Painter Training Program Development | Paints & Coatings | Pollution Prevention | Transfer Efficiency Paints & Coatings Development of Standard Protocols for the Testing, Evaluation and Qualification of Commercial Coatings used by FMC Manufacturing Divisions - 1977-1984 In 1977 Ron Joseph was hired by the FMC Corporation, Santa Clara, CA. to establish and run a paints and coatings laboratory within the Central Engineering Laboratory. He later became Corporate Manager of Coatings Technology. Prior to Joseph's employment at FMC, the Corporation had no standards for testing, qualifying or implementing commercial coatings used by FMC's diverse manufacturing divisions. During this period FMC divisions, located throughout the US and in Europe manufactured "LinkBelt" cranes and excavators, street sweepers, orchard sprayers, cherry pickers, logging machinery, ocean going barges, freight rail cars, oil well equipment, food processing machinery, food packaging machinery, fire engines, scissor loading platforms for jumbo jets, automotive wheel testing equipment, and materials handling equipment. Joseph, together with his staff, developed standard protocols for testing, evaluating and qualifying all coatings. As a result of this work all manufacturing divisions relied on Joseph's coatings laboratory before implementing new coatings. This became increasingly important when low-VOC coatings were being introduced.
Development of Protocols for Testing and Qualifying of Compliant Water-Borne Epoxy Primer - 1981-1983 This two-year program called for extensive research, development and implementation of a 2.8 lbs/gal water-borne primer to meet California's VOC limits. Joseph and his laboratory staff provided the contract proposal, testing protocols, selection of materials, laboratory testing of coatings and the final report. The work was conducted at FMC's Corporate Technology Center, and Joseph managed and supervised the project. After the laboratory had completed its work, Joseph and his staff worked closely with the FMC San Jose Ordnance Division to implement the new technology. The Department of the Army Fort Belvoir Coatings Laboratory, wrote specification MIL-P-53030, based on this work, and the technology was subsequently transferred throughout the military government and contractor community.
Development of Protocols for Testing and Qualifying of Compliant Camouflage Polyurethane (CARC) Coating - 1982-1984 This project, was sponsored by the Department of the Army, Tank Automotive Command (TACOM), and resulted in the selection, testing and implementation of a 3.5 lbs/gal high solids camouflage polyurethane, MIL-C-46168. Joseph played the same role in this project as in the previous one. Once again, he and his staff were responsible for the testing protocols, testing results, and final research report. He worked closely with the San Jose Ordnance Division to implement the coating.
Development of Protocols for Testing and Qualifying of Compliant Interior Epoxy Topcoat - 1982-1984 This third project, also sponsored by TACOM resulted in the selection, testing and implementation of a 3.5 lbs/gal high solids interior epoxy topcoat, MIL-P-53022. As a result of the successful implementation of the coating at FMC, the technology was transferred throughout the military government and contractor community.
Comment: As a result of the successful completion of these three programs, FMC became the first military contractor to identify and implement low-VOC coatings for Army contracts. Development of Protocols for Testing and Qualifying of Chromate-Free Conversion Coating for Treatment of Aluminum - 1982-1984 In this TACOM sponsored program Joseph's coatings laboratory developed the protocols and testing program for identifying the availability of non-chromate conversion coatings for the treatment of aluminum prior to painting. After extensive testing it was shown that no technology was yet available to meet the DoD's existing specification, MIL-C-5541 Class IA.
Comment: Such coatings are only now becoming available, and are still in the testing stages.
Development of Standard Protocols for Testing and Qualification of Low-VOC Coatings for Spectra Physics, Tandem Computers, Varian Associates - 1984 - 1985 Ron Joseph & Associates was retained separately by computer and electronic instrument manufacturers to develop standard corporate specifications for the testing and qualification of coatings. These specifications became increasingly important with the introduction of low-VOC coatings. Each protocol was tailored to the specific performance properties required of each client.
Development of Protocol for Testing and Qualification of VOC Compliant Coatings for Military Contractors for ESL (Div of TRW), ARGOSystems, Ford Aerospace - 1985 In 1985 Ron Joseph & Associates developed a detailed protocol for the testing and qualification of low-VOC military coatings, other than those used by FMC. The testing phase was conducted by Calcoast Laboratories, Berkeley, CA. Joseph monitored the project, wrote all protocols and reports, and was the liaison between his clients and the Army's Fort Belvoir Laboratory. As a result of this work, the companies listed above were able to get approval from their military customers to use the newly developed compliant coatings.
Development of Testing Protocols for Measuring Transfer Efficiency of Coating Application under Production Operating Conditions - 1986 - 1989 Throughout this period Ron Joseph & Associates has written numerous protocols for measuring transfer efficiency in operating facilities. Each protocol has been tailored to the specific process which was under consideration, and in most cases the protocols have been submitted to the SCAQMD for prior approval. Protocols have been written for: Miscellaneous Metal Parts coated with manual guns Metal truck wheels coated with manual guns Metal motor car wheels coated with automatic guns Plastic wheel covers coated with automatic guns Two-piece metal cans coated with automatic guns Three-piece metal cans coated with automatic guns Aerospace skins coated with manual guns 55-gallon drums, interior and exterior coated with both manual and automatic guns
Spray gun technologies which have been used have included: Conventional air atomizing Air-assisted airless Airless HVLP (turbine operated) HVLP (pressure reduction) Electrostatic (various types) Electrostatic bells Manual spray guns Automatic spray guns
Research and Development of Material for "Report on Compliance Coatings for the Miscellaneous Metal Parts Industry", EPA 340/1-91-009, August, 1991. Ron Joseph and Associates was retained by Alliance Technologies, a contractor to the USEPA, to research, develop and write a comprehensive manual on all aspects relating to the selection, testing, availability and implementation of VOC compliant coatings. The manual, published by the EPA in August 1991, is focused at the Miscellaneous Metal Parts industry.
Transfer Efficiency Development of Protocol to Measure Transfer Efficiency of Spray Guns for South Coast Air Quality Management District (SCAQMD) - 1989-1990 Ron Joseph & Associates was retained by the SCAQMD to conduct the first phase of a program to develop a testing protocol for evaluating the transfer efficiency of spray guns. This phase of the program was successfully completed in 1990.
Evaluation of SCAQMDs RECLAIM Proposal for Paint Manufacturers - 1992 Retained by Southern California Edison, this company reviewed the South Coast District’s proposal to allocate VOC emissions to all manufacturers of coatings, where such coatings would be delivered and used within the South Coast Basin. After reviewing the agency’s proposal, two focus groups were arranged; one with paint manufacturers, the other with end-user. Participants included both small and national corporations. The final report was submitted to the agency, and the RECLAIM proposal was eventually found to be unworkable.
Development of Transfer Efficiency Protocol Sponsored by the California Air Resources Board and Managed by the South Coast Air Quality Management District (SCAQMD) - 1993-1996 This was a two-year project in which RJA was retained to develop a protocol that could be used nationally to measure the relative Transfer Efficiency of various spray guns. To develop the protocol an in-depth research program was undertaken at the Southern California Edison’s CTAC Laboratories in Irwindale, CA. Spray guns evaluated included conventional air atomizing, three different types of HVLP designs and air-assisted airless. Two voluminous reports were submitted; the first detailing the results of the research, the second providing the test protocol. The reports are now available to the public through the SCAQMD.
Painter Improvement Training Programs (Transfer Efficiency in Practice) - 1995 - Present Since 1995 Ron Joseph has been conducting hands-on training programs, predominantly at air force basis, to help improve the performance of painters. The programs have been so successful, that since they were first introduced he has been inundated with requests to present the program at various bases. Some have asked for programs to be repeated. As part of the programs Ron Joseph has worked with a full range of conventional air atomizing and HVLP spray guns. The program includes data gathering and calculations of emission, hazardous waste and cost reductions. Moreover, during each program a video is taken of the painters as they apply coatings to various substrates. The videos are often edited and used as teaching tools.
Pollution Prevention Conducted Pollution Prevention Surveys at Several of FMC Corporation's Manufacturing Facilities - 1992 Ron Joseph worked closely with FMCs Corporate Technology Center to survey several of the paints and coatings facilities in their manufacturing operations. Each survey was followed by a detailed report outlining pollution strategies, and wherever possible providing recommendations that would ease compliance with the New Clean Air Act's Title V, permitting provisions.
Development of EPA Manual "Pollution Prevention in the Paints and Coatings Industry," EPA/625/R-96/003 - 1994 RJA was retained by Eastern Research Group, under contract to the EPA to develop a 16- chapter manual on Pollution Prevention opportunities in the Paints & Coatings industry. The manual covers the following topics: Chapter 1: Introduction Chapter 2: Overview of Paints and Coatings Operations Chapter 3: Adhesion as a Critical Factor Chapter 4: Considerations Regarding Vendor-supplied Materials Chapter 5: Surface Degreasing - Alternatives to Conventional Solvent-based Methods Chapter 6: Phosphating Metal Surfaces: Process Efficiency and Waste Minimization Chapter 7: Rinsing Process Efficiency and Alternatives to Chromate-based Sealers Chapter 8: Abrasive Blast Cleaning of Metal Surfaces: Process Efficiency Chapter 9: Transfer Efficiency as it Affects Air, Water, and Hazardous Waste Pollution Chapter 10: Liquid Compliant Coating Technologies Chapter 11: Powder Coatings Chapter 12: Viscosity Management for Pollution Prevention Chapter 13: Minimizing Solvent Usage for Equipment Clean-up Chapter 14: Paint Stripping: Alternatives to Solvent-based Methods Chapter 15: Minimizing Pollution from Spray Booths Chapter 16: Problem Solving: Case Studies of Some Typical Paint Facilities
This 190 page reference manual contains 66 tables and 55 figures. |
Painter Training Program Development Optimizing Painting Procedures for Large Aircraft Maintenance and Refurbishing Operations - 1998 RJA is currently working on an on-going program to optimize painting operations at large air force facilities. The first program concerns the painting of an F15 fighter aircraft. In this program all of the painting procedures (including application equipment) for the aircraft are being reviewed for cost and environmental efficiency. Where necessary, new procedures, equipment, etc. are being proposed. The goal is to demonstrate emission, hazardous waste, labor and operating cost reductions when the aircraft is repainted at an air force base. The first phase of the program has been completed, and it is expected that the entire project will be completed before the end of 1998. If the project proves to be successful, it is anticipated that the same approach will be taken for other large aircraft.
Video Training on Aerospace NESHAP - 1999 RJA was retained by the US Air Force to compile a 2-hour training video that teaches painters, supervisors and managers how they are affected by the Aerospace NESHAP regulation. The video covers every aspect of an Air Force painting operation and incorporates over 200 video clips, over 40 graphics, and over 100 word slides. In addition the video is accompanied by a workbook and quizzes. The training tape also includes numerous recommendations for pollution prevention (P2), and covers good painting practices even if they are not regulated by the NESHAP. 
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