REVISED 1/16/02 Pollution Prevention PP-1056 Low VOC Chemical Agent Resistant Coatings (CARC) Paladin with Low-VOC CARC Background: Federal and local regulations resulting from the Clean Air Act restrict the amount of Volatile Organic Compound (VOC) emissions allowed during the application of protective coatings. Chemical Agent Resistant Coatings (CARC), which are used for painting military vehicles, have a VOC content of 3.5 pounds per gallon. Current annual usage nationwide is estimated to be 3.0 million gallons per year. As additional states enact more stringent VOC regulations, fewer facilities will be able to use existing CARC formulations. Objective: This project (PP-1056) is developing a low-VOC CARC system suitable for use on military equipment by all Services in all aspects of application, stripping and disposal. The primary focus is to reduce the VOC content of the polyurethane topcoat from 3.5 to 1.8 pounds per gallon. Summary of Process/Technology: The technical approach for the reformulation work has been to focus on high performance, water reducible (WR) polyurethane binder systems that have the potential for chemical agent resistance and meet the performance requirements of the Army, Air Force, and Marines. Candidate polymers were obtained from raw material suppliers, screened for live agent resistance, and formulated into camouflage topcoats. The approach to the stripping work is to focus on evaluation of currently used methods of removal to optimize the processes for de-painting and disposal of the CARC developed under this project. Selected technologies are being tested to determine the applicability to strip the new CARC as applied to a variety of substrates (aluminum, steel, fiberglass). Benefit: A water-reducible CARC with a VOC content of 1.8 pounds per gallon will eliminate at least four million pounds of VOC emissions per year. Water-reducible CARC coatings also will have a longer life cycle due to their enhanced durability and weathering properties. By complying with VOC regulatory levels, there will be no need to install expensive pollution abatement equipment, and violations and consequent fines at maintenance depots, air logistics centers, and equipment manufacturers will be avoided. Total equipment cost avoidance of $60 million and annual operating costs of $3 million are predicted at 12 facilities. Accomplishments: Candidate polymers were obtained from raw material suppliers, screened for live agent resistance, formulated into camouflage topcoats, and tested in conventional spray delivery systems. For operational use, applicability to a variety of substrates was determined, and emphasis was placed on non-chemical means of paint stripping to minimize environmental impacts and disposal costs. As a result, the Army Research Laboratory successfully has developed and patented a water-reducible CARC which has passed all agent tests for the colors green, brown, black, and desert tan. This project was completed in FY99. Contact Information: Mr. Jeffrey L. Duncan U.S. Army Research Laboratory ATTN: AMSRL-WM-MA, Building 4600 Aberdeen Proving Ground, MD 21005-5069 Phone: (410) 306-0690 Fax: (410) 306-0676 E-mail: [email protected]

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Page 1: Low VOC Chemical Agent Resistant Coatings (CARC)infohouse.p2ric.org/ref/17/16450.pdf · Low VOC Chemical Agent Resistant Coatings (CARC) Paladin with Low-VOC CARC Background: Federal

REVISED 1/16/02

Pollution Prevention

PP-1056Low VOC Chemical Agent

Resistant Coatings (CARC)

Paladin with Low-VOC CARC

Background:Federal and local regulations resulting from the Clean AirAct restrict the amount of Volatile Organic Compound(VOC) emissions allowed during the application ofprotective coatings. Chemical Agent Resistant Coatings(CARC), which are used for painting military vehicles, havea VOC content of 3.5 pounds per gallon. Current annualusage nationwide is estimated to be 3.0 million gallons peryear. As additional states enact more stringent VOCregulations, fewer facilities will be able to use existingCARC formulations.

Objective:This project (PP-1056) is developing a low-VOC CARCsystem suitable for use on military equipment by all Servicesin all aspects of application, stripping and disposal. Theprimary focus is to reduce the VOC content of thepolyurethane topcoat from 3.5 to 1.8 pounds per gallon.

Summary of Process/Technology:The technical approach for the reformulation work has beento focus on high performance, water reducible (WR)polyurethane binder systems that have the potential forchemical agent resistance and meet the performancerequirements of the Army, Air Force, and Marines.Candidate polymers were obtained from raw materialsuppliers, screened for live agent resistance, and formulatedinto camouflage topcoats. The approach to the strippingwork is to focus on evaluation of currently used methods ofremoval to optimize the processes for de-painting anddisposal of the CARC developed under this project. Selectedtechnologies are being tested to determine the applicabilityto strip the new CARC as applied to a variety of substrates(aluminum, steel, fiberglass).

Benefit:A water-reducible CARC with a VOC content of 1.8 poundsper gallon will eliminate at least four million pounds ofVOC emissions per year. Water-reducible CARC coatingsalso will have a longer life cycle due to their enhanceddurability and weathering properties. By complying withVOC regulatory levels, there will be no need to installexpensive pollution abatement equipment, and violationsand consequent fines at maintenance depots, air logistics

centers, and equipment manufacturers will be avoided.Total equipment cost avoidance of $60 million and annualoperating costs of $3 million are predicted at 12 facilities.

Accomplishments:Candidate polymers were obtained from raw materialsuppliers, screened for live agent resistance, formulated intocamouflage topcoats, and tested in conventional spraydelivery systems. For operational use, applicability to avariety of substrates was determined, and emphasis wasplaced on non-chemical means of paint stripping tominimize environmental impacts and disposal costs. As aresult, the Army Research Laboratory successfully hasdeveloped and patented a water-reducible CARC which haspassed all agent tests for the colors green, brown, black, anddesert tan. This project was completed in FY99.

Contact Information:Mr. Jeffrey L. DuncanU.S. Army Research LaboratoryATTN: AMSRL-WM-MA, Building 4600Aberdeen Proving Ground, MD 21005-5069 Phone: (410) 306-0690Fax: (410) 306-0676E-mail: [email protected]