Document 2jVXr972RDe2DBLbKEpwoRq6N

BESTWALL GYPSUM COMPANY R&D REPORT FOR 6 MONTH PERIOD ENDING DECEi-iBER 31, 1964 TABLE OF CONTENTS PAGE NO. Foreword --------------------------------------------------------------------------------------------- -- Market Performance of New Products, Patent Data ------------------Distribution of Total R&D Expense ----------------------------------------------Distribution of R&D Salary Expense --------------------------------------------Design of First 2 Hour Fire Rated Wood Floor-Ceiling --------- 1 2 3 4 5 PROJECTS COMPLETED PLAINTIFF'S EXHIBIT I 2 Hour Fire Rated Wood Floor & Ceiling ----------------------------- - I 1 Hour Fire Rated Wood Stud Partition with Sound Deaden- I ing Board and Firestop----------------------------------------------------- 6 I Sound Test Program ------------------------------------------------------------------------ I New Wood Grain Products------------------------------------------------------------- -- I Particle Size Studies ------------------------------------------------------------------ I High Expansion Densite ----------------------------------------------------------------- I Dens-Cote System ---------------------------------- ------------------------ ----------- I Pre-decorated Wallboard ------------------------------------------------------------ -- Use of Polystyrene Beads in Wallboard----- --------------------------- Job Mixed Thincoat Plaster --------------------------------------------------------- 6 7 7 8 9 10 10 11 11 PROJECTS NEARING COMPLETION ) Joint System Textures------------------------------------------------- 13 New Glass Fiber------------------------------------------------------------------------------- 13 Analysis of National Gypsum Super-X Fireshield ----------------- 14 1 Hour Fire Rated Lath & Plaster Partition------------------------- 14 2 Hour Fire Rated Metal Stud Partition--------------------------------- 15 1 Hour Fire Rated Resilient Wood StudPartition----------------- 15 Competitive Thincoat Plaster Evaluation ------------------------------- 15 ) Use of Synthetic Gypsum for Wallboard Mfg.------------------------- 16 Hummer Systems -------------------------------------------------------------------------------- 16 Tooling Densite ------------------------------------------------------------------------------ 17 PROJECTS UNDERWAY Ram Process Plaster----------------------------------------------------------------------- 18 Vinyl Joint Compounds--------------------------- 18 Prepared Trowel Finish ----------------------------------------------------------------- 18 Radiant Heating Panels ----------------------------------------------------------------- 19 Gypsum Acoustical Tile ----------------------------------------------------------------- 19 Protein Joint Compounds -------------------------------------------------------------- 20 Dimensional Changes of Gypsum Products at extremely high temperature------------------------------------------------------------------------------------ 21 Cooperative Research Program with J-M -------------------------------- 21 2 Hour Fire Rated Concrete Floor with l/2" Firestop Cei ling ------------------------------------------------------------------------------------------------ 22 \ Self--Sealing Adhesives------------------------------------------------------------------ -- 22 1 Hour Fire Rated Gypsum Stud Partition with Sound Deaden ing Board -------------------------------------------------------------------------------------- 22 Pre-Coating of Gypsum Wallboard---------------------------------------------- 23 Ready Mix Joint Compound------------------------ -- 23 SUMMARY-------------------------------------------------------------- SGP 0015321 _ 24 & 25 FOREWORD This is a report of the activities of the Research Department for the last six months of 1964* During this period there were no personnel changes in the department. The major change which did take place was the restoration of the Research & Development testfacilities in a new building. Our large scale testing facilities had been removed during the consolidation of Bestwall's general offices in Paoli. In the new building, better equipment and more space have been provided for us to perform our function. The 1964 expenditure is estimated by the Cost Department at $133,880 as opposed to the figure of $150,000 which had been pro jected for 1964. In 1965, more reliable figures will be available because of the new accounting system which will be in effect. A better analysis of research expenses will therefore be possible. With the information available this year, the chart on the follow ing page was prepared and shows the approximate distribution of research costs in 1964. Also included in this report is a record of the market perfor mance of products which have resulted from the efforts of the Research Department. There is no sure method of evaluating certain accomplishments, such as fire rated constructions or sound rated constructions which were developed to provide assistance to Sales. The fact that our sales of l/2" Firestop are up 48.7% in 1964 and our sales of 5/8" Firestop are up 34.2% in 1964 over 1963, are indications that we are reaping some benefits from this work. This report is divided into three sections: Projects Completed Projects Wearing Completion Projects Underway These sections appear in the order named and indicate the progress to date for the projects within each section. -1- SGP 0015322 *1964 MARKET FERFCR NANCE ?F K E \ PRODUCTS PRODUCT FIRESTOP 120 GRABIT ADHESIVE ONE DAY JOINT COMPOUND DENS-COTE PLASTER DENS-COTE BASE DENS-COTE TAPE READY MIX TILE BACKER BOARD TILE BACKER TAPE MODEL DENSITE TOOLING DENSITE HIGH EXPANSION DENSITE BESTEX "C" TOTAL SALES VOLUME Last 6 Mos Year 251 M sq. ft. 557 M sq- *. o 53 T 75 T 284 T 548 T 911 T 1,629 T 4,952 M sq. ft. 8,774 M sq. .h * < 7,302 rolls 13,764 rolls 13,203 cans 15,617 cans 321 M sq. ft. 345 M sq. ft. 139 rolls 139 rolls 4.5 T 4.5 T 0.8 T 0.8 T 2.1 T 2.1 T 527 bags 527 bags PATENT INFORMATION Patents Issued - None Patents Applied For - None Patent applications previously submitted: Processing of Synthetic Gypsum One Day Joint Compound Grabit Adhesive Dens-Cote Plaster Dens-Cote Ease 2 SGP 0015323 MILL BASE SALES Last 6 Mos Year $ 34 , 380 10,048 45,826 49,124 209,280 7,465 57,488 25,058 1,273 158 41 99 2,848 443,088 $ 76,751 14,259 92,459 89,032 370,667 13,770 68,496 26,742 1,273 158 41 99 2,848 755,595 ESTIMATED GROSS PROF IT Last 6 Mos Ye ar $ 9,875 5,778 11,862 8,478 79,988 3,129 8,662 9,344 769 63 14 25 1,018 139,005 $ 22,432 8 y 18 1 24,346 16,228 143,909 5,801 10,279 10,390 769 63 14 25 1,018 243,455 *Cost figures computed by the Pinancial Department from the machine accounting records. SGP 0015324 PROJECTS NEARING COMPLETION JOINT SYSTEM TEXTURES * R&D #261 Objective: To develop a complete line of textures suitable for spray application. Investigation; Earlier field trials of a formula in the Fort Dodge market were unfavorable. It was found that the texture, when applied & dry, had a sheen which under certain t/pes of light appeared like shiny spots on the ceiling. This was over come with a revised formula, and a series of trials in the Brunswick area and elsewhere were conducted. These trials were moderately successful, but the texture still lacked adequate hiding properties. It was found that the texture as applied piled up in local areas instead of flattening out and resulted in small areas which were not covered by texture* The necessar formula revisions were made,and another series of trials were conducted. This time we returned to Kansas City, where some of the earlier unsatisfactory trials were held. The simulated acoustic texture was given the most attention, since this type is the most popular. Field trials of the simulated acoustic texture have all been quite favorable, and it has been released under the trade name of Bestex C. Other proposed products fere the spray texture line are currently undergoing field perfor mance trials. These are: Bestex A -- Non-aggregated texture for spray application. This texture is often applied to walls when one of the other textures is used on the ceilingo 3estex 3 - Sand finish type texture for contractors who prefer a lighter texture. BestexxD - Coarse, rust inhibiting texture for direct application to concrete slab ceilings. A great deal has been learned in the course of this investi gation which adds to our experience in the application of decorative materials. If the current field testing meets our expectations, the 3estex A, 3, Si D should be released within the next few months. NEW TYPE OF GLASS FI3ER - R&D #131 Objective: Evaluate Owens-Corning*s fine filament 636 glass fiber for use in our wallboard products. Investigation: The 636 glass fiber consists of .00026" diameter filaments. This compares to 710 fiber which has .00040" fila ments and 799 fiber which is a mixture of the two filament sizes. There are twice as many individual filaments per pound of 636 glass fiber than there are of 710 glass fiber. This 13 SGP 0015325 PROJECTS UNDERWAY 1. RAM PROCESS PLASTER - R&D #132 Objective: To develop a special pottery plaster for use in ram pottery making process. One of the requirements for the product is that the molds can be purged of excess water with air at 120 p.s.i. Investigation: This project has been marked with a number of unsuccessful attempts to produce an acceptable product. Another experimental formula was tried at Phaltzgraff Pottery in York, just recently, and again our product did not quite pass the requirements, as it was unable to withstand the 120 p.s.i. purging for the full 15 minutes. This is a test used by the pottery people to be sure the castings will not explode and injure someone while they are in actual use. The casts made with our material withstood the purging for only a few seconds at 120 p.s.i. This is the closest we have ever gotten to a successful product, and it is believed that further efforts are justified, since we are so close to having an acceptable product. It is our understanding that the volume of ram process plaster and particularly the regular pottery plaster sold alon^ with it is substantial. 2. VINYL JOINT COMPOUNDS - R&D #211 Objective: To develop joint system products with vinyl binders instead of casein binders. Investigation: This has been under investigation for some time? but the economics has always favored the protein binders. Also the inability of obtaining an adequate bond at low temperatures (below 45P.) with the vinyl products has slowed the progress0 A vinyl base topping compound was devloped, but when presented, to Sales their survey showed little interest in this productf particularly in view of the premium price we would have to asl: for it. This work has recently been intensified, in view of tlie price instability of casein and the present sharply higher casein prices. Our objective is a vinyl base joint compound (for taping & finishing) which can be sold at the same price as the casein counterpart. This product can also be used as a finishing material over One Day Joint Compound, if we are successful* We have experienced some incompatibility problems in using our present products fo finish over One Day joint system. 3,, PREPARED TROWEL FINISH PLASTER - R&D #228 Objective: To develop a finish plaster which can be used in lieu of the conventional lime-putty finish. USG is presently supplying a product in the Houston market, so the chief purpose of this product is to meet that competitive situation. 18 SGP 0015326 small acoustical tile specimens of various formulations were made. The Standing t.ave tester was repaired so that specimens could be compared acoustically with tiles of known sound absorption properties by comparing normal incidence sound absorption values. It was found that an inter-connecting cell structure was possible, and this, of course, gave better sound absorption. The 7/8" thicK tile samples compare favorably with competitive acoustical tile having an NRC of 65-75. Painting the surface of these tile samples with a non-bridging paint does not change the absorption. A cast density of 16-18 Ibs/cubic fool has been used thus far. A study of the effect of density, the effect of different resins, and the effect cf 1" glass fiber will be the next steps in the tile project. Following the establishment of a preliminary formula, a fire endurance test in our small furnace and an absorption test at a recognized acoustical testing laboratory will be recommended. We are shooting for a 2 hour fire rated lay-in tile with NRC of 70 or better. Raw material costs of this proposed tile should be less than 4 per square foot 1" thick. No estimate of manufacturing costs has been made as yet. It does, however, appear that the economics can be favorable, in view of the selling price of more than 20/sq. ft. for this type of tile (Armstrong's 2 hour rated Fire-Gard). PROTEIN JOINT COMPOUND FORMULATIONS - R&D #275 Objective: To make revisions or improvements whe re advisable in our Joint System product formulations. Investigation: Previous work consisted mainly of the substi tution of hydroxyethyl cellulose for alginate as the water retention agent in joint system, and the testing of a new alkali system which consists of soda ash and borax. The hydroxyethyl cellulose (Hercule's Natrosol) offers improved mixing & application properties, and the borax provides quicker solution of the casein and a more efficient binder system. In the old formulas, borax was not compatible with the alginates> so its use was dependent on our ability to use Natrosol as the water retention agent. Other hydroxyethyl cellulose products had been tried in the past, but their hygroscopicity always prevented successful use. This adverse characteristic has been overcome in Natrosol. Even before this work was completely finished, a casein shortage developed* and the price of casein began to skyrocket. Starting at 19/lb. in December, the price will reach 36d/ib. by March. Because of this, we were directed to intensify the work being done and to start a search for Sinder substitutes for casein. Since the new alkali system offers a quicker method of reducing cost by reducing casein content, it will be given first priority. The other approach involving binder substitutes and binder combinations has also been started, but this is a longer range program and will be given secondary attention. 20 SGP 0015327 Tnvestigation: The details of the construction have been worked out, and the test has been arranged to be run at Ohio Stateo All of the materials are at Ohio State, so this partition can be tested as soon as we can get on the schedule. 12. PRECOATING OF GYPSUM WALL30ARD - R&D #286 Objective a Apply a coating of joint system material to the surrace of the wallboard as an in-process operation. Investigation: It was found that a thin uniform layer cf joint compound could be spray applied over a wallboard surface. In certain cases, the area of the wallboard is given a coating of joint material as the last step in its installation and before painting. This operation was initiated by Mr.E. B. Hummer, and its prime purpose was to bring the surface textures of the wallboard & the surface covering of the joints, nailheads, etc. closer together. In other words, the shear coat provides a more nearly monlithic surface. Other advantages to be gained, from our standpoint, are that more paper defects could be tolerated - and perhaps a lower cost (grayback instead of ivory) paper could be used. The major problem is how to apply such a coating in the proper thickness and sufficent uniformity in our manufacturing process. However, before that stage is reached, a more precise appraisal of the coating and any problems it may present must be assessed. We are in the very early stages of this investigation and, at the moment, our attention has been diverted to other projects of higher priority. 13. RBADY MIX JOINT COMPOUND - R&D #211 Objective: Reduce the formula cost of our Ready Mix, in order to improve the profit on this item. Investigation: A comparison of Bestwall Ready Mix vs, GSG and other competitive products revealed that the competitive products have lighter weight pails. A difference of about 4 lbs/5 gallon pail was found. In exploring this, it was found that substitution of 3% highly absorbent Attagel Clay for 107o Kaolin Clay reduced the pail weight by A\ lbs. In the process, more water is required; and the net result is a 10% reduction in raw material usage. A series of tests is underway to evaluate this new formula, and indications thus far are that some quality advantages will be gained in addition to the improvement in Economics. 23 - SGP 0015328 SUMMARY The last 6 months in the Research Department have been high lighted by the reinstallation of our large-scale testing equipment in a new building, which was provided for that purpose* The major accomplishments during this 6-month period weses 1. The first 2-hour fire rated wood floor & ceiling assembly was granted to Bestwall, from our successful test of this construction at Underwriters1 Laboratories* 2. The first 1-hour rated wood stud partition with 1 layer of fiberboard and 1 layer of 5/8" Firestop was achieved as a result of another successful test? this time at Ohio State University. 3. A sound test program was completed which gives us a full range of sound transmission class (STC) values, to promote wood stud, metal stud, and gypsum partitions* 4. A new line of striated wood grain products has been readied for release early in 1965* 5. A vastly improved high expansion plaster has been developed and added to our industrial product line* 6. A series of particle size analyses has been completed recently* This study has provided our first knowledge of the particle si?e & gradation cf our materials in the subsieve (finer than 44 micron^'range * This is the start of a build-up of information that can be a basis for future developments* Having our equipment restored and some newer facilities which we did not have available previously, will enhance our ability to undertake developments and furnish information -hat can serve as a basis for the immediate & future growth of Bestwall Gypsum Company* A budget for next year in the amount of $170,000 was prepared* This includes $60,000 for new fire & sound test programs, as weli as continuing our present programs on the same basis as last year* Also, allowance has been made for the addition of one new man to the Research Department staff* The present plans for early 1965 call for the following work to be undertaken: 1* A large scale run of synthetic gypsum which will provide the final basis for deciding the future use of this process development* 2* The release of a full line of spray textures* 3* An extensive exploratory fire test program using our small furnace and the subsequent scheduling of large scale tests at U* L. and Ohio State based on our findings* 24 - SGP 0015329 4. The reduction of the glass fiber usage in regular wallboard based on experience with the finer filament glass fiber* 5c The pursuit of a cost reduction program in the joint system product line, by means of formula revision, 6. The search for new binders to supplant casein in joint system productsc 7, The development of comparative information on a dozen different thincoat plaster products which have been submitted. Projects absent from the present schedule are the particle size studies^ the gypsum acoustical tile, the pre-coating of gypsum board, and other more basic work. It is our fervent desire to pursue this work, as soon as time can be spared from areas of higher priority. These higher priority items are of more immediate significance to the Company, out spending our entire effort here completely ignores the projects which protect our future. It is our opinion that the longer term projects, when successful, result in far greater potential than the projects designed to fulfill immediate needs. It is our hope that a program encompassing both the immediate & future needs of the Company will be possible. 25 SGP 0015330 Page i Page 2 Page 3 Page 4 Page 5 Page 6 Page 7 Page S Page 9 Page 10 Page 11 BESTWALL GYPSUM COMPANY SBMI-ANNUAL RESEARCH AND DEVSLOPM5NT REPORT Jario Ip 1964 to June 30, 1964 TABLE OF CONTENTS ft ^ i* ,, Foreword ,, Market Performance of New Products Patent Information Projects Completed Ready Mix Joint Compound - R k D 211 ,, Ready Mix Joint Compound Picture o o U'ater Resistant iValiboard ~ R & D 26* Fire Rated Columns - R & D 270 0 9* 600 2*Hour Firestop Ceiling with Light o' Vent Openings - R & D 266 & Picture One-Hour Fire Rated Iracombustible Floor & Ceiling - R -y D 267 One Hour Ivood Floor Ceiling - R R D 256 2-Hour Rated Steel Corruform it Concrete Floor & Ceiling - R k D Co-operative Tests on Hof-Kor Honeycomb Panels - R & D 257 0 6 00 c> o One-Hour Rated Dens-Cote Partition R & D 219 Co-ccerstive Tests with Don'.- Products R S' D 259 Improved Sound Transmission Using the Combination of Insulation Board & Oypsui Board R k D 260 Projects Nearing Completion Joint System Textures - R & D 261 o r 9 o O Hummer System - R & D 209 & Picture qa* a o o High Expansion Densite - R k D 132 Ram Process ,)ensite - R & D 132 SGP 0015331 TABLE OF CONTENTS (COKTD} Pans lc l * a a improve Flame Spread Rating of Etsrnawall - R a D 215 2-Hour Fire Rated Wood Joisted. Floor-Ceiling - R & D 273 Page 13 a a o * Dry Vinyl Topping Compound - R & i> 21 Page 13 & 14 . . < Synthetic Gypsum - R & D 221 Page Projects Underway Owens-Corning Projects - R & D 210 Dens-Cote System R it D 219 Page 16 Tooling Densite - R & D 132 Radiant Heating Panel - R & D 235 Calcination and Particle Size Studies R & D 263 Page 17 * 4 tt O <5 New'Wood Grain Products - R a D 268 One-Hour Partition with Good Sound Properties R St D 271 Page 13 o <r e m Gypsum Acoustical Tile ~ R o* D 2?u Protein Joint Compound Formulations RmD 275 Page 19 cocd*oo Sound Rated Constructions - R D P/'d Disiensionai Change of Gypsum Product' at High Temperatures < R ii D 277 Page 20 Page 21 9*O Cooperative Research Program with Jch; i-ianvills - R ii D 278 Concrete &. Jar Joist Ceiling with 1/2' Firestop - R & D279 Summary SGP 0015332 PORBVv'ORD This report covers the activities and accomplishments of the Research Division for the first 6 months of 1964.. There has been no personnel change in the Research Division during this period. It was estimated last January that the total 1964 R&D expend:'.-* tures would approximate $150*000. The first half figures show that $65*895 has beenspent thus far. The Research Division had its third anniversary in June, h rundown of the last 6 months* market performance of products resulting from our efforts since that time follows. Some of the accomplishments* such as fire ratings acquired, cannot be directly assessed. However, the fact that our l/2n Pirestop sales are up 106% and our 5/S" Pirestop sales up 27% for the first 6 months cf 1964 over a like-period in 1963 is a good indication of the value of this effort. The major portion of this report is devoted to the progress made on the various projects during the past 6 months. It is divided into three sections, namely: 1. Projects Completed 2. Projects Nearing Completion 3. Projects Underway SGP 0015333 *MARKET PERFORMANCE OP NEW PRODUCTS JANUARY THRU JUNE 1064 PRODUCT a*. Pirestop 120 Ceiling Tile -> "Grabit" Masonry Adhesive -? One Day Joint Compound 4 Dens-Cote Plaster /- Dens-Cote Base (all) 6. Dens-Cote Tape 7, r|M Drywall Screws 8. Ready Mix Joint Compound So Water Resistant Board 10. Model Densite High Expansion Densite \ SALES VOLUME MILL BASE SALES /"*r if> r r> 306,000 sq.ft. $ 42,371 22 Tons 4,211 /s * - -- - r- `r' v' 7 /rT Ci *; v 264 Tons 718 Tons 46,633 38,908 12,484 7V750 3,821.6 H,,Sq.F ,, .141*337 63,921 6,462 Rolls 6,305 U .M *- 872 Gross 2,321 305 2,414 Pails 11,008 ` 1,617 23,700 Sq. Ft. 1,684 1,046 1 Ton 35 14 .7 Ton 31 7 $314,894 $104,776 ^Obtained from Paoli machine accounting records, PATENT INFORMATION Patents Issued - None Patent Applications Prepared -- Dens-Cote Plaster Dens-Cote Base Patents Applied For - None Patent Applications Previously Submitted -- Processing of Synthetic Gyp One Day Joint Compound Grabit Adhesive SGP 0015334 PROJECTS COMPLETED READY MIX JOIN f COMPOUND - R St D 211 Objectives To develop a ready mixed or paste type joint compound to be competitive with other similar products on the market. Investigation; About two years ago, a basic ready mix formula was developed and successfully field tested. At that time, it was decided that the product would not be put into the line, because (1) the product was not economical due to the freight involved in shipping the pails of ready mix to the potentially good markets; the freight involved in shipping the dry premix from Acme to other plants for conversion to the paste compound; and the relatively high cost of the formula. (2) The questionable market potential. Surveys indicate that the demand was spotty and confined to a few areas which would be least economical for us to ship. (3) The relatively large investment required for equipment to mix, fill pails, store and transfer emulsion, and provide storage for raw materials and finished products. The second phase of this investigation i*as begun because of renewed interest from certain parties in Sales, a second basic joint system plant put on stream at Akron, and our own reali zation that ready mix was becoming a product we would have to reckon with sooner or later* In order to overcome the necessity to purchase large tanks and provide warm storage for binder (PYA em&lsion), a ready mix formula which contained a dry binder was developed. This formula cost was Also high, but it did circum vent the large equipment expenditure. A small facility was set up at Akron to furnish the requirements of a large high-rise job. The job never materialized; the ready mix froze and thawed several times during the subsequent winter; and it was obvious chat the area serviced by Akron was not a good ready mix market, in view of the meager sales. In spite of this bad taste from ready mix, it had become apparent that ready mix was the preferred joint system in some markets. is becoming a factor in other markets and is being used for touchup and by "do-it-yourselfers" even in the areas where other joint system products are preferred, '"'ur previously expanding joint system business has leveled off the past two years, and it is felt that lack of a ready mix product has been one cause. It was decided that ready mix should be available from Acrae, Akron, Brunswick-, Fort Dodge, and Wilmington. This constituted the third phase of the ready mix investigation. Result: Brunswick and Fort Dodge have already been put into operation, and Akron is continuing to furnish their own require ments as well as supplying Wilmington. Based on the performance of these operations, the other facilities at Acme and Wilmington will be installed. The cost of the equipment including mixer, lid closer, pail filling ram & pump, accessories and installation or the equipment is about $6GQ0 per plant. The pail filling device which is rather inexpensive has improved the capacity of these installations. Some economies in the formula have also been realized, so that the ready mix operation should be more profitable 3 SGP 0015335 than originally expected. IVe returned to the emulsion binder, in view of its lower cost and also because it gave a better end product than the dry resin binder. If the volume can justify the purchase of emulsion in large quantities, a furthe avings of up to 20d/pail can be realized. A photograph of a -gallon pail of ready mix is shown beioiv: (Jl M -4 ~ SGP 0015336 PROJECTS NEAR INC COMPLETION o JOINT SYSTEM TEXTURES - R & D 261 Objective: To develop pre-aggregated textures for spray application. Specifically, these textures are: 1. Simulated Acoustic (coarse aggregate) 2. Sand Finish (fine aggregate) 3. Masonry (coarse aggregate with rust inhibition properties) A further object is to develop textures that can be used over surfaces where One Day Joint Compound has been used for the joint finishing, without the necessity of first using a primer. Investigation: The three products listed above were developed to tlie trial stage sometime ago. This was during the reorgani zation of the Sales Department, and the trials never materialized. In some instances the material was lost or used and never reported on. Additional trials were requested, and these were slow to be scheduled. In desperation, it was decided to make these textures available in the area served by the Fort Dodge plant. A quantity of each of the various textures, including a plain (non-aggregated) texture designed to cover One Day without a primer, was shipped to Fort Dodge. U'herever possible, the trials were witnessed by Laboratory personnel. The trials provided some differing opinions but, in general, some unfavorable characteristics prevented their acceptance. These were: 1. lYhen dry, the textures developed a sheen that made the ceilings appear blotchy under severe lighting conditions. 2. The textures would build up locally instead of flattening out as they were applied. This was not too detrimental for the simulated acoustic but caused the sand finish to be coarser than desired. 3. The plain texture covered the One Day satisfactorily in some cases but not in others, so it also failed to achieve our expectations. On the basis of this experience, it was decided to return all of this texture to Akron and rerun it at a later date. The texture project was brought back to the experimental stage, and means were sought to overcome the objections. It became evident at this tine that we should develop the basic textures needed for addition to the line, without regard to their ability to cover applications of One Day Joint System. After reformulating the products on this basis, some trials were conducted in the Brunswick area. The trial of masonry texture did not materialize, but the sand finish and simulated acoustic products were found to be satisfactory and overcame the previous objections. The field testing will be continued with additional trials in Kansas City and Hartford, Conn. Trials previously conducted at these locations drew unfavorable comments, so this will confirm whether Lhe necessary corrections to the formula have been made. If these trials are successful, we will consider c/id nm K't'iy approving the two products for release. As yet, insufficient trials of the masonry texture have been conducted to determine whether this product is going to be acceptable. 20 HUMMER SYSTEM - R & D 209 Objective: To develop improved laminated gypsum ribs for Hummer partition systems. Investigation: It was previously reported that a `2--n thick x 3" wide riB had been developed, and field trials were being requested After some futile attempts to have trial partitions constructed with these ribs, one was finally found in Washington, D, C, for approximately 100 linear ft, of partition. The advantages brought out in this trial were (1) the ease of installing electrical facilities, and (2) the increased stiffness of this partition. Concurrent with this development, Mr. Hummer modified the instalia tion procedures for the Hummer "B" System, so that the ribs could be set in metal U channels similar to the manner metal studs are set in place before the faces are applied,, The new rib and the improved method of installation should overcome all of the advan tages previously held by metal stud systems. The next phase is to have one large trial job completed with the new ribs, so a more thorough evaluation will be possible. A picture of the new rib is shown below: - 10 - SGP 0015338 We believe that if the face layer of 5/8" Firestop can be held in place longer, there will be a good chance of making the 2 hours. On this basis, the large scale test was recommended. Certain changes in fastening vill be made to hold the face layer on longer. The AFE has been approved, and the construction and test are scheduled for late July or early August, DRY VINYL TOPPING COMPOUND - R & D 211 Objective: To formulate a topping compound with a vinyl binder instead of a casein binder. It is intended that the vinyl top ping will be a superior product. Investigation: The investigation was originally directed to the development of a dry vinyl joint compound. Bonding difficulties at low temperatures caused us to direct our efforts to a topping compound, in which the bond is less critical* The advantages of a vinyl formula are: 1, Longer wet life, since it is not subject to putrefaction to the extent that casein topping is, 2, Offers better control from the plant standpoint because of simpler formula and more uniformity of the binder, 3, Requires less mixing water so there is less shrinkage, 4, Offers better working properties than its casein counter part . 5,, Is compatible with One Day, whereas casein topping is not. Field trials of the vinyl topping were conducted in Nashville. Tenn, and Hartford, Conn, The comments were favorable, and its performance was satisfactory. Also, this product was used for some of the joint finishing in the Laboratory during the rennovation of the building. Most applicators commented that it works like ready mix. It was hoped that the vinyl formula weald not be significantly higher in cost than regular topping, but this did not prove to be the case. The vinyl topping has a raw material cost of 84/ton as opposed to $6/t.on for the regular topping. In view of the advantages of this topping, the Laboratory will propose that the product be released and sold at a premium price. SYNTHETIC CfYPSU.M - R & D 221 Objective: To confirm the results of the initial trial run which indicated that synthetic gypsum could be successfully utilized for waliboard and plaster manufacture. This process involves conversion of the synthetic gypsum by product*of the manufacture of phosphroic acid to a useable form. Investigation: The basic operations of this conversion process for which a patent has been applied are as follows: i.Drying of the synthetic gypsum as received. The latest shipment containeo 20?, free water. SGP 0015339 9,, GYPSUM ACOUSTICAL TILE - R & D 274 Objective: To develop a gypsum acoustical tile using the resin reinforced foam idea. Investigation: Some previous work directed toward the developinent of a lightweight board confirmed a theory regarding the reinforced foams. The theory is that a foam cell containing some resin or other reinforcing material surrounding the ceil will act as an aggregate in a gypsum matrix. This would provide greater strength than normally expected of a foam gypsum struc ture. This theory was confirmed, but the economics of its use in board were not favorable. It was felt that this theory might be applied to a product for which the additional cost could be justified. With the knowledge that acoustical tile* particularly when fire rated, sells for 15 - 25 per sq. ft., some exploratory work was done. Sample 2* x 2* tiles at 15 - 17 Ibs/cu. ft. density were made, using reinforced foam and glass fibers to provide sufficient compressive and transverse strength. Sound absorption tests conducted by an outside laboratory indicate that our product is just about as good acoustically as Armstrong's 2 hour rated Fire-Gard tile. A fire test in our small scale furnace indicates that it performs better than either our Firestop 120 or Armstrong's Fire-Oard, both of which have 2 hour ratings. The estimated raw material cost, excluding paint, is 4q per square foot for 3/4M thickness, allowing 25% for waste. This acoustical tile appears to offer good potential and when presented to Sales, it was suggested that we assign a project to proceed with its development. This all occurred during the building renovation, and there was no space to set up for casting full size slabs. As soon as the new building is ready, the necessary foaming, mixing and casting equipment will be installed, in the meantime, our old Standing V/ave equipment for testing sound absorption has been sent out for repair so that it can be used to test the sample tiles which will eventually be made. o, protein joint compound formulations - r & p 275 Objective: To make improvements where advisable or necessary to our Joint System products. Investigation: A water retention agent from the hydrcxyethylcellulose family has been found which offers improved qualities and cost savings for our line of Joint System products. This product, called Natrosol, will be used as a substitute for Kelsise, which is a Kelp product. In conjunction with this substitution,one of the preservatives will be eliminated. This preservative was necessary because of the degenerative effects of the Kelsi2e. The improvements in quality expected are: 1. Easier mixing 2. Better working 3. Greater insurance against staining problems which stem from preservatives. -- 18 SGP 0015340 The savings vary with the formula? but'cased on the last six months* sales, the anticipated annual savings would be S22,300,, The savings do not include ready mix in which we have already incorporated Natrosol. A slow changeover to Natrosol in all products is already underway and should be completed by the end of the year* SOUND RATED CONSTRUCTIONS - R M D 276 Objective: To conduct a sound test program to establish sound ratings for various partition and floor & ceiling assemblies. Most of this is being done at Donn Products' Ohio Research facilities* Investigation; A rather complete group of sound ratings has been attained with sound transmission Class (STC) values of 50 or better for wood stud, metal stud, and laminated gypsum partition constructions. Other partitions of each type attained ratings in the 45 - 50 STC range. Two new constructions were originated in the course of the testing, t ne is a metal stud partition with an STC of 52 and the other is a 2\" x 3M gypsum stud partition with an STC of 50. Th^se can be promoted as firsts fof Uestwall. All of the data recently developed is being put into shape for distribution to the trade and to our sales pepple. Some further tests are planned, and this data will be added at a later date. Our problem in dispersing this information will be to present it in such a manner that it will be under stood by all. On the basis of some of the sound ratings obtained, fire tests will be proposed for identical construc tions. It is felt that sound and fire ratings go hand in hand, and wherever one is needed, so is the other. DIMENSIONAL CHANCE OF CYi'SUM PRODUCTS AT 111011 TEMPERATURES R & D 277 Objective: To measure the dimensional changes which occur in gypsum products at temperatures up to 2000F. and assess t he significance of the data obtained. A Oaertner Dilatometer V.V c-S purchased to make these determinations. Investigation; Our initial work will involve fire rated board with the idea that we may be able to predict what happens to this board in an actual fire test. During the calibration of the instrument, the element burned out, so it has been returned for repair. COOP TR.ATIVE RESEARCII PROORA`1 a I TV. JOHNS-MANVILLF. - R a D 278 Objective: To enter into such cooperative ventures as are considered to be of interest to both companies. The first venture agreed upon is a fire test of Soundike-Firestop installation. ~ -S Q - SGP 0015341 SUMMARY The highlights of the Research Acitiviries for the past six months have been: 1. The introduction of a ready mix joint compound; 2. The development of a v.'ater resistant wall board; 3. The second successful trial in the manufacturing of wallboard from synthetic gypsum; 4. The 2 and 3 hour fire ratings for columns; 5. The 2-hour rating for the Firestop 120 Ceiling with light Si vent openings; 6. The l\ hour rating for the concrete ceiling with l/2M Firestoo underneath; and 7* The sound test data attained thus far for the various partitions tested. Our efforts in certain areas have been retarded, since our shop facilities were removed during the renovation of the building. These facilities will be restored in the new building which is under construction. The installation of certain new equipment, the remodeling of some of the old equipment, and the additional space available will enhance our ability to provide information and conduct project investigations,, Our present plans for the last half of 1964 call for: 1. The continuation of our fire and sound, testing program 2. Attempts to complete the aggregated textures, new grainboard, and industrial gypsum product development; 3. The pursuit of potential cost savings in conjunction with the finer filament glass fiber and new water retention agent for joint system; and 4. Embarking on eew projects such as the development of a gypsum acoustical tile. It is also hoped that we can devote a certain amount of time to the search for knowledge, which is not necessarily directed to present objectives but which may serve as a basis for future developmentso SGP 0015342