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HQMC
30 Aug 00
E R R A T U M
to
MCO P4030.23F
GUIDE FOR BASIC MILITARY PRESERVATION
AND PACKING
1. Change "MCO P4030.23E" to read: "MCO P4030.23F" of 1 Dec 1999.
PCN 10204040080
*U.S. GOVERNMENT PRINTING OFFICE:2000-461-735/20033
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DEPARTMENT OF THE ARMY TRAINING CIRCULAR TC 38-3MARINE CORPS ORDER MCO P4030.23EDEPARTMENT OF THE NAVY PUBLICATION NAVSUP PUB 442DEPARTMENT OF THE AIR FORCE PAMPHLET AFPAM(I) 24-205DEFENSE LOGISTICS AGENCY INSTRUCTION DLAI 4145.1
_________________________________________________________________________________________________
GUIDE FOR BASIC
MILITARY PRESERVATION
AND PACKING
DISTRIBUTION RESTRICTION: Approved for public release; distribution is unlimited.
DEPARTMENTS OF THE ARMY, THE NAVY, THE AIR FORCE,AND THE DEFENSE LOGISTICS AGENCY
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This publication is available on the
General Dennis J. Reimer Training
And Doctrine Digital Library at
www.adtdl.army.mil
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i
*TC 38-3
MCO P4030.23E
NAVSUP PUB 442
AFPAM(I) 24-205
DLAI 4145.11 December 1999
DEP ARTMENTS OF THE ARMY,
NAVY, AND AIR F ORC E, AND TH E
DEFE NSE LOGI STI CS AGENCY
GUIDE F OR BASIC MILITARY PRE SERVATION AND PACKING
CH AP TE R P AGE
CHAPTE R 1 - INTRODUCTIONGENE RAL ..................................................................................................................... 1-1
CONTACT, F ORMAT, AND US E ................................................................................ 1-1
CHAPTE R 2 MILITARY PR ESE RVATIONINTRODU CTION TO PRESE RVATION .................................................................... 2-1
CORROSION CONTROL ............................................................................................. 2-9
CLE ANING AND DRYING .......................................................................................... 2-13
ELECTROS TATIC DISCHARGE CON TROL ............................................................ 2-36
PRES ERVATIVES ........................................................................................................ 2-41
PRESRE VATION MATERIALS AND HE AT SEALING EQUIP MENT .................. 2-57CUS HI ONI NG, BLOCKIN G AND BRACIN G............................................................ 2-72
METHO DS OF PRE SE RVATION ............................................................................... 2-91
MISCE LLANEOU S PACKAGING REQU IRE MEN TS.............................................. 2-109
CHAPTE R 3 MILITARY P ACKING
INTRODU CTION TO MILI TARY PACKI NG ............................................................ 3-1
FIBE RBOARD SH IPI NG BOXES (ASTM D 1974/ASTM D 51 18)............................ 3-9
TRIPLE -WALL CORRUGATED F IBERBOARD BOXES (ASTM D 5168 ................ 3-30
WOODE N BOXES ........................................................................................................ 3-39
CRATES ......................................................................................................................... 3-57
MISCE LLANE OUS CONTAINE RS ............................................................................ 3-78
CHAPTER 4 - P ACKI NG PROCE DURES AND OPE RATI ONSWEATH ERPROOF ING TH E PACK ........................................................................... 4-1
CARGO UN ITIZATION................................................................................................ 4-10
MARKING AND LABELING....................................................................................... 4-28
HAZARDOUS MATERI ALS ........................................................................................ 4-61
SMALL P ARCEL SH IP MEN T..................................................................................... 4-68
* This training circular supersedes DA PAM 740-1/NAVSUP PUB 442/AFP 71-14/MCO P4030.23D/
DLAH 4145.1, Instructional Guide for Basic Military Preservation and Packing, 29 June 1990.DLAH 4145.1, Instructional Guide for Basic Military Preservation and Packing, 29 June 1990.
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Chapter 1
Introduction
GENERAL
P U R P O S E
This circular provides a series of lessons for use in training personnel in
preser vation and packing opera tions. These lessons ar e published for use as an
official document in the training of military and civilian personnel from all
segments of the Depar tmen t of Defense (DOD) and supporting a gencies. It
contains information based on specifications, standards, MIL-STD-2073-1C,
Stan dar d Practice for Military Packaging, an d other pert inent documen ts. In
keeping with the established preservation and packing policy, emphasis is
placed on efficiency and economy in all preservation and packing operations.
The use of this set of lessons will eliminate the need for the preparation of
similar guides at separ at e insta llations
CONTE NT, FOR MAT, AND USE
GENERAL
These lessons have been prepared for use in training operating personnel
working on preservation and packing lines at installations thr oughout DOD. In
the pr epara tion of these lessons, the dominan t consideration has been to make
them as flexible as possible so tha t th ey may meet the r equirement s of a var iety
of tra ining situat ions. The technical dat a and specifications r eferenced in t his
pamph let represent the cur rent pr eservation an d packing practices. The titles
of th e documen ts referenced in th e various lessons h erein ar e listed in a ppendix
A located immediately after chapt er 4.
F ORMAT AND C ONTENT
L e s so n C o n t e n t
This circular consist s of lessons on t he following:
Intr oduction to military pr eservation.
Corrosion cont rol.
Cleaning and drying.
Electrostatic discharge control.
Preservatives.
Preservation materials and heat sealing equipment.
Cushioning, blocking, and bracing. Methods of preservation.
Miscellan eous packaging requ irement s.
Intr oduction to milita ry pa cking.
Fiberboard shipping boxes.
Triple-wall corrugated fiberboard boxes.
Wooden boxes.
Crates.
Miscellaneous containers.
Weather proofing th e pack.
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Cargo un itization.
Marking an d labeling.
Hazardous mat erials.
Small parcel shipment .
KE E P I N G T H E TRAINING P RACTICAL
Ti m e All o t m en t s
In accordance with lesson objectives, methods of instruction, and time
allotments established for each lesson, it is suggested that all training be made
as pra ctical as possible. This will assur e an impr ovement in t he qua lity of
workm ansh ip. The allotmen t of approximat ely 25 percent of the t raining time
to conference instruction and 65 percent to demonstrations and practical
exercises should be followed as closely as possible. Actu al pres erva tion an d
packing working ar eas should be used.
Objec t ive
The what, how, when and why of each major preservation and packaging
principle has been em pha sized. These lessons will serve to keep instru ction
focused on the basic requirements of militar y preservat ion and packing.
LES S ON ARRANGEMENT AND SUGGES TED T IME ALLOTMENTS
The following lesson arrangement may be used as a guide in presenting the
informa tion in th is pamphlet:
Chapt er 1 - Introduction
Purpose
Content, Format, a nd Use
Chapt er 2 - Military P reservat ion
Intr oduction to Militar y Pr eservation, Conference (1 hour)
Corrosion Cont rol, Conferen ce (1 hour )
Cleaning and Drying, Conference (1 hour), Practical Exercise (1hour)
Electrostatic Discharge Control, Conference (1 hour)
Preservatives, Conference (2 hours), Practical Exercise (1 hour)
Preser vation Materials and H eat Sealing Equipmen t, Conference (1
hour), Practical Exercise (1 hour)
Cush ioning, Blocking, an d Bra cing, Conference (2 hour s), Pr actical
Exercise (1 hour)
Methods of Preservation, Conference (3 hours), Practical Exercise
( 1 hour)
Miscellaneous Packaging Requirements, Conference (2 hours)
Chapt er 3 - Militar y Packing Introduction to Military Packing, Conference (1 hour)
Fiberboard Shipping Boxes, Conference (1.5 hours), Practical
Exer cise (1.5 hour s)
Triple-wall Corrugated Fiberboard Boxes, Conference (1 hour),
Practical Exercise (1 hour)
Wooden Boxes, Conferen ce (2 hour s), Pra ctical E xercise (2 hour s)
Crates, Conference (2 hours), Practical Exercise (2 hours)
Miscellaneous Containers, Conference (1 hour)
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Chapt er 4 - Packing Procedures a nd Opera tions
Weatherproofing the Pack, Conference (1 hour), Practical Exercise
(1 hour )
Cargo Unitization, Conference (2 hours), Practical Exercise (1 hour)
Marking and Labeling, Conference 2 hours), Practical Exercise (1
hour)
Hazar dous Mater ials, Conference (2 hours)
Small Pa rcel Shipment, Conference (1 hour)
C h a n g e s a n d R e v i si o n s
Revisions or changes t o this pu blication, du e to m ajor changes in preservat ion
packing policy, doctrine, revision of specifications, and other official
preservation/packing instru ctions will be made on a continuing basis a s th e need
arises.
Users of this training circular are encouraged to submit recommended changes
or comments t o improve th e publication. Commen ts should be keyed to th e
specific page, and line of th e text in which th e cha nge is recommen ded. Reasons
should be provided for each comment to ensure understanding and completeevalua tion. Commen ts should be forwa rded to Dean , School of Milita ry
Pa ckaging Techn ology, ATTN: ATSL-MPT, 360 Lan yar d Road, Aberde en
Pr oving Gr ound , MD 21005-5003.
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CHAPTER 2
Military Preservation
INTRODUCTION TO MILITARY PR ESE RVATION
NE E D F OR T RAINING/P RESERVATION
N e e d fo r P r e s e r v a t i o n T r a i n i n g
An und erst an ding of preser vation is needed at a ll depar tm ent levels, especially
at th e operat iona l level. Personn el at th e operat iona l level have th e most
physical contact with preservat ion. They must kn ow wha t they ar e doing and
fully underst an d th e need for doing it.
Def i c ien ci es
Deficiencies in pr eservation are caused by man y different factors. Failure t o
employ proper preservation instr uctions results in deficiencies. Thesepackaging deficiencies are reported on SF 364, Supply Discrepancy Report
(SDR).
T r a i n i n g
To correct deficiencies, per sonnel mu st be tr ain ed in th e proper pr ocedu res for
preservat ion of militar y su pplies.
Wh a t i s P r e s e r v a t i o n ?
Preservation is the application or use of protective measures to include cleaning,
drying, preserva tive application, pr otective wra pping a nd/or cushioning, placing
the item into a conta iner, an d complete identification m ark ings. The basic steps
involved in pr eservation ar e illustr ated in figure 2-1.
C l e a n i n g
All substa nces (contam inan ts) which would cau se or promote corr osion mu st be
removed.
Dr yi n g
Must be a ccomplished immediat ely after clean ing to remove cleanin g solutions
or any other r emaining moisture.
Preservat i ve Appl ica t ion
A preservat ive is used to keep items in a u seful condition by pr oviding a bar rier
to keep out moisture, oxygen, and other causes of corrosion.
Wr ap a nd /or Cus h i on
Appropriate wrapping is used to retain the preservative on the item.
Cush ioning is used to protect the item aga inst physical an d mechanical damage
and to protect barr ier m aterials and containers a gainst puncture.
P l a c i n g i n C on t a i n e r
Inter ior conta iners are u sed to increase the assur ance tha t th e cleaned, dried,
an d pr eserved item will be in a ser viceable condition a fter shipm ent or storage.
Ma r k in g
Markings mu st be applied to identify the contents.
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Figure 2-1. Basic steps in Military Pr eservation.
H a z a r d s t o Mi li t a r y S u p p li e s a n d E q u i p m e n t
Ge ne r a l
We must pr otect our militar y supplies and equipmen t from both climatic and
mechanical hazards from procur ement t o end u se.
C l im a t i c h a z a r d s
Thirty minutes does not seem like a long time, yet 30 minutes of improper
storage could da mage some items wh en t hey ar e exposed to a var iety of clima tic
conditions such as those shown in figure 2-2.
Da m a ge by w a t er
Water dam age is the largest source of dama ge to militar y items. Water ma y
cau se dama ge in two ways:
Water combined with oxygen will cau se rust on iron an d steel. It will
cause corr osion on other k inds of met als. Corrosion ma y be caused by
water in one of thr ee forms. It ma y be liquid, such as ra in or snow. It
ma y be in th e form of mist or spr ay, such as fog or ocean sp ra y. Ocean
spra y conta ins salt a nd is especially corrosive. It ma y be in t he form of
invisible vapors. This form of water is nearly everywhere and is ha rd
to control since it can not be seen. Water vapor can penetr at e into th e
smallest crevice and cause dama ge to even th e most intricate item.
Water can cause da ma ge by aiding in t he growth of mold, mildew, fungi,
and rot.
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Figure 2-2. Climat ic Hazar ds.
D a m a g e b y D u s t a n d D i r t
Dust an d dirt can dam age small bearings, gears, and small moving part s. A
wristwatch, for exam ple, would be r uined if dust an d dirt were a llowed inside
it. Dust a nd dirt m ay conta in chemical ingredients which may pit or corr ode
polished or critical sur faces. Dust from factory wastes m ay be highly corr osive.
Dust and dirt may scratch precision lenses on binoculars, cameras, and fire-
control items. It ma y also scratch highly polished metal sur faces. Dust an d dirt
may also contamina te ster ile medical sup plies, such as medicines, bandages, an d
instruments.
D a m a g e b y D ir e c t S u n l ig h t
Direct su nlight will cau se some fabrics to fade when exposed an d m ay cause a
breakdown an d cha nge in certa in chemicals. Films, rubber, and sensitive paper
will be ruined by exposur e to sunlight or it may cause th e rupt ur e of cont ainer s
if th ey are filled to capa city with volat ile liquids. Direct sun light or heat m ay
cause expansion of metals, which could result in the decalibration of highly
precise instruments.
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Mec h a n i ca l h a z a r d s
The kind of hazar ds pictu red in figure 2-3 cau se severe dam age to our supp lies
an d equipment a nd is th e result of improper han dling, stacking, or th e improper
use of equipment, e.g., ships, cranes, slings, nets, etc.
Dam age by I n s ec t s , Ve r m i n , Roden t s , an d Bi r ds
Bird droppings and rodent excreta ma y soil items, par ticularly fabrics. Moth smay eat fabrics, especially wool. Insects an d rodents will eat perisha bles an d
food st uffs.
Spec i a l Cons i de r a t i on Neces s a r y i n S t o r age o f L i qu i ds
Liquids may leak or evaporate. This could cau se a safety haza rd if the liquid is
flamma ble, corrosive, or toxic. Heat can cause th e rupt ure of containers if
sufficient r oom for expan sion is not allowed. Man y liquids mu st be protected
from freezing or p revented from setting.
S t a t i c e l e ct r i c i t y
Some electronic componen ts a re sen sitive to electrosta tic discharge a nd mu st be
protected dur ing, han dling, stora ge, and sh ipment from this hazard.
Figure 2-3. Mechan ical Hazards.
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P o l icy fo r t h e Pa ckag i ng o f M a t e r i e l
Every company or business in operation today operates under some kind of
corpora te instr uctions, bylaws, policies, etc. The Depar tm ent of Defense also
ha s policies which mu st be followed. These policies are in th e form of
instru ctions a nd a re implemented by the m ilitary services and other components
of th e govern men t. The implemen tin g docum ent is AR 700-15/ NAVSUP INST
4030.28D/AFJMAN 24-206/MCO 4030.33D/DLAd 4145.7, Packaging of Materiel.
P o l ic y s t a t e m e n t
All defense materiel shall be afforded the degree of protection required to
prevent deterioration and damage dur ing shipment, handling and storage.
M il it a r y P a c k a g i n g Ve r s u s C o m m e r c i a l P a c k a g i n g
There is a clear distinction between the guidelines set forth for the military
packa ging concept an d those set forth for comm ercial packaging. The difference
between th e two is as follows:
Military packaging requires the use of specification materials;
interpretation of preservation/packing instructions; MIL-STD-129,
Militar y Markin g; an d th e preser vation met hods of MIL-STD-2073-1C,Stan dard Pra ctice for Militar y Packaging. Militar y packaging should be
used for items expected to enter t he military distribution system. The
military distribution system is the process by which materiel, not
intended for immediate u se, is stored a nd/or m oved within or between
DOD facilities. It ma y also cover items int end ed for delivery-at-sea,
items delivered durin g wartime, or items r equiring reusa ble containers .
Commer cial pa ckaging per mits use of nonspecification m ater ials, and
ASTM D 3951, Standard Practice for Commercial Packaging, provides
sta nd ar d comm ercial guidelines. Applicat ion of pres erva tion/packing
techniques is at the discretion of the contra ctor or th e activity. Items
not going into stock, items inten ded for immediat e us e (ex. AOG), items
for not mission-capable supply (NMCS), items intended for depot
operational consumption, small parcel shipments (CONUS, not-for-
stock) and direct vendor deliveries (CONUS) shall be packaged in
accordance with st an dar d commer cial pr actice a s defined in ASTM D
3951.
Leve l s o f Mi li t a r y P r o t ec t i on
A means of specifying the level of packing that a given item requires to assure
tha t it is not degraded dur ing shipment and st orage. Figure 2-4 shows the levels
of pr otection for milita ry packing. These levels are ident ified as level A and
level B. Level A provides maximu m protection, and level B provides moderat e
protection.
Levels of Pa cking. Level A. Pr otection t o meet the most severe worldwide shipment,
han dling, an d storage conditions. A level A pack mu st, in ta ndem
with the applied preservation, be capable of protecting materiel
from the effects of direct exposure to extremes of climate, terrain,
and operat iona l and tran sportat ion environment s. Exam ples of
situations which indicate a need for use of a level A pack are:
mobilization, strategic and theater deployment and employment,
open storage, and deck loadin g. Exa mples of cont ain ers used for
level A packing requirements include, but are not limited to,
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overseas type wood boxes, and plastic and metal reusable
containers.
Level B. Protection to meet moderate worldwide shipment ,
han dling, an d storage conditions. A level B pack must, in ta ndem
with t he a pplied preservat ion, be capable of protecting ma ter iel not
directly exposed to extremes of climat e terr ain a nd opera tional an d
tra nsporta tion environm ents. Exam ples of situat ions whichindicate a need for use of a level B pack are: securit y assista nce
(e.g., Foreign Military Sales (FMS)) and containerized overseas
shipment s. Exam ples of containers used for level B packing
requirements include, but are not limited to, domestic wood crates,
weather-resistant fiberboard containers, fastpack containers,
weather-resistant fiber drums, and weather-resistant paper and
multi-wall shipping sacks.
Figure 2-5 depicts progressive item protection based on levels of
protection.
Figur e 2-4. Levels of Pr otection.
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Proper supervision. The quality an d quan tity of work are directly
related to the kind of supervision given.
J ob requ iremen ts. It is importa nt t o show techn ical competen ce on th e
job and to u nder st and our in dividu al job ass ign men t and it s im pa ct on
the overall mission.
Plann ing. Ea ch operat ion in preservat ion an d packing should be well
plann ed in efficient u se of personnel an d m achines.
C h e c k u p
What a re th e basic steps of militar y preservation an d packing?
What are the two levels of militar y protection?
What level of pr otection is requir ed for th e protection of ma ter iel against
the most severe conditions known or anticipated to be encountered
during shipment, handling, and storage?
List some importa nt factors tha t can influence economy in pa cking.
Why is mar king an importa nt st ep of preservat ion?
Why is it importan t t o dry an item immediat ely after cleaning?
What is the r eason for u sing cush ioning inside a pa ckage?
Why is it importan t to tr ain personn el at th e operationa l level?
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CORROSION CONTROL
C ORROS ION
Corrosion is th e breakdown of meta ls when th ey are in cont act with water an d
air . Rust is often used to describe an y type of corr osion. It is actua lly a ter m
which describes corrosion on iron or relat ed metals. Ferr ous metals are an y
meta ls which conta in or are ma de from iron.
C ORROS ION OF F ERROUS AND NO N F E R R O U S METALS
Corrosion on iron an d steel (ferrous meta ls) is termed ru st. It is usua lly red in
color an d form s a ru sty film which holds moistur e and oxygen like a blott er. It
speeds up furt her corrosion by acting as a reservoir wh ich feeds moistur e an d
oxygen to unr usted area s, as shown in figur e 2-6.
Figure 2-7 illustr at es corr osion on n onferr ous meta ls such as zinc and cadmiu m
which is often white or gray in color. The ter ms "white ru st an d oxidat ion" are
often ap plied to th is type of corrosion.
Figur e 2-6. Corrosion of Fer rous Metals.
Figur e 2-7. Corrosion of Nonferr ous Metals.
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WHAT IS KNOWN ABOUT CORROS ION --BASIS FOR C ONTROL
For t he pu rpose of un derst an ding corr osion cont rol, corrosion will be explained
by compa rin g it to the operat ion of a stora ge batter y. In order for corrosion to
tak e place, cert ain elements ha ve to be present. They are a metallic par t, water,
and oxygen. In order for a bat tery to produce a charge, certa in element s must
also be present, as depicted in figure 2-8. They are positive and negat ive
met allic electr odes, and a n electrolyte. The positive electrode is constr ucted ofone kind of met al, and t he nega tive electr ode of a differen t kind of met al. This
potential difference (a positive and a n egative) mu st be pr esent for an electric
curr ent t o be produced. The electr olyte in the storage batt ery would be similar
to the water and oxygen in the corrosion process, and the battery's metal
electrodes ar e similar to th e meta l which corrodes.
Figure 2-9 shows th at when an item is made of two or more dissimilar m etals,
accelera ted corr osion will ta ke place. When only one kin d of met al exists,
normal corrosion will take place. With out th e th ree elements, shown in figure
2-9 th ere would be no electr ic curren t from a ba tt ery an d no corr osive action on
the met allic item. In ma ny cases, batter ies are packed in a "dry" stat e so th at
the bat tery will not generat e an electric curr ent. Similar ly, in corrosion,
basically no corrosive action will ta ke place un less moistu re is pr esent . Themost obvious thing to do to prevent corrosion would be to eliminate moisture.
This could be done by applying a wa ter proof or wat er-vaporproof bar rier t o the
item. Even if the par t is not ma de of two different meta ls (as t he electrodes in
the battery), there is enough potential difference between areas within one
meta l to cause corr osion. In order for t hese two area s to react, they ha ve to be
conn ected some way. This is done by the electrolyte (wat er).
Figure 2-8. Compar ing Corrosion with a St orage Battery.
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Figure 2-9. Corrosion Elements.
C ORROS ION C ONTROLS IN P RESERVATION
Simply stat ed, preser vation cont rols corrosion by cont rolling wha t would am ount
to the battery water in t he "corrosion battery." Cont amina nt s, which wouldmak e any moisture present a bett er electrolyte, must be removed. Moisture,
which would tak e conta minan ts int o solution t o make an electrolyte, must be
kept from th e sur face of th e part by preservat ive application and/or sealed unit
packages. Oxygen is somet imes contr olled by adding a su bstan ce (antioxidan t)
to the preservative. This substan ce removes the oxygen.
Corrosion controls are included in the three basic operations which make up
un it pr otection (cleaning, preservat ive application, an d u nit packaging).
Cleaning is the first operat ion in un it protection. Details of the cleaning
processes will be covered in a noth er lesson. The ma in rea son for cleanin g is to
remove contamina nt s from t he item t o prevent a bat tery-type action from taking
place. Immediat ely after cleaning, the item mu st be thoroughly rinsed toremove the residue of th e cleaning agent. Heavy empha sis is placed on
fingerprint removal when cleaning items which ha ve a h ighly polished critical
sur face. The r eason for t his is becau se oils from fingers ar e salty-acid cont am i-
na nts which act as an extremely effective electrolyte wh en combined with water.
Drying, although accomplished by separately identified procedures, becomes
par t of the overall cleaning opera tion.
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Pr eservat ive application is th e second opera tion in unit pr otection. Deta ils will
be covered in another lesson. The main r eason for a temporar y preservative
coating is to insulat e the meta l sur face from moistu re and conta minan ts. To
fight corrosion, we must apply a good, uniform, continuous coating of
preservat ive to the item. The heavier preservat ives may not be used on more
complex items because of th eir difficulty in removal. A lighter pr eserva tive may
be used within a sealed barr ier provided in th e meth od of unit pr otection.
Completing the method of unit protection is the third operation in unit
protection. Deta ils will be covered in anoth er lesson. The following genera l
observations r elate t he preservat ion meth ods to corr osion contr ol.
Cleaning, preservative application, and unit protection make up the techniques
required to prevent corrosion. These thr ee operat ions sh ould be carried out in
a contin uous cycle withou t layover between opera tions. It is especially
important that parts not be held over between cleaning and preservative
application.
C h e c k u p
In general, it can be stated that most corrosion takes place in thepresence of what thr ee things?
How would a zinc plated steel bolt appear as it becomes progressively
corroded?
Why can the operation of a storage battery and formation of corrosion
be compar ed?
What is the preservat ion appr oach to corr osion contr ol?
Preser vation operations sh ould be perform ed in one cont inuous cycle.
Fr om a corrosion cont rol stan dpoint , where is the most da ma ging place
to have a time break in operat ions?
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CLE ANING AND DR YING
C LEANING R EQUIREMENTS
The cleaning requirements differ for military preservation from those for
commercial packaging and are defined below.
C o m m e r c i a l P a c k a g i n gThe cleaning r equirem ent s for comm ercial packaging a re specified in ASTM D
3951. Item s will be free from dirt an d conta mina nt s which would contribut e to
deterioration of the item or which would require special cleaning by the
cust omer prior to use. Coatings an d preservatives applied to the item for
protection a re n ot considered conta minan ts.
TYP ES OF CONTAMINANTS
Before we discuss t he clean ing and drying operations, we will learn about t he
different types of contamina nts tha t m ust be removed a s shown in figur e 2-10.
A contam inant is any ma tter on the item, other t han the ma terial it was ma de
from. Dirt is often called a cont amin an t. In gener al, we are concerned with fourtypes of contam inant s.
Oil Soluble
This group includes all oily or grea sy substa nces. These should be the first
contam inan ts rem oved in an y cleaning operation.
Wat e r So lub l e
This group includes fingerprint s, perspirat ion, soldering a nd welding fluxes, and
mar king inks. These contam inan ts are not removed with ordina ry solvents or
cleaners. They are rem oved with a fingerpr int rem oving compoun d.
Figure 2-10. Types of Conta minan ts.
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I n s o lu b l e L o o s e ly A d h e r i n g C o n t a m i n a n t s
Loosely adhering contaminants may be solid dirt particles, abrasive grains,
meta l chips a nd filings which can be removed with wat er or solvents.
I n s o lu b l e T i g h t ly A d h e r i n g C o n t a m i n a n t s
Tightly adhering contaminants may be mill and heat scale, carbon deposits,
rust, and other corrosion products which must be removed by mechanicalclean ing pr ocesses.
Each of these groups of contam inant s mu st be removed by different mean s. If
contaminants from more than one group are on the item, the oils and greases
must be removed first, then the insoluble contam inan ts, followed by th e wat er
soluble contam inan ts.
B ASIC CLEANING R EQUIREMENTS
Good workm an ship is necessar y to do a good job in clean ing. The following
requiremen ts illustra ted in figure 2-11, have been esta blished for cleaning:
C le a n i n g M u s t b e T h o r o u g h
All contam inant s mu st be removed before the a pplication of a pr eservative. Anycontam inant left on an item will cause corrosion or deter iora tion.
Figur e 2-11. Basic Requirem ent s for Clean ing.
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P r o c e ss Mu s t N o t I n j u r e t h e I t e m
Select a process th at will not cause dama ge to an item. You wouldn't select a
harsh solvent for leather goods because of its damaging effect.
Di s as s em bl y Sha l l be L i m i t ed
Limit the disassembly to a point wher e reassembly can be easily done without
special tools or sk ills.
F i n g e r p r i n t s Mu s t b e R e m o v e d F r o m C r i t ic a l Su r fa c e s
The acid in our fingerprints is corrosive, and, if not removed from critical
(precision) surfaces, it will etch these surfaces in a short time.
To assu re th orough cleaning of the item, it should pass a cleanliness test. If any
contam inan t is left on the item, th e item must be recleaned.
C LEANING P ROCES S ES SELECTION
The selection of a clean ing pr ocess depen ds u pon th e following factors:
Com pos i t i on o f t he I t em
The composition of th e item limits th e choice of th e clean ing processes. Item smade from a luminum or zinc should n ot be cleaned in h ighly alkaline cleaners
because of th e detrim ent al effect of th e clean er. Nonm eta llic item s of ru bber,
fabric, cork, or oth er organ ic composition sh ould not be cleaned h aph azar dly in
organ ic or water -soluble alkaline cleaner s. If solvent clean ing is app lied to such
items, the solvent exposur e mu st be brief and scru bbing a ction limited wh en
dimensions and u se conditions of the item a re critical. Solvents ar e detriment al
to most rubber and synthet ic rubber ma terials. If meta llic and n onmetallic
mat erials are combined in an assembly, the cleaning process mu st be carefully
considered a nd t he choice of the process governed by th e na tu re of the ma terials
combined in t he assembly.
Sur face F i n i s h o f t he I t em
Some cleaning processes are safe to use on highly finished and precision
surfaces while oth er processes are likely to damage the finish. For insta nce,
alka line cleanin g should not be used on polished alum inum . Acid cleaner s are
used in iron an d steel with extr eme care. Solvent cleaning pr ocesses are usu ally
recommen ded for most critical sur faces of met al items. Sur faces of rough
forgings or cast ings, rough ground or r ough ma chined items, or sur faces having
no finishing after stamping or drawings are cleaned by alkaline cleaning
processes. Item s with porous sur faces, small crevices, or holes are n ot cleaned
with alkaline cleaning processes because the complete removal of all residues
is not possible an d corrosion will resu lt. Solvent clean ing can not be applied
indiscriminately to painted surfaces; however, zinc-coated primers, exterior
paints, lacquers, and en amels ar e usua lly han dled safely in solvent cleaners.
Com pl ex i t y o f t he I t em
Items h aving irregular su rfaces, crevices, undercuts, an d pockets t hat could tr ap
clean ing fluids m ay only be cleaned by br ush ing or wiping when solvent cleaning
is used. Clean complex assemblies before they ar e assembled. Assemblies such
as electric generators, motors, starters, gauges, meters, timing devices, and
other complex units should be cleaned before assembly and kept clean
thereafter.
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H e a l t h a n d S a fe t y H a z a r d s
All cleaning processes have health and safety hazards that must be recognized.
These cleaning processes must comply with the requirements of the
Occupational Safety and Health Act (OSHA) of 1970, or Executive Order 11612,
as applicable.
Ap p r o v e d C l ea n i n g P r o c e s s esThe selection of a cleaning process is very important; if not selected properly,
more harm than good may result .
C le a n i n g P r o c e s s
Items shall be cleaned and dried by any suitable process which is not injurious
to the item. The meth ods an d mat erials of clean ing may include th e following;
however, th ey ar e n ot limited t o those listed below:
Wire bru shing ma y be used to remove loose scales an d light ru st from
items. Oily or greasy contam inant s must be removed before wire
brush ing. Wire brushes should be made of th e same material as the
meta l being clean ed.
Air va cuu m cleaning should be used on items which can not be cleanedby oth er mecha nical or chemical processes. It can be used on ra dio an d
electronic items to remove dust, lint particles, etc.
Barrel tumbling cleans by the use of both chemical and mechanical
actions on the corroded surface. Chemical cleaners su ch as pickling bat hs.
So lven t C l ean i n g
Solvent cleanin g uses severa l differen t kind s of solvent s. Solvent clean ing is
used whe n th e only conta mina nt is a light gr ease or oil. It will not remove rust
or fingerprints an d oth er water-soluble contam inan ts. Fingerpr int removal is
used on a ll items wit h critical fun ctioning sur faces or items with close tolera nces
to remove fingerprints, perspiration, and other water-soluble contaminants.
Solvent cleaning followed by fingerprint removal is sometimes necessary.
Ma t er i a l s for S ol ven t Cl ea n in g
The ma terials used in solvent cleaning are dry cleaning solvent Type III, paint
thinn er a nd fingerprint remover corr osion pr eventive compoun d.
Dry clean ing solvent (P-D-680), Type III only. This is a wat er-clear
liquid that is neutral to metals and is sometimes known as Stoddard
solvent. It is slightly irrita ting to the skin an d may be mildly
na useating when excessive vapors ar e breathed. It can be used on meta l
surfaces by brushing, wiping, spraying an d immer sion to remove oils
an d light greases. The solvent mu st be used only at room temper atu res.
P-D-680, Types I and II are being phased out as environmentally
ha zardous solvents which must be disposed of as a ha zardous wast e.There a re environment ally compliant solvents th at clean as well as P -D-
680, Types I and II. Approved substitutes tha t are environment ally
compliant solvents at this time include Breakthrough, Electron 296,
Skysol 100, Skysol, an d PF. Do not use water -based enzymes as a
subst itut e for P-D-680 as th ey do not pr ovide corrosion pr otection. For
questions concerning the availability of solvent products, contact the
Defense Supply Center Richmond, 8000 Jefferson Davis Highway,
Richmond VA 23297-5100, or call 1-800-352-2852 and ask for the
En vironm enta l Products cat alog.
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Note: WARNI NG: Keep solvent away from an y open flame or source of
sparks.
Pa int Thinn er (TT-T-291). This mat erial is supp lied in two grad es and
only gra de I is used for solvent cleaning. It is similar to dry clean ing
solvent (P-D-680) in th at it rem oves oils and light greases, h aving a lowflash point a nd degree of toxicity. Used pain t thin ner m ust be disposed
of as a h azar dous waste.
Fin gerpr int Rem over Corr osion Pr eventive Compound (MIL-C-15074).
This mater ial is a mixture of solvent, soap an d water. It is used to
remove fingerprints, su ppress perspira tion corrosion, a nd temporar ily
protect steel su rfaces.
E qu i p m en t f or S olven t Clea n in g
Metal tanks are required for solvent cleaning, and they usually contain
provisions for spr aying operat ions. The ta nks sh ould be equipped with safety
featur es consisting of a tight fitting lid, a fusible link, a nd a ground conn ection,
as shown in figure 2-12. The rea sons for the safety feat ur es are as follows: if
th e solvent sh ould cat ch fire, the h eat would melt t he fusible link an d allow th etight fitting lid to close and smoth er th e fire, and t he groun d conn ection is used
to car ry off an y stat ic cha rges of electr icity. It is importan t t ha t th e fusible link
always be in an operable condition and that the lid should never be wired or
fasten ed in t he open position.
Figure 2-12. Solvent tan k with safety featu res.
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Saf e t y P r ecau t i ons fo r So lven t C l ean i n g
Observe th e following:
When n ot in use, covers mu st be k ept closed on all solvent t an ks.
Provide adequate ventilation t o prevent vapor fume build up. Inha ling
solvent vapors ma y cause d izziness, fainting a nd n au sea.
Fire extinguishers must be located in the area , and personnel must betrained in their use.
A fire blanket should be located near by.
Since solvents may cause skin irritations, operators should wear oil
resistant rubber or plastic gloves and work aprons during cleaning
operations as illustra ted in figure 2-13.
So l v e n t Cl e an i n g
Figure 2-14 depicts two tan ks required to clean by immersion. One tan k is used
for cleaning an d th e other for r insing.
Cleaning by immersion. The solvent clean ing immer sion steps are
illustra ted in figure 2-15. These steps include placing items in th e
solvent clean ing ta nk so they r eceive th e most effective wash ing action;agitating the items thoroughly for complete cleaning; using a brush
where necessary t o remove hea vy contamina nts; rem oving clean items
from the tank and allowing them to drain completely; immersing the
items in a second tank (rinse tank) and agitating as necessary; and
removing items from the rinse tank and placing them on a tray to
thoroughly drain.
Cleaning by scrubbing and wiping. When conta minat ed items are too
large for the cleaning tanks, or because it is impractical to clean by
immersion or spra ying, they should be cleaned by scru bbing a nd wiping.
The solvent cleaning by scrubbing and wiping steps are as shown in
figur e 2-16. The steps include soaking clean cloth or bru sh in clean
solvent; masking off areas of the item th at can be da maged by solvent;
applying th e soaked cloth an d/or brush t o the dirty ar ea an d scrubbing
an d wiping as necessary; rinsing off the ar ea with a clean cloth soaked
in clean solvent; an d dra ining and wiping the cleaned ar ea dry.
Cleaning by spraying. When item s are of a simple constr uction, free of
cavities and inden tat ions wher e cleaning solvents can be tr apped, th e
clean ing can be done by spra ying as described in figure 2-17. The steps
involved in solvent cleaning by spraying include loading items in a work
basket an d lowering the basket into a spray tank; turn ing on th e spray
pum p an d directing the n ozzle at items, assu ring complete clean ing of
the item; and removing the basket of items from the spray zone and
allowing it to drain. A rinse is not required if th e spray system is
equipped with filters a llowing th e spra yed solvent to be cleaned.
Perspira tion an d fingerprint r emoval.
Solvent clean ing followed by finger prin t r emoval.
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Figur e 2-13. Solvent sa fety clothing.
Figur e 2-14. Solvent clean ing by immer sion.
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Figure 2-15. Solvent immersion steps.
Figure 2-16. Solvent scrubbing and wiping.
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Figur e 2-17. Solvent spra y clean ing.
P e r s p i r a t i on a n d F i n g e r p r i n t R e m o va l
Two tan ks are required for cleaning perspiration and fingerprints. One tan k
should conta in fingerprint remover compound (MIL-C-15074) and th e other a
clean ing solvent. This process is used on all item s having critical functioning
sur faces or close toleran ces. Before th is process is used , the item mu st first be
cleaned of all other conta minan ts. Steps involved in the perspirat ion an d
fingerprint removal process ar e illustr at ed in figur e 2-18 an d include immer sing
item(s) in per spiration an d fingerprint remover compoun d an d agitatin g while
in t he compound for 2 to 3 m inu tes; removing item (s) from fingerpr int rem over
compound and allowing them to drain; immersing item(s) in a second tank
conta ining clean dr y cleaning solvent a nd t horoughly rinsing; an d after rin sing,drain ing and drying th e item(s).
S o lv e n t C l e a n i n g F o l lo w e d b y F i n g e r p r i n t R e m o v a l
This process is accomplished by completing the cleaning steps described for
solvent cleaning, followed by perspira tion a nd fingerprint removal. Figure 2-19
details th e steps involved.
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Figure 2-18. Fingerprint r emoval operat ions.
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Va p o r D e g r e a s in g
Cleaning by vapor degrea sing. This pr ocess differs from th e previous processes
in removing conta mina nts from the items. As you r ecall, cleaning ma terials
were not heated. In th is cleaning process, we are going to heat nonflamm able
solvents and use th e vapors to throughly remove heavy oils, greases, and wa x.
This process should not be used on items th at can be damaged by heat. The
degreasing process is quite simple but m ust be done only in special equipmentbecau se of the h azar ds involved.
Material used in vapor degreasing. The mater ials used in vapor
degreasing are kn own a s chlorinat ed solvents such a s trichloroethan e-
1,1,1. Trichloroeth an e-1,1,1 is a clear, non-flam ma ble solvent a nd can
be used either in liquid form or in vapor form after hea ting. It ha s a
boiling point of 165F. These mat erials will not remove fingerpr ints,
ru st, or scale. Its pr imar y purpose is to remove hea vy oils, greases, and
wax. En vironm enta lly friendly degreasers are also available and are
highly recommended for this process.
Equ ipmen t for vapor degrea sing. This cleanin g process should only be
done in properly designed equipment t hat may vary in size and sha pe.
The ma nu factu rer s guide must be car efully followed. Figur e 2-20 shows
the pa rts of a typical vapor degreaser.
Safety precautions for cleaning by vapor degreasing are: (WARNING)
VAPOR HARMFUL!
1. Use only with adequa te ventilation.
2. Avoid pr olonged or repea ted brea th ing of vapor.
3. Avoid pr olonged or repea ted cont act with skin.
4. Do not tak e intern ally.
5. Conta ct with flam es or hot glowing sur faces ma y form corr osive
acid fumes.
6. The man ufacturers man ua l must be used as a guide, with
par ticular a tten tion focused on cleaning th e tan ks.7. Wear protective clothing, gloves, apr ons, an d goggles.
How the vapor degreaser cleans. This method of cleaning rem oves
hea vy oils an d greases. The cleaning a ction is due t o vapors conden sing
on the cool item, which t hen dissolves th e greases a nd oils and rinses
them from the item as illustra ted in figure 2-21. Cleaning steps
involved in vap or degrea sing ar e as follows:
1. Place items on racks or in baskets. Place in such a way th at when
th e greases a nd oils drain, th ey wont be tr app ed in pockets or crevices.
2. Lower th e items slowly into the vapor ar ea at a r at e of 10 to 12 feet
per minu te to prevent th e escape of vapors from th e tan k.
3. When vapors stop conden sing on th e item s, slowly rem ove from
tank.
4. If some conta mina nt st ill rem ain s on th e item, cool to room
temperatur e, then repeat the above steps.
5. Remove slowly from vapor ar ea an d allow item s to cool.
6. No dryin g process is requ ired.
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Figur e 2-19. Solvent clean ing followed by finger prin t rem oval.
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Figure 2-20. Vapor degreasing.
Figure 2-21. Vapor Degreasing an item.
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Va p o r D e g r e a s i n g F o ll ow e d b y F i n g e r p r i n t R e m o v a l
This clean ing process is a combina tion of two oth er cleanin g processes. If the
item h as a critical sur face an d is coated with h eavy oil or grease, the heavy oil
or grease mu st be rem oved before the fingerprin t r emoval compound is used on
the critical surface. Clean th e item by vapor degreasing first to remove theheavy oil or grea se. Allow th e item to cool un til it reaches r oom t empera tur e.
Then clean the item in th e fingerprint removal compound to remove any water
soluble contam inan ts on th e critical sur faces of the item.
For environmentally safe substitutes for Trichloroethane 1,1,1, refer to the
Environmental Products Catalog, Defense Supply Center, Richmond, VA,
ht tp://www.dscr.dla.mil. Manu factu rers recommen dations an d Material Safety
Data Sheets (MSDS) should be consulted.
J e t S p r a y Wa s h i n g
Procedures such as solvent cleaning that use solvents, which have
chloroflourocarbons in them or are ozone depleting chemicals or water
polluta nt s, are being replaced by environmen ta lly safer cleaning processes. J etspra y washing is a cleaning meth od designed to operate with th e lowest buildup
or generation of conta minan ts which pollute th e environmen t.
Items with heavy or light greases or oils are placed into units which are
preheat ed to temperatu res over 200 F. A clean ing compound is placed in the
un its an d mixes with t he very h ot water which is jet spr ayed with considerable
force onto the items u ntil th ey are clean .
As the items ar e being jet spra yed, th e conta mina nt is scra ped or skimmed from
the su rface of the solvent an d compr essed into a sm all unit for ea sy disposal.
The liquid portion of the cleaning compound provides for safer disposal into
norma l water dr ainage systems. The items receive thorough cleaning and ar e
very hot at th e end of th e clean ing cycle. No special drying techniqu e is
necessary.
Regardless of the high temperature, jet spray washing will not remove
fingerprints, perspira tion, etc. from meta l items with critical surfaces. The
finger prin t removal compound process will still be necessary. However, this
process does not provide the corrosion pr otection of th e chlorin at ed solvents .
Abr a s i ve B l a s t
The abrasive blast process consists of directing a high velocity stream of an
abra sive ma terial against th e surface of th e item. It should be used on sur faces
wher e th e abra sive action will not affect th e fun ction of th e item su ch as rough
castings. The choice of abra sive mat erials is so large th at almost an y type ofsurface finish ma y be obtained. These mater ials include harden ed cast steel
shot, san d, garn et abrasives, an d glass beads. The equipmen t used in this
process ran ges from sma ll blast cleaning cabinets to large blasting rooms a nd
open a ir blasting operations.
In general, th e following steps are performed:
Protect yourself with appr oved pr otective equipment.
Mask off any portions of work t ha t mu st n ot be blasted.
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Adjust pressu res of compressed a ir t o the t ype of sur face being clean ed,
60 to 100 psi for hard materials or 30 to 50 psi for the softer materials.
Direct the stream of abrasive at a 90 angle to the work surface and
move nozzle only as fast as t he su rface is clean ed.
If surfaces are dusty and have metal chips clinging to them after
blastin g, blow off with compressed a ir or rinse in a n inh ibited cleanin g
solution.
If iron du st a nd meta llic part icles cont inue t o adhere t o metal sur faces
after rinsing, demagn etize items pr ior to furth er cleaning.
Al ka l i ne C l ean i n g
The alka line cleanin g pr ocess, as pictu red in figur e 2-22, consist s of soaking the
items in a lkaline cleaner solution a nd r insing in clean h ot water a bove 180F.
Items cleaned by this pr ocess ar e of a simple constr uction ha ving noncritical
sur faces. Alka line clean ing will rem ove shop dirt , soil, oily and wa ter -soluble
contaminants, and heavy waxes.
El ec t r oc l ean i ng
This process consists of immer sing the item in a solution an d ma king th e iteman elemen t of an electrochemical cell. It mu st be rinsed in clean h ot water above
180F. Figure 2-23 illustra tes th e removal of rust by electrocleaning.
E m u l si o n C l e a n i n g
Figur e 2-24 shows th e emulsion clean ing process. This process consist s of
subjecting the item to a pressure spray or soaking in a tank of grease
emulsifying, solvent-soluble cleaning compound to remove solvent-soluble
grea se, oil, dirt , etc. from var ious su rfaces.
Figure 2-22. Alkaline cleaning.
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Figur e 2-23. Electr oclean ing.
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Figure 2-24. Emulsion cleaning.
S t e a m C l e a n i n g
The stea m cleaning process consists of subjecting t he item t o a strea m of stea m
with a n a dded cleaning compoun d followed by steam alone. Figure 2-25 depicts
a typical use of steam cleaning to remove heavy greases from automotive
equipment, such as trucks.
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Figure 2-25. Steam clean ing.
Abr as i ve B la s t ( Hon i ng P r oces s )The honing abr asive blast process consists of subjecting th e items to a st ream
of atomized water containing a fine particle size abrasive and a corrosion
inhibitor. It will rem ove light coats of ru st or scale. Equ ipmen t similar to th at
shown in figur e 2-26 is used for abr asive blastin g. Steps involved in clean ing by
th is process are as follows:
Place item into th e cleaning cham ber an d close door.
Thru st arms th rough rubber sleeve openings. Make sure tha t sleeves
fit tightly around t he wrist.
Hold item in one hand, while directing the blasting stream with the
other.
Continu e the a brasive blasting u ntil all contamina tion is removed. Remove cleaned item from cabinet and dip it in a tank of corrosion
inhibited rinse water.
Dry th e item as soon as possible after rinsing.
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Figur e 2-26. Abrasive blast cleanin g honin g process.
Sof t Gr i t Blas t
The soft grit blast process consists of subjecting the item to a high velocitystrea m of water containing a soft a brasive mater ial.
Ul t r a s on i c C l ean i ng
Ultrasonic cleaning should be used on nonabsorbent materials such as those
foun d in electronic devices. This pr ocess consist s of susp endin g the item to be
cleaned in a cleaning agent , th en directing th e force of high frequency sound
waves through th e agent against t he surfaces to be cleaned. The soun d waves
set up an agitation action along th e surface, so in r eality the bubbles scrub t he
contaminant off the surface by means of an implosion as shown in figure 2-27.
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Figure 2-27. Ultrasonic cleaning.
DRYING P R O C E D U R E S
Immediately after cleaning the item, it must be thoroughly dried to rem ove an y
cleanin g solutions or rem ainin g m oisture. Figur e 2-28 illust ra tes the approved
drying pr ocedures.
Dr y i ng W it h Com pr es s ed Air
The air for drying must be free from oil, dirt , and moistu re. Dry all surfaces of
the item by applying th e clean air u ntil all solvent s disappear.
Dr y i ng W it h Oven sThis is done by placing th e item into a hea ted a ir oven. The oven sh ould be well
ventilated and temperature controlled.
D r y i n g Wi t h I n f r a r e d L a m p s
This is done by placing the item between rows of infrar ed lamps. This is a
commonly used procedure for drying.
Dr y i ng b y Wi p i ng
This is done by wiping the item with clean , lint -free cloth s. It is difficult t o wipe
areas th at have blind holes and u ndercuts.
D r y i n g b y D r a i n i n g
This drying process is used only when the final step in cleaning involves a
petroleum solvent, and the item is to be preserved with a material using a
petroleum solvent a s a thinn ing agent.
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Figure 2-28. Drying procedures.
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C h e c k u p
What is th e first operation in th e preservat ion of meta l items?
What type of contam inant is removed by solvent cleaning?
Name the t hree sa fety featur e requirements of a solvent cleaning tank .
When can drying by draining be used to dry an item?
What are the requirements when drying with compressed air? What clean ing process mu st be used on items h aving a critical sur face?
How long mu st an item be in a fingerprint r emoval compound?
What must be done to an item after removing it from fingerprint
rem over compound (MIL-C-15074)?
C LEANING AND DRYING P RACTICAL E XERCISE
Objec t ive
The stu dent will answer questions on the p roper selection an d application of th e
various cleaning processes an d dr ying pr ocedures.
G e n e r a l D i r e c t io n s The exercise will requir e appr oximat ely one class per iod, includ ing th e
critique for complet ion.
The instructor will hold the critique when the students have completed
the practical exercise.
Cond uc t o f Exe r c i s e
S i t u a t i o n
You ha ve received classr oom inst ru ction on t he selection of clean ing pr ocesses
an d drying procedur es. Your job is to produce properly cleaned an d dr ied items.
R e q u i r e m e n t N o . 1. Answer the following questions on cleaning:
1. What cleaning materials may be used for solvent cleaning?
2. Why is it necessary to wear protective clothing during cleaning operations?
3. What contaminants are removed using solvent cleaning?
4. Are fingerprints removed by solvent cleaning?
5. What is the cleaning requirement for an item with a crit ical surface?
6. What cleaning process uses sound waves to create a cleaning action?
7. After a n item is cleaned in t he chemical process alkaline cleaning, what
must be done before we dr y or pr eserve the item?
8. What processes may be used to remove insoluble tightly adhering
contaminants?
9. What process is used to remove heavy greases from automotive equipment
such a s tru cks?
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10. If a cleaning compound is used in t he steam cleaning process, what mu st be
done immediately after th e cleaning compoun d is tu rn ed off?
11. What ar e the four general types of contam inants?
12. What m ust be considered in th e selection of a cleaning process?
13. What ar e the basic cleaning requirements?
14. What a re th e recommended safety features r equired on a solvent cleaning
tank?
R e q u i r e m e n t N u m b e r 2 . Answer the following questions on drying:
1. Why must an item be dried following cleaning?
2. Which pr ocess will be used if an item is cleaned by a solvent cleaning process
and is to be preserved with a mat erial using a petroleum solvent a s a th inning
agent?
3. Which drying procedures use heat?
4. What is meant by "Prepared" compressed air?
C r i t i q u e
Instr uctor will call on class members t o give the an swers to th e questions.
C a r e o f Ar e a , T r a i n i n g A id s a n d E q u i p m e n t
Not applicable.
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ELE CTROSTATIC DISCHARGE CONTROL
E LECTROSTATIC D ISCHARGE
We have been aware for quite some time that static electricity can impose
dam age on m etal oxide semiconductors (MOS). More r ecent ly, we have become
aware of the sensitivity of other parts to electrostatic discharge (ESD) through
use, tes ting, an d failure an alysis. Sources of ESD p olicy include MIL-W-87893and MIL-HDBK-773.
Trends in t echn ology are t oward greater complexity an d const ruction. Design
features of current microtechnology have resulted in parts which can be
destroyed or damaged by ESD voltages as low as 20 volts.
Various electrical and electronic parts which have been determined to be
sensitive to electrosta tic voltage levels commonly generat ed by pr oduction, t est,
opera tion an d maint enan ce personnel include:
Microelectr onic and semiconductor d evices.
Thick a nd t hin film r esistors.
Chips an d h ybrid devices.
Piezoelectric crysta ls.
All subassemblies, assemblies, and equipment conta ining these p art s n ot
ha ving a dequat e protection circuitry ar e also ESD sensitive (ESDS).
Materials which are prime generators of electrostatic voltage are common
plastics such as polyethylene, vinyls, foam, polyurethane, synthetic textiles,
fiberglass, glass, an d r ubber.
Actions which cau se th ese and other m ater ials to genera te electrostat ic voltages
are th e sliding, rubbing, or separ ation of mat erials. These movement s can
frequen tly resu lt in electrosta tic voltages of 15,000 volts.
Materials can be ra nked in a ccorda nce with their ability t o become positively
cha rged with respect to other mater ials. This ra nking is known as a
tr iboelectr ic series. Mate rial upperm ost in th e series becomes positively char ged
when ru bbed with a m ater ial lower in the series. The mat erials lower in the
series become negat ively charged. Conditions such as cleanliness, variat ion in
chemical composition an d pr ocesses, hu midity, and th e mechan ics of rubbing or
separa tion affect th e series to a great extent. Thus t he ra nking of elements or
compoun ds in th e series will not always be reproducible. One of th e man y
versions of th e ser ies follows.
Positive (+)
Air
Human hands.
Asbestos
Rabbit fur
Glass
MICA
Human hair
Nylon
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Wool
Fur
Lead
Silk
Aluminum
Paper Cotton
Steel
Wood
Amber
Sealing wax
Hard ru bber
Nickel, copper
Brass, copper
Gold, platinu m
Sulfur
Acetate rayon
Polyester
Celluloid
Orlon
Polyurethane
Polypropylene
PVC (vinyl)
KEL F
Negat ive (-)
Silicon Teflon
Protection of electrical and electronic ESDS parts assemblies and equipment can
be provided th rough t he implemen ta tion of low cost ESD contr ols. Lack of
control has resulted in high repair cost, excessive equipment downtime, and
reduced mission effectiveness because susceptible parts are being damaged
dur ing processing, assem bly, inspection, h an dling, packaging, shipping, storage,
stowage, testing, installation, and maintenance throughout the equipment's life
cycle, both at th e man ufacturer's a nd t he u ser's facility.
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The effects of ESD on electrical and electr onic items a re n ot gener ally recognized
becau se they ar e often masked by rea sons such as:
Failures due to ESD are often analyzed as being caused by electrical
overstress due to transients other th an static.
Failure caused by ESD is often incorrectly categorized as random,
unknown, manufacturing defect, or other, due to improper depth offailure an alysis.
Few failur e an alysis laborat ories ar e equipped with scan ning electron
microscopes or other equipment and technology required to trace
failures t o ESD.
Some programs a nd projects a re a ccepting high operat ional failure r ules
as n ormal an d simply procur e more spar es instead of recognizing a nd
solving the basic ESD problem.
Belief of personnel that static controls are necessary, for only MOS at
the part manufacturer's site and for handling of ordnance, is
widespread.
Also common is the belief that an ESDS part "protected" by a diode,
resistive network or other protective part is non-ESDS.
Static discharge failures do not always occur immediately following
exposur e but ma y result in latent defects.
In order t o protect ESDS devices while handling an d packaging, it is importan t
to provide a condu ctive path to groun d in the environm ent . Such a pat h should
provide for ra pid dissipat ion of th e sta tic electr ical cha rge. Figur e 2-29
illust ra tes a typical sta tic protective work sta tion which uses a condu ctive table
and floor mats a s well as a wrist str ap to groun d th e operat or.
Because the human body is a conductor, it may be effectively grounded.
Cloth ing, however, will genera te an d ret ain electrostatic cha rges, somet imes as
high as 30 th ousan d volts. These sta tic char ges will not bleed off whengrounded.
People ha ndling ESDS items sh ould wear long sleeved ESD pr otective smocks
or close-fitt ing, short sleeved shirt s or blouses .
If long sleeve clothes are worn, the sleeves must be rolled up or else covered
with a n a ntistat ic sleeve protector, called a gaun tlet, from th e bare wrist as far
up as th e elbow. When gaun tlets are worn, the clothing does not have to be
made of ESD pr otective mater ial.
Antistat ic garm ent s can be made by trea ting cott on or synt hetic cloth es with an
an tistatic chemical agent in final rinse during launder ing. Each time th e clothes
are washed, the antistatic agent must be reapplied.
The pr oper cont rol of sta tic electricity is often overlooked in t he field. Dur ing
in-field replacement of sensitive component s or print ed circuit boards, t he n ew
component or boar d ma y be destroyed or degra ded by an un grounded service
techn ician . An ESD pr otective field service kit is designed to help solve thes e
problems for the field service technician and for field packaging operations as
well.
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Figur e 2-29. P rotective Work Sta tion.
The ESD protective field service kit includes a grounded work surface mat
(typically 2' x 2') an d a conductive wrist str ap.
Some field work surface protective mats contain pockets which are sewn into the
mat and can be used to store ESDS components or boards wh ile tra nsporting to
and from the field. For larger boar ds, the mat is folded around th e boar d to
provide pr otection (the E SDS item may require additional protection).
The ground lead cont ains a cur rent limiting series resistor t o protect th e worker
from being shocked in case of accident al cont act with line volta ge.
For proper operat ion, th e wrist stra p cable is conn ected to the m at at t he sam e
term inal where the ground lead is also conn ected. Then th e ground lead is
connected to a bare meta l part of the m ain fram e of the system conta ining thepar t being worked on.
Packaging for protection for ESDS items requires the use of appropriate
mat erials. Protection sha ll be provided to prevent ph ysical dam age and to
maintain leads and terminals in an as-when-manufactured condition during
handling and tr ansportation.
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An acceptable means of packaging ESDS items would be to first place them in
an an tistat ic or stat ic dissipative environm ent by wrapping an d/or cushioning
them in one or more of the following materials:
MIL-PRF-81705, type II barrier material, transparent, waterproof,
electrostatic protective.
PP P-C-795, class 2 an tistat ic (pink tint ed) cush ioning mat erial, flexible,cellular , plast ic film.
PPP-C-1842, type III, type A or B cushioning material, plastic open cell.
PPP-C-1797, type II cushioning material, resilient, low density,
unicellular, polyproplene foam.
After being protected by a nt istatic or st at ic dissipat ive ma terials, th ey
ma y then be shielded in a ba g or pouch conforming to MIL-PRF -81705,
type I bar rier m ater ial water vaporproof, greaseproof electrostat ic and
electr omagn etic protective (opaque).
Marking of ESDS items will be per MIL-STD-129, which requires that unit
packs, interm ediate and exterior conta iners be marked with th e ESDS device
cau tion label, which is a trian gle and r eaching hand . All unit packs shall bemarked with the ESD label prescribed by ASTM D 5445, Standard Practice for
Pictorial Markin gs for Han dling of Goods. The symbol an d letter ing sha ll be
mar ked in black on a yellow backgroun d. The label sha ll include the E SD
sensitive device symbol and the words ATTENTION STATIC SENSITIVE
DEVICES and the statement HANDLE ONLY AT STATIC SAFE WORK
STATIONS. Unit packs that a re not overpacked and are used as exterior
containers sh all be mar ked with th e unit pa ck label.
Intermediate and exterior containers shall also be marked with the ESD
sensitive devices symbol and the words ATTENTION OBSERVE
PRECAUTIONS FOR HANDLING ELECTROSTATIC DISCHARGE
SEN SITIVE DEVICES. One 2 by 2-inch label sha ll be placed on th e
ident ificat ion-ma rked side of th e int erm ediat e conta iner . Two 4 by 4-inch labels
sha ll be placed on ea ch exterior cont ainer th at exceeds one-half cubic foot. One
label shall be placed on t he identification-marked side, and one label shall be
placed on the opposite side. Sma ller exterior conta iners sha ll be mark ed in the
sam e man ner except th at t he 2 by 2-inch label ma y be used in lieu of th e larger
label. The min imum size of the symbol shall be five-eights of an inch mea sur ed
vertically at th e base of th e trian gle.
C h e c k u p
What actions cau se ma terials to genera te electrostat ic voltages?
Are certain m aterials when placed together more apt to genera te stat ic
electricity th an others?
How can electronic items be pr otected from stat ic electr icity?
What documen t covers th e basic ma rkings r equired for E SD sensitive
items?
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PRESERVATIVES
GENERAL
Conta ct preservatives are ma terials th at a re applied to, or come in cont act with,
items to protect them from deterioration resulting from exposure to
environm enta l conditions during shipmen t an d storage.
Some preservatives protect items by providing a physical barrier against
moistur e, air, and other agents of corr osion. These are conta ct preservatives.
Preservatives should be applied whenever items require protection against
deteriorat ion. Some met als such as gold, platinu m or beryllium ar e immun e to
corrosion under ordinary conditions and seldom require the application of a
preservative.
Many items susceptible to corr osion can be m ade less su bject to deterioration by
the application, at the time of manufacture and subsequent operations, of a
protective coating or plating which rema ins an integral part of the item during
its useful life. Such coatings and platings ar e called perman ent pr eservatives.
Many items, however, because of close tolerances, operating characteristics such
as rolling, sliding, or bearing surfaces, or other limiting factors cannot be
protected with a perm an ent coat ing, but mu st be protected durin g shipment an d
storage by temporar y preservatives. These preservative mat erials are applied
after th e item has been ma nu factu red an d must be removed before the item can
be used.
AP P LICATION R EQUIREMENTS
Most contact preservatives are oily or greasy in nature, and vary greatly in
chemical composition and consistency; therefore, they cannot be used
indiscriminat ely on all kinds of mat erials. They may even destroy the
usefuln ess of an item d ue t o the difficulty of rem oval.
A preservative may penetrate into unwanted areas and cause swelling or
decomposition of th e ma ter ial, or r educe its electrical condu ctivity.
Petr oleum p reserva tives are a pplied to th ose meta l surfaces on wh ich corr osion
in an y form would impair th e usefulness of the item or a ssembly.
E XCEPTIONS TO AP P LICATION R EQUIREMENTS
Petr oleum preservat ives ar e not ap plied to surfaces which a re pr otected by solid
film lubricant s, plastic or paint coatings. They are not norma lly used on
noncritical metal surfaces that are inherently resistant to corrosion such as
items made from copper, nickel, chromium, brass, bronze, or other corrosion
resistant metals.
Oily type preservatives are not app lied to items tha t ar e vulnerable to damage
by the pet roleum ingredients su ch as textiles, corda ge, plastics, mica, r ubber,
paper, felt, leather or prelubricated bu shings.
Preservatives are not applied to certain types of electrical and electronic
componen ts or equipm ent such a s conden sers, electr ical conn ectors, distr ibutor
rotors, circuit breakers, fuses, switches, resistors and rectifiers.
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Preser vatives are not applied to any items which would suffer da mage to th e
mechan ism or str uctur e, or wher e malfunction or un safe opera tional conditions
would r esult from th e application or r emoval of th e preservat ive.
N e e d fo r T e m p o r a r y P r e s e r v a t i v e s
A great number of military supplies are made of such materials or are so
complex that it is either impossible or impractical to apply a permanentpreservat ive to them. Working par ts of ma chiner y, for example, ar e often
precision fit an d mu st be free from a ny type of coating when in use.
Some bare met al items mu st be given a coating wh ich will protect t hem from t he
time they are made un til th ey are used. This coating must be readily applied
and ea sily removed. Petr oleum t ype preservatives ar e used for this purpose.
Other metal items must be protected by volatile corrosion inhibitors (VCI) or
desiccated packs.
Formerly, lubricating oils and greases were used. This was better t ha n no
preservat ive, but these oils and greases pr oved inadequa te for the full protection
desired.
To achieve full protection, ther e ar e two kinds of additives used in pr eservatives
to help preven t corrosion. They are kn own as inh ibitors an d polar compoun ds.
An inhibitor is a su bstan ce that slows down or prevents ru sting by chemical
action. A polar compound is a su bstan ce th at gives water displacing properties.
Various t ypes of preservative oils and greases conta ining inhibitors and polar
compoun ds a re referred t o in m ilitar y pr eservation specifications.
SELECTING THE P RESERVATIVE
It should be realized that there is no one preservative suitable for all purposes.
Selecting th e right pr eservative must be as carefully considered a s selecting a
proper cleaning pr ocess. In m ost instan ces, selection of the preservat ive ha s
been prescribed in procurement documents, process data sheets, special
packaging instr uctions, or similar form s.
Care must be taken that the preservative selected will not damage the
mechanism, str uctur e, or function of the item, either when applied, in use, or
dur ing removal. In ma king a selection, the following considera tions should be
used.
I t em Com p os i t ion
As shown in figure 2-30, the composition of an item determines whether it needs
to be preserved and, if so, what kind of preservat ive will be used. Genera lly,
meta l items are pr eserved with an y of the petroleum type compounds.
S u r f a c e F i n i s h
If the item is forged, stam ped, rough cast, rough ground, or rough m achined,
and has nonprecision surface, it may be protected by almost any of the
petroleum type preservat ives. On the other h an d, items with pr ecision surfaces
should be protected with an oil or light grease type preservat ive. Figure 2-31
illustra tes var ious sur face finishes.
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Figur e 2-30. Composition of th e item .
Figur e 2-31. Sur face finish of th e item .
Com pl ex i t y o f Cons t r uc t i onItems should be cleaned, dried, and preserved in as simple a unit state as
possible. Disassem bled item s with close toleran ces should n ot be coat ed with
heavy greases or ha rd dr ying types of preservatives which m ay inter fere with
or prevent reassem bly. If disassembly is not pr actical or the item is highly
irregu lar with blind holes and crevices, heavy pr eservat ives may be difficult to
app ly an d impossible to rem ove. Complexity of const ru ctions is depicted in
figur e 2-32.
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E x t e n t o f P r o t e c t i on R e q u i r e d
When an item is made from two different materials, for example, metal and
plastic, only th e meta l part of th e item would be coated with a pr eservat ive. In
the case of the m allet, as sh own in figure 2-33, no petroleum preservat ive would
be required.
Eas e o f, or Need fo r , Rem ova lThe user of th e item mu st be kept in mind when choosing the preservat ive. The
time required for removal, the equipment available, and the necessity for
removal are of importan ce to th e user. Figure 2-34 illustra tes this
consideration.
Figur e 2-32. Complexity of const ru ction.
Figure 2-33. Extent of protection r equired.
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Figur e 2-34. Ea se of, or nee d for, removal.
O t h e r F u n c t io n s o f t h e P r e s e r v a t i v e
In some instances, the nature of the item or assembly requires that the
pres erva tive also act as a lubricatin g oil or hydra ulic fluid. Figur e 2-35 shows
items that h ave this requirement . In such cases, the lubricating requirement s
must be met first and the pr eservative properties secondarily.
C ONTACT P RESERVATIVES
There a re several different temporar y contact preserva tives. We will describe
only the m ore frequent ly used.
MIL-P RF -16173, Gra de 1 , Har d Fi lm, Cor r os ion Pr even t ive Compou nd , Solvent Cutb ack ,
Co ld App l i ca t i on (f or m er l y P - 1)
Des cr i p t i on a n d Ch a r a ct er i st i cs
This is an a spha lt compound dissolved in petroleum solvent. It dries to a ha rd,
thin, opaque film on the item when th e solvent evaporat es. Flashp oint of the
solvent is 100F. It is suitable for protection of noncritical meta l items t ha t ar e
stored outd oors or where a "dry-to-touch" film is desired. In m ost cases,
overwra pping of an item coat ed with t his compound is n ot necessary, due to th e
har dness of the film.
I n t en d ed Uses
For preservation of items a nd equipment when r emoval prior t o using the itemis not required. Exam ples of items preserved are simple han d tools, nu ts,
washer s, cha ins, etc.
Met h od s of A p p l ica t ion
This preservative can be applied by brush, dip, or spr ay. For effective spray
application, th e preservat ive mat erial requires dilut ion with dry cleaning
solvent to a greater degree tha n for dipping or bru shing.
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Figure 2-35. Other fun ctions of the pr eservative.
M I L-PR F-16173 , Gr a de 2 , So ft F i lm , Cor r os i on P r even t i ve Com pou nd , Sol ven t Cu t ba ck ,
Cold App l ica t ion ( form er ly P -2)
Des cr i p t i on a n d ch a r a ct er i s t i cs
This is a solvent-dispersed, corrosion-preventive compound, which deposits a
th in, soft film on th e item. Fla shpoint of solvent is 100F. Items preserved with
this requ ire a pr eliminar y greaseproof wrap or ar e enclosed in a gr easeproof bag
when a submeth od requires a bag as th e preliminary conta iner, becau se it is a
soft pr eservative an d will be absorbed by the packing mat erials.
I n t en d ed UsesIt is used t o protect int erior a nd exterior meta l surfaces destined for extended
undercover storage. Examples of items preserved are pipe and tube fittings,
pistons, piston rings, bearings and instruments, and exterior surfaces of
ma chiner y. It is used out doors for limited periods only.
Met h od s of A p p l ica t ion
It is usu ally applied by brush , dip, or spr ay.
M I L-PR F-16173 , Gr a de 3 , Wa t e r Di s p lac i ng , Cor r os i on P r even t i ve Com p oun d , So lven t
Cu t b ack , Co l d App l i ca t i on ( fo r m er l y P -3 )
Des cr i p t i on a n d Ch a r a ct er i st i cs
This is a solvent-dispersed, water-displacing corrosion-preventive compound,
which deposits a thin, nondrying film on the item upon evaporation of the
solvent . F lashp oint 100F. Due to its chemical composition, th is ma ter ial has
a great er att raction to metal surfaces th an wa ter an d actually displaces water
from m etal su rfaces.
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TC 38-3/MCO P4030.23E/NAVSUP PUB 442/AFPAM(I) 24-205/DLAI 4145.1
2-47
I n t e n d e d U se s
This water -displacing preser vative is inten ded for u se where fresh or salt wa ter
must be displaced from corrodible surfaces and for the protection of interior
sur faces of ma chinery and equipmen t un der cover. Exam ples of items on which
it is u sed ar e ra diators, boilers, and cooling systems.
Met h od s of A p p l ica t ionThis preservative is generally applied by bru shing, dipping, or spr aying when
used to preserve exterior sur faces. When u sed on inter ior or enclosed sur faces,
it ma y be app lied by filling or flushin g.
M I L-PR F-16173 , Gr a de 4 , T r a ns p a r en t F i l m , Cor r os i on P r even t i ve Com poun d , Sol ven t
Cu tba ck , Cold App l ica t ion ( form er ly P -19)
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