Document 2J5r7zjpp7x5pZBxq11oXm7Vp

FILE NAME: Phenolic Resins (PHR) DATE: 1962 DOC#: PHR044 DOCUMENT DESCRIPTION: Unpublished Report - Kaylo Improvement Progra Progress Report, Jan-Feb-Mar, 1962; from Owens-Corning Fiberglas File r r O KAYLO raPiTOVLTCI rr PROGRA.V PROGRESS REPOR? JA ].TARY - FEBRUARY -M A RCE, 19&2 I v? 8 CONTENTS QNase F ib e r s Stress Corrosion Formulation Studies Coro M aterial Bond&d A ggregates Raw M a te ria le In p act Machine 36" Pouring Device In crea se Opening Between Core and S h e ll Kaylo=FJ.ad Aluninua Ivo Layer High Temperature Pipe In su la tio n Reduce or E lim in a te Dust on Kaylo Block Boiler Insulation Process Shrinkage rs 1 , 0LA5S FIBERS (a) Coatings o f various typos have been tr ie d fo r a p rotective covering fo r g la ss fib e r s , to reduce or elim inate a t t r it io n through the autoclave p ro cess. Soso o f these tr ie d by General Research a re : (1) Vinyl Chloride Plns tis o l - E x c e lle n t, but is high in ch lo rid e and i s c o s t l y . (2) Vinyl A cetate S55 - Coating disappeared during process fib er attacko (3) Urea Formaldehyde - Prac l8o - C o atin g disappeared, but f ib e r appeared to be in good c o n d itio n . No adhesion to KaylOo (*0 S h e ll Expoxy 528 - Trace o f o o atin g l e f t a f t e r p ro ce ssin g . F ib er appeared In good c o n d itio n . High c o s t . (5) Dow P olyetrycr.e - PS? - R esin d isap p ea red . Being therooplajstio nay have been absorbed by the K a y lo . (6) Helen:-ire Helene - Sane r e s u lt s as 2r3, form aldehyde, (7) HI Temp Phen o l i c , Monsan to ^1013 - E x c e lle n t r e s u l t s . S l ig h t ly su p erio r to Tybon very high coot0 (8) Novels}: Type Fb e n o iic . Acme X-^7p| * Poor r e s u lt s when coopared to Tybon 3^lSo (9) " Newark P la n t - Poor r e s u lts when compared *\Ath Tybon"3^1^o (10) Helasinc - Phenolic Copolymer - Newar k P la n t - Poor r e s u lt s when compared w ith Tybon 3^1-8 (11) Gener a l M i l l s Polyanl d - Hot M elt - R esin absorbed sway fro a fib e r in to Kaylo m atrix during process. Fiber appeared in good condition, . . The fo llo w in g s p e c if ic a t io n was s e t fo r a c o a tin g th a t gave the b est r e s u l t s , and which was low in c h lo r id e c o n te n t. I t was Tybon 3*+lS Phenolic R e sin (American - K a ria tta .) a t 62/ so lid s, I t vas used on K75 1/0 yarn a t 636 s in e , w ith kCQo nominal ig n it io n lo o a , w ith 33~i*5*> rangCo There are approxim ately fo u r (*0 beads/inch o f length, There were v a rio u s runs cade w ith v a r ia tio n s in percent o f o o atin g ran g in g from 38.5 to 57^1 chopped le n g th s a t 1- 1/ 2" to 211, r " <fo 1- i r F A (' t ' The maiii reaso n s fo r u s in g Tyboa JjA l8 P h en o lic R esin o re: (1 ) Lover cost (2) Su rvival o f autoclaving process . ( 3) Low c h lo r id e co n ten t (0 Beading a b i l i t y (5) Good adherence to Kaylo body (b) Teet runs v e r 6 made w ith v a rio u s form u lation s fo r d iffe r e n t percentages o f coated f ib e r s , which gave a s im ila r variance in glass percentages; d iffe re n t types of fib e rs; m ultiple lengths o f fib ers; pouring method voriani-eso In the Jan uary t e 6te the v in y l c h lo rid e coated fib e r s gave su p e rio r t e s t r e s u lt s to any o f the p h en o lic f i b e r s . Some o f the fib e r s , co a tin gs, etc, used are; (1) V in yl chloride - 2" length (2) Phenolic 1 -3 A " length (3) Phenolic - 1-1/2" length (*0 Com binations o f (2) and (3) (5) Sprcut-h'aldron opened V3 a n o s ite asb esto s (6) Com binations o f v in y l ch lo rid e ana Sprout-Valdron opened W3 a s b e e to so (7) Com binations o f P h en o lic R esin and Sprou t-V ald ron opened W3 a c o n ite ,, Runs u sin g above v a r ia t io n s o f coated g la s s fib e r s and dry m ille d opened W3 am osite were cade u sin g d if fe r e n t d esig n s o f the 36" pouring d e v ic e ; The presence o f a i r h o les and s l i p p la n e s , forced by c lo g g in g o f the n o z s lo , a t too frequ en t in t e r v a ls , was the main d e fe o t and was the te c h n ic a l p ro b lea to be overcome,, A com bination o f 9* opened a c o s it e ; 9^ c h r y s o t ile j and 3^ v in y l coated g la s s f i b e r , fo r a t o t a l o f 21^ o f f i b e r , gave a-maximum o f e ig h t ( 8) drops; an average o f 5 S and 6e8 dropa0 The o r ie n ta tio n o f the f ib e r van goode The 36" Bauer H i l l was redesign ed fo r a dry m ill b a s is , fo r opening V3 and o th er a o o s ite and c h r y s o tile grades o f asbostoso V ariou s types o f coated fib e r s were u se d , both p h en olic and vinyl The v in y l c o a tin g gave a more p lia b le g la s s f i b e r , which r e s u lte d in le s s c lo g g in g o f the pouring n o z z le s , than was experien ced from the s t i f f phenolio covering V in y l coated g lo s s f ib e r s were used in many o f the February and e a r ly Haroh t e s t t r i a l s 0 These re e u lts are ehsmarizod: (l) I t waa found th a t a fib e r co n ten t o f l 8 to 2&%% o f yhich a t l e a s t 15^ based on batch w e ig h t, vas dry m ille d opened a n o s ite or ar,osit plus coated g la s s f ib e r , produced a s ig n ific a n t in crease In the drop te s t resu lts,, (2) A lthough r e s is ta n c e to breakage in the drop to s t was markedly In creased by the In c lu s io n o f 5 to 7% o f p h en o lic coated f i b e r , these amounts o f the s t i f f fib e r contributed to forming d i f f i c u l t i e s , that resulted in a p oorly co n so lid a te d body and low modulus or rupture v a lu e s . The varc vas g en era lly un acceptab le, in sp ite o f rath er high drop te st values,, *f -2 - r\ astie o sM e ^ ff ? r. V?w e a s i l y obcervod in the p ro d u e t. roTM d f l b " r r<T U e i l a TM B a=c>QIlt o f vir^ 1 fib e r m *y * * , in th . w h , t0 ro^Jltod in 00 advereo effects, pziccas or^?od" t 0flte,i flbi,r- drop than s i ^ \ Z t " d i i t r ^ ^ ^ " " aTora e o f 1*3 or,i Graid Tio K ^ c i l e i f v T ! ! " * ^ h 0r" n n . " TM Orleans cent used In those ahipocats ,,si" ~ t u r n e d to B e r lin . The e qu ip - (2) t v " r \ U ' " Cc" l!r c l'a truck v ) ura^n Rapids - C o c s e r c ia l LTL tru ck Abuee in tr a n s it v a r ie d , in nanner o f ,, u ip n e n t , ra th e r then d is ta n c e . C . (U i o ^ e a ^ S s ! 1 K>a' C<irt0DS * oo evidence o / h o r S n t i i f 1^ ! I ^ by droppingo ^ ^ ~ d a ^ s to cartons 0 > ! J i r r,V % > r e t '1`~I tD B e r ll" ` I a r r t abuse on LrnL g p .^. ' Cc L- t'3t^oa ^p al llle tMiz e^d da` nda tmi ',ertahl eoat^ran"o t o r i s l lomaded on c u ttin g in to carton s and c r a c k y ^ U sht* ^ ^ t o n a loaded on aide la r g e s iz e 1 ? i j 1/7 had co n sid e ra b le danage - LTL ohipcento 1 " 1^2 vore fo r a t o t a l 5 2 08& The r e s u lt s v & r :' * ^ Bf r ^in s h iFaen ts , 599 piece*, ' 5jJCludcd CDP titore v a r e , (1) Carey-Teap - H ighest dasa-r C3> p- ^ t i o o second h i g W d a r a * . (^0 01_X66 f ib e r re in fe r^ ^ -'w rf 4 <** , (5) Sprout Waldron o p e ^ ,, 1 ^ % ? * * * * " * T S r iib lM ^ w *? OO o 3- On these ehiocenta th e-a 15 , 5-,' to New O rle an s: Va7 % 760^ To e ls e d e fe c tiv e : . ? l ? 0 t a l , vare shipF-ed to retu rn f r o - Nav O ri ears G ranrllle to B erlin . 3x1 x l 6xl 8 x 1-1/2 12 x 1-1/2 153 pcs 211 tl I 87 II Zb n Zb 599 pc a 0 25.5/ 3 5 .# 31.2/ boOZ JjoO / 100/ T o ta l p ie ce s shipped were 11340 * - E t S & J T " & 4*4 sooe vaar marks on both a id e s o f c a r t o n . r ` ^ Cartons very d e f i n i t e l y shoved the In ter fo rm a tio n le "*' on a s b e s to s , It, the fo r n u la tlc a d l h o M l c ^ l M Bf U9r 11111 Fe;,od' ^ v a i, a fte r in sp ectio n out of the t o / l * L ^ D" ^ S 12 x 1- 1/2 8 x 1-1/2 ?* 1 80cCtt 3 3 .# 17o5* l ie 135 relatld01^ T o l s ^ l f ^ n ^ ^ 12 x 1-1/2 8 x 1 - 1/2 ?x 1 kx 1 68,,lS 8. 5/ l b 0$% 8 ,# of t o S iu areet:tio ^ e1cr P: c^ I<towd teif - 12 x l l /2 8 x 1- 1/2 ? x 1 * x1 25. 0/ 3, 1/ 5c%- 3.1/ . .1. excepUor-aH^ h a ^ ' a t j ^ b / b e - n / h f r i ` ' n t i m i g h most o f the ware suffered reflected the I s / v e o e c t S i e " " ^ , 1 , " " / ? =* P * r o u t s . BeDt - * <* to = r a n ,l l u ! CKef : T r : I S / S L r S : ftrrt U (d) A Kaylo Product Innrovp-anf , aa York, Tuesday, March 20, 196 2 0 ^ v *a a -- e " C 1 S Waa h e ld Kow form ulation would be placed In nrodimM &* * ^ere th at the Improved % 1962, and I t wan, The 35"' R i u e ^ V l u a t ` 5 S e r U n P la n t, on March 21, dry ta llie d a r o e lte and o th e r ^ a d u n p ln f S u f f ic ie n t v in y l coated x l '-fn f .,y/ d ^ e c t l y in to the hyd rortilp or, w s in r o n a u K t lc n : 2, S: ^ o d 10.5 per. me dent annunt'vaa t *> # f ' A * ^ t y van act at amount could bo had and m lr .ta ln o d ' 500 lb = ". thin has oontxnued in production w ith the a V i- 1\ . ^-n^ a-'^-nS l i n e a 0 The p la n t Sone p ro b le m v ero ^ en co u n te r^ tu t ^ ^ ^ le a s t to the poin t where th ey i r e not In * ! ' 8t1^ ove"coae, at the v in yl coated g la ss fib e r s vc-e secured la a 3i i i c a t l ^ o C u tte ra fo r len gth f i r s t usc-d0 ` ^ d * choP tho fib e r to the 1-1/2" (e) The General P m in -rii t -.*-- * c o m i t t e c , to proceed a s . u l c k l ^ a s ^ s m u ' t T d l 01 in stru c t'!'1 the glana fib e r s th at would; ^ possib le to dieoover a co atin g fo r ( 2) m v o 'tl3 C 3 t ly **" ^ 1 'W o r l d . co a tin g f , S f ,tfc5, 6`- r a d d itio n a l f l . a b i l i t y COn',a in le 3 s c h lo r id e ^ W Hare a rap id drying r a t e , K a y l o ^ t c r i r e ^ 60"^ 68 f th pr sra,a o f UeijlS coated g la s s f ib e r s in C 316 C l) DiscontiJTUC the Ufii n f fii/b , TM a . replacing S ^ T i C ^ S t " fib * rS' general p / d u c t-s I t e f PreSen!: Klaas fib B r ' * V - t i l l t i n g t e a m , or glaas v a s tP to by (3) and^dry L Y f Y S a U Y Y *" 31"117 * o t e la b s " " b a s p r e p a r e and ( ^ L Y e Y a a a r c c , v it h low est fre P g h t =0. ^ a t B arrlaSt`'n through ,, ,, o f ^TM ^ / * Fib^ * * S ire s the M ^ e s t Y S i r Y d Y s Y r e l Y t V coat han dlin g abuse before c w t ^ r b ^ I k S ^ e U '" f l b r o > " t l c h Stern e. re su lts, take, atod su Y f a0t r U percentages o f . / w -5 - 2 STRESS CORROS Tor: co m p e tito rs' c e a w r a b lf c h i o r i d f c o J I t e n t i 1^ " "^ Pf ^ 1c t v ith a lowGr than ' ' . e u la tio n , fo r use in combat-* t , * I to be the le a d e r in heat iu - or v e a s e le ; when such a tta c h i s ag ^ ra v a to d b y th n e U ltllo G i: 8 te e l P1** p a r tic u la r ly sea water,, S * d the Presence o f m oisture, o f Drc Fontana o f Ohio S ta te r e ^ r r f u end p ro d u cts, p a r t ic u la r ly d' I n v euhareanaenrtG,o ttiongset^h er w* *ith *these P?Q c h lo r id present in Kaylo u r i . : r X P7 o " r t r Z ! L n ? p0B t' ' PT I>le d id o t * would be a cce p ta b le as a he: t k Per0ODnel did s ta te th at Kaylo In the fo ra o f aodlun s ilic a t e vere p reaeiw S t id n U s s s t " 1' i f " In h ib itor f o l l o v alo n g with S o c t ^ r e o - c s - i - a t l i ' r ' t d r' J t.,0t p r cl' `-'-r- ' r , would ~ y p e i p l T i S L u d ^ ' a d i t u f d the iJ1>` i b i t o r - * s ilic a te , that through the pro c c ^ f J TMv. i e , 7 r ro bin 1J ^ th<! t h is can be a . b e a r a b l s ta g e and f o llo v e " " " t j e i t h e r ' f L ^ r ^ i p c ' o ? L ? c COatll,g' , t0 " s r:- t Eor coated m a te r ia lj ^ f o r e ^ - D * <>' i r s : .- (e) Some com " P la c it e 7122" on san ies. Carbide Chem icals in c lu d e d , use a m ateria l c a lle d including Kaylo, i t c o s ts S0o50 a ' T? hhe uupopfeirr trem8p^eraitu1rebelriocrei t is only +82*decreed F arfd ' as K Bone, has a tta^mp neier!ar\artuuarrpeap lilr^Cdi;t ^Ro-rf a-n2wd0-0vR0, jdh_0e_"_g_3r_e_es* bF_ic.h is It nsh.oovudld"eosh^^i svi e-t eeaudn a p p lic a t io n co st f l e s s than w0o50 per s q 0 f t D However, i t has a pot l i - V l8c-20 cirruteso th at outweigh the 0 f e e l t h i s OCF d is t r ib u t e d K Bond m a te r ia l has advan^a-en is to be made whe t i r -her f a O r . 0 " * 1" O u u l,. spray nay be u s e a d, hort w ith pet th . 1 210, .., I nlmute d" pot ' I * lf ' . ( f ) S a le ? w il l want a l l m aterial ... A c h lo r id e content T h is , whether they the t- c ^o to a e ra to be o f a low s t a in le s s e t e e l or o th e r S - i l e a M ^ thB. c" Bte" `>--a, in ten d to U s . I t on > *ay q u estio n o f h u n j J a l l J r a I t L , f l " 00" 1 th a t th c r ' to be placed on s t a i n l e s s - T h e d fo r e i t i's ' c R 1*' reln f U lo tlo n l s Pr c 'h t , an a batch component, so as to h . ,, t i l s l o ^ t c T i n ^ ! ^ : n ^ ln e ^ l e r " ' A ' w f 0r , C T l l 'S " t n in le s s s t e e l H" ~ " ' ' c .a a f.U y is fa . batch, a . I . t r a L M ^ a i l ^ * ^ " ^ " * c t^ . L f r - 1ot * * " ' aovess th . o vcrU ! P la c id . c o n U ^ o V * ^ ' h ^ T ^ i a t u t chlorido ^ the Plant to conduct end product c U o r ^ , 1 1 e ^ ^ , J' ' ?*' B" l l n , , > Tn le i , an chiohdo co n -.-t e " ? " tf' e F" rr" " 18 to 8 t * < ^ .U The o o r - l i c - n .-c o d i l o ' L T ! . L s ta b U a h e i a `- the low est ppi p o s s ib le . L a b o r a t o r ie s "" ^ de/ieed and s e t up by G eneral Research aid T e a tia g cau ein - s tr e s s - c o r r o s i I r a c l ^ ' 1" i>r J " 8 U " ' ' . l a t l v e l , fre e o f ( 1 ) Uni beeto* - 1200r e cs( 2 ) Carcv le-sp - 275*F mnxO ) Foa.*} G la ss - 300F tna>.i ( b ) Hi^rld uro thane fear; - 15C F b s v < /! the ^ l a ^ n ' S ^ c e ^ n M S o r t ie 6 D e ro rt.-:e A an^ i s nt *' K r . J . W Allen is ^ consul tar.. in DuPont' s Engineering w P n u t i , C ^ i u h . ib -' Wle" ? ^ e ; f f DX , , , , * , , Th" TM * * | c a t e r s do net l ik e to work wJ fch n ^ K . f ^ ^ `e QaJ o r i t 7 Dumont's a p p li- I Core v Tenp ^ l i n - t ^ J h" ' ^ 10 l t 8 ^ t a n d le a b ll l t p ! [Isfct o r t a to lo s e i t s t e r r e p e l l e r c / c ^ c ^ a " ^ ^ 3''3' ! 1 1? ^ T" p- oan g la a ie U n it e d tc 300P Tl < ? 17, a t PP13^ t e l y 275"F . a p p lic a t io n s , but R r0 A lie n g *-'**-* Pf on low temperature l a lo se expensive on an a p p l l e T w u ! " P erl<l, ` hTM hown th a t urethane wishes t o ^ t U. - " h i ? L ^ o 1' " ` U U i " that l f O v ^ n ^ o rn in j so li* aH icate*beveieht* " * ##" " * * do 08 1 * H S 5 * *2 ^P U j:'_yri t h .c u t _ - p ir i nr tcT^S 7 7 y * n l 7 _ESl ate use a a o d iu c'a ilica te f tron3*y reccEaandcd th at w* r water r e p e lle n t" . U " ra th 8 r tfcan a t t M F` to n e l:, our product o f the B t a i n l e s r e U c r L ' d ^ h ^ C a i e Y ' T ^ 1^ ' df l p P1',E wat" r on U i" In te r fa c e he lo concerned t !^ t t h U te s t f l ' W " - M o n a . as applicable to ncnvichln* t c r i S ** D * aCO1 * ^ ) s o lu tio n 1 - r u n t e d fo r's o d ^ , u . on the . U i n j f lo o r or on t * . ^ U n " L V K t n " ^ `- n c j. e ith e r n a a i g n if ica r.t re d u ctio n In c o n a l e t .s j j M t e ^ S ' ` P 1' f d l c a t " oodlun B ilic a t# w ill r r m i n on < ,,.a M e x?7td, c in e * the powdered to autoclavingo'' V ^ P ' ^ e n t in th hatch u n t i l s u b je c t 7- "DuPont charges as much aa 3 ,5 8 cen ts core per pound s o lid s fo r the powder, d eliv ere d to B e rlin Sodium s i l i c a t e s o lu tio n d e liv e re d to B e r lin 6 3 o60 cen ts per l b * . Sodiun e i l i c a t e powder d e liv e re d to B e r lin i a 7 l8 cen ts p*r pound*" Above from R . F 0 Shannon's l e t t e r to R0 Co Amos, dated 3/27/62* ` (a) The b a ric sodium s i l i c a t e i s producod a t Gr&33e l l i , Jersey, by DuPontc General Research Laboratory ia to conduct a te s t to determine whether or not thec'O bneic sodium a i l i c a t e chunks can bo run through a Bauer H i l l and ground s u f f i c i e n t l y f i n e , fo r in co rp o ra tio n in to the Kaylo batcho T h is should produce evon lover d eliv e ry coats to B e r lin . (n) T e sts are to bo run a t B e r lin , to produce Banplea fo r IXiPont to ch e ck , t e s t and ap p raise the week o f A p r il 2 , 19620 (o) I t io rsported that Hr* A llen has retracted h is in ference th at if podiun s i l i c a t e were placed in Kaylo b a tc h , th a t immediate approval could be secured w ithout te c tin g o These samples are to be subm itted, but w ill have to undergo a s ix nonths te s tin g ap p licatio n period, before acceptance ia forthcom ing, as an approved in su la tio n c e t e r ia l r e la t iv e ly fr e e from c h lo r id e s th a t cause s tr e s s -c o r r o s io n cra ck in g on a t a in le s s e te e lo 3 jTORKUUTICr? SrJD IP S (a) P ast standard K-10 l i g h t d e n sity batch was geared to 300$ o f duato V ariou s problems o f dust d e liv e ry have been overcome. Form ulation changes have made i t p o s sib le to use a d d itio n a l amounts o f dusto * T h is dust amount was in crea sed to 300$ per batch on Karch 26, which i s the maximum the system can co n tin u o u sly d e liv e r , and there are tin e a when no dust a t a l l i a a v a il a b l e , the weigh hopper i s to be in crea sed to 730,'' c a p a c it y . An a d d itio n a l blower i s to be procured, fo r the in crea sed dust c a p a c it y , in the 15 minute d e liv e r y c y c le re q u ir e d . The equipment i n s t a l l a t i o n should be com pleted, a f t e r blower d e liv e r y , the week o f K a y 21, 1962o (b) I t i s probable a t 500-600# dust per b a tc h , th at t h is amount w ill not be a v a ila b le c o n tin u o u sly , from s c a lp in g , k e r fin g and trim o p eratio n s,. I t may then be necessary to i n s t a l l g r in d in g o qu ipcen t, which would reduce a l l Kaylo processed o ffv a re to d u st, fo r in clu sio n in batch* (c) Sh arp ies C o rp o ratio n recoamends th e ir model P2000 Eorinonhal Seep sr-D Canter for conversion o f 70,000 l b s . o f slu rry per day, haring a w ater/colid* r a t io o f about 20, to one h a rin g a co n stan t and d e f in it e w ater/co lid a r a t io o f about 6. An experim ent o f t h is treatm ent o f waste s lu r r y v i l l be made by the Sharp1e3 C o rp o ratio n on A p r il l 8, 1962, T h is equipment w ill handle a l l o f the waste s lu r r y and remove the v a r i a b i l i t y o f w a te r/e o lid s now encountered, whan placed in b a tc h . T h is t e s t w i l l be follow ed with d ilig e n c e fo r fav o rab le re s u lts * (d) 'Read Standard, a D iv isio n o f C a p ita l Products Incorporated, located a t York, Pen n sylvan ia had a r e p r e s e n ta tiv e c a l l a t the p la n t and we discussed v ario u s p r o je c ts with him-. One th a t they expressed immediate in t e r e s t in van co n cen tratio n co n tro l o f v ae tc s lu r r y , fo r water s o lid s . They produce a d evice fo r th ick e n in g sludge and upgrading s l u r r i e s . A sample was sent to thf o f / a3te elur-ry a t a water s o lid a r a t io o f ^ 3 . They w ill attempt tc raduoe i t to a 7-10 to 1 r a t io 0 (e) The g rin d in g o f dust through the wet process o f the 18" Bauer K i l l on a .023 s e t t in g v tg eet-u p as a standard procedure. Where and when ne-- essary t h is i s coupled with the v e t m illin g o f asbestos f ib e r s , a t the elms plate aettingBo , W i l i n g o f a o o e ite f ib e r s - W3 and AV, as w ell as i*T-3 Lake a s b e s to s , has been su ccessfu lly acco m p lish ed . The p la n t i s u sin g the 36" dry D i l l p la t e s , o f d e v il tooth d e s ig n . The 3 a n o s ite and other a n o site and o h r y e o tile f ib e r s are being s u c c e s s fu lly opened* without len gth a t t r i t i o n 0 Some changes in p h y sic a l lo c a tio n o f the Bauer H i l l were cade fo r d ire c t in tr o d u c tio n o f opened a sb e sto s f ib e r s in to h y d r o ju lp e r . An unloading o f a s b e sto s bag equipment and a subsequent fe e d in g conveyor, in to charge sid e , o f Bauer M i l l are new being designed by G eneral E n g in e e rin g . Increased s tr e n g th and r e s is ta n c e to impact was secured by t h is dry B i l l i n g method. I t was adopted aa the standard procedure o f m illin g o f a sb e sto s fib e r s on March 2 1, 19o2. ( g j he dry m illin g o f a sb e sto s makes i t mandatory th a t a l l ashes tO B ^ be sto red under ro o f and kept d r y . T h is poses a problea in an alread y ( crowded raw m a te ria l sp a ce , but i t must be done to secure the b e n e fits o f the procedure. . (h) K fa c to r t e s t a are to be run a t General T e stin g L ab o rato ry , on present production which has a d d itiv e s s t i l l incorporated fo r a lo v er K 1 fa c to r r e s u l t . T e sts w ill a ls o be made on samples with a d d itiv e s removed. I f K f a c t o r h olds on non a d d itiv e specim ens, the a d d itiv e s v l i l "be removed, fo r K f a c t o r i s now c o m p e titiv e ly s t a b l e . T h is w i l l r e s u lt in a lo v e r c o st per b atch and in creased s tr e n g th , as r e f le c t e d in the modulus o f r u p tu r * . ( i ) The production fo rm u latio n as o f March 21, 1962 i s a t 10.5 p c f . The M/2 fo r t h is b r i e f period seems to be s a t is f a c t o r y } w e ll above oiniiaua in E ay lo CAS fo r K-10 l i g h t d e n s ity . A fte r a at- b i l i z l n g period i t i s planned to reduce density s t i l l fu rth e r, without any d e te rio ra tin g e ffe c ts on K~10 l i g h t d e n sity product q u a l i t y . (j) Q uicklim e was s u b s titu te d fo r hydrated lim e , g iv in g a high er con s is t e n c y , in h-17 cor m a t e r ia l. A fte r some t r i a l s i t was adopted as the standard fo rm u la tio n . I t reduced the d r ip lo s s damage and the offw are fo r (k) The prehardening o f K-17 core m a te ria l i s to be tr ie d during week o f A p r il 16( a t B e r lin , using the c o llo id a l s i l i c a nade a t the G ra n v ille Research L aboratory. Commercial Ludox, jir chased fro a Dupont has been trie d j ^ ( the r e s u lt a V6ra o u c c e s e fu l. The K-17 core m a te ria l was prebardened. -9 - The c o a t vas fa r too h ig h . The co st o f the nrehardenlng a g e n t made at G r a n v ille la orach l e s s . However, the present p la n t K-17 cor* fo rm u latio n , u sin g q u ic k lin e i e g iv in g the p la n t improved o p era tin g r e s u lt s and lo v e r offw are. Unless th is form ulation is d ir e c tly responciblo fo r proved "blova" in Roddis door m an u fa ctu rin g p ro ce sse s, the K-17 oore D a t e r ia l w ill not be prehardened, with the agent Deceseary to speed up the chem ical renotion being addedo This w ill keep the coat o f producing K-17 core m a te r ia l at a lower baeoo Tho r e s u lt s o f t h is prehardening t e s t run w ill be kept fo r fu tu re o s, i f needed, tho same v it h the process procedures fo r making, as developed by the G eneral Research group0 (1) The present p rodu ction form u lation has been su b jected to a temperature o f 1200 degrees F,, fo r 96 h o u rs, on the hot pipe te s te r a t B e rlin ,, This c o n ta in s Oo5% o f coated v in y l g la s s f i b e r . Fu rther t e s t s are to be conducted a t once to determine whether the maximum temperature o f s e r v ic e a b ilit y fo r K-10 l i g h t d e n s ity can be in crea sed to 1500 degrees F 0 4 e CORK Ka.TEP.IAI- (a) A meeting vas h eld Jan uary 24a with Roddis D iv is io n p erson n el, o f the Weyerhaeuser Conp-any and General Research and S a le s , reg ard in g p o s s i b i l i t i e s o f m utually developing a 1-1/2 hour rated fir e door. Another desire vas to have a lo v co st door v it h a 3/4 hour f i r e r a t i n g . About 100 degrees in crease in tem perature on c o ld sid e o f door would be needed. At one hour present r a t in g the tem perature i s from 1700 to 1750 degrees 7 . The weakness in present oho hour f i r e doors i s t.he s a l t s impregnated wood r a i l s . To reach 1-1/2 hours advancement In f i r e r e s is t a n c e o f t h is wood oust be secured ` (b) The R and R bond fire retarding agent, has r e s is t a n c e . T h is work o f cement, which i s now known as K Bond, being a good a good chance o f in cre a sin g the range o f f ir e development i s to continue as ra p id ly as poasiblo (c ) I t should be the concern o f a l l in te r e s te d OCT p a r tie s to make . any improvements r e s u ltin g in a 1 - 1/2 f ir e rated door a p ro p rietary process or p ro d u ct, r a th e r than one m utually shared v it h one customer o n ly 0 (d) Roddis D iv is io n , o f Weyerhaeuser Company has been granted perm ission by U n d e rw riters' Lab o ratory to s u b s titu te K-17 fo r K-20 core m a te r ia l, fo r use in one hour B l a b e l d o o rs. K-17 core m a te ria l has been sent to Roddis fo r t h e ir t r i a l s . Roddis i s now r e c e iv in g K-17 core m a t e r ia l, except fo r K-20 core s t i l l in sto ck fo r them a t B e r lin . ( 0) C u r t is Companies, I n c . saw a f i r e te s t a t F o re s t Products Lab a t Kadi so n , W isconsin th a t vas s u c c e s s f u l hop per's tr e a te d s t y le s and r a i l s , with B a lts im pregnation to 3 to 4 l b s . were used a A change from standard Kaylo door assembly was made0 Tvo p ie ce s nominal 24" x Z&n were used on to p , ra th e r than stan d ard 12" x l 8" and l 8" x 3^"o However, temperature on co ld sid e 0 30 m inutes was 190Fo For Roddis a t U nd erw riters' i t was 156 F o ' ' . -IO - J glue wheel, with hand placed /L? b 10 n t on fou r Ck) glu ed by hand placed c la n p s , in h o rtn o n U l n< i ,1 Maftsbl*<1 by hand and vare made under in a p * c tio o f Unde^ t e ^ ^ n T ' n t a b l* ` 113 to Chicago on Febi-uary 9, 1962 " * in s p e c to r . They were chipped lllj r ^ t e d the cold s id e ! otocKl up p e r f e c t l y . The s t i l e s and r a i l ? ^ oah w c ^ P t round Hearom3 r e p o r t, "the Kaylo v ^ llo At approxim ately ko airm tes n ^ ' a ^ T f ? ld ^ ctand nP the door knob and the top o f the d o s i T t l * h a I f ^ ^ t v e o f the door i g n it e d . T h is was t^e north / 1 ?' ]* eura3^ ' th* whole f ao* B lm te c the face started to biro a t I t r * 00 th# >th door a t k5 I t worked i t s way down the ^ our6 nAt the #ad o f the Id e * ^ *><* corner. te st continued through t h T burned o f f the north door and the f - r * ^ ld edd<5^ waa alm ost com pletely o r . Wh,, th .j- h lt u * " ^ 0 - c . taracd h a lf v a , o ff o h th Kaylo ana the door (north) c o e p l e t e l v ^ ^ f the tLr9 hose. the b & lf o f the door d isap p eared ." ^ appeared} the south doer about f l x . t to r t a t K s d is S , i - a ^ l a i o ^ a2 h* " ' h ' f 5' 3 - U t h o " ^> t h . C u r t i , v& very s u c c e s s f u l. p ro b lt with f i r e , the second teat aeain a n j M otier l a t e n t )to T^ f ^ i . ^ 0a ^ hfl" thB Wstr. a a j u a ltg K-17, as th . a ia a ra l c o r " J ? e! i h Kar-ch 1, 1952, ^ K. 17 cor(, B' ' T 3 f a ' * . H r . door, * target date o f Sunbury P la n t, where e x n e ric e n ta l Wa sn i??sd fr ^3 B e rlin to th e ir plan to t e s t these doors a t an e a s t ^ n ? aJ-" fa c tlir * Waa to b e g in . They acceptance test at Bndervritere* l l h b* f re fo r 411 3 .e <? ! ,, a: r ! S i 4i : " s ci ^ i o bj " r ed * leading to "blows" in hot pre^s . . of ^ it r ic * for detection of defeots n ^ 10 Apru ^ 1 r 5 ` B ffPijD . ACKIPJXiVreS . - i (a) U nited C la y Hines C o rp o ra tio n , In ? b ru ary , sta te d to R F . Shannon, th at th ey had davoiOped a h igh toaperatur bonded aggregate paroduot th a t does not cra ck on d ry in g , w ith 12" x 12" samples The? had secured H/R , - Ta^U8a in excess o f 110 pal a t 135 l b . density They hare submitted theca ' ' samples to OCF fo r e v a lu a tio n . They are f i l i n g p a te n ts on th ie p ro d u ct. I and C D iv is io n have in d ic a te d they are in te r e s te d in fo llo w in g th is d erelo p - e e n t. Jo Bc Dennis o f U nited C la y has s ta te d th a t i f we do not talc* the p ro d u ct, they w il l go to J - H , who hare in d ic a te d they want it o (b) I t van proposed s e v e ra l uontha go th a t t r i a l s U Bade on a proceed cincture o f Kaylo dust and Ludoxo I t i s now proposed th at each a H ixture b strengthened by the a d d itio n o f n on-coated g ia c a f ib e r s , o f randoo le n g th s , i f necessary (c) A combination o f Z e o d l , which i s an u lt r a f in s , p re cip itated s i l i c o - a lu a in a te compound, w ith lim e , asb e sto s and water h a c , on s n a il la b sample te s t s given good s tr e n g th s , when dried a t 8 hours a t 15C*F R e c a ll i s v e ry ' reac .ivc- with CaD I t i s nanufaefcured by the J K . Haber C o rp o ration , Eaver*'De-=o. a c e , Maryland I t i s planned to try t e s t s o f our own during the week o f A p r il 9 producto Gr a nv i l l e 0 This o f f e r s another lead fo r a do n--au toe laved (d) The n e c e s s ity fo r a non--a u to c la v e d , high temperature heat in s u la t io n product, is co st pronounced fo r the fo re ig n m arkets, such as Mexico, South A fr ic a and Australia The n on-autoclaved p ro d u ct, i f strengthened with non- coated g la s s f i b e r s , p a r t ic u la r ly o f waste d e r iv a t iv e , would be o f immense valu e to fo re ig n sube'i'dl o r i e s o f Cve ns-Com ing The co st o f rem ixin g, p re ssin g and d r y ir g equipment, w ith as few molds as n e c e s sa ry , would g r e a tly reduce tae in/eswoent co st fo r g e ttin g In to p ro d u ctio n . A good top grade product, could g iv e Carey Temp r e a l co m p e titio n . I f the o o st can be lowered and t h is passed on to the custom er, t h is has a l l o f the ear marks o f a r e a l in d n otry le& d o r Ve in te n t to keep p re ssin g on t h is d erelo p aen t work, with the General Research group a t G r a n v ille 0 6 RAW MATERIALS (a) R ice sized jA pebble lim e produced by R a tio n a l Gypsua i s y e t to ba evaluated a t General Research Laboratory (b) Z o o sil has prospeota as a prehardening agent fo r K-17 coro m aterial and the p o s s ib le source o f s i l i c a fo r t n o n -au to claved o a lc iu a s i l i c a t e c a t e r i a l . Thin i s a J 0M. Huber p ro d u ct. T e sta are to be made in A p ril (o) Caddo T r i p o li , o f Glen wood, A rk an sas, produced by Baker and C o llin o o n , i s in production on 200 and 32^ ne-h m a t e r ia l. This pay a ffo r d a oourc* fo r a second supply vendor, i f m ateria l and p rice are s a tis fa c t o r y . -1 2 - S/ r (d) Johns-W anvi 1 1 # expects to be in production o f a nev type ( fo r them) < o f d ia tco ace o u a e a r th , onetime in the fo u rth qu arter o f 1962. There la reason to b e lie v e th a t the d ep o sit i s in Rev K e x io o . T h is tm aterial ay be . c s a t i s f a c t o r y aa a aeoond source o f di&tomaceous earth and co at and fr e ig h t w i l l probably be co m p e titiv e to other s u p p lie r s , ouch a E a g le -P ic b e r 0 ' (e) Long fib ero d a o o s ite , p a r tic u la r ly V3, has been opened by dry Bauer H i l l i n g , on the J 61' n i l l o T r i a l fo rm u lation runs have in d ic a te d th a t a su p e rio r product r e s u l t s , g iv in g added stre n g th and in cre a se d r e s is ta n c e to is p a c t and ab use0 There io not a u f f i c i e n t VTJ a r o s ite a v a ila b le in the now req uired tonnages, s in c e i t was s u b s titu t e d fo r lik e amounts o f c h r y s o til# a s b e s to s . The AV on band w il l be u s e d , but t h is grade i s in sh o rt supply a l s o . A k j grade o f am osite i s to be t r i a l te ste d a t the G eneral Research Laboratory and i f su cce ssfu l, t r i a l tested in several production runs in the p la n t. I t is a n t ic ip a te d th a t t h is grade o f a n o site w il l be acce p ta b le fo r s u b s titu t io n , s in c e i t was so s u c c e s s f u lly te ste d s e v e r a l y ea rs a g o . T h is should b completed by A p r il 20 and General Purchasing then can c o n tr a c t fo r the K J grade o f amositeo 7o IMPACT HACHIKS The G eneral T e s tin g Laboratory has oompleted the developm ent, b u ild in g , c a l i b r a t i n g , in fo o t pounds and t e s t in g , o f the requested impact machine* * I * As soon as the t e s t data has been analyzed and the machine d e c la r e d , .by the G eneral T e s tin g L ab o rato ry , to be ready fo r p la n t Q u a lity C o n tro l t e a t s fo r im pact measurements, i t w ill upon req uest from the p la n t , be sen t to B e r lin . Another machine i s to be b u i l t and kept in the General T estin g Lab fo r c o rre la tio n o f re s u lts with B erlin Q u ality Control Bopartcentc T h ia d e t a i l should be handled in A p r i l 0 80 POURING DEVICE * ( r ) A d d itio n a l changea^have been made to the 6" pouring d e v ic e . The pouring technique has demonstrated th a t a s u c c e s s fu l o p e ra tio n can be erpec'tod on 1 - 1/ 2" minimum th ic k n e s s s iz e s , where the opening i s s u f f i c i e n t to allow coated g la s s f ib e r to pass through the mold f i l l i n g s l o t , w ithout c lo g g in g and cau sin g s l i p p la n e s and a i r h o le s . D esign must be scoured to allow the f i l l i n g o f the d ev ice to be in proportion to the s iz e o f the n ozzle opening and t h is to be v a r ia b le and c o n t r o lla b le . E n g in ee rin g and D esign a p p lic a tio n i s to be follow ed c lo s e ly to s u c c e s s fu lly complete th is d e v ice . P re lim in a ry t e s t a have in d ic a te d th a t s l i p p la n e s, a i r h o le s and pouring fo ld s can be e lim in a te d , i f the n o zzle v e lo c it y i s not too g re a t and no c lo g g in g i e had# ' r sz - 1y - 9o INCREASE OF OT O W EET/EOf CORE AND SHELL OK 1" HOLDS (a) The use o f dry a l l i e d opened a sb e sto s f i b e r s , as v e i l as coated g la s s f ib e r s hao r e s u lte d in core c lo g g in g , ropin g and b a llin g o f these . f ib e r s in the trarsniissdoQ l i n o s , T a lv e s , and pouring n o zzle s,, Opened aDordte clo ggin g is p re -n o z z it, in areas o f reg u la tin g valves* Coated g la ss fib e r s , 'p a rticu la rly the hard coated phenolic ones hare a tendency to clo g a t the pouring nozzle* I t i s an advantage to have the pouring nozzle as large as p o s s ib le , to reduce such c lo g g in g to a minimum, T h is p o in t i s true a lo o , as experienced on the 1inite-d use o f the t r i a l s v it h a ^6" pouring dericeo (b) C o sts are to be procured from an o u tsid e shop, fo r the t r ia s in g o f cores on the 1" th ick n ess co ld s o f pipe co v e rin g , to a mininun o f 1/8" * T h is w ill in c re a se tl e opening in the hand pouring n o zzle s,, By u t i l i z i n g a th in n er, but stro n gir m etal, fo r nozzle fa b r ic a tio n , ad d itio n al opening can be secu re d , over <md above t h is l / 8ne . (o) The p la n t i s to proceed, a s soon as p o s s ib le , to open t h is s lo t on s e v e ra l f l i g h t s o f ? x 1 c o ld e . These aro to be placed in to production to see i f the 1/ 8* re s a in in g l i p i s s u f f i c i e n t to secure good s tr ip p in g s Based upon these and other t r i a l r e s u l t s , the d e c is io n w ill be cade whether or not to trim back the 1 * cores* 1 0 . KAYIO-KLAD * ' (a) Aluminas A sample from Ir s u l-C o u s t ie s p r e s e n tly fu m ie h ed aluminum embossed Ja c k e t fo r Kaylo--K lad was rep orted by them to be f u l l hard Alcoa Aluninun* T h is statem ent was suspool- upon exam ination o f the m a te ria l,, The sample was ren t fo r ch eck in g to the m e t a llu r g is t a t A lc o a , Tennessee L ab o ratory fo r A lcoa and the r e s u lt v ast (1) 3003 I I 07 ( 2) HI5^ t.vapor (3) Hardnees between 1/2 ( E l1*) and J>/h (H l6) (**) Was not HI 8 or f u l l hard , te c par 0 The p re se n t aluminum Ja c k e t i s somewhat harder than the f i r s t s ta c k s o f aluminum fr>m which tha f i r s t months o f Kaylo Ja c k e ts ver R ip p lied o I t i s not as hard as l-M ' s p la in aluminum Jacket, I t docs not have the sp rin g-b ack th a t J->M's aluminum Ja c k e t Las* I t w i l l be determined a t once whether or not the eoboosing can be done on H l8 or f u l l temper I t w ill fu r th e r be determined what degree o f embonLag p o n etratjo n can bo had from A lco a* " I t was s ta te d soae months ago th a t the H I1* f u l l hard temper oould not be embossed* Thin statem ent w ill be checked fo r aocu racy0 ue TEMPERATURE PIPS TN.qtrr^-yn (a) Work w i l l be done a t one to d e t e r o i L i f a tw o -U y e r h i A 4l " ui atlon b . developed b , p la c in g a T l " or M / 2" a c t i o n o f Kaylo in sid e a sim ila r thickness o f F ib e rg la s, oeoentod in to p la c and producing good handling r e s u lt s , with oorrect n e stin g and f i t . 1-2 REDUCE OR ELIMINATE DCST ON KAYLO BLOCK that tbi X- 1CCk J " r`U" rJ' 196a- c"J' r i " d t b . racconendatlon tt8 dU6ti" S8 f th * ** . a ? 1 n a t e r la I to do t h is i s LudoXo T h is can bo d ilu te d with wate *** f ?'ra7 bS d i r * ctfrd on on r both s id e s . T h is , w ith one aide * sprayed g r e a tly reduces the d u st. With both sid e s sprayed, the dust i s S f o i t r t ^ d CM rai^ h edo * n e ra l ^ S ^ e e r i n g and Research are combining d ^ ec^u i ^ nt Eeded f r a p p lic a tio n and dryin g a f t ? h i r h ^ n i d i t i f ne f tS PrOV ti'iB i s D icee5ar7 . to avoid n ild e v a tta c k in t d l i a p p S c it " . . ' ?*ratU r' co M U 1 m . P ^ tlc n la r ly In s te r n * ,, before 15 BOILER I NSULATION , 18 dt sixj OUB a ls o o f having an in s u la t io n th a t could bo b i l e r s by in p a lin g upon fasten ed sharp p o in ts , in a ranner TO,ol# ^ y i n explore the p o s s i b i l i t i e s o f developing ' euoh a product and Bake t r i a l t e s t s o f those form ulation s showing p r o o ie f. (b) Product T e stin g L ab o rato rie s issued on February 12 . a rep ort Monsanto. i t t ^ w ^ e T ^ " ^ D V tt8 " ' * " * ** CC? P la r t / L lS 'I10 CnrVei MOCk * 10 ^ St 550r - A 'V11"*" at . , (3) K aylo b lo ck - double la y e r - 10 y ea rs a t 600*F on duct 11184 h e a d e r b * * * - . .S i X . a ir duct rT b,, b il^ r ! W " - 1- 1/2 je a ro a t 600*7 on ooooniarr S ' V lle o n r t U * n it - B & V co al firw S ^