Why Should My Business Try To Reduce Air Pollution?
Fiberglass and composite manufacturers generate hazardous and non-hazardous air emissions, solid waste, and water wastes. The emissions from processes and materials may also impact worker health and safety.

The most significant environmental concern is due to the use of resins and gelcoats during fabrication. These materials are considered hazardous substances and sources of toxic air emissions, primarily because of styrene content. Styrene is used as a reactive diluent in the fabrication process - it thins the polyester resin, and also provides the "bridge" to "crosslink" the polyester molecule chains. Styrene is a volatile substance, and a percentage of it escapes from the resin during application and curing phases. As it escapes from the resin matrix, it becomes an "air contaminant" that is regulated by SCAPCA and other health and safety and environmental agencies.

Other hazardous substances used in the fabrication process are resin catalysts, solvents, paints, thinners, foaming agents, and adhesive products.

Businesses that choose to minimize the use of traditional resins and solvents and change to low volatile organic compounds (VOC) and low hazardous air pollutant (HAP) products are moving in the same direction as federal, state and local regulations. The switch to these new materials not only decreases emissions, but may also reduce nuisance complaints from neighboring businesses and the public.

How Does SCAPCA Regulate Fiberglass and Composite Manufacturing?
All new air pollution sources, modifications to existing sources, and new or altered air pollution control equipment in Spokane County are required to obtain an approved Notice of Construction from SCAPCA prior to the construction, installation, establishment, or modification of the source, according to SCAPCA Regulation I, Article V. This includes chemical processes which release VOCs and HAPs into the air. Visit the previous menu for information on the Notice of Construction process and/or an application packet.

In addition, SCAPCA Regulation I, Article IV lists categories of sources that have been identified as having potentially significant air emissions. Businesses that fall into these categories, including fiberglass and composite fabricators, are required to register with SCAPCA unless an exemption is granted. SCAPCA regularly inspects registered businesses. Information on the registration process may be found in the previous menu.

What Does SCAPCA Look For During A Facility Inspection?
Periodically, a SCAPCA inspector will conduct an inspection of your facility. Your operations will be examined to verify compliance with local, state and federal air quality regulations.

• Notice of Construction conditions of approval (if applicable)
• Types of products and solvents used
• Weekly/monthly product and solvent purchase/usage records
• Material Safety Data Sheets (MSDS)
• Equipment maintenance logs
• Waste disposal manifests
• Pollution prevention techniques and opportunities
• Application equipment operation
• Spray booth and filter condition, if applicable
• Process techniques and controls
• Clean-up procedures
• Products and solvents storage
• Waste storage
• System air flow

Which Products Are Of Air Quality Concern?
Emissions from fiberglass and composite manufacturing include VOCs and toxic air pollutants. In the presence of sunlight, VOCs participate in a complex reaction with oxides of nitrogen to form ozone. Ozone is a strong irritant that attacks the lungs, makes breathing difficult, and irritates the eyes. Toxic air pollutants may be carcinogenic and have other potential health impacts.

The major toxic air pollutants emitted during fiberglass and composite manufacturing are styrene, methyl ethyl ketone peroxide (MEKP), methyl methacrylate, toluene, xylene and methylene chloride.

Air quality concerns include:

• Resins and Gelcoats are hazardous because they contain VOCs and toxic air pollutants. Styrene, a common component of resin and gelcoats, is the main toxic air pollutant of concern. It also has a low odor threshold and may cause nuisances.
• Initiators and catalysts are hazardous because they often contain the toxic air pollutants methyl methacrylate and MEKP.
• Solvents such as acetone, methylene chloride, toluene, xylene, and various alcohols are toxic air pollutants and VOCs. Many solvents are probable carcinogens.
• Paints and stains, thinners, adhesives, and foaming agents contain VOCs and may also contain toxic air pollutants. Waste streams containing VOCs and toxic air pollutants must be managed properly to reduce air emissions.

Why Should I Evaluate My Environmental Management Approach?
Your fiberglass and composite manufacturing shop can become both environmentally friendly and cost efficient by establishing an effective environmental management program. Good environmental management can limit some typical business expenses and help avoid environmental compliance costs.

In addition to reducing emissions to the air, your business can gain an economic edge by reducing waste management costs, improving worker safety, decreasing future liability, and increasing productivity.

What Technologies Can Help Me Reduce Air Emissions & Improve Efficiency?
Pollution Prevention (P2) is any practice that reduces or eliminates the creation of pollutants through increased efficiency in the use of raw materials, energy, water, or other resources.

Fiberglass and composite fabrication activities that can benefit from P2 include:

• equipment or technology modification;
• process modifications;
• reformulation or redesign of products;
• substitution of raw materials; and
• improvements in housekeeping, maintenance, training, and inventory control.

A variety of fiberglass fabrication technologies and materials have been evaluated to identify P2 opportunities. The evaluations, derived from the publication, "Waste Reduction Strategies for Fiberglass Fabricators", by David Hillis and Darryl Davis of Eastern Carolina University, and from suppliers and vendors of the technologies, can be reviewed on the Pollution Prevention Research CenterÆs web page (http://www.pprc.org/pprc/sbap/fiber/p2techs.html). Additional informational resources are listed at the end of this publication.

The technologies and/or opportunities are organized in two different categories - Process Methods and Equipment and Process Materials. For each technology, case studies from Northwest companies using the technology, as well as vendors selling the technology, are presented. They include:

Process Methods and Equipment:

• Prepreg Fiber Reinforcing
• In-House Resin Impregnation
• Resin Rollers - Spray-less Application Systems
• Flowcoaters and Flowchoppers
• Vacuum Bag Molding
• Infusion or SCRIMP Process
• Infusion with a Semi-Rigid Cover
• Resin Transfer Molding (RTM)
• Rotational Molding of Small Tanks
• Electrostatic Gel Coating
• Controlled Spraying

Process Materials:

• Low Styrene Resins (25-35% styrene)
• Vapor Suppressed Resins
• Catalysts
• Laminating with UV Resins
• Waterborne Gel Coats
• Polyurethanes and Polyurethane/Polyester Blends
• Acetone Substitutes

How Can I Optimize My Spraying Techniques?
Optimization of spray gun set-up and spraying technique is the first line of pollution prevention and source reduction in polyester/vinyl ester resin spraying operations. These methods provide a "win-win" scenario for mitigating styrene emissions while providing cost savings. It is recommended that all spray application equipment be optimized, and spraying techniques aimed at reducing overspray be adopted to achieve emissions reductions. Following are specific recommendations for spray application optimization:

1. High-Volume, Low-Pressure Spray Guns: Use high transfer efficiency methods, such as HVLP spray guns, to increase the percentage of product deposited during surface applications. If you use application methods with high transfer efficiencies, preferably in excess of 65%, you will buy less raw material and save money.
2. Spray Equipment Set-up: Spray tips should be sized for a specific application, in order to spray from between 12" - 18", or as close as reasonably possible, from the surface. The primary method for adjusting material flow rate is varying the spray tip orifice size. The fan pattern width is adjusted by selecting the appropriate orifice angle.
3. Tip Pressure: The spray gun should be adjusted to the lowest possible pressure that produces an acceptable fan pattern.
4. Spray Operator Training: Operator training is a critical part of the optimization plan. This training should include:
   • The use of proper spraying techniques;
   • An understanding of the function and proper set-up of spray equipment; and
   • An understanding of the effects of overspray.
5. Spraying Technique: Handling of the spray gun is a critical element of optimizing the process. In simple terms, where the gun is "aimed" is very important. The following techniques are designed to minimize "off-spray" and reduce wet surface area surrounding the mold.
   • The spray gun should be held as close to the mold surface as possible, in consideration of the material output, fan pattern size, and size and configuration of the mold.
   • The fan pattern intercept angle should be maintained as close to perpendicular to the mold surface as possible.
   • The perimeter of the mold should be sprayed as accurately as possible, avoiding spraying off the edge to the greatest extent possible.
6. Overspray Capture/Mold Edge Configuration: It is a distinct advantage to capture "off-spray" as close to the mold edge as possible. When considering the geometry of spray off the edge of the mold, the total wet surface area increases considerably as the "footprint" of the overspray area increases. It is recommended that a wide flange be incorporated at the mold perimeter, or an arrangement of masking the mold edge be used. The objective is to spray to the useful edge of the part and contain as much overspray as possible with the masking around the mold perimeter.

What Else Can I Do To Improve My Environmental Management?
A variety of practices will help your shop realize the benefits of effective environmental management. Consider the following suggestions:

Where Else Can I Find Information To Help My Business?
There are a variety of resources available that will help you learn more about ways to reduce air emissions and reduce environmental problems. Many of the following resources will also help you identify ways to save money and stay competitive: