ApndxB2_MXG_MOI_21-023_Corrosion_Prevention.pdf

BY ORDER OF THE COMMANDER 142 MXG OPERATING INSTRUCTION 21-023

142D MAINTENANCE GROUP MARCH 2016

Maintenance

CORROSION PREVENTION AND CONTROL

PROGRAM

OPR: 142 MXG/MXQ (CMSgt Norio Colipano)

POC: 142 MXM/MXM1 (CMSgt Daniel Conner)

Supersedes: 142 OI 21-023, March 2014

This Maintenance Operating Instruction (MOI) prescribes procedures for the Corrosion Prevention and Control Program. To include painting aircraft and support equipment in the Corrosion Control Facility, Bldg. 250 the use of small paint booths in the Aircraft Maintenance complex, and the use of aerosol paint cans. This MOI applies to all aircraft maintenance personnel within the 142d Maintenance Group.

SUMMARY OF CHANGES: Biennial Review

1. Reference:

T.O.’s: 1F-15A-23, 35-1-3, 1-1-8, 1-1-691, 42B-1-22

AFOSH Std's 48-137 PIA/Sup1, MXMFS OI 48-137, AFI 91-203, 90-821/PIA Supplement 1, 21-101, ANGI 21-105

AF Portal - Air Force Corrosion Prevention and Control Office (RXSSR)

2. Responsibilities:

2.1. Commanders, Supervisors, Clinic, Bioenvironmental and Painters are responsible for protection of personnel from exposure to the hazards of washing, sanding and painting aircraft and support equipment.

2.2. Unit Corrosion Prevention and Control Manager is appointed by MXG/CC as the ASM (Aircraft Structural Maintenance) Supervisor.

2.3. Supervisors and equipment monitors will make sure their equipment is protected from corrosion. Damage to protective coatings will be treated as necessary. Corrosion treatment beyond the user’s capability will be documented in maintenance forms and reported to the Maintenance Operations Center (MOC) for necessary action.

2.4. Scheduling aircraft painting will be coordinated with the Pro Super, ASM, and Plans and Scheduling then published in the Weekly Flying Schedule. Support equipment corrosion control will be coordinated through AGE at ext. 5-4238 and ASM at ext. 5-4334.

2.5. Training is provided by the unit training office in conjunction with the ASM supervisor.

Initial training is provided using multimedia media through the unit training office. Refresher is provided during annual ancillary training. Aircraft washing and lubrication training is provided for personnel performing such activities using multimedia media by the unit training office and

ADLS.

3. Aircraft/ AGE/ Support Equipment Washing/ Sanding and Painting:

3.1 Aircraft washing is performed by flight line personnel to include managing aircraft soap and required supplies.

https://www.my.af.mil/gcss-af/USAF/ep/globalTab.do?command=org&pageId=681742&channelPageId=-1986143

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3.2. Aircraft / large AGE/ Support Equipment will be sanded/ painted in the Corrosion Bay of

Bldg. 250 and Aircraft Painting Checklist (Attachment 1) will be followed. Major aircraft paint jobs will be scheduled through; ANG Paint Facility, 2920 Headquarters Ave. Sioux City, IA.

51111-1300, DSN: 585-0624, COM: (712)233-0624

3.3. Use of authorized paint in aerosol spray cans is authorized in approved spray booths and can be used outdoors in areas that do not present a health hazard. Workers are advised to read MSDSs for respiratory protection requirements before using aerosol cans outdoors.

3.4. When an Aircraft/ AGE/ Support Equipment is moved into the Corrosion Bay of Bldg.

250 for sanding/ painting, aircraft and facility maintenance will be suspended until approved by ASM personnel.

3.5. A majority of the AGE and Support equipment will be painted in Bldg. 250 paint booth depending on size constraints.

3.6. Aircraft/ support equipment oil, fuel and hydraulic leaks shall be repaired and de-fueled prior to paint.

3.7. All aircraft, unless otherwise coordinated with ASM supervisor, will have external pylons and tanks removed prior to paint.

3.8. ASM personnel will wear NIOSH approved respirators and protective devices as directed by Bioenvironmental. The Base Bioenvironmental Engineering Office is the local approving authority for all respiratory protection devices and must be consulted when respirator usage is contemplated for operations other than those originally requiring the wear of respirators.

3.9. Hangar entry and Post-Wash Corrosion Control Inspection (Attachment 4), Aircraft Painting Check list (Attachment 1) check lists will be followed, filled out and signed off prior to aircraft prep and painting.

3.10. Two-ASM personnel minimum is required to prepare and paint an aircraft.

3.11 Aircraft/ AGE/ Support Equipment will remain in hangar for the cure schedule of the applied protective coating, and stay indoors and not fly for 72 hours after coatings are applied.

Ref: 1-1-8, Para 5.6.3

4. Paint Booths:

4.1. Bio-Environmental Engineering must approve small paint booths inside shops.

4.2. Supervisors will ensure:

4.2.1. Users are aware of safety and health hazards associated with washing, sanding, and painting.

4.2.2. Users are aware of regulations pertaining to handling, storing, and proper disposal of flammables and other hazardous waste.

4.2.3. Users are trained and certified to use respirators, if necessary.

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4.2.4. Users are trained to use and maintain painting equipment.

4.2.5. Warning signs are posted.

MICHAEL K. FIELDS, Col, ORANG

Commander Reviewed by Quality Assurance

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Attachment 1:

A/C Painting Checklist

AIRCRAFT/ SUPPORT EQUIPMENT SANDING / PAINTING CHECKLIST BLDG 250

Date Tail Number Job Control #

Before painting aircraft verify all items on this check list are complied with:

1. Review Hangar entry checklist, ensure aircraft is parked on nose landing gear tire marker. N/A Support Equipment

2. Review aircraft painting procedures guide (attachment 2) on reverse. See attachment 3 for Support Equipment sanding and painting procedures.

3. MOC is notified that, all other work is suspended on aircraft to be painted.

4. All unnecessary equipment removed from Corrosion Bay. Remaining equipment is protected from over-spray.

5. Floor is free of fuel and oils.

6. Ultra Violet-Infra Red fire sensors (2) are unobstructed.

7. There are no portable electronic devices in bay. All appliances are intrinsically safe.

8. Emergency evacuation routes unobstructed.

9 Ensure canopy, wheels, aircraft vents, engine exhausts and static ports are covered or masked and 781A aircraft form entries are made. N/A Support Equipment

10. Lock out devices and signs posted on all personnel doors to prevent entry. Except for the painter entry control point will have the sign only.

11. Post sign on outside of hanger door.

12. Covers are removed from filters and exhaust fans turned on.

Initials:

Sanding

Painting

Stenciling

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Attachment 2:

A/C Painting Procedures

Aircraft Painting Procedures

1. Complete MOI 21-023 Attachment 1 Aircraft Painting Checklist prior to sanding/ painting and marking operations.

2. Qualified 5-level structural technician will evaluate painting requirements by using

Aircraft paint condition scoring sheet Attachment 5, Ref: 1F-15A-23.

3. Ensure proper PPE is available, worn and functioning prior to sanding and painting operations.

4. Utilize Clayton vacuum sanding system to mechanically remove finish, Ref: 1-15A-

23and 1-1-8. Remove deteriorated and improperly applied decals, including updating tail-flash and crew names, Ref: 1-15A-23.

5. Re-inspect to evaluate sanding operation complete, Ref: 1-1-8.

6. Call MOC to dispatch wash team.

7. Perform Aircraft Post Wash Corrosion and Cleanliness Inspection Ref: Attachment 4.

8. Re-inspect to determine if further sanding is required, if so re-sand spots and wipe with thinner to eliminate re-washing aircraft. Ref: 1-1-8.

9. Touch up bare aluminum spots with Alodine 1132. Ref: 1-1-8.

10. Tape and mask aircraft. Ref: 1-1-8 Prime all bare aluminum spots with epoxy primer.

Ref: 1F-15A-23 and 1-1-8 Apply ELT (Extended Life Top Coat) paint. Ref: 1F-15A-23, and 1-1-8 Paint all sanded areas and fastener heads. Ref: 1F-15A-23 and 1-1-8 Touch up and replace external markings. Ref: 1F-15A-23.

11. Replace Ceramkote 54. Ref: 1F-15A-23.

12. Inspect topcoat paint and external markings to verify proper application.

13. De-mask and remove all covers.

14. Remove all overspray if necessary.

15. Inspect aircraft, sign off 781A entries and IMDS.

Attachment 3:

AGE Equipment Painting Procedures:

AGE And Support Equipment Sanding/Painting Procedures

1. Coordinate painting priorities with ASM supervisor.

2. Determine touch up or full paint requirement with qualified ASM painter Ref: 35-1-3.

3. Decals and reflective tape will be removed by owning shop prior to sanding of equipment. Ref: 1-1-8.

4. Equipment will be washed by owning shop using approved soap Ref: 1-1-691 and 35-1-3.

5. Ensure proper PPE is worn and functioning prior to sanding or painting operations.

Ref: 35-1-3 Removal of paint to be completed by owning shop as required. Ref: 35-1-

3 and 1- 1-8.

6. Mask and tape to be completed by owning shop, to cover areas on equipment not to be painted. Ref: 1-1-8.

7. Move equipment to paint booth or corrosion bay in bldg 250.

8. ASM Painter will paint equipment Ref: 35-1-3 and 1-1-8 ASM Painter and Owning

Shop Representative will review finished product, and owning shop will recommend touch-up painting as required.

9. ASM Painter and Owning Shop Representative will remove covering and tape from equipment. Ref: 1-1-8 Owning shop will retrieve equipment and apply decals to equipment Ref: 1-1-8 and 35-1-3.

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Attachment 4:

A/C Post Wash Inspection

AIRCRAFT POST-WASH CORROSION CONTROL

The aircraft post-wash corrosion control inspection is accomplished by Aircraft Structural

Maintenance Personnel. Aircraft cleanliness inspection will be accomplished by Flight Chief.

Ref: ANGI 21-105.

1. Visually inspect aircraft for the following conditions: corrosion, soap residue, paint-condition, and sealant-condition.

2. Inspection Requirements:

1. Area 1 - Forward Fuselage.

a. Radome.

b. Forward Fuselage skin.

c. Pitot Static Probe left/right.

d. Angle of attack Transmitter left/right.

e. Ramp Boundary Layer Bleed Ports left/right.

f. Outboard Plate Bleed Louvers.

g. Gun Port.

h. Forward Gun, by louvers.

i. Access Step Assembly, door and well.

j. Secondary Heat Exchanger Exhaust Vent.

k. Total Temperature Sensor Probe left/right.

l. Avionics and Cabin Air Discharge door.

m. Right/Left Engine intake ducts.

n. Nose Landing Gear:

1. Strut and all associated hardware.

2. Wheel.

3. Doors.

4. Wheel well and all associated hardware

3. Area 2 – Center Fuselage (top, sides, and bottom).

a. Main Landing Gear:

1. Struts left/right and all associated hardware.

2. Wheels left/right.

3. Doors left/right

4. Wheel wells left/right and all associated hardware.

Attachment 4 (cont.):

A/C Post Wash Inspection

b. Missile Launcher Pylons left/right.

c. Speed Brake and associated hardware.

4. Area 3 – Left/Right Wings.

a. Skin and fasteners.

b. Panels and fasteners.

c. Leading edges.

d. Wing tips.

e. Trailing Edges.

f. Flaps.

g. Ailerons.

h. Torque box.

i. Fuel Dump Mast.

j. Engine vent scoop.

k. Primary Heat Exchanger Inlet.

l. Primary Heat Exchanger Exhaust.

m. Pylons and Associated Hardware, if installed.

5. Area 4 – Aft Fuselage (Including vertical stabilizers and Horizontal stabilizers)

a. Skins and Fasteners

b. Rudder left/right

c. Horizontal Stabilizers left/right.

d. Vertical Stabilizers left/right.

e. Augmentor and associated hardware

f. ECM antennas left/right

g. Convergent Exhaust Nozzle Controls left/right.

h. Arresting hook.

i. Arresting hook doors, wells and associated hardware.

6. Area 5 – Clean-up of Corrosion Control Hangar (To be accomplished by personnel performing aircraft wash)

a. Personal Protective Equipment removed from area

b. Hoses rolled up

c. Aircraft washing tools put away

d. Aircraft washing garbage removed and trash cans emptied.

7. Clear the post-wash corrosion and cleanliness inspection in AFTO 781A and IMDS after the inspection is accomplished.

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Attachment 5

Aircraft Paint Condition Scoring Work Sheet.

The aircraft surface will be inspected and a value will be recorded as a percent of area that is deteriorated.

All exterior surfaces will be inspected and the grid marked with an X for areas needing touch up.

A. The evaluation will include inspection of:

1. Panel or component surfaces and edges.

2. Fastener heads. (More than 75% of heads per panel without paint)

3. Attachment points.

B. Deterioration involves:

1. Chipped, peeled or blistered paint on panel surfaces.

2. Corrosion under the paint evidenced by paint lifting or blistering.

3. Cracked or peeled paint at panel seams.

4. Cracked or peeled coating at attachment points.

5. Paint deterioration caused by environmental agents, ultraviolet light corrosive fluids as evidenced by a chalky residue on painted surfaces.

Procedures for gaining the paint score.

1. Count the number of marked squares and record in the correct blocks.

2. Total the scores for each page and put them in the corresponding block.

3. Write the page totals on the last page of scoring sheets.

4. Divide weapon system platform total by 844 to get the percent of defective paint.

5. This percent will be the paint score.

Save a digital copy of the completed form in the paint scoring folder. Name the file the date the scoring was completed, i.e.: 20140301. The folder is located in Structural\Aircraft Info\Aircraft

Paint Scoring\”ACFT Tail Number”.

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