YOLO-SOLANO AIR QUALITY MANAGEMENT DISTRICT

RULE 2.30 - POLYESTER RESIN OPERATIONS
(Revised August 13, 1997)

INDEX

100 GENERAL

101 PURPOSE

102 APPLICABILITY

110 EXEMPTION, TOUCH-UP AND REPAIR

200 DEFINITIONS

201 AIRLESS SPRAY

202 AIR-ASSISTED AIRLESS SPRAY

203 CATALYST

204 CLEANING MATERIALS

205 CLOSED MOLD SYSTEM

206 CONTROL SYSTEM

207 CORROSION-RESISTANT MATERIALS

208 CROSS-LINKING

209 CURE

210 ELECTROSTATIC SPRAY

211 FIBERGLASS

212 GEL COAT

213 GRAMS OF VOC PER LITER OF MATERIAL

214 HIGH-VOLUME LOW-PRESSURE

215 INHIBITOR

216 LOW-VOC EMISSIONS RESIN SYSTEMS

217 MONOMER

218 POLYESTER

219 POLYESTER RESIN MATERIALS

220 POLYESTER RESIN OPERATIONS

221 POLYMER

222 REPAIR

223 RESIN

224 SPECIALTY RESIN

225 TOUCH-UP

226 VOLATILE ORGANIC COMPOUND (VOC)

227 VAPOR SUPPRESSANT

228 WASTE MATERIALS

300 STANDARDS

301 REQUIREMENTS

302 CLEANING MATERIAL REQUIREMENTS

303 STORAGE AND DISPOSAL REQUIREMENTS

304 COMPLIANCE DATES

400 ADMINISTRATIVE REQUIREMENTS

401 PROHIBITION OF SPECIFICATION

402 PROHIBITION OF SALE

500 MONITORING AND RECORDKEEPING

501 TEST METHODS

502 RECORDS




100 GENERAL

101 PURPOSE: The purpose of this rule is to control Volatile Organic Compound (VOC) emissions from polyester resin operations.

102 APPLICABILITY: This rule is applicable to all commercial and industrial stationary sources performing polyester resin operations.

110 EXEMPTION, TOUCH-UP AND REPAIR: The provisions of Section 300 shall not apply to touch-up and repair.

200 DEFINITIONS

201 AIRLESS SPRAY: A coating spray application system using high fluid pressure to atomize the coating without compressed air.

202 AIR-ASSISTED AIRLESS SPRAY: A coating spray application using fluid pressure to atomize the coating and lower pressure air to adjust the shape of the spray pattern.

203 CATALYST: A substance added to the resin to initiate polymerization.

204 CLEANING MATERIALS: Materials used for cleaning, including but not limited to: hands, tools, molds, application equipment, and work areas.

205 CLOSED MOLD SYSTEM: A method of forming an object from polyester resins by placing the material in a confining mold cavity and applying pressure and/or heat.

206 CONTROL SYSTEM: A control device and its associated collection system.

207 CORROSION-RESISTANT MATERIALS: Materials that are halogenated, furan, bisphenol A, vinyl ester, or isophthalic resins that are used to make products for corrosive or fire retardant applications.

208 CROSS-LINKING: The chemical process of chemically bonding two or more polymer chains together.

209 CURE: To polymerize, e.g., to transform from a liquid to a solid or semi-solid state to achieve desired product physical properties, including hardness.

210 ELECTROSTATIC SPRAY: The spray application of coatings whereby an electrostatic potential is created between the part to be coated and the coating particles.

211 FIBERGLASS: A fiber similar in appearance to wool or cotton fiber but made from glass.

212 GEL COAT: A polyester resin topcoat that provides a cosmetic enhancement and improves resistance to degradation from exposure to the environment.

213 GRAMS OF VOC PER LITER OF MATERIAL: The weight of VOC per volume of material as calculated by the following equation:

D

=

(Ws - Ww - Wes)

 

 

Vm

where:

D = Grams of VOC per liter of material

Ws = Weight of volatile materials in grams

Ww = Weight of water in grams

Wes = Weight of exempt compounds in grams

Vm = Volume of materials in liters.

214 HIGH VOLUME-LOW PRESSURE: Spray equipment used to apply coatings by means of a gun which operates between 0.1 and 10 psi air pressure.

215 INHIBITOR: A substance used to slow down or prevent a chemical reaction.

216 LOW-VOC EMISSIONS RESIN SYSTEMS: Polyester resin materials which contain vapor suppressants to reduce monomer evaporation loss.

217 MONOMER: A relatively low-molecular-weight organic compound that combines with itself, or other similar compounds to become a cured thermosetting resin.

218 POLYESTER: A complex polymeric ester containing difunctional acids and alcohols dissolved in a monomer.

219 POLYESTER RESIN MATERIALS: Materials including, but not limited to, unsaturated polyester resins such as isophthalic, orthophthalic, halogenated, bisphenol-A, vinyl-ester, or furan resins; cross-linking agents; catalysts, gel coats, inhibitors, accelerators, promoters, and any other VOC-containing materials used in polyester resin operations.

220 POLYESTER RESIN OPERATIONS: Methods used for the production or rework of products by mixing, pouring, hand lay-up, impregnating, injecting, forming, winding, spraying, and/or curing unsaturated polyester resin materials with fiberglass, fillers, or any other reinforcement materials and associated cleanup.

221 POLYMER: A chemical compound comprised of a large number of chemical units and which is formed by the chemical linking of monomers.

222 REPAIR: The part of the fabrication process that requires the addition of polyester resin material to portions of a previously fabricated product in order to mend structural damage.

223 RESIN: Any of a class of organic polymers of natural or synthetic origin used in reinforced products to surround and hold fibers, and is solid or semi-solid in the cured state.

224 SPECIALTY RESIN: Any halogenated, furan, bisphenol-A, vinyl ester, or isophthalic resin used to make products for exposure to one or more of the following extreme environmental conditions: acute or chronic exposure to corrosive, caustic or acidic agents, or flame.

225 TOUCH-UP: The portion of the fabrication process that is necessary to cover minor imperfections.

226 VOLATILE ORGANIC COMPOUND (VOC): Any compound containing at least one atom of carbon, except those compounds exempted under Section 214 of Rule 1.1, General Provisions and Definitions.

227 VAPOR SUPPRESSANT: A substance added to a resin to minimize the outward diffusion of monomer vapor into the atmosphere.

228 WASTE MATERIALS: Those materials that include, but are not limited to: scraps resulting from cutting and grinding operations, any paper or cloth used for cleaning operations, waste resins, and any spent cleaning materials.


300 STANDARDS

301 REQUIREMENTS: Any person operating a polyester resin operation shall comply with one or more of the following, as applicable:

301.1 The use of polyester resin material with a monomer content of no more than 35 percent by weight and low VOC gel coat with a monomer content of no more than 45 percent by weight and low VOC specialty resins and clear gel coat with a monomer content of no more than 50 percent by weight, as applied and as determined by the manufacturer's specification;
301.2 The use of a resin containing a vapor suppressant, such as that weight loss from VOC emissions does not exceed 60 grams per square meter of exposed surface area during resin polymerization; as determined by Section 501.1;
301.3 The use of a closed-mold system;
301.4 Polyester resin operations shall install and operate an emissions control system which is designed and operated for the collection of fugitive emissions from polyester resin material and which system is approved by the District, and has a control device with a overall control and capture efficiency of 85 percent or more on a mass basis as determined by Sections 501.2 and 501.7; and
301.5 Only airless, air-assisted airless, high volume-low pressure, or electrostatic spray equipment shall be used for the application of polyester resin materials in spraying operations.

302 CLEANING MATERIAL REQUIREMENTS: Where the use of cleaning materials containing more than 1.7 pounds per gallon of VOC material as applied and as determined by Section 501.3 or having a initial boiling point less than 190oC, as determined by Section 501.4, exceeds four (4) gallons per day, a cleaning material reclamation system shall be used. Such a reclamation system shall operate at least 80 percent efficiency. Solvent residues for on-site reclamation systems shall not contain more than 20 percent VOC by weight as determined by Section 501.5.

303 STORAGE AND DISPOSAL REQUIREMENTS:

303.1 Closed containers shall be used for the storage of all polyester resin materials, cleaning materials, and any unused VOC-containing materials except when being accessed for use.
303.2 Self-closing containers shall be used in such a manner to effectively control VOC emissions to the atmosphere for the disposal of all polyester resin materials, cleaning materials, waste materials, and any unused VOC-containing materials.

304 COMPLIANCE DATES:

304.1 Any person subject to the requirements of this rule shall be in compliance by (six months from date of adoption).
304.2 Facilities operating prior to (date of adoption) and which elect to install and operate an emission control system pursuant to the requirements of Section 301.2 shall have the control system installed and operating by (18 months from date of adoption).

400 ADMINISTRATIVE REQUIREMENTS

401 PROHIBITION OF SPECIFICATION: A person shall not specify the use of any gel coat or polyester resin material subject to the provisions of this rule that does not meet the limits and requirements of this rule where such applications result in a violation of this rule. The requirements of this Section shall apply to all written or oral contracts.

402 PROHIBITION OF SALE: A person shall not sell or offer for sale any gel coat or polyester resin material subject to the provisions of this rule that does not meet the limits and requirements of this rule where such applications result in a violation of this rule.

500 MONITORING AND RECORDKEEPING

501 TEST METHODS: The analysis of cleaning materials, polyester resin materials, and control/collection efficiency shall be determined by the appropriate test methods as follows:

501.1

Laboratory Static Test for Polyester Resin Materials:

  1. Principle: A weighed amount of polyester resin material is reacted with a methyl ethyl ketone peroxide (MEKP) catalyst to form a 14.5 cm diameter casting. The volatility loss is determined at room temperature (77o ± 3o F) and 56 percent room humidity over a specified time period. This method is applicable only to polyester resin materials and does not simulate spray booth operations.
  2. Apparatus:
    1. Analytical Balance, top-loading, capable of measuring up to 0.01 gram.
    2. Gallon can lid or equivalent. The lid should be 14.5 cm inside diameter (165.13 cm2). Different size lids should be measured prior to testing.
    3. Paper clip, bent to 90o.
    4. Clock or timer capable of reporting time to a precision of 0.01 minute.
    5. Constant temperature and humidity room, as described above. If a constant temperature room is not available, measure temperature and humidity prior to each weight measurement or test procedure.
  3. Determination of VOC Loss:
    1. Place the bent paper clip[ on a gallon can lid, or equivalent.
    2. Tare weight to ± 0.01g the gallon can lid and clip. Record the weight as W1.
    3. Catalyze 200 grams of polyester resin material with the recommended type and amount of catalyst and promoter. Ensure that the resin temperature is 77oF at catalyzation.
    4. Add 100g (± 0.05g) of catalyzed polyester resin material to the gallon can lid. Record the weight of the lid plus the polyester resin material to ± 0.01g as W2. Start timer.
    5. At five (5) minute intervals, record the gross weight loss to ± 0.01g as Wt and check the catalyzed resin for gel point. Gelling has occurred when either the resin tears or the can lid raises when the paper clip is lifted. Record gel time to the nearest one (1) minute.
    6. To include both gel and cure time of the resin rate loss in the calculations, it is recommended that weight measurements continue at fifteen (15) minute intervals for sixty (60) minutes after the gel point.
    7. At sixty (60) minutes after the gel point (or constant weight), record the final weight of the lid plus the polyester resin material to ± 0.01g as Wf.
  4. Calculations: Determine VOC loss per square meter as follows:

    Loss = (W2 - Wf) x 60.56

    where:
    60.56 = 1/A
    A = The area of the gallon can lid in square meters - [(d/2)
    2 x 3.14159]/(10,000 cm/m), where d is in cm.
    W1 = Tare weight of the gallon can lid (plus paper clip if used).
    W2 = Initial weight = W1 plus the polyester resin material and catalyst (if used).
    Wt = Sample weight after (t) minutes have elapsed.
    Wf = Sample weight at final measurement.

  5. Reporting:
    1. Product tested and catalyst system.
    2. Room temperature and relative humidity (for each reading if necessary).
    3. All Recorded weights (W1, W2, Wt, Wf), gel time, and amount of catalyst used.
501.2
  1. EPA Method 25A, "Determination of Total Gaseous Organic Concentration Using a Flame Ionization Analyzer".
  2. EPA Method 18, "Measurement of Gaseous Organic Compound Emissions by Gas Chromatography".
501.3 ASTM D3960-81, "Determining Volatile Organic Content (VOC) of Paints and Related Coatings".
501.4 ASTM D1078-86, "Distillation Range of Volatile Organic Liquids".
501.5 California Air Resources Board Method 401, "Gravimetric Purge and Trap".
501.6 EPA Method 24, "Determination of Volatile Matter Content, Water Content, Density, Volume Solids,and Weight Solids of Surface Coatings".
501.7 40 CFR 52.741, Appendix B, "VOM Measurement Techniques for Capture Efficiency".

502 RECORDS: Any person subject to this rule shall comply with the following requirements:

502.1

A person shall maintain, or have available, a current list of polyester resins and cleaning materials in use which provides all of the data necessary to evaluate compliance, including the following information:

  1. Polyester resin, catalyst, and cleaning materials used;
  2. The weight percent of VOC in each of the polyester resin materials, and the grams of VOC per liter for the cleaning materials;
  3. For approved vapor suppressed resins, the weight loss (grams per square meter) during resin polymerization, the monomer percentage, and the gel time for each resin;
  4. The amount of each of the polyester resin materials and cleaning materials used during each day of operations;
  5. The volume of polyester resin materials and cleaning materials used for touch-up and repair during each day of operation; and
  6. Records of hours of operation and key operating parameters for any emissions control system.
502.2 All records required by this rule shall be retained and made available for inspection by the Air Pollution Control Officer for the previous 24 month period.