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com

TO 35-1-3
TECHNICAL MANUAL

CORROSION PREVENTION AND CONTROL, CLEANING,

PAINTING, AND MARKING OF USAF SUPPORT
EQUIPMENT (SE)

This manual supersedes TO 35-1-3 dated 1 September 2006, Change 10 dated 5 August 2013.

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited. PA Case Number 05-07173. Other requests for this
document shall be referred to 406 SCMS/GUEE, Robins AFB, GA 31098. Questions concerning technical content shall be referred to AFRL/
RXSSR.

Published Under Authority of the Secretary of the Air Force

26 APRIL 2014
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INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES NOTE The portion of the text affected by the changes is indicated by a vertical line in the outer margins 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. . . . . . .26 April 2014
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A USAF
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TABLE OF CONTENTS
Chapter Page Chapter Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . v 1.7.1 Uniform Etch Corrosion . . . . . . . . 1-9

1.7.2 Galvanic Corrosion. . . . . . . . . . . . 1-9
LIST OF TABLES . . . . . . . . . . . . . . . . . . . . vi 1.7.3 Pitting Corrosion . . . . . . . . . . . . . 1-10
1.7.4 Intergranular Corrosion . . . . . . . . . 1-10
FOREWORD ....................... vii 1.7.5 Exfoliation Corrosion . . . . . . . . . . 1-11
1.7.6 Concentration/Crevice
SAFETY SUMMARY ................. xi Corrosion . . . . . . . . . . . . . . . . 1-11
1.7.7 Stress Corrosion Cracking . . . . . . . 1-12
1 CORROSION THEORY, IDENTIFICATION, 1.7.8 Hydrogen Embrittlement . . . . . . . . 1-12
CAUSES AND EFFECTS . . . . . . . . . . . . 1-1 1.7.9 Corrosion Fatigue. . . . . . . . . . . . . 1-12
1.7.10 Filiform Corrosion . . . . . . . . . . . . 1-13
1.7.11 Fretting Corrosion . . . . . . . . . . . . 1-14
1.1 PURPOSE. . . . . . . . . . . . . . . . . . 1-1
1.8 METALS AFFECTED BY
1.2 DEFINITION OF
CORROSION . . . . . . . . . . . . . 1-14
CORROSION . . . . . . . . . . . . . 1-1
1.8.1 Magnesium . . . . . . . . . . . . . . . . . 1-14
1.3 CHEMICAL DEFINITIONS . . . . . 1-1
1.8.2 Steel. . . . . . . . . . . . . . . . . . . . . . 1-14
1.3.1 Atom . . . . . . . . . . . . . . . . . . . . . 1-1
1.8.3 Aluminum. . . . . . . . . . . . . . . . . . 1-14
1.3.2 Electron . . . . . . . . . . . . . . . . . . . 1-1
1.8.4 Copper and Copper Alloys. . . . . . . 1-14
1.3.3 Ions . . . . . . . . . . . . . . . . . . . . . . 1-1
1.8.5 Stainless Steel . . . . . . . . . . . . . . . 1-15
1.3.4 Electrolyte. . . . . . . . . . . . . . . . . . 1-1
1.8.6 Nickel and Chromium. . . . . . . . . . 1-15
1.4 THEORY OF CORROSION . . . . . 1-1
1.4.1 Anode . . . . . . . . . . . . . . . . . . . . 1-1
1.4.2 Cathode . . . . . . . . . . . . . . . . . . . 1-1 2 CLEANING . . . . . . . . . . . . . . . . . . . . . . . 2-1
1.4.3 Electrolyte. . . . . . . . . . . . . . . . . . 1-1
1.4.4 Electrical Path . . . . . . . . . . . . . . . 1-1 2.1 GENERAL . . . . . . . . . . . . . . . . . 2-1
1.5 DEVELOPMENT OF 2.1.1 Introduction. . . . . . . . . . . . . . . . . 2-1
CORROSION . . . . . . . . . . . . . 1-2 2.1.2 Support Equipment (SE) Wash
1.5.1 Corrosion Origination Cycles . . . . . . . . . . . . . . . . . . 2-1
Locations . . . . . . . . . . . . . . . . 1-2 2.1.3 Definition of Cleaning. . . . . . . . . . 2-1
1.5.2 Corrosion Under Painted 2.1.4 Types of Cleaners. . . . . . . . . . . . . 2-1
Surfaces . . . . . . . . . . . . . . . . . 1-2 2.1.5 Methods of Cleaning . . . . . . . . . . 2-1
1.6 FACTORS INFLUENCING 2.1.6 Cleaning Materials . . . . . . . . . . . . 2-6
CORROSION . . . . . . . . . . . . . 1-4 2.1.7 General Cleaning Material and
1.6.1 Type of Metal . . . . . . . . . . . . . . . 1-4 Processes . . . . . . . . . . . . . . . . 2-11
1.6.2 Dissimilar Metal Coupling (Galvanic 2.1.7.1 Cleaning Solutions . . . . . . . . . . . . 2-11
Corrosion). . . . . . . . . . . . . . . . 1-4 2.1.7.2 Cleaning Compounds . . . . . . . . . . 2-12
1.6.3 Anode and Cathode Surface 2.1.7.3 Water Temperature . . . . . . . . . . . . 2-12
Area. . . . . . . . . . . . . . . . . . . . 1-4 2.1.7.4 Deployed/Remote Sites . . . . . . . . . 2-12
1.6.4 Climate. . . . . . . . . . . . . . . . . . . . 1-4 2.1.8 Cleaning of Non-metal Parts Prior to
1.6.4.1 Desert . . . . . . . . . . . . . . . . . . . . 1-4 Painting . . . . . . . . . . . . . . . . . 2-12
1.6.4.2 Temperate Zones . . . . . . . . . . . . . 1-4 2.1.8.1 Composites . . . . . . . . . . . . . . . . . 2-12
1.6.4.3 Tropics . . . . . . . . . . . . . . . . . . . . 1-4 2.1.8.2 Plastics . . . . . . . . . . . . . . . . . . . . 2-12
1.6.5 Heat Treatment and Grain 2.1.9 Cleaning of Electrical Parts . . . . . . 2-12
Direction. . . . . . . . . . . . . . . . . 1-5 2.1.10 Preparation of SE for Cleaning. . . . 2-13
1.6.6 Electrolytes . . . . . . . . . . . . . . . . . 1-5 2.1.11 Cleaning of Engine Components and
1.6.7 Microbial Induced/Influenced Enclosures. . . . . . . . . . . . . . . . 2-13
Corrosion . . . . . . . . . . . . . . . . 1-7 2.2 MECHANICAL CLEANING . . . . . 2-14
1.6.8 Mechanical Stress. . . . . . . . . . . . . 1-7 2.2.1 General Information . . . . . . . . . . . 2-14
1.6.9 Time . . . . . . . . . . . . . . . . . . . . . 1-7 2.2.2 Coating Removal on Composite
1.6.10 Manufacturing . . . . . . . . . . . . . . . 1-7 Surfaces . . . . . . . . . . . . . . . . . 2-14
1.6.11 Storage . . . . . . . . . . . . . . . . . . . . 1-7 2.2.3 Coating Removal on Metallic
1.6.12 Degradation of Non-metals . . . . . . 1-8 Surfaces . . . . . . . . . . . . . . . . . 2-15
1.6.13 Preventive Maintenance (PM) . . . . 1-8 2.2.4 Grinding . . . . . . . . . . . . . . . . . . . 2-15
1.7 TYPES OF CORROSION . . . . . . . 1-8 2.2.5 Wire Brushing . . . . . . . . . . . . . . . 2-15

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2.2.6 High-Pressure Water (HPW) Paint 3.9 ACOUSTICAL MATERIAL

Removal Method . . . . . . . . . . . 2-15 PRECAUTIONS . . . . . . . . . . . 3-12
2.2.6.1 Authorized HPW Equipment . . . . . 2-15 3.9.1 Coustifoam PUI and AF . . . . . . . . 3-12
2.2.6.2 Training Requirements . . . . . . . . . 2-16 3.9.2 Nonmetallic Fasteners . . . . . . . . . . 3-13
2.2.6.3 Personnel and Equipment Prepara- 3.10 DRAINAGE . . . . . . . . . . . . . . . . 3-13
tion Prior to HPW . . . . . . . . . . 2-16 3.10.1 Fluid Collection Points . . . . . . . . . 3-13
2.2.6.4 HPW Paint Removal Operation . . . 2-16 3.10.2 Modifying Fluid Collection
2.2.6.5 Post HPW Paint Removal Points. . . . . . . . . . . . . . . . . . . 3-13
Cleaning . . . . . . . . . . . . . . . . . 2-16 3.11 MAINTENANCE STAND RAILS
AND RAIL HOLDERS. . . . . . . 3-13
3 PAINTING, SEALING, CORROSION PRE- 3.11.1 Drain Holes. . . . . . . . . . . . . . . . . 3-13
VENTIVE COMPOUND 3.11.2 Drain Hole Corrosion Prevention
APPLICATION . . . . . . . . . . . . . . . . . . . 3-1 and Treatment . . . . . . . . . . . . . 3-13
3.12 HOLLOW STRUCTURAL
3.1 GENERAL . . . . . . . . . . . . . . . . . 3-1 MEMBERS . . . . . . . . . . . . . . . 3-14
3.2 DEFINITION OF EXPOSURE. . . . 3-1 3.12.1 Drainage for Closed Hollow Mem-
3.3 REQUIREMENTS FOR PAINTING bers, When Open Drain Holes are
- FIELD LEVEL . . . . . . . . . . . 3-1 Possible . . . . . . . . . . . . . . . . . 3-14
3.3.1 Corrosion Control Scoring Program 3.12.2 Drainage for Closed Hollow Mem-
and Complete Repainting bers, When Open Drain Holes are
Criteria . . . . . . . . . . . . . . . . . . 3-1 Not Possible . . . . . . . . . . . . . . 3-14
3.3.1.1 Corrosion Scoring . . . . . . . . . . . . 3-1 3.13 CORROSION PREVENTIVE
3.3.1.2 Scoring Categories . . . . . . . . . . . . 3-1 COMPOUNDS (CPC). . . . . . . . 3-14
3.3.2 Abrasive Blasting . . . . . . . . . . . . . 3-2 3.13.1 MIL-PRF-81309. . . . . . . . . . . . . . 3-15
3.3.2.2 Medium Pressure Water 3.13.2 MIL-DTL-85054 . . . . . . . . . . . . . 3-15
Blasting . . . . . . . . . . . . . . . . . 3-2 3.13.3 MIL-PRF-16173 CPC Solvent Cut-
3.3.2.3 Scuff Sand and Overcoat . . . . . . . . 3-2 back, Cold Application . . . . . . . 3-15
3.3.3 Temporary Coating Repairs . . . . . . 3-3 3.13.4 MIL-PRF-63460 Lubricant, Cleaner,
3.3.3.1 Rust Converters . . . . . . . . . . . . . . 3-3 and Preservative for Weapons and
3.3.4 Touch-up Primer . . . . . . . . . . . . . 3-3 Weapon Systems . . . . . . . . . . . 3-15
3.4 REQUIREMENTS FOR PAINTING 3.13.5 MIL-L-87177 Lubricants, Water
- DEPOT LEVEL AND CON- Displacing. . . . . . . . . . . . . . . . 3-15
TRACTOR SUPPORT . . . . . . . 3-3 3.13.6 CPC Methods of Application . . . . . 3-16
3.4.1 Corrosion Rework 3.14 CPC APPLICATION ON FER-
Determination . . . . . . . . . . . . . 3-3 ROUS ALLOYS . . . . . . . . . . . 3-16
3.4.2 Contractor Compliance . . . . . . . . . 3-4 3.15 CPC APPLICATION ON OTHER
3.5 AUTHORIZED COLORS, SEM- ALLOYS . . . . . . . . . . . . . . . . 3-16
PENS, AND MATERIALS . . . . 3-4 3.16 COATING APPLICATIONS . . . . . 3-18
3.5.1 SE Standardized Colors. . . . . . . . . 3-4 3.16.1 Material Selection . . . . . . . . . . . . 3-18
3.5.2 SE Standard Topcoat. . . . . . . . . . . 3-4 3.16.2 SE Surface Preparation
3.5.3 Authorized Colors for Liquid Oxy- Categories . . . . . . . . . . . . . . . . 3-18
gen, Nitrogen, Storage Carts and 3.16.3 Organic Zinc-Rich Primer . . . . . . . 3-18
Tanks . . . . . . . . . . . . . . . . . . . 3-4 3.16.4 MIL-PRF-85285 Polyurethane, Type
3.5.4 Passenger or Loading Ramps . . . . . 3-5 I ...................... 3-19
3.5.5 Presidential Support Equipment and 3.16.5 Thermal Spray Coating
USAF Demo Team . . . . . . . . . . 3-5 Systems . . . . . . . . . . . . . . . . . 3-19
3.6 CORROSION TREATMENT FOR 3.17 FIELD LEVEL MAINTENANCE
STEEL CABLES . . . . . . . . . . . 3-10 PAINTING
3.7 PIANO TYPE HINGES . . . . . . . . 3-10 REQUIREMENTS . . . . . . . . . . 3-21
3.8 MATING SURFACES PROTEC- 3.17.1 Touch-Up Painting . . . . . . . . . . . . 3-21
TION REQUIREMENTS . . . . . 3-11 3.18 MAINTENANCE PAINTING . . . . 3-21
3.8.1 Mating Surfaces - Bare Steel . . . . . 3-11 3.18.1 Maintenance Painting
3.8.1.1 Mating Surfaces - All Other Restrictions . . . . . . . . . . . . . . . 3-21
Metals . . . . . . . . . . . . . . . . . . 3-11 3.18.2 Prepackaged Coating Touch-Up
3.8.2 Sealers and Sealant Usage . . . . . . . 3-11 Kits . . . . . . . . . . . . . . . . . . . . 3-22

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3.18.3 Radiators Coatings . . . . . . . . . . . . 3-22 4.5.1 Use of Reflective Tape, Decals, and
3.19 LIQUID OXYGEN AND LIQUID Vinyl Lettering . . . . . . . . . . . . 4-4
NITROGEN SERVICING 4.5.2 Field Numbers . . . . . . . . . . . . . . . 4-5
CARTS AND STORAGE 4.5.3 USAF Legends . . . . . . . . . . . . . . 4-5
TANKS . . . . . . . . . . . . . . . . . 3-22 4.5.4 Color Numbers . . . . . . . . . . . . . . 4-5
3.19.1 Authorized Materials for Liquid 4.5.5 Markings Size . . . . . . . . . . . . . . . 4-5
Oxygen and Nitrogen Tanks. . . . 3-22 4.5.6 Tire Pressure/Tow Speed . . . . . . . . 4-5
3.20 WALKWAYS AND STEPPING 4.6 MAINTENANCE OF
SURFACE COATINGS. . . . . . . 3-22 MARKINGS . . . . . . . . . . . . . . 4-5
3.21 COLORS FOR WASTE 4.6.1 Markings Removal . . . . . . . . . . . . 4-5
CONTAINERS . . . . . . . . . . . . 3-22 4.6.2 National Guard Decalcomania . . . . 4-5
3.22 SE UNDERCOATING . . . . . . . . . 3-23 4.7 CAUTION/WARNING
3.22.1 SE Undercoating MARKINGS . . . . . . . . . . . . . . 4-5
Considerations . . . . . . . . . . . . . 3-23 4.7.1 Pintle Hook Caution Marking. . . . . 4-5
3.23 STORAGE COMPARTMENTS . . . 3-23 4.7.2 Spring Loaded Warning
3.24 SPLIT WHEEL ASSEMBLIES . . . 3-23 Marking . . . . . . . . . . . . . . . . . 4-5
3.24.1 Split Wheel Coating 4.7.3 Aircraft Towbar Caution
Requirements. . . . . . . . . . . . . . 3-23 Marking . . . . . . . . . . . . . . . . . 4-5
3.25 MUFFLERS . . . . . . . . . . . . . . . . 3-23 4.7.4 Tire Pressure/Tow Speed
3.26 MISCELLANEOUS CLEANING, Markings . . . . . . . . . . . . . . . . 4-5
SEALING, AND CPC 4.7.5 Personnel Static Discharge
REQUIREMENTS . . . . . . . . . . 3-24 Marking . . . . . . . . . . . . . . . . . 4-5
3.26.1 Sealing of Addressograph or Dash-A 4.8 FUEL CELL REPAIR SE
Plates . . . . . . . . . . . . . . . . . . . 3-24 IDENTIFICATION . . . . . . . . . . 4-5
3.26.2 Electrical Hardware and
Terminals . . . . . . . . . . . . . . . . 3-24 5 CORROSION PREVENTION AND CON-
3.26.3 Light Assemblies . . . . . . . . . . . . . 3-24 TROL OF HUSH HOUSES . . . . . . . . . . . 5-1
3.26.4 Internal Electrical Components: Cir-
cuit Breakers, Relays, etc . . . . . 3-24 5.1 MATERIALS . . . . . . . . . . . . . . . 5-1
3.26.5 Electrical Connectors . . . . . . . . . . 3-25 5.1.1 Fastener Replacement . . . . . . . . . . 5-1
3.26.6 Switches . . . . . . . . . . . . . . . . . . . 3-25 5.2 REPAIR . . . . . . . . . . . . . . . . . . . 5-1
3.26.7 Wire Harness and Cables. . . . . . . . 3-25 5.2.1 Galvanized Steel . . . . . . . . . . . . . 5-1
3.26.8 Heli-Coil Insert Replacement . . . . . 3-25 5.2.2 Carbon Steel . . . . . . . . . . . . . . . . 5-1
5.2.3 Stainless Steel . . . . . . . . . . . . . . . 5-2
4 MARKING OF SUPPORT EQUIPMENT . . . 4-1 5.2.3.1 Type 321 Stainless Steel . . . . . . . . 5-2
5.2.3.4 American Iron and Steel Institute
4.1 GENERAL . . . . . . . . . . . . . . . . . 4-1 (AISI) 409 Stainless Steel . . . . . 5-2
4.1.1 Marking Illustrations and 5.2.3.7 Sealing . . . . . . . . . . . . . . . . . . . . 5-3
Legends . . . . . . . . . . . . . . . . . 4-1 5.3 PRETREATMENT
4.2 SAFETY AND SERVICING COMPOUNDS . . . . . . . . . . . . 5-3
MARKINGS . . . . . . . . . . . . . . 4-1 5.3.1 Rust Remover 81287 (Naval
4.2.1 National Star Symbol . . . . . . . . . . 4-1 Jelly) . . . . . . . . . . . . . . . . . . . 5-3
4.2.2 Marking Requirements . . . . . . . . . 4-1 5.4 PRIMERS . . . . . . . . . . . . . . . . . . 5-3
4.2.3 Product Identification . . . . . . . . . . 4-2 5.4.1 Organic Zinc-Rich Primers . . . . . . 5-3
4.2.4 SE Reflectorization . . . . . . . . . . . . 4-2 5.4.2 Inorganic Zinc-Rich Primers . . . . . 5-3
4.3 AGENCY IDENTIFICATION 5.5 PAINTING . . . . . . . . . . . . . . . . . 5-3
MARKINGS . . . . . . . . . . . . . . 4-2 5.5.1 Structural Corrosion Protection. . . . 5-3
4.3.1 Air Force Owned - Contractor Oper- 5.5.2 Camouflage Requirements . . . . . . . 5-3
ated Equipment . . . . . . . . . . . . 4-2 5.6 INORGANIC ZINC PRIMED
4.3.2 Mobilized Equipment . . . . . . . . . . 4-2 SURFACES. . . . . . . . . . . . . . . 5-4
4.4 INFORMATIONAL MARKINGS 5.6.1 Primer Requirements on the Door
(OPTIONAL) . . . . . . . . . . . . . 4-4 Frame Beams, Support Beams,
4.5 COLOR, STYLE AND SIZE OF and Exhaust Tube. . . . . . . . . . . 5-4
MARKINGS . . . . . . . . . . . . . . 4-4 5.7 GALVANIZED SURFACES. . . . . . 5-4

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5.7.1 Roof. . . . . . . . . . . . . . . . . . . . . . 5-4 7 SOUTHWEST ASIA OPERATIONS AND

5.7.2 Walls and Doors . . . . . . . . . . . . . 5-5 ENVIRONMENTS . . . . . . . . . . . . . . . . . 7-1

6 CORROSION PREVENTION AND CON- 7.1 GENERAL . . . . . . . . . . . . . . ... 7-1

TROL OF NOISE SUPPRESSOR SYS- 7.1.1 Environmental Effects . . . . . . . ... 7-1
TEMS (NSS) . . . . . . . . . . . . . . . . . . . . . 6-1 7.1.1.1 Soils and Humidity. . . . . . . . . ... 7-1
7.2 SE SWA AOR
6.1 GENERAL . . . . . . . . . . . . . . . . . 6-1 DEPLOYMENT. . . . . . . . . ... 7-2
6.2 MATERIALS . . . . . . . . . . . . . . . 6-1 7.2.1 Pre-deployment . . . . . . . . . . . ... 7-2
6.3 FASTENER REPLACEMENT . . . . 6-1 7.2.2 Deployment Location . . . . . . . ... 7-2
6.4 STRUCTURAL REPAIR. . . . . . . . 6-1 7.2.2.1 SE Units Requiring Additional
6.4.1 Structural Repair Carbon Steel . . . . 6-1 Cleaning . . . . . . . . . . . . . . ... 7-2
6.4.2 Galvanized Steel . . . . . . . . . . . . . 6-1 7.2.3 Maintenance Touch-Up
6.4.3 AISI 409 Stainless Steel . . . . . . . . 6-1 Painting . . . . . . . . . . . . . . ... 7-3
6.5 SEALING . . . . . . . . . . . . . . . . . . 6-2 7.2.3.1 Temporary Coating Repair . . . . ... 7-4
6.6 PRIMERS . . . . . . . . . . . . . . . . . . 6-2 7.2.3.2 Permanent Authorized
6.6.1 Organic Zinc-Rich Primers . . . . . . 6-2 Touch-Ups . . . . . . . . . . . . ... 7-4
6.6.2 MIL-PRF-23236, Type I, Class 7.2.4 Equipment Storage . . . . . . . . . ... 7-4
3...................... 6-2
6.6.3 Heat Resistant Primer Briner APPENDIX A EQUIPMENT AND CONSUM-
2905. . . . . . . . . . . . . . . . . . . . 6-2 ABLE MATERIALS USED FOR CORRO-
6.6.4 Heat Resistant Silicone Coating - SION CONTROL . . . . . . . . . . . . . . . . . . . A-1
Briner 2986 . . . . . . . . . . . . . . . 6-2 A.1 EQUIPMENT AND CONSUM-
6.6.5 High Temperature Resistant Silicone ABLE MATERIALS. . . . . . . . . A-1
Coating - Briner 4765 . . . . . . . . 6-3
6.6.6 High Temperature Resistant Silicone
Coating Thurmalox 270-18 . . . . 6-3

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TO 35-1-3

LIST OF ILLUSTRATIONS
Number Title Page Number Title Page

1-1 Diagram of a Simplified Corrosion Cell 4-16 B-1/B-2 Air Conditioner, Trailer
and an Example of Raised Corrosion Mounted . . . . . . . . . . . . . . . . . . . . . 4-30
Product . . . . . . . . . . . . . . . . . . . . . . 1-2 4-17 B-4 Maintenance Stand . . . . . . . . . . . . . 4-32
1-2 Galvanic Series of Metals and Alloys . . . 1-3 4-18 B-5 Maintenance Stand . . . . . . . . . . . . . 4-34
1-3 Corrosion Accelerated by Condensed 4-19 B-2 Maintenance Stand . . . . . . . . . . . . . 4-36
Moisture . . . . . . . . . . . . . . . . . . . . . 1-6 4-20 B-7/B-1 Maintenance Stand . . . . . . . . . . 4-38
1-4 Open Cell Foam and Resulting 4-21 B809A Generator Set . . . . . . . . . . . . . . 4-40
Corrosion . . . . . . . . . . . . . . . . . . . . 1-6 4-22 C-1 Maintenance Stand . . . . . . . . . . . . . 4-42
1-5 View of the Results of Microbial Induced 4-23 Spraying Unit, Corrosion Control Wash
Corrosion . . . . . . . . . . . . . . . . . . . . 1-7 Cart . . . . . . . . . . . . . . . . . . . . . . . . 4-44
1-6 Example of Uniform Etch . . . . . . . . . . . 1-9 4-24 EPU-6 Aircraft Power Supply. . . . . . . . . 4-46
1-7 Example of Galvanic Corrosion - Steel 4-25 FDECU-3 Environmental Control
Hinge Bolted to an Aluminum Unit . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Door. . . . . . . . . . . . . . . . . . . . . . . . 1-9 4-26 Fuel Bowser 400 Gallon . . . . . . . . . . . . 4-50
1-8 Example of Pitting Corrosion . . . . . . . . . 1-10 4-27 H-1 Heater . . . . . . . . . . . . . . . . . . . . . 4-52
1-9 Illustration of an Intergranular Corrosion 4-28 HDU-13M Heater . . . . . . . . . . . . . . . . . 4-54
Cell . . . . . . . . . . . . . . . . . . . . . . . . 1-10 4-29 Hydraulic Cart . . . . . . . . . . . . . . . . . . . 4-56
1-10 Example of Exfoliation Corrosion . . . . . . 1-11 4-30 Jack, Hydraulic 10 - 30 Ton . . . . . . . . . . 4-58
1-11 Examples of Concentration/Crevice 4-31 Jack, 35 Ton, Axle . . . . . . . . . . . . . . . . 4-60
Corrosion . . . . . . . . . . . . . . . . . . . . 1-11 4-32 Liquid Cooling Service (LCS) Cart . . . . . 4-62
1-12 Example of Exfoliation Corrosion . . . . . . 1-11 4-33 Liquid Oxygen Cart . . . . . . . . . . . . . . . 4-64
1-13 Example of Filiform Corrosion . . . . . . . . 1-13 4-34 LN2 Liquid Nitrogen Cart . . . . . . . . . . . 4-66
1-14 Illustration of a Fretting Corrosion 4-35 MC-1A High Pack Air Compressor . . . . . 4-68
Cell . . . . . . . . . . . . . . . . . . . . . . . . 1-13 4-36 MA-3D Air Conditioner. . . . . . . . . . . . . 4-70
3-1 Example of Standing Water Due to Inad- 4-37 MC-2A Air Compressor. . . . . . . . . . . . . 4-72
equate Drainage Provisions . . . . . . . . 3-13 4-38 MC-7 Air Compressor . . . . . . . . . . . . . . 4-74
3-2 Hollow Member Drain Hole 4-39 MD-1 Towbar . . . . . . . . . . . . . . . . . . . 4-76
Configuration . . . . . . . . . . . . . . . . . . 3-13 4-40 MEP Generators . . . . . . . . . . . . . . . . . . 4-78
3-3 Hollow Member Weld-Nut 4-41 MHU-83C/E Bomblift Truck . . . . . . . . . 4-80
Configuration . . . . . . . . . . . . . . . . . . 3-14 4-42 MJ-1B Bomblift Truck . . . . . . . . . . . . . 4-82
3-4 Corrosion Under Data Plate . . . . . . . . . . 3-24 4-43 Hydraulic Test Stand . . . . . . . . . . . . . . . 4-84
4-1 NATO Liquid Oxygen Servicing 4-44 Light Cart, FL-1D . . . . . . . . . . . . . . . . 4-86
Markings. . . . . . . . . . . . . . . . . . . . . 4-1 4-45 NF-2D Light Cart, Diesel . . . . . . . . . . . 4-88
4-2 NATO Liquid Nitrogen Servicing 4-46 Oil Cart . . . . . . . . . . . . . . . . . . . . . . . 4-90
Markings. . . . . . . . . . . . . . . . . . . . . 4-2 4-47 Purging Unit GSU-62M LOX
4-3 Sample Mobility Placard . . . . . . . . . . . . 4-3 Storage . . . . . . . . . . . . . . . . . . . . . . 4-92
4-4 1,500 LB Utility Crane . . . . . . . . . . . . . 4-6 4-48 Radome Dolly . . . . . . . . . . . . . . . . . . . 4-94
4-5 ACE Air Conditioner MC1A, Diesel . . . . 4-8 4-49 Self-Generating Nitrogen Cart . . . . . . . . 4-96
4-6 AF/M27M-1 Pumping Unit, Hydraulic, 4-50 Service Cart. . . . . . . . . . . . . . . . . . . . . 4-98
Diesel Driven. . . . . . . . . . . . . . . . . . 4-10 4-51 Trielectron Generator . . . . . . . . . . . . . . 4-100
4-7 AF/M32T-1 Cabin Leakage Tester . . . . . . 4-12 4-52 Universal Maintenance Stand . . . . . . . . . 4-102
4-8 Aircraft Oxygen Servicing Cart. . . . . . . . 4-14 4-53 New Generation Heater . . . . . . . . . . . . . 4-106
4-9 A/M24T-8 Load Bank . . . . . . . . . . . . . . 4-16 5-1 Angle Iron Sealant Application . . . . . . . . 5-2
4-10 A/M32A-60A Gas Turbine Generator. . . . 4-18 7-1 SWA AOR. . . . . . . . . . . . . . . . . . . . . . 7-1
4-11 A/M32A-86 Generator, Diesel . . . . . . . . 4-20 7-2 Sand/Dust Intrusion . . . . . . . . . . . . . . . 7-2
4-12 A/M32A-95 Compressor, Gas Turbine, 7-3 Residue from Salts Caused by
Trailer Mounted . . . . . . . . . . . . . . . . 4-22 Condensation . . . . . . . . . . . . . . . . . . 7-2
4-13 A/M32C-10C/10D Air Conditioner 7-4 Locally Manufactured Permeable
Set . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Covers . . . . . . . . . . . . . . . . . . . . . . 7-3
4-14 A/M32C-5 Air Conditioner Set . . . . . . . . 4-26 7-5 Wire Bundle Sand/Dust
4-15 Auxiliary Ground Power Unit Accumulation. . . . . . . . . . . . . . . . . . 7-3
(AGPU) . . . . . . . . . . . . . . . . . . . . . 4-28

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LIST OF TABLES
Number Title Page Number Title Page

1-1 Corrosion of Metals - Type of Attack and 4-1 Mobility Placard Construction
Appearance of Corrosion Products . . . 1-15 Information . . . . . . . . . . . . . . . . . .. 4-3
2-1 Wash Interval Based on Corrosion Sever- 4-2 Mobility Placard Stencil
ity Zones. . . . . . . . . . . . . . . . . . . . . 2-2 Requirements . . . . . . . . . . . . . . . . .. 4-4
2-2 Authorized Cleaning Materials . . . . . . . . 2-8 5-1 Hush House Coating Chart. . . . . . . . . .. 5-3
2-3 Authorized HPW Equipment . . . . . . . . . 2-17 A-1 Equipment and Consumable Materials
3-1 Authorized Coating Systems . . . . . . . . . 3-6 List . . . . . . . . . . . . . . . . . . . . . . .. A-1
3-2 SE Scoring/Category Criteria . . . . . . . . . 3-10
3-3 Pretreatment Instructions . . . . . . . . . . . . 3-16
3-4 Metalization Material Sources of
Supply . . . . . . . . . . . . . . . . . . . . . . 3-21

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FOREWORD
1 PURPOSE. 2.5 Chapter 5 Description. This chapter covers the mate-
rials and processes for construction and maintenance of Hush
The purpose of this manual is to provide information neces- Houses.
sary to prevent or minimize the impact of corrosion on Sup-
port Equipment (SE). This manual is designed to provide 2.6 Chapter 6 Description. This chapter covers the mate-
basic corrosion principal, theory, identification, prevention rials and processes for Noise Suppressor Systems (NSS).
and control information to enable SE technicians to differen-
tiate between the different types of corrosion in order to 2.7 Chapter 7 Description. This chapter covers opera-
identify the appropriate temporary repair materials and pro- tions unique to the Southwest Asia Region.
cesses. This technical order is specific to SE; however, for
areas not covered in this manual, or expanded information 2.8 Appendix A Description. This appendix provides a
on a particular material or process, technicians or contractors list of consumable material authorized for use on SE.
should refer to TO 1-1-691, “Aircraft Weapon Systems
Cleaning and Corrosion Control”. For additional guidance, 3 ABBREVIATIONS.
refer to TO 1-1-8, “Application and Removal of Organic
Coatings, Aerospace and Non-Aerospace Equipment”, and All abbreviations used in this manual are in accordance with
TO 1-1-689, “Avionic Cleaning, and Corrosion Prevention/ ASME Y14.38, Abbreviations and Acronyms for Use on
Control”. Drawings and Related Documents.
2 SCOPE. AF Air Force
AFI Air Force Instructions
This manual is designed to provide basic information to be
used by Organizational/Unit, Intermediate, and Depot levels AFOSH Air Force Office of Safety and Health
of maintenance. This manual shall also be used to provide AFRL/RXSSR Air Force Corrosion Prevention and Con-
guidance for corrosion prevention and control activities of trol Office
contracted maintenance inspection, repair, and overhaul of AFTO Air Force Technical Order
SE. If conflicting instructions occur, the end item manual AISI American Iron and Steel Institute
takes precedence over this manual. Conflicts in resolving any AOR Area of Responsibility
conflicting materials and processes application requirements BBE Base Bioenvironmental Engineer
shall be referred to the Air Force Corrosion Prevention and
Control Office, AFRL/RXSSR, Robins AFB, GA. Conflicts BG Bag
regarding all other criteria in this manual shall be referred to BOD Biochemical Oxygen Demand
WR-ALC, Robins AFB, GA for resolution. BX Box
C Celsius
2.1 Chapter 1 Description. This chapter provides the ba- CA Cartridge
sic information needed by SE technicians to accurately iden- CAGE Commercial and Government Entity
tify the causes, types of corrosion and how to minimize the CARC Chemical Agent Resistant Coating
factors that cause and accelerate corrosion. This chapter also
provides procedures for the SE technicians to be able to treat cc Cubic Centimeter
corrosion in the early stages. CFE Contractor Furnished Equipment
CN Can
2.2 Chapter 2 Description. This chapter establishes the CO Container
recommended SE wash cycles based on location; provides a CPC Corrosion Preventive Compound
listing and description of authorized cleaning compounds; CRES Corrosion Resistant Steel
and lists specific cleaning processes for SE. CS Case
DO Dissolved Oxygen
2.3 Chapter 3 Description. This chapter provides the SE
technician with the coating requirements authorized coating DoD Department of Defense
systems, sealing requirements, and corrosion preventive DFT Dry Film Thickness
compound applications. It also provides the only authorized DR Drum
colors for USAF SE. DZ Dozen
EA Each
2.4 Chapter 4 Description. This chapter displays autho- ESD Electrostatic Discharge
rized markings and their locations on SE.

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F Fahrenheit TU Tube
ft Feet USAF United States Air Force
GL Gallon VOC Volatile Organic Compound
GPM Gallons Per Minute
HP Horsepower 4 RELATED PUBLICATIONS.
HPW High-Pressure Water
I&S Interchangeability and Substitution The following publications contain information in support of
this technical manual.
lbs Pounds
ID Inside Diameter
List of Related Publications
in. Inch
KT Kit Number Title
LOI Local Operating Instructions ASME Y14.38 Abbreviations and Acronyms
MAP Military Assistance Program for Use on Drawings and
Related Documents
MIG Gas Metal-Arc
DODI 5330.03_AFI 33-395 Document Automation and
MSDS Material Safety Data Sheet
Production Service
MWAS Metallization Process Metal Wire Arc (DAPS)
Spray
MIL-HDBK-263 Electrostatic Discharge Con-
MX Thousand trol Handbook for Protec-
NACE National Association of Corrosion Engi- tion of Electrical and
neers Electronic Parts, Assem-
NATO North Atlantic Treaty Organization blies and Equipment
NSN National Stock Number TO 00-5-1-WA-1 Air Force Technical Order
NSS Noise Suppressor Systems System
OD Outside Diameter TO 00-25-195-WA-1 Source, Maintenance, and
OSHA Occupational Safety and Health Adminis- Recoverability Coding of
tration Air Force Weapons, Sys-
oz Ounce tems, and Equipment
PG Package TO 00-25-234-WA-1 General Shop Practice Re-
quirements for the Repair,
pH Potential of Hydrogen Maintenance, and Test of
PM Preventive Maintenance Electrical Equipment
PN Part Number TO 1-1-3 Inspection and Repair of
PPE Personal Protective Equipment Aircraft Integral Tanks and
PSI Pounds Per Square Inch Fuel Cells
PSIG Pounds Per Square Inch Gauge TO 1-1-691 Aircraft Weapons Systems -
PT Pint Cleaning and Corrosion
QPL/QPD Qualified Products List/Database Control
QT Quart TO 1-1-8 Application and Removal of
Organic Coatings, Aero-
REF Reference
space and Non-Aerospace
RDS Rapid Desealing System Equipment
RH Relative Humidity TO 35C2-3-1-426WC-4-20-1 Periodic Inspection Work
RO Roll Cards - Diesel Engine
RTV Room Temperature Vulcanizing Driven Generator Sets
SC Sealing Compound A/M32A-86 Series
SCC Stress Corrosion Cracking TO 36-1-191 Technical and Managerial
SCFM Standard Cubic Feet Per Minute Reference for Motor Ve-
hicle Maintenance
SE Support Equipment
TO 42B-1-23 Management of Recoverable
SSDC Steel Structure Painting Council
and Waste Liquid Petro-
SWA Southwest Asia leum Products
TDS Total Dissolved Solids
TIG Gas Tungsten Arc 5 RECORD OF APPLICABLE TIME COMPLIANCE
TOMA Technical Order Management Agency TECHNICAL ORDERS (TCTOS).

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List of Time Compliance Technical Orders

TCTO TCTO TCTO

Number Title Date

None

6 HARDNESS CRITICAL ITEMS (HCI). 8 CHANGE RECOMMENDATIONS.

Recommendations proposing changes to this technical order

shall be submitted on an AFTO Form 22 in accordance with
TO 00-5-1-WA-1. Forward completed AFTO Form 22 to the
The HCI symbol ( ) establishes special re- Technical Order Management Agency (TOMA) at:
quirements limiting changes and substitutions and robins.ce.afto22@robins.af.mil. Changes should not be sub-
that the specific parts listed must be used to ensure mitted for Chapter 4 marking legends and illustrations. Mark-
hardness is not degraded. ing and illustrations in Chapter 4 are for reference use only.
AFTO 22s addressing specific markings of SE should be
If included, items with nuclear survivability requirements are directed to the end-item specific technical orders.
marked with the HCI symbol ( ). All changes to, or pro-
posed substitutions of, HCIs must be approved by the ac-
quiring activity.

7 ELECTROSTATIC DISCHARGE SENSITIVE

(ESDS) ITEMS.

All ESDS parts shall be handled in accordance

with the ESDS device handling procedures in TO
00-25-234-WA-1.

If included, items containing ESDS parts are marked with

the ESDS symbol ( ).

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TO 35-1-3

SAFETY SUMMARY
1 GENERAL SAFETY INSTRUCTIONS. 3 MATERIALS HANDLING.

This manual describes physical and/or chemical processes 3.1 Personnel Hazards. Many of the materials and pro-
which may cause injury or death to personnel, or damage to cedures outlined in this technical order are potentially haz-
equipment, if not properly followed. This safety summary ardous to personnel, if used improperly. When using chemi-
includes general safety precautions and instructions that must cals such as paint strippers, cleaning compounds, conversion
be understood and applied during operation and maintenance coatings, and solvents, follow the correct procedures and
to ensure personnel safety and protection of equipment. Prior wear appropriate protective gear to prevent injury to person-
to performing any specific task, the WARNINGs, CAU- nel. Read the appropriate Material Safety Data Sheet
TIONs, and NOTEs included in that task shall be reviewed (MSDS), manufacturer’s instructions and be familiar with
and understood. The safety precautions in AFI 91-203 and related warnings and cautions in this technical order prior to
OSHA Standard 1910.107 are applicable to the operation of using any material. Misuse of certain materials can also
paint shops and spray-painting equipment and shall be fol- damage parts or cause corrosion. Refer to DOD 6050.5-LR,
lowed during cleaning and repainting of SE. Hazardous Material Information System, FED STD 313,
Material Safety Data, Transportation Data, and Disposal Data
2 WARNINGS, CAUTIONS, AND NOTES. for Hazardous Material Furnished to Government Activities,
or the appropriate systems command documents for the han-
WARNINGs and CAUTIONs are used in this manual to dling, storage, and disposal of hazardous materials. When in
highlight operating or maintenance procedures, practices, doubt, contact the local safety office, base bioenvironmental
conditions, or statements which are considered essential to office, or regional medical center for guidance.
protection of personnel (WARNING) or equipment (CAU-
TION). WARNINGs and CAUTIONs immediately precede 3.2 Environmental Hazards. Many of the materials and
the step or procedure to which they apply. WARNINGs and procedures outlined in this technical order are also poten-
CAUTIONs consist of four parts: heading (WARNING, tially hazardous to the environment. Wherever possible,
CAUTION, or icon), a statement of the hazard, minimum methods for preventing pollution, minimizing waste, and us-
precautions, and possible results if disregarded. NOTEs are ing less toxic materials are given. Consult the base bioenvi-
used in this manual to highlight operating or maintenance ronmental office for information about the handling, storage,
procedures, practices, conditions, or statements which are not and disposal of hazardous waste.
essential to protection of personnel or equipment. NOTEs
may precede or follow the step or procedure, depending upon 4 GENERAL PRECAUTIONS.
the information to be highlighted. The headings used and
their definitions are as follows: The following general safety precautions are not related to
any specific procedure and therefore do not appear elsewhere
in this technical manual. These are general safety precau-
tions and instructions people must understand and apply dur-
ing many phases of operation and maintenance to ensure
Highlights an essential operating or maintenance personal safety and health and the protection of Air Force
procedure, practice, condition, statement, etc., property.
which if not strictly observed, could result in in-
jury to, or death of, personnel or long term health 4.1 Live Circuits. Operating personnel must observe all
hazards. safety requirements at all times. Do not replace components
or make adjustments inside equipment with the electrical
supply turned on. Under certain conditions, danger may exist
even when the power control is in the off position due to
charges retained by capacitors. To avoid injuries, always re-
Highlights an essential operating or maintenance move power, discharge, and ground a circuit before touching
procedure, practice, condition, statement, etc., it. Adhere to all lock out/tag out requirements.
which if not strictly observed, could result in dam-
age to, or destruction of, equipment or loss of mis- 4.2 Resuscitation. Personnel working with or near dan-
sion effectiveness. gerous voltage shall be trained in modern methods of resus-
citation. Information and training sources may be obtained
NOTE from the Director of Base Medical Services.

Highlights an essential operating or maintenance

procedure, condition, or statement.

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TO 35-1-3

4.3 Finger Rings/Jewelry. Finger rings have caused many evaluation of the operation from the Bioenvironmental Engi-
serious injuries. Remove rings, watches and other metallic neer. The Bioenvironmental Engineer or Base Safety Office
objects that may cause shock or burn hazards. Unless spe- will determine the required precautions and approved PPE.
cifically allowed by shop safety procedures, remove finger
rings during all maintenance activity. 6 CLEANERS/CHEMICALS/PAINTS/PRIMERS.

4.4 Compressed Air. Use of compressed air can create an Some cleaners, chemicals, paints, and primers have adverse
environment of propelled particles. Do not direct air streams effects on skin, eyes, and the respiratory tract. Observe
towards yourself or other personnel. Air pressure shall be manufacturer’s warning labels, Material Safety Data Sheet
reduced to less than 30 Pounds Per Square Inch Gauge (MSDS) and other instructions for proper handling, storage,
(PSIG) and used with effective chip guarding and personal and disposal; and current safety directives. Use only in au-
protective equipment. thorized areas.

4.5 Dangerous Pressures. Care must be taken during 7 ELECTROSTATIC DISCHARGE (ESD).
testing to ensure that all test connections are proper and tight.
All system components must be compatible with applied Certain circuit card assemblies and their components will be
pressure. Personnel must be protected by a safety shield or damaged by seemingly undetectable electrostatic discharge.
located at a distance sufficient to prevent injury. Care must be exercised during handling/repair of those items.
Use Electrostatic Discharge (ESD) precautionary procedures
5 PERSONAL PROTECTIVE EQUIPMENT (PPE). outlined in TO 00-25-234, General Shop Practice Require-
ments for Repair, Maintenance and Test of Electrical Equip-
If unique local conditions make compliance with the protec- ment, and MIL-HDBK-263, Electrostatic Discharge Control
tive clothing or other occupational health requirements speci- Handbook for Protection of Electrical and Electronic Parts,
fied in this manual unnecessary or impractical, obtain an Assemblies and Equipment.

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CHAPTER 1
CORROSION THEORY, IDENTIFICATION, CAUSES AND EFFECTS
1.1 PURPOSE. 1.3.4 Electrolyte. A liquid solution (usually water) con-
taining ions. Salt water is an electrolyte, an aqueous (i.e.,
The purpose of this chapter is to provide Support Equipment water) solution of sodium ions and chloride ions.
(SE) maintenance personnel with the basic knowledge nec-
essary to understand the causes of corrosion, identify the 1.4 THEORY OF CORROSION.
different types of corrosion that will in-turn help minimize
corrosion damage through prevention and early detection and A corrosion cell is much like a battery. When a metal cor-
treatment. To help prevent corrosion, SE technicians must rodes, the metal atoms lose electrons and become metal ions
first need to understand corrosion causes and effects and be in an electrolyte solution. The positively charged metal ions
able to recognize there are several types of corrosion with can combine with negatively charged ions to form corrosion
different preventive measures. This chapter is an introduc- products, such as metallic chlorides, oxides, hydroxides, and
tion to corrosion theory, the causes of corrosion and the fac- sulfides. Four conditions must exist before this type of cor-
tors that influence its development. The various forms of rosion can occur.
corrosion and the effect of corrosive environments normally
on SE are also described in this chapter. 1.4.1 Anode. A metal must be present that has a tendency
to corrode. The corroding metal is known as the anode.
1.2 DEFINITION OF CORROSION.
1.4.2 Cathode. A dissimilar conductive material (the cath-
Corrosion is the electrochemical deterioration of a metal be- ode) that has less of a tendency to corrode than the anode
cause of its chemical reaction with the surrounding environ- must be present. Examples include a different metal, a pro-
ment. This reaction occurs because of the tendency of metals tected part of the same metal, or conductive plastics/compos-
to return to their naturally occurring states, usually oxide or ite.
sulfide ores. For example, iron in the presence of moisture
and air will return to its natural state, iron oxide or rust. 1.4.3 Electrolyte. A conductive liquid (electrolyte) must
Aluminum and magnesium form corrosion products that are connect the anode and cathode so that ions can carry electri-
white oxides or hydroxides. When corrosion occurs, water is cal current between them.
usually present in some form (e.g., humidity, moisture, con-
densation, rain, salt spray, etc.), acting as an electrolyte and 1.4.4 Electrical Path. Electrical contact between the an-
reacting chemically with metal surfaces. ode and cathode (usually in the form of metal-to-metal con-
tact) must exist so that electrons can move from the anode,
1.3 CHEMICAL DEFINITIONS. where they are released, to the cathode. Eliminating any one
of these four conditions, illustrated in Figure 1-1, will stop
1.3.1 Atom. The smallest unit of an element. There are corrosion. For example, a paint film on a metal surface will
more than 100 elements, including metals (such as alumi- prevent the conducting liquid (electrolyte) from connecting
num, magnesium, iron, nickel, titanium, cadmium, chro- the anode and cathode, thereby stopping the electric current.
mium, copper, and carbon) and non-metals (such as hydro- Another example is when two connected dissimilar metal
gen, oxygen, sulfur, and chlorine). parts placed in pure water corrode very slowly because of
the lack of ions to conduct the electric current. In seawater,
1.3.2 Electron. A negatively charged particle much the corrosion reaction is accelerated by a factor of 1,000 or
smaller than an atom. An electrical current occurs when more.
electrons are forced to move through metal conductors. Elec-
trons also flow through water solutions, but only in the pres-
ence of ions.

1.3.3 Ions. Atoms or groups of atoms bound together that

is either positively or negatively charged. An electrical cur-
rent occurs when ions are forced to move through water so-
lutions. Ions cannot move through metal conductors.

1-1
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Figure 1-1. Diagram of a Simplified Corrosion Cell and an Example of Raised Corrosion Product

1.5 DEVELOPMENT OF CORROSION. the bulging/blistering of the metal surfaces. Thin film corro-
sion forms on electrical contact points and pins may appear
1.5.1 Corrosion Origination Locations. All corrosive at- as a tarnish, or powdery deposit on the metal surface.
tacks begin on the surface of metals whether it is the inside
of a bolt hole, border of a metal crystal, hand rail interior or 1.5.2 Corrosion Under Painted Surfaces. Paint coatings
bottom of a frame. If allowed to progress, corrosion can pen- can mask the initial stages of corrosion. Because corrosion
etrate into and through the metal. When corrosion products products occupy more volume than the original metal, fre-
form, they often precipitate onto the corroding surface as a quently inspect paint surfaces for irregularities such as blis-
powdery or scaled deposit. Other evidence of corrosion is ters, flakes, chips, and lumps.

1-2
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Figure 1-2. Galvanic Series of Metals and Alloys

1-3
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1.6 FACTORS INFLUENCING CORROSION. ode) is smaller than the surface area of the less active metal
(the cathode), corrosion will be rapid and severe. However,
Both natural and man-made environments cause corrosion of if the corroding metal is larger than the less active metal,
SE. Natural conditions that affect the corrosion process are corrosion will be slow and superficial. For example, an alu-
moisture, temperature, salt atmospheres, ozone, sand, dust, minum fastener in contact with a relatively nonreactive
solar radiation, insects and birds, and microorganisms. Man- Monel structure may corrode severely, while a Monel bracket
made conditions that affect the corrosion process are indus- secured to a large aluminum member would result in a rela-
trial pollution, manufacturing operations, storage conditions, tively superficial attack on the aluminum.
and shipment. By understanding these conditions, mainte-
nance personnel will be better able to prevent SE damage. 1.6.4 Climate. Warm, moist air, typically found in tropical
Factors that influence metal corrosion and the rate at which climates, tends to accelerate corrosion because of the higher
it occurs are outlined in Figure 1-2. concentration of water vapor in the air. Additionally, high
temperature environments tend to produce more rapid corro-
1.6.1 Type of Metal. The metals most commonly used in sion because of accelerated chemical reactions. Conversely,
SE construction are aluminum, steel, and to some extent cold dry air, typically found in colder regions of the world,
magnesium. Cadmium, nickel, chromium, and silver are tends to slow corrosion rates due to less water vapor in the
sometimes used as protective plating. Metals have a wide air. Corrosion does not occur in very dry conditions. For this
range of corrosion resistance. The most active metals (i.e., reason, desiccants or dehumidification systems are placed in,
those that tend to lose electrons easily), such as magnesium or connected to shipping or storage containers to create very
and aluminum, corrode easily and are listed at the top of dry local environments. The equipment’s proposed opera-
Figure 1-2. The most noble metals (i.e., those that do not tional environments and established corrosion prevention and
lose electrons easily), such as gold and silver, do not corrode control optimal design parameters should be considered in
easily and are listed at the bottom of Figure 1-2. SE design and procurement.

1.6.2 Dissimilar Metal Coupling (Galvanic Corrosion). 1.6.4.1 Desert. Hot, wind-swept deserts create a severe
When two dissimilar metals make electrical contact in the maintenance problem because powdery dust can penetrate
presence of an electrolyte, the rate at which corrosion occurs even supposedly sealed components. Typically, desert condi-
depends on the difference in their location on the galvanic tions are thought to have low humidity and rainfall. How-
scale (see Figure 1-2). The greater the distance between the ever, there are areas of the world considered as desert with
metals, the faster corrosion occurs. For example, magnesium high daytime temperatures, moderate to low night time tem-
corrodes very quickly when coupled with gold in a humid peratures, high humidity (in areas such as the Persian Gulf),
atmosphere. However, pure aluminum corrodes very slowly, ultraviolet radiation, and fine dust. These conditions pose the
if at all, when in contact with cadmium. It is essential in the most serious, destructive elements of the desert climate due
repair of SE that compatible metals and metal fasteners, to the wide range of conditions experienced daily.
washers, etc., be selected for repair and refurbishment pro-
cesses. If dissimilar metal coupling must occur due to the 1.6.4.2 Temperate Zones. The temperate or intermediate
equipment design or configuration, contact the appropriate climate zone encompasses most of the North American and
system equipment specialist for the appropriate processes and European continents. These areas at various times of the year
materials to insulate the incompatible metals. may approximate the extremes of polar, desert, or tropical
temperatures and humidity. The temperate zone temperatures
1.6.2.1 Graphite or carbon fiber composites are materials range from -25 °Fahrenheit (F) to +59 °F (-32 °Celsius (C)
which consist of reinforcing fibers in a matrix made of or- to +15 °C) in the winter and from +59 °F to +125 °F (+15
ganic resin, usually epoxy. They are an important class of SE °C to +52 °C) in the summer. The relative humidity (RH)
construction materials because of their high strength-to- also fluctuates between five and 100%. The most critical ar-
weight ratios and high stiffness. Although graphite or car- eas are coastal locations, during the warm periods of the
bon/carbon composites appear as a plastic, the graphite ma- year in which the relative humidity approaches 100% RH at
terial is considered a metal. Care should be exercised when night and the air has high concentrations of salt. Moisture
attaching fasteners through the fibers. Use the appropriate from this salt laden air can condense on equipment during
sealant to insulate the composite from the metal parts. early evening and morning hours, thereby causing serious
corrosion. Because of its relatively mild temperatures, the
1.6.2.2 Since carbon is the least active metal in the gal- temperate zone is also the most heavily populated. Conse-
vanic series, it will accelerate the corrosion of any metal to quently the smoke, smog, ozone, and corrosive fumes asso-
which it is coupled. Insulation, with sealant or other noncon- ciated with heavy industry are also found there.
ductive coatings, between graphite or carbon epoxy compos-
ites and other metals surfaces or fasteners is necessary to 1.6.4.3 Tropics. One of the greatest challenges to SE
prevent dissimilar metal attack on the attached part. manufacturing industries is to the design equipment that is
protected from corrosion and deterioration in the continual
1.6.3 Anode and Cathode Surface Area. The rate of heat and humidity of tropical climates. Even though they
galvanic corrosion also depends on the size of the parts in encompass only a small portion of the earth’s land area, the
contact. If the surface area of the corroding metal (the an- tropics demand the greatest amount of consideration from

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the standpoint of corrosion treatment and control. Relative 1.6.6 Electrolytes. Electrically conducting solutions are
humidity of up to 100% RH at ambient air temperatures of easily formed on metallic surfaces when condensation, salt
85 °F (29 °C) and above create a formidable threat of corro- spray, rain, or rinse water accumulate. Dirt, salt, and carbon
sion. When high humidity and temperature conditions are deposits from engine exhaust and engine exhaust gases can
combined with saltladen air, the corrosive environment be- combine with water on wet surfaces thereby increasing the
comes extremely severe. The critical combination of high electrical conductivity of the electrolyte and the rate of cor-
temperatures, condensation, high relative humidity, and con- rosion. Improper dilution of cleaning chemicals, combining
taminants such as salt and sand may cause premature struc- cleaning compounds together, or the use of unauthorized
tural failure of equipment due to corrosion. Deterioration of cleaning material can cause the cleaning solution to become
the materials used in electronic equipment may also be ac- an electrolyte.
celerated. Thin film corrosion on electrical contact points
and pins act as insulators to electrical current adversely af- 1.6.6.1 Moisture is present in air as a gas (water vapor) or
fecting the operations of SE. as finely divided droplets of liquid (mist or fog) and often
contains contaminants (such as chlorides, sulfates, and ni-
1.6.4.3.1 Factors of Influence in Tropical Environ- trates) that increase its corrosive effects. Moisture will enter
ments. Tropical environments are noted for long periods of all areas of SE that air can enter. All enclosed areas, that are
heavy rainfall, during which 100 inch (in.) or more of rain not hermetically sealed, will allow air to enter and leave as
may fall. Extended periods of high heat and humidity con- the difference in pressure between the inside and outside the
tribute to rapid corrosion of metals, cracking and flaking of equipment changes. These pressure differences occur when
rubber and plastic materials, and deterioration of seals. atmospheric pressure changes and when the air temperature
Equipment, whether stored or in use, requires special protec- inside an enclosed area changes. As the surrounding surfaces
tive containers/measures and frequent preventive mainte- are heated, moisture-laden air is drawn into the enclosed area
nance. Microorganisms multiply excessively in tropical en- or absorbed in open cell foam. As the air around the equip-
vironments and attack many non-metallic materials. Many ment cool, moisture will condense in the enclosed areas and
items become covered with fungi in a matter of hours. Elec- settle in the lowest area of the part. The enclosed areas are
tronic equipment requires special efforts for effective opera- often hidden and/or inaccessible. Moisture is difficult to re-
tion in the tropics. Intensive preventive maintenance and the move and the subsequent corrosion may be difficult to iden-
best possible protective techniques are necessary for SE and tify in the early stages.
their components in tropical environments.
1.6.6.2 Salt laden atmospheres pose a continual problem
1.6.5 Heat Treatment and Grain Direction. When heat- in locations operating near coastal environments. When dis-
treated, heavy sections of metals do not cool uniformly be- solved in water, salt solutions form very effective electro-
cause the metallic grain/crystalline structures tend to vary in lytes. The ocean, which is 3.5% to 3.9% salt, is the world’s
chemical composition from one part of the metal to another. primary source of salt. Normal sea winds carry from 10 to
This can cause galvanic corrosion if the metal crystals are 100 pounds (lbs) of sea salt per cubic mile of air. Bases
more active than another or contain contaminates. Alloys that located close to marine environments are continually exposed
are fabricated by rolling, extruding, forging, or pressing have to the salt laden atmosphere. Because dissolved salts are
properties that depend highly on the metal grain/crystal di- strong electrolytes, it is easy to understand why coastal en-
rection (parallel to grain elongation vs. cross grain). For ex- vironments are listed in the moderate to severe corrosion
ample, exposed end grain corrodes much more easily than prone categories and require frequent rinsing and cleaning to
flattened elongated surfaces in sheet stock. This explains why remove the salt deposits.
exfoliation occurs at the structural edges or next to counter-
sunk fasteners on certain types of alloys.

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Figure 1-3. Corrosion Accelerated by Condensed Moisture

1.6.6.3 Condensed moisture will usually evaporate as the moisture and its contaminants can also be trapped in close
surrounding air warms but will leave behind its contami- fitting, wettable joints, such as faying surfaces. Some gasket
nants (residues), including salts. This can result in the and packing materials will absorb several times their weight
build-up of soils and salt contamination. Salt-laden conden- in water and, when heated, can transmit this retained mois-
sation may collect at the lowest surface of the equipment. ture into the sealed area. Moisture can accumulate in such
The lowest surfaces are usually the last to dry. As the con- areas through successive cycles of warming and cooling and
densation continues to collect at the lowest surfaces the con- cause corrosion on the interior of the part resulting in pre-
taminates/electrolytes become more concentrated. Condensed mature structural failure as shown in Figure 1-3.

Figure 1-4. Open Cell Foam and Resulting Corrosion

1.6.6.4 Open cell foam, see Figure 1-4, is a sponge-like installation in the SE, seal all open cell surfaces and sides of
material used mainly for sound suppression and insulation. any perforations in the foam with a polysulfide type sealant
Humidity, condensation, rainfall, etc., is absorbed into the such as MIL-PRF-81733. Sealing any tears in the foam or
foam and ultimately migrates to the mating metal surface to any unsealed sides and edges of the foam will preclude any
which it is attached. The absorbed moisture is very slow in fluid absorption by the foam.
drying out and provides the moisture/electrolyte against the
metal surfaces. When possible, open cell foam should not be 1.6.6.5 Airborne industrial pollutants also contribute to the
used. Closed cell types of foam may be suitable substitutes deterioration of nonmetallic materials and severe corrosion
for this material and will not absorb moisture. If open cell of metals. The most aggressive are: carbon (from internal
foam is the only material suitable for your needs, prior to

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combustion engine exhaust), nitrates (from agricultural fer- adjacent to metals may promote corrosion by depleting the
tilizers), ozone (from electrical motors and welding opera- oxygen supply or by releasing metabolic products. Anaero-
tions), sulfur dioxide (from engine exhaust and industrial and bic bacteria, on the other hand, can survive only when free
ship smoke stacks), and sulfates (from automobile exhaust). oxygen is not present. The metabolism of these bacteria re-
quires them to obtain food sources by oxidizing inorganic
1.6.6.6 Sand, dust, and volcanic ash are present in many compounds such as iron, sulfur, hydrogen, and carbon mon-
areas, but particularly in industrial areas where they often oxide. The resultant chemical reactions cause corrosion.
contain a number of tar products, ashes, and soot. Dust is
also found in tropical zones with plentiful rainfall and arid 1.6.7.2 Microbial attack can be prevented by frequent and
zones where there is little or no rainfall. Sand and dust are thorough cleaning of the affected areas and applying mois-
extreme problems in deserts because the wind carries dry, ture-proofing coatings to nutrient materials or by drying the
powdery sand and dust. During sandstorms, sand and dust interiors of compartments with desiccants. However, some
can penetrate sealed equipment and many internal areas of moisture-proofing coatings are attacked by microorganisms,
SE. Sand, dust, and volcanic ash are hygroscopic and can especially if they are used on contaminated surfaces.
absorb and hold moisture when present on internal or exter-
nal surfaces of SE or electronic parts. Dust from volcanic 1.6.7.3 When dry, some microorganisms can survive in
areas contains chlorides and sulfates, dust from desert areas spore form for long periods and can become active when
may contain chlorides, carbonates, and sulfates. These mate- moisture is available. When desiccants become saturated and
rials are extremely corrosive in the presence of moisture. unable to absorb the moisture passing into the affected area,
Although small amounts of sand or dust may be unnoticed microorganisms can begin to grow. Dirt, dust, and other air-
by operating personnel, they may be sufficient to initiate and borne contaminants are the least recognized contributors to
accelerate corrosion. microbial attack. Unnoticed, small amounts of airborne de-
bris may be sufficient to promote fungal growth.

1.6.8 Mechanical Stress. Manufacturing processes such

as machining, forming, welding, or heat treatment can leave
stresses in SE parts. Almost all alloys in SE construction are
sensitive to a form of corrosion known as stress corrosion
cracking. This residual stress causes corrosion to proceed
more rapidly in structurally important regions of the part
until failure occurs.

1.6.9 Time. As time goes on, metals naturally tend to cor-

rode. In some cases, the corrosion process occurs at the same
rate, no matter how long the metal has been exposed to the
environment. In other cases, corrosion can decrease with time
(because of the barrier formed by corrosion products) or in-
crease (if a barrier to corrosion is being broken down).

Figure 1-5. View of the Results of Microbial Induced 1.6.10 Manufacturing. During the manufacture, assembly,
Corrosion or repair of SE, many factors can cause the introduction of
corrosion. Use of unsuitable materials and improper materi-
1.6.7 Microbial Induced/Influenced Corrosion. Al- als processing can cause corrosion. Shearing or hole-punch-
though rarely seen on SE, microbial induced/influenced cor- ing operations on some metal alloys, especially on high-
rosion, as the term is used in this manual, includes the ag- strength aluminum, may create stresses that will lead to
gressive action of bacteria, fungi, or molds that can be found corrosion or provide a slight lip to inhibit complete drainage
on SE. Microorganisms are nearly everywhere and outnum- from an area. Raised edges of the hole-punching operations
ber all other types of living organisms. Those organisms may cause incomplete drainage of electrolytes once the pan-
causing the greatest corrosion problems are bacteria and els are installed. Assembly of parts in areas contaminated by
fungi. Damage resulting from microbial growth can result fumes or vapors from adjacent operations may entrap fumes
from: (1) the tendency of the growth to hold moisture which in the equipment, which might lead to future corrosion. Ar-
then causes corrosion; (2) digestion of the substrate as food eas without humidity control may be sources of condensed
for the microorganism; or (3) corrosion of the surface be- moisture. Inadequate or nonexistent sealant usage, improper
neath the growth by secreted corrosive fluids of the action of material selection, use of open cell foam for sound suppres-
bacteria, fungi, or molds on a metal surface, see Figure 1-5. sion are other causes that contribute to premature structural
failure of SE.
1.6.7.1 Bacteria may be either aerobic or anaerobic. Aero-
bic bacteria require oxygen to live. They can accelerate cor- 1.6.11 Storage. Even traces of corrosive vapor in pack-
rosion by oxidizing sulfur to produce sulfuric acid or by ages containing SE parts may result in serious corrosion.
oxidizing ammonia to produce nitric acid. Bacteria living Moreover, the natural “breathing” of packages may intro-

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duce moisture into parts and equipment. Decomposed pack- 1.6.13.3 Dedication to proper preventive maintenance
ing materials can emit corrosive vapors during prolonged practices will maximize equipment reliability and availabil-
storage, which can create serious corrosion of equipment and ity.
the parts stored in these packages.
1.6.13.4 A typical PM program should include personnel
1.6.12 Degradation of Non-metals. Nonmetallic materi- trained in corrosion identification, prevention, thorough cor-
als (plastics, elastomers, paints, and adhesives) are not sub- rosion removal, chemical treatment, paint removal, sealing,
ject to electrochemical corrosion because ions are not easily and repainting. An effective PM program also includes:
formed from nonmetallic elements and the electrical conduc-
tivity of non-metals is extremely low. The degradation of a. Proper SE washing and cleaning cycle based on the
non-metals depends on the chemical make-up of the material corrosion severity zone the equipment operates in.
and the nature of the environment. In general, nonmetallic
materials used on equipment are selected for their perfor- b. Daily cleaning or wiping down of all exposed un-
mance properties (flexibility, transparency, strength, electri- painted surfaces such as actuating rods of hydraulic
cal resistance, etc.) and their resistance to heat, impact, abra- cylinders.
sion, ultraviolet radiation, moisture, ozone and other
detrimental gases, and operational fluids (such as hydraulic c. Keeping all drains and drain holes open, and low parts
fluid, lube oil, cleaners, deicing fluids, etc.). However, the of the SE dry and free of salt deposits.
use of unauthorized maintenance chemicals and procedures
can accelerate degradation and ultimately lead to material d. Initial use, inspection, and reapplication of the appro-
failure resulting in leakage, corrosion, electrical shorts, craz- priate corrosion preventive compounds (CPC) follow-
ing, and/or mechanical failure. ing SE washing, repairs, and component replacement.
1.6.13 Preventive Maintenance (PM). PM is probably e. Early detection and thorough removal of corrosion and
one of the easiest, most effective, and least expensive means replacement of the damaged protective coatings and
of preventing corrosion and is the process organization main- sealants.
tenance personnel can control. Each type of corrosion has its
own peculiarities and will require special treatment. How-
f. Sealing gaps, seams, and holes to prevent moisture en-
ever, there is a common four point approach in developing
try. This is especially important around spot-welded
an effective corrosion prevention and control program. The
areas
four point approach consists of (1) the early identification of
corrosion, (2) the early and thorough removal of corrosion
and proper treatment of the corroded area (3) the complete g. Application/reapplication of sealants, where required,
removal of electrolytes through frequent cleaning with ap- to insulated dissimilar metals or prevent water intru-
proved, properly mixed cleaning compounds, (4) and the ap- sion following SE repairs, and component replace-
plication and maintenance upkeep of effective protective ments.
coatings.
h. Technician awareness of the importance of corrosion
1.6.13.1 Corrosion can be minimized by frequent washing prevention during regular maintenance activities (while
because the extent of corrosion depends on the length of performing daily repairs and maintenance tasks, always
time electrolytes are in contact with metals. If Qualified look for signs of corrosion or corrosion damage).
Product List/Database (QPL/QPD) approved cleaners and
additives are used, frequently cleaning of equipment based i. Track causes of initial corrosion to the source and
or operating in a corrosive environment will reduce the like- eliminate the source.
lihood and severity of corrosion.
1.7 TYPES OF CORROSION.
1.6.13.2 Keeping chemical treatments and paint finishes
in good condition will minimize corrosion. The degradation Corrosion is cataloged and classified in many ways. Occa-
of nonmetallic materials can be minimized by avoiding the sionally, different names are used for the same type of cor-
use of unauthorized maintenance chemicals, coatings, and rosion. Common types of corrosion are described below.
procedures.

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Figure 1-6. Example of Uniform Etch

1.7.1 Uniform Etch Corrosion. Uniform etch corrosion 1.7.2 Galvanic Corrosion. Galvanic corrosion (see Fig-
results from a direct chemical attack on a metal surface and ure 1-7) occurs when different metals are in contact with
involves only the metal surface. On a polished surface, this each other and an electrolyte (such as salt water). It is usu-
type of corrosion is first seen as a general dulling or etching ally recognizable by a buildup of corrosion at the joint be-
of the surface, and, if the attack continues, the surface be- tween the metals. If two dissimilar metals that are widely
comes rough and possibly frosted in appearance. This type separated in Figure 1-2 are in direct electrical contact, gal-
of corrosion appears uniform because the anodes and cath- vanic corrosion is probably occurring. The less corrosion-
odes are very small and constantly shift from one area of the resistant metal (the higher metal in Figure 1-2) becomes the
surface to another. An example is the etching of metals by anode and the more corrosion-resistant metal (the lower
acids or by the use of unapproved or improperly mixed metal in Figure 1-2) becomes the cathode. As stated earlier,
cleaning compounds (see Figure 1-6). The discoloration or the anode will corrode. The farther apart the metals are in
general dulling of metal created by exposure to elevated Figure 1-2, the more severe will be the corrosion of the an-
temperatures is not considered to be uniform etch corrosion. odic metal if the metals are joined electrically and placed in
an electrolyte. In most cases, the galvanic series listed in
Figure 1-2 is a good predictor of how metals will corrode in
a galvanic couple. A major factor in galvanic corrosion is the
size of the anode and cathode. A small anode in contact with
a large cathode will corrode much more severely than a large
anode in contact with a small cathode.

Figure 1-7. Example of Galvanic Corrosion - Steel

Hinge Bolted to an Aluminum Door

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powdery deposit, similar to dust, that blotches the surface.

When the deposits are cleaned away, tiny pits or holes can
be seen in the surface. Pitting corrosion may also occur in
other types of alloys. The combination of small active an-
odes to large passive cathodes causes severe pitting. Pitting
starts as an advanced form of uniform etch. It can worsen
into very severe corrosion that results in localized and rela-
tively deep holes in the metal. Pits are isolated holes that can
vary in shape and size and usually take several months to a
year before they become visible. Pitting is an extremely de-
structive and insidious form of corrosion. It causes equip-
ment to fail because of perforation with very little weight or
material loss on the entire structure. It is also difficult to
detect because the pits are often covered with corrosion
products. Pitting usually initiates at anodic points on a metal
surface such as breaks in protective coatings or films,
scratches, and irregularities that are exposed to an aggressive
electrolyte. Even though a pit is slow to initiate, once started,
Figure 1-8. Example of Pitting Corrosion
it will progress at an ever-increasing rate and will tend to
undercut the surface as it grows.
1.7.3 Pitting Corrosion. The most common corrosion on
aluminum and magnesium alloys is called pitting corrosion
(see Figure 1-8). It is first noticeable as a white or gray

Figure 1-9. Illustration of an Intergranular Corrosion Cell

1.7.4 Intergranular Corrosion. Intergranular corrosion fined boundary that chemically differ from the metal within
(see Figure 1-9) is an attack on the grain boundaries of the the grain. The grain boundaries are frequently anodic (i.e.,
metal. A highly magnified cross-section of any commercial tend to corrode more easily) to the metal within the grain.
alloy shows the granular structure of the metal. This consists When in contact with an electrolyte, rapid corrosion occurs
of quantities of individual grains, each having a clearly de- at the grain boundaries.

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Figure 1-10. Example of Exfoliation Corrosion

1.7.5 Exfoliation Corrosion. Exfoliation corrosion (see the metal grain boundaries. The lifting up or swelling is vis-
Figure 1-10) is an advanced form of intergranular corrosion ible evidence of exfoliation corrosion. Exfoliation occurs on
and occurs when the surface grains of a metal are lifted up extruded, rolled, wrought, and forged high strength alumi-
by the force of expanding corrosion products occurring at num and magnesium parts.

Figure 1-11. Examples of Concentration/Crevice Corrosion

Figure 1-12. Example of Exfoliation Corrosion

1.7.6 Concentration/Crevice Corrosion. Crevice corro- contains less oxygen and more metal ions than electrolyte
sion (see Figure 1-11 and Figure 1-12) occurs when the elec- just outside the crevice. As a result, the metal surfaces have
trolyte in a crevice has a different concentration than the area different activities, even though they may be part of the same
adjacent to the crevice. This type of corrosion is also known metal, and corrosion occurs inside the crevice. This form of
as concentration cell corrosion. Electrolyte inside the crevice corrosion often occurs between faying surfaces or when a

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surface is covered by a foreign material (such as dirt) or will cause SCC in all metals. SCC is most prevalent and of
under gaskets, rubber, or plastic tape. The mechanisms in- the most concern in high strength steels, stainless steels
volved in crevice corrosion are very similar to pitting corro- (mostly in the austenitic group), high strength aluminum al-
sion. Crevice corrosion most often occurs where there are loys (2000 and 7000 series), copper-based alloys, and tita-
stagnant solutions (electrolytes) in holes, gasket surfaces, lap nium alloys.
joints, under surface deposits (sand, dirt, corrosion products,
etc.), and in crevices under bolt and rivet heads. To become 1.7.8 Hydrogen Embrittlement. Hydrogen embrittlement
a site for corrosion, a crevice must be wide enough to allow is the weakening of materials such as high-strength steel
liquid entry but narrow enough to keep the liquid stagnant. (typically 180 Ksi and above), some high-strength alumi-
As with pitting, crevice corrosion is slow to start, but once num, titanium, and some types of stainless steels when they
started, progresses at ever increasing rates (due to various are exposed to acidic materials such as acid paint removers,
electrochemical factors). Crevice corrosion is also most in- acidic metal pretreatments and cleaners, plating solutions,
tense in solutions containing chlorides (saltwater). Metals and some alkaline materials. This occurs when the materials
susceptible to pitting (stainless steel, aluminum, magnesium) causes a cathodic reaction on the metal surface that produces
are also susceptible to crevice corrosion. However, not all hydrogen. The hydrogen diffuses into the bulk metal, accu-
metals that are susceptible to crevice corrosion will be sus- mulating at grain boundaries and weldments weakening the
ceptible to pitting. Three general types of crevice corrosion structure. If the part is under load or contains residual manu-
are: Metal ion concentration cells, Oxygen concentration facturing stresses, sudden catastrophic failure occurs when
cells, Active-passive cells. the part can no longer sustain the internal and/or applied
stresses. Hydrogen embrittlement has been known to occur
1.7.7 Stress Corrosion Cracking. Stress corrosion crack- in parts stressed to only 15% of nominal tensile strength.
ing (SCC) is the intergranular cracking of a metal caused by
the combined effects of constant tensile stress (internal or 1.7.9 Corrosion Fatigue. Corrosion fatigue is the crack-
applied) and corrosion. Internal or residual stresses are pro- ing of metals caused by the combined effects of cyclic stress
duced by cold working, forming, and heat treatment opera- and corrosion and is very similar to stress corrosion crack-
tions during manufacture of a part and remain concealed in ing. If it is in a corrosive environment, no metal is immune
the part unless stress relief operations are used. Other hidden to some reduction in resistance to cyclic stressing. Corrosion
stresses are induced in parts when press or shrink fits are fatigue failure occurs in two stages. During the first stage,
used and when slightly mismatched parts are clamped to- the combined action of corrosion and cyclic stress damages
gether with rivets and bolts. All these stresses add to those the metal by pitting and forming cracks in the pitted area.
caused by applying normal loads to parts in operation. Met- The second stage is the continuation of crack propagation, in
als have threshold stresses below which stress corrosion which the rate of cracking is controlled by. In simplified
cracking will not occur. This threshold stress varies from terms, corrosion fatigue is mechanical fatigue aggravated by
metal to metal and depends on the characteristics of the stress a corrosive environment. In corrosion fatigue, the corrosive
that is applied. The following conditions must be present for environment causes a lowering or reduction of the fatigue
SCC to occur. The component or structure must be under a limit (the ability of a metal to resist fatigue cracking) of a
tensile stress. This tensile stress may be provided by an ex- metal as it undergoes cycles of stress. In the absence of a
ternally applied service load or a residual stress resulting corrosive environment, this same metal would be able to
from manufacturing procedures such as rolling, punching, withstand significantly more cycles of stress before cracking.
deep drawing, or welding. The material must also be ex- Corrosion fatigue seems to be most prevalent in environ-
posed to an environment that causes SCC. Whereas all met- ments that cause pitting corrosion.
als will form stress corrosion cracks in some environment
under the proper conditions, there is no one environment that

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Figure 1-13. Example of Filiform Corrosion

1.7.10 Filiform Corrosion. Filiform corrosion is a special surfaces and may lead to more serious corrosion in some
form of oxygen concentration cell corrosion (or crevice cor- locations. Filiform corrosion can be prevented by: storing
rosion) that occurs on metal surfaces having an organic coat- equipment in an environment with a relative humidity below
ing system. It is recognizable by its characteristic wormlike 70%; using coating systems with a low rate of diffusion for
trace of corrosion products beneath the paint film (see Figure oxygen and water vapors; maintaining coatings in good con-
1-13). Filiform occurs when the relative humidity of the air ditions; and washing equipment to remove acidic contami-
is between 78% and 90% and when the surface is slightly nants from the surface (such as those created by air pollut-
acidic. It starts at breaks in the coating system (such as ants). Filiform corrosion most often occurs in humid
scratches and cracks around fasteners and seams) and pro- environments. Once the humidity drops below 65%, Filiform
ceeds underneath the coating because of the diffusion of wa- corrosion stops. When the humidity rises above 95%, blis-
ter vapor and oxygen from the air through the coating. Fili- ters form rather than filaments. Filiform corrosion forms
form corrosion can attack steel, magnesium, and aluminum mostly on steel, aluminum, magnesium, and zinc.

Figure 1-14. Illustration of a Fretting Corrosion Cell

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1.7.11 Fretting Corrosion. Fretting corrosion (see Figure 1.8.2 Steel. Ferrous (iron) alloys are used to manufacture
1-14) is a special form of concentration cell corrosion that many components and assemblies in SE and other equip-
occurs in combination with surface wear. The corrosion ment such as frames and bodies of trailers, and lesser struc-
products increase the wear of the surface, and the wear ex- tural parts such as brackets, racks, and panels. If unprotected,
poses additional bare metal surface to be corroded. The over- ferrous alloy surfaces, (with the exception of stainless steels
all effect is greater than the single effects of corrosion and also known as corrosion resistant steel (CRES)), corrode
wear added together. It has the general appearance of gall- easily in the presence of moisture. Ferrous alloy surfaces are
ing, in which chunks of metal are torn from the surface with normally painted or plated to prevent corrosion. Corrosion of
corrosion at the torn areas or ragged pits. This type of cor- steel is easily recognized because the corrosion product is
rosion occurs on faying surfaces of close tolerance and on red or black color. When ferrous alloys corrode, a dark cor-
parts under high pressure in a corrosive environment when rosion product usually forms first. When moisture is present,
there is slight relative movement of parts (such as that caused this coating is converted to the common red or black corro-
by vibration). Fretting corrosion is normally encountered in sion product.
heavily loaded static joints that are subject to vibration and
that are not sealed to prevent moisture entry. Fretting corro- 1.8.3 Aluminum. Aluminum and aluminum alloys are
sion is corrosion that occurs between metals that are under widely used for SE construction. Aluminum is highly an-
load and subject to vibration and/or slip. It appears as pits or odic, as evidenced by its position in the galvanic series.
grooves in the metal surrounded by corrosion products. Fret- However, the formation of a tightly adhering oxide film of-
ting corrosion can be very destructive in that it loosens mated fers increased resistance under mild corrosive conditions.
parts and close tolerance fittings that in turn lead to stress or Some aluminum parts are protected with an electrochemi-
fatigue failures. In the case of iron alloys, brown to red iron cally applied anodized coating. Aluminum oxide film on alu-
oxide will be visible from the area or interface experiencing minum is a naturally occurring protective film; anodizing
fretting corrosion. On aluminum alloys, a black corrosion increases the thickness of the oxide film. When this coating
product is evident. Fretting corrosion is most commonly is damaged, it can only be partially restored by chemical
found in heavily loaded joints that are subject to vibration surface treatment. Avoid unnecessary destruction of the an-
such as press fitted ball bearing races, bolted flanges, fayed odized surface layer during the processing of anodized alu-
surfaces, electrical connections, and riveted areas. minum.

1.8 METALS AFFECTED BY CORROSION. 1.8.3.1 The corrosion product of aluminum is a white to
gray powdery material (aluminum oxide or hydroxide),
The characteristics of corrosion on SE metals are summa- which can be removed by mechanical polishing or brushing
rized in Table 1-1. The following is a discussion of corrosion with an abrasive. Aluminum is anodic to most other metals,
characteristics of commonly used metals. and, when in contact with them, galvanic corrosion of the
aluminum will occur. Aluminum alloys are subject to pitting,
1.8.1 Magnesium. Magnesium alloys are the lightest intergranular corrosion, and stress corrosion cracking. In
structural metals used for SE construction. These alloys are some cases, the corrosion products of a metal in contact with
highly susceptible to corrosion, which appears as white, aluminum are corrosive to aluminum. Therefore, it is neces-
powdery mounds or spots when the metal surface is exposed sary to clean and protect aluminum and its alloys against
to the environment without a protective finish. The normal corrosion.
oxide-carbonate film formed on magnesium alloys does not
provide sufficient corrosion protection even in the mildest 1.8.3.2 Because pure aluminum is more corrosion-resis-
environment. The rate of corrosion of a magnesium alloy tant than most alloys, aluminum sheet stock is often covered
increases when the alloy is immersed in water or periodi- with a thin layer of nearly pure aluminum called cladding.
cally subjected to moisture. Corrosion may also be acceler- Cladding is often removed by harsh treatment with abrasives
ated by dissimilar metal couples and when conductive con- and tooling, exposing a more corrodible surface. In such ar-
taminants are dissolved in water. Corrosion of magnesium eas, paints and CPCs are especially important. However, in
alloys can be greatly diminished by the use of the proper environments where SE is exposed to salt-laden atmosphere
protective finish. Some magnesium parts in use were origi- or significant industrial pollutants, all bare aluminum sur-
nally protected by anodizing processes, such as HAE and faces require protection.
DOW 17 coatings. The HAE process can be identified by the
brown to mottled gray appearance of the unpainted surface. 1.8.4 Copper and Copper Alloys. Copper and copper al-
DOW 17 coatings have a green to grayish-green color. Elec- loys are quite corrosion-resistant, with corrosion usually lim-
trolytic coatings are thicker than those applied by immersion ited to staining and tarnish. Generally, such changes in sur-
or brushing. Electrolytic finishes cannot be restored in the face conditions are not dangerous and usually do not affect
field. Take care to minimize removal of these coatings. At the part. Copper corrosion is evidenced by the accumulation
the field level, corrosion removal and surface pretreatment of blue or blue-green corrosion products. Protective paint
on magnesium parts should be referred to the Aircraft Struc- coatings are seldom required because of the inherent resis-
tural Maintenance Technicians for repair of the conversion tance of the metal. However, paint finishes may be applied
coatings.

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for appearance purposes. The green patina is merely a thin ditions that can destroy the oxide film on their surfaces.
coating consisting mainly of basic copper sulfate and per- Stainless steels are highly susceptible to crevice corrosion
haps some hydrated copper carbonate. The patina in the thin, and stress corrosion cracking in moist, salt-laden environ-
firmly adhering state actually offers increased corrosion pro- ments. In addition, if proper techniques of sealing and pro-
tection to the base metal, but the patina in a rough or frosted tective coating are ignored, they can cause galvanic corro-
state should be removed. When coupled with most metals sion of almost any other metal with which they are in contact.
used in SE construction, copper is the less active metal and Stainless steels may be magnetic or nonmagnetic. Magnetic
greatly accelerates the corrosion of other metals. This is es- steels are identified by numbers in the American Iron and
pecially true in copper/aluminum couples. Examples are Steel Institute (AISI) as 400-series (such as 410 and 430).
usually found in electrical components and in areas where These steels are not as corrosion-resistant as nonmagnetic
copper bonding strips or wires are fastened to an aluminum steels, which are identified by numbers in the AISI 300-se-
chassis or structural components. ries (such as 304 and 316). The AISI 300-series steels have
nickel contents ranging from 6% to 22%; the 400-series
1.8.5 Stainless Steel. Stainless steel or CRES, as they steels have nickel contents of only 2%.
are more properly described, are alloys of iron with chro-
mium. Many other elements such as nickel, sulfur, molybde- 1.8.6 Nickel and Chromium. Nickel and chromium are
num, vanadium, cobalt, columbium, titanium, and aluminum used as protective plating. Chromium plating is also used to
are added in various amounts and combinations to develop provide a smooth, wear resistant surface and to reclaim worn
special characteristics. Stainless steels are much more resis- parts. A nickel undercoat is used for corrosion resistance in a
tant to common rusting, chemical actions, and high-tempera- marine environment. The degree of protection depends on
ture oxidation than ordinary steels because of the formation plating thickness. Both of these metals form continuous ox-
of an invisible oxide film or passive layer on the surface of ide coatings that can be polished to a high luster and still
these alloys. Corrosion and heat-resistance are the major fac- protect themselves and any underlying metal. Chromium
tors in selecting stainless steels for a specific application. coatings contain cracks, and corrosion originates at the base
However, it should be emphasized that stainless steels are metal below these separations.
not a cure for all corrosion problems because of service con-

Table 1-1. Corrosion of Metals - Type of Attack and Appearance of Corrosion Products

Alloy Corrosion Susceptibility Appearance of the Corrosion

Magnesium Pitting Rough, white powdery deposits
Low Alloy Steel Surface oxidation, pitting, concentration Reddish-brown or black deposits
cell
Aluminum Alloy Surface oxidation, pitting, intergranular, White to gray powdery deposits
exfoliation, stress corrosion, fatigue,
and fretting, concentration cell
Stainless Steel/CRES (300-400 Series) Crevice corrosion, some pitting in a Rough surface, sometimes a red,
marine environment or water storage brown, or black uniform stain or
containers with high chlorine levels, pits
corrosion cracking intergranular cor-
rosion (300 series) and surface corro-
sion (400 series)
Copper-Base Alloys, Brass, Bronze Surface oxidation, pitting Blue to blue-green powdery deposits
Chrome/Nickel Pitting (promotes rusting of the sub- Usually there are no visible corrosion
strate steel where the pits in the plat- products on the plating surfaces.
ing occur). Blistering of the plating is due to
the rusting and lifting of the sub-
strate metal.

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CHAPTER 2
CLEANING
2.1 GENERAL. the nearest base location unless within 1.25 miles of salt
water. Locations within 1.25 miles of salt water are consid-
2.1.1 Introduction. A well developed cleaning program ered severe and require 90 day wash. Contact AFCPCO for
utilizing approved cleaning materials and processes is a key further guidance if needed.
factor in reducing the impact of corrosion. Use of untested
or unauthorized cleaning materials may cause premature 2.1.3 Definition of Cleaning. Cleaning is a broad term
coating system failure and or accelerated corrosion. covering methods and materials needed to remove soils from
a surface. Selection of an appropriate cleaning method in
2.1.2 Support Equipment (SE) Wash Cycles. any given case depends on three important factors: (1) type
and amount of soil, (2) base material composition and sur-
NOTE face condition, and (3) degree of cleanliness required.

Washing is a critical element of a comprehensive 2.1.4 Types of Cleaners. Cleaners that are used in this
corrosion program which also includes using only technical manual may be placed in types as follows:
qualified products for washing, painting, and other
corrosion prevention processes. This program must 2.1.4.1 Alkaline cleaners remove soil by displacement of
include refurbishment of the equipment prior to the contaminants from the surface rather than by direct solu-
deterioration from corrosion, routine touch-up of tion in the cleaner. After displacement, the soils may be car-
the coating system, use of corrosion preventive ried in the body of the cleaner as a suspension; it may sepa-
compounds (CPC) where touch-up cannot be ac- rate, or in the case of fatty soils, it may react partially or
complished immediately, and covered storage completely with the cleaner to form water-soluble soap.
where practical. Cleaners of this type usually have components that aid in
cleaning by lifting the soils and other contaminants from a
For the purpose of this chapter SE refers only to powered surface.
and non-powered Aerospace Ground Equipment to include
propulsion and munitions handling trailers. However, when 2.1.4.2 Solvent cleaners remove a soil by dissolving the
unique operational requirements exist for specific equipment, soil and usually leave a thin film or residue of an oily nature.
the wash schedules, corrosion prevention and inspection pro- Removal of this oily film or residue is accomplished by us-
cesses can be extended and called out in the equipment/end- ing an alkaline cleaner.
item specific commodity manual, if approved by the cogni-
zant engineering authority. Corrosion prevention, 2.1.4.3 Solvent emulsion cleaners remove a soil by emul-
maintenance inspection, repair and overhaul addressed in sifying the oil constituent of the soil and holding it in sus-
equipment/end-item commodity manuals take precedence pension until rinsed from the surface with water.
over this manual. MAJCOMs may add additional types of
equipment to the wash program. SE must be washed in ac- 2.1.5 Methods of Cleaning. Methods of cleaning used in
cordance with Table 2-1. Wash can be scheduled in conjunc- this technical manual are four types, as follows:
tion with phase inspection if scheduled within due month.
MAJCOMs and local units may mandate or implement wash
2.1.5.1 Hand cleaning is commonly used when the parts/
intervals more frequently than those reflected in Table 2-1.
equipment cleaning volume of work is too small, or the parts
When determining more frequent wash cycle intervals, a va-
too large to justify the expense of special equipment. Clean-
riety of factors should be considered. If the corrosion protec-
ing solutions may be applied by means of brushes, swabs, or
tive systems (primers and topcoats) are in poor condition or
cloths. Wherever the cleaning materials may be harmful to
are compromised in any way, the coatings have not been
the skin, personnel shall be supplied with proper safety
touched up, the equipment is stored outdoors, and/or there is
equipment. Hand cleaning is time consuming and may use
already evidence of corrosion, more frequent washing and/or
more water than other washing techniques. Pressure washers
rinsing is of increased importance. Where corrosion of this
are normally used; however, organizations sometimes use
equipment is already a problem, wash cycles even more fre-
“Foamers” to wash equipment.
quent than 90 days/quarterly is recommended. If the SE is
temporarily assigned to locations where cleaning is not prac-
tical, the affected equipment shall be cleaned, inspected, and 2.1.5.2 Spray washing is usually the most-rapid method
lubricated within 30 days of returning to home station. Base for cleaning. The chief feature of spray washing is the appli-
locations not listed in Table 2-1 will use the requirements of cation of the mechanical force of the spray in addition to the

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chemical and physical actions of the cleaning solution. By duces a very thick, foamy solution that adheres well to the
means of these combined actions, the soil is rapidly wetted, exterior of the SE allowing the cleaning solution to maintain
penetrated, loosened, removed from the surface, and sus- contact with the surface being cleaned.
pended in the solution in a free-rinsing condition.
2.1.5.4.1 The solution is allowed to dwell on the SE
2.1.5.3 Immersion in cleaning tanks is usually used for briefly, scrubbed with wash pads or mops, then is rinsed off
disassembled parts submerged in an authorized cleaning the SE with fresh water.
compound(s). Since the cleaning compounds may act as an
electrolyte between two or more metals, care shall be taken 2.1.5.4.2 Detergent can be added at a pre-set and con-
not to intermingle the different metals together in the same trolled rate when using foamers or pressure washers for SE
cleaning tank. cleaning. Therefore, these methods are preferred over hand
washing, which cannot regulate the amount of detergent
2.1.5.4 Use of foamers involve injecting air into a tank used.
containing a soap solution, which rapidly mixes the air and
solution as it leaves the tank via a hose. This process pro-

Table 2-1. Wash Interval Based on Corrosion Severity Zones

Severe Moderate/Mild
Location (90 days) (180 Days)
Afghanistan (All Locations) X
AJ Taif, SA X
Al Dhafra, UAE X
Al Jouf, SA X
Al Udeid AB, Qatar X
Ali Al Salem, Kuwait X
Allen C. Thompson Fld.; Jackson, MS (ANG) X
Altus AFB, OK (AETC) X
As Sulayyil, SA
Anderson AFB, GU X
Anchorage IAP, AK (ANG) X
Andrews AFB, MD (Wash. DC) X
Atlantic City, NJ (ANG) X
Aviano AB, IT X
Bahrain X
Balad X
Bangor IAP, ME (ANG) X
Barksdale AFB; Shreveport, LA X
Barnes M. Apt; Westfield, MA (ANG) X
Battle Creek, MI (ANG) X
Beale AFB; Marysville, CA X
Boise Air Term., ID (ANG) X
Bradley IAP; Windsor Locks, CT (ANG) X
Brindisi/Casale AB, IT X
Buckley ANGB; Denver, CO (ANG) X
Burlington IAP, VT (ANG) X
Byrd Fld.; Richmond, VA (ANG) X
Camp Lemonnier, Djibouti X
Cannon AFB; Clovis, NM X
Capital Mun. Apt.; Springfield, IL (ANG) X
Channel Island; Port Hueneme NAS, CA (ANG) X
Cheyenne Apt., WY (ANG) X
Charleston AFB, SC X

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Table 2-1. Wash Interval Based on Corrosion Severity Zones - Continued

Severe Moderate/Mild
Location (90 days) (180 Days)
Charleston Apt., WV (ANG) X
Columbus AFB, MS (AETC) X
Curacao, Netherlands, Antilles X
Danelly Fld.; Montgomery, AL (ANG) X
Davis-Monthan AFB; Tucson, AZ X
Des Moines IAP, IA (ANG) X
Dhahran, SA X
Diego Garcia X
Dobbins ARB; Marietta, GA (AFRC) X
Douglas IAP; Charlotte, NC (ANG) X
Dover AFB, DE X
Duluth IAP, MN (ANG) X
Dyess AFB; Abilene, TX X
Eareckson (Shemya) AFB, Aleutian Is., AK X
East WV Reg. Apt: Martinsburg, WV (ANG) X
Edwards AFB; Rosamond, CA X
Eglin AFB; Valparaiso, FL X
Eglin AFB (Aux Fld. #3), FL X
Eielson AFB, AK X
Ellington Fld.; Houston, TX (ANG) X
Ellsworth AFB; Rapid City, SD X
Elmendorf AFB; Anchorage, AK X
Fairchild AFB; Spokane, WA X
Fairford, UK X
Falcon AFB, CO X
Forbes Fld.; KS (ANG) X
Fort Smith Mun. Spt., AR (ANG) X
Fort Wayne Apt., IN (ANG) X
Francis E. Warren AFB; Cheyenne, WY (ANG) X
Fresno Air Term., CA (ANG) X
Geilenkhirchen, GE X
Gen. Mitchell IAP.; Milwaukee, WI (ANG) X
Grand Folks AFB; Emarado, ND X
Great Falls IAP, MT (ANG) X
Greater Peoria Apt.; IL (ANG) X
Griffiss AFB; Rome, NY X
Grissom ARB; Peru, IN (AFRC) X
Hancock IAP; Syracuse, NY (ANG) X
Hanscom AFB; Bedford, MA X
Harrisburg IAP, PA (ANG) X
Hector IAP; Fargo, ND (ANG) X
Hickam AFB; Honolulu, HI X
Hill AFB; Ogden, UT X
Holloman AFB; Alamogordo, NM X
Homestead AFB, FL (AFRC) X
Howard AB; Panama X
Hulman Reg. Apt., IN (ANG) X
Hurlburt Fld.; Fort Walton Beach, FL X

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Table 2-1. Wash Interval Based on Corrosion Severity Zones - Continued

Severe Moderate/Mild
Location (90 days) (180 Days)
Incirlick AB, Turkey X
Istres AB, France X
Jacksonville IAP, FL (ANG) X
Jeddah, SA X
Joe Foss Fld.; Sioux Falls, SD (ANG) X
Kadena AB, Japan X
Keesler AFB; Biloxi, MS X
Key Fld.; Meridian, MS (ANG) X
Khamis Mushay, SA X
Khandahar, Afghanistan X
Kiruk, Iraq X
King Khalid, SA X
Kingsley Fld.; Klamoth Falls IAP, OR (ANG) X
Kirtland AFB, NM; Albuquerque, NM X
Fort Kutaka Army Base, AZ X
Kunsan AB; S. Korea X
Lackland AFB, TX X
Lajes Fld.; Azores, Portugal X
Lambert Fld.; St. Louis IAP, MO (ANG) X
Langley AFB; Hampton, VA X
Larnaka International Apt., Cyprus X
Laughlin AFB; Del Rio, TX X
Lincoln Mun. Apt, NE (ANG) X
Little Rock AFB, AR (AETC & ANG) X
Luke AFB; Glendale, AZ X
MacDill AFB; Tampa, FL X
Malmstrom AFB; Great Falls, MT X
Manas, Kyrgystan X
Mansfield Lahm Apt., OH (ANG) X
Mantas, Ecuador X
March ARB; Riverside, CA (AFRC & ANG) X
Martin St. Apt.; Baltimore, MD (ANG) X
Maxwell AFB; Montgomery, AL X
McChord AFB; Tacoma, WA X
McConnell AFB, Wichita, KS X
McEntire ANGB; Columbia, SC (ANG) X
McGhee Tyson Apt; Alcoa, TN (ANG) X
McGuire AFB; Wrightstown, NJ X
McMurdo Station, Antarctica X
Memphis IAP, TN (ANG) X
Minot AFB, ND X
Minn.-St. Paul IAP, MN (ARFC & ANG) X
Misawa AB, Japan X
Moffett Fld., CA (ANG) X
Moody AFB; Valdosta, GA (AETC) X
Moron AB, Spain X
Mountain Home AFB; Boise, ID X
NAS Fort Worth, TX (ANG & AFRC) X

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Table 2-1. Wash Interval Based on Corrosion Severity Zones - Continued

Severe Moderate/Mild
Location (90 days) (180 Days)
NAS Keflavik, Iceland X
NAS New Orleans, LA (ANG & AFRC) X
NAS Rota; Rota, Spain X
NAS Sigonella; Sicily, Italy X
NAS Souda Bay (Chania Apt.), Crete X
Nashville Met. Apt, TN (ANG) X
Nellis AFB; Las Vegas, NV X
Newburgh Apt. NY (ANG) X
New Castle Co. Apt.; Wilmington, DE (ANG) X
Niagara Falls IAP, NY (AFRC & ANG) X
Offutt AFB; Omaha, NE X
O’Hare IAP; Chicago, IL (AFRC) X
Osan AB; S. Korea X
Otis ANGB; Falmouth, MA (ANG) X
Patrick AFB; Cocoa Beach, FL X
Pease ANGB; Portsmouth, NH (ANG) X
Peterson AFB; Colorado Springs, CO X
Pittsburgh IAP, PA (AFRC & ANG) X
Pope AFB; Fayetteville, NC X
Portland IAP, OR (ANG) X
Prince Sultan AB, Al Kharj, SA X
Puerto Rico IAP/ Muniz ANGB; San Juan X
Quonset St. Apt; Providence, RI (ANG) X
RAF Akrotiri, Cyprus X
RAF Lakenheath, UK X
RAF Mildenhall, UK X
Ramstein AB, GE X
Randolph AFB; San Antonio, TX (AETC) X
Reno/Tahoe IAP, NV (ANG) X
Rhein-Main, GE X
Richenbacker IAP; Columbus, OS (ANG) X
Riyadh, SA X
Robins AFB; Warner Robins, GA X
Rosecrans Mem. Apt.; St. Joseph, MO (ANG) X
Salt Lake City IAP, UT (ANG) X
Schenectady Co. Apt. NY (ANG) X
Scott AFB; Belleville, IL X
Selfridge ANGB; Mount Clemens, MI (ANG) X
Seymour Johnson AFB; Goldsboro, NC X
Shaw AFB; Sumter, SC X
Sheppard AFB; Wichita Falls, TX (AETC) X
Sioux Gateway Apt.; Sioux City, IA (ANG) X
Sky Harbor Apt.; Phoenix, AZ (ANG) X
Spangdahelm AF, GE X
Springfield-Bleckley Mun. Apt., OH (ANG) X
Standiford Fld. IAP; Louisville, KY (ANG) X
Suffolk Co. Apt., NY (ANG) X
Tabuk, SA X

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Table 2-1. Wash Interval Based on Corrosion Severity Zones - Continued

Severe Moderate/Mild
Location (90 days) (180 Days)
Taegu, S. Korea X
Talil, Iraq X
Thumrait, Oman X
Tinker AFB; Oklahoma City, OK X
Toledo Exp. Apt.; Swanton, OH (ANG) X
Travis AFB; Fairfield, CA X
Travis Fld.; Savannah, GA (ANG) X
Truax Fld./ Dane City Reg. Apt.; Madison, WI (ANG) X
Tuscon IAP, AZ (ANG) X
Tulsa IAP, OK (ANG) X
Tyndall AFB, Panama City, FL X
Utapao IAP, Thailand X
Vance AFB; Enid, OK (AETC) X
Vandenberg AFB; Lompoc, CA X
Westover AFB; Chicopee, MA (AFRC) X
Whiteman AFB; Knobnoster, MO X
Willow Grove ARS; Philadelphia, PA (AFRC & ANG) X
Will Rogers IAP; Oklahoma city, OK (ANG) X
Wright-Patterson AFB; Dayton, OH X
Yeager Apt.; Charlesron, WV (ANG) X
Yokota AB, Japan X
Youngstown-Warren Reg. Apt. ARS, OH (AFRC) X

2.1.6 Cleaning Materials. An effective cleaning program NOTE

significantly reduces the adverse impact of corrosion. The
cleaning program includes the selection of authorized clean- • A listing of the most current QPL/QPD for a
ing materials, mixed in the proper ratio for the surface to be specific cleaning compound can be found on
cleaned, properly applied, and removed. the Defense Logistics Agency website for
specifications, handbooks, and QPL/QPD data
2.1.6.1 Material compatibility is a key element in a clean- (http://assist1.daps.dla.mil/quicksearch.) or on
ing program. Cleaning material composition and surface the Air Force Corrosion Prevention and Con-
condition affect the methods and materials to be used in trol office website located on the Air Force Por-
cleaning. Certain nonferrous metals, such as zinc and alumi- tal.
num, present special problems because heavy-duty alkaline • Many of the authorized cleaning compounds
or strong acid cleaners attack the metal. Roughness of sur- are biodegradable in many waste treatment fa-
face tends to hold a soil, thereby making it harder to remove. cilities, however some are not, before purchas-
ing and using a specific product, consult with
the base environmental management to verify
that the cleaners can be introduced into the
waste water treatment system.
Selection and use of unapproved cleaning com-
pounds or approved cleaning compounds improp- 2.1.6.2 Authorized cleaning materials, mixing ratios and
erly diluted may cause damage to the components cleaning procedures that may be used on SE are shown in
or painted surfaces. Each cleaner has specific uses, Table 2-2. MIL-PRF-87937, Cleaning Compound Aerospace
and must be carefully used to prevent personal in- Equipment, is the preferred cleaning compound for SE. How-
jury or damage to equipment. Only use authorized ever, if MIL-PRF-87937 is not available, MIL-PRF-85570;
cleaners that are listed on the Qualified Product Cleaning Compound Aircraft Exterior, may be used. The fol-
List/Database (QPL/QPD) for a specific specifica- lowing is a brief general description of the different cleaning
tion. Also, ensure all cleaning compounds are compounds.
properly diluted for the types soils to be cleaned.

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2.1.6.2.1 MIL-PRF-85570, Cleaning Compound Aircraft effective as a spot cleaner. It should not be used where ven-
Exterior, Type I, is for general use on exterior surfaces, and tilation is poor or on nonpolyurethane paints/markings, vinyl
is effective for use on heavy soils and grease. Type I contain markings/decals, unpainted/unprotected plastic or composite
solvents and should not be used in poorly ventilated areas or surfaces.
on painted lacquer surfaces, unpainted plastic or unpainted
composite surfaces. 2.1.6.2.8 MIL-PRF-87937, Cleaning Compound Aero-
space Equipment, Type I, is a terpene based solvent emul-
2.1.6.2.2 MIL-PRF-85570, Cleaning Compound Aircraft sion cleaning for general use on exterior surfaces. It is effec-
Exterior, Type IA, is the same product as Type I, but is in an tive for removing heavy oils, greases and carbon deposits.
aerosol used for spot cleaning on exterior surfaces. Type IA Suitable for use on high gloss or tactical paint systems. Type
contains solvents and should not be used in poorly ventilated I should not be used in poorly ventilated areas. Do not heat
areas or on painted lacquer surfaces, unpainted plastic or above 115 °Fahrenheit (F). Type I will separate-out oily
unpainted composite surfaces. waste, so the waste can be removed and disposed of while
the remainder of the liquid is sent to a waste treatment facil-
2.1.6.2.3 MIL-PRF-85570, Cleaning Compound Aircraft ity.
Exterior, Type II, does not contain solvents and is used for
general use on exterior and interior surfaces. It is effective 2.1.6.2.9 MIL-PRF-87937, Cleaning Compound Aero-
on light oils and hydraulic fluids. space Equipment, Type III, is a gelled cleaner, and is effec-
tive for cleaning medium to heavily soiled surfaces. May be
2.1.6.2.4 MIL-PRF-85570, Cleaning Compound Aircraft used on painted or unpainted surfaces where additional dwell
Exterior, Type III, is for use on high gloss surfaces only. It time is desired. It should be used in areas that can tolerate
contains abrasives that remove soils by wearing away the high volumes water rinsing necessary to remove the gelled
surface that holds the soil. This cleaner will raise the gloss of cleaning compound. Since the cleaning compound is a gel, it
gloss, semi-gloss, or flat topcoats. Type III is used to spot will adhere to vertical surfaces for more effective cleaning.
clean, and clean engine exhaust areas on gloss finishes. To ensure the cleaning compound effectiveness, apply the
cleaning compound to dry surfaces. Type III will separate-
2.1.6.2.5 MIL-PRF-85570, Cleaning Compound Aircraft out oily waste, however, because the cleaning compound is a
Exterior, Type IV, contains solvents, detergents, and sus- gel-type material the oil/cleaner separation is difficult to de-
pended rubber particles. It is a spot cleaner, for use on tacti- termine unless the solution sits for several hours.
cal paint systems. It effectively cleans exhaust tracks,
smudges, boot marks, or other embedded soils. When the 2.1.6.2.10 MIL-PRF-87937, Cleaning Compound Aero-
cleaning compound containing the rubber particles are rubbed space Equipment, Type IV, is heavy duty cleaner, effective
on a soiled surface, the particles act like tiny erasers and for cleaning heavy oils and greases. This material differs
remove soil by entrapping the soil in the rubber particles. from Type I in that it has no flash point. Suitable for use on
This cleaner will not alter the gloss of a camouflage coating. high gloss or tactical paint systems. Type IV will separate
out oily waste, so the oil can be removed and disposed of
2.1.6.2.6 MIL-PRF-85570, Cleaning Compound Aircraft while the remainder is sent to a waste treatment facility.
Exterior, Type V, is a low solvent (less than ten percent),
gelled cleaner which can be used to replace solvent cleaning 2.1.6.2.11 MIL-PRF-87937, Cleaning Compound Aero-
where water rinsing can be allowed, and can be used to clean space Equipment, Types I and IV cleaners may be used in
vertical surfaces where thin cleaners will run off. To be fully dip tanks but are not formulated for use in vapor degreasing
effective, Type V must be applied to a dry surface, do not tanks. The gel-type cleaning compounds are not suitable for
prerinse the SE before application of the Type V cleaning dip tank cleaning operations.
compound.

2.1.6.2.7 MIL-C-43616, Cleaning Compound Aircraft Sur-

faces, Class IA, is an aerosol version of Class I as is very

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Table 2-2. Authorized Cleaning Materials

Type of Soils or
Surfaces To Be Cleaning Mixing Cleaning
Cleaned Material Directions Procedures Comments
Light Soils (Dirt, Dust, MIL-PRF- 1 part cleaner Apply cleaner solution Best used for general cleaning
Mud, Salt, Loose Soot) 85570, Type to 16 parts with a foam generator, on painted and unpainted
I water spray, sponge, soft surfaces. Suitable for use on
MIL-PRF- 1 part cleaner bristle brush or cloth. high gloss or tactical paint
85570, Type to 9 parts Scrub and then rinse systems.
II water with fresh water and
MIL-PRF- 1 part cleaner dry.
87937, Type to 20 parts
I water
MIL-PRF- Undiluted Allow the cleaner to The gel-type cleaning com-
87937, Type dwell for 1-2 minutes, pound is designed to adhere
III or MIL- then agitate with a to vertical surfaces for more
PRF- 85570, brush and completely effective cleaning. The
Type V rinse with water and cleaning compound contains
allow drying. abrasives that remove soils
by wearing away the surface
that holds the soil. This
cleaner will raise the gloss
of gloss, semi-gloss, or flat
topcoats. The cleaning com-
pound should be used in
areas that can tolerate high
volumes water rinsing nec-
essary to remove the gelled
cleaning compound. Do not
use on plastic parts.

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Table 2-2. Authorized Cleaning Materials - Continued

Type of Soils or
Surfaces To Be Cleaning Mixing Cleaning
Cleaned Material Directions Procedures Comments
Moderate to Heavy Soils, MIL-PRF-680, Undiluted Apply with a brush, pad,
Oils Hydraulic Fluid, Type II or or cloth and agitate,
Lube Oil, Light Preser- III, (CID repeat until surface
vatives and Carbon A-A- 59601) contaminants are re-
Buildup moved from the sur-
face or suspended in
the solvent. If oily
residue is acceptable,
rinse with water and
wipe dry with a clean
cloth. If oily residue is
not acceptable use the
diluted cleaning com-
pounds listed under the
moderate soils section
of this table.
MIL-PRF- Undiluted Allow the cleaner to The gel-type cleaning com-
87937, Type dwell for 1-2 minutes, pound is designed to adhere
IV or MIL- then agitate with a to vertical surfaces for more
PRF- 85570, brush and rinse with effective cleaning. The
Type III water. If the surface is cleaning compound contains
oily or greasy apply abrasives that remove soils
the cleaning compound by wearing away the surface
to the dry surface, al- that holds the soil. This
low the cleaning com- cleaner will raise the gloss
pound to dwell for of gloss, semi-gloss, or flat
5-15 minutes, then topcoats. The cleaning com-
agitate and rinse with pound should be used in
water. Agitate the area areas that can tolerate high
again with a brush and volumes water rinsing nec-
rinse with water to essary to remove the gelled
completely clean/rinse cleaning compound. Do not
the area. use on plastic parts.
MIL-PRF- 1 part cleaner Apply with a brush, pad, Has a very high solvent con-
85570, Type to 9 parts or cloth and agitate, tent. Should not be used
I water repeat until surface where ventilation is poor or
MIL-PRF- 1 part cleaner contaminants are re- on nonpolyurethane paints/
85570, Type to 4 parts moved from the sur- markings, unprotected plas-
II water face or suspended in tics or composite surfaces.
MIL-C-43616, 1 part cleaner the solvent. Com-
Class I to 16 parts pletely rinse with clean
water water. Wipe dry with a
clean cloth.

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Table 2-2. Authorized Cleaning Materials - Continued

Type of Soils or
Surfaces To Be Cleaning Mixing Cleaning
Cleaned Material Directions Procedures Comments
Heavy Oils, Greases and MIL-PRF-680, Undiluted Apply with a brush, pad, MIL-PRF-680 Type II or III,
Carbonized Exhaust Type II or III or cloth and agitate, also known as Stoddard’s
Deposits repeat until surface Solvent or Dry Cleaning
contaminants are re- Solvent, can be used to
moved from the sur- clean a variety of soils, par-
face or suspended in ticularly oils, greases and
the solvent. If oily hydraulic fluids. Type III has
residue is acceptable, a flash point of over 200 °F.
rinse with water and MIL-PRF-680 will leave a
wipe dry with a clean slight oily residue. This is
cloth. If oily residue is desirable if flash-rusting pro-
not acceptable use the tection is needed. If the part
diluted cleaning com- cleaned with MIL-PRF-680
pounds listed under the is to be painted or surface
heavy soils section of bonding is to occur, wiping
this table. the affected surfaces with a
lean cloth dampened with a
nonpetroleum based cleaning
compound, or solvent
cleaner such as Isopropyl
Alcohol TTI- 735 or Ac-
etone O-A-51, is necessary.
MIL-PRF- 1 part cleaner Wet surface with fresh Solvent emulsion cleaner.
87937, Type to 4 parts water. Apply cleaning Should not be used in
I water solution and scrub poorly ventilated areas. Do
briskly with abrasive not heat the cleaning com-
mat (MIL-A-9962, pound above 115 °F.
MIL-PRF- 1 part cleaner Type I, Grade A or B). Should not be used in poorly
85570, Type to 4 parts Rinse with fresh water ventilated areas or on
I water and dry. painted lacquer surfaces,
MIL-PRF- No mixing, this unpainted plastic or un-
85570, Type is a premixed painted composite surfaces.
IA aerosol After cleaning, the area
MIL-C-43616, 1 part cleaner must be thoroughly rinsed
Class I to 4 parts with water to prevent streak-
water ing or paint deterioration.
MIL-C-43616, No mixing, this
Class IA is a premixed
aerosol

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Table 2-2. Authorized Cleaning Materials - Continued

Type of Soils or
Surfaces To Be Cleaning Mixing Cleaning
Cleaned Material Directions Procedures Comments
Spot Cleaning - Engine MIL-PRF- Undiluted Type IV: Apply full Do not allow the cleaner to
Exhaust Areas 85570, Type strength with a non- dry on the surfaces or rins-
IV or V abrasive cleaning pad. ing may be difficult.
Allow 1 to 3 minutes
dwell time. Scrub with
a circular motion.
Rinse thoroughly, and
then dry with a clean
cloth. Do not allow
cleaner to dry on sur-
face.
Type V: Apply full
strength with brush or
pump spray device.
Allow 5 minutes dwell
time. Brush if neces-
sary, then spray with
fresh water to rinse.
Spot Cleaning - Stubborn MIL-PRF- Undiluted Apply full strength with Abrasive spot cleaner for gloss
Soil on Gloss Painted 85570, Type damp cloth. Allow the surfaces only. This cleaner
Surfaces III cleaner to dwell for will raise the gloss of gloss,
1-2 minutes. Rub with semi-gloss, or flat topcoats.
a circular motion. If
the surface is oily or
greasy apply the clean-
ing compound to the
dry surface, allow the
cleaning compound to
dwell for 5-15 min-
utes, then agitate and
rinse with water. Rub
with a circular motion
and completely rinse
area, then dry with a
clean cloth. Do not
allow cleaner to dry on
surface.
Spot Cleaning - Stubborn MIL-PRF- Undiluted Apply cleaner with a Cleaning compound contains
Soils on Tactical Paint 85570, Type nonabrasive cleaning rubber particles that aid in
Schemes Exhaust IV pad. Allow 1-3 min- the cleaning process. Do not
Tracks, Smudges, Boot utes dwell time. Rub allow the cleaner to dry on
Marks, or Other Em- with a circular motion. the surfaces or rinsing may
bedded Soils Rinse thoroughly, and be difficult.
then dry.

2.1.7 General Cleaning Material and Processes. operations because concentrated soap solutions tend to make
Cleaning compounds facilitate oils, grease, and soil removal. surfaces slippery, the cleaning solutions will not properly
However, cleaning compounds can damage certain material dissolve or lift the contaminants from the surface being
surfaces and parts if they are improperly diluted and applied. cleaned, and can impede the washing pads from loosening
the soils. In addition, concentrated solutions require more
2.1.7.1 Cleaning Solutions. Using cleaning solutions rinse water to remove excess cleaner and may cause paint
more concentrated than the manufacturer’s dilution rates are deterioration or corrosion.
not acceptable. This action may actually hamper washing

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2.1.7.2 Cleaning Compounds. Cleaning compounds may a. (MIL-PRF-87937 only). Rinse with water or wipe clean
impart Biochemical Oxygen Demand (BOD) to the washwa- with a damp cloth.
ter and increase the pH. Therefore, use of excessive amounts
of cleaning compounds should be avoided. b. (MIL-PRF-87937 only). Allow to dry or blow dry with
compressed air not to exceed 30 Pounds Per Square
2.1.7.3 Water Temperature. Hot-water washing breaks Inch Gauge (PSIG).
the bond between the grease/oil and the SE, flushing away
the grease and oil. Engineering studies have concluded that 2.1.8.2 Plastics. Clean with a solution of one part MIL-
hotwater washers reduces the cleaning compound usage, as PRF-87937 to four to fifteen parts water, depending on the
opposed to cold water washing, by approximately 80 per- soil. The heavier the soil, the stronger the solution needs to
cent, cleaning times by 20 to 75 percent, and potable water be. MIL-PRF-87937 must be diluted to work effectively.
usage 30 to 90 percent. Hot water shall be used, when fea-
sible, for SE cleaning operations. a. Rinse or wipe clean with a damp cloth.

2.1.7.4 Deployed/Remote Sites. At deployed/remote b. Allow to dry or blow dry with compressed air at less
sites, untreated, raw water can significantly impact the levels than 30 PSIG.
of dissolved metals/minerals in the washwater. Raw water
could dissolve metals from building and washwater plumb- 2.1.9 Cleaning of Electrical Parts. The electrical insula-
ing systems, including copper from copper pipe, zinc and tion, wiring, contact pins and components are subject to the
lead from galvanized pipe, etc. To assist units in deployed collection of oil, fungus, and dirt. Cleaning can be accom-
locations the following water quality standards are listed be- plished as follows:
low. Unless an emergency exists, organizations should have
the nearest Department of Defense (DoD) civil engineer as-
sess the water quality standards at the deployed locations
prior to the commencement of washing operations. Refer to
Chapter 7 for units deploying or returning from Southwest
Asia (SWA) environments. Do not clean electrical equipment with the power
on. There are hazards of personnel being shocked
or electrocuted. Disconnect batteries prior to
2.1.7.4.1 Water Assessment. In assessing the site wash
cleaning electrical generator sets as shorting of
water, the key water quality parameters: Potential of Hydro-
switches may cause power to be applied to sys-
gen (pH), water hardness, total dissolved solids (TDS), and
tem.
dissolved oxygen (DO) help assess the corrosivity of the wa-
ter supply. In general, low pH (less than 7.0), and hardness
(less than 50 milligrams per liter), and high DO content,
values approaching saturation, greatly increase the corrosiv-
ity of the water.
Any solvent must be used with extreme care on
2.1.7.4.2 Engines and Engine Components. Engines insulation and insulated wires, particularly in elec-
and engine components are usually washed in a washrack tric equipment.
using a pressurized hot water or steam cleaner. Cleaning
compounds may be used in the washing process. Care should 2.1.9.1 Insulation, wiring and parts shall be cleaned with a
be taken to ensure the forced water and/or steam is not al- clean cloth or sponge and the use of TT-I-735 Isopropyl Al-
lowed to migrate or be forced into confined areas that would cohol. Solvents such as dry cleaning fluids, mineral spirits,
prevent proper drying as subsequent corrosion could result. or paint thinners shall not be used to clean electrical insula-
A water displacing CPC should be applied as soon as pos- tion, insulated wiring and parts because of the injurious af-
sible after washing to corrosion prone areas such as piano fect of these solvents on materials, such as rubber and fiber,
hinges, behind seals, etc. and they are fire hazards.

2.1.8 Cleaning of Non-metal Parts Prior to Painting. 2.1.9.2 Pins (male contacts) and receiver holes (female
To ensure proper adhesion between the coating and non- contacts) which are contaminated by fungus growth can be
metal part being painted special consideration must be given cleaned by wiping with TT-I-735 Isopropyl Alcohol. A clean,
to ensure the part is properly prepared for painting. lint-free cloth moistened with the solvent should be used to
wipe the pins and a toothpick or pipe cleaner saturated with
2.1.8.1 Composites. Clean with Isopropyl Alcohol, TT-I- the solvent should be used to wipe out the holes.
735, Acetone, O-A-51, or a solution of one part MIL-PRF-
87937 to fifteen parts water.

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2.1.10 Preparation of SE for Cleaning. The cleaning cleaned by using large amounts of clean water. Heated water
operation is recommended in planned steps to obtain satis- (approximately 140 °F) will give best results.
factory results. In general, steps to be followed are as fol-
lows: NOTE

2.1.10.1 To protect against cleaning solution entrapment, Water needed for thoroughly rinsing shall be read-
lubricate all fittings which will be exposed to wash solutions ily available at the surface being cleaned. Streak-
in accordance with maintenance manuals or maintenance ing (white powder and surface dulling) will result
cards. If fittings do not accept lubrication, replace and lube if the cleaning solution remains on the surface be-
prior to wash. ing cleaned too long or dries.

2.1.10.2 Inspect the surface to be cleaned and refer to 2.1.10.9 If streaking appears, immediate reapplication of
Table 2-2 to determine the type of cleaning compound and the cleaning solution will usually reduce or eliminate this
mixing ratio of cleaning compound that should give the sat- condition.
isfactory cleaning results. From the inspection, determine
what areas should be masked or protected. 2.1.11 Cleaning of Engine Components and Enclo-
sures. Remove carbon from disassembled engine parts with
2.1.10.3 Protect louvers, scoops and other natural entrap- Specification SAE-AMS-C-19853 cleaning compound. Fol-
ments from the cleaning mixture by masking. Masking tape low material manufacturer’s instructions on the use of this
AA-883, and/or barrier paper, MIL-PRF-121, can be effec- product. This is a compound for removing or loosening car-
tively used for masking purposes. bon from engine components by means of immersion at am-
bient temperatures without agitation. This solution will re-
2.1.10.4 The cleaning solution shall not be allowed to dry move many standard paint finishes. This material shall be
on plastics, plate glass, and painted surfaces. The cleaning used in a tank provided with a cover and in a well-ventilated
solution shall not be applied to large areas that cannot be area, although a water seal is provided to reduce evaporation
adequately agitated and thoroughly rinsed before it dries. and loss of the solvent. The water seal aids in pre-rinsing,
Streaks and less effective cleaning will result if mixture dries reduces toxicity somewhat, and absorbs a portion of the cor-
on the surface being cleaned. roding type contamination introduced when parts are being
cleaned.
2.1.10.5 Outside cleaning will be closely controlled or not
done during the warmest part of the day or on windy days,
as the cleaning solution will dry rapidly. Wetting the surface
with water before applying the cleaning solution will cool
the surface and help prevent fast drying in hot weather. Carbon remover compound SAE-AMS-C-19853
Cleaning shall be accomplished in shaded areas whenever contains chemical compounds that are hazardous
possible during hot weather (above 80 °F). and must be confined to tank use. Disposal of this
compound must be in accordance with state, local,
2.1.10.6 Apply the cleaning solution until the area to be and federal requirements.
cleaned is completely covered.
2.1.11.1 To prevent contamination of carbon remover so-
2.1.10.7 Agitate the compound by scrubbing the surface lution, remove all loose oil, grease and dirt from the parts
with a nonmetallic brush. Vigorous scrubbing action with a with solvent MIL-PRF-680, Type II or III, A-A-59601 or
brush is not usually required except in extremely soiled ar- MIL-PRF-32295, Type II.
eas. Depending on weather conditions, allow approximately
five to ten minutes from application of mixture before rins- 2.1.11.2 Place parts in a mesh basket, or suspend by wire,
ing. and immerse in the lower layer of the solution. Agitation or
excessive mixing of the two layers shall be avoided during
NOTE cleaning operations.

Do not allow the cleaning mixture to dry on the

equipment before rinsing.

2.1.10.8 Thoroughly rinse mixture from the area being

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• Ensure the parts are below the water seal. Do Paints may contain toxic materials such as chro-
not allow the basket or parts to rest on the bot- mates, barium, strontium, or lead. Use goggles,
tom of the tank. gloves, and cartridge respirator during mechanical
cleaning of painted surfaces. Hearing protection
• Do not intermingle ferrous and nonferrous and air respirator shall be worn during plastic me-
metal parts in the same immersion tank of car- dia blasting operations as directed by local bioen-
bon remover or other cleaning compounds as vironmental engineer. Contact the local safety and
corrosion will likely occur. health office for proper personal protection equip-
ment (PPE).
2.1.11.3 Close the lid of the tank and allow the parts to
soak approximately two hours, depending on the hardness
and extent of the deposits to be removed.

2.1.11.4 Raise the parts slowly, permitting the parts to • SE personnel assigned to coating removal tasks
come in contact with the upper layer for approximately 30 must be specifically trained for the function to
seconds, then remove from the tank. which they are assigned such as, the use of
chemical paint removers, abrasive blasting ma-
2.1.11.5 Rinse parts with hot water under pressure and al- terials and processes, powered tools, and dam-
low to dry. When heated water is not ready available, cold age limitations. Inadequate training will lead to
water may be used. However, longer rinsing is required with further damage of equipment and poses a safety
cold water than heated water. hazard to the individual.

2.1.11.6 If the SAE-AMS-19853 cleaning compound is not • For repainting operations, under no circum-
available, MIL-PRF-87937, Type I is capable of removing stances shall the primer be completely removed
carbon. Use it in a concentration of two parts water to one to expose the composite material substrate.
part cleaner at ambient temperatures in the tank. Do not al- Damage to surface fibers usually occurs when
low parts to remain immersed in the MIL-PRF-87937, Type primer is completely removed.
I for more than four hours without removal and inspecting
the parts for cleanliness. For heavy carbon deposits 16-hour Coatings shall be removed from composites, such as fiber-
total immersion may be necessary. After immersion, rinse glass, carbon/graphite, and Kevlar® using only mechanical
with clean water. removal techniques as specified in this chapter, unless spe-
cific exceptions are provided in the appropriate maintenance
2.2 MECHANICAL CLEANING. manuals. Due to the irregularities in composite surfaces,
complete removal of the paint and primer can damage fibers
NOTE in the composite surface layers. Therefore, paint removal,
for the purposes of recoating operations shall not go beyond
Do not blast valve stems or precision-machined the initial primer coat.
parts. All oil ports, passages and coolant passages
shall be taped or plugged to prevent grit or beads 2.2.2.1 Coatings removed from composite surfaces for the
from entering. purposes of performing coating repairs shall be performed
by hand sanding or by using an orbital sander. The use of
2.2.1 General Information. For the purposes of this TO, other types of powered sanders is prohibited due to the high
mechanical cleaning consists of sanding, grinding, wire potential for causing laminate damage. Use extreme care
brushing of the repair areas only or general scuff sanding during topcoat and primer removal to prevent sanding into
only. For complete SE chemical or mechanical depainting the laminate.
and/or corrosion removal using medium pressure water blast-
ing, abrasive media blasting operations to remove coatings 2.2.2.2 To scuff sand a composite surface for overcoating
and corrosion refer to TO 1-1-691 for information for ad- only use medium grade (Grade C) abrasive mats (A-A-
vanced corrosion removal and surface treatment and TO 58054) without powered tools for scuff sanding of painted
1-1-8 for complete paint removal and replacement of protec- composite surfaces. Fine (Grade B) or very fine (Grade A)
tive finishes. abrasive mats may be used with an orbital sander. The abra-

2.2.2 Coating Removal on Composite Surfaces.

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sive mat can be wet with fresh water, or diluted cleaning Wire brushing is a mechanical cleaning operation usually
compounds listed in Table 2-2 for light soils, to prevent accomplished with a hand wire brush or a wire brush
clogging the pad. mounted on a motor driven wheel. By using different types
of brushes, and various kinds, length, and gages of wire, a
2.2.3 Coating Removal on Metallic Surfaces. For areas wide, range of mechanical cleaning actions are possible. Wire
of several square inches, paint may be removed using abra- brushing is used to remove heavy corrosion and imbedded
sive mats or flap brushes, taking care not to remove under- paint or dirt. A typical wire brushing procedure follows:
lying metal. Chemical paint removal, may be used for areas
larger than several square inches. Plastic media blasting or 2.2.5.1 Protect adjacent components from scale, chips, and
medium pressure water blasting, may be used at organiza- corrosion products.
tional levels of maintenance activities and depots to remove
paint on equipment with panel skins thicker than 0.0625 in. 2.2.5.2 If grease or oil is present, clean areas with the
(16 gauge). appropriate cleaner(s) listed in this TO prior to wire brushing
operations. Ensure all oil and grease residues are removed
2.2.4 Grinding. Grinding is normally accomplished with before proceeding.
motorized grinding equipment and rubberized abrasive
wheels, discs or abrasive belts. Grinding is normally used to 2.2.5.3 Remove loose corrosion with a hand scraper or
remove heavy corrosion by wearing the corrosion away. Care pneumatic tools.
should be taken with this corrosion removal process as sound
metal is also removed with the corrosion product. The basic 2.2.5.4 Wire brush area to a sound metal subsurface, en-
steps in grinding are: suring all of the corrosion deposits are removed from the
corrosion pits.
2.2.4.1 Protect adjacent components from scale, chips, and
corrosion products. 2.2.5.5 After mechanical cleaning and rework has been
completed, a final surface treatment and/or protective paint
2.2.4.2 If grease or oil is present, clean areas with the finish, as listed in this TO, shall be applied as soon as pos-
appropriate cleaner(s) listed in this TO prior to mechanical sible.
removal operations. Ensure all oil and grease residues are
removed before proceeding. 2.2.6 High-Pressure Water (HPW) Paint Removal
Method.
2.2.4.3 Remove paint and corrosion until a corrosion-free
surface is reached. Continue grinding to remove coarse ir-
regularities. Use fine abrasive paper to polish the surface to
the desired finish.
HPW paint removal system can cause severe dam-
2.2.4.4 Immediately apply the final protective paint or age to equipment and injury of personnel if in-
other corrosion preventive finish. structions are not followed properly.

2.2.5 Wire Brushing. High-pressure water (40,000 pounds per square inch (PSI))
paint removal is authorized for use at depot and field-level
operations subject to meeting all personnel training, safety,
and technical data requirements. HPW equipment is an ex-
cellent method for paint removal from support equipment.
The use of goggles or face shield is mandatory The HPW system can be used with or without blast abrasive
when using motor driven wire brushes since cor- such as bicarbonate of soda. These instructions are not in-
rosion particles can break loose and fly off. Con- tended to be all-inclusive, but are general guidelines to be
duct all painting operations only in an approved used in conjunction with applicable system specific equip-
spray booth equipped with adequate ventilation ment manuals and/or a definitive process order.
and exhaust.
2.2.6.1 Authorized HPW Equipment. This removal
method requires the use of high-pressure water and may be
used with a bicarbonate of soda injection system with con-
trol hoses, and handheld nozzles of various configurations.
Do not use carbon steel or copper wire brushes on The injection system shall consist of a positive feed control
aluminum surfaces. Carbon steel or copper par- system, such as an auger/computer controlled system. Only
ticles may become embedded in the aluminum the equipment listed in Table 2-3 has been approved for Air
causing galvanic corrosion to occur. Force use.

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2.2.6.2 Training Requirements. There are several types minum with a 5-in. wide by 6-in. long instep section
of training that can be used to properly train personnel in the attached by a hinge assembly to a shin section of at
proper use and safe operations of the HPW equipment and least 20-in. length.
processes. Regardless of the training method, all personnel
shall be properly trained prior to operating equipment. 2.2.6.4 HPW Paint Removal Operation. HPW Paint re-
moval operations can damage equipment and personnel if
2.2.6.2.1 Manufacturer Provided Training. The equip- instructions and precautions are not followed. Following the
ment manufacturer may provide on-site, video, or computer- requirements below are necessary to prevent damage:
based training for the safe operations of the equipment.
a. The HPW equipment should have the operating pa-
2.2.6.2.2 Locally Developed Training. A locally devel- rameters of water pressure not to exceed 40,000 PSI;
oped training program can be used for general instruction of water flow of 2.85 gallons per minute (GPM), bicar-
equipment operation and safety requirements. This training bonate of soda blast media flow rate 1/4 to 1/2 lb. per
should include hands-on practical training in HPW paint re- minute.
moval using all appropriate safety equipment.
b. The nozzle standoff distance should be within the range
2.2.6.3 Personnel and Equipment Preparation Prior to of 2 to 4 in. from the tip of the nozzle to the working
HPW. surface.

c. The angle if incidence between the nozzle and the work

surface should be within the range of 40 to 60 degrees
from the surface being stripped.
• High Pressure water can cause serious personal
injury if the nozzles are directed at personnel. d. The nozzle should be moved across the surface at a
Never point the nozzle in the direction of other minimum rate of 4 in. every second.
personnel.
2.2.6.5 Post HPW Paint Removal Cleaning.
• Water and blast media can create slippery con-
ditions. Walking on top of equipment should be
avoided. Use fall protection and all work stands
shall have guardrails in place.
Care should be taken in HPW paint removal op-
Prior to performing the HPW paint removal process, the fol- erations to preclude blasting media intrusion and
lowing measures should be taken to ensure the safety of per- warpage of unsupported thin panels.
sonnel and protection of the equipment to be depainted.
NOTE
a. Defuel and disconnect the battery of the equipment to
be depainted. HPW Paint Removal will present a high potential
for flash rusting on equipment. Ensure equipment
b. Ensure the SE seams, and crevices are protected from is primed or treated with a Flash Rust Inhibitor
water intrusion/entrapment to prevent corrosion. within a maximum of 48 hours after paint removal.

c. Remove and protect from the high-pressure water After completing the HPW paint removal process the fol-
steam, all soft metal/non-metal components such as lowing steps should be taken to ensure equipment is pro-
data plates, copper parts, hoses, etc. tected again flash rust and corrosion:

d. All sources of ignition shall be kept a minimum of 50 a. Remove any protective materials.
feet (ft) way from the HPW paint removal process.
b. Areas where the coating was shielded from the HPW
e. Personnel involved in the HPW process shall wear as a process should have paint mechanically or chemically
minimum earplugs, earmuffs, full-face shield, removed per TO 1-1-8.
wetweather gear, water-resistant hood, waterproof
shoes, and shin and instep guard assemblies. The skin c. Open, inspect, and flush all areas where blast media
and instep assembly should be puncture resistant alu- may be entrapped with clean, fresh water.

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TO 35-1-3

d. The equipment or components should be thoroughly f. Prepare equipment and/or components for a coating
washed in accordance with Chapter 2 of this technical system or treat with a Flash Rust Inhibitor such as
order. Hold - Tight 102. Flash Rust inhibitors are temporary
rust inhibitors that usually allow an additional 48-hour
e. Allow the equipment and/or components to thoroughly interval before priming without flash occurring.
dry.

Table 2-3. Authorized HPW Equipment

National Stock Number Notes

Equipment (NSN)
E75 Electric Unit 4940-01-438-7212 Aqua Miser water only unit, with 75 horsepower
(HP) motor; includes rotary gun and 50 foot hose
assembly.
D-115 Diesel Unit 4940-01-451-0022 Aqua Klean Centrifuge Unit, 115 HP diesel; 40,000
PSI with abrasive injection; includes rotary gun
and 50 foot hose assembly.
E25M Electric Unit 4940-01-413-5627 Electric, 25 HP, Utilities required 30 standard cubic
feet per minute (SCFM) at 100 PSI of com-
pressed air, 6 GPM at 45 PSI clean fresh water,
70 AMP service of 460 volts, 60 cycle 3 phase
electricity w/exact feed media controls.
E25M Electric Unit 4940-01-395-9471 Aqua Miser has controls, breaker box, and a com-
puter to regulate the pressure of bicarbonate of
soda; the computer gives the exact amount con-
tinuously without flexuating.
D44 Diesel Unit w/o Rotating 4940-01-411-9826 Diesel, 44 HP, without Rotating Gun.
Gun
D44 Diesel Unit 4940-01-413-5629 Diesel, 44 HP, 16-1/2 gal fuel tank, pressure feed
media system with micro adjusted regulator.
Utilities required 6 GPM at 45 PSI clean fresh
water.
D44 Repair Kit Model 900-500 4940-01-411-9829 Repair Kit for D44 High Pressure Cleaner Unit.
B-25 Electric Unit 4940-01-451-0020 Least Expensive basic Aqua Miser unit. 25 HP elec-
tric unit without stainless steel enclosure; includes
rotary gun, fan gun and 50 foot hose.
Trailer, Pressure Cleaner 4940-01-413-5602 Over the road trailer with lights to make high pres-
sure cleaner unit portable.
Rotary Gun Commercial Purchase Contact the manufacturer for part number and infor-
mation.
Bicarbonate of Soda Blast Media 5350-01-414-1894 Water, Soluble, Powder Form, 50 lb. bag.
Combo Foot Shin Guard Commercial Purchase Contact HPW equipment vendor directly for part
number and ordering information.

2-17/(2-18 blank)
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TO 35-1-3

CHAPTER 3
PAINTING, SEALING, CORROSION PREVENTIVE COMPOUND
APPLICATION
3.1 GENERAL. be prioritized and scheduled on a “worse first” basis. The SE
owning work center will develop a tracking system to anno-
Operators may need to wear respiratory protective equip- tate the scores using categories 1-4 as described in Table 3-2.
ment when spray painting, or the area may need proper ex-
haust ventilation. United States Air Force (USAF) organiza- 3.3.1.1.1 SE will be evaluated to determine an accurate
tions that apply protective coatings will request initial and corrosion score. The minimum areas evaluated for deteriora-
annual surveys by the local Bioenvironmental Engineer and tion and corrosion are:
Safety Officer. Their recommendations for complying with
Air Force Occupational Safety and Health Standards • Panels or component surfaces.
(AFOSH) will be followed. Contractor personnel will com-
ply with all Bioenvironmental Engineer, Safety Officer guide- • Framework, sub-frame, chassis, and axles.
lines and Occupational Safety and Health Administration • Panel or component edges.
(OSHA) Standards. • Welds and spot welded panel seams.
• Fasteners and latches.
3.2 DEFINITION OF EXPOSURE. • Attachment points.
Deterioration involves:
Exposure is defined as support equipment (SE) that is sub- • Chipped, peeled or blistered paint on panel sur-
jected to combined direct action of climatic elements (to in- face.
clude the interior of such units). Climatic elements include
• Visible corrosion (rust, pits, white powdery de-
temperature extremes, humidity extremes, rain, hail, snow,
posits or rust leaching from panel seams).
sleet, salt-laden air, industrial atmospheres, direct solar ra-
diation, dust and scouring action of wind-blown sand. • Cracked coating around welds or fastener heads.
• Cracked, peeled or discolored paint at panel
3.3 REQUIREMENTS FOR PAINTING - FIELD seams.
LEVEL. • Cracked or peeled coating at attachment points.
• Coating deterioration caused by environmental
NOTE agents, ultraviolet light, corrosive fluids as evi-
denced by excessive fading or a chalky residue
Flight Chiefs/Superintendents are authorized to on panel surfaces.
make the determination if the unit requires com- • Missing coatings over recent weld repairs.
plete repainting.

SE shall be repainted when painted surfaces have become 3.3.1.2 Scoring Categories. In order to set the priority of
bare or exposed because of paint deterioration or damage, or scored equipment, technicians evaluate the unit and place in
when it is determined that the equipment is inadequately one of four categories (Table 3-2) with category 1 being
protected from corrosion. Repainting of SE for purely cos- best, requiring no touch-up and category 4 as worst, requir-
metic reasons is prohibited. SE units will be prioritized ing extensive disassembly, repair, and refurbishment. Lead-
through the work flow on a “worst first” basis as determined ership should utilize this tool to determine the priority for
by SE Scoring documentation. Refer to Table 3-2 for SE induction of “worst first” into the refurbishment workflow.
scoring guidance.
3.3.1.2.1 Complete Repaint Criteria. SE requires com-
3.3.1 Corrosion Control Scoring Program and Com- plete repainting when the coating system fails. A coating
plete Repainting Criteria. SE requires a robust corrosion system is considered failed when over 75% of the total ex-
program to ensure the longevity of the equipment. A system terior surface displays obvious oxidation, bleaching, peeling,
of scoring, prioritizing and scheduling will assist with pres- cracking, flaking, etc. When the coating system has failed it
ervation and refurbishment. will be completely stripped and repainted by qualified per-
sonnel in accordance with the standard paint system in Table
3-1. The corrosion control facility performing the SE repaint
3.3.1.1 Corrosion Scoring. The SE corrosion condition
(ie, Fabrication Flight, contractors, depot, etc.) will validate
will be scored annually during periodic scheduled mainte-
the need for a complete repaint prior to accepting the SE into
nance inspection. This allows prioritization and scheduling
the corrosion flow.
with the appropriate corrosion control facility. The SE will

3-1
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TO 35-1-3

3.3.2 Abrasive Blasting. The most effective means of www.optaminerals.com

completely depainting and removing corrosion from SE is
by mechanical means such as abrasive blasting using ap-
3.3.2.1.2 Dry Media Abrasive Blasting for Aluminum,
proved abrasive blasting dry media, water blasting, or water
Magnesium, Stainless Steel and Iron and Steel Less
blasting with abrasive grit injected into the water stream.
Than 0.063. For complete coating and corrosion removal
Plastic media blasting is effective in removing coatings and
and surface preparation to include white metal or near white
light surface corrosion from SE but will not effectively re-
metal surface condition of aluminum, magnesium, stainless
move heavy corrosion TO 1-1-691, Cleaning and Corrosion
steel alloys and for iron and steel substrates less than 0.063,
Prevention and Control Aerospace and Non-Aerospace
use abrasive blasting dry media qualified to MIL-PRF-9954
Equipment, and TO 1-1-8, Application and Removal of Or-
(reference Table A-1).
ganic Coatings, Aerospace and Non-Aerospace Equipment,
provides in depth guidance on abrasive blasting material se-
lection and processes. Refer to these TOs for the effective 3.3.2.2 Medium Pressure Water Blasting. Medium
development and execution of all SE abrasive blasting cor- pressure water blasting, with operating pressures less than
rosion and coating removal programs. 40,000 pounds per square inch (PSI) is also authorized for
coating removal on SE. All requirements and safety consid-
erations listed in abrasive blasting sections of TO 1-1-691
3.3.2.1 Several coating systems require the complete coat-
and TO 1-1-8 apply. Ensure the SE seams, and crevices are
ing removal and surface preparation to include a white metal
protected from water intrusion/entrapment to prevent subse-
or near white metal surface condition with a minimum of a 2
quent corrosion. Remove or protect from the high pressure
mil surface profile. This requirement can only be achieved
water stream, all soft metal/non-metal components such as
through abrasive grit blasting or high pressure water blast-
data plates, copper parts, hoses, etc.
ing. Several high-pressure water blasting systems will allow
the injection of abrasive grit into the water stream to achieve
the required surface profile. Consult the equipment manufac- 3.3.2.2.1 The use of the optional variable speed drive for
turer’s data sheet for additional guidance. Ensure the combi- the medium pressure water blasting units is required if abra-
nation of abrasive grit and medium/high pressure water will sive media will be introduced into the pressurized water
not cause warping or other structural damage to SE and that stream.
this process is environmentally acceptable prior to the requi-
sition of the abrasive blasting equipment.

3.3.2.1.1 Dry Media Abrasive Blasting for Iron and

Steel. For complete coating and corrosion removal and sur- • Care should be taken in coating removal prepa-
face preparation to include white metal or near white metal ration with all pressurize coating/corrosion re-
surface condition of iron and steel substrates (other than moval processes to preclude blasting media in-
stainless steel), 0.063 (16 gauge, US Standard) or thicker, trusion and warpage of unsupported thin panels.
use one of the approved products listed below:
• Water blasting of equipment that has been
primed with a chromate containing primer may
STARBLAST XL Cage Code: 9Z037 allow leaching of the chromate into the waste
DBA Dupont water. Organizations shall gain approval from
4641 County Rd 230 the appropriate environmental management of-
Starke, FL 32091 fice of primary responsibility prior to the com-
mencement of water blasting activities.
Quickstrip 20-40G Cage Code: 1AM56 3.3.2.2.2 Use the lowest effective water pressure when re-
US Technologies Corp moving paint or when abrasive media is used in combination
4200 Munson St NW with the medium pressure water to remove corrosion.
Canton, OH 44718
Phone: 770-254-9449 3.3.2.3 Scuff Sand and Overcoat. If disassembly and
www.ustechnology.com complete mechanical removal is impractical within the orga-
nization, due to environmental constraints, the requirements
of Table 3-1 for mechanical removal and application of the
Garnet Galaxy (Garnet) Cage Code: L4566 two layer zinc-rich primer (MIL-PRF-26915)/intermediate
Opta Minerals Inc primer (MIL-DTL-53030), on ferrous alloys waived and re-
407 Parkside Dr. placed with MIL-DTL-53022, Type II Aluminum, fiberglass,
P.O. Box 260 and stainless steel equipment and parts will not be coated
Waterdown, Ontario LOR 2HO with zinc-rich primer at any time.
Phone: (888) 689-6661

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TO 35-1-3

3.3.2.3.1 Unless otherwise directed, bare aluminum parts Rust Trapper

and equipment shall be primed with MIL-PRF-23377, Type Image 2000 (order by product Name)
I, Class C.
PO Box 753
3.3.2.3.2 All equipment receiving the scuff sand and over- Ione, CA 95640
coat type of maintenance painting, where bare metal is not
exposed, may use the listed non-chromated tiecoats over ex- Rust Reformer (Rust-Oleum)
isting MIL-PRF-85285 paint systems: 11 Hawthorn Parkway
Vernon Hills, IL 60061
• MIL-PRF-23377, Type I, Class N
Extend (Loctite)
• MIL-DTL-53022
32150 Just Imagine Drive
• MIL-DTL-53030 Avon, OH 44011

• 8010-01-482-8620, Aeroglaze 9741 (light gray) U/I VpCI CorVerter (Cortec)

KT 4119 White Bear Parkway
Saint Paul, MN 55110-7632
• 8010-01-483-4363, Aeroglaze 9743 (red) U/I KT
3.3.3.1.2 Lightly abrade the surface with a Scotch-brite
• 8010-01-483-4365, Aeroglaze 9744 (dark gray) U/I pad, wire brush, sandpaper, or other equivalent material to
KT remove loose rust only, leave adherent rust on surface; gen-
tly wipe abraded area with towel or cloth to remove dust and
3.3.3 Temporary Coating Repairs. For temporary repairs debris. Apply the rust converter in accordance with manufac-
of chipped paint and mild to moderate corrosion, use the turer’s instructions. Apply a second coat if required.
appropriate corrosion preventive compound (CPC) listed in
Paragraph 3.13. For severe corrosion that cannot be perma- 3.3.3.1.3 After the rust converter has cured per the manu-
nently repaired the use of rust converters is recommended. facturer’s instruction apply a MIL-PRF-85285 topcoat. Re-
For more permanent repairs of small chipped areas, use au- pair area utilizing standard maintenance painting procedures
thorized coating systems that are contained in items such as as soon as possible.
but not limited to: SEMPENS, Preval compressed air spray
packs, Clip-Pacs, Brush and Roller, or AKZO Nobel Two - 3.3.4 Touch-up Primer. On steel surfaces, if the SE re-
Component MIL-PRF-85285 Aerosol can. Single component quires scuff sanding and overcoating and the prepared sur-
aerosols, enamels or laquers are not authorized coatings. In- face is not exposed to bare metal, the use of non-chromated
formation about these materials can be viewed on the tie coat in lieu of zinc-rich primer is authorized. Zinc-rich
AFCPCO website on the AF Portal Larger defects in paint or primer will not adhere to painted surfaces nor provide corro-
damaged areas will be grounds to repaint the complete sec- sion protection unless the primer is in contact with properly
tion as determined by Flight Chief or Superintendent. prepared steel surfaces.
3.3.3.1 Rust Converters. Rust converters typically con- 3.4 REQUIREMENTS FOR PAINTING - DEPOT
sist of mixtures of phosphoric acid, organic alcohols, and LEVEL AND CONTRACTOR SUPPORT.
tannates in a latex matrix that forms a protective film on the
metal surface that protects against rust. They are designed to 3.4.1 Corrosion Rework Determination. The extent of
be applied directly to rusty surfaces to convert residual rust rework to be accomplished during overhaul will be deter-
on steel surfaces to harmless and adherent chemical com- mined by the Repair Contract. The decision on extent of
pounds. Unlike the standard scrape, prime, and paint regime, corrosion repair will be determined by the government qual-
the surface does not require stripping to bare metal. Rust ity assurance personnel utilizing the requirements of this
converters, topcoated with MIL-PRF-85285, serve as a 180- technical order.
day temporary repair.
3.4.1.1 When it is determined that corrosion is a signifi-
3.3.3.1.1 Recommended Rust Converter Products: cant factor, and total repaint of the unit is within economic
repair, then disassembly, abrasive blasting, proper conver-
Neutra-Rust 661 sion coating of the substrate metals and application of the
8030-01-369-4416 preferred paint system described in Table 3-1 will be accom-
8030-01-369-4417 plished. The lack of conversion coating capability or abra-
sive blasting capability by a contractor is not authority to
deviate from the requirements.

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TO 35-1-3

3.4.1.2 When it is determined that corrosion is not a sig- NOTE

nificant factor, or the units are not within economic repair
limits, then paint touch-up will be accomplished. The paint Certain manufacturers of MIL-PRF-85285, Type
material used in the touch-up should be the same material III require their coating to have continual stirring
that is on the equipment unless otherwise specified. If the SE during mixing operations. A continual stirring paint
requires scuff sanding and overcoating and the prepared sur- agitator is required to use with this material. Fail-
face is not exposed to bare metal, the use of non-chrome tie ure to constantly mix the Type III material will
coat in lieu of a primer is authorized. cause the material to expand and overflow from
the mixing container.
3.4.2 Contractor Compliance. If contractor supported
corrosion prevention and control is utilized, compliance with 3.5.2.1 The organization’s equipment preparation capabil-
the proper coating cleaning, surface preparation, preserva- ity, base, state, federal and overseas government environ-
tion, pretreatment, and painting requirements of this manual, mental authorizations, and equipment material substrates will
TO 1-1-691, and TO 1-1-8 shall be included in the contrac- determine the coating system (primer and topcoat) used on
tors’ Statement of Work. specific SE MIL-PRF-85285, Type II should only be used
where environmental restrictions require topcoating materi-
3.5 AUTHORIZED COLORS, SEMPENS, AND MA- als containing less than 340 grams/liter VOC.
TERIALS.
3.5.2.2 Table 3-1 identifies authorized coating materials
3.5.1 SE Standardized Colors. for SE.

NOTE 3.5.2.3 Air Force will accept Chemical Resistant Coating

(CARC) painted SE procured through US Army when it
It is possible to have slight variances in color. would increase the cost to change the coating to an epoxy/
Equipment will not be repainted so as to have all polyurethane coating system (MIL-PRF-23377/MIL-PRF-
equipment or components the same shade. 85285). If CARC painted equipment needs to be painted, the
units shall refinish and maintain equipment using the appro-
The Air Force has instituted a tone down program for SE. priate coating system required for the assigned location/mis-
The standard color for all flight line SE is gray 26173 FED- sion. This is to be accomplished only during the normal
STD-595, MIL-PRF-85285 (Type I Top Coat). The color maintenance cycle.
change shall be integrated into the units’ regular corrosion
schedule and equipment will be aligned with the new scheme 3.5.3 Authorized Colors for Liquid Oxygen, Nitrogen,
on an attrition basis. Newly manufactured or refurbished Storage Carts and Tanks. All liquid oxygen, liquid nitro-
equipment will be painted gray 26173. Flight line support gen servicing carts and storage tanks shall be finished in
equipment being deployed to Southwest Asia will no longer color schemes as follows:
be required to be painted tan. Mobile communication equip-
ment will maintain its current color scheme to meet mission 3.5.3.1 Liquid oxygen servicing carts used on flight line
needs/requirements. The authorized colors for mobile com- shall have all of the control housing, interior and exterior,
munications equipment are green FED-STD-595, color no. and cart frame shall be painted gray, Federal Standard 595,
24052/34052, light tan no. 33303, tan color no. 30279, and No. 26173.
brown no. 20400, all FED-STD-595/MIL-PRF-85285, Type
I as preferred topcoat. This guidance does not apply to Basic 3.5.3.2 Liquid nitrogen servicing carts used on flight line
Expeditionary Airfield Resources (BEAR) SE All BEAR shall have all of the control-housing, interior and exterior
support equipment will be painted MIL-PRF-85285, Color shall be painted gray, Federal Standard 595, No. 26173.
33446 (Tan).
3.5.3.3 Only 2000 gallon or larger liquid oxygen and ni-
3.5.1.1 SE metalized with 85/15% zinc/aluminum will re- trogen tanks not used on the flight line shall be painted white
main in the original gray color without a topcoat applied. according to Federal Standard 595, No. 17925. All 50 and
400 gallon liquid oxygen and liquid nitrogen tanks will be
3.5.2 SE Standard Topcoat. High solids polyurethane painted per Federal Standard 595, No. 26173 for liquid oxy-
MIL-PRF-85285, Type I is the preferred standard SE top- gen and Federal Standard 595, No. 26173 for liquid nitro-
coating material. There are three types of MIL-PRF-85285 gen.
Type I contains 420 grams/liter VOC, Type II contains 340
grams/ liter VOC and Type III is maximum 50 grams/liter
VOC.

3-4
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TO 35-1-3

3.5.4 Passenger or Loading Ramps. Passenger or load- 3.5.5 Presidential Support Equipment and USAF
ing ramps may be painted white, Federal Standard 595, No. Demo Team. Presidential support equipment and the USAF
17925. The steps and lettering shall be blue, Federal Stan- Demo Team are authorized to deviate from the color and
dard 595, No. 15045, except those surfaces covered with coating requirements of this technical order.
anti-skid walkway coatings.

3-5
3-6
Table 3-1. Authorized Coating Systems

Coating Intermediate
TO 35-1-3

Process Substrate System Pretreatment Primer (Tie-coat) Topcoat Remarks Finish Process
1 Abrasive Ferrous Alloys Two-Part Depot and/or MIL-PRF- MIL-DTL- MIL-PRF- Use only 1. (Depot and/or con-
Blast, other than Primer contractor 26915, Type 53030 if the 85285 spray paint tractor level of
White Stainless and level of main- I, Organic zinc-rich equipment maintenance only)
(Bare) Steel, Mill- Top- tenance only) Zinc-Rich primer ex- designed for Apply Zinc phos-
Metal galvanized, coat Apply Zinc Primer hibits the applica- phate, TT-C-490,
Para- mill-electroz- System phosphate, Paragraph roughness tion of zinc- Type I.
graph inc coating, TT-C-490, 3.16.3) (Paragraph rich primer. 2. Primer - Apply
3.16.3) or mill-alu- Type I 3.16.3.1) MIL-PRF-26915,
minized sur- Type I to a dry
faces film thickness
(DFT) of 2.0 - 2.5
mils.
3. Intermediate Primer-
Apply MIL-DTL-
53030 shortly
thereafter over the
zinc-rich primer.
DFT shall be 0.9
to 1.1 mils. If the
zinc-rich primer
exhibits roughness
(Paragraph
3.16.3.1.
4. Topcoat - Paint with
MIL-PRF-85285
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applied to a DFT
of 1.6 to 2.4 mils.
 Table 3-1. Authorized Coating Systems - Continued

Coating Intermediate
Process Substrate System Pretreatment Primer (Tie-coat) Topcoat Remarks Finish Process
2 Abrasive Non-Ferrous Standard Pretreat bare MIL-PRF- Tie-coats can- MIL-PRF- MIL-PRF- 1. Pretreat bare alumi-
Blast (bare alumi- Primer aluminum 23377, not be used 85285 23377 is num areas with
(Bare num alloys) and areas with Class C on bare suitable for MIL-DTL-5541,
Metal) High MIL-DTL- (Bare fer- metal sur- both bare Class 1A or Anod-
(Para- Solids 5541, Class rous/ alumi- faces. ferrous and ize per MIL-A-
graph Top- 1A III (Depot num bare alumi- 8625, Type II or
3.3.2.1.2) coat or Contractor num. III (Depot or Con-
level only) tractor level only)
Anodize per per TO 1-1-691.
MIL-A-8625, 2. Prime bare alumi-
Type II or per num areas with
TO 1-1-691. MIL-PRF-23377,
Type I, Class C to
a DFT of 0.6 to
0.8 mils.
3 Scuff- Ferrous alloys Standard Pretreat bare MIL-DTL- Tie-coats can- MIL-PRF- MIL-DTL- 1. Pretreat bare alumi-
sand and bare alu- Primer aluminum 53022, Type not be used 85285 53022 can num areas with
and minum alloys and areas with II (Bare on bare be used on MIL-DTL-5541,
Over- High MIL-DTL- Ferrous Al- metal sur- bare ferrous Class 1A or Anod-
coat Solids 5541, Class loys only) faces (Para- alloys or ize per MIL-A-
(Para- Top- 1A III. graph any painted 8625, Type II or
graph coat 3.3.2.3.2). metal. III (Depot or Con-
3.3.2.3.2) tractor level only)
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MIL-PRF- MIL-PRF- per TO 1-1-691.

23377, 23377 is 2. Prime bare alumi-
Class C suitable for num areas with
(Bare fer- both bare MIL-PRF-23377,
rous/alumi- ferrous and Type I, Class C to
num alloys) bare alumi- a DFT of 0.6 to
num. 0.8 mils.
3. Prime bare ferrous
areas with MIL-
DTL-53022, Type
II to a DFT of 0.9
to 1.1 mils.

3-7
TO 35-1-3
 Table 3-1. Authorized Coating Systems - Continued

3-8
Coating Intermediate
Process Substrate System Pretreatment Primer (Tie-coat) Topcoat Remarks Finish Process
TO 35-1-3

4. Recommend use of
non-chromated
tie-coats over ex-
isting coating sys-
tem (Paragraph
3.3.2.3.2).
4 Units de- Ferrous alloys Chemical MIL-DTL- Three-part 1. Pretreat bare alumi-
ployed and bare alu- Agent 64159 waterborne num areas with
with minum alloys Resis- coating sys- MIL-DTL-5541,
Army tant tem requires Class 1A or Anod-
(Para- Coat- specialized ize per MIL-A-
graph ing application 8625, Type II or
3.5.2.3) (CARC) equipment. III (Depot or Con-
If unit is not tractor level only)
to be de- per TO 1-1-691.
ployed with 2. Prime bare alumi-
the Army, num areas with
use MIL- MIL-PRF-23377,
PRF-85285 Type I, Class C to
topcoat. a DFT of 0.6 to
0.8 mils.
3. Prime bare ferrous
areas with MIL-
DTL-53022, Type
II to a DFT of 0.9
to 1.1 mils.
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4. Recommend use of
non-chromated
tie-coats over ex-
isting coating sys-
tem (Paragraph
3.3.2.3.2).
5 Thermal Abrasive Metali- None None None MAJCOM Topcoating is 1. Refer to Paragraph
Coating Blasted Fer- zation Option not required. 3.16.5.
Systems rous alloys
(Para- and bare alu-
graph minum alloys
3.16.5)
 Table 3-1. Authorized Coating Systems - Continued

Coating Intermediate
Process Substrate System Pretreatment Primer (Tie-coat) Topcoat Remarks Finish Process
6 Walkways Anti-skid None A-A-59166 MIL-PRF- 1. Follow manufactur-
and 17951, Ad- er’s application
Step- hesive instructions.
ping backed;
Sur- non-slip
faces material
(Para- may be used
graph as an alter-
3.20) nate.
7 Under- Under- A-A-59295 Topcoating in 1. Follow manufactur-
coating coat this area er’s application
(Para- prior to un- instructions.
graph dercoating
3.22) is not re-
quired.
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TO 35-1-3
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TO 35-1-3

Table 3-2. SE Scoring/Category Criteria

Category Deterioration/Corrosion Action Required

Category 1 New paint or recently touched-up. Unit requires no touch-up.
No chips, cracks, or scratches exposing bare Apply CPCs in corrosion prone interior and exterior
metal Coating not faded or mismatched. areas as preventive maintenance. No visible rust or
No visible rust or blistering of coating at seams. blistering of coating at seams. Refer to Paragraph
3.13.
Category 2 Minor corrosion or surface rust that can be re- Any of there conditions can be repaired by spot sand-
moved by sanding or wire brush. ing or wire brushing and touch-up on the spot aero-
Minor paint chipping, peeling or scratches. sol spray, brush or roller. Refer to Paragraph 3.3.3
Minor paint fading or chalking. for touch-up guidance.
Replacement of corroded fasteners, latches, fit- An application of CPC can be applied as a temporary
tings, and handles. repair until the unit can be scheduled for permanent
repair Refer to Paragraph 3.13.
Once the above repair actions are accomplished, the
unit can be placed in Category 1.
Category 3 Moderate corrosion or surface rust. Conditions can be repaired by removing panels and
Moderate paint chipping, peeling or scratches. routing through fabrication flight for repair and re-
Moderate paint fading or chalking. painting or by sending whole unit for a partial or
complete scuff and overcoat. Refer to Paragraph
Moderate to localized extensive corrosion on re-
3.3.2.3 for scuff sand and overcoat instruction.
movable panels or parts.
There is excessive paint chipping, peeling or An application of CPC can be applied as a temporary
scratches. repair until the unit can be scheduled for permanent
There is excessive amount of paint missing. repair. Refer to Paragraph 3.13.
Spot-welded panel seams leaching rust.
Overall look is excessively faded or weathered. Once the above repair actions are accomplished, the
unit will be placed in the appropriate category.
Category 4 75% of the total exterior surface displays obvious Conditions necessitating extensive disassembly of the
oxidation, bleaching, peeling, cracking, flaking, unit prior to complete stripping by media blasting to
etc. remove corrosion.
Severe corrosion or surface rust and pitting. Unit will be de-painted and repainted in accordance
Extensive paint chipping or peeling covering with the standard paint system in Table 3-1.
whole sections.
Rusting through leaving holes through panels, An application of CPC can be applied as a temporary
seams, framework, chassis or axles. repair until the unit can be scheduled for permanent
Units requiring extensive local manufacturing of repair. Refer to Paragraph 3.13.
new panels, framework or chassis components. Once the above repair actions are accomplished, the
unit will be placed in the appropriate category.

3.6 CORROSION TREATMENT FOR STEEL tive compound (CPC) to the cable surface by aerosol spray
CABLES. or a cloth dampened with the CPC followed by a liberal
application of MIL-PRF-16173, Class II, Grade 4 CPC with
If the surface of a cable is corroded, relieve cable tension a non-metallic brush. Wipe off any excess CPC. If excessive
and carefully force the cable open by reverse twisting. Visu- CPC is allowed to build up, it will interfere with the opera-
ally inspect the interior. Corrosion on the interior strands tion of cables at fairleads, pulleys, or grooved bell-crank ar-
constitutes failure and the cable must be replaced. If no in- eas.
ternal corrosion is detected, remove loose external rust and
corrosion with a clean, dry, coarse-weave rag or fiber brush. 3.7 PIANO TYPE HINGES.
Clean the control cables with a clean dampened cloth with
MIL-PRF-680, Type II or III, CID A-A-59601, or MIL-PRF- Water displacing, corrosion inhibiting CPC are often applied
32295, Type II. After thorough cleaning, apply a thin film of to hinge pins and nodes to provide lubrication and to reduce
either MIL-L-87177, Type I or II, Grade B, or MIL-PRF- corrosion problems Unless otherwise directed by a specific
16173, Class II, Grade 3 water displacing corrosion preven-

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system workcard, immediately after SE washing conclude, maintenance manual. In addition to faying surface sealing,
apply a coating of MIL-PRF-63460 or MIL-L-87177, Type I fillet seal all interior seams and all exterior seams (those
or II, Grade B to the piano hinge, hinge pins and nodes. exposed to the outside environment) that would allow water
intrusion using MIL-PRF-81733, Type II, Class 1 or 2, Grade
3.8 MATING SURFACES PROTECTION REQUIRE- A sealant.
MENTS.
NOTE
To prevent corrosion between mating surfaces (faying or
back to back surfaces of a part) on attaching parts, fasteners The following does not apply to parts that are lu-
and panels, the metal surfaces shall be insulated with the bricated in the joint areas immediately before or
proper primer following Paragraph 3.8.1 and Paragraph after installation, or to close tolerance bolts and
3.8.1.1 or with sealant following the information in para- parts that are removed frequently for maintenance
graphs and subparagraphs of Paragraph 3.8.2. requirements.

3.8.1 Mating Surfaces - Bare Steel. For clean bare steel 3.8.2.3.1 Attaching parts, such as nuts (standard, speed,
alloys, except stainless steel, the primer will be the Organic and self-locking), bushings, spacers, washers, screws (stan-
Zinc-Rich Primer, MIL-PRF-26915 or MIL-DTL-53022, dard and self-tapping), sleeves for shake-proof fastener studs,
Type II. Spot or tack welding can be accomplished through clamps, bolts, etc., do not need to be painted in detail except
the zincrich primer but not the MIL-DTL-53022. If the sur- when dissimilar metal or wood contact is involved with the
face or part is already primed and the primer is intact, fur- materials being joined or exposure to a corrosive interior
ther coating of the mating surface is not required. environment or the exterior environment will occur in ser-
vice. However, all parts shall be installed wet with sealant.
For permanent installations, use MIL-PRF-81733, Type I or
3.8.1.1 Mating Surfaces - All Other Metals. For nonfer-
IV, Class 1 or 2, Grade A sealant and coat the entire mating
rous metals, the primer will be MIL-PRF-23377, Type I,
surface of the parts. For removable installations, use SAE
Class C.
AMS 3367, Class A or PR-1773, Class B sealant and coat
only the lower side of the heads of screws and bolts with
3.8.2 Sealers and Sealant Usage. Sealants prevent the sealant. For removable installations, do not coat the threads
intrusion of moisture, rain, salt water, dust and other fluids and shanks of screws and bolts or the holes into which they
which can lead to extensive corrosion. Sealants are one of are inserted because this will make future removal almost
the most important tools for corrosion prevention and con- impossible without damaging the parts. As an alternate for
trol. removable installations, the shanks, threads, and lower side
of the heads of standard screws and bolts may be coated
3.8.2.1 Many sections of the SE contain joints and flanges. with MIL-PRF-63460, MIL-PRF-16173, Class II, Grade 3
The use of an appropriate sealer to prevent the entry of water before they are installed. Close tolerance bolts and parts shall
and contaminants into crevices and joints is an excellent way be coated with corrosion inhibiting, solid film lubricant. Use
to minimize corrosion. Sealers can also be used to separate MIL-L-23398 or MIL-PRF-46147 (air curing type) on alu-
two conductive metal surfaces preventing galvanic or crev- minum parts and on all types of metallic parts. The solid film
ice corrosion. lubricant shall be applied and completely cured prior to as-
sembly. Bolts shall be coated on shanks and threads only. A
3.8.2.2 For sealants to be effective, it is critical that the thin bead of sealant shall be applied under the bolt head to
correct sealant be chosen for a specific area/situation and impart a wet seal.
that it be applied correctly. TO 1-1-691 dedicates the entire
Chapter 6 to the advanced selection and applications of seal- 3.8.2.3.2 All rivets shall be installed wet with MIL-PRF-
ants. Refer to that chapter if sealing conditions or require- 81733, Type I or IV, Class 1 or 2, Grade A sealant. In fuel
ments are encountered that are beyond the scope of this contact areas, the exposed rivet head and approximately 1/4
manual. - inch (in.) of the adjacent structure shall be brush over
coated with SAE AMS-S-8802 Class A sealant.
3.8.2.3 When repairs are made on equipment or accesso-
ries and/or components are installed or structures are rein- 3.8.2.3.3 All machine screws, countersunk fasteners, bolts
stalled, the attaching or faying surfaces shall be protected by (head end) and nuts which are used in contact with magne-
sealing all metal-to-metal and composite to metal contact sium shall be installed with 5056 aluminum alloy washers.
surfaces. All permanent structures shall be installed with fay- These parts, including the washers, shall be installed wet
ing surfaces wet with MIL-PRF-81733, Type I or IV, Class 1 with MIL-PRF-81733, Type II, Class 1, Grade A sealant and
or 2, Grade A sealant. All removable structure such as access shall be completely fillet sealed with the same material after
doors, inspection plates, floor panels and plates, and other installation.
removable panels (components requiring frequent removal
for maintenance requirements) shall either be installed with 3.8.2.3.4 Adjustable parts, such as tie rod ends and turn-
faying surfaces wet with AMS 3367, Class A or B or PR- buckles shall be installed as follows: (1) If possible, surfaces
1773, Class B sealant or Av-DECTM HT3935-7 or HT3000FR and threads shall be lubricated and protected before assem-
sealant tape in the joints as specified by the system specific

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bly with a film of MIL-L-23398 or MIL-PRF-46147 (air cur- °Fahrenheit (F) (24 °C) and 50 percent relative humidity.
ing type) corrosion inhibiting, solid film lubricant which shall This time (in hours), known as a dash number, is denoted as
be completely cured prior to assembly. After installation, ap- the last number in a sealant designation (e.g. MIL-PRF-
ply a thin coating of MIL-PRF-63460; MIL-PRF-16173, 81733, Type II, has an application life of two hours). For
Class II, Grade 3; or MIL-PRF-81309, Type II, water dis- each 18 °F (10 °C) increase in the temperature above 75 °F
placing, corrosion preventive compound (CPC), to all sur- (24 °C), the application time is cut by approximately half
faces of these parts. (2) If solid film lubricants cannot be with a similar reduction in tack free and cure time. When
applied, use a thin coating of MIL-PRF-63460; MIL-PRF- sealants are applied in an environment where the relative
16173, Class II, Grade 3; or MIL-PRF-81309, Type II water humidity is greater than 50 percent, its application life is
displacing, corrosion preventive compound (CPC) after as- shortened to some degree. Maintenance personnel should be
sembly. aware of the effects of temperature and humidity on the ap-
plication life of a sealant. Mix only the amount of material
3.8.2.3.5 When practical, slip fit parts shall be assembled that can be applied during the rated work life of the sealant.
with mating surfaces wet with MIL-PRF-81733, Type I or
IV, Class 1 or 2, Grade A sealant. If this process is not prac- 3.8.2.7 There are sealants that can damage SE. For ex-
tical, coat the interior diameter (ID) of the holes in the re- ample Room Temperature Vulcanizing (RTV) Adhesive/Seal-
ceiving part, which is normally the larger structure with a ant, MIL-A-46106, unless it is called-out for a specific re-
corrosion inhibiting, solid film lubricant conforming to MIL- pair, should not be used in sealing metal parts. This sealant
L-23398 or MIL-PRF-46147 (air curing types) and the outer evolves acetic acid during its curing process and can cause
diameter (OD) of the mating part with one conforming to corrosion when sealing metals or when sealing non-metals in
MIL-L-23398 or MIL-PRF-46147 (air curing types). The a confined metallic lined space. The approved qualified prod-
solid film lubricant shall be applied and completely cured uct for use is MIL-A-46146 (non-corrosive). Both sealants
prior to assembly. are packaged alike and are often substituted within the base
supply system. A telltale odor of vinegar identifies the acetic
3.8.2.3.6 All cut edges and holes drilled or reworked for acid (corrosive version) evolving is being used.
bolts, screws, rivets, studs, and bushings of aluminum alloy
structures or parts shall receive a chemical conversion coat- 3.8.2.8 Remove sealant with a non-metallic scraper, such
ing treatment prior to the installation of the fasteners or as plastic or phenolic. The Pneumatic Vibro Gun Sealant
bushings and prior to installing or refinishing the structure or Removal Kit or Rapid Desealing System (RDS) may also be
parts. Apply a conversion coating to aluminum surfaces, us- used (Refer to Table A-1). Clean remaining residue from the
ing Touch-N-Prep pen containing AlodineTM 1132. On steel component or structure using undiluted Acrastrip 600 or
surfaces use the appropriate primer to coat the cut edges of SkyKleen® 1000.
holes prior to reinstallation of the parts.
3.9 ACOUSTICAL MATERIAL PRECAUTIONS.
3.8.2.4 Sealant may be applied by brush, spatula, or caulk-
ing gun application. Most of the acoustical material used in powered SE is open
cell polyurethane foam. The property of open cell polyure-
3.8.2.5 To prevent sealant from contacting adjacent areas thane that results in the reduction of sound also results in the
during application and smoothout, outline the areas being foam holding water and water vapor like a sponge. In severe
sealed with masking tape (AMS-T-21595, Type I) so that corrosion prone areas, the foam also absorbs the contami-
each tape strip is 1/8 to 1/4 in. from the edge of the seams. nates in the water vapor such as salt. The water vapor is
slow to dry and will be sufficient to cause and accelerate
3.8.2.5.1 Apply the sealant between tapes with a nonme- corrosion. Additionally, as the water vapor evaporates it will
tallic spatula or spreader, brush or caulking gun. Avoid the leave the contaminates lodged in the foam against the metal
entrapment of air. Work sealant into recesses by sliding the surfaces and over time the concentration of the contaminates
edge of the spatula firmly back over the recesses. Smoothing will worsen the corrosive effects. To prevent corrosion that
will be easier if the nonmetallic spatula is first dipped in will occur from the open cell polyurethane, field units are
water. authorized to remove existing foam and replace with Cous-
tifoam PUI or AF (heat reflective) or equivalent.
3.8.2.5.2 Remove masking tape after the sealant has been
applied and before it begins to set. Cure time will depend 3.9.1 Coustifoam PUI and AF. The Coustifoam PUI and
upon the application life of the materials used. AF is also an open cell polyurethane foam but the side that
has the vapor/waterproof backing shall be installed against
3.8.2.6 Sealant application life and cure times are depen- the metal panels. This action will help prevent fluid transfer
dent on environmental considerations and the formulation to the metal surfaces of the equipment where the foam is
cure times. The application life of a sealant is the length of mounted. All exposed edges, tears, and perforations of the
time that a mixed sealing compound remains usable at 75 foam will be sealed prior to installation. Sealing can be ac-

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complished by brushing the edge with MIL-PRF-81733 or 3.11 MAINTENANCE STAND RAILS AND RAIL
equivalent sealant. The sealant shall also be used to repair HOLDERS.
any tear or puncture in the polyvinylfluoride film that are
made to accommodate fastener installation. 3.11.1 Drain Holes.

3.9.2 Nonmetallic Fasteners. Nonmetallic fasteners shall

be used to mount the foam in the SE. Corrosion inhibiting
sealant, MIL-PRF-81733 or PR-1733 shall be applied around
the fastener head and the fastener shank, which protrudes Do not drill drain holes in weldments seams or
through the equipment structure/skin, thoroughly sealing the beads.
fastener hole to prevent water intrusion. Do not apply sealant
to threaded portions of the fasteners. NOTE
3.10 DRAINAGE. Using activities that find standing or entrapped
water in equipment due to the lack of drainage
3.10.1 Fluid Collection Points. Angles, channels, panel should forward this information to the responsible
lips, hand rail holders, or other pockets that can collect water equipment specialist or system engineer for action
will be avoided or have adequate drainage when stored in through Material Deficiency Reporting channels as
the equipment’s normal position, see Figure 3-1. outlined in TO 00-35D-54.

3.10.2 Modifying Fluid Collection Points. Sealants such Field units are authorized to drill necessary drain holes at the
as MIL-PRF-81733 or self leveling sealing compounds such lowest point on the maintenance stands rail holders to avoid
as Zip Chem HT3326-5-50 or TF2219 or equivalent may be water from collecting in the holders.
used to fill voids and entrapped areas, redirecting the water
to the appropriate drain-through-drain-to location. The mini- 3.11.2 Drain Hole Corrosion Prevention and Treat-
mum size for any drain hole is 0.25 in. ment. Paint the edges of the drain holes after drilling to
prevent corrosion from occurring around the holes.

3.11.2.1 Since repeated installation and removal of the rail

into the rail holder will result in damage to the paint on both
items, additional protection is required on the ID of the
holder and the OD of the bottom part of the rail.

3.11.2.2 Coat the ID of the rail holder and the bottom part
of the stand rail that are inserted into the holder with solid
film lubricant conforming to MIL-L-23398 or MIL-PRF-
46147 (air curing types). The solid film lubricant shall be
applied and completely cured prior to assembly.

3.11.2.3 To prevent corrosion, CPC, MIL-PRF-16173,

Grade 4, or MIL-PRF-81309, Type II should be applied pe-
riodically to the exterior bottom of the rail and interior of the
holder and the interior of the stand rails. Use the appropriate
length 360 degree FORMIT® spray wand or equivalent to
apply CPC through the drain holes the entire length of the
Figure 3-1. Example of Standing Water Due to stand rails.
Inadequate Drainage Provisions

Figure 3-2. Hollow Member Drain Hole Configuration

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Figure 3-3. Hollow Member Weld-Nut Configuration

3.12 HOLLOW STRUCTURAL MEMBERS. has to be drained, completely dry the area and reapply the
appropriate CPC the entire length of the hollow member.
3.12.1 Drainage for Closed Hollow Members, When After a period of two to three years the rubber may compress
Open Drain Holes are Possible. A completely air tight in the hole, if this occurs remove the screw, cut the weld-nut
weld is required for closed hollow members to prevent con- flush with the surface, punch the remainder of the nut inside
densation of moisture in the interior surface. To prevent the hollow member and install a new weld-nut.
moisture accumulation from occurring (since it is difficult to
obtain perfect welds), all closed hollow members will have 3.13 CORROSION PREVENTIVE COMPOUNDS
drainage provisions at the lowest drain-through-drain-to point (CPC).
of the member, reference Figure 3-2.
Corrosion Preventive Compounds (CPC) are used for tempo-
3.12.1.1 For horizontal members, drain hole(s) will be rary protection of painted and unpainted surfaces and where
provided on the lower side equally spaced across the hollow coating system has been damaged or removed. CPC’s func-
member at an approximately thirty-six inch interval. tion by preventing corrosive materials from contacting and
corroding bare metal surfaces. The selection for the type of
3.12.1.2 For vertical members, drain hole(s) will be pro- CPC to be used shall take into consideration CPC appear-
vided on bottom end-cap. ance to help maintain overall condition of the SE for scoring
purposes and help reduce the need for increased complete
3.12.2 Drainage for Closed Hollow Members, When repaints. Dark color CPC should not be used in highly vis-
Open Drain Holes are Not Possible. If a drain hole is not ible areas. Transparent or lightly tinted CPCs are the best
possible due to design (such as a butt joint with a plate selection for temporary corrosion prevention and control on
behind it or two pipes forming a saddle joint) then a drain visible areas. Some of the compounds have the capability of
hole should be placed at the lowest possible drain-through- displacing moisture in seams, joints and faying surfaces.
drain-to point, see Figure 3-3. Application of sealant that is Some CPC’s also provide lubrication as well as corrosion
formed to direct the drainage to the drain hole is authorized protection. The thicker CPC’s provide the best corrosion
to facilitate fluid drainage. protection, are longer lasting, and more difficult to remove.
The thinner materials provide some lubrication and do not
3.12.2.1 The drain hole should not penetrate a weld and crack; chip or peel but must be removed and replaced. The
must be approved by the responsible engineering organiza- protection provided is temporary, so the compound must be
tion. Since the location of the drain hole could allow water reapplied periodically and after removal by washing or con-
inside the hollow member insert a removable plug (weld- tact with solvents or fuel. The recommended maximum fre-
nut) into the drain hole. Preferred size of the hole for the quency of application is based on the corrosion severity of
weld-nut is 0.50 in., minimum size is 0.375 in. Length will the operational environment. The frequency of application
be as determined by the hollow member wall thickness. A can be set to coincide with wash cycles and periodic inspec-
suggested source of supply for the weld nuts is available tions, but should not be extended. These compounds should
from the Molly Division of USM Corp., 504 Mt. Laurel Av- not be considered as a long-term alternative for proper paint-
enue, Temple, Pennsylvania 19560 or any Chevrolet Truck ing. The CPCs should not be applied at temperatures above
Parts Department. 95 °F or below 50 °F. A brief description of authorized CPC’s
are listed below.
3.12.2.2 Weld nuts should be removed periodically so the
hollow member can be checked for water accumulation and
condition of the corrosion prevention compound. If water

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3.13.1 MIL-PRF-81309. spray tip several times to clear the delivery tube and spray
head. If the can still does not spray, remove and clean the
plastic spray head then spray again to clear the delivery tube.
Since MIL-DTL-85054 buildup is difficult to remove, espe-
cially after prolonged exposure to direct sunlight, previously
CPC shall not be used on or adjacent to oxygen applied coatings should be removed with MIL-PRF-680,
lines, fittings or equipment. The compound shall Type II or III (CID A-A-59601) or MIL-PRF-32295, Type II.
not be used on surfaces where temperatures ex-
ceed 300 °F. Failure to comply may result in fire 3.13.3 MIL-PRF-16173 CPC Solvent Cutback, Cold
hazard. Application. MIL-PRF-16173, Class 2, covers five different
grades of CPCs that can be applied by brushing or dipping.
Grades 1, 2, 4, and 5 do not displace water and must be
applied to dried surfaces or to surfaces that have been treated
with MIL-PRF-81309. Grade 3 is a water displacing soft
Corrosion Preventive Compounds (CPC) can be film, but is not a substitute for MIL-PRF-81309. All five
separated into two major categories: water displac- grades are very effective in preventing corrosion. As a soft
ing and non-water displacing compounds (refer to film CPC, care must be taken to ensure dirt and other con-
TO 1-1-691). Some CPC’s have a flash point taminants do not collect on the soft CPC surface for ex-
above 100 °F, but contain flammable solvents. tended periods of time.
These compounds should be handled, stored, and
applied in accordance with manufacturer’s instruc- a. Grade 1. A thick hard, black CPC that is difficult to
tions and the product Material Safety Data Sheet remove. However, it offers the most corrosion protec-
(MSDS). tion of all the CPCs indoors and outdoors and may be
used at temperatures down to 0 °F. Should not be used
MIL-PRF-81309 (CPC Water Displacing Ultra Thin Film) is in highly visible areas. Use either Grade 4 or MIL-
a general-purpose corrosion preventive compound that can DTL-85054 semitransparent CPC.
be used whenever a CPC or a water-displacing compound is
called for but no specification is referenced. MIL-PRF-81309 b. Grade 2. A thick, soft, grease-like, brown CPC that
materials are excellent water displacing compounds that pro- remains tacky and can be removed with mineral spirits
vide an ultra thin, soft protective film (0.5 millimeter (mil) or dry cleaning solvent. It protects under relatively se-
or less). The specification covers two types, both of which vere conditions and, given adequate maintenance
can be applied by dipping, spraying, brushing, or an aerosol touch-up as necessary, can be used for most maximum
container. They provide temporary protection from corrosion protection requirement. It may be used at temperatures
and are easily removable with a solvent. The two types pri- down to -40 °F.
marily in used for SE are Types II and III.
c. Grade 3. A thin, soft film CPC. MIL-PRF-81309, Type
a. Type II. A soft, thin film for general use, particularly III can be used as a substitute for MIL-PRF-16173;
on moving or sliding parts where some lubrication is however, MIL-PRF-16173 cannot be used as a substi-
needed, such as hinges or bomb racks. It may be tute for MIL-PRF-81309.
washed away by rain or wash procedures. Type II shall
be used to protect areas which cannot be properly d. Grade 4. A thin, non-tacky, semitransparent film
drained or contain recesses that are particularly diffi- through which identification can be read. It may be
cult to reach. used at temperatures down to -40 °F.

b. Type III. An ultra thin, soft film primarily for use on e. Grade 5. A soft film CPC removable using low pres-
avionics and electronic equipment. Although this coat- sure steam.
ing is nonconductive, it will allow electrical contact
because it is soft and very thin. Do not use MIL-PRF- 3.13.4 MIL-PRF-63460 Lubricant, Cleaner, and Pre-
16173, Grade 3 as a substitute. servative for Weapons and Weapon Systems. MIL-PRF-
63640 is a thin, water displacing, protective, penetrating lu-
3.13.2 MIL-DTL-85054. MIL-DTL-85054 CPC is a water bricant used for cleaning, lubrication and preservation of
displacing CPC that forms a clear, dry, flexible film. It is components. This material has good lubricating properties
intended for use as a protective coating until painting is between -65° and 105 °F (-54° and 41 °C). It may be applied
practical. Because of its paint-like characteristics, this CPC by brushing, dipping, or spraying.
does not provide any lubrication. It can be applied by dip-
ping, brushing, spraying, or from aerosol containers. How- 3.13.5 MIL-L-87177 Lubricants, Water Displacing.
ever, dipping provides a very thin coating with less corrosion MIL-L-87177 covers several types and grades of a synthetic,
protection. After each use of an aerosol can, invert the can water displacing lubricant that has shown excellent corrosion
and spray until spray tip (nozzle) is clear of entrapped mate- preventive qualities, especially on electrical contacts, contact
rial. If an aerosol can does not spray, invert and depress the pins, electrical quick disconnect connectors, etc. There are

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two types and grades. Type I, Grade B is a water displacing sert the FORMIT® 360 degree extension wands, or equiva-
lubricant with an added corrosion inhibitor. Grade B is the lent applicators, into the drain hole and slowly withdraw the
preferred material for use on SE electrical contacts and con- spray wand while applying the CPC to the interior of the
nectors. hollow member. Repeat this process for each drain hole en-
suring complete coverage between drain holes. Depot over-
3.13.6 CPC Methods of Application. CPCs can be ap- haul or contractor maintenance shall condition the interior of
plied by brushing, dipping, or spraying. The area of applica- the hollow members with an iron phosphate pretreatment per
tion, viscosity of the CPC and the conditions under which TT-C-490, Type II, then apply the CPC as above.
the CPC need to be applied are factors which determine
which methods of application to use. Use of the FORMIT® 3.15 CPC APPLICATION ON OTHER ALLOYS.
extension wand applicator, or equivalent, may be used to fog
the thinner version of CPCs inside drain holes or other ac- Clean the surface where CPC is to be applied by removing
cess areas. loose/lifting materials with a stainless wirebrush or scotch-
brite pad. Wipe the area clean prior to applying CPC. Field
3.14 CPC APPLICATION ON FERROUS ALLOYS. organizations shall utilize spray wands, FORMIT® 360 de-
gree extension wands, or equivalent devices, to fog or spray
Clean the surface where CPC is to be applied by removing the CPC MIL-PRF-16173, Grade 4 or (MIL-PRF-81309
loose/lifting materials with a steel/stainless wirebrush or Type II), onto the interior surfaces of the hollow members
scotch-brite pad. Wipe the area clean prior to applying CPC. ensuring complete interior coverage. Depot overhaul or con-
Apply by brush, dip, or spray. For hard to reach recesses, tractor maintenance shall condition the interior of aluminum
field organizations, utilizing spray wands, aerosol extension hollow members per TO 1-1-691 with a chromate conver-
applicator such as the FORMIT® extension applicators, or sion coating per MIL-DTL-5541, Class 1A or anodize per
equivalent devices, to fog or spray the CPC MIL-PRF-16173, MIL-A-8625, Type II or III. The specific treatment shall de-
Grade 4 or Zip Chem, ZC-010 (MIL-PRF-81309 Type 2), pend on the alloy. Apply the appropriate CPC, as above,
onto the interior surfaces of the hollow members. Fully in- after the pretreatment operations.

Table 3-3. Pretreatment Instructions

Material Finish Process

A. FERROUS ALLOYS other than 1. Chemically clean the areas in accordance with Chapter 3. Remove all re-
stainless steel, mill-galvanized or maining coating and corrosion by abrasive blasting or other mechanical
mill-electrozinc coating, or mill- cleaning processes. Field organizations without abrasive blasting capabili-
aluminized surfaces. ties may proceed to Step 3. Depot and/or contractor level of maintenance
apply zinc phosphate TT-C-490, Type I.
2. The blasted surfaces will be in a near-white condition per Steel Structures
Painting Council (SSPC-SP 10). A near-white blast cleaned surface finish
is defined as one from which all oil, grease, dirt, mill scale, rust, corro-
sion products, oxides, paint or other foreign matter have been completely
removed from the surface except for very light shadows, very slight
streaks, or slight discolorations caused by rust stain, mill scale oxides, or
slight, tight residues of paint or coating that may remain. At least 95% of
each square inch of surface area shall be free of all visible residues, and
the remainder shall be limited to the light discoloration mentioned above.
The National Association of Corrosion Engineers (NACE) Standard TM-
01-70 (Visual Standard for Surfaces of New Steel Airblast Cleaned with
Sand Abrasive) surface was produced as a visual standard to compare
properly prepared surfaces. The Standard may be procured from NACE
International, 440 South Creek Drive, Houston, TX 77084-4906. The
blast-cleaned surface must be primed before any rusting occurs, otherwise
the benefit of the near-white blast cleaning is lost. Under normal atmo-
spheric conditions it is best practice to prime within one hour of blast
cleaning.
The following areas are exceptions to blasting:
a. Abrasive blasting will not be performed on surfaces where there is a danger
of warping or distorting the base metal. Sheet metal thinner than 0.0625
in. (U.S. Standard 16 gauge) will not be abrasive blasted.
b. Parts whose dimensions must be retained or parts with deep crevices,
threads, or machined surfaces will not be abrasive blasted.

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Table 3-3. Pretreatment Instructions - Continued

Material Finish Process

c. Heavy cast iron or tempered steel components such as engines, transmis-
sions, gearboxes, differentials, leaf or coil springs, etc., shall not be abra-
sively blasted.
d. Working surfaces that are to be lubricated.
3. Primer - The preferred coating system over abrasive blasted ferrous alloys is
a zinc-rich primer and intermediate primer system. The primers will be
applied in a “wet-to-wet” process. The basecoat zinc-rich primer, (MIL-
PRF-26915) is applied and the intermediate primer (MIL-DTL-53030) is
applied shortly thereafter over the zinc-rich primer.
Follow the coating manufacturers’ application instructions for the mixing,
delays between the primer application and the required application equip-
ment.
The base coat zinc-rich primer shall conform to MIL-PRF-26915. Dry film
thickness of the zinc-rich primer should be 2.0 - 2.5 mils. The intermedi-
ate primer shall conform to MIL-DTL-53030. Dry film thickness for
MIL-DTL-53030 shall be 0.9 to 1.1 mils. If the surface is not recondi-
tioned to bare metal, the use of a non-chromate tie-coat is recommended.
Apply MIL-PRF-23377, Type I, Class N or MIL-DTL-53022, Type II
over the areas to be painted.
4. Topcoat - Paint with one coat of MIL-PRF-85285, Type I applied to a dry
film thickness of 1.6 to 2.4 mils.
B. STAINLESS STEEL AND 1. Most stainless steel surfaces do not require finishing. If there are require-
NICKEL BASE ALLOYS. ments in the equipment specific technical order to coat stainless steel, and
the technical order provided the coating procedures those instructions
shall take precedence. If no instructions are available and coatings are
required use the following application processes.
2. Clean in accordance with Chapter 2, if the surface remains contaminated
refer to TO 1-1-691.
3. Passivate the surface in accordance with SAE-AMS-QQ-P-35 (Depot or
Contractor levels of maintenance only).
4. Primer - MIL-DTL-53022, Type II (Lead and Chromate Free, Epoxy
Primer). Allow the primer to dry. Dry film thickness for MIL-DTL-53022,
Type II primed surfaces shall be 0.9 to 1.1 mils.
5. Finish - Paint with one coat of MIL-PRF-85285 applied to a dry film thick-
ness of 1.6 to 2.4 mils. Total dry film thickness of all coatings: MIL-
DTL-53022, Type II primed surfaces shall be 2.5 to 3.5 mils.
C. MAGNESIUM ALLOYS 1. Clean in accordance with Chapter 2, if the surface remains contaminated
refer to TO 1-1-691.
2. Pretreat with dichromate film per SAE-AMS-M-3171, Type III.
3. Primer - Prime with one coat of epoxy primer, MIL-PRF-23377, Type I,
Class 2. Dry film thickness for MIL-PRF-23377 primed surfaces shall be
0.6 to 0.8 mils.
4. Finish - Finish with one coat of MIL-PRF-85285 applied to a dry film
thickness of 1.6 to 2.4 mils. Total dry film thickness of all coatings: MIL-
PRF-23377 primed surfaces shall be 2.2 to 3.2 mils.
D. CADMIUM OR ZINC PLATED 1. Clean in accordance with Chapter 2.
SURFACES, mill-galvanized, 2. Pretreat by applying MIL-C-17711 (Depot and/or contractors only).
millelectro-zinc coated. 3. Primer - Prime with one coat of epoxy primer, MIL-PRF-23377, Type I,
Class 2, or MIL-DTL-53022, Type II (Lead and Chromate Free, Epoxy
Primer). Dry film thickness for MIL-PRF-23377 primed surfaces shall be
0.6 to 0.8 mils, dry film thickness for MIL-DTL-53022, Type II primed
surfaces shall be 09 to 1.1 mils.

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Table 3-3. Pretreatment Instructions - Continued

Material Finish Process

4. Finish - Finish with one coat of MIL-PRF-85285 applied to a dry film
thickness of 1.6 to 2.4 mils. Total dry film thickness of all coatings: MIL-
PRF-23377 shall be 2.2 to 3.2 mils; total dry film thickness for MIL-
DTL-53022, Type II primed surfaces shall be 2.5 to 3.5 mils.
E. MILL-ALUMINUM STOCK. 1. Clean in accordance with Chapter 2.
2. Pretreat with MIL-DTL-5541, Class 1A or Anodize per MIL-A-8625 Type
II or III (Depot or contractors only) per TO 1-1-691.
3. Primer - Prime with one coat of epoxy primer, MIL-PRF- 23377, Type I,
Class C. Dry film thickness for MIL-PRF-23377 primed surfaces shall be
0.6 to 0.8 mils.
4. Finish - Finish with one coat of MIL-PRF-85285 applied to a dry film
thickness of 1.6 to 2.4 mils. Total dry film thickness of all coatings for
MIL-PRF-23377; total dry film thickness for MIL-DTL-53022, Type II
primed surfaces shall be 2.5 to 3.5 mils.

3.16 COATING APPLICATIONS. 3.16.3.1 The MIL-PRF-26915 will be stock listed and a
QPL/QPD is being established. Until such time that a QPL/
3.16.1 Material Selection. To provide optimum protec- QPD is available, one of the organic zinc-rich primers in
tion from deterioration and corrosion, the proper coating sys- Paragraph 3.16.3.2 is authorized. Refer to Table A-1 for Na-
tem (a combination of cleaning, pretreatment, priming and tional Stock Number (NSN) information. If the zinc-rich
topcoat) must be selected for a specific application. See Table primer sprayed surface exhibits roughness, the application of
3-1 for authorized coating systems. Table 3-3 is a brief ab- the intermediate primer, MIL-P-53030 shall be used as a in-
stract of the priming and painting functions necessary to termediate coat to provide additional corrosion protection,
maintain the coating systems on SE. an improve topcoat appearance, and prevent minute zinc ox-
ide spotting normally associated with zinc-rich primers. If
3.16.2 SE Surface Preparation Categories. SE surface the intermediate primer is required, utilize the 3-part coating
preparation for painting operations fall into four general cat- system identified in Table 3-1.
egories:
3.16.3.2 Approved alternates until the QPL/QPD for MIL-
a. Paint removal (removal of old coating system). PRF-26915 is published:

b. Cleaning. a. Deft 44 GY-16, zinc-rich water reducible epoxy poly-

amide primer
c. Corrosion removal and prepaint treatment.
DEFT Inc.
d. Prime and topcoat. 17451 Von Karman Ave
Irvine, CA 92614
3.16.3 Organic Zinc-Rich Primer.
b. Azko Nobel 10P3-2
NOTE
For specific information not covered in this tech- Akzo Nobel Aerospace Coatings
nical order consult TO 1-1-691 and TO 1-1-8 re- 1 East Water Street
garding more specific instructions on depainting,
Waukegan, IL 60085
corrosion treatment, prepaint treatments and coat-
ing application procedures.
c. Amercoat 68A
For abrasive blasted ferrous alloys the preferred finish sys-
tem consists of a organic zinc-rich primer and a chrome and Ameron
lead free, low VOC, MIL-DTL-53030, intermediate primer Industrial Coatings Division
over the organic, zinc-rich primer and a polyurethane MIL-
P.O. Box 2153
PRF-85285, Type I topcoat. The following information is
designed to assist in the application of the zinc-rich primer 16116 East 13th Street
and polyurethane topcoat.

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Wichita, KS 67201 3.16.3.7 When applying the intermediate primer, applica-

tion shall be wet-to-wet. Wet-to-wet means at the completion
of the first coat of zinc-rich primer, MIL-PRF-26915, a coat
d. ZRC® 221
of intermediate primer, MIL-P-53030 is applied directly over
the zinc-rich primer before the base primer is dry. Both sys-
ZRC tems are then allowed to dry completely before topcoat ap-
145 Enterprise Dr. plications.
Marshfield MA 02050
3.16.3.8 Follow the manufacturer’s application data sheet
e. Aeroshield ZRP for all coating thinning, application, and curing data.

3.16.3.9 If the zinc-rich primer cannot be topcoated within

AKZO Nobel Aerospace Coatings 48 hours, activation of the surface may be necessary. This
1 E Water St can be accomplished by lightly wiping the surface with a
Waukegan, IL 60085-563 scotchbrite pad, A-A-58054, Type I, Grade A, dampened with
MIL-PRF-87937 diluted to manufacturer’s instructions. Af-
3.16.3.3 The zinc-rich primer should be constantly mixed ter wiping with cleaner, wipe the surface with clean cloth
during application to obtain a homogenous even applied film. dampened with water and dry with clean cloth.
Constant agitation will prevent the heavy zinc pigment from
settling to the bottom of the spray pot/cup that would cause 3.16.4 MIL-PRF-85285 Polyurethane, Type I. The stan-
the spray gun to surge or apply uneven levels of the zinc dard topcoat used on SE is MIL-PRF-85285, High Solids
pigment to the SE surfaces. A heavy buildup of the zinc Polyurethane, Type I. This section is relative to coating tou-
pigment will result in a weak porous film. chup operations for that topcoat. The selection of polyure-
thane paint, MIL-PRF-85285, by field, depot, and contractor
3.16.3.4 The wet film thickness required to achieve a dry operations, is restricted to only those companies who have
film thickness of 2.0 to 2.5 mils is dependent upon the vol- been qualified to the performance specification. Those ven-
ume of solids content and amount of thinner used. Zinc-rich dors are listed on Qualified Products Database, QPD-85285.
primers usually have about 72% volume of solids so a wet To download the latest version of current specifications,
film thickness of 3.0 to 4.0 mils should result in the desired handbooks, or QPL/QPD use the Defense Logistics Agency
dry film thickness. Specification search engine (http://assist.daps.dl.amil/quick-
search) or visit the Air Force Corrosion Prevention and Con-
trol Office website located on the AF Portal.
NOTE
Applicators will confirm the correct dry film thick- 3.16.5 Thermal Spray Coating Systems.
ness with a dry film thickness tester that is capable
of measuring multi-levels of coatings NOTE

3.16.3.5 Primer overspray (a deposit of loose dusty coat- When polyurethane is applied below 40 percent
ing on the primer surface) can be a major problem when relative humidity and/or 60 °F, the cure time is
topcoating zinc-rich primers. Like other surface contami- appreciably lengthened. The coating application
nants, overspray hinders topcoat wetting and provides a poor range for MIL-PRF-85285 is relative humidity 20
anchor for paint. The overspray can be removed from the to 80 percent and ambient temperature 50 to 90
primer by rubbing the surface with a clean bristle brush and °F.
then blowing off all loose particles with oil free, dry com-
pressed air. There are several methods of thermally spraying metal al-
loys. For coating large pieces of SE, the most commonly
3.16.3.6 Zinc-rich primer surfaces, because of their poros- used equipment in the Air Force is dual metal wire electric
ity are readily contaminated by oil, dirt or atmospheric pol- arc spray. The equipment recommended should be for high,
lutants; therefore primed equipment should remain indoors field and depot level production levels. Organizations may
in a controlled environment until topcoated. use the Thermion 500 and the Thermion Bridgemaster or
equivalent systems for metalizing operations. Thermion
equipment may be procured from Thermion Metalizing Sys-
NOTE
tem, Ltd., P.O. Box 2136, Silverdale, WA 98383-2136. Table
Use only paint spray equipment designed, or modi- 3-4 lists currently authorized metalization materials and pre-
fied, for zinc-rich primer application. Failure to do ferred sources of supply.
otherwise will allow the zinc-rich primer to col-
lect on the needle and air cap or settle to the bot- 3.16.5.1 Metalization Process Metal Wire Arc Spray
tom of the paint spray cup rendering the spray (MWAS). MWAS is a thermally sprayed, sacrificial metal-
equipment inoperative. ized coating for effective protection of structural iron and

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steel in corrosive environments. For ferrous metal surfaces, contaminated surfaces should not be reused for the final blast,
other than stainless/corrosion resistant steel, 85/15% zinc/ even though it is rescreened as the media may contain con-
aluminum alloy wire has shown the widest application and taminates that will be re-embedded in the metal surface
corrosion protection latitude. 85/15% zinc alloy, 1/8-in. di- causing corrosion and/or coating adhesion failure.
ameter is the common wire diameter. Organizations may use
this alloy for all application on properly prepared ferrous 3.16.5.1.4 Follow the thermal spray equipment manufac-
metals over 1/8-in. thick, except stainless/corrosion resistant turers’ preparation and application instructions. The metal
steel alloys. For aluminum equipment or ferrous metal used coating shall be applied to a minimum thickness of 6 mils
in a high temperature zones use METCO Aluminum wire or and maximum of 8 mils.
equivalent, 99.0% purity, 1/8-in. diameter.
3.16.5.1.5 Any surface, which shows visible moisture,
3.16.5.1.1 In the MWAS process, two electrically isolated rust, scale or other contamination shall be re-blasted before
wires of the selected coating material are given opposite DC spraying. The surface must be completely coated to the
polarity using an arc-welder power supply. The wires are specified thickness within six hours of abrasive blasting.
simultaneously fed to an application gun where they are
brought into close proximity to initiate an electric arc. The
arc between the two impinging wires results in a local region
of high temperature plasma and molten metal. A jet of com-
pressed air, directed through the arc region from behind, dis- The correct thickness of thermal spray coating in
perses and projects the molten metal to the surface being this application is critical. A coating that is too
coated. The metal droplets impinge on the substrate; solidify thin will not provide corrosion protection while a
and bond to form a continuous barrier/sacrificial metal coat- coating that is too thick will chip and flake off.
ing for cathodic protection of the metal structure. The appli-
cation gun remains 8-12 in. from the metal surface and neg- 3.16.5.1.6 The metalized coating shall be inspected for
ligible heat is imparted to the substrate even during extended thickness by using the multi-metal dry film thickness gage to
coating activities. ensure correct surface thickness is achieved. Any thin or un-
coated areas must be immediately roughened with a mechani-
NOTE cal grinder with a minimum of a 25 grit disc to apply a
“cross-hatch” pattern to the substrate. Immediately apply the
The air supply must be sufficiently free of oil and
thermal spray coating to reach the proper coating thickness.
moisture so that no visible oil or moisture appears
on the blasted surface.
3.16.5.1.7 On high temperature components metalized
with aluminum, organization may use METCOSEAL SA
3.16.5.1.2 All surfaces to be thermal sprayed shall be
silicone aluminum sealer to prevent any rust staining that
abrasive blasted to a minimum of a near-white metal blasted
may occur. This sealer is available from:
surface and roughened to a minimum of a 2 mil surface
profile. If paint, oil or bituminous materials are present they
must be removed prior to the final blast operation. If the METCO INC.
surface is chemically contaminated, it may be necessary to 1101 Prospect Avenue
wash it or neutralize it before final blasting. Westbury, L.I., N.Y. 11590

The MWAS process produces high localized noise

levels and ultraviolet radiation emissions from the
arc region. Prior to commencing initial MWAS
operations consult with the base bioenvironmental
engineer (BBE) for approval. Proper hearing, eye
protection, and respiratory personal protective
equipment (PPE) will be designated by the local
BBE.

3.16.5.1.3 The abrasive media used for cleaning heavily

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Table 3-4. Metalization Material Sources of Supply

Material Use Source of Supply

85/15% zinc/aluminum alloy Best overall general purpose corrosion pro- The Platt Brothers & Company
tection on abrasive blasted carbon steel P.O. Box 1030
surfaces. Waterbury, CT 06271
AUFHAUSER Corporation
39 West Mall
Plainview, NY 11803
100% aluminum For coating hot sections of equipment, muf- Alcotec Wire Corporation
flers, and aluminum equipment. 2760 Aero Park Dr.
Traverse City, MI 49686
AUFHAUSER Corporation
39 West Mall
Plainview, NY 11803
90/10% aluminum/aluminum For the application of a tough durable, Alcotec Wire Corporation
oxide alloy long-term anti-slip coating to steel and
aluminum surfaces. 2760 Aero Park Dr.
Traverse City, MI 49686
AUFHAUSER Corporation
39 West Mall
Plainview, NY 11803
100% zinc Excellent corrosion protection except in The Platt Brothers & Company
seawater immersion conditions P.O. Box 1030
Waterbury, CT 06271
AUFHAUSER Corporation
39 West Mall
Plainview, NY 11803

3.17 FIELD LEVEL MAINTENANCE PAINTING RE- AFCPCO website located on the AF Portal. Larger scratches/
QUIREMENTS. chips in paint or damaged areas will be grounds to repaint
the complete section per Paragraph 3.3.
Field level maintenance-painting requirements for SE with
polyurethane are divided into two types, touch-up painting 3.18 MAINTENANCE PAINTING.
and general maintenance painting.
3.18.1 Maintenance Painting Restrictions. Although it
3.17.1 Touch-Up Painting. Touch-up painting is defined is not recommended, it is a common field level practice dur-
as minor touch-up and/or sectionalized painting of equip- ing maintenance painting to repeatedly overcoat the entire
ment using authorized coating to prevent corrosion. When exterior surface. Under no circumstance should the total
spot painting, the amount of paint used should be enough to number of layers of paint ever exceed six (6). The number of
cover the affected area plus a one-inch overlap to seal the layers can be determined during the featheredge sanding of
area’s edges. Treat scratched areas that are one half inch damaged areas. Count each layer of primer as one and each
wide by three inches long or less, or chips one inch in diam- layer of topcoat as one, the total of which should never ex-
eter or less will be touched-up with CPC (temporary repair), ceed six.
or approved primers and topcoats preloaded in items such as
but not limited to: SEMPENS, Preval compressed air spray 3.18.1.1 Equipment exceeding this maximum number of
packs, Clip-Pacs, Brush and Roller, or Akzo Nobel Two- paint layers should be scheduled for complete coating re-
Component MIL-PRF-85285 Aerosol Can. Single component moval and repainting.
aerosols, enamels or lacquers are not authorized coatings.
Information about these materials can be viewed on the

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CPC buildup, remove and reapply the CPC, MIL-DTL-85054

during normal wash cycles. Use of soft film CPC is not rec-
ommended as they tend to collect contaminates and would
Excessive numbers of paint layers will result in reduce the cooling efficiency of the radiator.
hidden corrosion going unnoticed or interlaminar
failure of the coatings at one of the coating 3.19 LIQUID OXYGEN AND LIQUID NITROGEN
boundaries. SERVICING CARTS AND STORAGE TANKS.

3.18.1.2 Powder coated equipment shall be touched up us- Liquid nitrogen and liquid oxygen servicing carts and stor-
ing MIL-PRF-85285, Type I or II. SEMPEN or the prepack- age tanks will be drained and purged in accordance with the
aged spray touch-up kits shall be used on small areas less applicable equipment technical order prior to cleaning and
than one square foot. All damaged areas shall be feather- painting.
edge sanded along the edge damaged area to allow the repair
coating to blend in the surrounding areas. The remaining 3.19.1 Authorized Materials for Liquid Oxygen and Ni-
areas to be touched-up shall be scuff sanded with 180 or 240 trogen Tanks.
grit abrasive paper. All bare aluminum areas resulting from
coating failure shall be pretreated with the chromate conver-
sion coating SEMPEN prior to priming. The bare areas shall
be primed and topcoated with one of the authorized organic
coating systems listed in Table 3-1. All valves and instrumentation shall be masked
after draining and purging to prevent contamina-
3.18.2 Prepackaged Coating Touch-Up Kits. For minor tion and explosion hazard during cleaning and
primer and paint touch-up such as scratches and other small painting.
repair, the use of prepackaged touch-up kits manufactured
with the compatible the authorized conversion coatings, The colors for liquid oxygen, liquid nitrogen servicing carts
primers and topcoats are encouraged. and storage tanks will be according to Paragraph 3.5.3. Liq-
uid oxygen and nitrogen servicing carts and storage tanks
3.18.2.1 Use of the prepackaged touch-up kits minimizes will be primed with one coat of epoxy primer, MIL-PRF-
material waste and personnel exposure to paints and solvents 23377, Type I, Class 2, or MIL-DTL-53022, Type II (Lead
while allowing for the use of the proper coating system for and Chromate Free Epoxy Primer), 0.6 to 0.8 mil dry film
the repair. thickness, then finished with one coat of MIL-PRF-85285
applied to a dry film thickness of 1.6 to 2.4 mils. Exceptions
3.18.2.2 SEMPENs, Preval compressed air spray packs, to this finish system shall be approved by Warner Robins
Clip-Pacs, or Akzo Nobel Two-Component MIL-PRF-85285 ALC/LESG.
Aerosol Can are currently obtainable in MIL-PRF-85285,
Type I, high solids polyurethane. Single component aerosols, 3.20 WALKWAYS AND STEPPING SURFACE
enamels or lacquers are not authorized coatings. Information COATINGS.
about these materials can be viewed on the AFCPCO web-
site located on the AF Portal. The stepping, standing and/or walking surfaces of stands,
metal ladders, platforms, tops of deicing-decontamination
3.18.3 Radiators Coatings. Radiator coatings are preap- unit tanks, etc., shall be coated with walkway coating, A-A-
plied at the OEM. Field repair is limited to touch-up of the 59166. Expanded metal, grating and other anti-skid plates
body and attach points of the radiator but not the radiator are exempted as long as they are safe from slippage. Adhe-
vanes/core. For touch-up, use the appropriate color of poly- sive backed, non-slip material MIL-PRF-17951 may be used
urethane from Appendix A. A thin layer of water displacing, as an alternate. Follow the non-slip material manufacturers’
hard film CPC, MIL-DTL-85054, may be fogged into the application instructions.
radiator vanes for added protection or for temporary repair.
Do not use soft film CPC materials as the coating may col- 3.21 COLORS FOR WASTE CONTAINERS.
lect dirt and debris on the cooling vanes reducing the effi-
ciency of the radiator. An aerosol extension kit such as the Containers (Bowsers) used for holding explosive or highly
FORMIT® 90 degree applicator, or equivalent, may be used flammable materials will be painted and marked in accor-
to fog the CPC into recessed areas of the radiator. Heavy dance with TO 42B-1-23.
buildup of the paint and/or CPC is to be avoided. To prevent

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3.22 SE UNDERCOATING. c. Apply 85/15% zinc/aluminum metallization 4-6 mils

thick on bare, abrasive blasted steel surfaces.
A-A-59295 undercoating is authorized for use by field units.
The undercoating is intended for use in one thick coat (1/8 d. Apply a sprayable polyurethane truck bed liner type
in.) on the underside of fenders, floors, etc., to deaden noise, coatings, Morton Paint Company, PN 1440-2, or
to act as a seal against fumes and to protect the metal from equivalent on high wear areas and storage compart-
corrosion. ment interiors. Colors shall be black or consistent with
the existing color utilized on the equipment. The coat-
3.22.1 SE Undercoating Considerations. The undercoat ing shall be applied over the existing primer and poly-
may be applied to a primed surface. Topcoating in this area urethane topcoat paint system.
prior to undercoating is not required. Ensure the undercar-
riage of the equipment is clean prior to application of the 3.24 SPLIT WHEEL ASSEMBLIES.
undercoating. Do not apply over corrosion.
3.24.1 Split Wheel Coating Requirements. To prevent
NOTE corrosion on the mounting flanges of the split wheels accom-
plish the following:
For maximum corrosion protection, undercoating
should be applied by the original equipment manu- 3.24.1.1 Remove all corrosion and clean the flanges.
facturer during production.
3.24.1.2 For carbon steel wheels mechanically clean the
3.22.1.1 The undercoat is not fluid resistant and fuels/flu- split wheel assemblies and apply 0.002-in. thickness of zinc-
ids/ solvents will readily cause deterioration of the coating. rich primer, MIL-PRF-26915, to each of the surfaces. Allow
Undercoat should not be used in an area subjected to fluid paint to completely dry per the manufacturers application
spills. data.
3.22.1.2 The undercoat should never be applied over a 3.24.1.3 MIL-DTL-53022, Type II, is an acceptable alter-
component (such as a transmission) where the coating would nate for zinc-rich paint on split wheel assemblies only if the
result in the undesired retention of heat. necessary surface preparation equipment is not available.
3.22.1.3 Undercoating is not resistant to temperatures in 3.24.1.4 If primer is used, apply a thin film of uncata-
excess of 325 °F and should not be used in such areas. lyzed, low adhesion sealant PR-1773 to the mating surfaces
of the split wheels after the primer has cured to prevent fluid
3.23 STORAGE COMPARTMENTS. intrusion and assist in future wheel disassembly.
Storage compartments for ducts or hoses, which use a pad, 3.24.1.5 Reassemble per applicable technical order and
or matting for abrasion resistance are highly susceptible to apply a bead of sealant RTV MIL-A-46146 around the infla-
corrosion because of the water absorbing characteristics of tion valve stem to prevent water entry. Tires will be treated
those materials. Field activities should remove the pads/mat- with a commercial tire dressing, and all valve stem caps will
ting and replace the mat with an abrasion resistant floor cov- be plastic.
ering by using one of the following techniques after removal
of all corrosion and the surface is completely prepared for 3.25 MUFFLERS.
the selected coating.
To reduce corrosion problems on muffler components a ther-
a. Apply MIL-PRF-81733 sealant 1/8 in. thick over a mal sprayed aluminum coating may be used. The effective-
clean primed and painted surface. ness of the coating is dependent upon the particular compo-
nent and the environment (temperature, time at temperature,
b. Apply Scotch Brand Abrasion-Resistant Polyurethane and time to reach temperature). The effectiveness will also
Film (8561) over a clean primed and painted surface. be dependent upon the condition of the component prior to
The film is available in four inch wide rolls and can be thermal spraying, the coating will be more effective on a
easily trimmed to fit any contour or shape. The surface new component than on a reconditioned component that had
must be clean to permit the adhesive backing to bond already rusted.
properly.

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Figure 3-4. Corrosion Under Data Plate

3.26 MISCELLANEOUS CLEANING, SEALING, AND 3.26.3.1 Remove corrosion with abrasive mat, A-A-58054
CPC REQUIREMENTS. and MIL-PRF-680, Type II or III, CID A-A-59601 or MIL
PRF-32295, Type II, wipe off residue and allow to air dry.
3.26.1 Sealing of Addressograph or Dash-A Plates.

NOTE
Do not apply thermal spray pure zinc, 85/15% Solvent will cause softening and deterioration of
zinc/ aluminum or pure aluminum to stainless steel rubber gaskets, seals, and insulation.
muffler components.
3.26.3.2 Clean electrical contacts with MIL-PRF-29608,
Whenever an Addressograph or Dash-A-Plate is used in lieu Type I, Electrical Contact Cleaner.
of die cut vinyl markings or stencils as data plates, they
should be installed wet with corrosion inhibiting sealant, 3.26.3.3 Apply a thin layer of CPC, MIL-L-87177, Grade
MIL-PRF-81733. The requirement for wet installation also B, to the contacts.
includes the fasteners used for installation. Using the sealant
will prevent corrosion from occurring between the data plate 3.26.4 Internal Electrical Components: Circuit Break-
and SE. ers, Relays, etc. Instructions for removing and cleaning
internal electrical components are as follows:
3.26.2 Electrical Hardware and Terminals.

NOTE
Clean corrosion on terminal studs with a wire
brush or terminal stud-cleaning tool. Do not remove thin plating on electrical compo-
nents. Always use the mildest method of corrosion
3.26.2.1 For cables and terminal posts, brush on a light removal.
coat of petrolatum, VV-P-236 Grease.
3.26.4.1 Remove heavy corrosion by rubbing contact sur-
3.26.2.2 For battery frame and holder, apply one coat of faces with an abrasive typewriter eraser. Remove light to
primer, MIL-PRF-23377, Type I, Class 2 or MIL-DTL- medium corrosion by rubbing contact surface with ruby red
53022, Type II (Lead and Chromate Free Epoxy Primer) and eraser.
one coat of MIL-PRF-85285 applied to a dry film thickness
of 1.6 to 2.4 mils. 3.26.4.2 Clean contacts with MIL-PRF-29608, Electrical
Contact Cleaner, Type 1, Class C. Clean relay or circuit
3.26.3 Light Assemblies. Instructions for cleaning the breaker assembly with acid brush, A-A-289. Remove foreign
light assemblies are as follows: matter with a soft brush.

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3.26.6.2 Apply a thin coat of CPC MIL-L-87177, Grade B

to the electrical contact points.

• Do not apply CPC MIL-C-81309 to printed cir- 3.26.6.3 Wipe all sliding contacts, cams, and contact
cuit boards. Contact points must be clean for points with a clean cloth, CCC-C-46, Class 4 or pipe cleaner
CPC to function properly. to remove CPC.
• Care must be taken to avoid removing thin 3.26.7 Wire Harness and Cables. Instructions for clean-
plating. ing the wire harness and cables are as follows:
3.26.4.3 Apply a thin coat of CPC MIL-L-87177, Grade NOTE
B, to relays and contacts.
• Contact points must be clean of CPC to func-
3.26.5 Electrical Connectors. tion properly.

• Cleaning solvents and compounds may ad-

versely react with plastics such as harness tub-
ing, gaskets, seals, etc. Test a small area for
Replace all connectors that show moderate to se- softening or reaction prior to general use.
vere corrosion damage.
3.26.7.1 Scrub corroded area with MIL-PRF-29608. Flush
Remove light corrosion with toothbrush, A-A-59 or A-A- area with cleaning compound. Shake excess solvent from
123, soaked in solvent, TT-I-735, isopropyl alcohol. wire harness. Remove residue with a clean cloth, CCC-C-46
and allow to air dry.
3.26.5.1 Apply CPC MIL-L-87177, Grade B, to internal
surfaces. Preserve outer shell with MIL-PRF-16173, Grade 3.26.8 Heli-Coil Insert Replacement. Steps for removal
4. Wipe off excess with a clean cloth. of the insert are as follows:

3.26.5.2 For equipment operating, deploying to, or based 3.26.8.1 Remove the defective insert.
in, severe corrosion prone locations, the use of Av-DEC “Hi-
TAK” polyurethane stretch seal is authorized for use around 3.26.8.2 Clean and dry the female thread from which the
mated electrical connectors, coaxial connectors, and electri- defective insert was removed.
cal quick disconnect fittings.
3.26.8.3 Apply MIL-PRF-23377, Type I, Class 2 primer
3.26.6 Switches. Cleaning instructions for the switches sparingly to the cleaned female thread.
are as follows:
3.26.8.4 Before the primer dries, install new insert and
3.26.6.1 Scrub switch with isopropyl alcohol, TT-I-735 remove the insert driving tag.
and toothbrush, A-A-59 or A-A-123. Wipe with clean cloth,
CCC-C-46. Allow to air dry.

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TO 35-1-3

CHAPTER 4
MARKING OF SUPPORT EQUIPMENT
4.1 GENERAL. 4.2.2.1 Safety/Danger/Caution/Information/and Agency
Identification Markings for liquid oxygen/nitrogen storage
Support equipment will bear the agency marking, model or and transfer tanks will be marked in accordance with Chap-
type number and safety markings and war readiness material ter 4 of this book.
markings when applicable.
4.2.2.2 Danger areas of turbines shall be marked as di-
4.1.1 Marking Illustrations and Legends. Many differ- rected by specific SE technical order data.
ent model configurations exist for the same types of support
equipment (SE) units. The marking illustrations and legends 4.2.2.3 Other Safety/Danger or Caution/Warning decals or
included in this technical manual are for reference use only stencils shall be installed as required by safety regulations
and will not be updated. Refer to the specific SE Technical and/or environmental health directives.
Order, Air Force Instructions (AFI), and/or Local Operating
Instruction (LOI) for specific marking requirements. 4.2.2.4 Lifting capacities of aircraft jacks and similar lift-
ing devices shall have capacity clearly marked.
4.2 SAFETY AND SERVICING MARKINGS.
4.2.2.5 Warning instructions shall be marked on ground
NOTE heaters (combustion-type) as shown in Chapter 4.
Requests for deviation to stenciling/marking re- 4.2.2.6 At the option of the local commander, liquid oxy-
quirements in Chapter 4 will be approved at MA- gen and liquid nitrogen carts/tanks subject to deployment to
JCOM level. Illustrations will be included in re- or already assigned in North Atlantic Treaty Organization
quests to identify exact location, size, and color of (NATO) countries may have the fill and servicing point
markings. Should conflict arise between the spe- marked in accordance with Military Standard 33739 (NATO
cific SE Technical Order and TO 35-1-3, the spe- markings). The NATO symbols for fill and servicing points
cific SE Technical Order will take precedence. of liquid oxygen and liquid nitrogen carts/tanks are as fol-
lows:
4.2.1 National Star Symbol. The National symbol, a five
point star, may be applied to support equipment operated by 4.2.2.7 Liquid oxygen carts/tanks: Two horizontal “fill
the United States Air Force (USAF) in overseas theaters at rectangles” as shown in Figure 4-1.
the direction of the theater commander.
4.2.2.8 Liquid nitrogen carts/tanks: One “Filled square”
4.2.2 Marking Requirements. with quarter arcs removed from corners as shown in Figure
4-2.
NOTE
Tone down marking procedures are mandatory
Deviations require Major Command approval.

US Air Force decals, stencils or placards will be installed as

required by technical orders for the individual SE unit, safety
regulations and/or environmental health regulations. Figure 4-1. NATO Liquid Oxygen Servicing Markings

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4.2.3.7 Application of NATO marking will be accom-

plished by stencil or decal as appropriate. The symbol and
letters will be black color 37038.

4.2.3.8 Special marking for fuel dispensing equipment,

now classified as vehicular SE in FSC 4930 will include “No
Figure 4-2. NATO Liquid Nitrogen Servicing Smoking within 50 feet (ft)” on front portion of filter body
using 3 in. silver reflective letters on a red background or red
Markings
letters on olive drab or matching unit color (gray/green/
brown) surfaces for tone down equipment.
4.2.3 Product Identification. Product identification is as
follows: 4.2.4 SE Reflectorization. SE will be reflectorized using
black reflective strips 2 in. wide and 6 in. in length conform-
NOTE ing to L-S-300C, Type II, Class 1, Reflectivity 2, Durability
Service point marking will be located near the end 1.
of the hose that will be attached to the aircraft.
4.2.4.1 Tape will identify length, width, and height of unit.
4.2.3.1 AVGAS Octane rating and NATO Product identi- Units exceeding 6 ft in length will have the center of unit
fication shall be 4 inch (in.) silver reflective letters on purple marked. Distances between edges of reflective tape will not
background placed on front or back portion of filter body, exceed 6 ft and will be equally spaced. Units less than 6 ft in
depending on space available. length will have only the top and bottom corners identified.
The outermost edges of the unit must be readily identifiable
4.2.3.2 All other product identifications and NATO mark-
ings shall be 4 in. silver reflective letters on a red back- 4.2.4.2 Use of sound judgment for reflectorization and
ground. marking of smaller SE is authorized.

4.2.3.3 Registration number and US Air Force decals shall 4.2.4.3 Aircraft tow bars have additional reflectorization
be placed on rear portion of the filter body if stenciled. requirements due to their length. Distance between edges of
reflective tape will not exceed 6 ft. (72 in.) in length and will
be equally placed on both sides of the tow bar.
4.2.3.4 Other optional information markings shall be in
accordance with Paragraph 4.7.
4.3 AGENCY IDENTIFICATION MARKINGS.
4.2.3.5 Fuel servicing NATO compatibility markings/de-
cals shall be installed as outlined in Chapter 2 of TO 36-1- 4.3.1 Air Force Owned - Contractor Operated Equip-
191. ment. Air Force owned SE operated by a contractor under
terms of a contract with the Air Force, will be marked in a
conspicuous location on both sides of the equipment as
4.2.3.6 Special markings for aircraft hydraulic servicing/
follows:
testing SE are as follows:

4.2.3.6.1 Color/markings to identify hydraulic oil contents AIR FORCE EQUIPMENT

will be filler cap painted blue, with MIL-PRF-5606, MIL- Operated by
PRF-83282, SKYDROL, etc., whichever is applicable, sten- (Name and Address of Contractor)
ciled in 1 in. black letters on filler cap or most conspicuous
area adjacent to filler cap. 4.3.2 Mobilized Equipment. All equipment that is re-
quired in support of flight line operations, which may be
4.2.3.6.2 Color/markings to identify fuel content on all SE relocated and deployed, based on their assigned mission
will be filler cap painted same as the unit, with fuel designa- tasking, will require a mobility placard. These placards can
tion (Diesel, MOGAS, JP-5, JP-8, etc.) whichever is appli- be permanently installed as a local option in accordance with
cable, in 1 in. black letters on filler cap or most conspicuous the following assembly instructions and illustrations.
area adjacent to filler cap.

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NOTE 4.3.2.2 Using 1/2-in. black letters, stencil mobility placard

with the information in Table 4-2 for open viewing.
• On contractor bailment equipment, the registra-
tion number, when applicable, will be stenciled NOTE
beneath the hood of the equipment. The only
other external markings authorized are safety Use black reflective tape to highlight TCN areas.
markings and reflectorized markings required
for night visibility. 4.3.2.3 Stencil the mobility placard as follows. Folded
View (Refer to Figure 4-3).
• Placards already installed will remain on the
equipment. Place mobility information sheet on
a. Use 1/2-in. black letters centered on the placard.
the front left corner of the unit. On equipment
where this is not feasible or practical, place
mobility information sheet in most practical b. USAF
visible location.
c. Unit organization
4.3.2.1 If computer generated, mobility placards maybe
assembled per Table 4-1. d. Model number

NOTE
When automated/computer generated placards are
used then stenciling requirement in Paragraph
4.3.2.2 is optional.

Figure 4-3. Sample Mobility Placard

Table 4-1. Mobility Placard Construction Information

Placard Assembly Instructions

a. Assemble placard by connecting two-each 1/8-in. X 10-in. X 6-in. pieces of sheet metal with a piano hinge.
b. Drill 1/4 in. diameter mount holes 2-in. down from the top and 2-in. in from each side of the sheet metal placard.
c. Drill 1/4 in. diameter hole 2-in. from the left side and 2-in. up from bottom of placard.

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Table 4-1. Mobility Placard Construction Information - Continued

Placard Assembly Instructions

d. Paint for placard will be the same color as the paint applied to unit.
e. Mount placard to unit by using 1/4 in. bolts, washers, and nuts. Use a longer bolt for the left side to secure placard
in the folded position.

Table 4-2. Mobility Placard Stencil Requirements

Placard Stencil Instructions

a. INC: (increment) 1/4-in. from top and 1/4-in. from the placard side. Highlight the area using 1/2-in. black reflec-
tive tape. Start from INC to the middle of placard.
b. CUBE: 1/4-in. from side and 1/8-in. from bottom of highlighted chalk area. All other stencils will have 1/8-in. line
spacing between them.
c. W/B: Wheelbase.
d. LWH: Length x width x height.
e. CB FFE: Center of balance from front end.
f. TCN: Transportation control number.
g. ORGANIZATION STENCIL: Start at middle of placard 1/8 in.from top.
h. MODEL NUMBER: Example: A/M32A-86D.
i. GVW: Gross axle weight in pounds as certified by the transportation management office (TMO) with approxi-
mately 1/2 tank of fuel. NOTE: As the actual fuel quantity is approximated the GVW will not be stenciled on
the placard. The GVW will remain blank and the GVW will be written-in by the appropriate official after weight
checks.
j. RAW: Rear axle weight in pounds.
k. FAW: Front axle weight in pounds.
l. PACKAGE ENVELOPE: Attach to bottom of placard.

4.4 INFORMATIONAL MARKINGS (OPTIONAL). 4.5.1.2 The use of local manufacture or commercial ac-
quired decals and/or vinyl markings is encouraged as a sub-
Instructions that would aid in the operation and prevent po- stitute for paint stencil to reduce the use of aerosol paint
tential damage to equipment may be applied to units without systems in the Air Force.
instruction plates. The instructions will be held to a mini-
mum and will not exceed those specified in the applicable 4.5.1.3 Commercial or locally manufactured decals or let-
equipment technical order. Marking will be of the smallest tering shall be manufactured from exterior grade, dimension-
readily readable size. ally stable material procured in the appropriate colors and
gloss equivalent to Fed Standard 595b color requirements.
4.5 COLOR, STYLE AND SIZE OF MARKINGS. Matte/flat colored vinyl material shall be used on semi-gloss
or flat finished SE. Gloss vinyl material shall be used on
4.5.1 Use of Reflective Tape, Decals, and Vinyl Letter- gloss-finished equipment. Commercially procured decals
ing. Use reflective tape and vinyl stencils (vinyl machine shall conform to AA-59485. The preferred local manufacture
National Stock Number (NSN) 3417-01-247-8063 or equiva- vinyl decal/lettering material is Gerber High Performance
lent) in lieu of spray painted stencils is highly encouraged. Series 220 Premium Film, 3M ScotchcalTM ElectrocutTM
Film Series 7725 or equivalent.
4.5.1.1 Decals and/or vinyl lettering is specially prepared
plastic film containing designs, words, numerals or colored 4.5.1.4 Safety/Danger/Warning stencils will be non-reflec-
marking stripes, which may be applied or attached to Air tive red.
Force equipment as a method of marking or identification.
The decals maybe locally manufactured using equipment 4.5.1.5 Caution/Informational stencils will be non-reflec-
such as Gerber Sign Maker or equivalent or commercially tive black.
procured.

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4.5.1.6 Decals/vinyl markings are not authorized on un- c. Upon transfer to Military Assistance Program (MAP),
painted surfaces as possible concentration cell corrosion may all Air Force markings will be removed.
occur.
4.6.2 National Guard Decalcomania. The use of the Air
4.5.1.7 Unless otherwise directed in this manual, follow National Guard decalcomania on SE is optional at the dis-
the material manufacturer’s directions on application and re- cretion of the local base detachment commander.
moval of the marking material.
4.7 CAUTION/WARNING MARKINGS.
4.5.1.8 Use of pneumatic drill and 3M Rubber Wheel, PN
07498, is authorized as an alternate decal removal method. 4.7.1 Pintle Hook Caution Marking. Near pintle hooks
(if space is available), stencil in 1/2 in. letters the following
4.5.2 Field Numbers. MAJCOMS have the option to use before towing, latch pintle, close trip lock and install lock
white or black letters for field numbers. Field numbers will pin”. On SE using pintle pins stencil: “Before towing, install
be 4-in. letters unless smaller size lettering is required due to pintle pin and insert safety pin.”
limited space. Location will be all four sides, upper right
corners or where practical. 4.7.2 Spring Loaded Warning Marking. Organizations
with spring-loaded draw, towbars, or other equipment will
4.5.3 USAF Legends. When US Air Force legends are have “Warning Spring Loaded” stenciled (1 in. RED) on
used, the background color will be the same as color of the conspicuous area. Decal may be used in lieu of stenciling.
equipment on which it is being applied. Color of letters will
be black in one of the below sizes. USAF may be used in 4.7.3 Aircraft Towbar Caution Marking. On top of air-
lieu of U.S. AIR FORCE. craft towbars, just aft of the lunette eye and/or handle, add a
stencil or decal which states: “CAUTION: Do not allow
4.5.4 Color Numbers. The colors listed in this technical towbar to contact tow vehicle.”
order are based on Federal Standard 595b, Colors Used in
Government Procurement. Commanders are encourage to 4.7.4 Tire Pressure/Tow Speed Markings. Should con-
maintain marking colors as near the indicated shade as pos- flict arise between technical orders/work cards and this TO
sible, but should not delay marking for lack of particular regarding tire pressure and the tow speed, then the appli-
color shade. Also, when marking camouflaged SE, deviation cable end item technical order/work card take precedence.
from glossy colors is authorized. For stenciling purposes, “TP” is authorized in place of “tire
pressure”. If tow speed is not called out in end item techni-
4.5.5 Markings Size. Block-type letters and numerals of cal order/work card, then contact the local Safety Office for
1/2, 1, 1-1/2, 2, 3, or 4 in. size will be used for marking guidance.
unless otherwise specified, the size selected shall be the larg-
est practicable size in the available space consistent with 4.7.5 Personnel Static Discharge Marking. When mo-
good appearance and visibility. bile work platforms are used in operations such as fuel cell
repair or refueling vehicle maintenance where static electric-
4.5.6 Tire Pressure/Tow Speed. If conflict should arise ity is hazardous the platform shall comply with the require-
between end item technical order/inspection work cards and ments of AFI 91-203, TO 00-25-172, and other applicable
TO 35-1-3 regarding tire pressure and max tow speed, then instructions. Refer to TO 1-1-3 for detailed marking instruc-
the applicable end item TO/WC takes precedence. For sten- tions of maintenance stands used during fuel cell mainte-
ciling purposes, “T.P.” is authorized in place of “Tire Pres- nance.
sure”. If maximum tow speed is not called out in end item
TO/WC then contact the local Safety Office for guidance. 4.8 FUEL CELL REPAIR SE IDENTIFICATION.

4.6 MAINTENANCE OF MARKINGS. Fuel cell repair SE complying with the requirements of TO
1-1-3 will be painted, marked, and reflectorized with the
4.6.1 Markings Removal. Markings should be maintained same colors and in the same manner as the activity’s other
on all units of equipment at all times, except as follows: flight line SE. Commands at their option may add secondary
identification markings consisting of bands two in. wide.
a. Upon transfer from the USAF, all markings except These bands will be applied with either tape or paint that is
registration numbers will be removed. compatible with the painted surface and of a contrasting
color.
b. Upon permanent transfer to disposal agencies or upon
sale to commercial contractors, Air Force (AF) mark-
ing will be obliterated or removed.

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Figure 4-4. 1,500 LB Utility Crane (Sheet 1 of 2)

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TO 35-1-3

Figure 4-4. 1,500 LB Utility Crane (Sheet 2)

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Figure 4-5. ACE Air Conditioner MC1A, Diesel (Sheet 1 of 2)

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Figure 4-5. ACE Air Conditioner MC1A, Diesel (Sheet 2)

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TO 35-1-3

Figure 4-6. AF/M27M-1 Pumping Unit, Hydraulic, Diesel Driven (Sheet 1 of 2)

4-10
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TO 35-1-3

Figure 4-6. AF/M27M-1 Pumping Unit, Hydraulic, Diesel Driven (Sheet 2)

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Figure 4-7. AF/M32T-1 Cabin Leakage Tester (Sheet 1 of 2)

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TO 35-1-3

Figure 4-7. AF/M32T-1 Cabin Leakage Tester (Sheet 2)

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TO 35-1-3

Figure 4-8. Aircraft Oxygen Servicing Cart (Sheet 1 of 2)

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TO 35-1-3

Figure 4-8. Aircraft Oxygen Servicing Cart (Sheet 2)

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Figure 4-9. A/M24T-8 Load Bank (Sheet 1 of 2)

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TO 35-1-3

Figure 4-9. A/M24T-8 Load Bank (Sheet 2)

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TO 35-1-3

Figure 4-10. A/M32A-60A Gas Turbine Generator (Sheet 1 of 2)

4-18
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TO 35-1-3

Figure 4-10. A/M32A-60A Gas Turbine Generator (Sheet 2)

4-19
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TO 35-1-3

Figure 4-11. A/M32A-86 Generator, Diesel (Sheet 1 of 2)

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TO 35-1-3

Figure 4-11. A/M32A-86 Generator, Diesel (Sheet 2)

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TO 35-1-3

Figure 4-12. A/M32A-95 Compressor, Gas Turbine, Trailer Mounted (Sheet 1 of 2)

4-22
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TO 35-1-3

Figure 4-12. A/M32A-95 Compressor, Gas Turbine, Trailer Mounted (Sheet 2)

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TO 35-1-3

Figure 4-13. A/M32C-10C/10D Air Conditioner Set (Sheet 1 of 2)

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TO 35-1-3

Figure 4-13. A/M32C-10C/10D Air Conditioner Set (Sheet 2)

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TO 35-1-3

Figure 4-14. A/M32C-5 Air Conditioner Set (Sheet 1 of 2)

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TO 35-1-3

Figure 4-14. A/M32C-5 Air Conditioner Set (Sheet 2)

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TO 35-1-3

Figure 4-15. Auxiliary Ground Power Unit (AGPU) (Sheet 1 of 2)

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TO 35-1-3

Figure 4-15. Auxiliary Ground Power Unit (AGPU) (Sheet 2)

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TO 35-1-3

Figure 4-16. B-1/B-2 Air Conditioner, Trailer Mounted (Sheet 1 of 2)

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TO 35-1-3

Figure 4-16. B-1/B-2 Air Conditioner, Trailer Mounted (Sheet 2)

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TO 35-1-3

Figure 4-17. B-4 Maintenance Stand (Sheet 1 of 2)

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TO 35-1-3

Figure 4-17. B-4 Maintenance Stand (Sheet 2)

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TO 35-1-3

Figure 4-18. B-5 Maintenance Stand (Sheet 1 of 2)

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TO 35-1-3

Figure 4-18. B-5 Maintenance Stand (Sheet 2)

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TO 35-1-3

Figure 4-19. B-2 Maintenance Stand (Sheet 1 of 2)

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TO 35-1-3

Figure 4-19. B-2 Maintenance Stand (Sheet 2)

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Figure 4-20. B-7/B-1 Maintenance Stand (Sheet 1 of 2)

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TO 35-1-3

Figure 4-20. B-7/B-1 Maintenance Stand (Sheet 2)

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TO 35-1-3

Figure 4-21. B809A Generator Set (Sheet 1 of 2)

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TO 35-1-3

Figure 4-21. B809A Generator Set (Sheet 2)

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TO 35-1-3

Figure 4-22. C-1 Maintenance Stand (Sheet 1 of 2)

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TO 35-1-3

Figure 4-22. C-1 Maintenance Stand (Sheet 2)

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Figure 4-23. Spraying Unit, Corrosion Control Wash Cart (Sheet 1 of 2)

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Figure 4-23. Spraying Unit, Corrosion Control Wash Cart (Sheet 2)

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TO 35-1-3

Figure 4-24. EPU-6 Aircraft Power Supply (Sheet 1 of 2)

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TO 35-1-3

Figure 4-24. EPU-6 Aircraft Power Supply (Sheet 2)

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Figure 4-25. FDECU-3 Environmental Control Unit (Sheet 1 of 2)

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TO 35-1-3

Figure 4-25. FDECU-3 Environmental Control Unit (Sheet 2)

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Figure 4-26. Fuel Bowser 400 Gallon (Sheet 1 of 2)

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TO 35-1-3

Figure 4-26. Fuel Bowser 400 Gallon (Sheet 2)

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Figure 4-27. H-1 Heater (Sheet 1 of 2)

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Figure 4-27. H-1 Heater (Sheet 2)

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Figure 4-28. HDU-13M Heater (Sheet 1 of 2)

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Figure 4-28. HDU-13M Heater (Sheet 2)

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Figure 4-29. Hydraulic Cart (Sheet 1 of 2)

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Figure 4-29. Hydraulic Cart (Sheet 2)

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Figure 4-30. Jack, Hydraulic 10 - 30 Ton (Sheet 1 of 2)

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Figure 4-30. Jack, Hydraulic 10 - 30 Ton (Sheet 2)

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Figure 4-31. Jack, 35 Ton, Axle (Sheet 1 of 2)

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Figure 4-31. Jack, 35 Ton, Axle (Sheet 2)

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Figure 4-32. Liquid Cooling Service (LCS) Cart (Sheet 1 of 2)

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Figure 4-32. Liquid Cooling Service (LCS) Cart (Sheet 2)

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Figure 4-33. Liquid Oxygen Cart (Sheet 1 of 2)

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Figure 4-33. Liquid Oxygen Cart (Sheet 2)

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Figure 4-34. LN2 Liquid Nitrogen Cart (Sheet 1 of 2)

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Figure 4-34. LN2 Liquid Nitrogen Cart (Sheet 2)

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Figure 4-35. MC-1A High Pack Air Compressor (Sheet 1 of 2)

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Figure 4-35. MC-1A High Pack Air Compressor (Sheet 2)

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Figure 4-36. MA-3D Air Conditioner (Sheet 1 of 2)

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Figure 4-36. MA-3D Air Conditioner (Sheet 2)

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Figure 4-37. MC-2A Air Compressor (Sheet 1 of 2)

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Figure 4-37. MC-2A Air Compressor (Sheet 2)

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Figure 4-38. MC-7 Air Compressor (Sheet 1 of 2)

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Figure 4-38. MC-7 Air Compressor (Sheet 2)

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Figure 4-39. MD-1 Towbar (Sheet 1 of 2)

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Figure 4-39. MD-1 Towbar (Sheet 2)

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Figure 4-40. MEP Generators (Sheet 1 of 2)

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Figure 4-40. MEP Generators (Sheet 2)

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Figure 4-41. MHU-83C/E Bomblift Truck (Sheet 1 of 2)

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Figure 4-41. MHU-83C/E Bomblift Truck (Sheet 2)

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Figure 4-42. MJ-1B Bomblift Truck (Sheet 1 of 2)

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Figure 4-42. MJ-1B Bomblift Truck (Sheet 2)

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Figure 4-43. Hydraulic Test Stand (Sheet 1 of 2)

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Figure 4-43. Hydraulic Test Stand (Sheet 2)

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Figure 4-44. Light Cart, FL-1D (Sheet 1 of 2)

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Figure 4-44. Light Cart, FL-1D (Sheet 2)

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Figure 4-45. NF-2D Light Cart, Diesel (Sheet 1 of 2)

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Figure 4-45. NF-2D Light Cart, Diesel (Sheet 2)

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Figure 4-46. Oil Cart (Sheet 1 of 2)

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Figure 4-46. Oil Cart (Sheet 2)

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Figure 4-47. Purging Unit GSU-62M LOX Storage (Sheet 1 of 2)

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Figure 4-47. Purging Unit GSU-62M LOX Storage (Sheet 2)

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Figure 4-48. Radome Dolly (Sheet 1 of 2)

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Figure 4-48. Radome Dolly (Sheet 2)

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Figure 4-49. Self-Generating Nitrogen Cart (Sheet 1 of 2)

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Figure 4-49. Self-Generating Nitrogen Cart (Sheet 2)

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Figure 4-50. Service Cart (Sheet 1 of 2)

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Figure 4-50. Service Cart (Sheet 2)

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Figure 4-51. Trielectron Generator (Sheet 1 of 2)

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Figure 4-51. Trielectron Generator (Sheet 2)

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Figure 4-52. Universal Maintenance Stand (Sheet 1 of 4)

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Figure 4-52. Universal Maintenance Stand (Sheet 2)

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Figure 4-52. Universal Maintenance Stand (Sheet 3)

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Figure 4-52. Universal Maintenance Stand (Sheet 4)

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Figure 4-53. New Generation Heater (Sheet 1 of 3)

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Figure 4-53. New Generation Heater (Sheet 2)

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Figure 4-53. New Generation Heater (Sheet 3)

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CHAPTER 5
CORROSION PREVENTION AND CONTROL OF HUSH HOUSES
5.1 MATERIALS. 5.2.2.1 If an entire component (panel, plate, beam, sup-
port) is replaced. Then every side of that component must be
There are three basic materials used in the construction of primed prior to installation. If any part of the installation
Hush Houses. The primary material being galvanized steel, process, such as welding, damages the paint, the exposed
the galvanizing will offer improved corrosion protection over damage area will be cleaned and repainted with thinned in-
the plain carbon steel. The second material used is carbon organic zinc-rich primer.
steel, which is susceptible to a corrosion environment. The
third material used are Types 321 and 409 stainless steel that
may be specified in numerous rework contracts for use in the
hot section. Types 321 and 409 stainless steel is weldable
and will offer adequate corrosion protection. Failure to prime faying (back to back) surfaces of
carbon steel will result in corrosion that cannot be
5.1.1 Fastener Replacement. Any fastener replacement treated without extensive repair or disassembly.
should be accomplished using either stainless steel fasteners
or hot dip galvanized fasteners. 5.2.2.2 Carbon Steel (Angle Iron) seams, such as a T-
angle, having corrosion, will require the following procedure
5.2 REPAIR. to remove and treat corrosion.

a. Apply phosphoric acid corrosion removing compound.

Allow the material to dwell on the surface for 30-45
minutes - add additional material to keep the surface
To prevent dissimilar metal related problems, do wet. Agitate with thin bristled steel brush, if necessary,
not use zinc plated or hot dipped zinc fasteners on to remove heavier rust.
stainless or corrosion resistant steel parts.
b. Rinse area and check for rust; metal conditioner if nec-
5.2.1 Galvanized Steel. The amount of corrosion present essary.
will determine what is required for repair. If the corrosion is
minor, then either abrasively grind the corrosion or chemi- c. Allow area to dry.
cally treat with pretreatment compound. If the corrosion is
severe or widespread, abrasive blasting may be required. d. Mask gaps at lower sides of “angle iron” T’s with
masking tape per SAE-AMS-T-23397 or equivalent.
5.2.1.1 If an entire galvanized steel component is replaced,
then every side of that component must be primed prior to NOTE
installation. If any part of the installation process, such as
welding, damages the paint, the exposed damaged area will • Use of sealant gun is recommended for inject-
be cleaned and repainted with thinned organic zinc-rich ing sealant into entire gap.
primer.
• Above procedure should only be accomplished
5.2.1.2 Hush House galvanized sheet should be hot dip for treating existing corrosion problems in this
galvanized per ASTM A446 Grade C, coating G-210. area.

5.2.2 Carbon Steel. All accessible carbon steel items re- e. Fill entire gap using sealant MIL-PRF-81733, Type IV.
quire sandblasting prior to application of the respective zinc-
rich paints. The sandblasting and subsequent painting of an
assembled structure will provide protection to the exposed
portion of the structure. If there is corrosion in a seam or
joint, refer to Paragraph 5.2.2.2.

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Figure 5-1. Angle Iron Sealant Application

5.2.3 Stainless Steel. Characteristics of stainless steel are 5.2.3.4 American Iron and Steel Institute (AISI) 409
as follows. Stainless Steel. AISI 409 Stainless Steel is the lowest cost
of all stainless steels yet it has good resistance to oxidation
5.2.3.1 Type 321 Stainless Steel. Type 321 stainless and corrosion. Because of a small amount of Titanium, the
steel has good corrosion resistance to oxidation and corro- AISI 409 does not harden during welding and; therefore,
sion. Because of a small amount of titanium, Type 321 stain- does not require a post weld relief. Normally the steel has a
less steel does not harden during welding and therefore, does shiny surface with areas of dull gray streaks. The streaking
not require a post weld relief. Normally, the steel has a shiny is caused by the titanium content and is not harmful.
surface with areas of dull gray streaks. The streaking is
caused by the titanium content and is not harmful. 5.2.3.5 The AISI 409 has the following weld properties:

5.2.3.2 Type 321 has the following weld properties: • Gas Metal-Arc (MIG). The electrode wire should
be Type 309 stainless steel when welding AISI 409
• Gas Metal-Arc (MIG). When welding Type 321 to to mild steel. When welding AISI 409 to itself, use
itself, use Type ER321 wire electrode. Type W 414 T filler.

• Shielded Metal-Arc (covered electrodes). Use • Shielded Metal-Arc (covered electrodes). Use W
ER321 wire electrode. 17-4 PH, 12 Cr-4 MO or Type 330-04 electrodes.

• Gas Tungsten-Arc (TIG). This procedure should be • Gas Tungsten-Arc (TIG). When fillers are required,
used when welding Type 321 to mild steel. Filler use Type 410 with 0.08% Max C or W 414 Ti. He-
metals should be ER308L. lium shielding is preferred over argon shielding.

5.2.3.3 Do not coat Type 321 stainless steel with any of 5.2.3.6 Do not coat the AISI 409 with any of the zinc-rich
the zinc-rich paints. The zinc in the paints can embrittle the paints. The zinc in the paints can embrittle the stainless steel
stainless steel under certain conditions. The use of Type 321 under certain conditions. The use of AISI 409 that is in con-
that is in contact with zinc-rich painted carbon steel (as in tact with zinc-rich painted carbon steel (as in the hot section)
the hot section) is acceptable. is acceptable.

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5.2.3.7 Sealing. Mating surfaces where moisture could Permatex

enter from the top or horizontal will be sealed with sealant Rocky Hill CT, 06067
MIL-PRF-81733 (cold section) and sealant SAE-AMS-3374,
Type I (hot section) after primer application and before top- (860) 571-5100
coat application.
5.4 PRIMERS.
5.3 PRETREATMENT COMPOUNDS.
5.4.1 Organic Zinc-Rich Primers. The primer will be one
5.3.1 Rust Remover 81287 (Naval Jelly). of the previously described zinc-rich primers as identified in
Chapter 3.

5.4.1.1 Dry film thickness should be 3.0 mils and approxi-

mately 5.0 mils wet.
Rust remover Permatex 81287 contains phosphoric
and sulfuric acid. Use with adequate ventilation. 5.4.1.2 This primer requires top coating when used on ex-
Consult with the local bioenvironmental engineer terior surfaces (refer to Table 5-1).
for approved personal protective equipment. In
event of skin or eye contact, flush immediately 5.4.2 Inorganic Zinc-Rich Primers. MIL-PRF-23236,
with plenty of water. Type I, Class 3 is an inorganic zinc/rich primer that is usu-
ally furnished as two or three components.
Rust remover Permatex 81287 is a biodegradable rust re-
mover and pretreatment compound for galvanized steel. 5.4.2.1 Follow the manufacturer’s instructions for mixing,
thinning, and application.
5.3.1.1 Follow the manufacturer’s application instructions
for corrosion removal. Repeat the process until all corrosion 5.4.2.2 Only those products listed on QPD-23236 are au-
is removed. Allow to air dry prior to the application of a thorized.
protective coating.
5.4.2.3 During application of the MIL-PRF-23236 primer,
5.3.1.2 Rust remover Permatex 81287 is available from the product should be constantly agitated to prevent the zinc
dust from settling.

Table 5-1. Hush House Coating Chart

Area Material Primer Topcoat

Hot Section Carbon Steel MWAS, 100% Aluminum or MIL-PRF-23236, Type VI, Class 13 MIL-PRF-85285
(Exterior)
Door Struc- Carbon Steel MWAS, 85/15% Zinc/Aluminum or Organic Zinc-Rich Primer MIL-PRF-85285
ture MIL-PRF-26915
Cold Section Galvanized Permatex 81287 (Pretreatment) and Organic Zinc-Rich Primer MIL- MIL-PRF-85285
Steel PRF-26915 or MWAS, 85/15% Zinc/Aluminum

5.5 PAINTING. PRF-23236 inorganic zinc primed steel (door frame beams,
support beams, exhaust tube) and ASTM A446, Grade G210
5.5.1 Structural Corrosion Protection. galvanized panels (roof, walls, door). This corrosion protec-
tion system should be adequate in all but extremely severe
NOTE corrosion environments.

Prior to total repaint of Hush House, accomplish 5.5.2 Camouflage Requirements. The selection of col-
corrosion repair procedures in accordance with ors for an exterior camouflage pattern should be restricted to
Paragraph 5.2. those readily available for MIL-PRF-85285. MAJCOM will

Corrosion protection for the Hush House consists of MIL-

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determine the need and color requirements for the operating 5.7 GALVANIZED SURFACES.
locations requesting the application of a camouflage pattern
to the Hush House. NOTE

5.6 INORGANIC ZINC PRIMED SURFACES. • To prevent streaking and other problems, it is
necessary to work from the bottom to the top
NOTE and not allow previously worked surfaces to
dry.
• To prevent streaking and other problems, it is
necessary to work from the bottom to the top • The amount of surface area to be worked at
and not allow previously worked surfaces to any time should not exceed the surface area
dry that can be zinc conversion coated epoxy
primed and polyurethane topcoated in one day.
• The amount of surface area to be worked at
any time should not exceed the surface area 5.7.1 Roof. Drape a barrier of paint drop cloths, barrier
that can be epoxy primed and polyurethane paper or other suitable material on the walls directly below
topcoated in one day. area of roof to be worked. The drape should be such to
prevent fluids from contacting the wall.
5.6.1 Primer Requirements on the Door Frame
Beams, Support Beams, and Exhaust Tube. Primer re- NOTE
quirements are as follows
Examine the galvanized surface prior to cleaning.
NOTE If the surface appears to be dirty (not oily), then
MIL-PRF-87937, Type IV soap should be suffi-
Examine the primed surface prior to cleaning. If cient to clean the surface. If the surface is oily, it
the surface appears to be dirty (not oily), then will be necessary to use one of the soaps (MIL-C-
MIL-PRF-87937, Type IV soap should be suffi- 43616, Type II or MIL-PRF-87937, Type I), which
cient to clean the surface. If the surface is oily, it contain solvent. In either case, it is absolutely nec-
will be necessary to use one of the soaps (MIL-C- essary that the surface be scrubbed while then soap
43616 or MIL-PRF-87937, Type I), which contain is being applied. A clean water break free surface
solvent. In either case, it is absolutely necessary is necessary prior to additional treatment.
that the surface be scrubbed while the soap is be-
ing applied. A clean water break free surface is 5.7.1.1 On the day prior to painting, the surface to be
necessary prior to additional treatment. coated the next day is to be cleaned. Use aircraft cleaning
soap MIL-PRF-87937 as appropriate. Always clean from the
5.6.1.1 Preferably on the day prior to painting, the surface bottom to the top to prevent streaking and have one person
to be coated the next day is to be cleaned. Use aircraft clean- applying rinse water to previously clean surfaces to also pre-
ing soap, MIL-PRF-87937, or MIL-C-43616, as appropriate. vent streaking.
Always clean from the bottom to the top to prevent streaking
and have one person applying rinse water to previously 5.7.1.2 Early on the second day, apply the pretreatment
cleaned surfaces to also prevent streaking. compound. Again work from bottom to top applying the
compound. Keep lower surfaces (even where the pretreat-
5.6.1.2 Early on the second day, apply one coat of MIL- ment compound was previously applied) flooded with water
PRF-23377, Type I, Class 2, or MIL-DTL-53022, Type II to prevent streaking.
(Lead and Chromate Free Epoxy Primer) primer to a dry
film thickness of 0.6 to 1.1 mils. Drying time should be from 5.7.1.3 As soon as the pretreatment compound has dried,
one to two hours. apply one coat of organic zinc-rich primer to a dry film
thickness of 2.0 to 3.0 mils.
5.6.1.3 Apply two thin coats of polyurethane MIL-PRF-
85285 (total dry film thickness of 1.6 to 2.4 mils). 5.7.1.4 Apply one heavy coat of polyurethane MIL-PRF-
85285 (dry film thickness of 1.6 to 2.4 mils).
5.6.1.4 After the first topcoat has been allowed to dry a
maximum of 4-6 hours, apply the desired camouflage pat- 5.7.1.5 After the entire roof has been topcoated and al-
tern. If using polyurethane, lightly scuff sand the area to be lowed to dry a maximum of 4-6 hours, apply the desired
overcoated, then solvent wipe with Acetone, O-A-51, ASTM camouflage pattern. If using polyurethane, lightly scuff sand
D329, prior to painting. the area to be overcoated, then wipe with a scotch-brite pad,

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A-A-58054, Type I, Grade A, dampened with MIL-PRF- protected during repainting operations to prevent entry of
87937 diluted per manufacturer’s instructions. After wiping chemicals and paints. Cut pieces of plywood (or other bar-
with cleaner, rinse surface with clean cloth dampened with rier type materials) and push the plywood against the screen
water and dry with clean cloth prior to painting. wire from the interior side. Because of the difficulty in
cleaning and painting the solid wall area formed by acousti-
5.7.2 Walls and Doors. The walls should be worked only cal panels and screen wire, it is recommended that a galva-
after the roof painting is complete. Work on the door can be nized panel equal in width and length be fabricated and at-
accomplished as desired. The air intake space in the wall tached to the solid wall areas by means of locally fabricated
formed by the screen wire and acoustical panels must be standoffs.

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CHAPTER 6
CORROSION PREVENTION AND CONTROL OF NOISE SUPPRESSOR
SYSTEMS (NSS)
6.1 GENERAL. subsequent painting of an assembled structure will provide
protection to the exposed portion of the structure, but if there
NSS are divided into the Cold Section (temperatures of less is corrosion in a seam or joint, then disassembly would be
than 300 °Fahrenheit (F)) and the Hot Section (temperatures required.
of 300 °F or more). Table 5-1 will identify the coating for a
particular section based on the material and temperature. 6.4.1.1 If an entire component (panel, plate, beam, sup-
Earlier NSS were coated with alkyd enamels (TT-E-489, TT- port) is replaced, then every side of that component must be
E-527) and high temperature aluminum paint (TT-P-28) both primed prior to installation. If any part of the installation
of which are ineffective for corrosion prevention. process, such as welding, damages the paint, the exposed
damaged area will be cleaned and repainted after installa-
6.2 MATERIALS. tion.

There are three basic materials used in the construction of 6.4.2 Galvanized Steel. The amount of corrosion present
NSS. The primary material being carbon steel this is ex- will determine what is required for repair. If the corrosion is
tremely susceptible to the corrosive environment generated minor, then grind the corrosion and recoat with the pretreat-
by the suppressor. The second material used is galvanized ment MIL-P-15238, and epoxy primer, MIL-PRF-23377, or
steel and the galvanizing will offer improved corrosion pro- MIL-DTL-53022, Type II. If the corrosion is severe or wide-
tection over the plain carbon steel, but can be used only in spread, abrasive blasting may be required. When galvanized
the Cold Section due to temperature limitations of the galva- steel has been sandblasted, the primer will be organic zin-
nizing. The third material used is American Iron and Steel crich.
Institute (AISI) 409 stainless steel and the material has been
specified in numerous rework contracts for use in the Hot 6.4.2.1 If an entire galvanized steel component is replaced,
Section. AISI 409 is the least expensive of all stainless steel, then every side of that component must be primed prior to
is weldable and will offer adequate corrosion protection. installation. If any part of the installation process, such as
welding, damages the paint, the exposed damaged area will
6.3 FASTENER REPLACEMENT. be cleaned and repainted after installation.

Any fastener replacement should be accomplished using ei- 6.4.2.2 Any replacement galvanized sheet should be hot
ther stainless steel fasteners or hot dip galvanized fasteners dip galvanized per ASTM A525, coating G-210. All struc-
per ASTM A394, A325, or A153 (as applicable). tural steel in the galvanized condition should be hot dip gal-
vanized per ASTM A123.
6.4 STRUCTURAL REPAIR.
6.4.3 AISI 409 Stainless Steel. Characteristics of AISI
6.4.1 Structural Repair Carbon Steel. 409 Steel are as follows:

6.4.3.1 AISI 409 Stainless Steel is the lowest cost of all

stainless steels yet it has good resistance to oxidation and
corrosion. Because of a small amount of titanium, the AISI
Failure to prime faying (back to back) surfaces of 409 does not harden during welding and; therefore, does not
carbon steel will result in corrosion that cannot be require a post weld relief. Normally the steel has a shiny
treated without disassembly. surface with areas of dull gray streaks. The streaking is
caused by the titanium content and is not harmful.
All carbon steel items require sandblasting prior to applica-
tion of the respective zinc-rich paints. The sandblasting and 6.4.3.2 The AISI 409 has the following weld properties:

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• Gas Metal-Arc (MIG). The electrode wire should 6.6.2.2 Only those products listed on QPD-23236 are au-
be Type AISI 409 to mild steel. When welding AISI thorized.
409 to itself, use Type 309 stainless steel when
welding W 414 T filler. 6.6.2.3 During application of MIL-PRF-23236 primer, the
product should be constantly agitated to prevent the zinc
• Shielded Metal-Arc (covered electrodes). Use W dust from settling.
17-4 PH, 12 Cr-4 MO or Type 330-04 electrodes.
6.6.3 Heat Resistant Primer Briner 2905. Instructions
• Gas Tungsten-Arc (TIG). When fillers are required, for applying Briner 2905 are as follows:
use Type 410 with 0.08% Max C or W 414 Ti. He-
lium shielding is preferred over argon shielding. NOTE

6.4.3.3 Do not coat the AISI 409 with any of the zinc-rich Briner 4765 or Briner 2905 shall be used as a
paints. The zinc in the paints can embrittle the stainless un- primer for Briner 2986.
der certain conditions. The use of AISI 409 that is in contact
with zinc-rich painted carbon steel (as in the Hot Section) is 6.6.3.1 Briner 2905 is two component, silver, heat resis-
acceptable. tant silicone coating. The zinc powder must be mixed into
the SE before using.
6.5 SEALING.
6.6.3.2 Thinning should not be necessary, but the coating
Mating surfaces where moisture could enter from the top or can be thinned with Briner 70 Silicone Reducer to facilitate
horizontal will be sealed with sealant MIL-PRF-81733 (cold spray painting.
section) or sealant SAE-AMS-3374, Type I (hot section) af-
ter primer application and before topcoat application. 6.6.3.3 Apply Briner 2905 by conventional spray. De Vil-
biss MBC-510 Gun, 704 Air cap with E needle and Tip or,
6.6 PRIMERS. the equivalent in Binks.

6.6.1 Organic Zinc-Rich Primers. 6.6.3.4 Drying time is one hour (dust free), but will re-
quire 400 °F temperature before it cures completely. Curing
with topcoat applied can be accomplished by normal opera-
tion of the suppressor.

6.6.3.5 Apply one coat with a dry film thickness of 2.5

Respirator with organic vapor cartridges is re-
mils. A dry film of 2.5 mils will require a 5.0 mil wet film
quired for all painting/priming operations unless
thickness.
Bioenvironmental Engineer has approved the work
place for no respirator protection.
6.6.3.6 Briner coatings are available from:
The primer will be one of the previously described primers
as identified in Chapter 3. Briner Paint Mfg. Company
3713 Agnes Street
6.6.1.1 Dry film thickness should be 3.0 mils and approxi- Corpus Christi, TX 78405
mately 5.0 mils wet. (512) 884-4804
6.6.1.2 Prior to repainting the exhaust area (or initiating a
6.6.4 Heat Resistant Silicone Coating - Briner 2986.
contract for repaint) it is important to know the surface tem-
Instructions for applying Briner 2986 are as follows:
perature of the exterior walls of the exhaust section. Ap-
proximate temperatures can be obtained with the use of Wahl
Temp-Plate, Wahl Instruments, Inc., Culver City, California, NOTE
(800) 421-2853, or equivalent. If the temperature is below Briner 2986 shall be used only as a topcoat for
300 °F this area shall be coated with Cold Section finishes. Briner 2905 or Briner 4765.
6.6.2 MIL-PRF-23236, Type I, Class 3. MIL-PRF- 6.6.4.1 Briner 2986 is a one component, black, heat resis-
23236, Type I, Class 3 is an inorganic zinc-rich primer that tant silicone coating. The material is ready mixed, but should
is usually furnished as two or three components. be thoroughly stirred before use.
6.6.2.1 Follow the manufacturers’ instructions for mixing,
thinning, and application.

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6.6.4.2 Thinning can be accomplished using Briner 70 6.6.6 High Temperature Resistant Silicone Coating
Silicone Reducer. Thurmalox 270-18. Instructions for applying Thurmalox
270-18 are as follows:
6.6.4.3 Apply Briner 2986 by brush, conventional spray,
or airless spray. NOTE
Thurmalox 270-18 shall be used as a topcoat for
Conventional Airless Airless MIL-PRF-23236, Type I.
78, 765, 704 Air cap with E 0.017-inch (in.) tip at 1,700
or EX needle and tip. De lbs 6.6.6.1 Thurmalox 270-18 is low-sheen green, one-com-
Vilbiss MBC-510 Gun or ponent, heat resistant coating of silicone resin.
the equivalent in Binks
6.6.6.2 Mix to a uniform consistency by ordinary stirring.
6.6.4.4 Briner 2986 will not cure without 350 - 400 °F for
1 hour. The coating will not cure during normal operation of 6.6.6.3 Thinning can be accomplished using Thurmalox
the suppressor. 295 thinner. Do not use more than 1 1/2 pints per gallon.

6.6.4.5 Two coats at 1.5 mils each of dry film are recom- 6.6.6.4 Apply Thurmalox 270-18 by airless, conventional,
mended. A dry film of 1.5 mils will require a 4.5 mil wet or electro-static spray equipment. The following equipment
film thickness. is recommended by the manufacturer as a guide:

6.6.5 High Temperature Resistant Silicone Coating -

Spray gun DeVilbiss P-MBC or JGA
Briner 4765. Briner 4765 is a two component, gray, high
temperature resistant silicone coating. Air hose 5/16 in (I.D.)
*Fluid hose 3/8 in (I.D.)
6.6.5.1 The zinc powder must be mixed into the SE before Air cap 704
using. Fluid nozzle FX (0.042 in.)
Pot pressure 15 - 20 lbs
6.6.5.2 Thinning should not be necessary but Briner 4765 Atomizing pressure 40 - 45 lbs
can be thinned with Briner 70 silicone reducer. Needle adjustment Half open
Distance from work 8 - 10 in.
6.6.5.3 Apply Briner 4765 by conventional spray. De Vil-
biss MBC-510 Gun, 704 Air cap, an E needle and tip or the * Smaller hose diameters, or hose lengths greater than 25
equivalent in Binks. ft, may make it necessary to increase pressures.

6.6.5.4 Drying time is one hour (dust free). Curing with 6.6.6.5 Drying time at 77 °F, set to touch, is 30 minutes.
topcoat applied can be accomplished by normal operation of
the suppressor. 6.6.6.6 Dry film thickness should be 1.0 mil.

6.6.5.5 Apply one coat of Briner 4765 with a dry film

thickness of 2.5 mils; this will require a wet film thickness
of 5.0 mils.

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CHAPTER 7
SOUTHWEST ASIA OPERATIONS AND ENVIRONMENTS
7.1 GENERAL. 7.1.1 Environmental Effects. Extensive operations in a
desert can result in very fine sand and dust intrusion into
The Southwest Asia (SWA) Area of Responsibility (AOR) support equipment (SE). SE that is positioned in SWA for
consists of various regions from Afghanistan to South Africa extended periods is more prone to exhibit significant corro-
(Figure 7-1). The environmental conditions range from sea- sion problems. Sandstorms, which are usually seasonal, can
sonal high winds and high humidity to arid areas and low cause sand/dust to penetrate equipment and become en-
winds. In many locations, there are negatively charged ions trapped in inaccessible areas. During the periods of relative
called anions in soils which when combined with aggressive calm there are usually significant amounts of airborne dust,
sand storms, can spread through SWA. The degree that sand seen as a general haze, in the atmosphere.
and dust can penetrate equipment is dependent on many
variables such as wind speed and direction, size of the dust/ 7.1.1.1 Soils and Humidity. Soils exposed to high hu-
sand particles, protective shelter availability, and condition midity in many of the operating SWA AOR locations will
of the equipment, such as deteriorated seals/gaskets and bent cause corrosion or accelerate existing corrosion growth if
doors. left in contact with metal surfaces. Even in arid areas, hu-
midity is usually present. During daylight hours, SE stored
outdoors will heat up causing expansion of panels which
allows hot, moist air to migrate into enclosed areas (Figure
7-2) or under non-permeable equipment covers. When the
equipment cools, the moisture condenses and combines with
the fine dust/sand particles, increasing the potential for cor-
rosion. The soluble materials in the dust/sand form a crust as
they dry (Figure 7-3) making removal difficult. Anion-laden
sand/dust entrapped in SE exposed to high humidity will
gather in the available moisture, extract the soluble salts, and
a corrosion cell could be established. These salts will appear
as white streaks on SE after the water has evaporated off the
units (Figure 7-3).

Figure 7-1. SWA AOR

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b. Inspect entire exterior/interior surfaces for missing or

deteriorated primer/paint.

c. Touch-up all deficient areas with approved processes

and materials per Chapter 3.

d. Inspect and remove any standing water in unit.

e. Inspect and clean all drain holes.

f. Minimize lubrication by removing all excess greases/

oils to limit sand/dust entrapment.

7.2.2 Deployment Location. Soils in SWA AOR locations

should be considered suspect and removed on a regular ba-
sis. A constant regimen of vacuuming or brush removal of
sand/dust accumulations is necessary to reduce potential cor-
Figure 7-2. Sand/Dust Intrusion rosion problems.

7.2.2.1 SE Units Requiring Additional Cleaning. Some

units require additional cleaning process due to air filters,
exposed lubrication areas, and areas that may be more prone
to sand/dust entrapment.

7.2.2.1.1 Radiators, Vanes, Filters and Coils. SE that

have radiators, vanes, filters, and coils require additional
cleaning to remove dust/sand that can block cooling ports
and filters which are drawn into the units during operation.
Clean using engineering approved materials. Allow the units
to dry in an enclosed area to prevent airborne sand/dust from
adhering to wet surfaces.

7.2.2.1.2 Portable Hydraulic Test Stands/Mobile Air

Compressors. These units typically have interior fluid leaks
that will allow sand/dust to cling to the surfaces. Close in-
Figure 7-3. Residue from Salts Caused by spection and wipe down of these units are necessary to
Condensation maintain proper operation.

7.2 SE SWA AOR DEPLOYMENT. 7.2.2.1.3 Aircraft Jacks and Tow Bars. Jackscrew bod-
ies and adjustable arms should be kept free of sand/dust at
7.2.1 Pre-deployment. Prior to deployment of SE to SWA all times. The use of locally manufactured permeable covers
AOR it is recommended that the following actions be taken (Figure 7-4) will assist in prevention of sand/dust intrusion.
to prevent sand/dust intrusion during deployment. Lubricate units using corrosion preventive compound, MIL-
L-87177, Type 1 to reduce corrosion problems.
a. Accomplish a complete SE wash per Chapter 2 prior
to deployment.

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Figure 7-4. Locally Manufactured Permeable Covers

7.2.2.1.4 Open Circuit Boards/Cards. After cleaning equipment operation can result in abrasive action that can
open circuit boards/cards per TO 1-1-689-3, apply a thin coat cause chafing of the wiring (Figure 7-5). Remove trapped
of avionics grade corrosion preventive compound, MIL-PRF- sand from around and between bundled wires to prevent
81309, Type III, to the board to insulate the circuits from electrical problems.
sand/dust intrusion.

7.2.2.1.5 Wire Bundles. Sharp angular sand/dust particles

can migrate into wiring bundles where vibration caused by

Figure 7-5. Wire Bundle Sand/Dust Accumulation

7.2.2.1.6 Felt-Soundproofing Insulation. Periodically in- 7.2.3 Maintenance Touch-Up Painting. Maintenance
spect areas where felt-soundproofing insulation is present for touch-up painting of small areas should be accomplished
moisture and/or sand/dust accumulations. Insulation found to when bare metal surfaces are exposed to prevent further de-
be wet should be removed and allowed to dry before replac- terioration and protect against corrosion. Touch-up painting
ing or replaced with new clean, dry insulation. Inspect areas should only be accomplished using approved touch-up mate-
behind insulation for corrosion or deteriorated coatings. Re- rials listed in Chapter 3.
pair areas as required prior to reinstalling installation.

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7.2.3.1 Temporary Coating Repair. Temporary coatings 7.2.4 Equipment Storage. In the harsh environments of
are to be used to protect the surfaces until the unit can be SWA it is recommended that SE be stored indoors or under
permanently repaired as required. Corrosion preventive com- covers. Permeable fabric covers are recommended for short
pound, MIL-DTL-85054 is a water displacing corrosion pre- and long-term storage of equipment. These covers can be
ventive compound (CPC) that forms a clear, dry, flexible purchased or locally manufactured. They allow for airflow to
film on the surface. This is temporary and will require reap- prevent condensation and sand/dust buildup on/in the equip-
plication as needed. Refer to Chapter 3 for application and ment.
removal instructions.

7.2.3.2 Permanent Authorized Touch-Ups. For perma-

nent touch-up of small areas use only authorized coating
systems listed in Table A-1. The use of primer and topcoat
are required for permanent touch-ups.

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APPENDIX A
EQUIPMENT AND CONSUMABLE MATERIALS USED FOR CORROSION
CONTROL
A.1 EQUIPMENT AND CONSUMABLE MATERIALS.

Table A-1. Equipment and Consumable Materials List

Nomenclature/Description Specification Stock Number Unit of Issue

• The following RTV silicone sealants are corrosive and will not be used on ground support equipment.

• DC Silastic 730 RTV, 732 RTV, 734 RTV, 736 RTV, 784 RTV, 1890 RTV; DC 781 RTV, 4-2817, 90406 RTV,
93-006 RTV, 96-081 RTV, GE RTV 102, RTV 103, RTV 106, RTV 108, RTV 109, RTV 112, RTV 116, RTV
118, RTV 157, RTV 159, RTV 1502, RTV 1503, RTV 1508.

• The following RTV silicone sealants are corrosive and have been discontinued but may be remaining in the
supply system. These sealants will not be used on ground support equipment.
• DC Silastic 140 RTV, 142 RTV, 731 RTV, 785 RTV, 891 RTV; DC 236 RTV, 780 RTV, 3144 RTV, 20-046
RTV, 20-078 RTV, 30-079 RTV, 30-121 RTV, 90-092 RTV, 92-005 RTV, 92-007 RTV, 92-009 RTV, 92-018
RTV, 92-024 RTV, 92-048 RTV, 92-055 RTV, 93-043 RTV, 94-002 RTV, 94-003 RTV, 94-009 RTV, 94-034
RTV, 96-005 RTV, 96-080 RTV, Q3-6069 RTV

• GE RTV 154, RTV 156, RTV 158, RTV 192, RTV 198

Abrasive Blasting MIL-PRF-9954

Media, Glass Beads Sieve Size 8 5350-00-012-1869 Container (CO) (50
pound (LB))
Sieve Size 10 5350-00-110-2981 CO (50 LB)
Sieve Size 13 5350-00-576-9634 CO (50 LB)
Sieve Size 2 5350-00-935-7697 Bag (BG) (50 LB)
Sieve Size 3 5350-00-935-7698 CO (50 LB)
Sieve Size 6 5350-00-950-9766 CO (50 LB)
Sieve Size 12 5350-01-023-0302 BG (50 LB)
Sieve Size 5 5350-01-368-6707 BG (50 LB)
Sieve Size 1 5350-01-565-8141 CO (50 LB)
Adhesive-Sealant Silicone, Room MIL-A-46146
Temperature Vulcanizing Type I White 8030-00-938-1535 Tube (TU)
(RTV) Non-corrosive Type I White 8040-00-118-2695 TU
Type I White 8040-00-938-1535 TU
Type I, (High Strength) 040-00-117-8510 TU
Type I, (High Strength) 040-00-144-9774 Cartridge (CA)
Type I, (High Strength) 8040-00-145-0020 TU
Alcohol, Isopropyl TT-I-735 6810-00-753-4993 Can (CN)
6810-00-983-8551 Quart (QT)
6810-00-286-5435 Gallon (GL)

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Table A-1. Equipment and Consumable Materials List - Continued

Nomenclature/Description Specification Stock Number Unit of Issue

Applicator, Corrosion Preventive The non-stocklisted Formit spray 6850-01-492-2942 Dozen (DZ)
Compound (CPC) FORMITÒ wands are described with the
90 degree angle middle number being the
Formit-18-360 PN 006227 length of the spray can wand. NSL DZ
Formit-18-F PN 006224 The second designator is the NSL DZ
type of spray pattern issuing
Formit-18-FOG PN 008352 NSL DZ
from the wand such as 360 is
Formit-18-90-FOG PN 009134 a full circle, F is a fan, and NSL DZ
Formit-18-180 PN 006226 FOG is a fine mist. STD-FOG NSL DZ
Formit-36-F PN 009130 signifies the fogging spray NSL DZ
Formit-36-360 PN 009131 comes from the center of the NSL DZ
Formit-48-STD-FOG PN 009133 spray-head. The 90-FOG signi- NSL DZ
Formit-48-360 PN 009132 fies the spray comes from the NSL DZ
side of the spray head. Formit
Formit-48-90-FOG PN 009134 applicators may be obtained
from Zip-Chem Products, 1860
Dobbin Drive, San Jose, CA
95133,1-800-648-2661
Barrier Material, Water Vapor- MIL-PRF-121, Grade A, Type 2, 8135-00-753-4661 Roll (RO)
proof, Flexible, 36 inch (in.) Class I
Barrier Material, Water Vapor- MIL-PRF-131, Class I 8135-00-282-0565 RO
proof, Flexible, Heat Sealable,
36 in.
Cleaner, Pipe 840507 9920-00-292-9946 Package (PG)
Cleaning Compound, Aerospace MIL-PRF-87937, Type I 6850-01-390-7808 GL
Equipment 6850-01-390-7811 Cn
6850-01-390-7816 Drum (Dr)
6850-01-390-7821 Bulk
MIL-PRF-87937, Type III 6850-01-390-9530 GL
6850-01-390-9453 Dr
6850-01-390-9558 Bulk
MIL-PRF-87937, Type IV 6850-01-429-2368 GL
6850-01-429-2371 Dr
Cleaning Compound, Aircraft MIL-PRF-85570, Type I 6850-01-237-7482 Cn
Exterior
6850-01-237-8003 15 GL
6850-01-237-8004 Dr
MIL-PRF-85570, Type II 6850-01-239-0571 GL
6850-01-235-0872 Cn
6850-01-248-9828 15 GL
6850-01-236-0128 Dr
MIL-PRF-85570 Type III 6850-01-232-9164 Cn
MIL-PRF-85570 Type IV 6850-01-235-0873 Cn
6850-01-248-9829 15 GL
6850-01-248-9830 Dr
MIL-PRF-85570 Type V 6850-01-234-0219 Cn
6850-01-248-9831 15 GL
6850-01-235-7458 Dr
Coating, Polyurethane, Flat Ad- Thousand (MX)
vanced Performance Coating/
Extended Life Topcoat
36118 Gray 99GY013 8010-01-501-5577 Box (BX)

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Table A-1. Equipment and Consumable Materials List - Continued

Nomenclature/Description Specification Stock Number Unit of Issue

37038 Black 99BK004 8010-01-501-5590 BX
Coating, Polyurethane, Flat Tou-
chup Brush
31136 Red MIL-PRF-85285, Type I, 8010-01-441-6008 Each (EA)
33538 Yellow SEMPEN 8010-01-441-6009 EA
35044 Dark Blue Color per Fed Std 595 8010-01-441-6010 EA
36118 Gray 8010-01-441-6021 EA
37038 Black 8010-01-441-6028 EA
37875 White 8010-01-441-6016 EA
Coating, Polyurethane, Gloss MIL-PRF-85285, Type I, Preval
Advanced Performance Coat- Spray/ Power Pack Spray Sys-
ing/Extended Life Topcoat tem
11136 Red Gloss 99R020-1TU NSL EA
12197 International Orange 990R003-ITU 8010-01-501-5573 EA
13538 Yellow 99Y014-1TU NSL EA
15044 Dark Blue 99BL013 NSL EA
16473 Light Gray 99GY029 8080-01-501-5574 EA
17038 Black 99W035 8010-01-501-5575 EA
17925 White 99W009 8010-01-501-5576 EA
Coating, Polyurethane, Gloss
Touchup Brush
Clear 8010-01-441-6070 EA
11136 Red Gloss 8010-01-441-6018 EA
12197 International Orange MIL-PRF-85285, Type I, 8010-01-441-6019 EA
13538 Yellow SEMPEN 8010-01-441-6003 EA
15044 Dark Blue Color per Fed Std 595 8010-01-441-6004 EA
15050 Dark Blue 8010-01-441-6005 EA
16473 Light Gray 8010-01-441-6020 EA
17038 Black 8010-01-441-6026 EA
17925 White 8010-01-441-6029 EA
Coating, Polyurethane, Semi-
Gloss Advanced Performance
Coating/ Extended Life Top-
coat
23538 Yellow 99Y013 NSL EA
24052 Forest Green 99GN001 NSL EA
27038 Black 99BK005 NSL EA
Coating, Polyurethane, Semi- MIL-PRF-85285, Type I Color
Gloss Chip per Fed Std 595
26173 Gray
Type I 8010-01-339-7015 2-GL Kit (KT)
Type I 8010-01-344-3219 2-QT KT
Type I 8010-01-532-5336 10 cubic centimeter
(cc) SEMPEN
Type I 8010-01-532-5337 2 ounce (oz) Jar/
Container (Preval
Sprayer)
Coating, Polyurethane, Semi- MIL-PRF-85285, Type I, SEM-
Gloss Touchup Brush PEN, Color per Fed Std 595
24052 Semi-Gloss Forest Green 8010-01-441-6006 EA

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Table A-1. Equipment and Consumable Materials List - Continued

Nomenclature/Description Specification Stock Number Unit of Issue

Coating, Polyurethane, Flat MIL-PRF-85285, Type I, SEM-
Touch-up Brush PEN Brush
31136 Red 8010-01-441-6008 EA
33538 Yellow 8010-01-441-6009 EA
35044 Dark Blue 8010-01-441-6010 EA
36118 Gray 8010-01-441-6021 EA
37038 Black 8010-01-441-6028 EA
37875 White 8010-01-441-6016 EA
Coating, Polyurethane, 2-Compo- MIL-PRF-85285 Touch-up
nent Aerosol 26173 Gray Semi-Gloss 8010-01-538-9341 BX (6 Cans)
36118 Gray Matte 8010-01-528-4851 BX (6 Cans)
8010-01-573-5155 (6 oz)
37038 Black Matte 8010-01-528-4866 BX (6 Cans)
11136 Insignia Red, Gloss 8010-01-528-4840 BX (6 Cans)
15044 Insignia Blue, Gloss 8010-01-528-4841 BX (6 Cans)
16473 Light Gray Gloss 8010-01-528-4844 BX (6 Cans)
17038 Black Gloss 8010-01-528-4847 BX (6 Cans)
17925 Insignia White Gloss 8010-01-528-4848 BX (6 Cans)
24052 Green Semi-Gloss 8010-01-528-4849 BX (6 Cans)
Coating, Primer, Epoxy Chro- MIL-PRF-23377, Type I, 8010-01-528-4864 BX (6 Cans)
mated, 2-Component Aerosol Touch-up
8010-01-573-7608 (6 oz)
Coating, Primer, Epoxy Poly- MIL-PRF-23377
amide
Yellow 02Y040-2TU 8010-01-387-1033 KT
Coating, Primer, Epoxy Poly- MIL-PRF-23377, SEMPEN
amide Touch-up
Yellow 8010-01-441-6030 BX (24 EA)
Coating, Primer, Zinc-Rich MIL-PRF-26915
Type I, Non-water reducible 8010-00-964-6004 KT (QT)
(Solventbased) 8010-00-964-6798 KT (GL)
Aeroshield ZRP (Solvent-based) 8010-01-615-8541 KT (1.375 GL)
8010-01-615-8543 KT (1.375 QT)
ZRC-221 (Solvent-based) 8030-01-552-9033 GL
Type II, Water reducible (Water- 8010-01-380-0368 KT (QT)
borne) 8010-01-380-0398 KT (GL)
Coating, Preservative Rubber A-A-52408 (MIL-P-11520) 8030-01-282-5626 GL
Coating, Walkway Compound A-A-59166
Nonslip Dark Gray 36231 5610-00-641-0426 GL
Light Gray 36440 5610-00-141-7842 GL
Black 37038 5610-00-641-0427 GL
Corrosion Preventive Compound MIL-PRF-16173, Grade 4,16 oz 8030-00-142-9281 CN
aerosol
Corrosion Preventive Compound MIL-PRF-16173, Grade 2 NSL CN
Corrosion Preventive Compound MIL-PRF-81309, Type II, 16 oz 8030-00-938-1947 CN
aero-sol
Corrosion Preventive Compound MIL-PRF-81309, Type III, 16 oz 8030-00-546-8637 CN
aero-sol
Corrosion Preventive Compound MIL-DTL-85054 8030-01-041-1596 CN
Corrosion Preventive Compound MIL-DTL-85054 8030-01-045-4780 QT

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Table A-1. Equipment and Consumable Materials List - Continued

Nomenclature/Description Specification Stock Number Unit of Issue

Corrosion Preventive Compound, MIL-PRF-63460D 9150-01-079-6124 BT
Lubricant, Cleaner, and Preser- 9150-01-054-6453 PT
vative for Weapons and Weap- 9150-01-327-9631 QT
ons Systems (CLP)
Corrosion Preventive Compound, MIL-L-87177A 6850-01-328-3617 CN
Electronics Grade with VCI
Disc, Clean ’N Strip, 3 in. 5345-01-070-0447 EA
Disc, Rubber Wheel, 4 in. PN 07498 5345-01-549-0264 EA
Eraser, Typewriter 7510-00-619-7714 EA
Eraser, Pencil Ruby Red 7510-00-223-7046 EA
Film, Abrasion Resistant Scotch 9330-00-124-3730 RO
Brand Polyurethane
Mandrel, For Disc 3460-00-150-7164 EA
Pad, Abrasive, Non-woven, Non- A-A-58054
metallic Grade A (Very Fine) 5350-00-967-5089 BX
Grade B (Fine) 5350-00-967-5093 BX
Grade C (Medium) 5350-00-967-5092 BX
Paper, Abrasive Aluminum Ox- 240 Grit 5350-00-224-7205 PG
ide, Non-waterproof 320 Grit 5350-00-246-0330 PG
Paper, Abrasive Silicon Carbide, 320 Grit 5350-00-867-7665 PG
Waterproof
Paper, Abrasive, Silicon Carbide, 180 Grit
Disc, Pressure Sensitive Back- 3M (05114-01469) 5345-01-074-9404 RO
ing 280 Grit
3M (058144-01466) 5345-01-074-9406 RO
Pneumatic Vibrogun Sealant Re- PN 8400K, CAGE Code #65956 5130-01-514-0853 EA
moval Kit, Envision Pneumatic
(Includes: 1 Ea Ingersoll Rand
1000 RPM Right Angle Drive,
1/4 in Threaded Chuck Pneu-
matic Drill Motor; 1 Tube with
5 EA #8 SR Cutters; and 1
Tube with 5 EA #3 SR Cutters
Pretreatment Aluminum, Chro- MIL-DTL-81706 SEMPENS 8030-01-460-0246 Case (CS)
mate Conversion Coating
Primer, Waterborne Epoxy
Remover Sealant, SkyKleenÒ NSL GL
1000
Sealing Compound, Low Adhe- PR-1733
sion, Polysulfide (Note the B-1/2 8030-01-418-5415 Sealing Compound
number next to the B reflects (SC)
the working time of the seal- B-1/2 8030-01-418-5418 SC
ant)
B-2 8030-01-418-5415 SC
Sealing Compound, Self Level-
ing TM
For filling voids/cavities on hori- HT3326-5-50 8030-01-494-9650 CA
zontal surfaces where water
collects

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Table A-1. Equipment and Consumable Materials List - Continued

Nomenclature/Description Specification Stock Number Unit of Issue

Sealing Compound, ThioflexTM PN TF2219 8030-01-494-7677 CA
Orange Polyurethane Sealant
For filling voids/cavities on
vertical and overhead surfaces
Sealing Compound, PN DC-111 6850-00-294-0860 EA
Sealant, Low Adhesion and Cor- AMS 3267/PR1403G
rosion Inhibiting Class B-2 (Paste) 8030-01-104-5396 KT
Sealant, MIL-PRF-81733 8030-00-008-7205 TU
Sealant, AMS-S-8802 Fuel Cell Use Only 8030-00-723-5344 TU
Sealant Removal System, Aerow- RDS001, CAGE Code #3FM31 6635-01-572-5251 EA
ing Rapid Desealing System
(RDS) (Includes: 0.5” removal
tip (Pack of 10), 2” Shaft,
Shaft removal Tool, Operator’s
Manual)
Solvent, Dry Cleaning MIL-PRF-680, Type II or CID 6850-00-110-4498 Pint (PT)
A-A-59601 6850-00-637-6135 GL
6850-00-274-5421 CN
6850-00-285-8011 DR
MIL-PRF-680 Type III or CID 6850-01-331-3349 CN
A-A-59601 6850-01-331-3350 DR
MIL-PRF-32295, Type II 6850-01-606-8356 GL
6850-01-606-8357 5 GL
6850-01-606-3293 15 GL
6850-01-606-8358 55 GL
(As an alternate method) use a
(5PC-local purchase) 3m Rub-
ber wheel, part number 07498
for removing vinyl reflectors
and vinyl stencils from equip-
ment
Spray Kit, Preval with Com- 267-1 8020-01-501-3127 EA
pressed Gas Canister and Glass
Bottle
Spray Kit, Preval Spray Com- 268-1 8020-01-496-2473 EA
pressed Gas Canister
Tape Pressure Sensitive SAE-AMS-T-23397, Type II
1/2-in. 7510-00-476-8841 RO
1-in. 7510-00-473-9855 RO
2-in. 7510-00-473-9513 RO
NOTE

• SEMPENs are approved for touch-up on polyurethane surfaces. Respirator use is not normally required; how-
ever, organizations shall gain approval from the local bioenvironmental engineer prior to using the SEMPEN
without a paint respirator.

• Preval Spray System/Power Pack Spray Systems are atomizing paint touchup spray systems. Personal Protective
Equipment (PPE) shall be worn when spraying polyurethane and epoxy primer.
• Single component aerosols are not authorized for use on any SE.

A-6