U.S. ARMY 1 Sustainable Painting Operations for the Total Army Mr. Patrick Taylor Dr. Daniel Verdonik Hughes Associates, Inc. Presented at Joint Services Environmental Management Conference & Exhibition April 14, 2005

2 U.S. ARMY Solving Environmental Problems for Army Programs Outline  Approach  Risk Mitigation  Program Areas De-Painting Rubber to Metal Bonding CARC and Other Paints Solvents / Cleaners / Thinners Sealants, Adhesives & Miscellaneous Coatings Munitions Coatings  Implementation  Conclusion

3 U.S. ARMY Solving Environmental Problems for Army Programs Two Parts of the Equation Get Funding Provide Solutions

4 U.S. ARMY Solving Environmental Problems for Army Programs Questions…  What Are the Bad Actors?  Which Ones Are Easy and Which Are Hard?  Will the Alternatives End Up Costing More than the Controls?  Are there Hidden Implementation Costs to the PMs?  Is this Approach Going to Fail and Force Me to Install the Controls Anyway?

5 U.S. ARMY Solving Environmental Problems for Army Programs …Answers  What Are the Bad Actors? Over 500 Suspected (Based on MMPP/PPP) Site Visits, Detailed Databases in Hand  Which Ones Are Easy and Which Are Hard? Easy: De-Painting, Non-Munitions Coatings & Sealants Hard: Solvents, Munitions Coatings Potential Alternatives Identified  Will the Alternatives End Up Costing More than the Controls? NO  Are there Hidden Implementation Costs to the PMs? Cost is Major Driver in Downselects Picture Looks Good Overall – PMs Will Be Involved  Is this Approach Going to Fail and Force Me to Install the Controls Anyway? Our Track Record Says NO!

6 U.S. ARMY Solving Environmental Problems for Army Programs Program Areas Process AreaBad ActorsAlternatives Identified Total Cost De-Painting118$XXX Rubber to Metal Bonding 23$XXX CARC and Other Paints 2225$XXX Solvents / Cleaners / Thinners $XXX Sealants, Adhesives & Misc. Coatings $XXX Munitions Coatings33 $XXX Implementation PEO/PM Support $XXXX

7 U.S. ARMY Solving Environmental Problems for Army Programs Mitigating Risk  RDECs Developed Original Program Plans and Estimates  Collected Data from Army Industrial Base Facilities Identified the Bad Actors, How Much, Where, on What  Performed Industrial Base Operational Analyses Prioritized Bad Actors – Easy to Hard Identified Opportunities for EPA Negotiations  Performed Trade Studies Analyzed COTS, GOTS, and the Gaps Estimated Costs of Alternatives and Alternative Approaches Prepared Roadmaps to Implementation (by Industrial Site and by Commodity)  Risk Mitigation Plan Verified RDEC Program Plans and Estimates Work with Vendors & Suppliers Negotiations with EPA RDEC Involvement, PM Implementation No Basic Research or Applied Research

8 U.S. ARMY Solving Environmental Problems for Army Programs De-Painting  Bad Actors – 1  Performed at Depots and Troop Installations  Advanced Technology Development: FY03-FY06 Trade Study Identified 34 Potential Alternatives Selected 18 for Performance Evaluation Coordinate Depot Implementation Technology Demonstration at ANAD  Demonstration / Validation: FY06-FY08 Performed at Three Sites: CCAD, LEAD, and ANAD Coordinate PM Approval  Operations & Maintenance 24 Specifications / Documents Identified SOPs, TMs, DMWRs, etc. Will be Modified ANAD High Volume Dip Tank  Two Approaches for ANAD Alternative Materials – Higher Risk Housekeeping and Dip Tank Changes – Low Risk No Cost Trade-Off – Both Options have Zero Net Cost Reduced Material Costs More than Cover Changes Covered Through AWCF/CIP 5% Army Usage 15% VOHAPs

9 U.S. ARMY Solving Environmental Problems for Army Programs Rubber to Metal Bonding  Bad Actors – 2  Performed Only at RRAD  Advanced Technology Development: FY06 Reformulate 2 Existing Adhesives – Change Solvents Evaluate 3 COTS Alternatives Coordinate RRAD Implementation  Demonstration / Validation: FY06-FY07 Conduct Qualification / Validation Testing Support PEO GCS and PEO CS&CSS Approval  Operations & Maintenance 3 Specifications and 5 DMWRs/SOPs  Cost Trade-Off Scrubber: Capital Investment + Annual Maintenance Alternative COTS Materials: Capital Investment + Higher Annual Material Cost Reformulated Materials: No Cost Difference

10 U.S. ARMY Solving Environmental Problems for Army Programs CARC and Other Paints  Bad Actors – 22  Performed Everywhere Except Ammo Plants  Aerosols – Expect to be Exempted  CARC Family: 9 Specifications – No Cost Re-Formulated CARC has No Cost Changes New CARC More Durable, More Expensive (~$20/ GL) PM Can Choose Best Option  Non-CARC: 13 Specifications Advanced Technology Development: FY03-FY06 Re-Formulate 5 and Evaluate 20 COTS Coordinate Depot Implementation Demonstration / Validation: FY06–FY08 Downselect and DEM/VAL 13 at Depots DEM/VAL CARC at 3 Remaining Depots Coordinate PM Approvals Operations & Maintenance 13 Specifications  Cost Trade-off No Performance Gains – Expect Comparable Cost 45% Army Usage 40% VOHAPs

11 U.S. ARMY Solving Environmental Problems for Army Programs Solvents / Cleaners / Thinners  Bad Actors – 100  Performed Everywhere  Trade Study Identified 350 Potential Alternatives with 33 Solvent, 19 Cleaner, and 12 Thinner Specifications)  Advanced Technology Development: FY03-FY06 Joint Service Solvent Substitution Methodology Sharing Costs Evaluate 40 – Downselect to 8 for DEM/VAL  Demonstration / Validation: FY06-FY08 DEM/VAL at LEAD, CCAD, ANAD, and TYAD Coordinate PM Approval Transition through TM to Field  Operations & Maintenance Revise 3 Specifications, Develop 1 New Specification Cancel / Inactivate for Army Coating Use 61 Specifications  Cost Trade-Off CCAD Experience – $1M to $2M per Year (Aerospace Rule) Requires Process Relocations New Solvents Generally Cost More Cost Validated During Downselect Working with EPA on Emission Standards / Limits 20% Army Usage 40% VOHAPs

12 U.S. ARMY Solving Environmental Problems for Army Programs Sealants, Adhesives & Misc. Coatings  Bad Actors 400 out of 1500 Many Low Use – Expect to be Exempted Many Small Container Sizes – Expect to be Exempted  Performed Everywhere  Advanced Technology Development: FY04-FY07 ASTM Test Standard Evaluate 100 materials Downselect 60 to 75 for DEM/VAL  Demonstration / Validation: FY06–FY08 Qualification Less Complicated and Smaller Scale DEM/VAL Up to 75 Materials PM Approval Expected for 400 Current Materials  Operations & Maintenance 25 Specification Changes Anticipated  Cost Trade-off Requires Process Relocations New Materials Generally Cost More Cost Validated During Downselect 30% Army Usage 5% VOHAPs

13 U.S. ARMY Solving Environmental Problems for Army Programs Munition Coatings  Bad Actors – 33  Performed at All Plants except 1  Joint Service Requirements – Investigating Shared Cost  Delayed Compliance Date for Munitions Clean Air Act Emissions Reductions in Other Areas Good Performance Demonstrated by the Army in Exceeding Reductions Gained by Aerospace, Shipbuilding NESHAPs EPA Working with Us – This Program Shows Commitment  Ammunition Coatings Drivers – Throughput & Costs Changes Require Round Qualifications GOCO / AAP Implementation is Intricate  Analyses Identified 33 Different Coatings at AAPs  Advanced Technology Development: FY04-FY09 33 Reformulations and Laboratory Validations  Demonstration / Validation: FY06-FY10 30 Round Qualifications  Operations & Maintenance: FY06-FY11 33 Specification Revisions Drawing / TDP Changes  Coordinating PEO Ammo IB Approval

14 U.S. ARMY Solving Environmental Problems for Army Programs Implementation  Operations & Maintenance funds FY06-FY11 Tied Directly to Non-Munition Areas Non-Specification Document / TDP Changes 99 TMs & TBs Identified Commodity Management NSNs Prevent Re-Introduction of Bad Actors Reduce Recordkeeping Burden and Costs  RDT&E Management Support: FY06-FY09 Provide Direct Support to PMs & Depots for Implementation Annual Management Oversight Coordination with EPA

15 U.S. ARMY Solving Environmental Problems for Army Programs Program Areas 20% 45% 5% Usage 40%350100Solvents / Cleaners / Thinners 40%2522CARC and Other Paints 15%181De-Painting VOHAP Emissions Alternatives Identified Bad ActorsProcess Area 30%5%100400Sealants, Adhesives & Misc. Coatings

16 U.S. ARMY Solving Environmental Problems for Army Programs Without ANAD Methylene Chloride 20% 50% Usage 50%350100Solvents / Cleaners / Thinners 45%2522CARC and Other Paints VOHAP Emissions Alternatives Identified Bad ActorsProcess Area <1% 181De-Painting 30%5%100400Sealants, Adhesives & Misc. Coatings

17 U.S. ARMY Solving Environmental Problems for Army Programs Bottom Line  Compliance-Driven Option: Install and Operate Controls $XXXM  Pollution Prevention Option: Reformulate, Qualify & Implement Alternatives $ XXM