Ameren UE's Callaway Nuclear Plant, Fulton, MO

Laboratory Cabinets - Fume Hood

Painted with Epoxy
Completed: 04/26/02

Painted inside and out with sliding doors a contrasting color

 Original Color: Light Gray Frames with Blue Drawers and Doors 
 New Colors: Sliding Doors - Steel Blue   Balance - Morning Fog

Every once in a while, you get one of those requests that you just can't turn down! 
So it was when we received an email from Bob Kelley at AmerenUE's Callaway Nuclear Plant 
inquiring about electrostatic painting of laboratory cabinets. 

Hmmm... a nuclear facility.  No, we'd never worked in a nuclear facility.  Yes, we felt we could meet the safety, environmental, and security requirements.  Yes, we felt we could paint lab cabinets at a reasonable price 
even with extensive travel expenses.  Yes, we would travel as far as Missouri.

Normally, we bid this type of work only after a site visit and a face-to-face question and answer session. 
 Because of the distance involved in this particular case; we had to handle these functions via email
and telephone beginning with a series of digital photos.
 

  Immediately below are the digital photos that were emailed to us for our initial review.
Approximate dimensions were provided to supplement the photos.

Yes, we were interested.  Using only the digital photos, Mr. Kelley's measurements, and our 
previous experience painting similar cabinets; we prepared and submitted our bid.

Tentative approval led to further questions such as:

• Can the company provide proof of insurance and worker's compensation coverage?
  Answer:  Yes, the company carries $2 million worth of commercial liability and is fully covered under
  Ohio Workman's Compensation coverage.
  
  

• Could the work be done without totally shutting down the lab? 
  Answer: Yes, if employees were willing to work around us and didn't mind some paint odor.
  
  

• What precautions would need to be taken to protect sensitive and expensive lab instruments?
  Answer: Disconnect and remove whenever possible.  Insulate non-moveable instruments from any ground
  by placing rubber or plastic pads underneath.
  
  

• Could we meet the necessary environmental, safety, and security requirements?
  Answer: Yes.  MSDS information was provided for all chemicals taken into the plant.  Ameren provided
  their plant safety manual in advance of our work.  Abbreviated security checks were performed on all
  incoming personnel.
  
  

• What safety equipment do you provide?
  Answer: Personal safety shoes and respirators.  Safety glasses and ear plugs provided by Ameren.
  
  

• What actual processes are utilized during the project?
  Answer: Disassembly of components to be painted a contrasting color.  Removal of labels and stickers
  with razor blades and scrapers.  Masking all non-paintable surfaces with masking tape and/or Kraft paper.  Scuffing surfaces with medium grit abrasives.  Cleaning surfaces with a water based cleaner/degreaser. 
  Priming of bare metal prior to painting.  Electrostatic painting of surfaces with a two-part catalyzed epoxy.
  
  

• What chemicals or compounds will be used?
  Answer:  A water-based cleaner/degreaser; a solvent-based primer; and a solvent based epoxy paint and catalyst.
  
  

• How long would it take?
  Answer: Four to five working days.

The project was approved!

MSDS information was submitted on every chemical we would conceivably use.  The information was reviewed
by Ameren's Industrial Hygiene Department; and appropriate exposure limits for the various compounds contained therein were determined and made available to all personnel via Ameren's computer system (sampling of the
levels of volatile compounds was completed by Ameren at various stages throughout the painting process).

  With the approval process complete, we made arrangements to be at the Callaway Plant at 9:00am
Monday April 21st, 2002.  Badging, background checks, and inspection of incoming tools, equipment,
and materials consumed most of the morning.  Actual work began shortly after lunch.  We began by painting
the shelves and doors Steel Blue (all of which had to be removed, transported to a separate area, painted,
returned, and eventually reinstalled).  We then painted the upper and lower cabinets and the fume hood in 
Morning Fog (a light silvery gray).  Although the lower cabinets had been two tone (gray frames with blue
drawers or doors); we decided to go with a single color to avoid having to empty the drawers, to lower
project costs, and to shorten total project time.  As an added benefit. it lightened up the entire facility and gave 
it a modern, professional look.  The entire project was finished late Friday of the same week - a total of 5 days. 

 The pictures below show the finished results.

Thanks to all the wonderful people at Ameren who worked with us throughout the week.  Without the digital
photos, the excellent communication, help with food and lodging, and so much more; this could have been
a very difficult project.  A great facility and great people to work with.