UNICOAT, developed by Naval Air Warfare Center (NAWC) Warminster, is a self-priming topcoat for aircraft and other industrial applications that is applied directly to metal without a primer. UNICOAT, which is formulated lead and chrome-free, replaces the two-coat system with a blend of organic and inorganic zinc compounds that are nontoxic. UNICOAT, like traditional topcoats, is polyurethane; however, UNICOAT is different because corrosion inhibitors and adhesion promoters have been added. It has demonstrated equivalent or superior performance compared to the toxic paints that have been used in the past. A federal specification (TT-P-2756) has been developed for this technology.

The UNICOAT process does not contain chromates. As a result, the waste streams generated with the UNICOAT process are less hazardous than conventional processes. These waste streams include air emissions and wastes generated from cleanup operations. Since the UNICOAT process, a one-coat process, replaces a two-coat process, waste is reduced by approximately 50%.

• Reduced emissions of volatile organic compounds (VOCs) from solvent cleaning and from paint since only one coat of paint is applied. VOCs are associated with the formation of smog and typically regulated by federal and state agencies as well as local air pollution control districts.
• Reduced emissions of hazardous air pollutants (HAPs) from solvent cleaning, which is regulated by Federal, state, and local regulations including the National Emissions Standards for Hazardous Air Pollutants (NESHAPs) (40 CFR 63).
• Reduced storage and use of substances that are regulated by SARA Title III (TRI, Tier I /Tier II) if certain thresholds are exceeded (40 CFR 300, 355, 370, and 372).
• Reduced generation of waste cleaning solvents and waste paint that must be handled and disposed as hazardous waste under 40 CFR 260 and related sections.
• Reduced hazardous materials usage as required of federal facilities by Executive Order (EO) 13148, Greening the Government Through Leadership in Environmental Management.
• Potentially reduced occupational exposures that are regulated under 29 CFR 1910.

Other compliance benefits include:

• Reduced recordkeeping and reporting requirements under the Title V Operating Permits Program, NESHAP Program and SARA programs.
• Reduced administrative burden associated with hazardous waste (i.e., tracking, plans, reports, training).
• Reduced administrative burden associated with OSHA (i.e., training and recordkeeping).

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.)

Consult your local industrial health specialist, your local health and safety personnel, and the appropriate MSDS prior to implementing this technology.

• Contains no toxic pigments (i.e., chromate, lead, etc.).
• Reduces VOC emissions and hazardous waste generation by 50 - 70%.
• Yields paint and primer cost savings of approximately 65%.
• Reduced paint weight on equipment and aircraft.
• Yields labor cost savings since only one coat is applied.
• Yields stripping cost savings since only one coat is applied.

• UNICOAT may not be suitable for all coating applications.
• Labor and stripping costs are increased due to corrosion and paint failure.
• UNICOAT usage on Air Force aircraft has documented limitations when applied to the fleet of KC-135 aircraft, the paint did not perform well. The major problems involved poor adhesion, leading to corrosion problems due a lack of protection. UNICOAT is not approved for use on Air Force aircraft.

Assumptions:

• 36 aircraft painted annually with a total surface area of 111,600 ft² (3,100 ft² per aircraft).
• All paint is consumed and no waste is generated from painting operations.
• Thickness of all coatings: 1 mil.
• Surface area coated with one mil thickness: 842 ft² per gal.
• Gallons of UNICOAT used annually: 135 gals.
• Gallons of epoxy primer used annually: 135 gals.
• Gallons of topcoat used annually: 135 gals.
• UNICOAT cost: $75/gal.
• Epoxy primer cost: $70/gal.
• Topcoat cost: $150/gal.
• Labor required to apply one coat: 50 hrs.
• Labor rate: $40/hr.

Annual Operating Cost Comparison for UNICOAT System and Two-Coat System

Economic Analysis Summary:

• Annual Savings for UNICOAT System: $91,575
  
• Capital Cost for Diversion Equipment/Process: N/A
  
• Payback Period for Investment in Equipment/Process: Immediate

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Do You Paint Military Aircraft Or Support Equipment? - Navy Environmental Quality Initiative (EQI)

Diagram of UNICOAT Paint System – Navy Environmental Quality Initiative (EQI)