TO 1-1-8 BASIC AND ALL CHANGES HAVE BEEN MERGED TO MAKE THIS A COMPLETE PUBLICATION TECHNICAL MANUAL APPLICATION AND REMOVAL OF ORGANIC COATINGS, AEROSPACE AND NON-AEROSPACE EQUIPMENT F09603-87-D-2264 FA8501-05-D-0002 DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited (WR-ALC/PA Public Affairs Certificate Number PA05-0758). Other requests for this document shall be referred to 584 CBSS/GBHDE, Robins AFB, GA 31098.
TO 1-1-8 LIST OF EFFECTIVE PAGES INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES. NOTE The portion of the text affected by the changes is indicated by a vertical line in the outer margin of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands. Dates of issue for original and changed pages are: Original. . . . . .0. . . . . .15 February 2006 Change . . . . . . 1 . . . . . . 14 February 2007 Change. . . . . . . . 2 . . . . . . .
TO 1-1-8 TABLE OF CONTENTS Chapter Page LIST OF ILLUSTRATIONS . . . . . . . . . . . vi LIST OF TABLES . . . . . . . . . . . . . . . . . . vi FOREWORD . . . . . . . . . . . . . . . . . . . . . vii SAFETY SUMMARY . . . . . . . . . . . . . . . xi 1 INTRODUCTION AND GENERAL DISCUSSION OF COATING MATERIALS AND TERMS . . . . . . . . . . . . . . . . . . . 1.1 1.2 1-1 INTRODUCTION . . . . . . . . . . . . GENERAL DISCUSSION OF ORGANIC COATINGS . . . . . . . . . Coatings Systems For Metal Surfaces . . .
TO 1-1-8 TABLE OF CONTENTS - CONTINUED Chapter Page 3 SURFACE PREPARATION AND CHEMICAL PREPAINT SURFACE TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8 3.1.9 3.1.10 3.1.11 3.1.12 3.1.13 3.1.14 3.1.15 3.1.16 3.1.17 3.1.18 3.1.19 3.1.20 3.1.21 3.1.22 3.1.23 ii SURFACE PREPARATION FOR PAINTING AND CHEMICAL PREPAINT SURFACE TREATMENT . . . . . . . . . . . . . . . . . . Surface Preparation For Painting . .
TO 1-1-8 TABLE OF CONTENTS - CONTINUED Chapter 5.5.3 5.5.4 5.5.5 5.5.6 5.6 5.6.1 5.6.2 5.6.3 5.6.4 5.6.5 5.6.6 5.6.7 5.7 5.7.1 5.7.2 5.7.3 5.8 5.8.1 5.8.2 5.8.3 5.8.4 5.8.5 5.8.6 5.8.7 5.8.8 Electrostatic Aircraft Painting . . . . . Atmospheric Conditions For Painting . . . . . . . . . . . . . . . . . . . . . Test Panels . . . . . . . . . . . . . . . . . Material Requirements, General . . . THE AIRCRAFT PAINTING PROCESS SEQUENCE OF EVENTS . . . . . . . . . . . . . . . .
TO 1-1-8 TABLE OF CONTENTS - CONTINUED Chapter Page 6.12.18 Coating, Corrosion Preventive, For Aircraft Integral Tanks, MIL-C27725/SAE AMS-C-27725 . . . . . 6.12.19 Coating Compound, Nonslip (For Walkways), A-A-59166 . . . . . . . 6.12.20 Coatings, Polyurethane, Rain Erosion Resistant For Exterior Aircraft and Missile Parts, MIL-C83231/SAE AMS-C-83231 . . . . . 6.12.21 Coating System, Polyurethane, NonYellowing White, Rain Erosion Resistant, Thermally Reflective, MIL-C-83445/SAE AMS-C83445 . . . . . . .
TO 1-1-8 TABLE OF CONTENTS - CONTINUED Chapter 8.4.9 8.4.10 8.4.11 8.4.12 8.4.13 8.4.14 8.4.15 8.4.16 8.4.17 8.4.18 8.4.19 Page Markings for Servicing, Ground Handling and Hazard Warning . . Markings for Engine Compartment Fire Access Panel . . . . . . . . . . . Ejection Seats . . . . . . . . . . . . . . . Identification of Ballistic Hose Assemblies . . . . . . . . . . . . . . . . . Markings for Tank Filler Areas . . . . Marking of Emergency Lighting (Flashlight) for Cargo &Transport Aircraft . . . . . .
TO 1-1-8 LIST OF ILLUSTRATIONS Figure 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-18 4-19 4-20 4-21 4-22 5-1 5-2 5-3 5-4 6-1 7-1 Title Page Nozzle Pressure Gauge . . . . . . . . . . . Simple Spray System Setup . . . . . . . . Airless Spray System . . . . . . . . . . . . . Complete Spray System . . . . . . . . . . . Sectional View of Spray Gun . . . . . . . Proper Installation of Air Compressor, Piping . . . . . . . . . . . . . . . . . . . . .
TO 1-1-8 FOREWORD 1 PURPOSE. The purpose of this technical order is to prescribe standard procedures for the removal, application, and maintenance of coating systems on Air Force systems and equipment. Its applicability is generally imposed by reference in system or item technical data. It also should be used where there is an absence of paint process requirements in system or item technical data.
TO 1-1-8 Volatile Organic Compound VOC List of Related Publications - Continued Number CID A-A-3054 4 LIST OF RELATED PUBLICATIONS. The following publications are to be used for reference. Maintain only those publications required to perform assigned mission. This list is not all inclusive. This list also includes general information TOs pertaining to inspection, maintenance, storage, and use of personal flying and survival equipment.
TO 1-1-8 List of Related Publications - Continued Number GGG-C-520 Title Cloth and Disks, Abrasive, Open-Mesh, Waterproof (Repl. by ANSI B74.
TO 1-1-8 List of Related Publications - Continued Number SAE AMS-3819 SAE AMS-C-27725 SAE AMS-C-83231 SAE AMS-C-83445 SAE AMS-M-3171 SAE AMS-T-21595 SAE AMS-T-23397 SAE AS-22805 TT-E-751 TT-I-735 TT-N-95 TT-P-1757 TT-P-2760 TT-P-28 VV-P-236 TO 00-25-172 x Title Cloths, Cleaning Coating, Corrosion Preventive, Polyurethane, for Aircraft Integral Fuel Tanks (to 250° F) (Repl. MIL-C-27725) Coating, Polyurethane, Rain Erosion Resistant, for Exterior Aircraft and Missile Plastic Parts (Repl.
TO 1-1-8 SAFETY SUMMARY 1 GENERAL SAFETY INSTRUCTIONS. This manual describes physical and chemical processes, which may cause injury or death to personnel, or damage to equipment if not properly followed. This safety summary includes general safety precautions and instructions that must be understood and applied during operation and maintenance to ensure personnel safety and protection of equipment.
TO 1-1-8 CHAPTER 1 INTRODUCTION AND GENERAL DISCUSSION OF COATING MATERIALS AND TERMS 1.1 INTRODUCTION. NOTE See Chapter 8 for Air Force policy on determining when individual aircraft are to be repainted or touched up. The surfaces of aircraft, missiles, and associated equipment are subjected to hostile environments both natural and manmade.
TO 1-1-8 meric materials which are not truly “paints,” and also certain chemical surface-treating materials which are not truly organic. These materials may or may not be applied by painters, 1-2 but are closely associated with painting operations. Also, the term “to paint” will continue to be used to signify the application of organic coatings by painters.
TO 1-1-8 CHAPTER 2 ORGANIC FINISH SYSTEM REMOVAL 2.1 INTRODUCTION. The most important factor in removal of organic finish systems (coatings/paints) is complete removal without damaging surfaces on which they are applied. A variety of materials and either chemical or mechanical methods can remove finish systems. In choosing a material and a method, a compromise between maximum removal power and maximum protection for the equipment being stripped must be made.
TO 1-1-8 is removed, it is a lacquer or alkyd enamel coating. If it is not removed, or very little is removed, it is a polyurethane or an epoxy coating. (2) For polyurethane and epoxy coatings, scrape off the topcoat from a small area down to the primer coating with a knife blade or razor blade. If the primer is rubbery and a tan-gray color, it is a polysulfide primer. If the primer is hard and either a yellow, light brown, or dark green (olive drab) color, it is either an epoxy or a polyurethane primer. d.
TO 1-1-8 d. For air and water-driven abrasive removal operations unless otherwise noted, the same materials listed for chemical removal operations shall be used for masking of areas which will not be exposed to direct impingement of the abrasive media to prevent abrasive media intrusion.
TO 1-1-8 NOTE For extensive chemical removal operations such as entire aircraft exterior finish system, some residual stripping will be required. For this limited stripping, it may be more efficient and practical to strip those areas of the finish system which will be covered by masking tape by the hand residual finish system removal procedures in this chapter prior to masking for the over all media removal operation.
TO 1-1-8 NOTE All chemical removers have a shelf life of six months from the date of manufacture unless otherwise specified, if they are stored and maintained under the proper conditions. They should be ordered in quantities and by intervals which allow all chemical removers on-hand to be used prior to the shelf life expiration date.
TO 1-1-8 Part Number Intex 857 CeeBee A-292 Source of Supply EZE Products Inc, Intex Chemical Div Cage Code: 8Z357 603 High Tech CT Greer, SC 29650 CeeBee Div.; McGean-Rocho, Inc. Cage Code 8U841 1314 Murphy Ave. Atlanta, GA 30310-4004 2.6.3 Remover For Polysulfide Primer With A Polyurethane Topcoat.
TO 1-1-8 2.6.4.2 Removers for polysulfide primers 6850-01-4950150 (55 GL DR), 6850-01-495-0149 (5 GL), 6850-01-4950235 (1 GL). Part Number CeeBee E-1058 & E-1058A Source of Supply CeeBee Div, McGean-Rohco Inc. Cage Code: 8U841 1314 Murphy Ave. Atlanta, GA 30310-4004 SR-125A, SR-145, Eldorado Solutions, Inc. & PR-3133 Cage Code: 55208 11611 N Meridian ST, STE 600 Carmel, IN 46032 DBA of Eldorado Chemical CO Inc. 5151B B&B Tritech, Inc.
TO 1-1-8 2.7 GENERAL OVERALL CHEMICAL REMOVAL PROCEDURES. Chemical removal of organic finish systems shall be performed in accordance with the following sequential steps: Chemical removers are toxic to skin, eyes, and respiratory tract. Skin and eye protection required. Contact Bioenvironmental Engineering for determination of need for and selection of proper respiratory protection. a.
TO 1-1-8 NOTE • Never allow a chemical remover to dry on the surface to which it is applied as it is extremely difficult to remove after it dries. • Never rinse surfaces with water between chemical remover applications as this stops the removal action and tends to set up the remaining finish system on the surface making it very difficult to remove. Schedule removal operations so that once started on an area, they proceed without interruption through the entire sequence to complete removal to bare metal.
TO 1-1-8 NOTE Only those aluminum wools and brushes specified shall be used to agitate metallic surfaces during finish system removal operations. Other types of metallic wools and brushes, such as steel, copper, brass, beryllium copper, etc., shall not be used as they will either embed in or smear on the metallic surface and cause severe galvanic corrosion problems.
TO 1-1-8 the next step. If other areas are to be worked, repeat Paragraph 2.7 step g through step n on the next area. Application of chemical remover on a new area may begin as soon as the flushing operation is completed and while the residual finish system removal operation is in progress on an area being worked as long as enough personnel are on hand to work both areas effectively. p.
TO 1-1-8 2.9 MECHANICAL REMOVAL OF ORGANIC FINISH SYSTEMS. • Reference Table 3-1 for the minimum recommended PPE for paint removal operations using hand held or motor driven abrasives (sanding and grinding). Reference Table 2-4 for the minimum recommended PPE for abrasive blasting paint removal operations. • Abrasive blasting, motor-driven wire brush and motor-driven abrasive disc operations create airborne particles that are hazardous to the eyes, skin, respiratory tract.
TO 1-1-8 • Plastic media blasting (PMB) may be used on composite materials in accordance with procedures in Paragraph 2.11, providing its use has been approved by the specific aircraft’s SPD. In all cases, use PMB to remove only the topcoat from composite surfaces. The underlying primer must be used as a “flag” to signal the PMB operator that the topcoat has been removed.
TO 1-1-8 underlying surface. Table 2-1, Table 2-2, and Table 2-3 shall be used to determine the abrasive material to be used for topcoat or primer removal and the substrate metal it may be used on. 2.10.3 Hand Held Abrasive Removal. • Damage to clad/Alclad or anodize surfaces will reduce the corrosion protection in those areas.
TO 1-1-8 Table 2-1. Hand Held Abrasives Abrasive Cloth 120 grit ANSI B74.18/GGG-C-520, Type II, Class 1 240 grit ANSI B74.18/GGG-C-520, Type II, Class 1 Abrasive Paper 120 grit ANSI B74.18/A-A-1047 silicon carbide paper 240 grit ANSI B74.
TO 1-1-8 Roloc™ or hook and loop mounted surface conditioning discs Very fine grade “Scotch-Brite” aluminum oxide/nylon mesh Fine grade “Scotch-Brite” aluminum oxide/ P P nylon mesh Medium grade “Scotch-Brite” aluminum T T oxide/nylon mesh Roloc™ Bristle discs and Radial Bristle TP TP discs Grade 120 Abrasive Flap Brush/Wheels Aluminum oxide coated nylon mesh T TP Abrasive Disks 120 grit ANSI B74.18/GGG-C-520, Type T T II, Class 1 240 grit ANSI B74.
TO 1-1-8 Table 2-3. Item Roloc Plastic Holder Roloc Plastic Holder Roloc Bristle Disk Roloc Bristle Disk Roloc Bristle Disk Surface Conditioning Disk Surface Conditioning Disk Metallic Wool Metallic Wool Metallic Wool Metallic Wool Metallic Wool Abrasive Mat carbon steel stain.
2-18 Change 1 d c b a Blasting helmet with suppliedair None None HEPA vacuum HEPA vacuum Abrasive blast enclosure None Leather and disposable nitrile gloves None Leather and disposable nitrile gloves None None Ear Plugsd Ear Plugsd Tyvek or cotton coveralls Tyvek or cotton coveralls Personal Protective Equipment Ear Eye Body None None Noneb Safety goggles or Tyvek or cotton Noneb faceshield coveralls Ear Plugs None Tyvek or cotton coveralls; leather shoulder coverc Ear Plugs None Tyvek or co
TO 1-1-8 2.11 PMB REMOVAL METHOD. PMB is an excellent and rapid method for finish system removal, but it can cause severe damage to structure and injury to personnel if not done properly with the right type of equipment in the an approved facility. In addition, proper waste management must be ensured for economic and environmental reasons. Some types of materials and material thicknesses cannot be plastic media blasted under any circumstances.
TO 1-1-8 2.11.3.1 Pressure shall be within the range of 40 to 60 PSI at the blast nozzle for 3.0 MOH hardness media (Type I), 25 to 40 PSI at the nozzle for 3.5 MOH hardness media (Type V), and 20 to 30 PSI at the nozzle for 3.5 MOH hardness media (Type II). See Paragraph 2.11.1 for recommended parameters for stripping AGE and vehicles. 2.11.3.2 The blast nozzle tip to work surface standoff distance shall be within the range of 12 to 24 inches for 3.0 MOH hardness media (Type I), 12 to 24 inches for 3.
TO 1-1-8 U.S. Technology Corporation Poly V (Type V) 1446 West Tuscarawas Street Canton, OH 44702-2038 Cage Code: 1AM56 Composition Materials Co., Inc. 125 Old Gate Lane Milford, CT 06460-3611 Cage Code: 98231 Mac’ants Abrasives Limited Todwick Road Dinnington, Sheffield England, S25 3SE Cage Code: Unknown Abrasive Supply Co., Inc./Zirocblast SDN.
TO 1-1-8 Facility Reference Guide on the Air Force Corrosion Prevention and Control office’s website. • When using the PMB method of paint removal on non-metal (composite) surfaces, it is important to limit the amount of time the surface is exposed to the PMB blast. To limit this “dwell time” and still allow paint to be removed, operators should use the primer coat as a “flag.” That is, when the primer begins to become visible, the PMB blast should be aimed at another section of the surface to be stripped.
TO 1-1-8 instruction in Paragraph 2.3 step d of this technical order and the applicable system specific aircraft or equipment technical order for the item being blasted such as the aircraft system specific -23 manual. 2.11.9 Postblast Cleaning. When the finish system has been completely removed by PMB, thoroughly vacuum all surfaces of the aircraft, equipment, or component with a heavy duty, pneumatic type, wet/dry HEPA filtered vacuum cleaner to remove all finish system dust and media residue.
TO 1-1-8 250 ml Pyrex beaker 500-ml graduated glass cylinder Two jug-type glass storage bottles, gal, with screw caps Hydrometer, 1.60 - 1.80 specific gravity Pyrex watch glass, 75 - 90mm dia Nalgene polyethylene wash bottles, 250 ml Bar magnet Spatula, stainless steel Glass stirring rods, 10 inch Neoprene gloves, size as required such as: Playtex neoprene.
TO 1-1-8 Tapping the side of the separatory funnel may help to remove the high-density particles. Do not allow fluid level to get too low, because it might allow some floating media to be deposited with the high-density contaminants. Additional fluid may be added to separatory funnel taking care not to agitate mixture. If agitation occurs, allow 10 minutes for suspended dust particles to float/settle prior to continuation.
TO 1-1-8 causing contamination or damage to equipment, systems, or structure. All surfaces where tape is to be applied shall be wiped down with isopropyl alcohol, TT-I-735 or acetone, O-A51/ASTM D 329. The solvent used during the wipe down operation shall not be allowed to evaporate from the surface, but shall be wiped from the surface with a dry, clean cloth. Masking shall be accomplished according to instructions in Paragraph 2.
TO 1-1-8 areas. Protective clothing worn during water stripping shall remain in the work area and shall not be taken home for cleaning. f. MPW nozzle operators shall never direct a nozzle at other personnel. If more than one MPW nozzle operator is involved in an operation at the same time, they shall be located on opposite sides and/or ends of the aircraft or equipment being stripped to ensure safe separation of personnel. g.
TO 1-1-8 2.14.2 Mechanical Paint Removal on Fiber Glass, Arranged Fiber (“Kevlar”)/Epoxy, and Graphite or Boron Fiber/Epoxy Composite Surfaces. Do not mount an abrasive on a motor driven tool having an operational speed higher than the maximum RPM rating of the abrasive. This can result in disintegration of the abrasive and can cause injury to personnel. NOTE The following procedures are not applicable to radomes. Finish system removal from radomes shall be accomplished per instructions in TO 1-1-24. a.
TO 1-1-8 CHAPTER 3 SURFACE PREPARATION AND CHEMICAL PREPAINT SURFACE TREATMENT 3.1 SURFACE PREPARATION FOR PAINTING AND CHEMICAL PREPAINT SURFACE TREATMENT. The life of an organic coating system, its effectiveness and the appearance of organic finishes depend more on the condition of surfaces receiving them than any other factor.
TO 1-1-8 or hook and loop mounted surface conditioning disc, or a disc fabricated from an abrasive cloth sheet. Use sanders and grinders attached to high efficiency vacuum systems for dust recovery. Keep sander heads approximately flush against the surfaces being sanded and apply the least amount of pressure necessary to accomplish feathering of the paint. NOTE It is essential that a formal maintenance/repair schedule be instituted for the high efficiency vacuum units.
TO 1-1-8 NOTE It is essential that a formal maintenance/repair schedule be instituted for the high efficiency vacuum units. Replace bags in vacuum units after each aircraft or large part has been sanded. Do not use vacuums when the hoses have holes or tears. Use the minimum length of hose attached to vacuum units to ensure the highest airflow rates through the vacuum. Use the vacuum at the manufacture’s recommended compressed air pressure. 3.1.3.3.
3-4 Change 1 f e d c b a General dilution ventilation Air-purifying with OV cartridgesf Engineering Controls Respiratory None None General dilution Air-purifying ventilation with HEPA filter General dilution Air-purifying ventilation with HEPA filter General dilution None ventilation General dilution None ventilation HEPA-ventilated Air-purifying sander with OV/HEPA cartridgese HEPA vacuum None Disposable nitrile Ear plugsc gloves Disposable nitrile Noneb gloves None Tyvek or cotton coveralls Sa
TO 1-1-8 3.1.5 Surface Preparation For MIL-C-27725/SAE AMS-C-27725 Integral Fuel Cell Coating. These solvents should not be used on polycarbonates or acrylics. These solvents will cause most rubber products to swell; however, the rubber will return to its original shape when the solvent evaporates. • A-A-59281 is flammable and toxic to eyes, skin, and respiratory tract. Eye and skin protection required. Good general ventilation is normally adequate.
TO 1-1-8 A-A-2904, Mineral Spirits G Ketones Acetone Methyl Ethyl Ketone (MEK) Methyl Propyl Ketone (MPK) GF F GF Specialty Solvents Parachlorobenzotrifluoride (PCBTF) G Solvent Blends MIL-T-81772, Type II 1:1 MEK Toluene 1:1 MEK Acetone 1:1 MPK Naptha 1:1 Acetone: PCBTF A-A-59231 DS-104, Dynamold Solvents, Inc DS-108, Dynamold Solvents, Inc SD 1291, Brulin Corp. Super 140, LPS Industries GF F GF G GF F GF GF G G Terpenes Citra Safe, Inland Technology De-Solv-It , Orange-Sol, Inc.
TO 1-1-8 * = These solvents are composed of a mixture of photochemically reactive hydrocarbons and oxygenated hydrocarbons and have a maximum vapor pressure of 7 mm Hg at 20° C (3.75 in H2O at 68° F). There are no reporting requirements or containment controls on the use of these solvents. NOTE: These solvents evaporate slowly and must be completely dried prior to application of paint. FL 3 = These solvents are exempt from any reporting and controls under the NESHAP.
TO 1-1-8 flashing out suddenly over a large area, it shall be considered as evidence of impurities on the surface such as free alkali, residual detergents, etc., and the surface shall also be considered as failing the cleanliness test. If the water drops coalesce (go together) into a continuous film of water without a sudden flash out and form a lens, then the surface shall be considered as having satisfactorily passed the water break test.
TO 1-1-8 corrosion rework areas on clad and unclad aluminum alloys. This specification covers the preparation and application of chemical conversion materials, and film formation or consistency. These coatings are not as abrasion-resistant as anodized coatings conforming to specification MIL-A-8625, even though they do provide an effective means for re-establishing the corrosion resistance of mechanically damaged anodic coatings in the field.
TO 1-1-8 paint may require more than one application and rinse. Examine suspect areas being treated with a 4 to 10 power magnifying glass to determine if another application is required. b. All requirements of Paragraph 3.1.18 through Paragraph 3.1.18 step b shall be complied with prior to the “wipe-on and blot-off” method. c. MIL-DTL-5541/MIL-C-81706/MIL-DTL-81706 chromate conversion coating shall be applied immediately after the evaporation period.
TO 1-1-8 3.1.18 Mixing MIL-C-81706/MIL-DTL-81706 Solution. The use of MIL-C-81706/MIL-DTL-81706 requires that the following precautions be observed. • MIL-C-81706/MIL-DTL-81706 conversion coating materials are toxic and require the use of rubber gloves and eye protection (goggles and face shield) by personnel mixing or applying. If the material (which is an acid) accidentally contacts the skin or eyes, flush immediately with plenty of clean water.
TO 1-1-8 on MIL-C-81706/MIL-DTL-81706 solution immediately after rinsing the MIL-C-38334/SAE AMS-1640 compound from aircraft surfaces which are to be painted and while these surfaces are still wet. Allow the gross amount of rinse water to run off the aircraft, but do not wait for completed drying before applying MIL-C81706/MIL-DTL-81706 solution.
TO 1-1-8 3.1.20 Alternate Surface Preparations For Aluminum Surfaces (PreKote SP). Avoid excessive pressure or repeated passing over the same area while sanding. Excess sanding can cause damage to the surface of the aircraft. PreKote SP is for exterior mold line applications only. NOTE • PreKote SP requires specific System Program Office (SPO) approval prior to use. • PreKote SP will only be used with chromated primers.
TO 1-1-8 b. Apply and agitate first coat of PreKote SP in small sections (approximately 16 square feet per person working an area). NOTE Do not allow PreKote SP to dry prior to rinse. c. Rinse area with water. d. Repeat Paragraph 3.1.21 step a and Paragraph 3.1.21 b until entire area to be painted has been covered. m. Let the surface of the aircraft static air dry. 3.1.22 Use of PreKote SP on Exterior Surfaces Where Paint and Primer Have Been Removed During Scuff Sand, Touch-up or Repair.
TO 1-1-8 NOTE • PreKote SP may be applied by pressure sprayer, spray bottle or fluid feed attached to sander. • The first coat of PreKote SP may be hand or pneumatic scrubbed using 180-grit scrub pads. • All coats of PreKote SP may be removed using a clean, lint-free cotton rag moistened with isopropyl or denatured alcohol, instead of rinse with water. e. Follow procedures outlined in application of PreKote SP, Paragraph 3.1.20. 3.1.23 sium.
TO 1-1-8 Water to make 1 gal Chromic Acid Solution (Also known as Dow 19) Chromium Trioxide (A-A-5587 1 1/3 oz Type III) (99.5% pure) Calcium Sulfate 1 oz (CaSo44•2H2O) Operating Temperature 70° F to 90° F Container Stainless steel, Aluminum, vinyl Polyurethane or rubber Rubber gloves, acid apron, and eye protection shall be worn by personnel during all mixing operations. 3.1.25 Surface Preparation For Steel.
TO 1-1-8 Care should be taken when cutting and trimming of the barrier/tape to prevent damage to any transparent plastic and glass surfaces. NOTE For general large area masking use either Type I or Type II. For operations involving sharp, fine line color separation such as aircraft markings and two tone gloss color schemes, use Type III tape only. This tape is designed to prevent edge bleeding and is more flexible for masking shapes, curves, etc. e. Use only approved masking paper for large area masking.
TO 1-1-8 CHAPTER 4 PAINTING APPLICATION METHODS 4.1 GENERAL. Spray application is the standard for painting Air Force aircraft and most other equipment. It is fast, and in the hands of skilled operators, produces films of good uniformity and quality. When application is described in this technical manual without specifying the method, High Volume Low Pressure (HVLP) spray application is implied.
TO 1-1-8 4.2.3 Airless Spray. The term airless comes from the fact that no air pressure is used with this paint application method. Instead, hydraulic pressure is used to deliver the coating material, heated or unheated, to the gun head and atomize it by ejecting it from special spray nozzles. These nozzles increase the pressure by a factor of approximately 100. Atomization of the coating material and formation of the spray pattern are created by the gun nozzle.
TO 1-1-8 completely drain, minimizing paint waste. Gravity feed guns supply paint to the orifice solely by means of gravity. The air pressure at the orifice of these guns is typically 40 to 50 psi. 4.3.4 Material Containers. Two types of containers serve as material reservoirs for spray guns, the cup and the tank. Both cups and tanks are available with agitators to provide constant mixing to keep materials in suspension during application.
TO 1-1-8 Figure 4-2.
TO 1-1-8 air. A condenser is usually equipped with pressure gages, but may be found without gages where a regulated supply of air is available. NOTE Air condensers and transformers shall be drained at least daily and more frequently in humid weather. 4.3.8 Air Supply. Figure 4-6 illustrates proper installation of an air supply for paint spraying. 4.3.9 Hose. Hoses shall always be thoroughly cleaned by flushing with solvent appropriate for the coating material used.
TO 1-1-8 Figure 4-4.
TO 1-1-8 Figure 4-5. Sectional View of Spray Gun 4.4.1.1 Distance. Distance depends on the desired width of the paint fan and the type of gun used (Figure 4-7, Detail A). When all adjustments to the spray gun are correct and the spray gun is held at too great a distance from the surface, it will result in a dry spray (dusting) and excessive overspray. Conversely, if the spray gun is too close to the surface, it will result in too heavy a coating with a tendency for sags or runs to develop. 4.4.1.
TO 1-1-8 without a cross coat may be used. The process control must be adequate to prevent holidays or other finish defects that may result from a single heavy application. 4.4.1.3 Triggering. Proper triggering of the gun is difficult to learn. The variations of triggering technique which may be called for in special situations can only be developed by practice. It is a matter of judgment and experience.
TO 1-1-8 Figure 4-7.
TO 1-1-8 Figure 4-8. Fifty Percent Overlap Figure 4-9.
TO 1-1-8 4.4.2 Gun Adjustments. The flow of air and fluid at the gun must be adjusted or balanced to obtain proper atomization and other desired spraying characteristics. 4.4.2.1 The first consideration in obtaining this balance is the proper combination of air cap and fluid tip for the particular material being sprayed as recommended by the equipment manufacturer and the coating material manufacturer. 4.4.2.
TO 1-1-8 4.4.3 Painting Difficulties and Remedies. Coating troubles may be divided into five groups: (1) Inadequate surface preparation, (2) Incorrect methods or techniques of application, (3) Unusual climatic or atmospheric conditions, (4) Unsuitable equipment, and (5) Faulty finishing material. Inadequate surface preparation is self-explanatory and is discussed in Chapter 3. Incorrect methods of application should be discontinued upon discovery of the discrepancy.
TO 1-1-8 Figure 4-13. Table 4-1. Trouble Sags and Runs Spray Coating Troubles, Possible Causes, and Remedies Possible Causes 1. 2. 3. Streaks Gun Sputters Constantly Dirty air cap and fluid tip (distorted spray pattern). Gun stroked too close to the surface. Preventive Measures Or Remedies 1. 2. 4. Trigger not released at end of stroke (when 3. stroke does not go beyond object). Gun stroked at wrong angle to surface. 4. 5. 6. Coating material too cold. Coating applied on too heavily. 5. 6. 7.
TO 1-1-8 Table 4-1. Trouble Paint will not come from Spray Gun Possible Causes Out of paint (gun begins to sputter). 1. Add paint, correctly thinned out and strained. 2. 3. Settled, cake pigment blocking gun tip. Grit, dirt, paint skins, etc., blocking gun tip, fluid coatvalve or strainer. 2. 3. Remove obstruction, stir paint thoroughly. Clean spray gun thoroughly and strain the coating material. Always strain materials before using. Lack of proper air pressure in the pressure tank. 1.
TO 1-1-8 Table 4-1. Trouble Spray Coating Troubles, Possible Causes, and Remedies - Continued Possible Causes Preventive Measures Or Remedies Paint Leaks from 1. Spray Gun (Figure 4-12) 2. 3. 4. Fluid needle packing nut too tight. 1. Loosen nut, lubricate packing. Packing for fluid needle dry. Foreign particle blocks fluid tip. Damaged fluid tip or needle. 2. 3. 4. Lubricate this part daily. Remove tip and clean. Replace both tip and needle. Gun Sputters Con- 1. stantly (Figure 4-13) 2.
TO 1-1-8 Table 4-1. Trouble Spray Coating Troubles, Possible Causes, and Remedies - Continued Possible Causes Crazing, Mud 1. Cracking, Checking (Figure 4-17 and Figure 4-18). These three defects 2. are all very similar in that they all consist of surface cracks in varying degrees. Crazing is a fine surface crack while cracking and checking often extend to the metal surface. 3. 4. Preventive Measures Or Remedies Painting over a hard glossy coat. A base 1.
TO 1-1-8 Table 4-1. Trouble Possible Causes Inconsistent Coloring Defective Spray Patterns (Heavy Center) Spray Coating Troubles, Possible Causes, and Remedies - Continued Pigment not evenly distributed as a result of settling or insufficient mixing. Apply additional coats after thoroughly mixing the finish material. 1. Setting too low on fan adjustment. 1. Adjust fan adjusting valve. 2. Air cap; atomizing pressure too low. 2. Adjust atomizing pressure. 3.
TO 1-1-8 Table 4-1. Trouble Spray Coating Troubles, Possible Causes, and Remedies - Continued Possible Causes Fish-Eyes and Poor Wetting, Crawling, Poor Flowout. (Figure 4-20) Preventive Measures Or Remedies Use of waxes or sealants and adhesives containing silicones. Presence of other types of oils, greases, or hydraulic fluids on the surface. Solvent clean with silicone-removing compounds. NOTE Minute quantities of silicones can cause this film. Lifting (Figure 4-21) 1.
TO 1-1-8 Figure 4-14. Orange Peel Figure 4-15.
TO 1-1-8 Figure 4-16. Wrinkling Figure 4-18. Figure 4-17.
TO 1-1-8 Figure 4-19. Blistering Figure 4-20. Fish Eyes Figure 4-21. Figure 4-22.
TO 1-1-8 4.5 CLEANING AND MAINTENANCE. Proper maintenance of spray guns is necessary to preserve the life of the gun and ensure high quality results. The gun requires little other maintenance if kept clean. a. Basic maintenance consists of occasional lubrication. The packing surrounding the air valve stem shall receive a few drops of light oil to maintain easy movement of the air valve.
TO 1-1-8 4.6 MECHANICAL PAINT GUN WASHER. When lower vapor pressure solvents are used to clean paint guns and their paint supply lines/ hoses, the paint guns must be blown out with clean, compressed air and the lines/hoses must be flushed with MIL-T-81772, Type I thinner immediately after they are removed from the paint gun washer and prior to use to eliminate all traces of these solvents from the guns and lines/hoses.
TO 1-1-8 CHAPTER 5 PAINTING OPERATIONS FOR AIRCRAFT AND EQUIPMENT 5.1 GENERAL. This chapter describes coating application procedures for aircraft and equipment used by the Air Force. Except when otherwise directed by this technical order or by local requirements or limitations, protective organic coatings may be applied by spraying, brushing, or any other approved method which results in continuous adherent films.
5-2 d c b a None None Disposable Nitrile Noneb gloves Local Bioenvironmental Engineer may recommend more restrictive controls or PPE based on exposure monitoring Hearing protection may be required in locations where hazardous noise is produced from other sources A powered air-purifying respirator (PAPR) with hood is the best choice for spray paint application Not required if a full-facepiece or hooded respirator is worn None Noneb None None Personal Protective Equipment Hand Ear Eye Body Safety g
TO 1-1-8 5.2.1 Respiratory Protection. Many toxic materials are found in spray painting shops which may impair the health of personnel if control measures are not provided. Harmful concentrations of these materials may be reduced to a safe level by an efficient mechanical exhaust system supplemented with personal respiratory protection.
TO 1-1-8 5.4.3 Cleaning and Maintenance. A suitable coating should be applied to all dry interior surfaces of a booth to facilitate cleaning. Paint residue which floats on the surface of the water should be removed each day to prevent it from settling to the bottom of the tank. Spray booths should be coated with an approved fireproof material. The applicable equipment manual should be consulted for complete information on paint spray booths.
TO 1-1-8 h. All aircraft, equipment, work stands, solvents containers/buckets, people, and adjacent equipment shall be grounded prior to using the painting equipment. i. Prior to cleaning electrostatic paint guns, the operators shall ensure that they and the gun are grounded, and that the equipment is de-energized. All spray nozzles and auxiliary equipment being cleaned with flammable solvents shall be done inside the paint hangar facility with the ventilation system operating. j.
TO 1-1-8 b. Electrostatic coating application equipment shall be used only in paint hangars or other areas designated and approved by the local base Fire, Safety, Bioenvironmental, and Environmental Office. c. The ventilation system is on and operating and must also provide sufficient exhaust to remove the solvent vapors generated by the process.
TO 1-1-8 5.5.4.6 The aircraft skin temperature must be at least 60° F prior to any application of coatings. During extremely cold weather, this may require placing the aircraft in a heated paint facility several days in advance to ensure proper skin temperature. 5.5.5 Test Panels. To test suitability of materials, conditions, etc., spray test panels prior to beginning operations.
TO 1-1-8 5.6.1 Aircraft Paint Application Sequence. • Aircraft shall be primed and painted so painter’s exposure to the spray mist or cloud is minimized. • Always spray with painter’s back or side upwind, and never direct spray upwind. • Two or more painters spraying at the same time shall never spray directly at each other and shall be positioned as far apart as possible or on opposite sides of the aircraft.
TO 1-1-8 (5) Apply topcoat to the fuselage aft section starting at the wing trailing edge and the top moving aft and down to the aft end with the initial stroke perpendicular to the aircraft length. Apply the criteria in Paragraph 5.6.1.1 step b (1). Topcoat any aft fuselage mounted engine nacelles using the same techniques at this time.
TO 1-1-8 e. Begin overcoating within 48 hours after scuff sanding and conversion coating operations and immediately after solvent wipe down. Apply one thin/mist coat of MIL-PRF-23377 Type I, Class C1 or C2 (one full wet coat per Table 5-2, to large bare metal areas) to the entire aircraft or equipment exterior painted surface per instructions in Paragraph 5.6.
TO 1-1-8 Table 5-2. Allowable Coating Thickness for Production Level Finishing (Depot, Original Manufacture, Field) Dry Film Coating Specification MIL-PRF-23377 and MIL-PRF-85582 Epoxy Primers TT-P-2760 Elastomeric Polyurethane Primer MIL-PRF-85285 High Solids Polyurethane Coating MIL-PRF-22750 Topcoat MIL-C-27725/SAE AMS-C-27725 Fuel Tank Coating (1) (2) (3) (4) Number of Coats Thickness Range (inches)(1) Minimum(2) Maximum(2) One coat 0.0006 0.
TO 1-1-8 sheet taped on the area under inspection. The test area shall be soaked for a 24 hours minimum, and shall have a minimum diameter of 3 inches. 5.6.6.1.4.3 Remove the wet cloth and plastic sheet and blot up the surface water. Immediately apply a 1 inch strip of tape, PN 250, manufactured by 3M Company, (NSN 751000-283-0612), age of tape not to exceed 3 years, adhesive side down. Press the tape down, using two passes of a 4 1/2 pound rubber covered roller or employ firm pressure with the hand.
TO 1-1-8 5.6.7 Soil Barrier Coating. If approved by weapon system technical order, this coating may be applied to all newly painted aircraft in the jet engine exhaust, APU exhaust, and gun/rocket blast exhaust areas to protect the newly painted surfaces. If left unprotected, the above areas will be very difficult to clean after exposure to the aforementioned exhausts. This material and application procedures are called out in TO 1-1-691.
TO 1-1-8 a. Touch-up using MIL-PRF-23377 Type I, Class C1 or C2 or MIL-PRF-85582 Type I, Class C1 or C2 epoxy primer and MIL-PRF-85285 Type I high solids polyurethane in the touch up applicator pen. These self contained touch up applicators are available by national stock number under the coating specification. After mixing, remove the brush cap and press the applicator against a test article to bleed off any internal pressure that may have formed during storage. Figure 5-3. Figure 5-1. Sempen b.
TO 1-1-8 5.8.4.9 PPE is limited to chemical type gloves and eye protection (face shield or chemical type goggles). 5.8.5 Brush Application. It is very difficult to get a smooth professional appearance without brush strokes with the brush touch-up method on metal surfaces. Therefore, brush touch-up should be limited to areas of one square foot or less and preferably to areas of one square inch or less such as fastener heads.
TO 1-1-8 5.8.6 Roller Application. While not as good as sprayers for metal surfaces, rollers do provide a smoother and more professional appearance than brushes. Therefore, rollers may be used to touch-up large areas. The most effective roller covers for application of primer are manufactured from ultra-high density sponge. The most effective roller covers for topcoat are manufactured from lint-free, extra-density, highquality soft-woven fabric, with a maximum nap length of ¼ inch.
TO 1-1-8 5.8.8.2 Maintenance Painting. Maintenance painting of thermoplastic/thermoset powder coatings shall be accomplished using epoxy or polyurethane topcoat procedures listed in Paragraph 5.8.
TO 1-1-8 CHAPTER 6 USAF STANDARD COATING SYSTEMS FOR AIRCRAFT AND EQUIPMENT 6.1 CLASSIFICATION OF ORGANIC COATINGS. Customarily, finishing materials are classed as paints, enamels, lacquers, and special coatings such as epoxies and polyurethanes. The word “paint” is loosely used to mean all finishing materials. Modern coatings now include quite different components in combinations that do not fall into the old categories.
TO 1-1-8 a. Allow materials to come to room temperature. b. Remove lids and inspect paint for skin-over, gelling, lumps, etc. Skins, if present, shall be carefully removed and discarded, retaining liquids which drain from them. Gelled, lumpy, or otherwise deteriorated paints shall not be used. NOTE Cans of pigmented paint with non-resealable lids should not be opened and inspected until after the original mechanical agitation. c.
TO 1-1-8 of color or flow will indicate incomplete mixing. Comparison of materials from the bottom and top of a container may be made by this method. 6.7 SOLVENTS, DILUENTS AND THINNERS. At ordinary room temperatures, the consistency or viscosity of mixtures of oils, pigments, and resins that make up coating materials is too high to allow spreading them effectively over surfaces in the desired thickness. Also, most resins are solids and need to be dissolved in a liquid before they can be dispersed.
TO 1-1-8 the spray gun or brush, tendency to sag or run, drying time, etc. Volatility also largely governs the flash point of materials. 6.7.2 Thinners. The very properties that make a substance a good solvent for organic materials tend to make it harmful to the body. Many are also hazardous due to flammability. Use caution to avoid unnecessary and continued exposure to the volatile constituents of paints either by inhalation or by skin contact.
TO 1-1-8 NOTE the cup from the moment the cup clears the liquid surface to the point where the first break in the flow stream is noted. This time is the viscosity in No. 2 Zahn seconds. Slight blushing may sometimes be detected by noting faint dissimilarities of appearance in the film occurring over structural members underlying the surface such as bulkheads, ribs, etc.
TO 1-1-8 mixed with a base material prior to application, starting a chemical reaction that continues after application to develop a film with good performance characteristics. The Air Force uses Specification MIL-PRF-23377 and MIL-PRF-85582 primers. 6.9.7 Polyurethane. Polyurethane resins are also catalyzed coatings.
TO 1-1-8 Class C1 Class C2 Class N Barium chromate based corrosion inhibitors Strontium chromate based corrosion inhibitors. Non-chromate based corrosion inhibitors. Class N shall not be substituted for Class C, unless authorization is given by the engineering authority for the system or item on which the primer is used. 6.12.2.2 Uses.
TO 1-1-8 6.12.3.1 Characteristics. This is a two-component, lead free, water-reducible corrosion inhibiting, epoxy primer formulated to meet most local environmental pollution regulations. This primer is available in two different types each with three different classes. Type I Type II Class C1 Class C2 Class N Standard pigments (yellow). Low infrared reflective pigments (dark green). Barium chromate based corrosion inhibitors.
TO 1-1-8 material thoroughly following manufacturer’s instructions. Do not mix more material than can be used in four hours. NOTE Some materials are mixed in a three to one by volume ratio. 6.12.4.4 Thinning. • MIL-T-81772 is flammable and moderately toxic to eyes, skin, and respiratory tract. Eye and skin protection required. • PCBTF, NSN 6850-01-399-0676, is combustible and an irritant to eyes, skin, and respiratory tract. Eye and skin protection required.
TO 1-1-8 proportions of 15 to one by weight. Always properly mix in the correct proportions by the manufacturer’s directions for optimum results. NOTE The base compound has a tendency to settle out in storage and should be thoroughly mixed prior to adding the accelerator. primer shall be applied to a wet film thickness of 3.0 to 4.0 mils which results in a dry thickness of 1.0 to 1.2 mils.
TO 1-1-8 and lubricants; but it has only fair weathering characteristics. Because it is an epoxy, this coating is difficult to remove with standard paint removers. 6.12.6.2 Uses. As a tiecoat over existing coating systems for the reapplication of MIL-PRF-85285 polyurethane topcoat on the exterior of painted aircraft and other aerospace equipment. 6.12.6.3 Mixing.
TO 1-1-8 resistance superior to conventional polyurethane topcoats. Although some degradation in fade resistance will occur if APC is applied over PR-1422GV elestomeric polysulfide primer, color retention still exceeds MIL-PRF-85285 requirements. 6.12.7.4 Mixing. • The catalyst portion of polyurethane topcoat contains a resin that may contain up to one percent Hexamethylene Diisocyanate (HDI).
TO 1-1-8 be greater than conventional MIL-PRF-85285, APC still meets the requirements of the military specification. 6.12.7.6 Thinning. PCBTF, NSN 6850-01-399-0676, is combustible and an irritant to eyes, skin, and respiratory tract. Eye and skin protection required. Disposable 8 mil nitrile gloves, splash goggles, tyvek/cloth coveralls are the recommended PPE. Use in well ventilated areas.
TO 1-1-8 inhibitive wash coat or metal conditioner with the properties of the conventional anticorrosive primer. This coating is furnished with a resin component and an acid component, which are mixed just prior to use. The resin component consists of an insoluble zinc chromate and magnesiumsilicate in a polyvinyl-butyral resin and alcohol vehicle. The acid component is phosphoric acid, ethyl alcohol, butyl alcohol, and water.
TO 1-1-8 may be minimized by thinning with one part by volume of thinner to five parts by volume wash primer with a thinner composed of two parts (by volume) of distilled or demineralized water and one part (by volume) of a 90:10 mixture of ethyl alcohol: butyl alcohol. The above thinner composition is a starting point and should be modified where local conditions warrant. Table 6-1 shows the amount of each component generally necessary to furnish a satisfactory wash primer. 6.12.9.6.
TO 1-1-8 cannot be raised, discard or set aside the wash primer being used and mix and thin a new batch following the instructions in Paragraph 6.12.5.3 and Paragraph 6.12.5.4. NOTE Isopropyl alcohol shall not be substituted for ethyl alcohol in thinning wash primer as the addition of water in the thinning process for low humidity will cause the material to gel. 6.12.9.8.2 High-Humidity Application.
TO 1-1-8 c. If it is required to mix batches smaller than the full unit size, strictly maintain the proportions of vehicle and pigment specified by the manufacturer. NOTE Proportions customarily are given by weight. If mixing less than a full kit, it can be done by using the volume of the vehicle and the weight of the zinc pigment.
TO 1-1-8 6.12.11.4 Thinning. Package viscosity is generally appropriate for brush application. Adjust viscosity of the primer for spraying by thinning in accordance with the manufacturer’s instructions. 6.12.11.5 Application. Apply by spray (hot or cold method) to solvent-cleaned, phosphoric acid treated or sandblasted steel. HVLP spray application is the preferred method; however, the material can be applied by brush, but only to small areas.
TO 1-1-8 6.12.15.1 Characteristics. This is a water emulsion, protective, strippable, sprayable, multi-coat coating for application over metallic, painted, and plastic surfaces that comes in one type with several classes. Type Type Type Type II, II, II, II, Class Class Class Class 1 5 6 7 Base coat (black) Topcoat (white or olive drab) Topcoat (white) Topcoat brushable 6.12.15.2 Uses. These materials are used to protect equipment and aircraft during shipment and storage. 6.12.15.2.1 Type II, Class 1.
TO 1-1-8 6.12.17.5 Application. Apply by HVLP spraying methods (hot or cold method) or as recommended by the manufacturer within the six hours at 75° F/24° C pot life of the material. 6.12.17.6 Drying Time. hard 18 hours. Set-to-touch - 5 hours and dry 6.12.18 Coating, Corrosion Preventive, For Aircraft Integral Tanks, MIL-C-27725/SAE AMS-C-27725. 6.12.18.1 Characteristics. This is a polyurethane material available in two types each with two classes.
TO 1-1-8 6.12.18.2 Uses. This coating is intended for the protection of aircraft integral fuel tanks against corrosion in a service temperature range of -65° F to +250° F. 6.12.18.3 Mixing. • MIL-C-27725/SAE AMS-C-27725 is flammable and toxic to eyes, skin, and respiratory tract. Eye and skin protection required. Consult Bioenvironmental Engineering to determine proper respiratory and ventilation requirements. • The coating material contains harmful solvents and free isocyanates.
TO 1-1-8 a metal spatula. Keep empty containers and those containing mixed and unmixed coating tightly closed when not in use. 6.12.18.4 Application. The dry film thickness of this coating shall be between 0.8 and 1.2 mils, see Table 5-2. Runs and sags shall be mopped immediately to prevent thick spots. Thicknesses over 1.2 mils result in cracking, flaking and peeling of coating while those less than 0.8 mils do not provide adequate protection.
TO 1-1-8 walkway coating need not be topcoated on interior walkways, ramps, steps, and doorways in high traffic areas. Before applying the non-slip coating, wipe primed surface with a clean lint-free cloth with solvent per Table 3-2, if necessary. Thoroughly mix the material, preferably with a mechanical shaker. The coating will normally have the proper viscosity for brush application. Application by brushing is recommended as the material is primarily formulated for this.
TO 1-1-8 6.12.22.3 Installation. c. Mask using above marks as guides. • The temperature during application shall be at least 60° F. This may be accomplished with a ground heater for small areas. Final sanding with anything coarser than A-A58054 Type I, Grade A abrasive (very fine 240320 grit) will adversely affect bond of tape. • Materials to make repairs or remove the tape must be available in case of errors in application. d.
TO 1-1-8 Table 6-2.
TO 1-1-8 e. Apply adhesive promoter per Table 6-2 to entire area. Allow to dry for 20 minutes. f. Apply film and rub thoroughly. NOTE Ensure air bubbles do not build under film. g. Inspect repair for air bubbles. Try pressing air out, allowing proper bonding. If not successful, insert needle or pin into the air bubble, and press out air before removing pin/needle. 6.12.22.6 Tape Removal. following methods: 6.12.22.6.1 Remove tape by either of the Removal Disc. a.
TO 1-1-8 CHAPTER 7 APPLICATION AND REMOVAL OF DECALS AND SILK SCREENING 7.1 DECALS - GENERAL. NOTE National Stock Numbers (NSN’s) for specific decals and related materials are to be obtained from Federal Supply Classes (FSC’s) 7690, 9330, 9905, and others as found in Illustrated Parts Breakdowns (IPBs or -4 manuals) for specific aircraft. Also, see the current FED Log and the D043 System to convert specification and part numbers to NSNs.
TO 1-1-8 Figure 7-2. Figure 7-3. Figure 7-5. Applying Large Emblems (Step 3) Figure 7-6. Applying Large Emblems (Step 4) Applying Marking Stripe Applying Large Emblems (Step 1) 7.3 LARGE EMBLEMS AND LETTERS USING HINGE APPLICATION METHOD. Apply these decals using a “Hinge” method as outlined below. a. Tape decal into position with small pieces of masking tape (See Figure 7-3) as step 1. b. Apply 1 inch or 2 inches wide tape over one edge to serve as a hinge. Whenever possible, hinge narrow edge.
TO 1-1-8 the surface with one hand and allow adhesive to touch only as pressure is applied. Be sure the edges are firmly adhered. (See Figure 7-6.) - Step 4. 7.4 DECALS APPLIED USING APPLICATION TAPE. This method is particularly useful with large or intricately shaped emblems or for hot weather applications. Steps 1, 2, and 3 under Figure 7-7, Figure 7-8, and Figure 7-9 are not necessary when decals are supplied premasked (cut to same shape as decal with application tape). a.
TO 1-1-8 with adequate ventilation. Avoid prolonged or repeated contact with skin. Avoid swallowing. • Eye protection must always be used when operating these tools. Power tools can cause flying particles which can cause injury. Figure 7-11. 7.6 Edge Sealing APPLICATION OF PREMASKED DECALS. Decals that have application tape (cut to the same shape as the decal) applied to the film side are supplied specifically for application on the primer coat (MIL-PRF-23377, MIL-PRF85582, or TT-P-2760 only). a.
TO 1-1-8 7.8 APPLICATION OF MARKINGS WITH SILKSCREEN. This method can be used for painting internal and external markings and insignias. 7.8.1 Materials and Equipment for Silkscreening. Equipment: Locally fabricated or commercially procured silkscreens are both authorized. Screen should be polyester monofilament (220-280 mesh). Silkscreen, squeegee, commercially procured. Materials: Colored marking paint, MIL-PRF-81352, Type I Acrylic, Type II - Alkyd, Type III - Polyurethane.
TO 1-1-8 CHAPTER 8 EXTERIOR FINISHES, INSIGNIA AND MARKINGS, APPLICABLE TO USAF AIRCRAFT 8.1 GENERAL. 8.1.1 Purpose. The purpose of this chapter is to standardize the painting and marking and exterior configuration of all Air Force, Air Force Reserve and Air National Guard aircraft. This chapter describes Air Force policy on the painting, marking, and exterior configuration of aircraft. Also described in this chapter are common internal markings and standardized international markings.
TO 1-1-8 8.1.12 Service Tests. Approved service test programs will be implemented by coordinated effort, monitored by the appropriate engineering function, SPD, AFRL, and the requesting MAJCOM. 8.1.13 Decals. Decals are special prepared film containing design, words, letters, or numerals and are intended to be permanently affixed to the aircraft. Decals may be used in lieu of paint for all external markings and insignia where the contact surfaces are of sufficient smoothness to permit good adhesion.
TO 1-1-8 8.2.4.3 In the absence of a tailored weapon system paint plan the above criteria will apply to all aircraft. 8.2.5 Camouflage. Camouflage is used for the purpose of deception, to conceal material from undesired observation, or to confuse and mislead observers as to the identity and number of assets available. Camouflage may be either pattern or non-pattern. Pattern camouflaging is based on optical principals that dictate certain non-reflective colors, color configurations and color portions.
TO 1-1-8 Table 8-1. Standard Markings Item General Location National Star Insignia “USAF” Marking “U.S. AIR FORCE” Marking Serial Number Aircraft Radio Call Number American Flag Aircraft Aircraft Aircraft Aircraft Aircraft Aircraft Table 8-2.
TO 1-1-8 Table 8-3. Aircraft Authorized United States of America Markings - Continued 76th Airlift Squadron USAFE E-4 Aircraft 8.3.6.1 In the event radio call number will contract year followed provide five numerals become 30023). five numerals are not available the include the second numeral of the by a sufficient number of zeros to (e.g., serial number 73-23A will 8.3.6.
TO 1-1-8 Table 8-4. Aircraft Authorized Multi-Colored Blade Tip Markings Air Attache MAAG USAF Mission 89th Airlift Wing 8.4.6 Helicopter Main Rotor Blade Markings. Classification numbers shall be stenciled on the inboard (butt end), flat surface of the ground side of each main rotor blade by facilities authorized to balance and alter the rotor blades.
TO 1-1-8 8.4.13 Markings for Tank Filler Areas. Fuel filler caps shall be painted red. A red band, one inch wide, around and two inches away from the fuel fill cap or over the cover door is optional. 8.4.14 Marking of Emergency Lighting (Flashlight) for Cargo &Transport Aircraft. Aircraft which have flashlights adjacent to natural or emergency exits will have a 1/2 inch yellow band around the base of the flashlight mount.
TO 1-1-8 8.5 ESTABLISHING REQUIREMENTS FOR MISSION ACTIVITY, CREW ACCOMPLISHMENT, AND ESPRIT DE CORPS INSIGNIA AND MARKINGS. Markings which reflect mission activity, crew accomplishment and esprit de corps are allowed at the discretion and 8-8 Change 3 final approval of the senior logistics official in each MAJCOM. A copy of all approved markings should be forwarded to HQ USAF/A4.
TO 1-1-8 APPENDIX A SHELF-LIFE EXTENSION PROCEDURES A.1 GENERAL TESTING PROCEDURES. WR-ALC/MXRE is the AF executive agent for the Shelf-Life Extension Data (SLED) program, reference AFMAN 23-110. The SLED program is managed by WR-ALC/MXRE at Robins AFB, GA (HQ USAF/SLED; DSN 468-0464, COM (478) 926-0464 or FAX (478) 926-0464 or FAX DSN 468-0464. Under their authority the following test procedures are provided for the testing of the most commonly used coatings in this technical order under the 8010 NSC.
TO 1-1-8 within five hours, and dry-hard (finger applied with reasonable force and turned with no deformation of coating) within eight hours after spray application. A.2.4 Surface Appearance. When sprayed on a vertical surface to a thickness of 0.0006 to 0.0018 inch, the primer coating shall not sag, run, or streak, and shall dry to a smooth, uniform surface free from grit, seeds, craters, blisters, and other irregularities. A.3 MIL-PRF-85582 WATERBORNE EPOXY PRIMER. A.3.1 Condition in the container.
TO 1-1-8 turer’s instructions (measuring each component), and spray the coating on the test panels. Test panels shall be aluminum measuring approximately 3 in x 6 in. A.6 NOTE For this coating test panels must be primed with either MIL-PRF-23377 or MIL-PRF-85582 primer applied to a thickness of 0.0006 to 0.0009 inch.
TO 1-1-8 APPENDIX B STANDARD AIR FORCE AIRCRAFT MARKINGS B.1 NATIONAL STAR INSIGNIA. (4) The National Star Insignia selected for the wing shall not exceed a maximum diameter of 60 inches nor have a minimum diameter of less than 20 inches (excluding border). The diameter of the circumscribed circle will be the standard size closest to but not exceeding 75% of the distance between the wing leading edge and the moveable surface cut-out at the point of application. a. Dimensions. (Figure B-1.
TO 1-1-8 Figure B-1.
TO 1-1-8 Figure B-2.
TO 1-1-8 Figure B-3.
TO 1-1-8 Figure B-4. Typical Marking For Paint Facility/Finish Identification Block NOTE For non-standard and unique coatings, such as APC, add manufacture product code.
TO 1-1-8 Figure B-5.
TO 1-1-8 Figure B-6.
TO 1-1-8 Figure B-7.
TO 1-1-8 Figure B-7.
TO 1-1-8 Figure B-8. Figure B-9.
TO 1-1-8 Figure B-10. Figure B-11.
TO 1-1-8 Figure B-12.
TO 1-1-8 APPENDIX C RESPIRATOR PROTECTION EQUIPMENT C.1 INTRODUCTION. Table C-1 provides a list of respirator equipment and related materials for use in aircraft, missile, and equipment corrosion prevention and control processes. This table provides only general information for respiratory safety devices. See the manufacturer’s technical data for detailed operating maintenance instructions. See the DO43 System for proper NSNs and to convert part numbers to NSNs.
C-2 Change 1 4240-01-247-8929 Open Purchase 4240-01-248-4634 4240-01-248-6435 4240-01-455-2787 Full Facepiece Respirator, Air Filtering (w/o Cartridges or Retainers) Full Facepiece Respirator, Air Filtering (w/o Cartridges or Retainers) Half Facepiece Respirator, Air Filtering (w/o Cartridges or Retainers) Filter Cartridges (Organic Vapor/ P100 Type) 3M Co. (Cage Code Respirator Lens Assembly #50378) for 3M Co. Full Facepiece Respirators (With Plastic PN 7884 Film Covers) PN 6898 3M Co.
Pump/Compressor, Breathable Air, Pneumatic (Air Motor) Driven, Portable 13 PN ADP-16/ADP-20 PN NF-1100 Bullard Co. (Cage Code #09729) Rhine Air, Inc. (Cage Code #58501) PN 504 3M Co. (Cage Code #50378) 4310-01-168-7302 4240-01-363-4699 4240-01-372-3078 3M Co. (Cage Code #50378) 12 4240-01-395-4128 PN 7925 11 Respirator Cleaning Wipes (Alcohol-Free Towelettes) 4240-01-455-2346 Spectacle Kit for 3M Co. Full Facepiece Respirators PN 6878 10 PN 7915-5 Tyvek™ Shroud for 3M Co.
C-4 Nomenclature Specifications/Part Number NOTE National Stock Number Unit Issue Respirator Protection Equipment - Continued Intended Use Change 1 Replacement Filter Cartridges for Breathable Air Pumps Compressed Air Inlet Hose Assembly, 1/2 in ID Hose Quick Disconnect Fittings for Inlet Hose Outlet Manifold, Quick Disconnect (Female Coupler Assembly) 14 15 16 17 4240-01-251-8159 4240-01-251-8160 4240-01-084-0921 PN ED-06-430 Rhine Air, Inc (Cage Code #58501) Open Purchase PN 3L25 (Male
TO 1-1-8 GLOSSARY A ACCELERATOR — A substance which speeds up the polymerization of a synthetic resin. ACRYLIC RESIN — Any of a group of transparent thermo-plastic resins formed by polymerizing esters of acrylic acid or methacrylic acid. ALIPHATIC — An organic chemical whose carbon atoms are not in a ring form. A straight-chain compound. Mineral spirits, some naphthas, and kerosene are typical aliphatic compounds.
TO 1-1-8 C CASE HARDENING — The formation of a hardened top surface with a soft underbody. Proper relative humidity conditions within the drying room will assist in eliminating this condition. CATALYST — A substance which changes the rate of a chemical reaction without itself undergoing permanent change in its composition. CHALKING — Deterioration of an organic coating upon exposure that results in a powdery, chalky residue on a painted surface.
TO 1-1-8 DRYING TIME — The time required for a coating to attain various stages of dryness. Three commonly referred to drying times are: dry to touch, dry to handle and dry hard (recoat). Drying time is greatly affected by temperature, humidity, and air movement. DUST COAT — a very light coat of a coating, which will improve adhesion. E EMULSION — An intimate suspension of two or more liquid substances which are not mutually soluble but which do not ordinarily separate.
TO 1-1-8 INTERCOAT — A layer of paint that is “sandwiched” between two others. Also refers to something occurring between coats, as in “intercoat adhesion”. L LATEX — A water suspension of fine particles of rubber or rubber-like materials. LEVELING — The degree to which a film will smooth out after application is its leveling ability. Improper solvent or driers may prevent proper leveling. LEAFING — The ability of an aluminum or gold bronze paint to exhibit a brilliant or silvery appearance.
TO 1-1-8 thick a coating can result in pock marks. To overcome this condition, apply thinner coatings, use less air pressure, and use a high solvency thinner. POLYMER — A substance composed of large molecules formed by the combination of a number of simple molecules with one another by chemical reaction. PRIMER — A coating applied directly to the basic metal or pretreated metal and upon which a subsequent coating or topcoat is applied. PSI — Pounds per square inch.
