As suppliers to the motor and generator industry, Astro recognizes the growing imperative to reduce health risks associated with Carcinogenic, Mutagenic, and Reproductive (CMR) substances found in paints, resins, and adhesives. Regulatory pressure, workforce health concerns, and operational efficiency demands call for a transition to safer, compliant materials. Astro is tackling this issue by proactively formulating and re-formulating resin systems and coatings to be non-CMR, and healthier for operator use.

1. Introduction

Motor and generator refurbishment often requires chemical products that, under traditional formulations, contain CMR-classified substances. These include benzene-based solvents, crystalline silica, and phenol-containing adhesives. While safety controls such as PPE and ventilation reduce acute exposure, the only effective long-term mitigation is product reformulation. Additional benefits to reformulating with less hazardous inputs include less stringent transportation requirements, which provide concrete and direct cost savings to manufacturers, MROs and operators.

As suppliers, we have proactively developed safer alternatives to align with industry needs, regulatory frameworks, and user expectations. This case study presents our approach and offers recommendations for OEMs and utilities to accelerate CMR elimination in the field.

2. The CMR Challenge for the Power Generation Industry

Recent regulatory frameworks have put a spotlight on the need for healthier materials for workers across industries. For instance, Directive 2004/37/EC (EU) mandates reduction or substitution of CMR substances wherever technically feasible. Compliance is not optional—it is essential.

CMRs in resin systems and coatings, and indeed in any chemicals, are linked to an array of health hazards:

• Carcinogens (e.g., benzene, carbon black): Associated with cancers and respiratory illness
• Mutagens (e.g., phenol): Can cause genetic mutations and long-term health effects
• Reproductive Toxins (e.g., toluene, benzene): Affect fertility and fetal development

The use of these materials, especially in the power generation refurbishment space, faces a number of operational constraints that potentially amplify those issues. Underground powerhouses have limited ventilation options, PPE compliance can be haphazard, and other nearby personnel may be exposed without having protective barriers implemented. Further, the use of more hazardous material often requires longer work stoppages for a more thorough isolation process of the work site.

Hazardous materials also come at a literal expense when their transportation to a work site is concerned; regulations around the world restrict the means by which such shipments can be hauled, and increase the size and weight of the freight packaging, as agents such as Vermiculite must be used to secure contents. Further, logistics companies charge a higher sum for the freight of these hazardous materials, and larger quantities of hazardous material may require air shipping rather than ground transportation, severely increasing freight costs.

Astro estimates that a U.S. domestic shipment of 5 gallons of non-hazardous protective paint, such as Astro 4803, can cost as much as $700 less than the same shipment of a hazardous coating, in cases the latter can only be shipped by air.