ATCH_2-_CCFRG_Version_10_17DEC2012.pdf

AF Corrosion Control

Facility Reference Guide

CCFRG, Revision 10 17 December 2012

Air Force Corrosion Control Facility

Reference Guide

This guide is intended for reference purposes only. It does not supersede or take precedence over cited documents herein. This document does not supersede applicable laws and regulations.

Other federal, state, and local regulations may apply that are not reference herein. Check with your fire, safety, bio-environmental, and other agencies prior to design of your facility.

Overseas locations also need to check country laws and regulations to insure conformity.

The Corrosion Control Facility Reference Guide (CCFRG) is a living document and will be periodically reviewed, updated, and made available to users via Air Force Corrosion Prevention & Control Office (AFCPCO) in the Air Force Portal.

DISTRIBUTION A. Approved for public release; distribution unlimited.

Questions concerning technical content should be directed to AFRL/RXSSR, 325 Richard Ray Blvd, Robins AFB GA 31098-1639. (Phone: DSN 468-3284) (Email: afcorr@robins.af.mil) https://www.my.af.mil/gcss-af/USAF/ep/globalTab.do?command-org&pageId=681742&channelPageId=-1986143

CCFRG, Revision 10 17 December 2012

Table of Contents

I. INTRODUCTION

A. OBJECTIVE

B. OBTAINING REFERENCED DOCUMENTS

C. CORROSION CONTROL FACILITY DESCRIPTION

D. INITIAL FUNDING ISSUES

1. Unexpected Ventilation System Costs

2. Source Permitting and Modeling Costs Attachment 3: DD Form 1391

3. Construction and Operating Permits

E. APPLICABLE ENVIRONMENTAL STANDARDS

1. Federal

a. Clean Air Act

b. Clean Water Act

c. Resource Conservation and Recovery Act

2. State

3. Local

FIGURE 1: APPLICATION OF AEROSPACE NESHAP TO VARIOUS OPERATIONS

II. GENERAL CORROSION CONTROL FACILITY

A. GENERAL FACILITY REQUIREMENTS

B. BASIC FUNCTIONAL REQUIREMENTS

C. SPACE CRITERIA

1. Minimum Interior Dimensions

2. Impact of Maintenance Stands and Other Support Equipment

3. Authorization for Additional Workspace

4. Dual-Use Facilities

5. Over-Complication of Facility Requirements

D. MINIMUM REQUIREMENTS FOR SPECIFIC CORROSION CONTROL FACILITIES

1. Aircraft Wash Facility

2. Aircraft Corrosion Control Paint Hangar

3. Ventilation For Control of Air Contaminates and Flammable Vapors

4. Plumbing

5. Compressed Air

6. Lighting

7. Electrical Installations

8. Corrosion Control Shops

9. Deluge Rinse Capability (Bird Baths)

E. GENERAL CONSTRUCTION INFORMATION

1. Industrial Waste Treatment System

2. Basic Layout

a. Hygiene Facilities/Sanitation

1) Drinking Water

2) Toilets

b. Administration Areas

c. Support Areas

d. Tool Crib

e. Stencil Room

f. Fire Protection

III. SPRAY PAINT BOOTHS

A. PAINT SPRAY BOOTHS GENERAL INFORMATION

CCFRG, Revision 10 17 December 2012

1. Types

a. Air-Water Wash

b. Dry

2. Configurations

a. Cross-draft

b. Downdraft

c. Semi-down Draft

B. SPRAY PAINT BOOTH DESIGN REQUIREMENTS

C. GENERAL CONSTRUCTION REQUIREMENTS

1. Walls, Ceilings, Floors and Doors

2. Electrical Requirements

3. Lighting

D. VENTILATION

E. FILTRATION

1. Exhaust Filters

2. Intake Filters

3. Air Velocity

4. Air Volume

5. Exhaust Air

6. Replacement Air

FIGURE 2. DECISION TREE FOR REPLACEMENT AIR SYSTEM DESIGN

7. Recirculation Replacement Air Systems

F. TEMPERATURE AND HUMIDITY CONTROL

G. PERSONNEL BREATHING AIR

H. COMPRESSED AIR FOR OPERATION OF TOOLS AND EQUIPMENT

I. FALL PROTECTION

J. EYEWASH UNITS AND EMERGENCY SHOWERS

K. EQUIPMENT

1. Paint Gun Washers

2. HEPA Vacuum Sanders

3. High Volume Low Pressure (HVLP) paint spray systems

L. PREFABRICATED PAINT BOOTHS OR INSERTS

IV. ELECTROSTATIC PAINTING

A. PAINT BOOTH DESIGN

B. VENTILATION

1. Air Velocity

2. Air Volume

C. FIRE PROTECTION

D. EQUIPMENT

V. DRYING ROOMS

A. DRYING AREAS

B. AMBIENT TEMPERATURE (AIR DRYING)

C. ELEVATED TEMPERATURE DRYING

VI. CORROSION CONTROL WASH RACK

A. LOCATION/SIZE

B. ADDITIONAL JUSTIFICATION

C. AIRCRAFT WASH FACILITY DESIGN

D. STORAGE AND MIXING CAPABILITY FOR AIRCRAFT CLEANING COMPOUNDS

E. PRESSURIZED CLEANING COMPOUND DISPENSING AND RINSE WATER SYSTEMS

F. WATER TEMPERATURE REQUIREMENTS

G. CLOSED-LOOP WATER RECYCLING SYSTEMS

CCFRG, Revision 10 17 December 2012

H. RECYCLING SYSTEM WATER QUALITY REQUIREMENTS

I. FALL PROTECTION

J. WASTEWATER TREATMENT/COLLECTION

K. LIGHTING TYPES

L. EYEWASH UNITS AND EMERGENCY SHOWERS

VII. ABRASIVE BLAST BOOTHS

A. GENERAL INFORMATION

B. EXHAUST FILTERS

C. BREATHING AIR

D. PREFABRICATED ABRASIVE BLAST BOOTHS

VIII. PAINT MIXING ROOMS

A. GENERAL INFORMATION

B. BASIC REQUIREMENTS

C. PREFABRICATED MIXING ROOMS

IX. FLAMMABLE AND COMBUSTIBLE MATERIALS STORAGE

A. FLAMMABLE AND COMBUSTIBLE LIQUIDS STORAGE GENERAL INFORMATION

B. REQUIREMENTS FOR DIFFERENT TYPES OF STORAGE

1. Storage Cabinets within the Facility

2. Inside Storage Rooms

3. Detached Building

4. Temperature-Controlled Storage

APPENDIX 1: AIRCRAFT CORROSION CONTROL FACILITY DESIGN

REQUIREMENTS

APPENDIX 2: REFERENCES AND RESOURCES

APPENDIX 3: LESSONS LEARNED

CCFRG, Revision 10 17 December 2012

I. Introduction Facility design is a complex issue with no easy interpretation of the laws and regulations. When building a facility that utilizes hazardous materials (i.e. paints, thinners, and cleaning solutions), the process is even more complex. This guide is intended for reference purposes only.

It does not supersede or take precedence over cited documents herein. This document does not supersede applicable laws or regulations. This document should be used in conjunction with UFC 4-211-02, which was updated to make recommendations from the AF CCFRG mandatory.

Other federal, state, and local regulations may apply that are not referenced herein.

Check with your fire, safety, bio-environmental, and other agencies prior to design of your facility. Overseas locations also need to check country laws and regulations to insure conformity.

The Corrosion Control Reference Facility Guide (CCFRG) is a living document and will be periodically reviewed, updated, and made available to users via the Air Force Portal.

This Corrosion Control Facility Design Guide provides basic guidance and criteria for constructing Air Force corrosion control facilities. Previous experience has shown that field-level aircraft maintenance personnel are frequently assigned key positions of responsibility to provide input into the design process for local corrosion control facilities.

However, in many cases, these personnel do not have sufficient resources, training, or experience to adequately meet these responsibilities. This Facility Design Guide is intended to help personnel in this situation better understand corrosion control facility requirements and design criteria so they can provide complete and accurate input into the design process.

It is equally important to construct a facility that not only meets the operational needs of the user, but also complies with the vast array of federal, state, and local, environmental, safety and occupational health requirements. Unfortunately, it is a difficult and often very confusing task to determine which laws, regulations and standards apply to each individual corrosion control facility. Therefore, it is absolutely essential that all applicable base agencies be involved in the facility design process as early as possible.

The three agencies that typically have the greatest input into designing a corrosion control facility are the Environmental Management, Fire Protection, and Bioenvironmental Engineering sections. Although it is important that these agencies get involved in the design process as early as possible, it is equally important that active and continuous communication channels be maintained throughout the entire design and construction process. Without active involvement from these agencies, as well as the user, it is very likely that the completed corrosion control facility will not meet expectations.

Section http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf

CCFRG, Revision 10 17 December 2012

A. Objective

This guide is intended to help the user identify facility design requirements contained in Air Force, Department of Defense, Occupational Safety and Health Administration (OSHA), Environmental Protection Agency (EPA), and National Fire Protections Agency (NFPA) policies, instructions, standards and technical orders. The primary objective of this guide is to provide a format that consolidates those significant requirements that are unique to corrosion control facilities into a single document. The information contained in this guide is not intended to address all of the requirements applicable to designing a corrosion control facility. Instead, it is intended to address those requirements which are unique to corrosion control facilities, and is specifically intended to address those requirements that have been overlooked or misunderstood during the design of previous corrosion control facilities.

Note: The requirements addressed in this guide are minimum standards and may need to be modified to meet unique or particularly stringent state, local, or base requirements.

B. Obtaining Referenced Documents

Not all documents referenced in this guide are available via websites. Some are only available in paper form; while others must be purchased from the preparing activity. This situation is particularly true for National Fire Protection Association (NFPA) and American National Standards Institute (ANSI) documents. These references may be purchased at the respective websites. Before purchasing copies of these documents, it is recommended that the local Civil Engineering function and Fire Protection branches be contacted to determine if they have copies available for base-wide use.

Note: Some links to reference documents will open the document’s homepage versus the actual PDF file. This will allow the user to view the latest version of the referenced documents. The official source for Military Handbooks is the Document Automation and Production Service (DAPS) ASSIST web site. At this website, type in the Military Handbook number in the Document number box (see sample below).

This will bring up a list of documents, select the document you wish to view.

Document ID Document Number 1008

Title Submit Reset

It is also highly recommended that an account with the Construction Criteria Base (CCB) be established. To establish an account go to www.ccb.org. Construction Criteria Base (CCB) is an extensive electronic library of construction guide specifications, manuals, standards and many other essential criteria documents, published on the Internet and on a set of eight CD-http://www.osha.gov/ http://www.epa.gov/ http://www.nfpa.org/ http://www.nfpa.org/Home/index.asp http://webstore.ansi.org/ansidocstore/default.asp http://webstore.ansi.org/ansidocstore/default.asp https://assist.daps.dla.mil/quicksearch/ http://assist.daps.dla.mil/quicksearch/doc_id_help.cfm http://assist.daps.dla.mil/quicksearch/doc_num_help.cfm http://assist.daps.dla.mil/quicksearch/title_help.cfm http://www.ccb.org/ http://www.ccb.org/

CCFRG, Revision 10 17 December 2012

ROM discs or one DVD by the non-profit National Institute of Building Sciences (NIBS).

The CD-ROMs and website will allow you to have all the MIL-HDBKs available to you.

Several of the MIL-HDBKs have been superseded by Unified Facilities Criteria (UFC) Technical Publications. UFCs were developed by a Tri-service committee which is comprised of representatives from the three military services and the Department of Defense. These UFCs can be found at Whole Building Design Guide (WBDG) using the Search CCB link.

C. Corrosion Control Facility Description

The typical corrosion control facility is usually not a single facility. Therefore, it is impossible to describe a typical corrosion control facility. At many bases/units, the various corrosion control functions are adequately performed in several different facilities. Only a very small number of units/bases have a single facility where all major corrosion control functions are performed. A single facility capable of supporting all corrosion control functions is certainly an ideal situation and generally contributes to a more effective unit/base corrosion control program. However, it is not the intent of this guide to mandate the construction of a single facility to house all corrosion control functions. It would be unreasonable and certainly not cost effective for a unit/base to design a consolidated facility if a particular corrosion control function is currently being performed in a suitable existing facility (i.e. an indoor wash rack). Instead of addressing design requirements for a consolidated corrosion control facility, this guide will instead concentrate on the significant design requirements needed to meet the most common federal and Air Force environmental, safety, fire, and occupational health regulations and standards applicable to individual corrosion control functions.

Although each corrosion control function will be addressed separately, many facility design requirements apply to more than one corrosion control function. Therefore, to reduce duplication in this manual, these general requirements will be grouped together and addressed in one section.

D. Initial Funding Issues

1. Unexpected Ventilation System Costs

A significant number of corrosion control facilities designed and constructed in recent years have failed to meet mandatory federal, state, and local occupational health and safety, environmental, and fire requirements. As a result, many Air Force bases have been forced to deal with expensive facility modifications and long delays in getting new corrosion control facilities operational. There are many different reasons for these problems, but one recurring issue has been the unexpected cost of the facility’s ventilation system. A typical corrosion control facility requires a very complex, and therefore costly ventilation system to ensure the facility complies with applicable environmental, fire protection, and occupational health requirements. Since this ventilation system is far more expensive than the systems typically required on other facilities, it is common for this extra expense to be overlooked when funding is first being sought for the corrosion control facility. This situation can lead to the http://www.nibs.org/ http://www.wbdg.org/references/pa_dod.php

CCFRG, Revision 10 17 December 2012 facility being significantly under-funded, which may necessitate changing the scope of the project and reducing or eliminating other features in the facility late in the design process.

In many cases, features that are eliminated to fund the costly ventilation system (i.e. fall protection cables) have dramatically reduced the operational usefulness of the facility. In some cases, these changes have created shortfalls in mandatory equipment or facility features that have made it difficult for the base to get required facility permits and open the facility on-schedule. To help eliminate this situation, it is absolutely crucial that a statement be included on the DD Form 1391, and consequent Statement of Work, the industrial ventilation systems requirements description and cost, which should include;

• Identification of all significant contaminant sources that require ventilation control.

• Consideration on how the facility is to be used or expanded in the future. It may be possible to initially specify fans that are capable of handling future nees at minimal increased cost.

• Identification of all required industrial ventilation system/s (e.g. paint booth, abrasive blast booth, paint mixing room, etc.) and approximate size that best suits the work piece and operations.

• Listing of any local air quality requirements that may impact the design and cost of the system (e.g., existing Title V permit).

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

“Mechanical ventilation is required for a Walk-in Spray Paint Booth (approximately 8ft by 10 ft by 20 ft) to remove paint particulates and solvent vapors from the corrosion facility. The base is currently under a Title V Major Air Source Operating Permit; contact the Base air Program Manager for details on local air quality requirements. Upon facility completion, an independent ventilation expert must access the mechanical ventilation system effectiveness. The ventilation expert shall provide a detailed ventilation system acceptance/discrepancy report.”

2. Source Permitting and Modeling Costs

Another significant cost frequently overlooked during development of the DD Form 1391 has been the funds required for facility air-emission source permitting and modeling after construction has been completed. Requirements for the facility air-emission source permitting and modeling can be located in the EPA Title V, which is administered by each state. This expense should also be included as a separate line item on the DD Form 1391 http://www.dtic.mil/whs/directives/infomgt/forms/formsprogram.htm

CCFRG, Revision 10 17 December 2012

Attachment 3: DD Form 1391

1. COMPONENT FY ____MILITARY CONSTRUCTION 2. DATE REPORT

CONTROL

PROJECT DATA (YYYYMMDD) SYMBOL

DD-

A&T(A)1610

3. INSTALLATION AND LOCATION 4. PROJECT TITLE

5. PROGRAM ELEMENT 6. CATEGORY CODE 7. PROJECT NUMBER 8. PROJECT COS T ($100)

9. COST ESTIMATES

ITEM UM QUANTITY UNIT COST COST

($000)

10. DESCRIPTION OF PROPOSED CONSTRUCTION

DD FORM 1391, JUL 1999 PREVIOUS EDITION IS OBSOLETE PAGE NO.

It is absolutely essential to clearly state all justification information on the DD Form 1391. It is important to remember that information on the DD Form 1391 will be used by higher high levels of management to reach decisions that will impact the approval of the project.

http://www.dtic.mil/whs/directives/infomgt/forms/formsprogram.htm

CCFRG, Revision 10 17 December 2012

3. Construction and Operating Permits

Many different types of permits must be obtained before beginning construction on the facility. Additionally, various types of permits must also be obtained prior to putting the facility into operation. These permitting requirements can be very complex and can vary greatly from state to state. The local Civil Engineering and Environmental Management functions typically have overall responsibility to obtain all permits that are applicable for construction and operation of the Corrosion Control Facility. Specific requirements in this area exceed the scope of this Facilities Guide and will not be addressed in detail. Contact the local authority for current information.

E. Applicable Environmental Standards

1. Federal [Ref: AFI 32-7040, AFI 32-7061, & AFI 32-7062]

Many different federal environmental standards and regulations significantly impact the design of a Corrosion Control Facility. This vast array of requirements exceeds the scope of this guide and will not be covered in significant detail. For more information of environmental standards and regulations, contact your local environmental engineer and bioenvironmental office. During the planning stage of the corrosion facility, planners will complete a General Conformity applicability analysis before completion of the Environmental Impact Analysis Process (EIAP) to allow incorporation of its information into the EIAP. Federal actions must conform to the approved State Implementation Plan (SIP) until the State modifies the SIP or EPA approves the SIP. [AFI 32-7040, AFI 32-7061, & AFI 32-7062]

a. Clean Air Act [Ref: 40 CFR Chapter I, Subchapter C, AFI 32-7040, & AFI 32-1054]

The Clean Air Act (CAA) is the major Federal statute [40 CFR Chapter I] governing the quality of ambient air and permitting releases to the air. There are several programs in the CAA that may have significant impacts or restrictions on the corrosion facility. One main way that the air quality is assured is the new source review (NSR) program. NSR program requires operators of certain types of air pollution-emitting facilities to apply for permission to build in certain areas to prove that the air will not result in worse air quality. These new major sources must not upset the established national ambient air quality standards (NAAQS) and may be required to implement Best Available Control Technology (BACT) to reduce hazardous air pollutants (HAPs) to Lowest Achievable Emission Rates (LAER).

There are three types of permits issued under the NSR Program. The permits are Prevention of Significant Deterioration (PSD), nonattainment area NSR, and minor source NSR. The permit is based basically on the threshold values of regulated pollutants. [AFI 32-7040] http://www.e-publishing.af.mil/shared/media/epubs/AFI32-7040.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-7061.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-7062.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-7040.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-7061.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-7062.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-7040.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-1054.pdf

CCFRG, Revision 10 17 December 2012

One air standard that might be of particular importance is the National Emission Standards for Hazardous Air Pollutants for Source Categories: Aerospace Manufacturing and Rework Facilities (commonly called the Aerospace NESHAP). This EPA standard applies to facilities that are a “major source” of hazardous air pollutants (HAP) and are involved in the manufacture or rework of commercial, civil, or military aerospace vehicles. (A “major source” of HAPs is defined as a facility or group of aerospace facilities within a contiguous area that emits or has the potential to emit 10 tons per year or more of any listed HAP or 25 tons per year or more of any combination of listed HAP) The local Environmental Management function will use many references, such as a NESHAP flow chart (figure 1) to determine if the proposed facility has the potential to be designated as a major source. This important determination will provide key information on whether or not Aerospace NESHAP requirements will apply to the facility, and will have very significant bearing on many design requirements for the facility.

It is important to note that many bases have elected to comply with NESHAP requirements even if they are not currently legally required to do so. Although the decision to voluntarily elect to comply with NESHAP requirements might initially lead to expensive facility design requirements, it ensures the facility will already be NESHAP compliant if circumstances change at the base and the facility is required to comply with NESHAP requirements at a later date.

b. Clean Water Act [Ref: 40 CFR Chapter I, Subchapter D, N, and O & AFI 32-7041, AFI 32-1054]

The Clean Water Act (CWA) is the primary Federal statue [40 CFR Chapter I] governing the quality of the Nation’s water. It prohibits the discharge of any pollutant into navigable waters without a permit. Review the National Pollutant Discharge Elimination System Permits (NPDES) permits, the installation of the Spill Prevention, Control and Countermeasures (SPCC) and related documents pertaining to water quality. Also, remember that the Storm Water Pollution Prevention Plan (SWPPP) may need to be reviewed or updated. If the construction disturbs one or more acres, a completed SWPPP and submission of Notice of Intent (NOI) must be timely. [AFI 32-7041]

Wastewater discharges from Federally Owned Treatment Works (FOTWs) that is a point source into waters of United States require a NPDES permit. Discharges to Publicly Owned Treatment Works (POTWs) are considered as secondary discharges and are regulated by the POTW authority. POTW authority may have applicable regulations, permits, and agreements. [AFI 32-7041]

c. Resource Conservation and Recovery Act [Ref: 40 CFR Chapter I, Subchapter I, AFI 32-7041, AFI 32-7042, & AFI 32-1054]

The Resource Conservation and Recovery Act (RCRA) is the broadest and widest waste law [40 CFR Chapter I, Subchapter I]. It manages waste included in a variety of other Federal http://www.epa.gov/ttnatw01/aerosp/aeroimp.pdf http://www.epa.gov/ttnatw01/aerosp/aeroimp.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-7041.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-1054.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-7041.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-7041.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-7041.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-7042.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-1054.pdf

CCFRG, Revision 10 17 December 2012 statues such as Toxic Substances Control Act (TSCA), Used Oil Recycling Act, CAA, CWA, and Occupational Safety and Health Act. RCRA regulates solid waste (SW) and hazardous waste (HW) under the concept known as “cradle to grave”. Many routine aircraft maintenance operations produce HW because of RCRA’s definition. The hazardous waste management plan (HWMP) covers issues such as training, characterization, accumulation, treatment, recycling, inspections, and disposal of HW. [AFI 32-7042] One area that might be overlooked is industrial wastewater. Governmental regulations may prohibit discharging such wastewater into domestic wastewater or other non-industrial sewer systems.

Pretreatment may not be practical also resulting in the wastewater to be managed under

RCRA. [AFI 32-7041]

The bulk of what has to be done as RCRA is actually found in the Hazardous and Solid Waste Amendment (HSWA) that was pasted in 1984. Care must be taken with RCRA regulations found in 40 CFR Chapter I, Subchapter I, Parts 260-281. In some activities, the generator can become the transporter or the treatment, storage, and disposal (TSD) facility based on HW duties and activities. This can have a major impact on training and the HWMP. Be sure to coordinate with local environmental engineers and bioenvironmental personnel for complete RCRA understanding.

2. State

In addition to meeting various federal laws, regulations and standards, the facility will also be required to comply with many different requirements mandated by the state the facility is located. Unfortunately, individual state environmental programs sometimes vary greatly.

Therefore, it is important for local base agencies assisting in the design process to have access to the most current information. This type of information that is specific to each state can be found at the following website: http://www.rmis.com/db/lawepa.htm.

Given the wide variety of applicable environmental quality requirements, it is imperative to consult with the base Environmental Management function as early as possible to ensure compliance with all the relevant federal, state and local environmental laws/regulations.

3. Local

More focus is being placed on the impact of local regulations through the Public Owed Treatment Works (POTW). Local systems are under tighter demands for drinking water, water usage, and sewer treatment. Industry programs many times focus only on the end-of-pipe solutions, which only handles wastewater pollutants. Yet, facilities that work with local regulators can help reduce pollution and waste cost. Ensure that local regulations are reviewed to prevent construction delays and reduce potential construction retrofits.

http://www.e-publishing.af.mil/shared/media/epubs/AFI32-7042.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-7041.pdf http://www.rmis.com/db/lawepa.htm

CCFRG, Revision 10 17 December 2012

Figure 1: Application of Aerospace NESHAP to Various Operations

CCFRG, Revision 10 17 December 2012

General Corrosion

Control Facility

CCFRG, Revision 10 17 December 2012

II. General Corrosion Control Facility

A. General Facility Requirements [Ref: AFH 32-1084]

General construction issues of the facility should follow UFC 4-211- 02, Corrosion Control and Paint Finishing Hangers. Many factors must be considered when deciding what type of corrosion facility is required to meet the operational needs of the unit or base. The type and size of aircraft, level of maintenance required, and suitability of existing facilities are only a few of the key considerations. As stated in AFH 32-1084 “ Specific workloads vary from base to base, but the minimum required facilities include a wash rack, shop space for complete corrosion treatment and painting removable aircraft parts and ground support equipment, and a corrosion approved facility to perform aircraft maintenance painting.”

B. Basic Functional Requirements [Ref: AFH 32-1084 & UFC 4-211-02]

Basic function requirements have been incorporated into UFC 4-211-02 for Countless local variables such as manpower, workload, and level of capability required, and existing capabilities make it impossible to establish specific functional requirements for unit/base-level Corrosion Control Facilities. AFH 32-1084 states: “The number and size of corrosion control facilities is the minimum size required to accommodate the largest aircraft serviced and workload required to support the Air Force corrosion control concept.”

C. Space Criteria

1. Minimum Interior Dimensions [Ref: AFH 32-1084 & UFC 4-211-02]

To determine the interior dimensions of the Corrosion Control facility, use the dimensions of the largest aircraft that will occupy the facility plus an additional 3m (10 ft) on each side of aircraft to facilitate maintenance stands, etc. Do not overlook tail heights, the height and width of door, openings, structural protuberances in facilities, and the turn radius of tow vehicles connected to aircraft. AFH 32-1084 and UFC 4-211-02 provides a means to determine minimum interior dimension requirements for an aircraft corrosion control hangar.

Section http://www.e-publishing.af.mil/shared/media/epubs/AFH32-1084.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFH32-1084.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFH32-1084.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFH32-1084.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFH32-1084.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFH32-1084.pdf

CCFRG, Revision 10

In addition to the clearances in AFH 32-1084 and UFC 4-211-02, the depth of the door and exhaust plenum is required to properly size the hangar bay. The equation T = 1/5H defines this depth where H is the height of aircraft at its highest point plus 1.6m (5 ft). Note that the depth (T) does not include the thickness of the structure of the door or the filter media.

2. Impact of Maintenance Stands and Other Support Equipment [Ref: AFH 32-1084]

One important factor frequently overlooked during the design phase of Corrosion Control Facilities is the importance of deciding very early in the facility design process what type of maintenance stands that will be installed or used in the facility. Decisions concerning how personnel will access all areas of the aircraft have a profound impact on the size and shape of the facility, and therefore must be addressed as part of the overall facility design process.

Unfortunately, it is not uncommon for extensive design modifications to be required to accommodate large maintenance stands or other types of support equipment. In situations where these design modifications were not identified early enough, overall usefulness of the facility has been degraded.

3. Authorization for Additional Workspace [Ref: AFH 32-1084]

The need for additional covered workspace (hangar space) to accommodate corrosion control workload is specifically addressed in AFH 32-1084. If the corrosion control workload exceeds the capability provided by the covered workspace allocated by Table 7.1 or paragraph 7.3, special authorization for one additional covered workspace is granted. An excessive corrosion control workload occurs with some combinations of numbers and types of aircraft, environmental and climatic factors, and the availability of scheduled depot maintenance. It is also important to note that the additional workspace must be provided as a single aircraft space because of isolation requirements driven by fire, occupational health, and environmental restrictions associated with most corrosion control functions.

4. Dual-Use Facilities [Ref: Various MAJCOM Corrosion Survey Reports]

In previous years, some units/bases designed facilities with the intention of utilizing them in a “dual-use” capacity. These facilities were most commonly designed to alternately accommodate both the primary corrosion control maintenance function and the fuel-cell repair function. Without exception, facilities designed with this intended purpose did not adequately meet the specific requirements of the individual maintenance functions, or were over-utilized by one function to the extreme detriment of the other function. Fortunately, this design philosophy has largely been abandoned, but the potential may still exist for this issue to resurface. Therefore, any unit that is contemplating the design of a dual-use facility should contact the AFCPCO for additional information.

http://www.e-publishing.af.mil/shared/media/epubs/AFH32-1084.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFH32-1084.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFH32-1084.pdf https://www.my.af.mil/gcss-af/USAF/ep/browse.do?programId=1358018&channelPageId=-1986143&parentCategoryId=-1996711

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5. Over-Complication of Facility Requirements Units are cautioned to avoid over-complication of facility design requirements. The addition of optional features, such as filtration or interlock systems that greatly exceed federal, state and local requirements, have created significant operational problems in many existing facilities. These optional features were generally extremely complicated, cutting-edge technology, that in many cases, had reliability and maintainability problems. These complicated systems were usually added with the intention of improving health, safety, or environmental compliance; frequent system malfunctions negatively impacted the facility’s ability support mandatory operational requirements.

D. Minimum Requirements for Specific Corrosion Control Facilities [Ref: AFH 32-1084]

1. Aircraft Wash Facility

The basic aircraft wash facility will be equipped with heating, hot and cold water, electric power, compressed air and a waste disposal system for oils, alkalis, salts, hydroxides and other industrial waste products generated by aircraft cleaning. See MIL HDBK 1138, Wastewater Treatment Systems , for the types of oil-water separators required for aircraft wash racks. See also, AFI 32-1054, AFI 32-7040, AFI 32-7041, UFC 3-260-02, and AFI 32-7042.

2. Aircraft Corrosion Control Paint Hangar

The basic aircraft corrosion control paint hangar will be equipped with hot and cold water, electricity, compressed air, waste disposal, and environmental controls necessary to meet EPA, OSHA, and state and local requirements. See MIL HDBK 1138, AFI 32-1054, and

UFC 4-211-02.

3. Ventilation For Control of Air Contaminates and Flammable Vapors [Ref: UFC 4-211-02, NFPA 33, & ANSI Z9.2,4,7]

For information on ventilation requirements refer to UFC 4-211-02. To avoid atmospheric downwash, all stacks must be designed to meet the minimum stack height requirements of 40 CFR 51.00 (ii).

4. Plumbing [Ref: UFC 4-211-02]

For information on plumbing requirements refer to UFC 4-211-02.

http://www.wbdg.org/ccb/DOD/UFC/ufc_3_240_03n.pdf http://www.wbdg.org/ccb/AF/AFI/afi_32_1054.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-7040.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-7041.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_3_260_02.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-7042.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_3_240_03n.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFI32-1054.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.nfpa.org/aboutthecodes/AboutTheCodes.asp?DocNum=33 http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf

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5. Compressed Air [Ref: UFC 4-211-02]

For information on compressed air requirements refer to UFC 4-211-02.

Quick connection fittings for shop air and breathing air should be different for each service and not be compatible with each other. Breathing air must meet the requirements by OSHA for a minimum Grade D air. Intake air for breathing air should be located in an uncontaminated and comfortable temperature area.

6. Lighting [Ref: UFC 4-211-02& UFC 3-530-01]

Interior lighting in the main hangar bays should provide 1076 lux (100 footcandles) measured 0.76 meters (30 inches) above the floor. Metal halide fixtures should be used and exterior lighting should be high-pressure sodium vapor where practical and in accordance with UFC 3-530-01, Interior and Exterior Lighting and Controls.

7. Electrical Installations [Ref: UFC 4-211-02, UFC 3-520-01, & NFPA 70]

Electrical systems should be in accordance with UFC 3-520-01, Interior Electrical Systems and UFC 4-211-02.

8. Corrosion Control Shops

The basic corrosion control shop will have electricity, hot and cold water, compressed air, waste disposal, and ventilation for the paint booth.

9. Deluge Rinse Capability (Bird Baths) [Ref: T.O. 1-1-691 & UFC 3-260-02]

Although not covered in detail in this guide, an automatic deluge rinse capability can play an important role in the corrosion prevention and control program of units based close to salt water or units that regularly fly low-level flights over salt water. This capability is typically provided by installation of appropriate water delivery and containment/drainage systems that are located in a taxiway area for use by aircraft immediately following return from flight.

These installations provide multiple jet sprays of fresh water to cover the entire aircraft exterior surface to rinse off salt and water-soluble contaminants. They provide an expedient means of meeting the clear water rinse requirements contained in T.O. 1-1-691. Since design and construction requirements for this capability varies greatly at individual bases, they will not be addressed in this guide. However, general information may be obtained by contacting the AFCPCO or visiting our website at Air Force Corrosion Prevention & Control Office. This is a secure site so; you must have military access to view this site.

http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_3_530_01.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_3_530_01.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_3_520_01.pdf http://www.nfpa.org/aboutthecodes/AboutTheCodes.asp?DocNum=70 http://www.wbdg.org/ccb/DOD/UFC/ufc_3_520_01.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.robins.af.mil/library/technicalorders.asp http://www.wbdg.org/ccb/DOD/UFC/ufc_3_260_02.pdf http://www.robins.af.mil/library/technicalorders.asp

CCFRG, Revision 10 17 December 2012

UFC 3-260-02, Section 8, Airfield Geometric Design, Other Airfield Pavements, also is an excellent reference for guidance on aircraft rinse facility design and equipment placement.

E. General Construction Information The following general information is applicable many different types of facilities that are used to house or support the various base-level corrosion control functions.

1. Industrial Waste Treatment System [Ref: UFC 4-211-02]

Refer to UFC 4-211-02for industrial waste treatment.

2. Basic Layout [Ref: AFOSHSTD 91-501]

Proper layout, spacing, and arrangement of equipment, machinery, passageways, and aisles are essential to safe and orderly operations, and to avoid congestion. A good layout can best be achieved in the design stage, with recommendations from the user, Base Ground Safety, Fire Protection, Bioenvironmental Engineering (BEE), and Civil Engineering (CE) representatives. All interior walking and working surfaces, which are part of the means of egress, shall comply with the requirements of National Fire Protection Association (NFPA) 101, The Life Safety Code. For guidance on walking surfaces, fixed stairs and portable/fixed ladders to be utilized in the facility refer to AFOSHSTD 91-501, Air Force Consolidated Occupational Safety Standard.

a. Hygiene Facilities/Sanitation [Ref: UFC 4-211-02]

1) Drinking Water An adequate supply of drinking water shall be provided in all places of employment.

Cool water shall be provided during hot weather.

2) Toilets [Ref: UFC 4-211-02]

Restroom facilities shall be provided in all places of employment. Refer to UFC 4-211- 02for addition information.

b. Administration Areas

Sufficient private office space should be provided in the facility to enable shop supervisors, who are typically senior non-commissioned officers or equivalent civilian personnel, to prepare paperwork, counsel subordinates, and perform other associated supervisory responsibilities. These offices should be located adjacent to the respective work areas.

Offices should also be acoustically treated to minimize noise levels.

http://www.wbdg.org/ccb/DOD/UFC/ufc_3_260_02.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.e-publishing.af.mil/shared/media/epubs/AFOSHSTD91-501.pdf http://static.e-publishing.af.mil/production/1/usafe/publication/afoshstd91-501_usafesup_i/afoshstd91-501_usafesup_i.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf

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c. Support Areas [Ref: UFC 4-211-02]

Support areas typically include break rooms, storage areas, supply/janitorial closets, and mechanical rooms. A break room should be provided that is large enough to comfortably accommodate the number if personnel working on each shift.

Storage areas include required space to store and issue tools, equipment, and supplies. The area designated to support these functions should be centrally located within the facility to allow easy access from the main work area. An area to store and issue publications and technical manuals should also be centrally located to provide easy access to all shop personnel.

d. Tool Crib

This area needs to be large enough to house equipment and materials. Examples include but are not limited to individual tool kits, paint guns, pressure pots, PE equipment, air hoses, water hoses, sanders, vacuums, paint filter replacements, and bench stock. This additional room is needed because of new tool controls in many locations.

e. Stencil Room

The area will be used primarily to house computerized stencil making equipment. This will help facilitate speed and area to properly generate necessary templates and space to perform detailed work.

f. Fire Protection [Ref: UFC 4-211-02, UFC 3-600-01, ETL 02-15, & ETL 98-8]

Extensive fire protection systems are mandatory for virtually all facilities that house corrosion control functions. It is absolutely critical the fire protection systems be designed for individual hazards, functions, and facilities in accordance with many different specific references. Some of the basic fire protection references are: UFC 4-211-02, UFC 3-600-01, ETL 02-15, and ETL 98-8. However, these documents also reference many applicable NFPA Codes. The vast array of very specific and absolutely critical design requirements for fire protection systems exceeds the scope of this Facilities Guide and will not be addressed in detail. Therefore, it is essential that the local Civil Engineering and Fire Protection functions be consulted to ensure all fire protection requirements applicable to specific corrosion control functions and facilities are met.

http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_3_600_01.pdf http://www.wbdg.org/ccb/AF/AFETL/etl_02_15.pdf http://www.wbdg.org/ccb/AF/AFETL/etl_98_8.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.wbdg.org/ccb/DOD/UFC/ufc_3_600_01.pdf http://www.wbdg.org/ccb/AF/AFETL/etl_02_15.pdf http://www.wbdg.org/ccb/AF/AFETL/etl_98_8.pdf

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Paint Spray

Booths

Spray painting of an entire aircraft is permitted only in hangars specifically designed for this purpose.

CCFRG, Revision 10 17 December 2012

III. Spray Paint Booths

A. Paint Spray Booths General Information [Ref: OSHA 1910.107, UFC 4-211-02& NFPA 33]

OSHA defines a “Spray Booth” as a powered-ventilated structure provided to enclose or accommodate a spraying operation to confine and limit the escape of spray, vapor, and reside and to safely conduct or direct them to an exhaust system. [OSHA

1910.107 & NFPA 33] This definition applies equally to large aircraft corrosion control paint hangars or smaller “walk-in” booths used to paint removable aircraft components and support equipment. Therefore, all design requirements are also equally applicable.

There are numerous types and configurations of paint spray booths to consider. The most common types are water-wash and dry-spray. The most common configurations are cross draft; downdraft, and semi-downdraft. The advantages and disadvantages of each particular booth should be closely evaluated before a final decision is made.

Various aspects of booth construction and installation are regulated by the National Electric Code (NEC 516), Uniform Fire Code (UFC 4500), National Fire Protection Association (NFPA 33), Uniform Mechanical Code (UMC 1107) and various state, local, DoD, and Air Force Regulations. A fully functional and usable facility must meet all the standards and regulations. If it is anticipated that powder coatings may be applied in the paint booth in the future, unique requirements may be applicable, Contact the AFCPCO for specific information.

1. Types

a. Air-Water Wash [Ref: T.O. 1-1-8, UFC 4-211-02 & OSHA 1910.107]

An air-water wash spray booth is designed to minimize airborne paint particles entering exhaust ducts through use of a water curtain. The water is supplied from a tank and is constantly circulated through the system while the booth is being used. One of the disadvantages of a water wash paint booth is that upon replacement with fresh water, the paint-contaminated water likely requires handling as hazardous waste. A paint sludge removal system may be installed to help reduce the amount of hazardous waste that must be disposed of before it may be discharged to a municipal treatment plant [UFC 4-211-02]. A water wash spray booth will remove up to 95% of paint residue before it is exhausted.

However, many locales may have efficiency requirements greater than 95%.

b. Dry [Ref: T.O. 1-1-8, OSHA 1910.107 & 40 CFR Part 63]

A dry booth uses filters instead of water to extract airborne paint particles before they enter the exhaust ducts. A dry spray booth is relatively low in cost and is generally easier to install than an air- water wash booth. These booths are available with various types of filters, sizes

Section http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9753&p_text_version=FALSE http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.nfpa.org/aboutthecodes/AboutTheCodes.asp?DocNum=33 http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9753&p_text_version=FALSE http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9753&p_text_version=FALSE http://www.nfpa.org/aboutthecodes/AboutTheCodes.asp?DocNum=33 http://www.nfpa.org/catalog/product.asp?pid=4500&target%5Fpid=4500&link%5Ftype=search http://www.nfpa.org/aboutthecodes/AboutTheCodes.asp?DocNum=33 http://www.robins.af.mil/library/technicalorders.asp http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9753&p_text_version=FALSE http://www.wbdg.org/ccb/DOD/UFC/ufc_4_211_02.pdf http://www.robins.af.mil/library/technicalorders.asp http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9753&p_text_version=FALSE http://ecfr.gpoaccess.gov/cgi/t/text/text-idx?c=ecfr&sid=e9dd0ed39203803071fc7e9c83392580&tpl=/ecfrbrowse/Title40/40cfr63_main_02.tpl

CCFRG, Revision 10 17 December 2012 and materials. It is important to note that applicable environmental regulations may dictate the number of filter banks required for a particular locale.

2. Configurations

Regardless of the size or type of the booth, they consist of one of three basic configurations for directing airflow.

a. Cross-draft

In a typical cross-draft booth, the air enters through filters in the front of the booth and is exhausted through filters in the back of the booth. Airflow is parallel to the floor. This type of ventilation system is usually the least expensive and is the most common type used on Air Force installations. This type of booth generally provides effective, consistent ventilation.

However, the horizontal movement of the air makes it very important that the painter be positioned correctly to avoid having paint-laden air directed toward him or her.

b. Downdraft

Downdraft booths are designed to let air enter through filters in the ceiling of the booth and leave through metal grating in the floor. Airflow is vertical to the floor. In most situations, this vertical airflow is more effective than the horizontal airflow in a cross-draft booth at removing paint-laden air from the vicinity of the painter.