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2005 | LEAD ABATEMENT ABRASIVE BLASTING PROJECT, FORT MONROE HAMPTON, VIRGINIA
In 2005, Earl Industries, LLC and it coatings division United Coatings was contracted to perform a steel repair and de-leading project, for the U.S. Army at the Fort Monroe – Hampton Roads Harbor Defense Base. The job was to remove all existing coatings from two, 3-inch WW II, rapid fire guns found in Battery Irwin, repair all deteriorated surfaces, and apply three coats of paint to preserve it for many years to come. The existing lead based paint (LBP) and other heavy metal coatings found on the structures; were in excess of 15% by weight, deeming them as extremely hazardous. The environmental regulations and restrictions for the removal of the existing coatings were extensive.
2 – 3 Inch Guns Description: Installed for shore protection from WW II enemy ships and landing crafts.
Lead Removal Process for the Steel Structure: During and prior to the installation of the shore battery guns; lead based coatings were widely used as a steel structure preservative. Lead is a systemic poison that can still be found on metal structures erected prior to 1970’s. The deleading process was performed by trained personnel following OSHA, SSPC & EPA guidelines for the protection of personnel and the environment.
Blast - Abrasive blasting of the steel structure with steel shot, to an SSPC-SP10 (Full Removal) was required.
Environmental Controls – A steel frame was built around the gun emplacement, and type B1-Air Impenetrable plastic sheeting was attached to the structure. A plastic ground cloth was placed under the gun mount to capture the spent abrasive and debris. A double sealable flap section was installed on the containment for and entrance. This double sealable section also provides a separation from the clean and dirty or lead contaminated side of the containment. A 5,000 cfm dust collector with particulate filters was incorporated into the containment on order to capture particulate emissions. As a qualified contractor United Coatings ensured that the lead based paint (LBP) removal process utilized, conformed to the requirements of the SSPC-QP2 (Industrial Hazardous Paint Removal Process). Spent abrasive and removed debris were vacuumed from the blast area with a HEPA filtered vacuum system, and placed in sealed drums. The drums were labeled I.A.W. DOT regulations for disposal by the base environmental facility. Barricades were erected at the work site to prevent uncontrolled access to the work area.
Steel Structure Re-construction: After the initial abrasive blast and decontamination of the shore battery; Earl Industries, LLC’s steel fabricators removed the corroded and deteriorated gun base plates and reinstalled newly fabricated stainless steel diamond plate, matching the original design.
Steel Structure Re-coating: The newly installed steel structure and new weld areas were blasted to provide the required anchor profile for coatings adhesion. The remaining areas were re-blasted in order to ensure that an SSPC-SP10 surface condition was still present. Two (2) coats of 100% solids epoxy paint were applied to each of the units as a base coat for the corrosion protection properties needed for the steel structures. When the base coats were properly cure one (1) coat of Army Green Polyurethane was applied as a protective topcoat.
Personal Protective Equipment and Decontamination System: Personnel assigned to this project were provided with the OSHA required lead worker training and medical monitoring. The abrasive blasters and painters were provided with air supplied Grade “D” breathing air and disposable protective outer garments. An Eagle filtered decontamination unit was provided and utilized for washing and showering; as required by the SSPC-QP2, OSHA lead worker requirements and the United Coatings Lead Worker Program for Removal of Hazardous Paint. Air Monitoring was conducted to ensure that contamination of Lead particulate remained below the required action level of 30 mg/m3. All federal, state and local requirements were followed regarding controls and disposal for Lead and Hazardous materials.
OSHA Lead Worker Standards: SSPC C-3 Supervisor/ Competent Person ensured standard, personnel protection, air and medical monitoring was followed There was a negative rise in Blood lead levels or ZPP, in any on site worker throughout the duration of the de-leading project.
United Coatings followed the OSHA, SSPC De-leading standards and its Best Management Practices.
