Document 373K85Br8JbJvgrn1nmgpD6pO

01-7 UJ671-R2 ) \\ I \ N ( Oli \ I \ (. Fl 15 K KG LAS r% PLAINTIFF'S 2 EXHIBIT UJ \ vJV-DPofl3ft TEST REPORT PRODUCT TESTING LABORATORIES FIBERGLAS TECHNICAL CENTER GRANVILLE, OHIO KAYLO HANDLEABILITY VS. COMPETITIVE HIGH TEMP. INDUSTRIAL INSULATION BLOCKS REPORT NO.: 20853-1 DATE: March 27 9 1961 CC: W. B. Ball, Jr. - New York B. E. Boyd - Toledo R. E. Grimmie - Berlin R. W. Henry G. L, Kalousek - New York - Granville (2)*-'^ D. W. Ladd, Jr. - New York H. N. Marsh, Jr. - Newark R. W. McArthur - New York (3) H. K. Nickell A. J. Pearson 0. W. Pfeifer J. B. Rhoads R. L, Schneider W. H. Sedgeman E. C. Shuman W. K. Sidwell A. C. Siefert H. V. Smith - New York - Newark - Berlin (2) - Berlin - New York - Toledo - New York - Toledo - Granville - Toledo (2) J. A. Toml inson - Santa Clara File The purpose of this report is to review the problem of handleability and to set forth criteria against which Kaylo and competitive products may be compared in the future. See Test Report 20745 (12/28/60) for work done leading to this study. RECOMMENDATIONS: It is recommended that the ball impact test be used as a handleability measuring devise. For 1-1/2" thick block or 3"x 1-1/2" pipe covering a criteria of 14 inches to the first crack (avg. of 5 pieces) should be the minimum for an acceptable material. It is also apparent from this study that dustiness is a major factor in evaluating the handleability or pleasantness of an industrial insulation. Because of this dust problem, a method must be developed to evaluate the amount of dust on a given sample. It is recommended that the Product Testing Laboratories start this investigation as soon as possible. The Handleability Index (Modulus of Resilience divided by density - see T. R. 20745 for details) also appears to be a good measure of handleability, but it is much more time-consuming than the ball impact test. This method is applicable only to block. An acceptable 1-1/2" thick block should have an index no less than 20 in. The block tested for this report will be cut down to l" thick to determine the effect of a different thickness on the test data. 01 041 1181 -2- T. R. 20853-1 HANDLEABILITY PANEL: On February 7, a meeting was held at the Berlin Plant to evaluate subjec tively the following products: 0-CF Kaylo Johns-Manville Thermobestos Ruberoid Calsilite Union Asbestos & Rubber Company Unibestos Philip Carey Careytemp Baldwin-Ehret-Hill Thermasil Keasbey & Mattison Kaytherm Philip Carey Calcium Silicate Block (which is Kaytherm purchased from K & M) Of these products, all are calcium silicates with the exception of Unibestos and Careytemp. Samples consisted of cartons of 1-1/2" thick block, 3" x l" pipe covering, 3" x 1-1/2" pipe covering, 6" x l" pipe covering, and 10" x 1-1/2" pipe covering. The following people comprised the panel: R. W. Henry G. L- Kalousek William A. Lotz J. B. Rhoads E. C. Shuman H. V. Smith 2 union members of the insulators local in Philadelphia (J. D. Simkins evaluated the materials after they arrived at Granville.) The panel defined good handleability as follows: "A product that is able to withstand normal abuse during shipping and application." Workability - east of fabricating - also plays a part in handleability. It was agreed that the major problem boiled down to producing a material with high impact resistance. Each member of the panel filled in a data form (Insulation Handleability Data, sample form attached) after conducting his own manual tests of a given material. He rated the product 1 to 5 according to his personal opinion based on the handling tests. These tests consisted of dropping the material on the floor, feeling, cutting, sawing, breaking the insulation with his hands, etc. The samples were then shipped to P.T.L. for testing. The panel rated the materials as follows: 01 041 1182 Panel rating (continued) -3- Avg. Rating 1.2 Product Thermbest#s T. R. 20853-1 No. of Samples 6 to o 2.5 2.7 2.9 3.2 Kaylo Calsilite -Unibestos - Careytemp Thermasil 4 2 3 2 6 *3.7 Kaytherm plus Carey calcium silicate TOTAL 6 29 Note: 1 is excellent 3 is average 5 is poor. In summarizing the panel ratings, the following items are of interest 1. Each panel member rated various materials from good to bad, that iS ;, nobody rated all materials average, etc. 2. There was good agreement that J-M Thermobestos was the best material. 3. There was good agreement that K & M Kaytherm was the worst product evaluated. 4. The widest variation in opinion was on Unibestos ( 1 to 5). The products that had an average rating generally had the wider variation in opinion (R. T. Sage states this is typical in surveys). In reviewing the test data, it is noted that the modulus of rupture has no correlation with the handleability rating of the panel. Strength tests do not give the complete story, as can be seen in the summary of panel members' comments. Items such as appearance and dustiness affected the ratings. Although the Ruberoid material generally had better strength than Kaylo, it rated slightly lower probably mostly due to the relative dustiness of the two plus the presence of air holes in the Ruberoid Calcilite. Two of the B.-E.-H. Thermasil samples and two of the K & M Kaytherm samples arrived at Granville so badly broken they could not be tested. This is quite significant,as resistance to shipping damage was defined as one of the major facets of handleability. Incidentally, these two products were rated lowest by the panel. 01 041 1183 -4- T. R. 20853-1 One unexplained aspect of the survey is that two materials (Kaylo and Calsilite) which were rated high by the panel had relatively poor hinging,and Kaytherm (rated lowest) was amont the best in hinging. The attached comments by the panel members provide an interesting insight into the problems of evaluating handleability. WAL:pso att. 9 01 041 1184 T. R. 20853-1 Attachment 2 INSULATION HANDLEABILITY DATA Product Name Manufacturer Date Block Pipe Rating (1 to 5) 1 - excellent, 5 - poor Reason for Rating*_________________________________ Size *Hinges after cracking, cuts readily, doesn't break when dropped, hard, soft, etc. What test or tests did you use to determine rating? WAL 1/25/61 Name of Evaluator 01 041 iisr. CO to CO CrOt rt CO CD ^4 03 cn /--V co O o P p p (D Pp rt Ort (D P <r<t PK P in c p 0) IT - 3 W co P vj p a> HW O' 1 (MD w j 3 EE p irrntt Po P1 << o rt 0 H Ch sr S mK 3 0 cr (D U) p+ ion H CO pi (wD M t 3 EE P in H- rt O P3 Prt p O' irrrrntttt 0rt 0rt a 0 H Ch Pi CD 5 K 3 0 O' CD in P* P rt Ps CD 33 rt CO i' c*-n* CO o rt CO ; rt ; cn rt 00 rt O CO rt rt cn CO rrtt cn rt rt rt rt rt rt rt rt rt CO CO CO CO CO CO CO . ,. cn rt 03 CO o CO rt CO <1 r[t \ 03 CO rt =o o p ** rt o p Ort P O P iPrrntt rt rt O rt P O P (inD HO W Prt h in rt rt 3 CrDt 0H> Z O >0 P O S- ort o (D t3 P o in Hi Hrt y-\ rs CO CO CO eCO cn 00 w 00 CO CO Ncnrt CO rt rt rt rt a CO CO CO CO . CO CD CO rt w 03 CO 03 /-N rt CO CO i o SP/ <] CO cn co ^4 Cn cn *4 O 03 03 00 O 00 CO 03 rts P P p rt <pTC rt P '(wD ' CTC *i0n cn 00 03 CD 00 > 00 CO o rt 03 rrtt -> - v rt 00 rt -00 cn 03 CO in Hrt 0 Hi g 0 rr-t H H- P a CO o O o 00 CO ^4 CD o in c rt O o ooooO rt ooooO c (D in P C(P rt O rt 50 0 S P c P (D Hi 0 oO o o ooo O o le H- rt in H- a1 p o rt o rt CO rt rt rt o P P rt rt CO 03 CO 00 CO 00 cn c CD cn in P E3 03 00 lc CO to 03 D 03 CO a> b 00 CO CO CO CO CO CO <1 CO b o o b W P P rt M D- P P rt o a (d p (D P (D cn x a rrtt << rtf > W P PX a in o (D O (D X ^ cn T3 in rt MO P >H P PO o 3W 0) o P 00 rt- cn CO CO 041 1186 TEST RESULTS: Product P/C 1, J-M Thermobestos 2 . P-C Careytemp 3 K&M Kaytherm 8,.& 29. B-E-H Thermasil 10 , O-CF Kaylo 11. Unarco Unibestos 13 ,. O-CF Kaylo 14. P-C Careytemp 15. B-E-H Thermasil 16. Unarco Unibestos 17. K & M Kaytherm 18. J-M Thermobestos 19 . B-E-H Thermasil 20. J-M Thermobestos 23 . K & M Kaytherm 25 . Unarco Unibestos 26. B-E-H Thermasil 27 . Ruberoid Calsilite 28. J-M Thermobestos 30 . O-CF Kaylo T. R. 20853-1 Attachment 4 Size Ball Impact Test Inches to No. of First Blows Crack Density, pcf Modulus of Rupture, psi Panel Rating (range) 3x1 3x1 3x1 3 x 1-1/2 6x1 6x1 3x1 6x1 10 x 1-1/2 10 x 1-1/2 10 x 1-1/2 10 x 1-1/2 15 Over 200 13 3 10 3 14 4 71 13 6 92 83 All cracked 26 Over 20 Cracked badly 23 Over 20 12.8 12.8 13.8 12 .9 12.7 18.2 12.5 13 .0 12 .8 18.8 14.5 90 89 71 64 91 89 112 64 "-- --" 1.7 (1-3) 2 .7 (2-4) 3.6 (2-4) 2.8 (2-3) 2 .5 (1-3) 3 .0 (2-5) 1.8 (1-3) 3.1 (275-4) 3 .2 (2-5) 2.6 (1-5) 4.6 (4-5) 1 .0 6x1 6x1 6x1 3x1 3x1 3 x 1-1/2 3 x 1-1/2 3 x 1-1/2 All cracked 12 Over 20 All cracked badly 14 Over 20 73 15 20 25 Over 20 15 3 12.7 14.0 "-- 14 .9 12.4 13 .0 13 .4 13 .0 43 78 -- 75 53 60 108 96 4.3 (3-5) 1.3 (1-2) 3.4 (2-5) 2.5 (2-3) 3 .2 (2-4) 2 .3 (2-3) 1.3 (1-2) 1.8 (1-2) 01 041 1187 T. R. 20853-1 Attachment 5 COMMENTS FROM INSULATION HANDLEABILITY DATA SHEETS MADE OUT BY THE HANDLEABILITY PANEL Johns Manville Thermobestos Sample 1 -- 3" x l" pipe covering Sample 18 Very little dust. Rigid. Does not break when handled. Strong. Clean. Doesn't crumble readily. Rigid. No dust. Rigid. Good hinging. Strong. Sample 20 Good hinging. Hard. Sample 5 - Johns Manville Block 1-1/2" x 6" Cuts readily. Very little dust. Rigid. No dust. Rigid. Hard. Cuts good. Doesn't break when dropped. Cuts readily. Very little dust. Very good hinging. Doesn't break when dropped. Hard. Square edges. Clean edges. Strong. Hard and strong. Free of voids. Good impact resistance. Very little dust. Not crumbly. Strong. Fair hinging. Philip Carey Careytemp Sample 2 -- 3" x l" pipe covering Good impact resistance. Good looking. Saws readily. Very good dimensions. Several were damaged in shipping, ends and edges cracked. Sample 9 - block, 1-1/2" x 12" Rigid. Very little dust. Hard. Hinges well. Excellent appearance. Hard. No voids. Square edges. Good hinging. Very little dusting. Beautiful appearance. Good hinging. Tough. Easy to fabricate. Does not break readily. Very dusty. Cuts very well. Hinges well. Crumbles readily. Reasonably clean. Cuts well. Good surface appearance. Easy to fabricate. Hinging fair. Impact resistance poor. Brittle. Hard. Cuts well. Hinges good. Edges damaged. Good appearance. Good hinging. 01 041 1188 Sample Block - 1-1/2" 4. K & li 22. K & 11 24. Carey C.-S. 5. J-M 9. J-M 6. Ruberold 7. B-E-H 21. B-E-H 12. 0-CF P/C 1. J-M 3x1 2. Careytemp 3x1 3. K b M 3x1 13. O-CF 3x1 25. Unarco 3x1 26. B-E-H 3x1 8 b 29. B-E-H 3 x 1-1/2 27. Ruberoid 3 x 1-1/2 28. J-M 3 x 1-1/2 30. 0-CF 3 x 1-1/2 10. 0-CF 6x1 11. Unarco 6x1 14. Careytemp 6x1 20. J-M '6x1 16. Unarco Unlbestos 10 x 1-1/2 18. J-M Thermobestos 10 x 1-1/2 T. R. 20853-1 Attachment 1 Test Summary - Ball Impact - |u/p - h! Panel Rating 1.0 2.0 3.0 4.0 5.0 , 10-5- 16.9-141 15-8 Il6-8.fr 11-4 17.8-131 18-11 126-3.51 20-15 136-3. Ol 15-2 . 3-2741 12-4 l21-3.ol 15-1 P-7-2.0| 12-2 ll0-4.2l 12 15-200 3 13-3 9-2 14-20 7-: 14-4 15-20 25-20 15-3 v 7-1 13-6 3-3 12-20 26-20 23-20 0! 041 Philip Carey Careytemp continued -2- T. R. 20853-1 Attachment 6 Sample 14 -- 6" x l" pipe covering Several blocks were damaged. Hinges good due to long fibers. Several pieces broken. Very dusty. Very dusty. Good hinging. Breaks easily. Cuts poorly. Crumbly. Dirty. Breaks easily. Crumbly. Breaks in hand. Keasbey and Mattison Kaytherm Very dirty. Good hinging. Sample 3 -- 3" x l" pipe covering Dusty. Soft. Several were cracked down cente Soft. Sample 23 -- 6" x l" pipe covering. Very dusty. Soft but strong. Cracks easily. Very dusty. All pieces were broken through Soft. the middle,, Crumbly. Sof t. Dirty. Cuts poorly. Very dusty. Dusty. Good hinging. Excellent hinging. Sample 4 -- 1-1/2" x 12" block. Soft. Dusty. Half of the blocks were cracked Breaks readily. Crumbly. or chipped. Good hinging. Soft. Very dusty. Ruberoid Calsilite Good hinging. Breaks readily. 1-1/2" x 12" block. Very dusty Easy to handle. Sample 17 -- 10" x 1-1/2" pipe covering. Edges chip readily. Little dusty. Very dusty. Sof t. Badly broken. Very long fibers. Cuts poorly. Dirty. Dus ty. Soft. Voids on surface. Cuts easi iy. Dirty. Fabricates well. Sheds. Feel bothers me. Breaks readily. Crumbly. Dusty. Does not break readily. Cuts well. Good hinging. Good hinging. Good hinging. Sample 27 -- 3" x 1-1/2" pipe covering. Not nice to handle. Very soft. Moderately hard. Good hinging. Long fibers. Cuts readily. Easy to work. Sample 22 -- 1-1/2" x 6" block Good hinging. Hard to break. Very dusty. Dusty. Hard. 01 041 1190 Soft. Rigid. Ruberoid Calsilite Sample 27 continued -3- T. R. 20853-1 Attachment 7 Fabricates well. Moderately dusty. Good hinging. Good impact resistance. Long fibers. Baldwin-Ehret-Hill Thermasil Crumbly. Good surface. Fair hinging. Long fibers. Good appearance. Fair hinging. Smooth surface. Sample 7 -- 1-1/2" x 6" block Sample 19 -- 6" x 1 Rigid. Very little dust. Several pieces broken in shipping. Sof t. All pieces were < Dusty. Weak. Little hinging. Fairly weak. Crumbly. Poor hinging. Cuts well. Good hinging. Good corners. Saws poorly. Poor hinging. Smooth surface. Edges crumbly. Sample 21 -- 1-1/2" Saws readily. Cuts well. Rigid. Good hinging. Good strength. Good surface. Full of voids. Dusty. Cuts readily. Sample No. 8 and 29 -- 3" x 1-1/2" pipe covering Dusty. Good appearance. Fair hinging. Very little dust. Soft. Fairly rigid. Several pieces broken in shipping. Very little dust. Soft. Dusty. Moderate impact strength Crumbly edges. Air holes. Not too strong. Dusty. Breaks easily. Good hinging. Cuts well. Sof t. Crumbly. Soft. Fair hinging. Sof t. Sample 26 -- 3" x 1 pipe covering pipe covering. Sample 15 -- 10" x 1-1/2" pipe covering. Rigid. Little dust. Both pieces cracked. Soft. Breaks when dropped. Crumbles easily. Excellent hinging. Soft. Not much dust. Sof t. Moderate impact strength. Sof t. Breaks but hinges well. Many voids. Cuts poorly. Hinging very good. Dusty. 01 041 1191 O-CF Kaylo 4- T. R. 20853-1 Attachment 8 Sample 10 -- 6" x l" pipe covering. Poor hinging. Good appearance. Rigid. Very little dust. Average strength. Breaks when dropped. No hinging. No dust. Rigid. Good appearance. Hard. Hard. Voids. Cuts very well. Clean. No hinging. Hard. Cuts well. Clean. Shatters when dropped. Does not crumble. Very good strength. Breaks fairly readily on dropping Hinging fair. Shatters when dropped. Good appearance. Saws well. Poor hinging. Cuts cleanly. Union Asbestos and Rubber Co. Sample 12 -- 1-1/2" x 6" block. Unibestos Rigid. Very little dust. Sample 11 -- 6" x l" pipe covering. Hard. Cuts easily. Doesn't break when dropped. Hard. No hinging. Good sharp corners. Little hinging. Damages easily. Very little dust. Very hard on the outside. Tough. Ends mashed. Tough Hard. Cuts well. Square edges. Sample 16 TM 10" x 1-1/2" pipe covering. No hinging. Fabricates easily. Fragile. No hinging. Good strength. Cuts well. Poor hinging. Rigid. Very little dust. Heavy. Hard to break. Hard to cut. No breakage in carton. Strong. Tough. Sample 13 -- 3" x l" pipe covering. Does not saw readily. Rigid. Very little dust. Tough. Hard to fabricate Hard. No dust. Easy to handle. Sample 25 -- 3" x l" pipe covering. Clean. Hard. No hinging. Good sawing. No hinging. Low impact resistance. Easy to damage. No dust. Soft inside. Very little breakage. Excellent hinging. Hard to cut. 01 041 1192 Union Asbestos & Rubber Co. Unibestos, Sample 25 continued Fabricates okay. Does not break. Can be crumbled in hand. Tough. Cuts poorly with saw. Strong. -5- T. R. 20853-1 Attachment 9 01 041 11 o >