Document 3NZXX8K1Y3ERbKqQD34warzEn

Mr. R- S, Grant, Toledo R. F. Shannon, Granville KAYLO RESEARCH AMD DEVELOPMENT MONTHLY REPORT FOR JANUARY 1968 February 5 1968 Mr. M. Hardwick, Berlin Mr, J. Helier, Berlin Mr, A. J. Pearson, Toledo Mr. J. Rhoads, Berlin Mr. H. V. Smith, Toledo This report summarizes major Process Development activities carried out in January by the Kaylo Research and Development Laboratory in cooperation with Berlin plant personnel in support of plant operations. It also briefly summarizes the status of Marketing supported Kaylo Product Development programs Process Development 1. Process Audit Continuing audits of the Berlin operation by R A D indicates a substantial upsurge in product quality, workmanship, plant appearance and equipment and mold maintenance. This was evidenced by higher job efficiencies and higher throughputs in December and January. A quality control product audit, conducted on February 1 by Marketing and Toledo and plant Quality Control personnel gave further evidence of the recent upsurge in product quality. Included in this audit were many ef the pipe sizes, which are considered the toughest to pour, i.e., those sizes which normally have the highest incidence of visual defects and low job efficiencies. The general concensus of those present at the audit was quality of Kaylo pipe had improved in recent months with fewer air holes and bok&n corners. Kaylo block was of very high quality, probably the,best on the market today. 2. Batch A. Carbon Modified K-10 Batch Approval was received from Marketing to oarry out an extended trial of carbon bldck modified K-10 batch. This study will determine whether elimination of mold oiling is possible, provided an internal lubricant is added to the batch. One block train is currently being cycled without oiling. As of February 1 the train had been cycled ten times and still looked good. Final results from this study should be available in late February. PROPRIETARY. This document or anv vzr should not to copru'. r.r Owens-Corning Fibcrglas Carp-ration. Mr.' ft. Q. Grant -2- February 5 1968 B. 7OO Pound Dust Batch J. Helser, of Berlin Process Control, summarized *nd Issued in report form all of the data from 700 pound dust batch formula tions poured at Berlin in recent months. These data, ooupled with RID data from Granville trials, all indicate the 90 called 700 pound dust batch (400 pounds of Berlin process dust and "}0d pounds of Jeffrey hammermilled offwaro) will produce a high quality product, whish fully meets the CAS. J The plant is in the process of preparing a 901 to oover the purchase of a Jeffrey hammermlll and supporting dust handling equipment. In the meantime, arrangements have been made to have substantial quantities ef offware processed through a Jeffrey hammermill. This will permit extensive 8 and 16 hour trials of the 7^0 pound dust batch to be conducted at Berlin so as to verify process performance and product quality under plant conditions. C. Prehardenable K-17 Core ` ' Extensive research has been directed toward A prehardenable K-17 batch, A cement modified batoh was developed, which fully meets GL product requirements and the CAS except for coppressive strength, A search of GL records confirm the fact compressive strength is not a part pi the current UL procedure. A asamary report on prehardenable K-17 batoh will bs issued by February 15 by a A D* A meeting of Marketing, Manufacturing, Toledo Quality Control and Process Control, R & D and Product Testing personnel Must follow for future action on this program. D. I-IO BLoqk Batch It has been a known fact for years that batch formulations designed for Kylo pipe did not always yield good Kaylo hlock and vice versa. With the greater process flexibility now avail able at Berlin, development of batoh formulations specifically designed for block or for pipe is now possible. A modified version of the 1QL-8 batoh designed especially for block Was placed in produfction in January. This batoh Is lower in cost, has an Improved visual appearance and yields a product of superior reality, , \ ... - ' ' 3. Prooeaa (f tL 1 * G tA. process Meeting lA comprehensive monthly process and quality review meeting was ;beld at Berlin on January 18, 1968. The next meeting la tentatively ^scheduled for February 21 to ooincide with the next plant trip \rf the writer. These meetings will provide for regular review pend follow-up of all plant and plant-R ito status, timing end responsibility. process programs as cj-U-.r .1 .t x. \ * ioiir-r an-: r oc Th ` b doc'xcrvt -i/'" v::'-- cf ?.t should nco be r.cr c_ rurr-..- to othere without permission cl Owens-Corning Fiberglas Corporatior L9 SXa.v* -- \jx Sat Hr. R. S. Grant ~3- February 5 1968 B. Bulk Storage r In December 1967 the plant vent full time on the 8 bag (752 pound) cement batch Identified as 10L-8. This batoh formulation oontains a substantially higher percentage of Portland cement than quicklime. Plans are to switch in early February one ef the bulk systems from quicklime to Portland cement with a possible daily savings of over $40. Installation of a third bulk system (in our plans for near future) to handle quicklime will bring daily savings over $?0. (Note! Plant Engineering informs me a third system can. be added to the present bulk system at minimum oost, a fourth system to handle dtatomaceoug earth would be quite expensive.) C. Water Control - Patch for years the Berlin process has been plagued with density control. The main cause for thia problem has been water measurement. Recently, the problem has been compounded by the practice of adding cement to the asbestos tank, causing build up in the tank, which affects the accuracy ef tha present water measuring' system. Purchase of a water meter is under consideration. Locating a meter, which will yield the accuracy needed to control water solids of Eaylo batoh, is currently undarvay. An alternate method of measuring water even more accurately than commercially available meters can is being studied by Plant Engineering, Plant Process Control and K & D. Results of this study will be reported In February. . , .. - D. Waste Slurry - T :- Plant audits conducted by R A D last summer and fall indicated one of the major causes for variability of batch properties, processing and product properties was use of waste slurry. Substantial improvements have been made reoently at the plant in the handling and holding (now under oonstant agitation) of waste slurry. A study will bo undertaken shortly to gain oven better oontrol over waste water composition and eollda. A piece of equipment comaercially available and now in use by the water treating and process industry for separating solids from water will be investigated.. From an economia standpoint, we must continue to use waste slurry. - At the same time reduction or It* effect on batch consistency, processing and product quality is of the utmost Importance to the plant operation. ... , 1`-- l *-: - E. Vacuum gtrlpplne r i - 1.' '' : -- t:'' ^ ' - > v:;v i- c ' t t.rt>rt ! ' A major Kaylo process problem, which has existed rrxffiftlay' one, has been stripping of flatware* A-concept known'a* *raouu ~ stripping', was suggested years ago as a Means for Werooaing this ' problem. In January, Berlin plant maintenance and engineering r< personnel on their own initiative built and successfully tested "' a prototype vacuum stripping device for flatware (oo're arvd block). PROPRIETARY This document or eny u?.rts of it Bhould not be copied nor divulged ^ to others without permission_of C c 3(57 Mr. R. S, Orant -4- Fobruary 5. 1968 E. Y>UUJB Stripping (Cont.) Once it is Installed on the line, we oan oxpect s reduction in block and oore offvare. NEM caused by chips remaining under the falsa bottom plates and ohlpped and broken' oorners should be reduced substantially. Pouring rates should also increase nine# stripping continues to be one of our current throughput bottlenecks. F. Prehardening Meetings were held with Toledo General Engineering personnel to review process problems relating to 'prehardening of Kaylo. General Engineering will conduct studies at Berlin directed toward collecting data as to rates of prehardening, temperatures required and alternate raothods for heating the molds and batch to reduce prehardening time. During these meetings Kaylo R & D passed on to General Engineering a number of suggestions relating to modifications which oould be made to the existing prehardeners -to make them even more effective. These modifications could also be incorporated into the deBlgn of the new prehardeners to be installed on pouring line 3. G. Graphite Treated Molds Dr. C. L. McKinnis of the Laylo R 4 D Lab has evolved a new concept for eliminating the need for oiling of molds. It involves the application of a molecular layer of graphite to the metal surface ef the mold. The current thinking is to apply this ooating in the mold shop at the tioe the train ts being cleaned. Initial lab data shows promise. Arrangements have been made with K- Hardwick to evaluate this oonoept at Berlin'under plant ^conditions, possibly in late February. H. ffID Cycles Back in the 19,50' it was believed long up and down cycles were necessary to prevent ware 'hlow-ups*. In fact, for years a multiple step operation was Used to bring the BID cylinder up to pressure. The sajse in reverse was used to lower the pressure. In the early i960'* experiments were conducted at Granville, ^whloh indicated up and down oyoles oould be reduced substantially without adversely affecting product properties. J. Heleer, ; Berlin Process Control, reduced the up and down cycle to one j Wlf hour and one hour pespeotlvely in recent years. In January t he further reduced the up cycle to 15 minutes and the* down cycle to 30 minutes. What does this mean? Capacity ef the present f BID'a has been lnoreaeed the equivalent of two er more trains ~per day, *Also, we amy have gained a foothold on extending the ?a tent ypotection on the SID process (OCF SID patent ha* expired), he special, proa*s 1 triors' needed to make such short op and ^<Jown <jycJ.es work without blowing up the ware are probably patentable, PROPEIEIARY This document or any parts of it should not be copi o nor divulged to others without ^ "-----:? ^--nr--.. penr.ir.Kion of 310 Hr. R. S. Grant -5- february 1968 4. Raw Materials A. Glass Technology A mooting vaa held at Berlin with Gitas Technology personnel to determine how and where they oould help. A comprehensive review of batch material used, sources of raw materials and methods of mixing were provided Glass Technology, Areas where Glass Technology could provide immediate help were defined. They include: Locate alternate vendors of lime and eilloa, chemical analysis of all batch materials as a prelude for writing tighter purohase specifications and analysis of Kaylo betoh and product on a regular basis to determine chemical variation for future upgrading and process -control. B. Platomaooous Earth ' ' - ' ' 1 " . - ' r L ' \ The ourrent 10L-8 batch requires substantially less dietomaoeous earth than previous batch formulations. K.en so, diatomaoeous earth is an expensive raw material. We need an alternate source for obvious reasons. Also, indications are a second source will ereate the competition needed to obtain lower prioes. Aotive programs are underway with both Plcalite and United Sierra. . . Plant trials of a Dioalite material is tentatively scheduled * for Eebruary. . ftmoalte Asbestos ' r r. A meeting was held with Hr. Cryor, President of Borth American t . . Asbestos Corporation, concerning fiber length of amoadte asbestos. The problem is purohase specs Tor amosite asbestos are SO loose .... At is difficult to have any basis for rejection. This meeting J was prompted by the fact it was the eombined 'belief' of plant - and RAD personnel K.-3 asbestos shipped to Berlin last fall v: . -as the equivalent of W-3 asbestos was actually shorter and could have been a possible cause for lower product strength. A basis for evaluating amosite asbestos fiber length and for oompllanoe i with a specification also ,to be worked out is under active T t negotiation. . . , ., ' Hr. Cryor is also arranging to have amoaite asbestos dry willed j. -- ~ In either Afrioa or England for us. All other manufacturers / s ! of calolum silicates dry mill their asbestos (we wet grind). V. Plant trials will be made with the dry milled asbestos as soOn b;^ -: as it arrives are possible. to determine f whether improved product L- ;;-> V a c.r * . .. ; properties ,Pv Chrysotlle Asbestos o -' v. vc b-c' or. ;.cr * . 1 if Krr- cp-:: r~.` \ - ' T: I: l-'r/;. ^4 r. t,; o,. tc 1 Bauer tfcKett testa ware tun at Granville *n 4T and Jb asbestos ent. r being used at Berlin. Both were found to be meeting Our Purohai Bpeaifioation a a to fiber length. PROPRIETARY This dec:': or a:\v parts of it E'. ruli r.u ce ccpi nor divulged to cthe:: uitkzut pert, i S3 ion of Xk;An c_dxxjrr ; T-i -r g, ore) aQ-*B .C n rj- in- r a t.JLcin < Os S/I O' Hr. R. S. Grant <*6- february 5, 1968 $. ^tarnate High Temperature Insulation Processes A. process - Nay Facility A comprehensive report is being prepared for Management oonoerning various processes which must be considered for the new facility and possibly later at Berlin. Various processes, lnoludlng filter press, bonded aggregate, vertical casting, Crosfield and pan pouring are being reviewed In depth as to advantages and disadvantages of eaoh, capital expenditures needed, throughputs and economics. The RAD report will issue on or about February 15. B. Crosfield Won^Autoclaved Process Arrangements were made with the Crosfield people to <btain samples of their product for physical property study and verification and a quantity ef their calcium silicate raw material for sample preparation at Granville. As of the date of this report, neither has been received at Granville.^ Product Development 1. stress Corrosion - The second 3,000 pound grind of 2399 glass from Philadelphia Quartz was released to Berlin for plant trials. A series of plant trials was made in January direoted toward evaluating the batch formulations developed last summer and fall at Granville. These formulations are expected to produce harder stronger ware and lower batoh costs. Samples are being shipped to Granvillo Produot Testing Lab for physical, thermal and stress oorrosion testing. The 10L-STS-1 batoh poured on December 28 passed the 6 day stress oorrosion test, but was marginal en the 10 day test (3 out of 10 samples oracked). This batch was identioal to the one poured and approved last February (I967) by duPont except for the substitution of Philadelphia Quarts 239? glass for Granville melted 2399 glass. The cause fcr this variation in results is currently under investigation. 2. 34 Inch Pipe A substantial percentage of our offware at Berlin Is defined as 'short ware'. A request was made last fall to Marksting to change pipe specifications from 35-7/8 Inch to 35-3/4 inch and to market a 34 inoh product, which could bs salvaged from wars with broken comers. Substantial increases in 'packed* ware would bo possible if Marketing approved these requests. Marketing rejected the pipe length specifica tion change from 35-7/8 inoh to 35-3/4 inoh. They did agree, however, to the marketing of cut downs (34 inoh). This program sf salvaging out downs was started in late Janaary. ._____ -- - ---------- This dec. should no other: Owens-Corni 735>TT Mr. R. S. Grant 7 February 1?68 3 Asbestos The experimental program on replacement of * obentoa by glass was resumed in January under the direotion of Dr. C. L. HcXinnis. Difficulty was encountered in diapersing ohemioally treated glaas fibers without attrition to fiber length. Ways of cirouravanting this difficulty are now being investigated. In the interim experi mental glass fiber Ka^lo batches mixed with conventional equipment are being run to check the resistance of these chemically treated fibers against the corrosive aotion of the Eaylo batch. 4. Multi-Temp Pipe Fittings R. F, Shannon and A. S. Kevlir\ of I and C Marketing, met with InsulCoustics on January 1? for purposes of reviewing the technical aspects of producing Multi-Temp pipe fittings. A detailed report will be prepared by Kaylo RAD covering the Multi-Temp process. Tentative plans call for Insul-Coustics to buy basic wool from OCF, mold to shape, saturate with the OCF developed inorganic aaturant, dry, trim and packaga. The fittings will be marketed by OCF. 5. Careytemp A report of R A D findings as to asbestos content of Careytemp was prepared and released to Marketing,- It 1* surprising to note C reytemp contains almost as much asbestos as Kaylo, yet their boxes do not carry any warning label and no mention of asbestos appears In thair literature. RFS/ris R. F. Shannon 'd... r*;.. t 7. * r* , < . tit ta-'n- jr.09.rt 3: of'"it U. S. DISTRICT COURT Case No__Jfd.3___ Ex. No..'$*+> Ident______________ __________ F.vid_____________ ______ _