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Table of Contents

1. Introduction

1. Introduction................................................................................................................................. 3 1.2 Expert Tasks ............................................................................................................................... 3

2 General Information and Hazard Potential of PCB

2.1 POP and PCB.............................................................................................................................. 4 2.2 Dioxins and Furans ..................................................................................................................... 5

3. Site Visits in Kragujevac

3.1 Introduction................................................................................................................................. 6 3.2 Power Plant ................................................................................................................................. 6 3.3 Paint Hall - Concrete Floor ......................................................................................................... 7 3.4 Paint Hall - Water Pits ................................................................................................................ 8 3.5 Storage Areas .............................................................................................................................. 8

4. Site Survey

4.1 Sampling ................................................................................................................................... 10 4.2 Methods of Analysis ................................................................................................................. 12 4.3 Analysis Results........................................................................................................................ 14

5. Conclusion and Recommendation

5.1 Power Plant ............................................................................................................................... 17 5.2 Paint Hall - Concrete Floor ....................................................................................................... 17 5.3 Paint Hall - Water Pits .............................................................................................................. 19 5.4 Storage Area.............................................................................................................................. 20

6. PCB Removal Project KR.1 Kragujevac

6.1 Introduction............................................................................................................................... 22 6.2 Proceedings ............................................................................................................................... 22 6.3 Protective Painting or Epoxy ................................................................................................... 23 6.4 Scope of Work .......................................................................................................................... 25 6.5 Safety Precautions..................................................................................................................... 27

7. General Recommendation

7.1 Part: Interim Storage, Packaging and Transport ....................................................................... 31 7.2 Part: Disposal............................................................................................................................ 33 7.3 Part: PCB-Inventory.................................................................................................................. 34

8. Annexes

8.1 Complete Analysis Reports 8.2 Epoxy Data Sheets 8.3 Details UN-Approved Steel Drums 8.4 List of Contributors

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1 Introduction Based on the UNEP Balkan Task Force Feasibility Study of April 2000, there were 27 clean-up projects identified to address the post-conflict environmental and humanitarian problems. This was followed by an implementation phase in order to proceed with the most urgent priority projects. The main criteria for appointing such projects are the urgency of impact mitigation, protection of the population from toxic contamination and hazardous waste, relevance over a longer term, environmental benefit and the potential of local capacities.

There are several projects in progress in Novi Sad, Pancevo, Bor and Kragujevac. This «Mission report» is focusing on the «Zastava Car Factory» in Kragujevac only. The main objectives are the KR.1 and KR.2 projects: «Removal of PCB-contaminated floor» and «Cleaning of the water pits and decontamination of the water». An international expert was appointed to examine the foreseen proceedings, visit the sites and perform a limited site survey including sampling and analysis. Corresponding results and recommendations are listed in this report. The general information about the handling and storage of hazardous goods and waste can not only be used for the Kragujevac case, but also for similar future projects. 1.2 Expert Tasks The main tasks of the international expert were: • Site survey in the paint hall of the «Zastava Car Factory» in Kragujevac including sampling

and analysis for the KR.1 and KR.2 projects, accompanied by the Public Health Institute Belgrade

• Comparison of analysis of international laboratory (see annexes) and the Laboratory of the Public Health Institute

• Adaptation and inputs for the proceedings with the KR.1 project • General recommendation and inputs for:

− Safety precautions during clean-up projects − Handling and packing of the arising hazardous waste from the clean-up projects − Temporary storage of hazardous waste and damaged transformers arising from the

conflict as well as from the production − Inventory of PCB-equipment in use − Transport and disposal of hazardous waste

Furthermore, the international expert presented an overall view about Hazardous Waste Management in practice as well as a case study of a PCB clean-up project, at the occasion of the Workshop at the City Public Health Institute in Belgrade on November 29, 2000.

This mission report shall enable the responsible people to proceed with the preparation of the tender documents, to finalise the tendering/bidding process and to award the contract for the KR.1 project. Furthermore, it shall give them the opportunity to supervise the projects from the safety point of view. It shall further be the basis for the implementation of a safe (interim) hazardous waste storage in order to keep all options open for a future disposal of those hazardous waste related to the conflict as well as in order to avoid any further cross-contamination by an improper waste storage. Finally, this report shall also provide background information on the Polychlorinated Biphenyls, Dioxins and Furans.

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2. General Information and Hazard Potential of PCB 2.1 POP and PCB Persistent Organic Pollutants (POPs) have been identified by the international community for immediate international action. The initial twelve POPs are Aldrin, Chlordane, DDT, Dieldrin, Endrin, Heptachlor, Hexachlorobenzene, Mirex, Toxaphene, Polychlorinated Biphenyl, Dioxins and Furans.

PCB (Polychlorinated Biphenyl) is one of the leading member in the group of POPs. PCB has serious health and environmental effects, which may include carcinogenicity, reproductive impairment, immune system changes and also the loss of biological diversity. PCB is an extremely stable and perfect isolator and therefore it was common to use PCB as cooling fluid in electrical equipment such as transformers and capacitors. These «closed systems» were mainly used in sensitive areas like airports, hospitals and public buildings. But PCB was also used in «open systems» such as plasticizers, rubbers, paints, sealants, etc. Those materials are not usually defined as PCB-containing and therefore find their way into the environment. Presently, the problem of «open systems» is given high priority in many European countries.

Table 1: Applications of PCB

Closed Systems Transformers 40 - 60 % CL Capacitors 20 - 42 % Circulating Systems Hydraulic oil 30 - 60 % CL Heating exchange oil 40 % Lubrication fluids 20 - 55 % Open Systems Plasticizers in rubber/plastic 20 - 70 % CL Synthetic resins 50 - 70 % Copying paper 40 % Adhesives 20 - 55 % Dust binders 55 - 60 % Paints 55 % Printing inks 55 % Flame retardant Open Applications Carrier for insecticides Polymerisation catalyst support for petrochemicals Cutting oils for machines Sealing materials of all types Binders for dye paste Immersion oils for microscopy

Although PCBs were already synthesised in 1866 for the first time, the commercial production began only in 1929 by the American Monsanto-Chemical Company under the trade-name «Askarel». PCΒs are colourless liquids and a class of chlorinated organic compounds. Depending on the number of chlorine atoms in their molecules, their physical, chemical and toxicological properties vary considerably. A total of 209 PCB compounds with the same basic organic structure but with a varying number of chlorine substituents could be possible but only approximately 50 of these compounds have been found in commercial mixtures. After the 2nd World War the production also started in Europe and in the late 60s the maximum production limits were reached with over 60'000 tonnes per year.

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Table 2: PCB Manufacturers

Manufacturer Trade name Country Quantities Monsanto Aroclor USA 647'000 t Monsanto Aroclor, Pyroclor England 66'848 t Bayer Clophen Germany 144'052 t Prodelec Pyralene, Pheoclor France 116'721 t Caffaro Fenclor, Apirolio Italy 28'008 t S.A.Cros Phenoclor, Pyralene Spain 28'964 t Kanegafuchi Kaneclor Japan together Mitsubishi - Monsanto Aroclor, Santotherm Japan 59'319 t Chemko Delor former CSSR no figures available Sovol Sovol former USSR no figures available DSW-VEB Orophene former DDR no figures available

PCB is only very slightly volatile and the greatest danger is therefore that of absorption of the substance through the body surface, for example as a result of splashes while working with PCB containing equipment. In addition, PCBs adhere to dust so that this substance can enter the respiratory organs via dust particles. Depending on the work to be performed, appropriate personal protective measures must be taken. Since PCB accumulates in the human body and is excreted only to a very small extent even over many years, extensive safety measures should always be taken when handling PCB. 2.2 Dioxins and Furans Dioxin is a generic term for various, chemically similarly constructed chlorinated compounds. The group of Dioxins consists of 75 polychlorinated Dibenzodioxins (PCDD) and 135 polychlorinated Dibenzofurans (PCDF). The PCB decomposition products in fire, a so-called «hot contamination», are regarded as a major hazard. Here, we make a distinction between polychlorinated Dibenzofurans (PCDF) and polychlorinated Dibenzo-para-dioxins (PCDD). We are more familiar with the latter as «Seveso poison» due to the disastrous chemical accident in Seveso nearby Milan, Italy, 24 years ago. However, it must be borne in mind that no PCB-cooling fluids were involved in that accident. The decomposition of PCB starts at temperatures of > 170° Celsius. In the range of 300 to 1000° Celsius, highly toxic substances can occur. The toxicity of such decomposition products depends on the chloride content of the original substance. High chlorinated PCB can result in a remarkably higher toxic concentration than lower chlorinated PCB. All such pollutants, as TCDD/PCDD/PCDF must be handled by specialists only. By the so-called toxicity equivalents (TE), the toxicity of Dioxins is compared to the toxicity of the highly toxic 2,3,7,8 TCDD. TE indicate the quantity of 2,3,7,8, TCDD to which the mixture of PCDD/PCDF corresponds. Depending on the dose of Dioxin, people can suffer from the wasting syndrome. Furthermore, Dioxin can produce skin effects (choloracne), cause damage to the immune and nervous system, the hormone balance and the enzyme system with all its consequences.

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3. Site Visit in Kragujevac 3.1 Introduction The «Zastava Car Factory» complex was targeted twice during the conflict: on 9 and 12 April 1999. There was heavy damage in various areas. At the time of the Expert’s site visit and sampling most of the reconstruction work had already be done and production is in progress again. This report is focusing on the paint hall, the power station, the conflict related hazardous waste, as well as on basic information about the handling and temporary storage of hazardous waste. 3.2 Power Plant Present Situation The power plant was also damaged during the conflict. According to the reports of the «BTF-Industry Mission», PCB had been found in the wall in front of one of the transformer locations and next to the rainwater drain (see picture 2). The PCB-concentration of 70 g/kg was even higher than in most of the samples from the paint hall.

Picture 1: Power House «Zastava Car Factory» I Picture 2: Power House «Zastava Car Factory» II

There is a gravel basin under the transformers that were leaking after the conflict. According to former interviews with the staff of the factory, the flowed out oil was bound with sand. The sand is presently being stocked in drums in the «waste storage». It is unknown if and how much of the initial gravel was removed. According to the information received from the staff during the visit of the «Expert-Mission» on Tuesday, November 28, 2000, there was a transformer on the left side (see picture 1) which was PCB-free, and only during the course of the reconstruction work after the conflict replaced by a PCB-cooling fluid containing transformer. Sampling and analysis of this area were not foreseen for the «Expert-Mission».

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Conclusion After Site Visit It is likely that there is a serious contamination in the walls, at least around the transformer in the middle, as well as in the floor around the rainwater drain. Also, large parts of the drain and drain system might be contaminated. As the power plant is exposed to weather factors, and as there is a constant flow of rain water, it is likely that the PCB-contamination constantly remobilises. Furthermore, the contamination can further penetrate into the building substance and cross-contaminate large areas. 3.3 Paint Hall - Concrete Floor Present Situation Two transformers had been in service in the paint hall and were damaged during the conflict. Extensive reconstruction work has been done in the meantime and only the area around the former location of the transformer remained restricted, closed off by plastic band (see picture 3) and a new glass partition (see picture 4). Some oil stains are still visible on the floor. Picture 3: Concrete Floor in Paint Hall II Picture 4: Part of Car Paint Hall

Apparently, more than 2'150 kg (ca. 1'400 litres) of PCB-containing cooling fluid flowed in direction of the pit «Jama za novu osnovnu boju» (new basic paint pit). The affected concrete floor seems to be very compact and according to the «Zastava Car Factory» the concrete is 1 m thick and reinforced. Nevertheless, there is serious suspicion that the contamination - at least partially - penetrated into deeper layers. Because of the concrete plate/sealants construction (typically shown in picture 4) it was hoped, that only the concrete at the former location of the transformer was highly contaminated, whereas the other concrete plates might be just lightly contaminated on the surface. Conclusion After Site Visit According to the remarks of the «BTF-Industry Mission» as well as interviews with management and staff during the «Expert-Mission» the cooling fluid that dropped from the damaged transformers was not in fire. However, it was exposed to the heat of the nearby fires and therefore the possible content of Dioxins and Furans in the concrete is of interest regarding the safety precautions during the foreseen clean-up. It was therefore decided that one of the drilling samples shall be used for PCDD/PCDF-analysis (sample No. PS 3).

Loc. 5

Loc. 6 Loc. 1

Loc. 7

Partition Plastic band

8

In order give evidence of higher contamination along the way of the leaking cooling fluid, corresponding samples were taken. Further staff interviews resulted in also taking samples in the not restricted working area in the paint hall. This due to the fact that the damaged transformers were transported on this way out of the paint hall, and it is likely that they were still leaking at that time. 3.4 Paint Hall - Water Pits Present Situation One of the priority projects in Kragujevac is the «KR.2 / Cleaning of the water pits and decontamination of the water». There are five pits in the paint hall. The ESKA pit, the pits L1 and L2 are connected, the pit for new basic paint is covered with wooden plates (see picture 5) and - according to previous reports - connected with ESKA whereas the pit L5 is empty and dry. It is assumed that the leaking PCB-containing oil was mixed in the water with paint-sludge, waste water from the fire extinguishing and debris. Access to the pit ESKA was impossible due to heavy steel plates covering the entrance to the pit and also the pits L1/L2 were not accessible at the time of the site visit. It was only possible to have a look at the new basic paint pit after removing a wooden plate. Picture 5: Jama for New Basic Paint Pit Picture 6: ESKA Pit

Conclusion After Site Visit Based on the impressions of the site visit, it was foreseen to enter the pits with the assistance of workers from the Zastava Car Factory for the sampling. Visually no relevant conclusions were possible, however it is obvious that a technically satisfying sampling of the sediments and concrete basin will only be possible after removal of the water from the pits. 3.5 Storage Areas Present Situation There are several hazardous waste storage areas in the «Zastava Car Factory» plant. Partly they are covered and there is some information about their contents on the drums. The drums with the contaminated sand from the power station and other contaminated solids are separately stored in a open, factory owned area. Nearby there is a large dump of not conflict related hazardous waste (see picture 8). The PCB-waste drums have been protected by an orange plastic cover from weather influence (see picture 14).

PL 2 PL 3

9

Two of the damaged transformers are separately stored in another area, uncovered and without any dip tray. There is a concrete wall around the area (see picture 13).

Picture 7: Typical Hazardous Waste Storage Picture 8: Hazardous Waste Storage (Production)

Conclusion After Site Visit The majority of the drums used for the hazardous waste are in a critical condition and probably cannot be used for any safe transportation. It could not be identified if the used drums are UN-approved. It is further unknown if the surface of the drums is clean or if they carry a potential for cross-contamination. No hazard classification labels (danger and/or waste class) could be identified. The access to the hazardous waste storage seems to be easy for any employee or visitor within the Zastava Car Factory.

The two damaged transformers were not covered at the time of the visit and it is uncertain if their surface was properly cleaned or if there remains a risk of cross-contamination. The units are directly stored on the ground, without any adequate protection. It is likely that there is still some remaining cooling fluid in the transformer carcasses. It is likely that some of the present storage areas are meanwhile contaminated too, at least partly.

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4. Site Survey 4.1 Sampling The sampling proceeding was according to the impressions and conclusions from the earlier site visit that day, the information received from staff interviews as well as the at that time available former reports. All the sampling took place in the paint hall as it may be seen on the following map (marked yellow).

Map 1: Sampling Locations

Sampling Concrete Floor The sampling was limited to 12 drilling samples. 10 out of these 12 were taken from the concrete floor in the restricted area at five locations and from two different depths each. The remaining two drilling samples were taken according to the already mentioned staff information outside the restricted area (Loc. 7 see picture 4 on page 7 and Loc. 4 see picture 9 below). Those samples were taken only from one depth, in order to confirm or exclude the suspicion of a contamination.

Picture 9: Contaminated Area Concrete Floor Picture 10: Partition to the Contaminated Area

Loc. 6

Loc. 5 Loc. 1

Loc. 2 Loc. 3

Loc. 4

PL 1

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The samples PS 3 (Loc.2), PS 8 (Loc.5) and PS 12 (Loc.7), were used as comparison samples and handed over to the Laboratory of Human Ecology of the Institute of Public Health in Belgrade. Map 2: Sampling Map Concrete Floor

Sampling Water Pits The sampling of the water pits was rather difficult and improvisation was necessary. At time of the sampling, the factory was closed due to a public holiday and no assistance was available to enter the pits. However, the sampling should allow an overall view about the present situation of the waste water in the pits L1/L2 (PL 1) as well as in the pit for new basic paint (PL 2). Also a surface water sample of the ESKA pit was taken (sample no. PL 3). As it only was possible to take this sample under «torch-light» condition, it was later excluded from analysis.

An additional solid sample was taken from the surface of the empty water pit (PSS 1). Laboratory results shall give an indication about the possible contamination after decontamination and removal of the water from the basins.

Loc. 7

Loc. 2

Loc. 3 Loc. 4

Loc. 6 Loc. 1

Loc. 5

Partition

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Map 3: Sampling Map Water Pits

4.2 Methods of Analysis The analytical determination of the PCB content is still - in spite of high technologies - complicated. The analysis may cause problems because of the chemical composition of PCBs. Polychlorinated Biphenyls are a mixture of 209 congeners. The common basic structure of these compounds is the chemical substance Biphenyl, which - reacting with chlorine - results in these Polychlorinated Biphenyls. Table 3: Schematic Syntheses of PCB

Structures: Biphenyl Polychlorinated Biphenyl

yClxCl

+ z Chlorine

Depending on the conditions of reaction few or several chlorine atoms are bound to the Biphenyl, i.e. the compound may have one or maximum ten chlorine atoms. Consequently, different PCBs with lower or higher chlorine content may result. These various types partially have different characteristics. PCBs with lower chlorine content show a lower viscosity, are rather volatile and they show a lower density. Highly chlorinated PCBs are very thick, therefore often di-, tri- and tetrachlorbenzenes were added for technical application.

PL 3

PL 2

PSS 1

PL 1

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Basically, there are two different methods of analysing PCB. For samples that normally do not contain any other chlorine compounds, it is possible to determine the PCB content based on the chlorine content. The gaschromatographic measurement is used as a direct method, which identifies and quantifies PCB in detail. With the GC (gaschromatography) analysis each compound of the mixture can be identified and quantified by means of reference solutions (standards). The technically produced PCBs contain between 60 to 130 single compounds. For the clean-up of the samples, solid phase extraction column with benzenesulfuracid and one with silicagel or floresil were used. The gaschromatography was run by a High Resolution Gaschromatography (HRGC) and a Electron Capture Detector (ECD). The quantifying was made according to DIN methods with internal standards as six single compounds (PCB no. 28, 52, 101, 138, 153 and 180). Picture 11: Sample Preparation for Soxhlet Picture 12: Analysis by Gaschromatography

In the laboratory it was decided to use the sample PS3 from location 2 for TCDD/PCDD/ PCDF analysis. Initially this was a comparison sample with the PHI, however it was taken from the suspected main hot spot on the concrete floor and should give the necessary information regarding safety precautions related to Dioxins and Furans. The procedure for the Dioxin analysis was generally in accordance with the US EPA method no. 8290. The sample was extracted by the soxhlet extraction technique with toluene as solvent. Prior to the extraction, the 13C12-isotope labelled reference solutions were added (each 2,3,7,8-substituted Dioxin and Furan). After a clean-up step, another 13C12-isotope labelled dioxin isomere was added to determine the recovery. The clean extract was measured by capillary column gas chromatography with mass spectrometry detection (HP GC-MSD 5971A, selected ion monitoring).

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4.3 Analysis Results The complete analysis reports are attached in annex 8.1. The report from the Public Health Institute of Belgrade is there also available as well as correspondence regarding the results of the comparison analysis. Analysis Results Related to the KR.1 Project Table 4: PCB Analysis Results - Concrete Floor

Location Sample Name PCB-Result ETI

PCB-Type PCB-Result PHI

LOC 1 PS 1 4-5 cm 20 mg/kg Laga PS 2 9-10 cm < 2 mg/kg Laga LOC 2 PS 3* 4-5 cm --- Sample used for PCDD/PCDF analysis 10'210.2 mg/kg

PS 4 6.5-7.5cm 4'309 mg/kg Clophen 60 LOC 3 PS 5 3-4 cm 6'356 mg/kg Clophen 60 PS 6 6-7 cm 582 mg/kg Clophen 60 LOC 4 PS 7 2-3 cm 41 mg/kg Clophen 60 LOC 5 PS 8* 2.5-3.5 cm 16 mg/kg Laga 26.4 mg/kg PS 9 4-5 cm < 2 mg/kg Laga LOC 6 PS 10 2.5-3.5 cm 9 mg/kg Laga PS 11 6-7 cm < 2 mg/kg Laga LOC 7 PS 12* 1-2 cm < 2 mg/kg Laga 8.9 mg/kg

Loc = Location of sampling * = Comparison samples with Public Health Institute of Belgrade Laga = (Länderarbeitsgemeinschaft Abfall) the sum of the six quantified PCB-isomers multiplied with the factor 5

The small difference between the results of the international laboratory and PHI in the samples PS 8 and PS 12 may be regarded as non relevant at this stage. The difference may occur due to slightly different sample preparation, different analysis and calculation (LAGA/Clophen 60). The exact method description (in German) has been made available to the PHI. It is recommended to translate this document and to provide the PHI with further information on PCB-analysis. At a later stage or possibly during the course of the clean-up project KR.1 some more comparison samples shall be analysed to support the local capacity building. The Public Health Institute and/or the laboratory of the University of Kragujevac could then be responsible for future PCB-sampling and analysis. To set the PCB-results in relation with actual Swiss and international limits, the following (guide) limits may be taken into consideration:

The PCB-limit in cooling fluids of electrical equipment is 50 mg/kg, there are some countries as e.g. Austria that are targeting at 20 mg/kg. The limits for waste disposal are depending on the type of treatment, the incineration in cement-kilns is usually restricted to < 2 mg/kg PCB.

There are no fixed limits for remaining PCB-contamination in building substance available. The authorities set the limits individually with regard to the consistence and location of the contamination (agricultural soil, industrial soil, building substance, etc.). These limits vary between 0.1 to 10 mg/kg PCB.

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Table 5: Dioxin and Furan Analysis Results - Concrete Floor

Sample description: LOC 2, PS3 (2.5 - 3.5 cm) ETI-No: 2000-773 Amount

ng/kg Tox.-factor Tox. Equivalent

ng/kg TE 2,3,7,8-TCDD Total-TCDD

< 80 < 800

1 0

< 80 ----

1,2,3,7,8-PCDD Total-PCDD

< 135 < 1’348

0.5 0

< 67 ----

123478-HxCDD 123678-HxCDD 123789-HxCDD Total-HxCDD

< 152 < 128 < 133 < 1’375

0.1 0.1 0.1 0

< 15 < 13 < 13

---- 1234678-HpCDD Total-HpCDD

68 135

0.01 0

0.68 ----

OCDD < 220 0.001 < 0.2 2378-TCDF Total-TCDF

5'597 30’235

0.1 0

560 ----

12378-PCDF 23478-PCDF Total-PCDF

2'540 5'667

27’261

0.05 0.5 0

127 2'833

---- 123478-HxCDF 123678-HxCDF 123789-HxCDF 234678-HxCDF Total-HxCDF

9'609 1'938

282 1'353

26’993

0.1 0.1 0.1 0.1 0

961 194

28 135 ----

1234678-HpCDF 1234789-HpCDF Total-HpCDF

5'593 5'352

18’534

0.01 0.01

0

56 54

---- OCDF 12’255 0.001 12.3 Total Tox.- ng/kg TE min. 4’961

Equivalent TE max. 5’150

Regarding Dioxins and Furans the German «Gefahrstoffverordnung» (Regulation on dangerous goods) can be regarded as a guiding instrument. If the sum of the relevant PCDD/ PCDF is more than 100 µg/kg the responsible authorities have to be notified. Such PCDD/PCDF contamination are clearly classified as dangerous. Even if the PCDD/PCDF content is more than 5 µg/kg experts should be consulted and involved, and precautions for people and environment have to be taken.

The Health Council of the Netherlands suggests the following limits for aquatic ecosystems: - Water: 0.1 pg 2,3,7,8-TCDD/l - Sediment: 13.0 pg 2,3,7.8.-TCDD/kg dw.

These values are set taking into account accumulation in the food chain and the consequences for birds and mammals (Health Council of the Netherlands 1996).

Analysis Results Related to the KR.2 Project

Table 6: Analysis Results of Heavy Metals and PCB in Solid Sample - Water Pits

Sample PSS1 ETI-No 2000-786

Method

Lead 2.0 % AAS Cadmium 0.53 mg/kg AAS PCB < 5 mg/kg GC/ECD

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Table 7: Analysis Results of Inorganic and Organic Impurities in Water Samples - Water Pits

ETI no.: Sample name:

2000-783 PL 1

2000-784 PL 2

Method

Dissolved organic Carbon 19.7 mg/l C 26.4 mg/l C IR Chromate (Cr6+) < 0.01 mg/l 0.01 mg/l Photometry Iron 1.62 mg/l 0.22 mg/l ICP-OES Manganese 0.13 mg/l 0.04 mg/l ICP-OES Cadmium < 0.005 mg/l < 0.005 mg/l ICP-OES Pentane < 2 µg/l < 2 µg/l Headspace GC-MS Hexane < 0.5 µg/l < 0.5 µg/l Heptane < 0.5 µg/l < 0.5 µg/l Octane < 0.5 µg/l < 0.5 µg/l Nonane < 0.5 µg/l < 0.5 µg/l Decane < 0.5 µg/l < 0.5 µg/l Benzene < 0.5 µg/l < 1 µg/l Toluene < 0.5 µg/l 1.5 µg/l Xylene < 0.5 µg/l 23 µg/l Ethylbenzene < 0.5 µg/l 2.8 µg/l Dichloromethane < 2 µg/l < 2 µg/l Trichloromethane < 0.5 µg/l < 0.5 µg/l Tetrachloromethane < 2 µg/l 3.1 µg/l cis-1,2-Dichloroethylene < 0.5 µg/l < 0.5 µg/l trans-1,2-Dichloroethylene < 0.5 µg/l < 0.5 µg/l 1,2 Dichloroethane < 1 µg/l < 1 µg/l 1,1,1-Trichloroethylene < 0.5 µg/l < 0.5 µg/l Trichloroethylene < 0.5 µg/l < 0.5 µg/l Tetrachlorethen < 0.5 µg/l < 0.5 µg/l

Polychlorinated Biphenyls 28 µg/l < 0.39 µg/l GC-MS The sample PL 3 (ETI-No. 2000-785) was excluded from analysis as explained in chapter 4.1 on page 11. For the assessment of contaminated sites and their influence on groundwater, lakes and rivers, the Swiss «Altlasten-Verordung (1998)» (Regulation on contaminated sites) can be consulted:

Chromate (VI) 0.02 mg CrVI/l Cadmium 0.005 mg Cd/l Benzene 10 µg/l Toluene 7000 µg/l Xylene 10000 µg/l Ethylbenzene 3000 µg/l Dichloromethane 20 µg/l Trichloromethane 40 µg/l Tetrachloromethane 2 µg/l 1,2 Dichloroethylene 50 µg/l 1,2 Dichloroethane 3 µg/l 1,1,1-Trichloroethylene 2000 µg/l Trichloroethylene 70 µg/l Tetrachlorethen 40 µg/l Polychlorinated Biphenyls 0.1 µg/l

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5. Conclusion and Recommendation 5.1 Power Plant Conclusion Please also see conclusions in chapter 3.2 on page 7. No further activities were foreseen for this area at the occasion of the «Expert-Mission». Recommendation The Zastava Car Factory and the national local focal point shall be made aware of the potential source of contamination and hence the possibility of continuous cross contamination. In order to minimise the remobilization of PCBs and to reduce future labour and costs, it is furthermore recommended that they investigate the present situation. If there should be a later conclusion that a clean-up should be necessary, the experience gained during the KR.1 project in the paint hall might be of help for the proceeding in the area of the power plant. 5.2 Paint Hall - Concrete Floor Conclusion The maximum PCB contamination found by the expert mission was 6'356 mg/kg in the sampling location 3 in a depth of 3-4 cm. At the former location of the damaged transformer (Loc. 2) the contamination was still 4'309 mg/kg PCB in a depth of 6.5-7.5 cm. The analysis of the sample PS3 by PHI from the same location, but in a depth of 4-5 cm, showed 10'210.2 mg/kg PCB. Bearing in mind the usual international limits for PCB in solids between 0.1 and 10 mg/kg, the pollution in the concrete can be regarded as significant. However, the results from other areas of the concrete floor show that the main contamination has remained locally at the former transformer location and in the way the leaking cooling fluid took. The concentration of Dioxins and Furans of max. 5'150 ng/kg ITE confirms that the PCB-containing cooling fluid was definitely not in fire, as the content of Dioxins is too low. In case of a fire, more Dioxins than Furans are produced. Usually, there are already traces of Furans in PCB-containing cooling fluids. Important for the KR.1 project is that the content at the hot spot is certainly lower than indicated in the German «Regulation on dangerous goods». This leads to the conclusion that PCB may be regarded as parameter for the whole clean-up exercise as well as for the safety precautions. The analysis results lead to the following further conclusions: − As expected, the relevant contamination at the hot spot (former transformer location) has

reached a depth of at least 15 cm, more likely 20 cm. − The main affected area around the locations 2 and 3, according to the sampling map, may

be calculated with a size of approx. 10 m x 10 m and therefore approx. 100 m2. − Therefore the total quantity of highly contaminated concrete floor in this part of the area

may be estimated with a volume of 15 m³ (15 cm depth) or 20 m³ (20 cm depth). − According to experience as well as recommendations of Civil Engineers, the relevant factor

for concrete is 2.5 (in previous reports a factor of 1.6 was used). Consequently, there would arise approx. 38 tons respectively 50 tons of concrete for disposal.

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− According to the analysis results from the locations 1, 4, 5 and 6, it is likely that the contamination on the surface of the concrete (to a depth of max. 3 cm) is so significant, that it is advisable to remove the surface, too.

− The whole affected area was measured to be approx. 480 m2. Therefore the total quantity of lower contaminated concrete floor in the remaining part of the restricted area as well as on the other side of the partition in direction to the new basic paint pit may be estimated with 380 m2 respectively a volume of 11.5 m³ (3 cm depth). Consequently there would arise approx. 29 tons of lower contaminated concrete for disposal.

− Considering a kind of worst case scenario there would arise in total approx. 67 to 79 tons of contaminated concrete for removal and disposal. Compared with the initially estimated 11 tons this would be a significant additional labour and cost factor.

− There remains the suspicion that through the sealant between the concrete plates, or even through the concrete itself, the contamination could have reached the soil and consequently there is harm for the groundwater.

In January 2001 Zastava Car Factory drilled a hole in the centre of the concrete floor in the paint hall in order to gain more accurate information about the floor consistence. According to this exercise the floor consists of: − 20 to 25 cm of concrete grade MB 30 − Reinforcement is placed approx. 20 cm from the top of the slab − Beneath the floor slab there are approx. 10 cm of lean concrete or gravel and soil

underneath Recommendation Regarding this specific project KR.1 it is proposed that the international limits for PCB shall be taken into consideration but separately and specifically set for the concrete floor project: − It seems to be sufficient to achieve a remaining contamination of < 50 mg/kg PCB in the

building substance. Such a remaining contamination would not be of major harm or danger of significant further cross-contamination anymore. In January 2001 the National Competent Authority has confirmed that a remaining concentration of < 50 mg/kg PCB in the concrete, after removal and replacement of the upper concrete layer, containing higher than 50 mg/kg PCB concentration, would be accepted.

− Depending on the intended future use of the affected floor, it should be covered after the reconstruction work either by an epoxy or just protective paint.

− Before starting the clean-up it is advisable to take some more surface samples from the concrete area around the hot spot in order to gain more information about the specific contamination levels. Such knowledge might partly reduce the depth and width of removal and thus result in cost savings regarding labour and disposal.

More details for the clean-up project KR.1 are separately shown in chapter 6, starting on page 22.

It is advisable to periodically check the groundwater with regard to the suspected penetration of PCBs through the sealant between the concrete plates and the concrete itself, respectively.

For the time being it is recommended to ensure that nobody enters the restricted area, as it is likely that there remains a contamination on the very surface that could cross-contaminate shoes while walking and consequently other areas.

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5.3 Paint Hall - Water Pits Conclusion The sample PL 1 was taken in a depth of 0.3 meters whereas the sample PL 2 was taken from the first 10 cm to the water surface. The results confirm the suspicion that the main part of the organic compounds have already evaporated respectively penetrated in the possible sludge on the bottom of the water pits as well as in the concrete. Thus, although the samples were taken on the water surface, they indicate that the main part of the water might not be significantly contaminated anymore. According to the analysis result of the solid sample PSS 1 there should be paid attention to significant contamination of the pits surface and the concrete by heavy metals. It is very likely that the source of those contaminants is not conflict-related. According to representatives of Zastava Factory there is flooded equipment in the pits, which must be taken care of after removal of the contaminated water. It is foreseen that new equipment will be installed in the ESKA pit. Recommendation Detailed recommendations for the project «KR.2 / Cleaning of the water pits and decontamination of the water» can be found in a separate document provided in collaboration with expertise from the Secretariat for the Basel Convention (Regional Centre in Bratislava). Additionally attention should be given to the following issues: − All water in the pits needs to be considered as contaminated and go through the cleaning

process. − Additional and representative samples should be taken from the deepest water layers

before starting the decontamination of the water pits, and from the sludge from the bottom of the pits after removal of the wastewater, as there remains the strong suspicion that some of the contamination concentrates on the bottom of the pits.

− Regarding the flooded equipment in the ESKA pit, it is advisable to categorise it after removal of the contaminated water regarding kind, consistence, future use or removal as well as regarding the best available options for cleaning respectively disposal.

− As the ESKA pit is going to be used as location for water treatment with workers passing, it is recommended to perform a representative sampling of the bottom of the pit after removal of the contaminated water and the flooded equipment. Such a sampling shall not only be limited to the surface, but also extended to deeper layers of the concrete (e.g. core samples). The analytical parameters shall be in accordance with the results available at that time.

− Depending on the results from this analytical investigation the best available option to stop evaporation from the concrete shall be evaluated.

− Generally, it is advisable that the local authorities also identify the contamination in the concrete basins of the other pits after removal of the water and surface decontamination.

− More details regarding safety and infrastructure for the clean-up project KR.2 are

separately shown in chapter 6.5, starting on page 27.

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5.4 Storage Area Conclusion Please also see chapter 3.4 on page 8. No further activities were foreseen for this area at the occasion of the «Expert-Mission». Recommendation The visits of the storage sites were focusing on the conflict related waste, however some of the recommendations should also be used for the hazardous waste arising from the production in order to minimise environmental pollution. The first important step for the disposal in an environmentally sound manner is the correct interim storage of PCB-containing waste. At this stage already it is advisable that the waste is packed into appropriate packaging which allow future transport and disposal without any additional handling such as i. e. re-packing into UN-approved steel drums. Furthermore, all the drums should be labelled for an easy identification, preferably in the local and English language (see proposal in chapter 7.1). There shall be an inventory list, which shall be permanently updated, showing all items coming in and going out of the storage facility. The storage area should only be accessible for responsible people and well trained workers. All storage areas should be far away from any food processing facilities respectively production areas, bearing the risk of incidents such as fire. Picture 13: Interim Storage Damaged Transformer Picture 14: Present Storage PCB-Waste

As the conflict related hazardous wastes are mostly highly contaminated, the following immediate actions should be taken in order to avoid cross-contamination: 1. Designate only one storage area for all conflict related waste. 2. If possible, the area should be at least sheltered and protected against weather factors. 3. Alternatively the drums could be stored in adapted, used 20’ Box Containers (see picture

15 and 16). From experience there is space for 36 x 200-litre steel drums in one layer, respectively 72 x 200-litre steel drums in two layers. The transformers may either be placed in a 20’ Box Container, too, or alternatively in a 20’ open top Container with cover. In both cases the floor of the Containers should be made of welded steel plates or at least the carcasses should be placed in steel dip trays.

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Picture 15: Box Container Used as Interim Storage Picture 16: Inside View (Welded Steel Floor)

For more details about the interim storage of drums in 20’ Box Containers also see chapter 7.1, starting on page 31. 4. The condition of all presently used drums should be carefully checked. Damaged and/or

leaking drums should be either re-packed into proper drums (adhering to safety precautions of environment and workers) or alternatively packed as they are into recovery drums, such as i.e. over drums of 320 litres (see picture 18). In case of a re-packing, the empty drums must be regarded as contaminated and therefore also disposed of accordingly.

Picture 17: Inside View Liquids Storage Picture 18: Example UN-Approved Recovery Drum

5. All the drums should be properly labelled describing the kind of waste and stating the place

of origin, before being temporarily stored (see also chapter 7.1) 6. All conflict related hazardous waste arising from future clean-up and removal activities

should be directly packed into UN-approved steel-drums in order to save further handling in case of export for disposal (see also chapter 7.1).

7. Possible contamination of all present and future storage areas should be monitored and in case of positive results steps for a clean-up shall be taken.

8. The storage area should be accessible for authorised staff, only. For more details about UN-approved drums and labelling according to international regulation also see chapter 7.1, starting on page 31.

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6. PCB Removal Project KR.1 6.1 Introduction The main objectives of the removal of the contaminated concrete floor are: To reduce the health risks for factory workers, to avoid further cross-contamination and immediate risks from storage of the waste as well as the reuse of the affected part in the paint hall. This project could be regarded as a UNEP/UNOPS clean-up pilot project in the FRY. It is recommended to proceed in all clean-up project phases according to adapted international standards in order to have experience and make use of the new knowledge in future projects, and also to establish a proper hazardous waste management in the FRY. During UNEP/UNOPS clean-up activities, the national focal point and competent authorities for the Basel Convention of FRY have responsibilities to note with opinion all ongoing projects concerning hazardous waste. 6.2 Proceedings

At the time of issuing of this report two clean-up options are possible: Alternative A includes the removal of the contaminated layers by a chipping technique followed by a new layer of concrete. Alternative B is based on covering the contaminated area by a layer of epoxy in order to prevent evaporation. It is obvious that at the sample locations 2, 3 and 4 (see pictures 9 and 10) the contamination has deeply penetrated in the concrete. At the sample locations 1, 5 and 6 the PCB-content is still 9 to 20 mg/kg in a depth of 2.5 to 5 cm. Furthermore, it must be considered that a protective painting or a layer of epoxy might only avoid the vaporisation of PCB at the surface but will not stop a vertical and horizontal cross-contamination. This would cause, in all probability, further harm as well as relevant labour and costs at a later stage. The sample locations 2 and 3 can be regarded as hot spots where the removal by using e.g. pneumatic hammers must be performed to a depth of at least 15 cm whereas at other areas the removal of the surface to a depth of 3 cm or application of protective painting or epoxy could be regarded as sufficient. As previously mentioned, a remaining concentration of < 50 mg/kg PCB can be regarded as tolerable for this project. Based on the results of the basic site monitoring during the «Expert Mission» respectively the dimensions of the contaminated area and therefore relevant costs, a compromise between alternative A and B should be generally preferred. The concrete should be removed in the hot spot area. Those parts of the concrete, which will not be removed, i.e. where the level of the remaining PCB-concentration is below 50 mg/kg (9 to 20 mg/kg) should be covered with either a protective paining or epoxy.

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During the course of the clean-up exercise it might be useful to make use of an on-site analyser. However, in such a case it is recommended to compare the results with the laboratory first or to make use of an experienced expert in this field. Such on-site analysis might have the further advantage that the success of the removal can be checked at any time. 6.3 Protective Painting or Epoxy Regarding possible alternatives to a complete removal of the contaminated concrete in the hot spot area respectively in order to protect the larger area of approx. 280 m2 with lower contamination, three options have been taken into consideration: − Epoxy coating − Protective painting − Utilising membrane The option of utilising HDEP membrane and casting a new reinforced concrete slab on the top seems to be rather difficult regarding justification beneath the new layer of concrete. However, it remains a viable alternative. The use of a protective painting is not recommended as it soon would be saturated with PCBs. After a certain point of saturation the evaporation would be as before. Furthermore, protective paintings tend to flake off - in case of mechanical abrasion especially. Thus, they would cause, additionally to the evaporation, a higher cross-contamination. The best available option seems to be an epoxy coating. Various products are available and the below mentioned technical specifications should be considered. It must be mentioned however, that such epoxy coatings have been tested in detail, but not specifically on porosity in case of Polychlorinated Biphenyls. For more details about the products from an international manufacturer see annex 8.2. Data below provided directly by Zastava. It is recommended that an experienced Civil Engineer compares this data with the attached product data sheets, in order to choose the best option for the specific paint hall project. Technical data for epoxy layer (280 m2):

a) Smooth, shine and easy for maintenance

b) Should be elastic to resist vibrations due to operation of equipment,

c) Resistant to water and cleaning detergents,

d) Resistant to solvents of mineral acids, alkalis and salts,

e) Resistant to oil & oil derivatives and non-polar solvents,

f) Non slippery,

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g) Compressive strength (DIN 53453 80-90Mpa

h) Bending strength (DIN 53462) 25-30Mpa

i) Bonding to a concrete (DIN/ISO 4624) >2,8 Mpa (fracture in a concrete)

j) Density 1,7g/cm3

Technical data for anti-static layer (100m2):

a) Compressive strength (DIN 53453) 80-90Mpa

b) Bending strength (DIN 53462) 25-30Mpa

c) Bonding to a concrete (DIN/ISO 4624) >3,1 MPa (fracture in a concrete)

d) Electrical resistance (JUS G. EO. 050) 10^4 - 10^6 Ω

e) Density ~1,65g/cm3

In case of applying one of the above-mentioned alternatives, it must be paid attention to the fact that there is still some contamination under the layer. Hence, in case of a future reconstruction or removal, respective protective actions must be taken and a disposal must be considered.

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6.4 Scope of Work

The contractor shall provide a detailed «Safety and Proceeding Manual» for the PCB Removal Project KR.1. Such a Manual shall include the foreseen safety precautions, the proceedings regarding the removal of the concrete, packing, labelling and temporary storage of the waste as well as information about hygiene for the involved workers. We recommend that the project shall be supervised either by an international expert and - or at least partly - by local specialists such as a skilled representative of the Public Health Institute in Belgrade or the University in Kragujevac. Such supervision shall comprise mainly the technical and safety aspects but could be extended to the analysis, too. The following draft proposal for the proceeding includes co-ordination meetings between the responsible people involved. The sequence of the below described actions and the single steps of the project proceeding can certainly vary and be adapted, if necessary.

Table 8: Draft Project Proceedings

Expert missionUNEP Balkan Unit

Site-monitoring (limited)ETI/PHI

Briefing clean-up Contractor/Workers/PHI/Experts

Co-ordination meeting IIContr./Zastava/UNEP/PHI/Experts

Clean-upContractor

De-briefingContractor/Zastava/UNEP/PHI/Experts

Report/recommendationETI

Temporary StorageContractor/Zastava/Experts

11/2000

01/2001

11/2000

Off-site analysisETI

12/2000

Safety and proceeding manual Contractor/(Experts)

Packing and labellingContractor

De-briefingUNEP/Expert

Tender/contractUNEP

Co-ordination meeting IUNEP/Contractor/Experts

Work preparation, safety check Contractor

Final analytical site surveyContractor/PHI

Repair work concrete floor

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The contractor shall decide whether he prefers to work under vacuum. It seems to be sufficient to simultaneously use an industrial vacuum cleaner with activated carbon filters in order to remove the dust while breaking off concrete (see picture 19). Special attention must be paid to the static of the concrete floor. The reinforcement is supposed to be approx. 20 cm from the top of the slab. From experience, possible sparks during the course of breaking off activities seem not to be a harm with regards to the described safety precautions of workers and environment. However, it might still be problematic to remove the concrete through the reinforcement and it must be verified beforehand, if those shall remain in the floor or rather be taken out during the course of the exercise.

Picture 19: Mechanical Breaking (Example)

After completion of the concrete removal, the whole are must be vacuum cleaned and additionally cleaned (damp) with a biological cleaning agent in order to remove all remaining dust and particles. All used personal protective clothing, working equipment and other associated waste shall also be packed in drums for temporary storage. The detailed weights shall be noted in the report.

After the clean-up a final sampling can be performed to confirm the success of the exercise. This analytical investigation could cover 8-12 samples for analysis by gaschromatography, e.g. in the Laboratory for Human Ecology of the Public Health Institute in Belgrade. Partially the samples might be integrated into batch-analysis in order to save costs. For the reconstruction of the concrete floor, local civil work suppliers should be considered. The Contractor shall supply, among others, the following equipment and services:

• UN-approved steel drums for the packing of contaminated concrete, used personal protective equipment and other associated waste. Those specially designed steel drums are necessary, as from experience it is the safest packaging equipment and easy for the handling and transport as well as for the destruction process at incineration plants. With regards to local capacity building in the FRY, drum manufacturers should be contacted in order to clarify if they are able to manufacture UN-approved drums. If they are not yet licensed to do so, they should receive assistance in the manufacture of UN-approved packaging.

• The Contractor shall also provide the necessary personal protective equipment, such as protective clothing, gloves, rubber boots, breath protection masks, etc.

• Furthermore the Contractor shall supply safety material for precaution on site, such as for dividing the contaminated area in the different zones of contamination, absorbing industrial carpets, industrial vacuum cleaners with special filters, etc.

• As previously described, the supply and use of field test kits might be integrated in the responsibility of the Contractor.

• Equipment available in the FRY itself should be procured to the extent possible in order to support the local capacities.

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• Appropriate storage area for the drums with hazardous waste respectively some 20’ Box Containers for interim storage

• Supply of water and electricity • Supply of changing room including facilities for shower/toilets for staff • One forklift, including driver for the movement of the drums with hazardous waste • Pallets in good condition for the drums • Fire extinguishers for safety precautions (preferably powder, no fire hoses as this could

in case of emergency spill the contamination in clean zones) In addition, Zastava Factory should appoint one person to be responsible for the hazardous waste management. 6.5 Safety Precautions As already mentioned, the greatest danger of PCBs to people arises from absorption through the skin, therefore protective suits, gloves, rubber boots and full-face covering respirator must be worn throughout the exercise. Respirators with a combination filter for organic pollutants and dust must be worn. To avoid entrainment of the contaminants, all working material needs to be either cleaned or disposed of as hazardous waste after the respective operations. Picture 20: Types of Personal Protective Clothing

Basic Medium Heavy

With regards to the analysis results it is proposed to choose the option «Heavy» as showed above for the clean-up. It should be the decision of the contractor if he additionally prefers to use ventilated respirators. The following aspects shall be considered in the Safety and Proceeding Manual of the Contractor: • Clear and agreed responsibilities • Constant communication between the involved parties • Safety and hygiene infrastructure • Knowledge (or training) of working with PPE (personal protective equipment) • Defined work shifts • Safety instruction to all involved staff and observer (briefing) • Emergency instructions (e.g. actions in case of an accident) • No use of dangerous cleaning substances (e.g. solvents) • Professional handling of hazardous waste

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For the KR.2 project it is recommended to use a slightly different version of the «heavy» personal protective equipment as shown in picture 20. Instead of the above mentioned throwaway protective suits, reusable, watertight suits shall be used. They are usually polymer coated. The workers may use a shower (decontamination cabin) on their way out of the protective area and thus use the same suit during the whole clean-up proceeding (as it may be seen in diagram 2 on page 30). Additionally, power assisted breathing protection should be foreseen for this part of the project (see picture 22). Such a filtering device provides also protection against solid and liquid particles, gases and vapours but does significantly facilitates breathing. Picture 21: Shower (decontamination cabin) Picture 22: Protective suit with power assisted

breathing protection.

Different Areas During a Clean-up Project We propose that for the clean-up the whole contaminated area will be «covered» and separated into different inside areas. Such a separation of areas shall prevent cross-contamination during operation. The below diagram shows a general draft of such a construction.

Diagram 1: Protective Construction / Cabins

Contaminated Area

Connecting Area

Accessible Area

Material /Waste

Staff

ChangingRoom

Area ofHot Spots

Partition

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In reality such protective constructions may look as shown in the below pictures 23 and 24. The type of construction depends on purpose of prevention and size as well as on availability of material. Pre-installed tents are made of light metal pipes, couplings and reinforced PE sheets. In this case the scaffolding is pre-installed - the couplings allowing any kind of construction - and then the welded tent sheets are fixed to the pipes. Such tents can be designed and manufactured according to the customer’s requirement. Doors, windows, compartments, flanges for gloves, etc. are integrated in the tent sheets. Also available are the already mentioned decontamination cabins (shower) as well as air and ventilation systems to guarantee the vacuum (see picture 23). Alternatively and certainly more cost effective, a simpler version can be constructed by using polyethylene plastic and wooden slats. In both cases there are different compartments necessary to construct. Picture 23: Pre-installed tent with under pressure

Picture 24: Alternative protective construction using wooden slats

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Staff, Material and Waste Flow During Clean-Up Exercise The below diagram shows the correct proceedings and use of such a protective construction. Certainly, it should be simplified and adapted according to the specific needs and possibilities regarding the KR.1 project. Diagram 2: Staff, Material and Waste Flow

STAFF "IN" PLASTIC CABINS STAFF STAFF "OUT"Protective clothing Protective clothing Protective clothing Protective clothing

(throwaway) (re-use) (throwaway) (re-use)

Take off clothes Take off clothes Put on clothes

Put on underwear Put on underwear Take off breath protection Take off breath protectionPut on protective overall, Put on breath protection mask, boots, gloves mask, boots, glovesboots, breath protection mask Take off underwear Take off underwearand protection gloves

Put on protective overall,boots, gloves Take off/dispose Take off

protective overall protective overall

Check quality of PPE

Shower

Enter plastic cabin, grey area(wearing PPE) Carefully clean protective Carefully clean protective

overall (vacuum cleaner) overall (vacuum cleaner)

Enter plastic cabin, red area Roughly clean protecitve overall(wearing PPE)

CONTAMINATED AREA

DECONTAMINATION CABINS

"IN" contaminated material (full drums)"IN" and "OUT" staff wearing PEE

Material Cabins Decontamination contaminated material"IN" equipment, empty drums (Equipment/drums)

"OUT" decontaminated material (full drums)

"OUT" decontaminated material(Equipment, drums)

MaterialCabin 1

White Area

Cabin 4Working Area

Cabin 5Area of

Hot Spots

Cabin 1Accessible Area

Cabin 2Changing

Room

Cabin 3Connecting

Area

DecontaminationCabin

Red Area

MaterialCabin 2

Green Area

MaterialCabin 3

Grey Area

DecontaminationCabin

Grey Area

With regard to capacity building in the country, the possibility of choosing skilled local construction companies should be taken into account. After a training they could perform the clean-up under supervision and also assist in future projects.

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7. General Recommendation 7.1 Part: Interim Storage, Packaging and Transport An important factor for disposal remains the transport and packaging according to international standards. Therefore some of the following basic information and requirements shall be already taken into consideration.

Firstly, the national authority for the Basel Convention respectively the transboundary movement of waste should be involved in the process of disposal in the earliest stage already. This can be very useful regarding latest available information as well as for processing application of necessary national and international permits.

In addition to the Basel Convention, the following regulations are applicable for the international transport of hazardous goods:

1. Recommendations on the transport of dangerous goods/«Orange Book» Classification and labelling according to a group of experts of the United Nations

2. ADR (European agreement on the international road transport of hazardous goods) 3. RID (Regulation for the international transport of hazardous goods on railways) 4. IMDG (International maritime dangerous goods code/transport by sea) 5. IATA DGR (IATA regulations on the transport of hazardous goods/air transport) It should be noted that various regulations (ADR/RID/IMDG/IATA-DGR) are substantially similar to one another. The only difference is that special packaging, labels or quantity limits are specified for the different means of transport, depending on the hazardous goods. The «Orange Book» defines the identification of a hazardous material or article. These assigned identification numbers are also generally referred to as «UN numbers». On the basis of this code, substances are divided into certain classes which are decisive for international transport. PCB is a member of substance class 9 and the UN number is 2315 and 3151 for PCB liquids, respectively. Further details with regard to the ADR, may be considered as the standard guide. In the ADR, the type of container and the requirements which it has to meet are exactly specified. Each container (drum, IBC, etc.) must have an approval (UN code) for the international transport of hazardous goods. A distinction is made between three packaging groups (I, II and III, or X, Y and Z), packaging group I being intended for the most hazardous goods. PCB is classified in packaging group II. Metal is mainly regarded as suitable packaging material. On the basis of the regulations, the drums must be equipped with the code UN-1A1/Y... for drums with bungs and UN-1A2/Y... for drums with lids. Please see annex 8.3 for more technical details about UN-approved 213 litres drums for solids and 215 litres drums for liquids (material quality St 12.03). The exact labelling of the waste is also defined in the ADR. This is based on the 9 classes in the «Orange Book». According to the IMDG code, PCB has also to be classified as a marine pollutant and requires an additional label [«Marine Pollutant»]. The picture on the next page shows a proposal for a complete label for drums as it might be used for the KR.1 project in Kragujevac.

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Picture 25: Proposal Labels for PCB-Waste from Zastava Automobili

In chapter 5.4 it was recommended to use 20‘ Box Containers as an alternative for the interim storage. In such a case, the hazardous waste drums could be loaded in such a manner that the Containers could be used for transportation at a later stage. This could save labour and costs, significantly. This possibility of cost saving should be clarified by the responsible people when comparing the rental/purchase costs of Containers (including costs for transport and crane) with the expense of constructing an interim storage and additional handling of the waste. Regarding the rental or purchase of Containers, the correct CSC approval must be paid attention to. CSC stands for «International Convention for safe Containers». The most important parts of this Convention are: A safety approval plate shall contain the following information in at least the English or French language: − CSC SAFETY APPROVAL − Country of approval and approval reference − Date (month and year) of manufacture − Manufacturer’s identification − Number of the container or in the case of existing containers, for which that number is

unknown, the number allotted by the administration − Maximum operating gross weight (kg and lbs.) − Allowable stacking weight for 1.8 g (kg and lbs.) − Transverse racking test load value (kg and lbs.) The interval from the date of manufacture to the date of the first examination shall not exceed five years. Subsequent examination of new containers and re-examination of existing containers shall be at intervals of not more than 24 months. All examinations shall determine whether the container has any defects which could place any person in danger. As it is unknown per today, for how long the Containers would be used as an interim storage, it should be made sure that the CSC-approval is new at the time of purchasing or rental in order to prevent any delay at the time of transport to the final disposal facility.

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Picture 26: CSD Safety Approval

7.2 Part: Disposal At the time of the issuing of this report, there are three options for the future disposal of the conflict related waste:

• Interim storage within the Zastava facility • Treatment or landfill within the FRY • Export for disposal Whatever option will be chosen, it is important that the arising waste is packed in such a way that no further handling is necessary at the time of transport to the disposal site. This includes UN-approved packaging, clean surface of those containers, proper labelling and a detailed inventory list (including individual weight of the packaging). Protection of human health and the environment requires that PCBs are disposed in such a way that they do not enter the environment. The specific options for the disposal also depend on the consistence of the waste as well as on the PCB-concentrations. In some countries there is an opportunity to store drained transformer and capacitor carcasses in former salt mines. However, for organic substances such as PCB the landfill is not a final solution and the risk of future remobilization and therefore threat to the environment and human beings must be regarded as too high. In most European countries the PCB-limits for special designed landfills are < 10 mg/kg. There are various dechlorination processes available, however those technologies target mainly the cooling fluids. Also the incineration in cement kilns cannot be recommended due to missing appropriate flue gas cleaning systems. Other techniques for PCB disposal are: Hydrogenation, gasification, evapo-incineration, electrochemical processing (based on silver nitrate) and plasma arc heating.

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The best available technology for the disposal of PCB-waste remains high-temperature incineration. There the Polychlorinated Biphenyls are completely destroyed. The incineration temperatures and the flue gas purification units are designed for substances of this type. The end products of complete combustion are water, carbon dioxide and hydrogen chloride. The existing European regulations for flue gas cleaning system are stricter than US EPA requirements. There are different rotary kiln technologies available. Some of the incineration plants operate in temperatures of 1300 - 1400 oC compared to 1000 - 1200 oC in conventional kilns. An important tool is the after combustion chamber which gives a complete mixing of gas stream and a sufficient retention time for gases. The advantages of this method of operation are:

• to reach the highest possible combustion efficiency • to have an insoluble and inert vitreous slag which is environmentally harmless • to increase the capacity of the kiln • to have the possibility to incinerate PCB and dioxin wastes In addition, it has to be proved that the concrete chunks after incineration will be able to meet the criteria of 10 mg/kg. 7.3 Part: PCB-Inventory The first of an environmentally sound management of PCBs is to identify their sources and to develop strategies for reducing or eliminating the risks. Originally, it was assumed that electrical equipment, such as capacitors and transformers, were only intentionally filled with PCB and accordingly identified. It was only in the late 80’s when it was discovered that many insulating oils were unintentionally contaminated with PCB. In particular, the mineral oil transformers produced between 1968 and 1978 are very often contaminated with PCB. The use of the same tanks, transport containers, pipe systems and valves by the insulating oil suppliers and the equipment suppliers are largely responsible for this fact. In addition, the user's equipment was contaminated by subsequent filling, and various plants have even been contaminated with PCB during overhauls. Owing to the various sources of contamination, the exact cause of the contamination is generally impossible to trace. Contamination after manufacture can be excluded out only in case of capacitors, since these are compact devices. Since PCB was no longer produced after 1984, electrical equipment manufactured after this date could have been contaminated only by subsequent manipulations. During the course of the site visit in Kragujevac and the various discussions at the occasion of the workshop in the Public Health Institute in Belgrade it became obvious that not all people involved into the «PCB-Management» in the FRY are aware, that different types of PCB respectively PCB-containing equipment exist. Also, it is likely that originally PCB-free transformers meanwhile might have been contaminated, too. Therefore, at a later stage, it might be useful to inform and train the responsible people in order to avoid possible pollution respectively the contamination of clean mineral oil caused by missing knowledge.

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We therefore strongly suggest implementing a PCB-inventory of the so-called «closed systems», such as transformers and capacitors. Such an inventory could easily be performed as a small pilot project at Zastava Automobili. All PCB-containing equipment - in or out of use - should be listed, giving detailed information about the equipment and their present location. All officially declared PCB-free or PCB-suspected transformers must be analytically checked. Basically, it would be sufficient to analytically check transformers manufactured before 1984 only, however, there remains a risk that initially PCB-free transformers might have been contaminated with Askarel, Pyralene, Clophen or other PCB-products during maintenance operations or refilling activities.

In a first step the analytical check can easily be done by test kits on site. There are various products from different producers on the market. Only in case of positive results the same samples would need to be analysed in a laboratory by gaschromatography.

Picture 27: CLOR-N-OIL Test Kits

For the inventory of transformers (and adapted for capacitors) a list as shown below could be used. After the inventory the transformers should be labelled either «PCB-free» or «PCB-containing» respectively. Picture 28: Example Inventory of Transformer

The exact knowledge of PCB-containing transformers allows corresponding maintenance, appropriate actions in case of an incident as well as proceedings in case of disposal. Therefore it results in the protection of human and environment aimed at.

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8. Annexes 8.1 Complete Analysis Reports See the following pages.

Page 1 of 3

PCB Results in soil samples

Location Sample Name ETI-No. PCB-Result PCB-Type Method LOC 1 PS 1 5 cm 2000-771 20 mg/kg Laga Soxhlet-Extraction, GC-ECD PS 2 10 cm 2000-772 < 2 mg/kg Laga Soxhlet-Extraction, GC-ECD LOC 2 PS 3* 5 cm 2000-773 --- sample used for TCDD/PCDD/PCDF analysis PS 4 7.5cm 2000-774 4'309 mg/kg Clophen 60 Soxhlet-Extraction, GC-ECD LOC 3 PS 5 4 cm 2000-775 6'356 mg/kg Clophen 60 Soxhlet-Extraction, GC-ECD PS 6 7 cm 2000-776 582 mg/kg Clophen 60 Soxhlet-Extraction, GC-ECD LOC 4 PS 7 3 cm 2000-777 41 mg/kg Clophen 60 Soxhlet-Extraction, GC-ECD LOC 5 PS 8* 3.5 cm 2000-778 16 mg/kg Laga Soxhlet-Extraction, GC-ECD PS 9 5 cm 2000-779 < 2 mg/kg Laga Soxhlet-Extraction, GC-ECD LOC 6 PS 10 3.5 cm 2000-780 9 mg/kg Laga Soxhlet-Extraction, GC-ECD PS 11 7 cm 2000-781 < 2 mg/kg Laga Soxhlet-Extraction, GC-ECD LOC 7 PS 12* 2 cm 2000-782 < 2 mg/kg Laga Soxhlet-Extraction, GC-ECD

Loc = Location of sampling * = Comparison samples with Public Health Institute of Belgrade Laga = (Länderarbeitsgemeinschaft Abfall) the sum of the six quantified PCB-isomers multiplied with the factor 5

Heavy metals in solid sample

Sample PSS1 ETI-No 2000-786

Method

Lead 2.0 % AAS Cadmium 0.53 mg/kg AAS PCB-Result < 5 mg/kg Soxhlet-Extraction, GC-ECD

Page 2 of 3

Inorganic and organic impurities in water samples ETI Nr: Sample name:

2000-783 PL 1

2000-784 PL 2

Method

Dissolved organic Carbon 19.7 mg/l C 26.4 mg/l C IR Chromate (Cr6+) < 0.01 mg/l 0.01 mg/l Photometric Iron 1.62 mg/l 0.22 mg/l ICP-OES Manganese 0.13 mg/l 0.04 mg/l ICP-OES Cadmium < 0.005 mg/l < 0.005 mg/l ICP-OES

Pentane < 2 µg/l < 2 µg/l Headspace GC-MS Hexane < 0.5 µg/l < 0.5 µg/l Heptane < 0.5 µg/l < 0.5 µg/l Octane < 0.5 µg/l < 0.5 µg/l Nonane < 0.5 µg/l < 0.5 µg/l Decane < 0.5 µg/l < 0.5 µg/l Benzene < 0.5 µg/l < 1 µg/l Toluene < 0.5 µg/l 1.5 µg/l Xylene < 0.5 µg/l 23 µg/l Ethylbenzene < 0.5 µg/l 2.8 µg/l Dichloromethane < 2 µg/l < 2 µg/l Trichloromethane < 0.5 µg/l < 0.5 µg/l Tetrachloromethane < 2 µg/l 3.1 µg/l cis-1,2-Dichloroethylene < 0.5 µg/l < 0.5 µg/l trans-1,2-Dichloroethylene < 0.5 µg/l < 0.5 µg/l 1,2 Dichloroethane < 1 µg/l < 1 µg/l 1,1,1-Trichloroethylene < 0.5 µg/l < 0.5 µg/l Trichloroethylene < 0.5 µg/l < 0.5 µg/l Tetrachlorethen < 0.5 µg/l < 0.5 µg/l

Polychlorinated Biphenyles 28 µg/l < 0.39 µg/l GC-MS Sample PL 3 (ETI-No. 2000-785) used as reserve sample (not analysed).

Page 3 of 3

Dioxin and Furans in soil samples Sample description: LOC 2, PS 3, 5 cm ETI-No: 2000-773 Amount

ng/kg Tox.-factor Tox. Equivalent

ng/kg TE 2,3,7,8-TCDD Total-TCDD

< 80 < 800

1 0

< 80 ----

1,2,3,7,8-PCDD Total-PCDD

< 135 < 1’348

0.5 0

< 67 ----

123478-HxCDD 123678-HxCDD 123789-HxCDD Total-HxCDD

< 152 < 128 < 133 < 1’375

0.1 0.1 0.1 0

< 15 < 13 < 13 ----

1234678-HpCDD Total-HpCDD

68 135

0.01 0

0.68 ----

OCDD < 220 0.001 < 0.2

2378-TCDF Total-TCDF

5'597 30’235

0.1 0

560 ----

12378-PCDF 23478-PCDF Total-PCDF

2'540 5'667

27’261

0.05 0.5 0

127 2'833

---- 123478-HxCDF 123678-HxCDF 123789-HxCDF 234678-HxCDF Total-HxCDF

9'609 1'938

282 1'353

26’993

0.1 0.1 0.1 0.1 0

961 194 28

135 ----

1234678-HpCDF 1234789-HpCDF Total-HpCDF

5'593 5'352

18’534

0.01 0.01

0

56 54

---- OCDF 12’255 0.001 12.3 Total Tox.- ng/kg TE min. 4’961

Equivalente TE max. 5’150 Method: HP GC-MSD

8.2 Epoxy Data Sheets

See the following pages.

Product Data Sheetpage 1 of 3

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01.99

Sikafloor-156 Epoxy Resin Binder for Priming, Levelling and Screeds

Description Solvent-free low viscosity two-component epoxy resin binder as primer and mortar screed.

Uses As primer and adhesion promoter for epoxy and pu-epoxy floors on:- Concrete- Cementitious mortars- EpoCem- Epoxy mortars

As abrasion- and skid resistant epoxy mortar screeds of 5-8 mm thickness for:- Factory- and warehouse floors- Workshop floors- Depots and loading docks- Industrial flooring subjected to medium to heavy wear

Advantages - Low viscosity- Good penetration- High mechanical resistance- Easy application- Short waiting times- Excellent bonding strength- Solvent-free according to KEL-CH

Test reports Polymer Institut Dr. R. Stenner, D-Flörsheim,(test when moisture ingress from beneath/ behind primer coat, test report No. P 1003-1)Polymer Institut Dr. R. Stenner, D-Flörsheim,(test of mechanical properties, test report No. P 1127-1)

Technical Data

Colour Yellowish-transparent

Density (DIN 53 217) ~ 1.1 kg/l unfilled (Comp. A + B)~ 2.1-2.2 kg/l (A+B+C) as mortar screed

Mixing ratio As Primer:- Parts by weight: A : B = 3 : 1- Parts by volume: A : B = 100 : 37

As mortar screed: Degree of filling 1 : 10 Degree of filling 1 : 7p.b.w. p.b.w.

- Comp. A 3 3- Comp. B 1 1- Comp. C Sikadur-506 40 28

page 2 of 3 Sikafloor-156

Shore D hardness(DIN 53 505)

After 7 days at 23°C: ~ 83

Compressive strength(EN 196 part 1)

After 7 days at 23°C, binder: 70 N/mm 2

mortar: 95 N/mm 2

Flexural strength(EN 196 part 1)

After 7 days at 23°C, binder: 75 N/mm 2

mortar: 30 N/mm 2

Pot life (in10 kg units)

Waiting time between working steps

Final Curing

Storage / Shelf life Stored in original sealed containers in cool conditions at temperatures between +5°C to +30°C shelf life is 2 years from date of production.

Packaging 10 kg units (Comp. A+B)20 kg units (Comp. A+B)

180 kg drums (Comp. A)180 kg drums (Comp. B)25 kg bags (Comp. C, Sikadur-506, pallets at 40x25 kg)

Application

Substrate The substrate must be of sufficient strength (min. compressive strength 25 N/mm 2, minimum pull-off strength 1.5 N/mm 2). The surface must be clean, even, fine gripping, dense, dry (max. 4% moisture content) and free from laitance, loose and friable particles.Uneven or porous areas must first be filled with Sikagard-720 Epo Cem, or levelled with Sikafloor-81 EpoCem New or Sikafloor-82 EpoCem New.

Surface preparation Friable layers and contaminations must be removed mechanically, e.g. by blastcleaning or scabbling.

Mixing Stir Comp. A quickly with an electrical stirrer before mixing Comp. A+B of Sikafloor-156 intensively in the correct proportion (approx. 300-400 rpm) for 3 minutes.The binder mixture (Comp. A+B) is added to the pre-proportioned C component into the running forced action mixer and mixed until a homogeneous, evenly moist mix is obtained.

Temperature +10°C +20°C +30°C

Time 60 min. 30 min. 15 min.

Temperature +10°C +20°C +30°C

Minimum 24 hrs. 8 hrs. ~ 5 hrs.

Maximum 4 days 2 days 1 day

Temperature +10°C +20°C +30°C

Can be walked on 24 hrs. 12 hrs. 6 hrs.

Subject to light wear 5 days 3 days 2 days

Subject to full wear 10 days 7 days 5 days

Sikafloor-156 page 3 of 3

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In case of doubt, always follow the directions given on the pack or label.The information, and, in particular, the recommendations relating to the application and end-use of Sika products, are given in good faith based on Sika‘s current knowledge and experience of the products when properly stored, handled and applied under normal conditions. In practice, the differences in materials, substrates and actual site conditions are such that no warranty in respect of merchantability or of fitness for a particular purpose, nor any liability arising out of any legal relationship whatsoever, can be inferred either from this information, or from any written recommendations, or from any other advice offered. The proprietary rights of third parties must be observed. All orders are accepted subject to our current terms of sale and delivery. Users should always refer to the most recent issue of the Technical Data Sheet for the product concerned, copies of which will be supplied on request.

SIKA AGP.O. Box 1300CH-8048 Zürich/Switzerland Sika – Construction ChemicalsPhone 01 436 40 40 Telefax 01 436 45 55 from Switzerland – For the World

Application /Material Consumption

PrimerThe homogeneous binder mix from which air has been detrained is poured in strips onto and worked evenly into the substrate by roller or suitable brush in not too thick layers.Material consumption approx. 0.3-0.6 kg/l depending on substrate conditions.

Mortar screed- PrimerSikafloor-156 Primer made thixotropic with:

0.2 kg Aerosil 200 (~ 1l) (supplied by Degussa AG, Zürich)+ 2.1 kg Quartzflour K-4 (~ 1.75 l) (supplied by Zimmerli AG, Zürich)for 10 kg Sikafloor-156 A+B Comp.

- MortarSikafloor-156 binder (A+B Comp.) are mixed with Sikadur-506 (C Comp.) at a ratio of between 1:7 to :10 p.b.w. depending on requirement.

The mortar is applied wet on wet to the still tacky thixotropic Sikafloor-156 Primer and distributed evenly with a rake. Level with batten drawn along steel rails and smoothe with suitable trowel.

Limits - Min. substrate temperature: +10°C- Max. substrate temperature: +30°C- Max. relative air humidity: 85%- Observe dew point- Always apply Sikafloor-156 mortar screed wet on wet with Sikafloor-156 Primer- Max. moisture content of substrate: 4% (or use Sikafloor EpoCem)- Sikafloor-156 mortar screed is not suitable for frequent or permanent contact with water

Overcoatability Sikafloor-156 can be overcoated with all Sikafloor epoxy-resin-sealers, coatings and screeds at temperatures above +10°C. Prior to overcoating, Sikafloor-156 must have cured tack-free.

Cleaning Clean all implements with Thinner C or Colma Cleaner immediately after use (before material has hardened).

Safety Instructions

Safety precautions During application in closed rooms, shafts and pits etc., sufficient ventilation must be provided. Keep away from open light, including welding.Product may cause skin irritations. Wear protective clothing (gloves, goggles). Put barrier cream on hands before start of work.If in contact with eyes or mucous membrane, rinse thoroughly with clean warm water imme-diately and consult your physician.

Ecology In not fully cured state the cleaner and the product are water contaminants. Therefore do not dispose of into water or soil but according to local regulations.

Toxicity Class 4 under the relevant Swiss Health and Safety Codes.

Transport Hazardous, - Comp. A Imco cl. 9 - Comp. B Imco cl. 8/66 c)

Product Data Sheetpage 1 of 4

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01.99

Sikafloor-261System Data Sheet

Description Solvent-free, pigmented, 2-component binder based on epoxy resin for:- Broadcast floors- Self-levelling floors- Mortar screeds- High-build-coatings- Textured coatings

Uses - Storage and logistic areas- Wet and dry processing areas- Institutional areas- Underground car parks

Advantages - Universally applicable- Good chemical und mechanical resistance- Jointless- Easy and fast application- Good adhesion to the substrate- Solvent-free according to KEL-CH

Test certificate Polymer Institute, Dr. R. Stenner D-Flörsheim (Germany),Certificate of conformity (Certificate Nr. P 1404-5a)

Coating systems 1. Broadcast floor: (3-4 mm layer thickness)

Build-up:Base layer: Sikafloor-261 (A + B + C) 2.8 - 3.8 kg/m 2

Broadcasting: Quartz sand (0.3 - 0.9 mm) approx. 4 kg/m 2

Top coat: Sikafloor-261 (A + B) approx 0.6 kg/m 2

Mixing ratio:Comp. A : comp. B : comp. C = 10 : 3 : 13 parts by weightComp. C = quartz sand (0.08 - 0.2 mm)

Mixing:Stir Component A well. Add component B in the right mixing ratio and mix by means of an electric stirrer (approx. 300 - 400 rpm).

Mixing time at least 3 minutes until a homogeneous mixture is obtained. Fill mixed material into a clean container and mix again quickly.

Application:Apply base layer evenly with a tooth trowel (6-8 mm notches) and detrain any entrapped air with a spiked roller. Broadcast the homogeneous base layer with sand in excess. As soon as the layer is ready for foot trafic the sand is brushed off, the surface slightly overworked with a grinding machine, vaccum cleaned and subsequently sealed with a short pile roller, a straight trowel or a squeegee.

2. Self-levelling floor: (1.6 - 2.0 mm layer thickness)

Build-up:Primer: Sikafloor-156 0.3 - 0.6 kg/m 2

Self-levelling floor Sikafloor-261 (A+B+C) 2.8 - 3.5 kg/m 2

Mixing ratio:Comp. A : comp. B : comp. C = 10 : 3 : 13 parts by weightComp. C = quartz sand (0.08 - 0.2 mm)

page 2 of 4 Sikafloor-261 System Data Sheet

Mixing:Stir Component A well. Add component B in the right mixing ratio and mix by means of an electric stirrer (approx. 300 - 400 rpm).

Mixing time at least 3 minutes until a homogeneous mixture is obtained. Fill mixed material into a clean container and mix again quickly.

Application:Apply self-levelling floor evenly with a tooth trowel (6-8 mm notches) and detrain any entrapped air with a spiked roller.

3. Mortar screed: (approx. 8 mm layer thickness)

Build-up:Primer: Sikafloor-156 (thixo) approx. 0.3 - 0.6 kg/m 2

Screed Sikafloor-261 (A+B+C) approx. 17 kg/m 2

Mixing rato:Comp. A : comp. B = 10 : 3 (parts by weight)Comp. A + B : comp. C = 1 : 7 (parts by weight)Comp. C = aggregate

In practice the following sand mixtures proved to be suitable (granulometry for a layer thick-ness of approximately 8 mm):33 pbw quartz sand 0.1 - 0.5 mm33 pbw quartz sand 0.4 - 0.7 mm33 pbw quartz sand 1.0 - 2.0 mmThe largest grain size should be approx. 1/3 of layer thickness. Depending on grain shape and application temperature the aggregates must be matched to each other by practical trials. Factory made sand mixtures (Sikadur-506) tend to segregate during transport, there-fore use whole bags only.

Mixing:Stir Component A well. Add component B in the right mixing ratio and mix by means of an electric stirrer (approx. 300 - 400 rpm).

Mixing time at least 3 minutes until a homogeneous mixture is obtained. Fill mixed material into a clean container and mix again quickly.

Application:Mix 10 kg Sikafloor-156 Primer with 0.2 kg Extender T and 2,1 kg quartz flour.Apply mortar layer evenly to the still tacky, thixotropic primer, using levelling boards and guide rails. Compact and smoothe with a trowel or teflon coated power float.

4. Coating: (high-build)

System (0.3-0.4 mm):Sikafloor-261 (A+B) approx. 0.4 - 0.5 kg/m 2

System (0.6-0.8 mm):1. layer: Sikafloor-261 (A+B) approx. 0.4 - 0.5 kg/m 2

2. layer: Sikafloor-261 (A+B) approx. 0.4 - 0.5 kg/m 2

Mixing ratio:Comp. A : comp. B = 10 : 3 (parts by weight)

Mixing:Stir Component A well. Add component B in the right mixing ratio and mix by means of an electric stirrer (approx. 300 - 400 rpm).

Mixing time at least 3 minutes until a homogeneous mixture is obtained. Fill mixed material into a clean container and mix again quickly.

Application:Both systems are applied evenly with a short piled lamb skin roller.

Sikafloor-261 System Data Sheet page 3 of 4

5. Textured coating (Approx. 0.8 mm layer thickness)

Build-up1. layer: Sikafloor-261 (A+B) approx. 0.4 - 0.5 kg/m 2

2. layer: Sikafloor-261(made thixotropic with extender T) approx. 0.5 kg/m 2

Mixing ratio:Comp. A : comp. B = 10 : 3 (parts by weight)Mix Extender T into comp. B(Dosage of Extender T = 1.0 - 1.5 % of Comp. A + comp. B)

Mixing:Stir Component A well. Add component B in the right mixing ratio and mix by means of an electric stirrer (approx. 300 - 400 rpm).

Mixing time at least 3 minutes until a homogeneous mixture is obtained. Fill mixed material into a clean container and mix again quickly.

Application:Apply the first layer evenly with a short piled skin roller. For the second layer use thixotropied binder, apply with a short piled lamb skin roller and finish with a textured roller in order to achieve an uniform texture.

6. Application on green/fresh and damp concrete

For the application of the before-mentioned coating systems on green/fresh and damp substrates the following build-ups are necessary:

Horizontal smooth surfaces:Primer: Sikafloor-155 W approx. 0.2 - 0.4 kg/m 2

Levelling layer: Sikafloor-81 EpoCem approx. 4.0 kg/m 2

Horizontal broadcast surfaces:Primer: Sika Repair/ Sikafloor EpoCem Modul approx. 0.2 - 0.3 kg/m 2

Broadcast layer Sikafloor-81 EpoCem broadcasted approx. 5.5 kg/mwith quartzsand in excess

Slopes:Levelling with Sikagard-720 EpoCem

Skirtings and covings:Filling with Sikagard-720 EpoCem extended with quartzsand (0.08 - 0.2 mm)

Technical Data

Colour Pebble grey (approx. RAL 7032)Other colours on request

Density (20° C) Comp. A: 1.52 kg/lComp. B: 1.01 kg/lComp. A+B: 1.36 kg/l

Pot-life

Shelf life In original sealed containers stored in dry conditions at + 5° C to + 30° C: min. 12 months from date of production.

Packaging Pre-proportioned units for 26 kg mixture ready for use (Comp. A + B)

Comp. A 200 kg drumsComp. B 180 kg and 60 kg drumsComp. C Quartzsand (can be obtained locally)

Extender T: Bags of 1 kg

Temperature + 10° C + 20° C + 30° C

Time 60 Min 30 Min 15 Min

page 4 of 4 Sikafloor-261 System Data Sheet

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In case of doubt, always follow the directions given on the pack or label.The information, and, in particular, the recommendations relating to the application and end-use of Sika products, are given in good faith based on Sika‘s current knowledge and experience of the products when properly stored, handled and applied under normal conditions. In practice, the differences in materials, substrates and actual site conditions are such that no warranty in respect of merchantability or of fitness for a particular purpose, nor any liability arising out of any legal relationship whatsoever, can be inferred either from this information, or from any written recommendations, or from any other advice offered. The proprietary rights of third parties must be observed. All orders are accepted subject to our current terms of sale and delivery. Users should always refer to the most recent issue of the Technical Data Sheet for the product concerned, copies of which will be supplied on request.

SIKA AGP.O. Box 1300CH-8048 Zürich/Switzerland Sika – Construction ChemicalsPhone 01 436 40 40 Telefax 01 436 45 55 from Switzerland – For the World

Application

Substrate The substrate must be dry, clean, and free of loose particles, liquid and oil. Unsound areas must be removed prior to application. Compressive strength min. 25 N/mm 2, pull-off strength min. 1.5 N/mm 2. Prior to application porous areas and unevenesses must be levelled with Sikafloor-81 EpoCem.

Mixing Stir Component A well. Add component B in the right mixing ratio and mix by means of an electric stirrer (approx. 300 - 400 rpm).

Mixing time at least 3 minutes until a homogeneous mixture is obtained. Fill mixed material into a clean container and mix again quickly.

Cleaning Implements must be cleaned at once with Colma-Cleaner or Thinner C. Fully cured material can only be removed mechanically. Clean hand and skin intensively with warm soap water.

Limitations - Substrate moisture content < 4 % (or use Sikafloor EpoCem)- Minimum substrate temperature: + 10° C- Maximum substrate temperature: + 30° C- Maximum relative humidity 85% r.h.- Observe dew point!- Stir comp. A well prior to each application- Maximum slope 1.5 %

Safety Instructions

Safety precautions Component B of Sikafloor-261 Binder falls under the dangerous goods regulations (class 8)The product may lead to skin irritation (Dermatosis)! Wear safety clothing (gloves, goggles). Apply barrier cream to hands. In case of contact with eyes or mucous membrane clean immediately with warm water and consult a doctor.During application and curing in confined areas, ditches, shafts etc. adequate ventilation must be provided.In a liquid or not fully cured state Sikafloor-261, comp. A + B contaminate water and should not get into drains, water and ground.Remnants of Sikafloor-261 must be removed according to regulations.During application risk and safety instructions on the containers must be observed.Furthermore local regulations must be adhered to.Further details are contained in our instructions „Health protection and prevention of acci-dents“.

Ecology In liquid state Sikafloor-261 Binder contaminates water and may therefore not be disposed off into sewage, waters or soil, but strictly in accordance with local regulations.

Toxicity Comp. A + B : Class 4 under the relevant Swiss health and Safety Codes.

Transport Comp. A : Non hazardousComp. B : 8/66c

Product Data Sheetpage 1 of 4

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01.99

Sikafloor-81 EpoCem NewSelf-Levelling Epoxy-Cement Floor Topping

Description Three-component, cementitious, epoxy-modified self-levelling floor topping.

Uses As a temporary moisture barrier (2 mm thick) for epoxy and polyurethane floors.

As a self-levelling topping of 1.5 - 3 mm thickness for:- Levelling or patching concrete surfaces, both unfinished and after grinding or planing- EpoCem floors on non ventilated damp substrates (also coloured) with low esthetic consi-

derations - Levelling layer beneath epoxy floor coatings- Self-levelling toppings as a substrate for synthetic floor coatings, carpets or wooden

parquet- Repair and maintenance of monolithic and vacuum concrete floors

Extended with quartz sand, as a patching and repair mortar for:- Surfaces to be coated with epoxy resins

Designed for use on cementitious, mineral-based substrates

Advantages - Simple application system- Can be overcoated with epoxy resin compounds after 24 hrs. (20°C, 75%r.h.)- Economical in use and easy to install- Good flowability- Waterproof- Frost and deicing salt resistant- Permeable to water vapour- Thermal expansion properties similar to concrete- Excellent adhesion to damp and green concrete- Excellent early and final mechanical strengths- Excellent resistance to water and oil- Will not corrode reinforcement- Predosed sets

Test reports LPM, Labor für Präparation und Methodik, Beinwil am See

page 2 of 4 Sikafloor-81 EpoCem New

Technical Data

Colour Light-grey (mix)For coloured Epo-Cem consult system data sheet.

Mix ratio Comp. A : B : C = 1.14 : 2.86 : 17-19 (by weight)

Storage Stored in dry conditions at temperatures between +6°C and 30°C.Comp. A+B must be protected from frost.Comp. C must be protected from humidity.

Shelf life 12 months from date of production if stored properly in original unopened packing.

Packaging Comp. A+B+C: 23 kg ready for use units

Comp. A+B: 4 kg pre-dosed units Sika Repair/ Sikafloor EpoCemModule (red coloured pails )

40 kg pre-dosed units : (10 dosing units)200 kg pre-dosed units : (50 dosing units)

Comp. C: 19 kg bags (50 per pallet)

Physical Data

Density (at 20°C) Comp. A: 1.05 kg/lComp. B: 1.03 kg/lComp. C: 1.72 kg/l (bulk density)Comp. A+B+C: 2.10 kg/l (when mixed)

Mechanical strengths · Compressive strength 10°C/75%r.h. 23°C/50%r.h. 30°C/40%r.h.

1 day ∼ 2.7 N/mm² ∼ 15 N/mm² ∼ 30 N/mm²7 days ∼ 43 N/mm² ∼ 50 N/mm² ∼ 58 N/mm²

28 days ∼ 55 N/mm² ∼ 60 N/mm² ∼ 66 N/mm²

· Adhesive tensile strength

1 day not measurable7 days 100% concrete failure

28 days 100% concrete failure

· Flexural tensile strength approx. 14 N/mm² (28 days, 23°C)· E-Module static +20°C ∼ 20’000 N/mm² (28 days, 23°C)· Coefficient of thermal expansion a ∼ 13·10-6 m/m°C

Reactivity (75% r.h.) 10°C 20°C

Pot life (23 kg) ∼ 40 min . ∼ 20 min.Waiting times- Can be walked on after: 24 hrs. 15 hrs.- Light mechanical loading after: 3 days 2 days- Fully cured after: 14 days 7 days- Can be overcoated with epoxy

based materials as soon assurface moisture content of EpoCem is less than 4%, however not earlier than : 2 days 1 day

Sikafloor-81 EpoCem New page 3 of 4

Application

Material consumption Primer (depending on application)- Sika Repair/ Sikafloor EpoCem Module (Comp. A+B), approx. 200 - 300 g/m² depending

on substrate condition. This primer must be used if Sikafloor-81 EpoCem New is being broadcast with sand in excess, or overcoated with a self-levelling floor coating on normal absorbent substrates. On porous or excessively absorbent substrates use Sikafloor-155 W instead.

- Sikafloor-155 W (Comp. A+B), thinned with 10% water, approx. 300 - 500 g/m² (depen-ding on substrate conditions). Sikafloor-155 W is being used when repairing Mono- or Vacuum- Concrete, also if Sikafloor-81 EpoCem New is applied without sand-finish or when Sikafloor EpoCem is overcoated with the same material.

Self-levelling floor- Sikafloor-81 EpoCem New (Comp. A+B+C) approx. 4.5 kg/m² for 2 mm layer thickness.

Limitations - Layer thickness: min. 1.5 mmmax. 3.0 mm

(holes of 3 - 5 cm diameter : Layer thickness max. 10 mm)- Min. substrate temperature: +8°C- Max. substrate temperature:

Mixing ratio :A+B:C = 4 : 19 +25°CA+B:C = 4 : 17 +30°C

- Max. ambient temperature: ∼ 30°C- Max. rel. air-humidity: ∼ 80%- On no account should any water be added to the mix.- If Sikafloor-81 EpoCem New is used as a temporary moisture barrier, the whole area must

be coated to a min. layer thickness of 2 mm.

Substrate preparation The substrate must be structurally sound and free from all traces of loose material, laitance, oil and grease. Substrates must be dry or saturated surface-dry (no standing water). Adhe-sive tensile strength at least 1.5 N/mm².

Mixing Shake Comp. A (white liquid) briefly, then pour into Comp. B and shake vigorously for at least 30 seconds.Stir material before taking it from a drum. Pour the binder mixture (A+B) into a suitable pail (approx. 30 litre capacity) and add Comp. C, whilst mixing with an electric stirrer. Mix thoroughly for at least 3 minutes.

Application Apply primer by roller. Avoid the formation of puddles. (For choice of primer, please refer to „Material Consumption“).At 20°C and 75% r.h. Sikafloor-81 EpoCem New mix may be applied to the primed substrate after the following minimum waiting time:- with Sika Repair/ Sikafloor EpoCem Module: 1hrs- with Sikafloor-155 W Primer: 12 hrs.

Sikafloor-81 EpoCem New must be evenly spread with suitable rubber or metal trowel and immediately rolled with spiked roller to remove entrapped air and to obtain an even layer thickness. Workability may be adjusted by slightly varying the Comp. C content. (see mixing ratio).

Extended mortar mix To repair surface irregularities and holes deeper than 3 mm, the standard Sikafloor 81 EpoCem New mix may be extended with dry quartz sand.

Mix-guide:

- Sikafloor-81 EpoCem New (Comp. A+B+C) 23 kg(mixed well for 3 minutes)add:

- Sikadur-509 (quartz-sand 0.7 - 1.2 mm) 5- 10 kg or - Sikadur-510 (quartz-sand 2 - 3 mm) 5- 10 kg

Final mix 33- 43 kg

To achieve good bond of the mortar to the substrate, SikaTop-Armatec 110 EpoCem must be used as a primer. Apply mortar wet on wet to the primer.

Cleaning Clean all tools with water immediately after use. Once cured, Sikafloor-81 EpoCem New can only be removed mechanically.

page 4 of 4 Sikafloor-81 EpoCem New

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In case of doubt, always follow the directions given on the pack or label.The information, and, in particular, the recommendations relating to the application and end-use of Sika products, are given in good faith based on Sika‘s current knowledge and experience of the products when properly stored, handled and applied under normal conditions. In practice, the differences in materials, substrates and actual site conditions are such that no warranty in respect of merchantability or of fitness for a particular purpose, nor any liability arising out of any legal relationship whatsoever, can be inferred either from this information, or from any written recommendations, or from any other advice offered. The proprietary rights of third parties must be observed. All orders are accepted subject to our current terms of sale and delivery. Users should always refer to the most recent issue of the Technical Data Sheet for the product concerned, copies of which will be supplied on request.

SIKA AGP. O. Box 1300CH-8048 Zürich/Switzerland Sika – Construction ChemicalsPhone 01 436 40 40 Telefax 01 436 45 55 from Switzerland – For the World

Safety Instructions

Safety precautions Product may cause skin irritation. Wear gloves and goggles and apply barrier cream to hands. In contact with eyes or mucous membrane, flush immediately with plenty of warm water and seek medical attention without delay.

Ecology In a liquid state Comp. A+B contaminate water.Do not dispose of into water or soil but according to local regulations.

Toxicity Comp. A: Class 4 under the relevant Swiss Health and Safety Codes.Comp. B: Non-toxic.Comp. C: Non-toxic.

Transport Non-hazardous.

8.3 Details UN-Approved Steel Drums Drum for Solids, 213 Litres, St. 12.03

Drum for Liquids, 215 Litres, St. 12.03/1.4301

8.4 List of Contributors Pasi Rinne UNEP/UNOPS clean-up project (Senior Advisor) Mikko Halonen UNEP/UNOPS clean-up project (Expert) Zoran Dimkic UNEP/UNOPS clean-up project (National expert) Juraj Silvan Regional training centre for Basel Convention in Bratislava (Head of RTC secretariat) Adam Ostrowski Regional training centre for Basel Convention in Bratislava (Expert) Urs K.Wagner ETI Environmental Technology International Ltd., Chur, Switzerland (Expert)