| Overview: |
A portable vacuum sanding system
will effectively capture sanding residue and be mobile/light enough to be
operated by one person. The unit can be used to sand composite structures
such as radomes. The system integrates a vacuum cleaner with vacuum assist
sanders for eliminating airborne toxins (including lead, chromium, and
dust) while removing paint from both metallic and nonmetallic aircraft
structures. The system incorporates three-stage filtration composed of a
filter bag, prefilter, and HEPA filter.
The effect this technology has on pollution
prevention is that the portable vacuum sander removes coatings and
corrosion from composite or metal structures while capturing the solid
waste. Vacuum sanding eliminates airborne particulate matter and potential
lead dust exposure hazard. When compared to chemical paint stripping, this
technology eliminates the generation of waste solvent.
OSHA 1910.1025 requires that sanding and
grinding operations take place without exceeding the lead permissible
exposure limit (PEL) of 50 g/m3. The vacuum sander helps meet
this requirement. OSHA 1910.1025 states: "Where vacuuming methods
are selected, the vacuums shall be used and emptied in a manner which
minimizes the reentry of lead dust into the workplace." Therefore workers
should exercise care when using and emptying vacuum units.
An example of one system is the Clayton
cleaner/sanding system Model 660-DM-1000. This system incorporates one
vacuum cleaner, two vacuum assist sanders, two vacuum assist grinders one
package of 6 mil polyliners, one Y adapter, one package of filter bags,
two packages of prefilters, and one tool caddy. All accessories are
compatible with each other. In 1994, the Navy procured approximately 124
units for use on both shore-based and shipboard activities. In addition,
several Air Force bases use the units. Currently, several vacuum sanding
units are being used on composite radomes at Naval Station Mayport in
Florida, but evaluation of the system is not complete.
|
| Compliance
Benefit: |
The portable vacuum sanding system
eliminates the generation of waste solvent when compared to chemical
stripping. This benefit may help facilities meet the requirements of waste
reduction under RCRA, 40 CFR 262; the Pollution Prevention Act (42 USC 13101-13109);
and Executive Order (EO) 13148, Greening the Government Through
Leadership in Environmental Management; and may also help
facilities reduce their generator status and lessen the amount of
regulations (i.e., recordkeeping, reporting, inspections, transportation,
accumulation time, emergency prevention and preparedness, emergency
response) they are required to comply with under RCRA, 40 CFR 262.
It should be noted that the portable vacuum sanding system generates slightly
more hazardous waste when compared to traditional hand sanding, but this
factor may be counterbalanced by reduced employee exposure benefits. In addition,
less hazardous materials (i.e., solvent) are required to be
purchased and stored on site and therefore the possibility that the
facility would meet any of the reporting thresholds of SARA Title III
(40 CFR 300, 355, 370, and 372) is decreased.
The compliance benefits listed here are only
meant to be used as general guidelines and are not meant to be strictly
interpreted. Actual compliance benefits will vary depending on the factors
involved, e.g., the amount of workload involved.
|
| Materials Compatibility: |
The system can be used in most
applications where chemical stripping, hand sanding, and mechanical
sanding methods are used. No materials compatibility issues were
identified.
|
| Safety and
Health: |
Airborne dust is a major
safety and health concern with any sanding operations and can be essentially
eliminated by using the vacuum sanding system. However, eye protection and
hearing protection are recommended. The system is designed to be in
compliance with OSHA 1910.1025 for use during sanding and
grinding operations. Consult your local industrial health specialist, your
local health and safety personnel, and the appropriate MSDS prior to
implementing this technology.
|
| Benefits: |
- Reduces airborne pollution from current
power sanding operations.
- Improves efficiency of operations.
- Improves personnel safety by collecting and
containing paint dust particles.
- Provides a cost-effective means to remove
paint from composite structures that cannot be removed from a ship.
- Reduces labor hours for manual sanding
operations.
- Portable unit.
|
| Disadvantages: |
- Capital equipment investment is
required.
- Operator training is necessary.
- Operator time, maintenance requirements,
handling, and disposal of waste varies with the material to be
stripped.
- Quality of stripping is dependent on skill
and experience level of the operator. Composite substrate can be
damaged.
|
| Economic
Analysis: |
Processing radomes and equivalent
composite structures using the vacuum sanding system has shown some
decrease in process time for a radome assembly. However the largest
benefit is personnel safety. The vacuum and filtration process eliminate
airborne toxins (including lead, chromium, and dust) generated when
preparing coated surfaces for refinishing. The vacuum sanding system
interfaces well with site operations, minimizes site clean-up, and
provides a safer, healthier work environment.
Assumptions:
- Labor for sanding and grinding is the same
for either system.
- Number of sanding disks or wheels is the
same for either system.
- Filter bags are changed once per month
taking 5 minutes.
- Prefilters are changed once per year taking
5 minutes.
- HEPA filters are changed once every ten
years taking 5 minutes.
- Filter bags cost $9; prefilters cost $18;
HEPA filters cost $369.
- Labor rate = $40/hr.
- Setup/Cleanup for conventional
sanding/grinding operation takes 80 hrs/yr.
- Setup/Cleanup for vacuum sanding takes 40
hrs/yr.
- Waste disposal quantities are slightly
higher for vacuum sanding because of the disposal of filters.
- Waste disposal costs $1,200/ton or
$0.60/lb.
- 500 lbs. of waste material from sanding
operations are generated/year.
- 25 lbs. of filters are
generated/year.
Annual Operating Cost
Comparison for Portable Vacuum Sanding and Conventional
Sanding
| |
Conventional
Sanding |
Portable
Vacuum Sanding |
| Equipment
Cost: |
$0 |
$4,955 |
| Operational
Costs: |
|
|
| Setup/Cleanup
Labor: |
$3,200 |
$1,600 |
Maintenance
Labor
(changing filters): |
$0 |
$43 |
| Filter
purchases: |
$0 |
$163 |
| Disposal: |
$300 |
$315 |
| Total
Operational Costs: |
$3,500 |
$2,121 |
Economic Analysis Summary:
- Annual Savings for Vacuum Sanding: $1,379
- Capital Cost for Equipment/Process: $4,955
- Payback Period for Investment in Equipment/Process: 3.6 years
Click
here to View an Active Spreadsheet for this Economic Analysis and
Enter Your Own Values. To return from the Active Spreadsheet, click the
Back arrow in the Tool Bar.
|
| NSN/MSDS: |
| Product |
NSN |
Unit Size |
Cost |
MSDS* |
| Vacuum Sander |
5130-00-596-9714 |
ea. |
$222.75 |
N/A |
| Vacuum Sander |
5130-00-889-8986 |
ea. |
$215.20 |
N/A |
*There are multiple MSDSs for most NSNs.
The MSDS (if shown) is only meant to serve as an example.
To return from the MSDS, click the Back arrow on the Tool Bar.
|
| Approving
Authority: |
Appropriate authority for making process
changes should always be sought and obtained prior to procuring or implementing any of the technology
identified herein.
|
| Points of Contact: |
For more information
|
| Vendors: |
This is not meant to be a complete list, as there may be other suppliers of this type of equipment.
Clayton Associates,
Inc
Farmingdale, NJ 07727
Phone: (800)
248-8650
Service: Dustmaster System Model
660-DM-1000
Nilfisk, Advanced America,
Inc.
300 Technology
Drive
Malvern, PA 19355
Phone: (800)
645-3475
URL: http://www.nilfisk-advance.com/
Tiger-Vac Inc.
14 Healey Ave.
Plattsburgh, NY 12901
Contact: Mr. Massimo De Pastena, Government Sales
Phone: (800) 668-4437 ext. 226
FAX: (800) 668-4439
URL: http://www.tiger-vac.com
Service: Industrial vacuum sanding kits and industrial vacuum cleaners
|
| Related Links: |
Do You Remove Paint Using Conventional Sanding Or Chemical Paintstripping? - Navy Environmental Quality Initiative (EQI)
|
| Sources: |
Mr. Massimo De Pastena,
Tiger-Vac Inc., September 2002.
Mr. Jim Clayton, Clayton Associates, Inc.,
March 1997.
Mr. Chris Mahendra, Naval Air Warfare Center, Aircraft Division, March 1997.
|
| Supplemental: |
Picture of
Portable Vacuum Sanding System – Environmental Quality
Initiative
|
