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Auto Refinishing Project ACaseStudy
What Is EPA's Design for
the Environment (DfE)
Automotive Refinishing
Partnership?
EPA's DfE Program forms
partnerships to reduce risk to
people and the environment through pollution
prevention. DfE has been working with the
automotive refinishing industry since 1997 to identify
and promote safer, cleaner, and more efficient
practices and technologies. The DfE team conducts
best practices workshops and site visits for collision
repair businesses and schools. A best practices
outreach kit, checklists, fact sheets, case studies,
health and safety information, and links to numerous
resources are available on the DfE web site at
http://www.epa.gov/dfe/pubs/proiects/auto.
A Switch to Waterborne Is on the Rise!
Switching to waterborne
from solvent-based
automotive refinishing
paints is becoming more
popular in the U.S. for
health and environmental
reasons, as well as stricter
environmental regulations in
California and Canada.
Original equipment
manufacturers (OEMs) and
collision repair shops in
Europe and some OEMs in
the United States already
use waterborne paints extensively.
Larry Visser, the owner of Visor's Collision Center in
Chicago, switched to waterborne basecoats in 2005
and learned a number of valuable lessons along the
way. This case study shares Larry's story and may
help you decide if your shop is ready to make a
switch from solvent-based to waterborne basecoats.
Should You Consider a Switch?
Larry successfully switched to waterborne basecoats
and liked the results, which include:
. Increased productivity: Fewer coats—and less
time—are required to complete a job. As a result,
Larry reports that he gets more jobs completed per
week and uses less paint. Waterborne basecoats
may cost more than solvent basecoats but,
according to Larry, "the cost is more than offset by
the increase you'll see in worker productivity and
the money you'll save by purchasing less paint."
. Painter Retention: Initially, Larry found it difficult
to convince his painter that switching to waterborne
basecoats was a good thing. Now, Larry's painter
actually prefers using waterborne basecoats and
enjoys a cleaner environment. Larry believes his
painter is unlikely to leave his shop to work for a
shop that still uses solvent basecoats.
. Reduced insurance costs: Waterborne
basecoats are less flammable and less toxic than
solvent-based paints. Larry believes this was a
factor in lowering his shop's insurance premiums.
. Staying ahead of the regulatory curve: Larry
finds it easier to comply with current federal and
state regulations limiting volatile organic
compounds (VOCs). By switching to waterborne
basecoats, Larry's shop has a head start in
complying with future regulations that require
further reductions of VOCs and/or hazardous air
pollutants (HAPs).
. Customer satisfaction. There is some evidence
that waterborne basecoats provide a more durable
finish (e.g., less brittle and more chip resistant) than
solvent-based finishes—an improvement Larry's
customers appreciate. Larry's customers also like
the color match of waterborne basecoats with the
OEM's finish on their vehicle.
May 2008
www.epa.gov/dfe
EPA 744-F-08-003
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Benefits of Waterborne Paints
Larry discovered that the benefits of waterborne
basecoats stretch far beyond business—they make
sense for worker health and safety, as well as the
environment. Solvent-based automotive paints
contain VOCs and hazardous air pollutants that
contribute to air pollution and cause numerous
adverse health effects, including eye/skin irritation,
and central nervous system effects. Organic solvents
may also damage the liver and kidneys, and cause,
cancer, respiratory, reproductive and other effects.
Waterborne paints contain much lower levels of
organic solvents and are less toxic than solvent-
based paints. However, automotive paint
manufacturers stress that automotive paints should
always be used by professionals, along with proper
control technologies and protective equipment to
minimize emissions of air toxics and prevent
respiratory, eye, and dermal exposures. In addition,
some basecoats still contain lead and hexavalent
chromium pigments.
Waterborne coatings, along with lead-free and
chromium-free paints, are safer choices for the
workplace and the environment!
Warning! Automotive paints contain isocyanates
(and polyisocyanates), the hardeners or catalysts in
clear coats and some primers. Isocyanates are
strong dermal and lung sensitizers and the leading
cause of occupational asthma, so protect your skin
and lungs from exposure to paints containing
isocyanates.
The Scene: Visser's Collision Center
Larry's shop, Visser's Collision Center, is a medium-
sized collision repair shop in the Chicago area with
two painters. The shop performs 15 to 20 jobs a
week and uses the Standox® paint system.
Larry's shop caters to high-end vehicles such as
Mercedes and has been using waterborne basecoats
since 2005. Larry
decided to switch
to waterborne
basecoats for
several reasons
after his paint
supplier recommended that his shop should try
waterborne technology. Larry wanted to protect his
workers from solvent exposures and he wanted to
make the switch for business purposes—he feels that
waterborne basecoats will become the trend in the
industry. Larry wants to be one step ahead of the
curve. Since the paint supplier encouraged Larry to
make the switch, Larry seized the opportunity and
took full advantage of the supplier's free training and
support.
Training your painter and following the paint
manufacturer's guidelines are keys to success!
Larry and his painters worked closely with the paint
supplier. The supplier came to the shop for two
weeks to provide training for his painters and to set
up the shop for use of waterborne basecoats. Today,
both Larry and his painters are happy with the results
and glad that they made the switch.
A Successful Conversion to Waterborne
Many shops can successfully use waterborne
automotive paints. If you have a well maintained, clean
shop and dedicated and talented workers, you should
consider using waterborne technology. As Larry
observed, "the switch to waterborne basecoats was
fairly easy with the help of my paint supplier and the
dedication of my painters. The product has saved
time and increased productivity and protects the
health of my workers and the community."
The Challenges...
Although sold on a switch to waterborne basecoats,
Larry still faced several challenges to get the new
system up and running, as described below.
• Booth Modifications: Waterborne basecoats need
heat and additional airflow to dry properly. Larry
retrofitted his two existing spray booths with
Junair's QADs™ auxiliary air movement system,
which provides additional blowers and heat to
existing spray booths that are required for
waterborne systems. The estimated cost to retrofit
one spray booth is approximately $25,000. Larry
says that spray booth filter maintenance is very
important, since clogged filters interfere with the
Note: The mention or illustration of any product or company does not constitute an endorsement by the U.S.
Environmental Protection Agency.
EPA 744-F-08-003
www.epa.gov/dfe
Page 2
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booth's airflow and affect the drying process.
Occasionally, a shop can also use a portable
blower to provide additional air movement for small
jobs and cut-ins.
V
Photo provided courtesy of Junair Americas
Adjustments to Spraying Technique:
Waterborne basecoats cover and dry differently
than conventional coatings. Waterborne basecoats
also differ in their viscosity, making them
particularly sensitive to changes in temperature and
humidity. To compensate for these differences,
Larry purchased new spray guns with the proper
spray tips (1.0-1.3 mm) and his painters adjusted
their spraying technique and drying time depending
on temperature and humidity. Larry's painters
adjusted quickly and felt comfortable with the
spraying technique after only one week of training
by the paint supplier. Larry also discovered that
waterborne basecoats require only one to two coats
to provide coverage and the color matching was
excellent. However, since fewer coats are needed,
it can be more challenging to achieve a proper
blend. Because fewer coats also mean that less
paint is needed per job, Larry's painters have
learned how to adjust the amount of paint to mix for
each job.
Disposal of Used Cleaning Water and Paint
Waste: Spray guns and other equipment in contact
with waterborne basecoats must be cleaned with
water between each color change. Used cleaning
water must be disposed of as hazardous waste.
Larry's shop set up a separate collection drum for
this wastewater and contracted with a new
hazardous waste hauler to take it away. Larry
noted that it was a challenge to determine the
proper disposal of this wastewater. However, he
found a new hazardous waste hauler that handles
both his wastewater and other hazardous waste
generated at his shop.
Always check with local authorities about proper
handling, storage, and disposal of hazardous
waste.
• Mixing Room Modifications: Generally,
waterborne basecoats must be maintained at a
temperature above 55°F, or the shelf life is
significantly reduced. This created a significant
challenge for Larry because the room gets fairly
cold over night and on weekends during the winter
months. Keeping potential fire hazards in mind,
Larry is considering adding heat to the space or
other paint storage options as a long-term fix.
Photo provided courtesy of DuPont Performance Coatings
Note: The mention or illustration of any product or company does not constitute an endorsement by the U.S.
Environmental Protection Agency.
EPA 744-F-08-003
www.epa.gov/dfe
Page 3
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The Regulatory Landscape
In the U.S., some state and local jurisdictions are
taking the lead in regulating automotive refinishing
emissions. California and several northeastern states
have developed practice standards for shops in
selected air districts to reduce VOC emissions.
Canada is also requiring a switch to waterborne
basecoats. Keeping on top of the regulatory
landscape can help you decide if the time is right to
switch to waterborne basecoats.
How Can I Get More Information on Switching
to Waterborne Basecoats?
Talk to your paint and equipment suppliers and ask
them to determine if your shop is a candidate for
waterborne technology. Visit a facility that uses
waterborne technology. Read about waterborne
conversions in the trade press and on paint
manufacturer's web sites. Take the first step!
Design for the Environment
Auto Refinish Project
www.epa.gov/dfe/pubs/projects/auto/
For additional information, visit the DfE Auto
Refinishing Partnership website at
http://www.epa.gov/dfe/pubs/proiects/auto
and the virtual auto body shop on the CCAR-
Greenlink website at http://www.ccar-
qreenlink.orq/cshops.
Taking the First Steps
If you decide to make the switch to waterborne basecoats, take these initial steps to make this change:
1. Contact your paint supplier about waterborne basecoat options and training opportunities. Your painters will need
training on how to effectively spray waterborne coatings, including use of spray gun tips that provide a larger spray fan
for applying thinner coats.
2. Evaluate your shop's equipment, especially the spray booth, and make the appropriate upgrades. The key to optimal
drying of waterborne paints is in the temperature, humidity, and air movement over the surface. One source suggests
uniform air flows of at least 11,000 cfm, sufficient heating, and clean air, among other factors. You may need to retrofit
your existing booth, use portable blowers, or a combination.
3. Spray gun passages and paint cups should be constructed from corrosion-resistant materials (e.g., stainless steel or
plastic). Consider replacing your aluminum cups with single-use/disposable plastic cups.
4. Evaluate your shop's air supply and filtration system. Compressed air used in spraying waterborne coatings, as well
as the hoses, must be very clean and free of any lubricating oil residues. Even a minute quantity of oil can
contaminate the coating.
5. Using dedicated spray guns and cleaning systems for waterborne vs. solvent-based coatings is highly recommended,
due to the different cleaning methods and waste streams generated by each.
Note: The mention or illustration of any product or company does not constitute an endorsement by the U.S.
Environmental Protection Agency.
EPA 744-F-08-003
www.epa.gov/dfe
Page 4
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