Ala. Admin. Code r. 335-3-6-.11

Current through Register Vol. 43, No. 1, October 31, 2024

Section 335-3-6-.11 - Surface Coating

(1)Can Coating.

(a) For the purpose of this paragraph, the following definitions apply:

1. "End Sealing Compound" shall mean a synthetic rubber compound which is coated onto can ends and which functions as a gasket when the end is assembled on the can.

2. "Exterior Base Coating" shall mean a coating applied to the exterior of a can to provide exterior protection to the metal and to provide background for the lithographic or printing operation.

3. "Interior Base Coating" shall mean a coating applied by roller coater or spray to the interior of a can to provide a protective lining between the can metal and product.

4. "Interior Body Spray" shall mean a coating sprayed on the interior of the can to provide a protective film between the product and the can.

5. "Overvarnish" shall mean a coating applied directly over ink to reduce the coefficient of friction, to provide gloss, and to protect the finish against abrasion and corrosion.

6. "Three-Piece Can Side-Seam Spray" shall mean a coating sprayed on the exterior and interior of a welded, cemented, or soldered seam to protect the exposed metal.

7. "Two-Piece Can Exterior End Coating" shall mean a coating applied by roller coating or spraying to the exterior of a can to provide protection to the metal.

(b) This paragraph will apply to coating applicator(s) and oven(s) of sheet, can, or end coating lines involved in sheet basecoat (exterior and interior) and overvarnish; two-piece can exterior (basecoat and overvarnish); two-piece and three-piece can interior body spray; two-piece can exterior end (spray or roll coat); three-piece can side-seam spray and end sealing compound operations.

(c) No owner or operator of a can coating line subject to this paragraph shall cause, allow, or permit the discharge into the atmosphere of any VOCs in excess of:

1. 0.34 kilograms per liter of coating (2.8 pounds per gallon), excluding water, delivered to the coating applicator from sheet basecoat (exterior and interior) and overvarnish or two-piece can exterior (basecoat and overvarnish) operations.

2. 0.51 kilograms per liter of coating (4.2 pounds per gallon), excluding water, delivered to the coating applicator from two-piece and three-piece can interior body spray and two-piece can exterior end (spray or roll coat) operations.

3. 0.66 kilograms per liter of coating (5.5 pounds per gallon), excluding water, delivered to the coating applicator from three-piece can side seam spray operations.

4. 0.44 kilograms per liter of coating (3.7 pounds per gallon), excluding water, delivered to the coating applicator from end sealing compound operations.

(2)Coil Coating.

(a) For the purpose of this paragraph, the following definitions apply:

1. "Coil Coating" shall mean the coating of any flat metal sheet or strip that comes in rolls or coils.

2. "Quench Area" shall mean a chamber where the hot metal exiting the oven is cooled by either a spray of water or a blast of air followed by water cooling.

(b) This paragraph, will apply to the coating applicator(s), oven(s), and quench area(s) of coil coating lines involved in prime and top coat or single coat operations.

(c) No owner or operator of a coil coating line subject to this paragraph, may cause, allow, or permit the discharge into the atmosphere of VOCs in excess of 0.31 kilograms per liter of coating (2.6 pounds per gallon), excluding water, delivered to the coating applicator from prime and topcoat or single coat operations.

(3)Metal Furniture Coating.

(a) For the purpose of this paragraph, the following definitions apply:

1. "Application Area" shall mean the area where the coating is applied by spraying, dipping, or flowcoating techniques.

2. "Metal Furniture Coating" shall mean the surface coating of any furniture made of metal or any metal part which will be assembled with other metal, wood, fabric, plastic, or glass parts to form a furniture piece.

(b) This paragraph, will apply to the application areas, flashoff area(s), and oven(s) of metal furniture coating lines involved in prime and topcoat or single coating operations.

(c) No owner or operator of a metal furniture coating line subject to this paragraph, may cause, allow, or permit the discharge into the atmosphere of any VOCs in excess of 0.36 kilograms per liter of coating (3.0 pounds per gallon), excluding water, delivered to the coating applicator from prime and topcoat or single coat operations.

(4)Surface Coating of Large Appliances.

(a) For the purpose of this paragraph, the following definitions apply:

1. "Application Area" shall mean the area where the coating is applied by spraying, dipping, or flowcoating techniques.

2. "Single Coat" shall mean a single film of coating applied directly to the metal substrate omitting the primer application.

3. "Large Appliances" shall mean doors, cases, lids, panels, and interior support parts of residential and commercial washers, dryers, ranges, refrigerators, freezers, water heaters, dishwashers, trash compactors, air conditioners, and other similar products.

(b) This paragraph, will apply to application area(s), flashoff area(s), and oven(s) of large appliance coating lines involved in prime, single, or topcoat coating operations.

(c) This paragraph, will not apply to the use of quick-drying lacquers for repair of scratches and nicks that occur during assembly, provided that the volume of coating does not exceed 757 liters (200 gallons) in any one year.

(d) No owner or operator of a large appliance coating line subject to this paragraph, may cause, allow, or permit the discharge into the atmosphere of any VOCs in excess of 0.34 kilograms per liter of coating (2.8 pounds per gallon), excluding water, delivered to the coating applicator from prime, single, or topcoat coating operations.

(5)Automobile and Light Duty Truck Manufacturing.

(a) For the purpose of this paragraph, the following definitions apply:

1. "Application Area" shall mean the area where the coating is applied by dipping or spraying.

2. "Manufacturing Plant" shall mean a facility where automobile and truck bodies are manufactured and/or finished for eventual assembly into a finished product ready for sale to vehicle dealers. Customizer, body shops, and other repainters are not part of this definition.

3. "Automobile" shall mean all passenger cars or passenger car derivations capable of seating 12 or fewer passengers.

4. "Light-Duty Trucks" shall mean any motor vehicles rated at 3,864 kilograms (8,500 pounds) gross weight or less which are designed primarily for the purpose of transportation or are derivatives of such vehicles.

(b) This paragraph will apply to the application area(s), flashoff area(s), and oven(s) of automotive and light-duty truck manufacturing plants involved in prime, topcoat, and final repair coating operations.

(c) No owner or operator of an automobile or light-duty manufacturing plant subject to this pargraph may cause, allow, or permit the discharge into the atmosphere of any VOCs in excess of:

1. 0.23 kilograms per liter of coating (1.2 pounds per gallon), excluding water, delivered to the applicator from prime application, flashoff area, and oven operations.

2. 0.34 kilograms per liter of coating (2.8 pounds per gallon), excluding water, delivered to the applicator from surface application, flashoff area, and oven operations.

3. 0.34 kilograms per liter of coating (2.8 pounds per gallon), excluding water, delivered to the applicator from topcoat application, flashoff area, and oven operations.

4. 0.58 kilograms per liter of coating (4.8 pounds per gallon), excluding water, delivered to the applicator from final repair application, flashoff area, and oven operations.

(6)Paper Coating.

(a) For the purpose of this paragraph, the following definitions apply:

1. "Knife Coating" shall mean the application of a coating material to a substrate by means of drawing the substrate beneath a knife that spreads the coating evenly over the full width of the substrate.

2. "Paper Coating" shall mean coatings put on paper and pressure sensitive tapes regardless of substrate. Related web coating processes on plastic film and decorative coatings on metal foil are included in this definition.

3. "Roll Coating" shall mean the application of a coating material to a substrate by means of hard rubber or steel rolls.

4. "Rotogravure Coating" shall mean the application of a coating material to a substrate by means of a roll coating technique in which the pattern to be applied is etched on the coating roll. The coating material is picked up in these recessed areas and is transferred to the substrate.

(b) This paragraph will apply to roll, knife, or rotogravure coater(s) and drying ovens of paper coating lines.

(c) No owner or operator of a paper coating line subject to this paragraph may cause, allow, or permit the discharge into the atmosphere of any VOCs in excess of 0.35 kilograms per liter of coating (2.9 pounds per gallon), excluding water, delivered to the coating applicator from a paper coating line.

(7)Fabric and Vinyl Coating.

(a) For the purpose of this paragraph, the following definitions apply:

1. "Fabric Coating" shall mean the coating of a textile substrate with a knife, roll, or rotogravure coater to impart properties that are not initially present, such as strength, stability, water or acid repellancy, or appearance.

2. "Knife Coating" shall mean the application of a coating material to a substrate by means of drawing the substrate beneath a knife that spreads the coating evenly over the full width of the substrate.

3. "Roll Coating" shall mean the application of a coating material to a substrate by means of hard rubber or steel rolls.

5. "Vinyl Coating" shall mean to apply a decorative or protective topcoat or printing on vinyl coated fabric or vinyl sheets.

(b) This paragraph will apply to roll, knife, or rotogravure coater(s) and drying ovens of fabric and vinyl coating lines.

(c) No owner or operator of a fabric coating line or a vinyl coating line subject to this paragraph may cause, allow, or permit discharge into the atmosphere of any VOCs in excess of;

1. 0.35 kilograms per liter of coating (2.9 pounds per gallon), excluding water, delivered to the coating applicator from a fabric coating line.

2. 0.45 kilograms per liter of coating (3.8 pounds per gallon), excluding water, delivered to the coating applicator from a vinyl coating line.

(8)Magnet Wire Coating.

(a) For the purpose of this paragraph, the following definition applies:

"Magnet Wire Coating" shall mean the process of applying a coating of electrically insulating varnish or enamel to aluminum or copper wire for use in electrical machinery.

(b) This paragraph will apply to oven(s) of magnet wire coating operations.

(c) No owner or operator of a magnet wire coating oven subject to this paragraph may cause, allow, or permit the discharge into the atmosphere of any VOCs in excess of 0.20 kilograms per liter of coating (1.7 pounds per gallon), excluding water, delivered to the coating applicator from magnet wire coating operations.

(9)Compliance Methods.

(a) The emission limits under this Rule shall be achieved by:

1. the application of low solvent content coating technology; or

2. incineration, provided that ninety percent (90%) of the nonmethane volatile organic compounds (VOC measured as total combustible carbon) which enter the incinerator are oxidized to carbon dioxide and water; or

3. a system demonstrated to have control efficiency equivalent to or greater than provided under subparagraphs (a)1. or (a)2. of this paragraph and approved by the Director; or

(b) the design, operation, and efficiency of any capture system used in conjunction with subparagraphs (a)2. and (a)3. of this paragraph shall be certified by the owner or operator and approved by the Director.

(10)Flatwood Paneling.

(a) For the purpose of this paragraph, the following definitions apply:

1. "Class II Hardboard Paneling Finish" shall mean finishes which meet the specifications of Voluntary Product Standard PS-59-73 as approved by the American National Standards Institute.

2. "Hardboard" shall mean a panel manufactured primarily from inter-felted ligno-cellulosic fibers which are consolidated under heat and pressure in a hot press.

3. "Hardwood Plywood" shall mean plywood whose surface layer is a veneer of hardwood.

4. "Natural Finish Hardwood Plywood Panels" shall mean panels whose original grain pattern is enhanced by essentially transparent finishes frequently supplemented by fillers and toners.

5. "Thin Particleboard" is a manufactured board 1/4 inch or less in thickness made of individual wood particles which have been coated with a binder and formed into flat sheets by pressure.

6. "Printed Interior Panels" shall mean panels whose grain or natural surface is obscured by fillers and basecoats upon which a simulated grain or decorative pattern is printed.

7. "Tileboard" shall mean paneling that has a colored waterproof surface coating.

8. "Coating Application System" shall mean all operations and equipment which apply, convey, and dry a surface coating, including, but not limited to, spray booths, flow coaters, conveyors, flashoff areas, air dryers, and ovens.

(b) This paragraph applies to all flatwood manufacturing facilities that manufacture the following products:

1. printed interior panels made of hardwood, plywood, and thin particleboard;

2. natural finish hardwood plywood panels; or

3. hardboard paneling with Class II finishes.

(c) This paragraph does not apply to the manufacture of exterior siding, tileboard, or particleboard used as a furniture component.

(d) No owner or operator of a flatwood manufacturing facility subject to this paragraph shall emit VOCs from a coating application system in excess of:

1. 2.9 kilograms per 100 square meters of coated finished product (6.0 pounds per 1,000 square feet) from printed interior panels, regardless of the number of coats applied;

2. 5.8 kilograms per 100 square meters of coated finished product (12.0 pounds per 1,000 square feet) from natural finish hardwood plywood panels, regardless of the number of coats applied; and

3. 4.8 kilograms per 100 square meters of coated finished product (10.0 pounds per 1,000 square feet) from Class II finishes on hardboard panels, regardless of the number of coats applied.

(11)Miscellaneous Metal Parts and Products

(a) For the purpose of this paragraph, the following definitions apply:

1. "Air Dried Coating" shall mean coatings which are dried by the use of air or forced warm air at temperatures up to 90° C (194° F).

2. "Clear Coat" shall mean a coating which lacks color and opacity or is transparent and uses the undercoat as a reflectant base or undertone color.

3. "Coating Application System" shall mean all operations and equipment which applies, conveys, and dries a surface coating, including, but not limited to, spray booths, flow coaters, flashoff areas, air dryers and ovens.

4. "Extreme Environmental Conditions" shall mean exposure to any one of the following; the weather all of the time, temperatures consistently above 95° C (203° F), detergents, abrasive and scouring agents, solvents, corrosive atmospheres, or similar environmental conditions.

5. "Extreme Performance Coatings" shall mean coatings designed for harsh exposure or extreme environmental conditions.

6. "Heat Sensitive Material" shall mean materials which cannot consistently be exposed to temperatures greater than 95° C (203° F).

7. "Low Solvent Coating" shall mean coatings which contain less organic solvent than the conventional coatings used by the industry. Low solvent coatings include water-borne, higher solids, electrodeposition and powder coatings.

8. "Single Coat" shall mean one film of coating applied to a metal surface.

9. "Transfer Efficiency" shall mean the portion of coating which adheres to the metal surface during the application process, expressed as a percentage of the total volume of coating delivered by the applicator.

(b) This paragraph applies to coating of miscellaneous metal parts and products in the following industries:

1. Large farm machinery (harvesting, fertilizing and planting machines, tractors, combines, etc.);

2. Small farm machinery (lawn and garden tractors, lawn mowers, rototillers, etc.);

3. Small appliances (fans, mixers, blenders, crock pots, dehumidifiers, vacuum cleaners, etc.);

4. Commercial machinery (office equipment, computers and auxiliary equipment, typewriters, calculators, vending machines, etc.);

5. Industrial machinery (pumps, compressors, conveyor components, fans, blowers, transformers, etc.);

6. Fabricated metal products (metal covered doors, frames, etc.); and

7. Any other industrial category which coats metal parts or products under the Standard Industrial Classification Code of Major Group 33 (primary metal industries), Major Group 34 (fabricated metal products), Major Group 35 (nonelectric machinery), Major Group 36 (electrical machinery), Major Group 37 (transportation equipment), Major Group 38 (miscellaneous instruments), and Major Group 39 (miscellaneous manufacturing industries).

(c) This paragraph does not apply to the surface coating of the following metal parts and products:

1. automobiles and light-duty trucks;

2. metal cans;

3. flat metal sheets and strips in the form of rolls or coils;

4. magnet wire for use in electrical machinery;

5. metal furniture;

6. large appliances;

7. exterior of airplanes;

8. automobile refinishing;

9. customized coating of automobiles and trucks, if production is less than 35 vehicles per day; and

10. exterior of marine vessels.

(d) This paragraph applies to the application area(s), flashoff area(s), air and forced air dryer(s) and oven(s) used in the surface coating of the metal parts and products in subparagraph (b) of this paragraph. This paragraph also applies to prime coat, top coat, and single coat operations.

(e) No owner or operator of a facility engaged in the surface coating of miscellaneous metal parts and products may operate a application system subject to this paragraph that emits VOCs in excess of:

1. 0.52 kilograms per liter (4.3 pounds per gallon) of coating, excluding water, delivered to a coating applicator that applies clear coatings;

2. 0.42 kilograms per liter (3.5 pounds per gallon) of coating, excluding water, delivered to a coating applicator in a coating application system that is air dried or forced warm air dried at temperatures up to 90° C (194° F);

3. 0.42 kilograms per liter (3.5 pounds per gallon) of coating, excluding water, delivered to a coating applicator that applies extreme performance coatings; and,

4. 0.36 kilograms per liter (3.0 pounds per gallon) of coating, excluding water, delivered to a coating applicator for all other coatings and coating application systems.

Author: Wm. Gerald Hardy

Ala. Admin. Code r. 335-3-6-.11

Effective Date: November 26, 1979. Amended: April 19, 1984. Amended: Filed October 17, 1996; effective November 21, 1996.

Statutory Authority:Code of Ala. 1975, §§ 22-28-14, 22-22A-5, 22-22A-6, 22-22A-8.