling . . . . . . . . . . . . . . . . . . . . . . 4-19 4-17 Crazing . . . . . . . . . . . . . . . . . . . . . . . . 4-19 4-18 Cracking . . . . . . . . . . . . . . . . . . . . . . . 4-19 4-19 Blistering . . . . . . . . . . . . . . . . . . . . . . 4-20 4-20 Fish Eyes . . . . . . . . . . . . . . . . . . . . . . 4-20 4-21 Lifting . . . . . . . . . . . . . . . . . . . . . . . . 4-20 4-22 Pitting or Cupping . . . . . . . . . . . . . . . . 4-20 5-1 Sempen. . . . . . . . . . . . . . . . . . . . . . . . 5-14 5-2 Sempen Mixing . . . . . . . . . . . . . . . . . . 5-14 5-3 Sempen Application . . . . . . . . . . . . . . . 5-14 5-4 Spray Tool. . . . . . . . . . . . . . . . . . . . . . 5-15 5-5 Two-Component Aerosol . . . . . . . . . . . . 5-15 6-1 Zahn Cup . . . . . . . . . . . . . . . . . . . . . . 6-4

Number PageTitle

7-1 Applying Small Decal . . . . . . . . . . . . . . 7-2 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) . . . . . 7-3 7-6 Applying Large Emblems (Step 4) . . . . . 7-3 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) . . . . . . 7-4 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

Number PageTitle

2-0 Chemical Stripping Approved Aluminum Backed Pressure Sensitive Tape . . . . . 2-3

2-1 Hand Held Abrasives . . . . . . . . . . . . . . 2-14 2-2 Motor Driven Abrasives. . . . . . . . . . . . . 2-15 2-3 Abrasive Materials . . . . . . . . . . . . . . . . 2-15 2-4 Recommended Controls and PPE for

Abrasive Blasting Operations . . . . . . . 2-17 3-1 Recommended Controls and PPE for Sur-face Preparation Operations . . . . . . . . 3-4.1 3-2 Wipe Solvents . . . . . . . . . . . . . . . . . . . 3-5 4-1 Spray Coating Troubles, Possible Causes, and Remedies . . . . . . . . . . . . . . . . . 4-12 5-1 Minimum Recommended Controls and

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

Number PageTitle

5-2 Allowable Coating Thickness for Produc-tion Level Finishing (Depot, Original Manufacture, Field). . . . . . . . . . . . . . 5-10

5-3 Gloss Requirements . . . . . . . . . . . . . . . 5-12 5-4 Suggested/Approved Rollers for

Primer . . . . . . . . . . . . . . . . . . . . . . 5-17 5-5 Suggested/Approved Rollers for

Topcoat. . . . . . . . . . . . . . . . . . . . . . 5-17 6-1 Leading Edge Tape Materials/Tools . . . . . 6-21 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 viii Change 11

Number PageTitle

8-4 Aircraft Authorized Multi-Colored Blade Tip Markings . . . . . . . . . . . . . . . . . . 8-5

A-1 Viscosity and Pot Life . . . . . . . . . . . . . . A-3

Number PageTitle

C-1 Respirator Protection Equipment . . . . . . . C-2

TO 1-1-8

LIST OF TABLES - CONTINUED

Change 11 ix/(x blank)

INTRODUCTION

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 20-114) 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 (OCR) (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 ef-fective finishes to interiors and exteriors of Air Force air-craft, missiles, and associated equipment. Painting techniques 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 Y14.38.

ACGIH American Conference of Government In-dustrial Hygienists

AFCPCO Air Force Corrosion Prevention and Con-trol Office

AFI Air Force Instruction 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 HAP Hazardous Air Pollutants 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 NESHAP National Emission Standards for Hazard-ous Air Pollutants No. Number NSN National Stock Number OCR Office of Coordinating Responsibilities 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/QPD Qualified Products List/Qualified Products

Database RPM Revolutions per Minute 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

Change 23 xi

UAV Unmanned Aerial Vehicle UV Ultra Violet 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 329 Acetone, Technical (Repl.

O-A-51) CCC-C-440 Cloth, Cheese, Cotton, Bleached and Unbleached CID A-A-289 Brushing, Acid, Swabbing 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 Car-bide, 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-3007 Thinner for Phenol-Formal-dehyde and Medium Oil and Styrenated Alkyd Paints and Varnishes (Repl. TT-T-306)

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-55827 Chromium Trioxide, Techni-cal (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-59106 Ethylene Glycol Monoethyl Ether, Technical (Repl. TT- E-781)

List of Related Publications - Continued

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

TT-T-548)

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-59323 Cloths, Cleaning, Low-Lint CID A-A-59485 Plastic Material, Pressure

Sensitive, for Aerospace Identification and Marking (Repl. MIL-P-38477)

ETL 02-15 Fire Protection Engineering Criteria - New Aircraft Fa-cilities

ETL 98-8 Fire Protection Engineering Criteria - Existing Aircraft Facilities

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 Alloys

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

MIL-C-38334 Corrosion Removing Com-pound for Aircraft Surfaces (Repl. by SAE AMS-1640)

MIL-C-81706/MIL-DTL-

81706

Chemical Conversion Mate-rials, for Coating Aluminum and Aluminum Alloys

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

MIL-C-8779 Color, Interior, Aircraft, Re-quirements for

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

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

MIL-H-17672 Hydraulic Fluid/10 wt. Oil Equivalent xii Change 23

List of Related Publications - Continued

Number Title MIL-M-3171 Magnesium Alloy, Processes for Corrosion Protection (Repl. by SAE AMS-M- 3171)

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

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

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-17672 Hydraulic Fluid, Petroleum, Inhibited

MIL-PRF-22750 Coating, Epoxy, High Solids MIL-PRF-23377 Primer Coatings, Epoxy, High Solids MIL-PRF-26514 Polyurethane Foam, Rigid or

Flexible, for Packaging MIL-PRF-26915 Primer Coating for Steel

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

MIL-PRF-32033 Lubricating Oil, General Purpose, Preservative (Wa-ter-Displacing, Low Tem-perature)

MIL-PRF-32295 Cleaner, Non-Aqueous, Low-VOC, Hap-Free (Repl. P-D-680)

MIL-PRF-4556 Coating Kit, Epoxy, for Inte-rior 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-7808 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base

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

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

List of Related Publications - Continued

Number Title MIL-PRF-85582 Primer Coatings, Epoxy, Wa-terborne MIL-PRF-87937 Cleaning Compound, Aero-space Equipment MIL-STD-3007 Unified Facilities Criteria and Unified Facilities Guide Specifications

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

MIL-T-81772 Thinner, Aircraft Coating NFPA 10 Standard for Portable Fire

Extinguishers NFPA 13 Standards for the Installation of Sprinkler Systems NFPA 33 Standard for Spray Applica-tion Using Flammable or Combustible Materials

NFPA 70 National Electrical Code NFPA 91 Standard for Exhaust Sys-tems for Air Conveying of Vapors, Gases, Mists, and Noncombustible Particu-late Solids

O-E-760 Ethyl Alcohol (Ethanol);

Denatured Alcohol; Pro-prietary Solvents and Spe-cial Industrial Solvents

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

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 Ex-terior 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, Processes for Corrosion Protection (Repl. MIL-M-3171)

Change 23 xiii

List of Related Publications - Continued

Number Title SAE-AMS-STD-595 Colors Used in Government

Procurement SAE AMS-T-21595 Tapes, Pressure-Sensitive

Adhesive, Masking, Non- Staining for Aircraft Paint-ing 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-489 Enamel, Alkyd, Gloss, Low VOC Content

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)

TT-T-2935 Thinner, Purging AFH 23-123 Materiel Management Refer-ence Information AFI 20-114 Air and Space Equipment

Structural Maintenance AFI 23-101 Air Force Materiel Manage-ment AFI 32-1067 Water Systems AFI 32-7001 Environmental Management AFI 32-7041 Water Quality Compliance AFI 32-7042 Waste Management AFI 32-7086 Hazardous Materials Man-agement AFI 48-137 Respiratory Protection Pro-gram

List of Related Publications - Continued

Number Title AFI 90-803 Environmental, Safety, and

Occupational Health Com-pliance Assessment and Management Program

AFI 91-203 Air Force Consolidated Oc-cupational Safety Standard

AFPD 91-2 Safety Programs AFMAN 23-122 Materiel Management Proce-dures AFMAN 48-155 Occupational and Environ-mental Health Exposure Controls

AFPAM 32-7043 Hazardous Waste Manage-ment Guide

TO 00-25-172 Ground Servicing of Aircraft and Static Grounding/ Bonding

TO 00-25-4 Depot Maintenance of Aero-space Vehicles and Train-ing Equipment

TO 00-5-1 Air Force Technical Systems TO 1-1-24 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 35-1-3 Corrosion Prevention, Paint-ing, and Marking of USAF Support Equipment

(SE)

TO 42B1-1-15 Cross Reference - NATO/ ASCC Interchangeability of Aviation Fuels, Lubri-cants and Allied Products xiv Change 23

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…