Document 5kmXB3L77YmvaxLbywZgBv6zz

/ * HAIG G'. SAKOIAN PITTSBURGH OFFICE - 7 ME. E. L. ROOY PITTSBURGH OFFICE - 23 1979 May 07 RE: ASBESTOS USES IN ALCOA INGOT PLANTS Thank you for your help in explaining some of the details regarding asbestos replacement materials available in our ingot casting areas. Please find attached the summary of the results of our asbestos use poll, specifically in ingot casting, that you requested. 1= It is evident that much work has been done in this area. However, it is also clear that much work still lies ahead. A complete asbestos use and available substitution summary is being prepared to aid the plants in their replacement efforts. If you would be interested in seeing a copy, I would be happy to send you one. Your support in this endeavor is greatly appreciated. D HAIG G. SAKOIAN HGS/eds cc: E. E. Rumberger - Pgh /n. ^ a i gjkz. ALCOA PLANT ATC Davenport Lafayette Massena Pt. Comfort Rockdale Tennessee Tifton Vancouver MOLTEN METAL MARINITE USES IN ALCOA PLANTS INGOT CASTING SPECIFIC APPLICATION AS REPORTED FROM PLANTS -Ingot casting items - Manufacturing Section -Variable head distributor float #2 DC pit -Float - 18X50 and 18X60 DC molds -Float - 12X48, 16X50, 16X43 DC molds -Float - Flow control DC casting unit -Float - 24X72 ingots #9 DC pit -Trough Plug - pouring troughs -Support - DC pits -Trough dam - pouring troughs -Trough dam - 503 and 528 filter boxes -Skim stick - DC pits -Float - DC pits -Float support - DC pits -Blinder - DC pits -(Marinite board) Doorframe insulation on melting and holding furnaces -Casting tools -Insulator - part for chip melter, side bay -Headers (sanding of Marinite headers in mold shop) -Float used for HDC sheet ingot tooling, 30 complex, level flow control, cast units -Miscellaneous Marinite: Spare parts for 30 complex; insulators? inserts? bearing housings; couplings; covers; etc. -Basins for HDC casting -Pre-cut Marinite for molten metal casting -HDC headers - South Plant -DC casting floats and spouts -Headers (Note: ceramic molds replace 2/3 of Marinite heads at present time.) PLANT Vernon Warrick Wenatchee Page 2 SPECIFIC APPLICATION AS REPORTED FROM PLANTS -Marinite board (Non-asbestos Marinite now being substituted on trial basis) -Also use asbestos rope for door seals (being replaced with ceramic) -Also use asbestos-containing block or brick -Trough liners; headers (partial substitution of plastic trough lining continues) NO REPORT HAIG G. SAKOIAN 1979 May 04/eds FROM A. A. KRON TO MR. R. P. CARTER MECHANICAL ENGINEERING DIVISION PITTSBURGH - 3 WPH PITTSBURGH OFFICE - 7 1979-03-21 RE; PLANT USAGE OF ASBESTOS PRODUCTS Please refer to our letter dated 1978JUL06 under the subject heading. This letter refers to a search for substitute furnace burner radiant tube gland packing materials. We are attaching 3 samples for your observation. The square brownish piece is probably Johns-Manville 869 asbestos, which has been our standard for many years. This piece has seen service in a Davenport preheat furnace for some time. The loose braided piece is ceramic fiber, and has been tried in a Davenport annealer with minimal success. The third piece, the square white one, is Anchor Packing Co. ANKO-TEX 1551, which is supposed to be satisfactory for plant use, and is the material in general use at the present time in new Davenport installations. We checked the temperatures to which this packing is exposed. At a preheat furnace temperature of 1160F, the packing is exposed to a maximum temperature of 500F on the radiant tube burner leg gland and 780F on the exhaust leg gland. Davenport is presently in the process of investigating a non asbestos packing material made by Pyrotek Inc. of Spokane, Washington under the designation of P-13. This is a carbon yarn material impregnated with graphite. Our present course of action is to work with the plants in the field testing of available products. A. A. KRON AAK/ccw Attachments cc: L. D. Tanis/J. F. Sanders/D. C. Allebach - Davenport J. D. Breazeal - Davenport M. J. Caprio - Pgh. 19 R. M. Trimble - ATC-B 0 ALCOA Sr-4363 or OJLodi^ i * PIT 243 t MSW PIT 1/27 R V KNAPP 0088 01/27/72 16. 16 16.24 L V DANFORTH___ W S BARR REURLET 1/25/72. MARINITE DOES CONTAIN 50Z ASBESTOS. RECENTLY JOHNS MANVILLE SALESMAN ADVISED PITTSBURGH PURCHASING THAT THE HEAT TREATING EMPLOYED FOR OUR MARINITE REDUCES TOXICITY SIGNIFICANTLY. VE ARE ASKING FOR DOCUMENTATION OF THIS BUT ARE NOT AWARE OF ANY SUCH WORK. THEREFORE TOM BONNEY FEELS WE MUST PROCEED AT PRESENT ON BASIS THAT FINES FROM MARINITE CUTTING OPERATIONS ARE^SUBJECT TO PROVISIONS OF THE EMERGENCY STANDARD PER MY LET 12/7/72 AND ADOPT REQUIRED ENGINEERING AND PROTECTION ACTION. ROBERT P CARTER PGH ES \ O O o K3-0%~25 Pv (c - ft `SubS'fi'fa&s Mjfct*4 (JlQftnLfe) VZ&4TL$JtiSl -fkoJr (X/y^ 'j^x' tfbC' j /Alftai AAJjlMu? ("fart ^j>JLna J(xi<xo Us7WU**c&aa^uJ gtouL- <ft>: \ift)j /. %c>r Cl3 Air. 2. Z)/ -fficu^ft % fibriamfe. lGYu*c&j- rt/tft ThW osJUP CfrdihAstt {s p&tfdi. fi^. a. gcclfaMt. J.R.Stemler, ATC-C 1- Designed low pressure nozzle for Al-Li fluxing to be used until the R798 nozzle is available. This nozzle was designed to operate in the unstable jet flow regime (Re >12,000) with a reduced out side diameter for smaller bubble formation. (CEE) 2. Visited Drexel University to complete filter bed flow visualiza tion formation. A video tape was made that clearly illustrates the flow of liquid (salt) inclusions through a filter bed and total lack of capture. The modelling system was chloroform ethyl phthalate continuous phase, borosilicate glass media, and propylene glycol inclusion phase. We are planning to determine conditions leading to filter release effects using the model in December 1982. (CEE) 3. A video tape of molten steel filtration modelling was made while at Drexel. This tape will be shown to Jim Everts (Pgh) for the purpose of possibly establishing a program. (CEE) 4. In-line alloying, R798, and cake mode filter program were discussed with Warrick visitors. TCEE) 5. Attended a meeting at Arkansas Operations with H.G. Reavis to discuss tabular alumina bed filter media quality requirements (RE: C.E.Eckert report to H.G.Reavis, 1982 October 20). The people at Arkansas are now cognizant of our quality needs and will reply with an intended action plan. (CEE) 6. Skim Cooler ("Remetal") performs very well. The product is separated in *'rechargeable for metal recovery" and fine fractions. Good recovery from charge into toilet bowl. Tests continue. (JVL) 7. The skim busting machine ("Geneco* from McBride Co.) is performing exceptionally well. Cooler product and skim patties are enriched in preparation for charging in the toilet bowl. The skim formation from the "rich skim fraction" is less than 30%1 (JVL) 8. / 9. Demonstrated all facets of the comprehensive skim treatment scheme to Warrick personnel with good results. Plans are to expand the proposal and provide test results to substantiate the potential savings. (JVL) Warrick recently had best run ever casting with a non-asbestos header. A Lumi N-12 header ran for 75 hours on 21X42" 5182 and terminated for non-header related reasons. Lubricant con sumption was normal. Trials will continue. (RB/VLH) cnjJS jr. \ R. E. MILLER cc: See page 2 gj ALCOA <v n a) Y Y3> y^ y\7< R, 1982 65M41008 - Technical Support of Operations - RCS Summary: A standard infrared method for the determination of butylated hydroxytoluene in the coolants from the Tennessee cold mills (10/12 and Tandem) was written and distributed. Additional quantitative methods were developed for cold and hot mill coolants. A plant trip to Tennessee was made to review and set up these methods. Statement: 1) A standard analytical method entitled "Determination of Butylated Hydroxytoluene (BHT) in the Tandem and 10/12 Mills by Infrared Spectrophotometry" was written and distributed to those personnel performing this analysis. This procedure is found under the heading "Analysis of Cold Rolling Lubricant" #479.5. 2) Cold Mill Lubricants - Quantitative infrared methods were developed for the determination of XL-5476 (10/12 mill) and XL-1468 (Tandem Mill) in their respective coolants. 3) Hot Mill Lubricants - An infrared procedure was developed for the analysis of XL-6082. 4) Several days (1982 October 26-28) were spent at the Tennessee Operations lab to check the operation of a recently purchased infrared spectrometer. The current method for determining the components of XL-2178 was reviewed. In addition, procedures were demonstrated for determining the constituents in XL-6082, 10/12 and Tandem mill oils (other than BHT in the latter). B. J. SPARR I FROM P. S. BUSSEY - SAFETY INDUSTRIAL HYGIENE DEPT, ALCOA TECHNICAL CENTER - D : : ' ' TO MR. E. E--.----R--U--M--B-E--R--G--E-R- ,. .HEALTH S SAFETYa DEPARTttENTTlr!^-jOS=- pitts;burgh off:ice' AITjnG! ~v'C3 9: ...F-ER'i 1983 September 26 "" RM^,9^2 La co ^JL LMN EDS J.' Vr':i . .? t4> f.p iV RE: POTENTIAL-USE,OF CALCINED,ASBESTOS^ORE,'AT ADDY , . ,,rs-r ...i got 2--*--l-i-a--s i'--f-ja o..J. -.jHsVto, c: **:.nor^y OsX' This is to conf 1 rmoourr.j rreecce^^tt^?cco<nwve^re^^aH^fmjQp^O..n^vj.t.he.cwaap^twlo.vn.edv subject^^jlc promote good ccoommmmunujn,cj.actaiotinosn^so^nonIj^&ttejeLn!gigdduuss^^nMaalji * nhYyg9i!eennee"r imp!l 1iccaattifoonbs ^ujthe captioned project,.attachedcog/ o^heg^^l2,1 g^ot^t Division Higni1ghtsjr^H^Fl;SSh)'lwa-.ii:T .mtu9di js I the for analysis for toxic components.' e of th Lab, ii:P?oai5 noctE 9f at r-;3 }t/r^nusu.--;.fji2 .gr Please let-me knoW^if the,fIe&a5e5any^que5iops95n3th4S sujjject?or jf _jfican be of assistancejinceyaluat,jog igdustp4iaia^ygiene2conceros.2 ^ J r'-}Tw *- norrto* dtsnodns? m-. r rf .T r T ~T>-1 ...? ofcfXCJ f.fij ?rP7 ' ' >* ?.* sis "'ns sr.'.-JS*5*V}0 pnrtsso _ ' -'-rrt*)>v 9 >m ,^f9ten trU .X- i 'tr>c: `Xj Ot bflUoV : V' ?v "x ' :or: : \ Z'.so /u.n v-:r: fUiQ*toa6 sPi 1 Efi i C.Q cc: Info. Dept., ATC - D D. E. Huddleston, Pittsburgh 6 AB R. S. Danchik/D. R. Balya, ATC - C L. D. Tanis/J. A. Shockey, ATC - D R. M. James, Pittsburgh 6 AB ALCOA j- - - * ; O'* . /1 -lWJ' ,.X- .A 3-JTA , i ?ic ? .'3 .a Q-3TA ,?ffT6T .0 .J fl-OfA i, :2sW .3 .3 A - "J ! A , VO i * 9^ . Li . W `".'Onfrr.2 pnr .D jopnl |f*49l J# -i' '"vf; J : J- - r< 33^30**^. 3, "**'cn >'a> CO y&Q} R; A.BONEWITZ - CONFIDENTIAL "`!*5' ?1983~September 12 'V~ Page 2 V' . ' s^v.vs*:-**- - . . v. .i1 **a*^-yi$>$ls5?*>:' ;', .: ":'; -/ 3&>`v- '; . ; v '' ` >": :u:,.1l i VT31A2:-v ^TteO'-liAJ :'. acwa` .'o ,- (' 9. For has a need to add | S10J arid MgO td-^-the^ Maqnethenn^furhaceivHthoutiaddinq additidnal 3?i ,-CaO. Union Carbide is offering to sell asbestos ore fr<mi California. ^ ^IChemicai|ly thiSisbufce-of^jnaifiesidin^fTfcate^iiS compatible witil NWA,ls<Ti> .'process'butvth'e!,asbestb5'hazard``iS'pFdHiBftiVii^fCarbide-is-so anxiousij ^ . LTm ^ ---- - -- 1 ii Aanir I Jam t am 1a4m4Wm lifcW. ore at the quarry. This * , produce a~non-^razardous material. With this issue resolved, NWA and , ' AfUhionCarbide?Sfe3taik1n`pfic1n98nd^6ant1 tlfs^Before^fenterlrigHntorl*; rij f^^agredneritT-e IK. - Al'Bdwinaa^M^^^? Pghf Procuf-emfent)*! sfc ' * i v-" /*s*$aefoq8icp Vi* *a;: z\ f errs' ,10^.- ..1P^C-SwaJjgaiwnts>^gt^C02jadfled^tp the protQctiye argon, atmosphere for meltsTSye^beefiPfoShd^td^malcS^a9^!^ desirable-'fdrm ofo^^ ' also-reduci hgyther-'chokfhg3fUm6l eCarbohsdi oxide^reacts jwi th lithium oxide to form lithium carbonate which is molten at molten * metal temperatures. This reaction was also hoped to minimize-fogging! Of the viewing windows so that casting operators could better Watch' ' and control the cast. .Unfortunately, significant quantitiescofe .ft EloPiVsonous darbon monoxide^ ard found to be formed as a side reactlon. Thiswi IT have to-be handled or the approach may be abandoned. (ICa. Bowman) >\ y'- : ! rj CV / ' :;f 35J ?A R. E. MILLER des Vifv DCcrf/l/v-'-v cr L *: - >**/. rr. ~ ; r i 1-. :,s:" `i. - - - -> . (T T -i M o j.'" . c . fl a .o. . j 9 < 't 4 mv cc: ID, ATC-D D. K. Ai, ATC^C A. Alexander, IATC-C W. S. Cebulak/J. T. Staley, ATC-C J. D. Dowd, ATCt-C N. L. Lawson, ATC-B J. L. Prohaska, ATC-D M. A. Rawlinson, ATC-C \ R. Rolles, ATC-C E. L. Rooy,, Pittsburgh-23 A. J. Sartschev, WPHi3^ R. E. Spear,| ATC-C ; L. D. Tarn's,) ATC-D \ \ C. E. West, ATC-B W. G. Zelley, ATC-A Ingot Casting Engineers .t } '.,pt _ * P-. /V;f .! . * ;.( , L". iK. 1' 1' '.,-sV ' -' vvvV'V -Vi-',.; ': 'ti- r* T-T* VIRGINIA L. HAMMERSMITH CHEMICALS AND CERAMICS DIVISION ALCOA TECHNICAL CENTER - B MR. ELWIN L. ROOYH^ M0LC_C. PITTSBURGH - 1981 JUNE 15 BDO EER TBS RNAJ c7:i- sm> cn Wmi tbt jEcV R\\F oi CO cl pw z ZD UAN --3 EDS RE: ASBESTOS REPLACEMENT - MOLTEN METAL MARINITS (&E' Alcoa's ongoing policy for several years now has been "to actively replace any asbestos containing material wherever possible". As we are all aware, the largest usage of such materials by Alcoa has still been with asbestos containing molten metal marinite manu factured by John's Manville at their Billerica, Massachusetts, plant. For the past few years, regular grade asbestos marinite has been no more than 5% of their total business, with the prime type, header grade molten metal marinite, no more than 2%. Certainly, it is in both John's Manville's and Alcoa's interest to remove these from their product line and, more specifically, to replace the materials with an asbestos-free type prior to any government edict. Comparable performance of their new Marinite C (a calcium silicate, fiberglass reinforced refractory board) to the regular grade molten metal marinite is certainly welcomed by some of our ingot operations. However, it has been brought to my attention that some locations are exceedingly slow to recognize a need to change quickly and to implement the new material across the board. OSHA maximum limi tations presently are no more than 2 fibers/cc air averaged over an eight hour period without being in violation, The OSHA action 1 evel, maximum of 0.1 fiber/cc, requires that we monitor the perso ns exposed for physical symptoms of lung damage and disease. In the case of our plants and most exposures, the short term limit is a maximum of 10 fibers/cc air over a 15 minute period. Most cou ntries have reduced this limit much further. How we, as a corporat ion, can afford this slowness of implementation Many people feel that OSHA, Alcoa Safety, and Alcoa Research are overly concerned and, hence, they have turned their ears and eyes away from citing violations such as the continuing use of asbestos materials when an alternative is available and to assume that "small" infractions (drilling, sanding, air hammer removal, etc.) should go unnoticed. Also, the notion is unfounded that as long as we, as a corporation, are not actively machining the material, the asbestos fibers are tied up in the matrix and pose no health hazard. Even transporting a small item of asbestos marinite can release surface fibers, especially in- the lengths most often associated with future lung disease. Certainly, I and other workers do not appreciate the fact that we are all exposed unknowingly due AI ( i i a Mr. Elwin L. Rooy 1981 June 15 Page 2 to these practices. Hence, I do not feel personally that removal and proper disposal of the asbestos containing marinite, which can be replaced with a more safe material in our operations, is any longer "only a moral issue" and to be taken lightly. Items of premi um grade asbestos marinite which should temporarily be exempt due to the un suitabili ty of the asbestos-free grade are really limited to only a few and necessarily must be handled very cautiously: 1. Sheet Ingot Headers (Tennessee South and Wa rrick) 2. Hunter Caster Tips (Badin) 3. Small round HDC Headers (Badin) 4. Tool and Jig Plate Headers (Vernon) The pursuit of our evaluations of the newer Marinite H and Pyrotek T-12 takes on increasing importance in the removal of those few items from the list also. However, your assistance and insight as to how we, as a corporation can more swiftly attack the implementation of the suitable asbestos free materials at all locations would certainly benefit the program Certainly, the seriousness of curtailing the purchase of marinite effective September 1 has not penetrated deep enough yet into operations and needs to be addressed. HAMMERSMITH VLH:dlw cc: ID, ATC-D T. L. Francis/File 8.140, ATC-B Ceramic Engineers, ATC-B K. E. Buchovecky, ATC-B J. R. Stemler, ATC-C R. E. Miller, ATC-B. H. Sakoian, Tennessee South H. E. Ellis , Badin / R. L- Parsons/K. P. Karsten, Warrick A. L. Piecka, Vernon J. A. Thompson, Wenatchee M. J. Caprio, Pittsburgh-19 H. G. Reavis, Pittsburgh-23 M . .J . CAI'K 10 PROCUREMENT DEPARTMENT - 19 M K M 0 H A N I) II H 1981 MARCH 30 RE: JOHNS-MANVILLE'S MARINITE PRODUCTS With the exception of the critical header applications for both HDC and FDC ingot operations, Johns-Manville's (J.M.) asbestosfree Marinite-C board should replace the asbestos Molten Metal Marinite. By means of this letter we are advising all plants to replace asbestos Molten Metal Marinite (S/N 094-210-xxxx) with asbestos free Marinite-C (S/N 094-218-xxxx) by 1981 September 01. The applications for Marinite-C include molten metal transfer troughs, baffles, basins, dams and floating skimmers. J-M's asbestos-free Marinite-I is not recommended for molten aluminum operations. In certain applications, an acceptable alternate for Marinite-C is Pyrotek's asbestos-free Pyrotherm B-3 manufactured by Cape Boards of England. Any questions on the acceptance of this board should be directed to Mrs. Virginia Hammersmith at ATC or the writer. If all things are equal, we favor the use of J-M's domestically produced Marinite-C. An asbestos-free material for the critical HDC and FDC header applications has yet to be developed for commercial use. Until this product is available, we will continue to use asbestos Header Grade Molten Metal Marinite, (S/N 094-220-xxxx). To insure continued availability of the header grade material, we request your estimated usage through 1982 June 30. In this manner J-M can be advised of our needs and insure adequate supplies of the SI1-65 amosite fiber. Your cooperation in forwarding the estimated usage for Header Grade Molten Metal Marinite to my attention by 1981 April 30 will be appreciated. If there are any questions on this matter, please contact me directly. r .> 'l t DISTRIBUTION J.D. Boyce - ATC W.K. Benefield - Badin T.W. Lee - Davenport R.C. Miessler - Lafayette H.L. Gallop - Lebanon T.E. Klenske - Massena D.J. Fisher - Point Comfort J.R. Fry - Rockdale W.S. Zuber - Tennessee M.D. Wooden - Vancouver J. Heron - Vernon W.V. Pataki - Warrick D. Lutz - Warrick J.R. Pargman - Wenatchee C.J. Cox - 3 WPH A.J. Sartschev - 3 WPH V.L. Hammersmith - ATC-B R.W. Flanagan - AB 6 zoc %X 3 7- ^\ vn rr I FRCV. MICHAEL J. VAUDREUIL PITTSBURGH OFFICE - 6 T0 MR. C. A. WHITING PITTSBURGH OFFICE - 20 I.. 1980 September 23 RE: SUBSTITUTES FOR TRANSITE IN INGOT CONTAINERS As per your request, I have attached some technical data and cost infor mation on a number of asbestos-free products. Glass reinforced cement (GRC) sheet is probably closest to transite in overall performance. It's major drawback is very low interlaminar shear strength. However, since compressive strength is of greater importance than shear strength in your application, GRC sheet may prove to be a viable alternative to transite. Marinite I and Pyrotherm B-2 have excellent high temperature resistance, but very low bending strength. Data on compressive strength is not available. Should GRC sheet prove to be unsuitable, I would recommend that you take a look at these materials. If I can be of any further assistance, please don't hesitate to call. MlUUACL. J . VAUUU.U 1. MJV:mlf cc: M. J. Caprio, Pittsburgh Office - 19 P. H. Scott, Pittsburgh Office - 6 Attachments COMPARATIVE DATA ON CHEMFIL GRC 125/S & JOHNS-HANVILLE ' S FLAT TRANSITE Technical Data Max. Service Temperature Density, Kg/m^ Pcf Water Absorption % of Dry Weight Modulus of Rupture, MPa Psi Compressive Strength, MPa Psi Shear Strength, MPa Psi Thermal Expansion cra/cm/K in/in/F Thermal Conductivity, W/mK Btu in/hr 'Ft2 CHEMFIL GRC-12 5/S JOHNS-MANVILLE FLAT TRANSITE 320C(600F) 320C(600F) 2000 1600 125 Max. 16% i 100 Max. 22% 27.6 4000 69.0 10,000 2^4 Interlaminar 9.7 -Jn-plane 350 Interlaminar 1400 In-plane 7xl0"6 ** 12xl0~6 27.6 4000 82.8 12,000 24.1 3500 5xl0~6 8.6x10~6 1 .9 5 4.5 ' The rigidity and toughness imparted by Cem-FIL* glass fibers enable tensile and flexural strength to be designed into cement based products. GRC has already found many applications in the construction and allied industries, where it has been used as an alterna tive material to precast concrete, sheet metal, cast iron, wood, plastics and asbestos cement Marty existing products make use of the inherent advantages and manufacturing flexi bility which, combined with the fact that GRC is non-combustible and rot corrosion and fire resistant make it an ideal material for many engineering applications. The properties of GRC are influenced by factors such as fiber content and distribution, type of matrix and method of manufacture: The properties can therefore be tailored to meet the design requirements of particular components. This data sheet gives typical property values for Cem-FIL* GRC sheet/125S which is a high density sheet material manufactured by the spray dewatering process. Hot bottle pusher bar and dead plate r'orn-CII r^'or'~i.'^rr5*ir>n ^ O n * 1. Product Description 2. Manufacture 3. Mechanical Properties Glassfiber reinforced cement (GRC) is the generic term for the composite material which consists of a matrix of Portland cement and fine aggregate ' reinforced with alkali resistant glass fibers. The fibers, trade name Cem-FIL* AR, are manufactured by Pilkington Brothers Limited. St Helens, England and are marketed in the USA by Cem-FIL Corporation. Cem-FIL* GRC Sheet/125Sis manufactured by a mechanical process which involves the spray deposition of the cement/sand slurry and chopped glass fibers on to a special table through which the so formed GRC sheet can be dewatered to provide maximum density and optimum physical properties. Typical Properties at 28 days:* 70 N/mm* Compressive Strength 10.000 psi 15 kN/mm* Young's Modulus 2x 10* psi 24 N. mm/mm* Izod impact Strength 120 in. tb/in* 11 N/mm* Ultimate Tensile Strength 1600 psi 7 N/mm* Effective Tensile Elastic Limit 1000 psi Ultimate Bending Strength 28 N/mm* (Modulus of Rupture in 4 point-bending) 4000 psi 12 N/mm* Effective Bending Elastic Limit 1700 psi 1.0% Strain to Failure 1.0% 2 N/mm* Interlaminar Shear Strength 350 psi 10 N/mm* In-Plane Shear Strength 1400 psi 41 N/mm* Punch-through Shear Strength 6000 psi 2.0 tonne/m* Density ' 125 Ibs/ft* 0.20-0.25 Poisson's Ratio 020-0.25 * The initial mechanical properties of GRC can vary with time depending upon the work ing environment In dry or hot and dry con ditions there is little change. In moist or wet conditions there is some loss of tensile and impact strength over a number of years to levels which are well above the normal work ing range. Conditions of use should there fore be taken into consideration at the design stage, and further information and advice is available from Cem-FIL Corporation. 4. Creep and Stress Rupture In common with other cementitious materials GRC components exhibit some creep under a maintained load. Creep strains are small (basically those associated with the matrix) and the creep strain rate decreases with time. Stress rupture has not been noted at stress levels in the normal working range of the material. Creep and stress rupture information is available from Cem-FIL Corporation. 5. Fatigue At the normal working stress levels fatigue lives greaterthan 10* cycles are obtained in both bending and tension. At stress levels dose to the elastic limit fatigue lives of 10s cycles in bending and 10* cydesjn tension are obtained. 6. Thermal Properties Effect of high temperatures: GRC has been used successfully at elevated temperatures. Although the predse maximum working temperature depends on duration of exposure at elevated temperatures and the pre vailing environment 600 F. is the maximum service temperature advised for prolonged exposure in air. Thermal Conductivity: Thermal Expansion: .. 4.95 Btu. in/h. ft* F (0.7 W/m *K) , * 7x10-perF(12x10-peroK) ' : Freeze/Thaw: No visible deterioration or change in mechanical )t properties has been recorded for GRC tested to >y.;;? the following standards. ; British Standard 4624 (1970)--25 cycles. .1: `: ASTM C666--25 cycles, DIN 274(1936>8 cycles"; with vacuum impregnation. 7. Effect of Moisture Shrinkage/expansion: Vapor permeability: Moisture absorption: f Maximum linear movement in going from completely wet to completely d/y is 0.14%../*',:-f '. Less than 2 perms.';^.-' Maximum 16% of dry weight; 8. Chemical Resistance The chemical resistance of GRC is largely dependent upon the resist- ance of the Portland cement to the particular chemical. In general GRC is least resistant to acid attack but is quite satisfactory when exposed to alkaline solution and organic solvents. . . r ' 9. Fire GRC is classified as non-combustible when tested to ASTM E136-73. li CORPORATION * 4 10. Electrical 11. Acoustical Arc Resistance (ASTM D495/73) Volume Resistivity (ASTM D257/75) Delectric Strength (ASTM D149/64) 406 seconds 1.26 x 10r ohm. inch 295 volts per mil (In all tests the samples were conditioned at 50% R. H. and 73 FJ GRC follows the mass law for sound reduction. X"GRC sheet/125S has a surface mass of 4 Ibs/ft1 and yields a sound reduction Index of 22db at 35Qhz rising to 39db at 4000hz.. 12. Cutting and Machining GRC can be cut and machined with tools suitable for masonry use. eg tungsten carbide tipped blades eta As GRC is based on cement and silica sand, dry cutting or machining will create dust and dust control equipment should be used. 13. Availability Cem-Fil GRC sheet/125S is available in standard thicknesses from VI" to 4'and astandard sheet size of 97"x 49* untrimmed. Sheets trimmed to 96"x 48* can be supplied. Approved fabricator/distributors are located throughout the countrywho can supplysheet cut to size and who also provide a complete range offabrication services. Yourlocaldistributor is: ' Ar.'-'V'ii.- r.' ' :; - For further information about . Cem-FIL* GRC sheet/125S and other sheet products produced by Cem-FIL Corporation write:- ' r.t >T?' [iZ-SL CORPORATION 120 Spence Lane Nashville, Tennessee 37210 Telex: 55-5120 Phone: (615) 883-7563 - C#m-FIL Coroorafion Sheet Products ASBESTOS-FREE PRODUCTS Density, Kg/ro^ pcf MARINITE I 736 46 MOR Rns Temp MPa Psi * 705C(.1300F) MPa Psi Shrinkage, 705C(1300F), % L.O.I., 705CC1300F), % 4.93 715 3.15 456 0.89 13.8 Corrosion E Handability (XIO^) ' (Strength at Heat Treatment/ Density) 4.72 736 6.4 Price/Board Ft $2.48 PYROTHERM B-2 960 60 5.93 860 3.17 460 0.04 6.4 E 3.78 960 3.9-; $5.32 G Good E Excellent INSURAL 1134 70 MOLTEN METAL MARINITE contains asbestos . 609 38 - 3.93 570 -- -- 6.44 933 2.21 320 0.32 0.43 6.1 E G to E 3.93 1134 6.44 r:609 - 3.5 - ' 10.6 . i ^ $6.00 4 ' * . * ^ - 'l '*>' ' $3.69 $7.38 (header grade FROM JAMES E. HINES INGOT CASTING DIVISION ALCOA TECHNICAL CENTER - B TO 1 MR. HAIG SAKQIAN PITTSBURGH OFFICE - 7 1980-01-21 RE: ASBESTOS USE IN ALCOA INGOT PLANTS In review there is only one application within the ingot plants where asbestos needs to be used; that is, for header applications. This is in the area of the mold where a thermal break is required to control the solidification of the metal. There are adequate replacements in Johns-Manville's Marinite I and Pyrotek, Inc.'s Pyrotherm B-2 board products, and R-680 for almost all other melting and casting needs. Asbestos-containing Molten Metal Marinite need not be used for floats, basins, troughing, dams, etc.; and therefore, plants such as Davenport, Rockdale and Tennessee North should be asbestos fFee. Even in header-related areas much of the asbestos can be replaced. It has been proven that R-680 can be used for all FDC ingot 635 mm (25 in) in diameter and below. The switch to R-680 takes some time because it involves header design modification and the fabrication of molds before the R-680 ceramic headers can be made. Plants which do FDC casting (Badin, Lafayette, Massena, Vancouver and Vernon) should begin or continue ordering more R-680 headers. ^>By this substitution Lafayette, Massena and Vancouver will become asbestos free. w*ro date no adequate substitute for HDC and tool and jig headers has been found. R&D programs at ATC address this need by (1) continuing a cooperative effort with suppliers of insulating boards, (2) starting our own board development, and (3) testing R-680 in these areas. Molten Metal Marinite must still be used for all J3h_eet_ ingot made at Point Comfort, Tennessee South, Warrick and Wenatchee; small HDC headers (152.4 and 177.8 mm [6 and 7 in]) at Badin and Wenatchee; and tool and jig headers at Vernon. Hopefully, the goal for this year in the ingot plants and at ATC is to have replaced asbestos in those areas identified and to find or develop an adequate substitute for those other applications. If there are any questions regarding substitutes, please contact Mario Caprio or myself. JAMES E. HINES JEH:bis cc: ID - ATC, D R. G. LaBar/R. E. Spear/ M. J. Caprio - Pittsburgh 19 File: 10.300 - ATC, B H. G. Reavis/E. L. Rooy - Pittsburgh 19 E. E. Rumberger - Pittsburgh 7 J. E. Jacoby/R. Bachowski - ATC, B R. E. Miller - ATC, B W. G. Truckner/T. Fujioka - ATC, B ALCOA WK WES HARVEY Mi JAMES E. HINES & JOHN E^Q(jg|Y INGOT CASTING DIVISION ALCOA TECHNICAL CENTEtn&strial 1980 JANUARY 07 RE: FIBERSEAL A-l ROPE - PYROTEK INCORPORATIVE BDD EER O cco* vF jn TF CCD OB LMNn F- EC L i- t Please refer to your letter of 1979 December 14. Vernon has been successfully using Ceramic Rope for over two years. The 6.35mm (1/4") size is used for sealing the gap between the mold and the bottom block, and the 25.4mm (1") size is used for sealing joints, for pouring troughs. Our findings confirm the good results mentioned in your recent letter. WES HARVEY lgg/5978 cc: D. 0. Collins - Lafayette M. J. Caprio - Pgh. 19 E. L. Roy/H. G. Reavis - Pgh. 23 W. K. Dalton - Lafayette M. L. Redhair - Vernon H. C. Sakoian - Pgh. 07 W. G. Truckner - ATCB R. E. Miller/R. G. Labar/File - Alcoa Technical Center FROM D. 0. COLLINS*npwr LAFAYETTE WORKS H fcS jndustriat HygiengO J. E. HINES J. k. JACOBY BOD o EER TBB O RML * mlf JD CCD DB ALC:OoAa TTEE<CHNICAL CENTER \J- 1980 January 2 PHS "> / EDS/ MJV RE: FIBERSEAL A-l ROPE - PYROTEK, INC. Lafayette Works ingot plant evaluated 6 min (1/4") diameter Fiberseal rope supplied by Pyrotek, Inc., in 1979 July as part of our asbestos substitute program. The primary use of this product is to seal the gap between the mold and bottom blocks in DC and FDC tooling. Of the several substitutes received and evaluated we found this product to be the best. The one disadvantage noted was the high strength of the product which prevents break ing by hand. We currently have two additional substitutes from NewTex Indus tries, Inc., and Frederickseal, Inc., on order in trial quanti ties. We anticipate making a final selection after evaluating these two new materials. D. O. COLLINS DOC:et i cc: E. L. Rooy/H. G. Reavis - Pittsburgh M. J. Caprio - Pittsburgh i H. C. Sakoian - Pittsburgh \ M.' L. Redhair - Vernon W. G. Truckner - ATC R. E. Miller/R. G. Labar - ATC W. K. Dalton - Lafayette ALCOA FROM JAMES E. HINES JOHN E. JACOBY INGOT CASTING DIVISION ALCOA TECHNICAL CENTER - B T0 MR. DARWIN O. COLLINS LAFAYETTE WORKS MR. WESLEY C. HARVEY VERNON WORKS Industrial Httgfefte 1979-12-14 RE: FIBERSEAL A-l ROPE - PYROTEK, INC. BDD EER TBB JDJJillJ1J/ o m o IVH.F 4D CCD DB .MJV V***>1 LMN EDS Enclosed with this letter is a piece of Fiberseal A-l rope distri buted by Pyrotek Incorporated. As you can see, the rope is flexible and has good mechanical stability. It also resists molten aluminum and can be used continuously up to 760C (1400F). Because of these properties, this product may replace asbestos rope in a number of applications. This rope is supplied in diameters of 6.35, 12.7, and 25.4 mm (0.25, 0.5, and 1 inch). See attachment for pricing. One particular area where you may have interest is for sealing the gap between,the mold and bottom block by placing ropje in _the periphery of..the bottom block. Massena has 'found that it prevents metal leak age and is thermally stable enough to be reused numerous times in this application because molten aluminum does not attach itself to the fibers and the material does not disintegrate in water. If you are currently using asbestos rope, this material should be a suitable substitute. Your comments concerning this rope will be appreciated. \fCtsy>i \LMES E. HINES JEH/JEJ:dsm Attachments cc: I.D. - ATC, D M. J. Caprio - Pittsburgh 19 W. K. Dalton - Lafayette Works M. [,. Redhair - Vernon Works E. Rooy/H.G. Reavis - Pittsburgh 23 H. C. Sakoian - Pittsburgh 7 ____^ W. G. Truckner - ATC,B R. E. Miller/R. G. LaBar/File 10.322- ATC,B SPECIFICATION SHEET ASBESTOS SUBSTITUTES 8. FIBERSEAL ROPES Jm. A-l A-l A-l A-l A-l D-l D-l D-l D-l D-l F--10 S-10 Lbs/Cu.Ft. 49 49 49 49 49 49 49 49 49 49 Color White White Whi te White White Red Red Red Red Red Red Yellow Max.F 1400 1400 1400 1400 1400 2000 2000 2000 2000 2000 2000 1200 Diameter 1/4" 1/2" 1" 1-1/2" 2" 1/4" 1/2" 1" 1-1/2" 2" 1" square 1" square Price/Lin.Ft. $0.40 .90 2.50 5.00 8.70 0.66 1.24 3.01 5.80 9.44 6.20 5.80 PYROSEAL TROUGH LINING MATERIAL Z-l Grey 1800 50 lb. bags $0.48 per lb 10. COMPOSITE MATERIAL Fiberseal Fabric H-3, Aluminum Foil plus Fiberseal Felt 1/4" M-6. Airtight blanket to withstand high temperatures and corrosive gasses. Price ............................... $1.95 per square foot Many combinations of these materials are available to fit particular requirements. 11. NOTE Sizes listed are for stocked items. Other widths, thicknesses, densities, etc., are usually available other than the stocked items. E. 9601 Montgomery Avenue Spokane. Washington 99206 (509) 926-6211 Box 77, RD - 1 Claremont Road Carlisle, Penna. 17013 (717) 249-2075 Telex 326404 H.G.SAKOIAN - PGH, 7 FROM JAMES E. HINES INGOT CASTING DIVISION ALCOA TECHNICAL CENTER - B TO MEMORANDUM 1979-12-13 DATA LETTER H&S Industrial Hygiene BDD EER TBB RMJ PHS MJV O MLF O JD, M CCD DB I RE: GRC SHEET 62S, 125S, AND CA BOARDS - Cem-FIL CORPORATION Summary The subject products are cement reinforced with glass fibers. These composite materials possess such properties as high impact strength, high strength-to-weight ratios, and good heat resistance. They also can be machined with carbide tools. Portland cement based 62S and 125S boards, although limited in temperature exposure and molten metal resistance, are suitable for replacing Transite, a structural, fire-retardant, asbestos-contain ing board used extensively in construction. These new materials do not contain any known health hazard. The third product, CA board, is difficult to manufacture. But because of its promising high temperature attributes and molten metal resistance, it is recommended that Alcoa provide some assist ance to Cem-FIL Corporation in solving their production problems. This material has potential as a Molten Metal Marinite substitute. Introduction GRC (glass-reinforced cement) is a trade name for a group of products developed by Pilkington Brothers Limited, England, and manufactured in the United States by Cem-FIL Corporation. GRC boards consist of cement, sand and glass. The principle ingredients are ordinary Portland or calcium aluminate cements, silica sand and water. The matrix is mixed with alkali-resistant glass fibers to produce an inorganic composite. The products formed do not consist of a single material composition but are composed from different formulations according to the properties required. Typically, the boards consist of between 5 and 6% by weight of zirconium borosilicate glass fibers mixed into a cement/sand mortar. The resulting composite normally has a cross-section of 3-12 mm in thickness. Methods of manufacturing vary and include spraying, casting, spinning, extruding, and pressing. Each technique imparts different characteristics to the end product. Spraying, either by simple hand equipment or mechanically on a production line, is the most commonly used method. Products GRC 62S, 125S, and CA board were received for testing. All boards were prepared by spraying. Products 62S and 125S are Portland cement based, whereas CA board contains Universal Atlas' Memorandum 1979-12-13 Page 2 Lumnite calcium aluminate cement. The difference ..between the 62S and 125S materials were their densities, 992 kg/ni (62 pcf) and 2000 kg/m (125 pcf), respectively. Experimental Procedures Testing was limited to measuring densities, firing shrinkages, loss on ignitions, and determining molten aluminum resistance. Physical properties were performed on 25.4 X 127 X 6.35-mm (1 X 5 X 0.25-in) samples according to ASTM methods, whereas larger specimens (101.6 X 152.4 X 12.7 mm J4 X 6 X 0.5 in]) were subjected to Alcoa's Modified B-Immersion test. Simply, the immersion experiments consisted of the following steps: 1. Weigh the sample to the nearest gram. 2. Preheat to 540C (1000F). 3. Immerse three-fourths of the sample length in molten 7075 alloy at 760C (1400F). 4. If results are warranted, repeat cycle a second time. Results are reported as percent weight retained. A nonwetting material will have zero weight loss. Results and Discussion ATC test results are listed in Tables I and II. The 62S and 125S boards had relatively low shrinkages and weight losses when heating to only 260C (500F). However, when tested at 540C (1000F), large changes were noted. Firing shrinkages and loss on ignition values increased by nearly a factor of two. These results indicate their temperature limitation above 260C (500F). The molten metal tests were poor, primarily because the samples cracked. The molten aluminum did not adhere to the materials, but when removing them from the 540C (1000F) preheat, they fractured. These limitations can be explained by the breakdown of the Portland cement binder. The set cement contains hydrated calcium compounds, particularly calcium hydroxide. When heated, calcium hydroxide loses its water and becomes calcium oxide above 400-450C (752-842F). If this calcium oxide becomes wetted after cooling or exposed to high humidity, it rehydrates to calcium hydroxide accompanied by an expansion in volume which will disrupt the material. Although the temperature limit is below 320C (600F) and the molten aluminum is poor, the excellent rigidity and toughness of these composite asbestos-free materials makes them important for many industrial construction applications. GRC 125S seems to be a direct replacement for Transite (asbestos fibers bonded with Portland cement). Table III gives comparative data of the Cem-FIL Memorandum 1979-12-13 Page 3 and Johns-Manville products- Note that both have a 320C (600F) temperature restriction. All properties are very similar except for the shear strengths- It is believed that the lower strength of 125S can be engineered so it will not be in that mode of failure during service. The last product, CA board, has different properties from both the 62S and 125S boards. The difference is in the calcium aluminate cement. This board did not degrade with temperature as the Portland cement boards. Although some shrinkage and weight loss occurred at 260C (500F), the board remained structurally sound at 540C (1000F). The decomposition of the cement hydrates C-AHand C^AHg takes place below this temperature. These hydrates form CA which does not rehydrate on exposure to moisture. In the B-Immersion (Figure 3), some-hairline cracks did form at the metal line but the metal adherence was minimal. The results are very promising if manufacturing problems of this board are solved by the Cem-FIL Corporation. Safety Statement Cem-FIL board products do not contain asbestos; however, dust is created when cutting or machining. Therefore, it is advised that dust control equipment be employed during those operations. No special precautions are required when disposing of these materials. Conclusions and Recommendations Although Cem-FIL GRC 62S and 125S boards are not suitable for high temperature or molten metal contact, they do have properties comparable to asbestos-containing Transite. Their only drawback is low shear strength. With proper engineering design, however, this can be resolved. Application areas where these boards should find use are architectual panels, fire resistant components, pipework, furnace shells, etc. CA board, on the other hand, possesses good molten metal resistance but it also has temperature stability problems and is difficult to fabricate. Because of its potential for molten metal applications, it is suggested that a cooperative effort be made between Alcoa and Cem-FIL Corporation to help solve these shortcomings. VJAMES E. HINES JEH:bis Attachments 9 Memorandum 1979-12-13 Page 4 cc: ID - ATC, D G. L. Baker - Pittsburgh 3 WPH M. J. Caprio - Pittsburgh 19 C. J. Cox - Pittsburgh 3 WPH C. F. Hartley, Jr. - Pittsburgh 3 WPH R. C. Holtz - Pittsburgh 3 WPH W. A. Keith - Pittsburgh 3 WPH J. W. Mclntee - Pittsburgh 3 WPH E. L. Rooy/H. G. Reavis - Pittsburgh 23 E. E. Rumberger - Pittsburgh 7 H. G. Sakoian - Pittsburgh 7 A. J. Sartschev - Pittsburgh 3 WPH D. L. Schaffer - Pittsburgh 23 AL Division/Department Managers R. E. Miller/V. L. Hammersmith - ATC, B M. B. Thomas/D. J. St. Jacques - ATC, C H. A. Traenkner - ATC, D D. J. Wainer - ATC, D R. G. LaBar/R. E. Spear/File: 10.322 - ATC, B J. E. Jacoby/R. J. Ormesher/R. Bachowski - ATC, B TABLE I PROPERTIES OF Cem-FIL CORPORATION'S GRC 62S, 125S AND CA BOARDS Color 3 Density, kg/m pcf Firing Shrinkage, % After 110C (230F) 260C (500F) 540C (1000F) Loss on Ignition, % After 110C (230F) 260C (500F) 540C (1000F) 62S Gray 992 62 0.03 0.02 0.40 9.10 9.70 16.60 125S Gray 2000 125 0.19 0.40 1.00 4.95 7.20 12.00 CA Brown 2240 140 0.07 0.21 0.22 1.40 8.98 11.25 JE Hines 1979-12-13 TABLE II MODIFIED B-IMMERSION TESTS ON Cem-FIL CORPORATION'S GRC 62S, 125S AND CA BOARDS 62S Weight Before Weight After 2 Cycles % Weight Retained Physical Appearance: Sample cracked upon cycling between 540C (1000F) and room temperature. 125S Weight Before 746.6 g Physical Appearance: Weight After 2 Cycles 645.3 g % Weight Retained 64.3 g No metal penetration occurred, cracking was also severe below metal line. CA Weight Before 362.3 g Physical Appearance: JE Hines 1979-12-13 Weight After 2 Cycles 303.6 g % Weight Retained 83.8 g After cooling to room tempera ture , most of the metal skull could be removed. Sample below metal line looked excellent, but has many hairline cracks at and above metal line. TABLE III COMPARATIVE DATA ON Cem-FIL'S GRC 125S AND JOHNS-MANVILLE'S FLAT TRANSITE Technical Data Cem-FIL GRC 125S Max. Service Temp. Density, kg/m^ pcf 320C (600F) 2000 125 Water Absorption % of Dry Weight Max. 16% Modulus of Rupture, MPa psi 27.6 4000 Compressive Strength, MPa psi 69.0 10,000 Shear Strength, MPa psi Thermal Expansion, cm/cm/K in/in/F 2.4 interlaminar 9.7 in-plane 350 interlaminar 1400 in-plane 12 X 10"6 7 X 10"6 Thermal Conductivity, W/m* K Btu-in/h-ft^ 1 5 Johns-Manville Flat Transite 320C (600F) 1600 100 Max. 22% 27.6 4000 82.8 12,000 24.1 3500 8.6 X 10"6 5 X 10"6 9 4.5 JE Hines 1979-12-13 FIGURE 1 FIGURE 2 FIGURE 3 cgm-piL GRC SHEET 125/S The rigidity and toughness imparted by Cem-FIL* glass fibers enable tensile and flexural strength to be designed into cement based products. GRC has already found many applications in the construction and allied industries, where it has been used as an alterna tive material to precast concrete, sheet metal, cast iron, wood, plastics and asbestos cement. Many existing products make use of the inherent advantages and manufacturing flexi bility which, combined with the fact that GRC is non-combustible and rot, corrosion and fire resistant, make it an ideal material for many engineering applications. The properties of GRC are influenced by factors such as fiber content and distribution, type of matrix and method of manufacture: The properties can therefore be tailored to meet the design requirements of particular components. This data sheet gives typical property values for Cem-FIL GRC sheet/l25S which is a high density sheet material manufactured by the spray dewatering process. Hot bottle pusher bar and dead plate Cem-FIL Corporation Sheet Product: 1. Produot Description 2. Manufacture 3. Mechanical Properties Glassfiber reinforced cement (GRC) is the generic term for the composite material which consists of a matrix of Portland cement and fine aggregate reinforced with alkali resistant glass fibers. The fibers, trade name Cem-FIL* AR, are manufactured by Pilkington Brothers Limited, St. Helens. England and are marketed in the USA by Cem-FIL Corporation. Cem-FIL* GRC Sbeet/125S is manufactured by a mechanical process which involves the spray deposition of the cement/sand slurry and chopped glass fibers on to a special table through which the so formed GRC sheet can be dewatered to provide maximum density and optimum physical properties. Typical Properties at 28 days:* 70 N/mm* . Compressive Strength 10,000 psi 15 kN/mm* Young's Modulus 2 x 10* psi 24 N. mm/mm*- Izod Impact Strength 120 in. Ib/in* 11 N/mm* Ultimate Tensile Strength 1600 psi 7 N/mm* Effective Tensile Elastic Limit 1000 psi Ultimate Bending Strength 28 N/mm* (Modulus of Rupture in 4 point-bending) 4000 psi 12 N/mm* Effective Bending Elastic Limit 1700 psi' 1.0% Strain to Failure 1.0% 2 N/mm* interlaminar Shear Strength 350 psi 10 N/mm* In-Plane Shear Strength 1400 psi 41 N/mm* Punch-through Shear Strength 6000 psi 2.0 tonne/m* Density 125 Ibs/ft* 0.20-0.25 Poisson's Ratio 0.20-0.25 * The initial mechanical properties of GRC can vary with time depending upon the work ing environment. In dry or hot and dry con ditions there is little change. In moist or wet conditions there is some loss of tensile and impact strength over a number of years to levels which are well above the normal work ing range. Conditions of use should there fore be taken into consideration at the design stage, and further information and advice is available from Cem-FIL Corporation. StfflFILGRC SHEET 125/S 4. Creep and Stress Rupture In common with other cementitious materials GRC components exhibit some creep under a maintained load. Creep strains are small (basically those associated with the matrix) and the creep strain rate decreases with time. Stress rupture has not been noted at stress levels in the normal working range of the material. Creep and stress rupture information is available from Cem-FIL Corporation. 5. Fatigue At the normal working stress levels fatigue lives greater than 10* cycles are obtained in both bending and tension. At stress levels close to the elastic limit fatigue lives of 10s cycles in bending and 10* cyclesjn tension are obtained. 6. Thermal Properties Effect of high temperatures: GRC has been used successfully at elevated temperatures. Although the precise maximum working temperature depends on duration of exposure at elevated temperatures and the pre- vailing environment. 600 F. is the maximum service temperature advised for prolonged ' exposure in air. Thermal Conductivity: Btu. in/h. ft.1 CF (1.0 W/m K) Thermal Expansion: 7 x 10-perF (12 x 10-per K) Freeze/Thaw: No visible deterioration or change in mechanical properties has been recorded for GRC tested to the following standards. British Standard 4624 (1970)--25 cycles, ASTM C666-25 cycles. DIN 274 (1936)-8 cycles with vacuum impregnation. 7. Effect of Moisture Shrinkage/expansion: Vapor permeability: Moisture absorption: Maximum linear movement in going from com pletely wet to completely dry is 0.14%. Less than 2 perms. Maximum 16% of dry weight. 8. Chemical Resistance The chemical resistance of GRC is largely dependent upon the resist ance of the Portland cement to the particular chemical. In general GRC is least resistant to acid attack but is quite satisfactory when exposed to alkaline solution and organic solvents. 9. Fire GRC is classified as non-combustible when tested to ASTM E136-73. 10. Electrical 11. Acoustical Arc Resistance (ASTM D495/73) Volume Resistivity (ASTM D257/75) Delectric Strength (ASTM D149/64) 406 seconds 1.26 x 107 ohm. inch 295 volts per mil (In all tests the samples were conditioned at 50% R. H. and 73 F) GRC follows the mass law for sound reduction. 34" GRC sheet/125S has a surface mass of 4 Ibs/ft* and yields a sound reduction index of 22db at 350hz rising to 39db at 4000hz. 12. Cutting and Machining GRC can be cut and machined with tools suitable for masonry use. eg tungsten carbide tipped blades etc. As GRC is based on cement and silica sand, dry cutting or machining will create dust and dust control equipment should be used. 13. Availability Cem-FIL* GRC sheet/125S is available in standard thicknesses 34". X". 34". and X" and a standard sheet size of 9634" x 49 X". Thickness tolerance is 10%. Certain other thicknesses can be supplied to special order. Approved fabricator/distributors are located throughout the country who can supply sheet cut to size and who also provide a complete range of fabrication services. For further information about Cem-FIL* GRC sheet/125S and other sheet products produced by Cem-FIL Corporation write: n CORPORATION 120 Spence Lane Nashville, Tennessee 37210 Telex: 55-5120 Phone: (615) 883-7563 I CORPORATION tea 120 Spence Lane Nashville, Tennessee 37210-Phone (615)883-7563-Telex 55-5120 Effective Date: March 1, 1979 PRICE LIST FOR Cem-FIL GRC SHEET/125S Thickness Inches Price Per Sheet Less Than Full Pallet Load* Full Pallet Load 1/8 1/4 3/8 1/2 5/8 3/4 1 1 1/4 1 1/2 1 3/4 2 2 1/2 3 3 1/2 4 $ 22.07 38.40 49-60 59-52 74-65 86.40 115-52 153-88 178.32 205-62 234.30 296.39 323-39 398.00 434.16 $ 30.90 53-76 69-44 83-33 104.38 120.96 161.73 215-43 249-65 287.87 328.02 414.95 452.75 557-20 607.82 No. of Sheets Per full Pallet Load 70 35 23 18 14 12 9 7 6 5 5 4 3 2 2 Full pallet loads weigh approximately 3.000 lbs. Truck load (12 pallets) prices are available on request. * The prices above apply to full pallet loads of one thickness. Prices for mixed thickness pallets are available on request. Availabi1ity Orders can be supplied direct or from one of the approved fabricator/distributors who are located throughout the USA. Fabricators/distributors also supply sheet cut to size and fabricated sheet. A list of the approved fabricator/distributors is available from Cem-FIL Corporation. Terms Net 30 days FOB Nashville, Freight Collect Product Description Cem-FIL GRC Sheet/125S is a composite material of portland cement and limestone fines reinforced with Cem-FIL AR glassfibers. AM sheets are 97" X 49" untrimmed. Cem-FIL Corporation Sheet Products TJJLX. u*v%rGXl\..*v<jr-VS-,z2rv. ** sr*^-^, - 7.5/Cem GRC ARCHITECTURAL PANELS CORPORATION P.pCpRODUCTS PRESENTATION GRC CURTAIN WALL AND SPANDRELS GRC curtain wall panels can be used almost anywhere pre-cast concrete curtain wall is used but the K to H lighter weight offers possible structural savings and potential per formance benefits in seismic areas. The lighter weight can facilitate instal lation of the panels with attendant cost savings. Fiberglass insulation can be built into the back of the panel providing U values up to .05 but without adding to overall panel thickness and thereby saving floor space. Panels can be pre insulated in the factory. GRC can often be used to advan tage in sun screen spandrels. The deep profiles necessary in these panels can be achieved without weight penalty and they can be installed without the' substantial internal steel support generally required. When panel design is integrated with design of the building structure, insulation and internal finish require ment, GRC wall panels can offer cost sovings over block or brick construc tion. GRC wall systems will also take up less floor space than blockwork and panels con be designed to hang outside the floor slob. U values up to -.05 can be provided without adding to wall thickness. Only very light structural frames are required. GRC COMPLETE WALL Architect: Toylor and Crabtree i CORPORATION GRC ARCHITECTURAL PANELS T. S. TECHNICAL SUPPORT Much of the data is based on British Standard tests of which we can provide copies. A program of tests is in process to establish appropriate ASTM and other U.S. Standards. Moisture Absorption Moisture absorption varies according to the density of GRC but will normally be in the range of 12%-16%. Moisture Permeability Laboratory tests have shown that no signs of moisture would appear on the inside of a GRC sheet %" (10mm) thick with rain blown onto it by a 75 mph wind. Water Vapor Permeance Less than 2 perms. Moisture-Induced Movement The extent of any dimensional change depends upon the particular GRC formulation and conditions of ex posure. Typically, with 25% sand con tent, laboratory experiments indicate that the maximum linear movement for material going from completely wet to completely dry would be 0.14 per cent. Under most climatic condi tions, the maximum expected move ment will be around 0.06 per cent. Thermal Expansion Coefficient of thermal expansion is 7 x 10-6 per F. (12 x 10-6 per K;) Thermal Conductivity 7.0 Btu. in/hft2 deg. F. {1.0 w/m K.) Freeie/Thaw No adverse effects were seen after 25 cycles of 12 hours immersion . .;>SK5 i -^rArchitect: Nes. Campbell 8 Associates TYPICAL 28 DAY PROPERTIES OF Cem-FIl GRC ; Flexural Properties s Limit of Proportionality 1000-1600psi -.1 (7-11 N/mm*) Modulus of Rupture '3000-4600 psi n. ! (21,-32 N/mm*) Compressive Strength t 720001.400 psi (50-80 N/mmfj . Impact Strength; ' 57-143 in-lb/in* (10-25 Nmm/mm*) Density 105-130 lb/ft* (1.7-2.1 tonne/m*) Youngs Modulus 1.5-3x10* psi , * (10-20 KN/mm?) MANUFACTURING SPECIFICATIONS Dimensionol Tolerances Units less than 10 Ft. * ${" h Units less than .20 Ft. + H" ~ J(s" Openings Within One Unit ; Thickness of Unit "H* Squareness (difference in diagonal lengths) K" per 6' or yC whichever is greater, Insert and Accessory Positions / Within K''of centerline as shown on drawings - Bowing (after installation) L/360-Factors relating to. bowing. ' including site storage, fastening techniques, and particular finishes. Specific panel designs & fastening systems often require additional specifications. VContact Cem-FIL Corporotionfor details. in water at 60F. (20C) and 12 hours at "4F. (--20C) (test done in accord ance with the Frost Cracking Test to British Standard 4036:1966 for, asbestos cement). Creep ;* GRC is quite capable of bearing | load over prolonged periods; and V-\. creep behavior is similar to that of other cement and concrete materials. : In general creep strains are smaller than expansion/contraction strains due to moisture. Complete creep and fatigue data is available from Cem-FIL Corporation. Fire GRC contains no organic material and when tested in accordance with ASTM El36, GRC has been determined to be non-combustible. Paneli with up to 4 hours fire , rating can be designed where required. Finishes; Textures .-V3 > ` . Any type of finish, successful with ' concrete will be acceptable on Cem-FIL GRC architectural panels. Textures availoble indude light texture,,such as light sandblast, light verticalshadow tones, etc; medium textures such as )T deep vertical grooves, medium sandblast; and heavy textures such as deep ribs, heavy sandblast simulation, arid exposed aggregate. Even a combi nation of textures, or panels with ; smooth areas plusexposed aggregate accent areas, can be supplied; ; Fasteners r .. . Cem-FIL Corporation alwoys designs and supplies fasteners re quired for,installation of the panels. Building Codes .< , Cem-FIL GRC panels are recom mended for acceptance by BOCA under Resebrch Report No. 76;60. Warranty. For many'GRC panel designs,, Cem-FIL'Corporation can,provide d re placement warranty against structural failure for a period of up to 10 yeors, ' for panels it manufactures. IKS GRC ARCHITECTURAL PANELS P. P. PRODUCTS PRESENTATION t---r--*"*-*-**- - ' v ' -*f,-T- --................ -- - GRC FASCIA PANELS Can be custom molded into a wide variety of shapes' and finishes. Architect: Warren. Knight & Davis The massive look of concrete without the weight of concrete. Average weight 9 Ibs./sq. ft. Architect: Coupard.S Associates ! WHY USE \ Cem-FIl GRC ARCHITECTURAL: PANELS ; : i j 1. Lightweight compared with ; concrete. 2. Will not burn or give off smoke or fumes. t ?. tj'' p, k 3, Superior resistance to water t" and vapor penetration than i ;; most masonry materials and wood. J! J 4. Less surface porosity than 1: i most masonry materials. f ; 5. No embedded metal that ^ can cause rust staining. F i. j 6. No plastic resinous materials !/ > to yellow. J. ; 7. Custom-molding provides integral comers and returns ~ which facilitates complete i weatherproofing. ' 8. All fastening hidden without \ patching, etc [ 9. Custom-molding provides t versatility in shape, size l and finish. i * t C f t r. !. A light metal stud frame, or even wood, will carry the weight. Average weight 12 Ibs./sq. ft. Architect: Nes. Compbell & Associates Costs: Prices always include: 1) Panel and fastener design. 2) Shop drawings. 3) Delivery of panels and fasteners to job site. Typically prices will range from S3.50 to S7.50 per sq. ft. 7.5/Cem Fill GRC CUSTOM-MOLDED <0 ARCHITECTURAL PANELS ASSEMBLY Oz Q -J mD` itu co O CL 2 CL h- co o -sj Project: Nashville House, Metro Center, Nashville, Tennessee Finish: Exposed aggregate Panel Specification: Nominal K* thickness single skin with ribs and 4" returns. Architect: Hart, Krivatsy and Stubee T3 -K> O GLASSFIBER REINFORCED CONCRETE GRC is a composite material consisting of a mix of cement and fine aggregate reinforced with Cem-FIL AR glass fibers. It is totally inorganic so it will not burn or produce noxious gases or smoke ond it provides the performance turer and developer of the "float glass process" and Cem-FIL AR glass, and Ferro Corporation --a multinat ional manufacturer of specialty chemicals ond coatings. The GRC panels are produced in our custom-built factory in Nashville, Tennessee, for distribution through v Ow mH ca> rgz a and durability associated with cement and concrete but at % to Vi tbe weight of concrete. Cem-FIL Corporation is a jointly owned company of Pilkington Brothers Ltd. --a multinational glass manufac out the U.S. Cem-FIL GRC architectural panels are custom de- ` signed and molded for each project. All panel design and fastening details are provided by Cem-FIL Corporation. cempir COPOPATO\ G EiUi 120 Spence Lone Nashville. Tennessee 37210 Phone (615) 883*7563 Telex 55-5120 FftOM JAMES E. HINES INGOT CASTING DIVISION ALCOA TECHNICAL CENTER - B TO MR. HAIG G. SAKOIAN- . /.M & PITTSBURGH 7 1979-12-07 RE: ASBESTOS SUBSTITUTES - INGOT CASTING SEMINAR I appreciated your participation in the Asbestos Replacement por tion of the Ingot Casting Seminar. The metallurgists in attendance are now better informed about existing safety programs throughout the company. Attached for your reference are the overlays that I used during my presentation on asbestos-free boards. JANES E. HINES JEH:pm Attachments cc: ID - ATC, D E. E. Rumberger - Pittsburgh 7 R. E. Miller/R. G. LaBar/File 10.320 0 ALCOA SF4963 property requirements NOT WETTED BY MOLTEN ALUMINUM "SKULL" EASILY REMOVED NO METAL CONTAMINATION READILY MACHINED AND FABRICATED HOLDS METALS AT UNIFORM TEMPERATURE NO PREHEATING REQUIRED MAINTAINS STRENGTH AT HIGH TEMPERATURES RESISTANT TO LUBRICATING OILS ASBESTOS-FREE REFRACTORY BOARD PRODUCTS MARINITE I PYROTHERM B-2 INSURAL MARINITE C GRC PRODUCTS MARINITE I -- THERMAL AND PHYSICAL PROPERTIES Physical Properties: ' Bulk Density -736 kg/m *. r. ** .T Properties After. . M.O. R. Firing To: MPa (psi) . Shrinkage l (46 pc) . .* " * ' Height Loss * 590C 650C 705C 815C 290*C (1100F) (1200F) (1300F) (1500T) ( 550F) : 4.52 ' 3.54 3.15 4.43 4.72 (655) (513) (456) . (643) (685) '.is 0.37 0.5* 4 .3.9 0.35 . 2.9 3.2 4.3 5.3 10.5 Modified "3* Inaaersion: Excellent PXROTHERH B--1 THERMAL AND PHYSICAL PROPERTIES 3 -Physical Properties: Bulk Density = 960 kg/in (60 pcf) .* .? . * **t*% ;; ' h. Properties After O-R- Firintj To: . . HPa (psi) i Shrinkage -% * * * * Weight 'V- ' S/ . Loss % . 590#C 650C 705C 815C 551C (HOOT) . 2.48 (1200oF> (1300T) 2.97 (1500F) . 0.83 (1025T) 3.78 (360) (430) (120) (548) 0.02 0.02 . 0.00 . 0.00 0.53 2.9 3.5 4-1 5.5 12H ./ .* Modified "B" Inmersion: Excellent c ASBESTOS-FREE PRODUCTS Density, Kg/m3 pcf MARINITE I 736 46 MOR Rm Temp MPa Psi 705CC1300F) MPa Psi 4.93 715 3.15 456 Shrinkage, 705C(1300F), % 0.89 L.O.I., 705C (1300F) , % 13.8 Corrosion E Handability (X103) (Strength at Heat Treatment/ Density) 4.72 736 6.4 Price/Board Ft $2.48 PYROTHERM B-2 960 60 5.93 860 3.17 460 0.04 6.4 E 3.78 960 3.9 $5.32 G Good E Excellent INSURAL MOLTEN METAL MARINITE 1134 70 609 38 3.93 570 -- -- 6.44 933 2.21 320 0.32 0.43 -- 6.1 E 3.93 1134 3.5 G to E 6.44 609 10.6 $6.00 $3.69 $7.38 (header grade) EVALUATION LOCATIONS MARINITE I - ATC VERNON WENATCHEE LAFAYETTE DAVENPORT MASSENA TENNESSEE WARRICK PYROTHERM B-2 - ATC ROCKDALE BADIM DAVENPORT WENATCHEE MASSENA WARRICK TENNESSEE COMPARATIVE DATA ON CHEMFIL GRC 125/S & JOHNS-MANVILLE'S FLAT TRANSITE Technical Data Max. Service Temperature Density, Kg/m3 Pcf Water Absorption % of Dry Weight Modulus of Rupture, MPa Psi Compressive Strength, MPa Shear Strength, MPa Psi Psi Thermal Expansion cm/cm/K in/in/F Thermal Conductivity, W/mK Btu in/hr Ft3 CHEMFIL GRC-125/S 320C(600F) 2000 125 Max. 16% 27.6 4000 69.0 10,000 2.4 Interlaminar 9.7 In-plane . 350 Interlaminar 1400 In-plane 7xl0"6 . 12xl0"6 1 5 JOHNS-MANVILLE FLAT TRANSITE 320C(600F) 1600 100 Max. 22% 27.6 4000 82.8 12,000 24.1 3500 5xl0"6 8.6xl0~6 .9 4.5 H. G. Sakoian - Pittsburgh 7 FROM JAMES E. HINES INGOT CASTING DIVISION 7 ALCOA TECHNICAL CENTER - B TO MEMORANDUM 1979-11-08 Industrial Hygiene BOD K MLF EER 2? JD TBB CM CCD DATA LETTER RE: ASBESTOS-FREE MOLTEN ALUMINUM BACKUP INSULATIONS Summary As part of Pittsburgh Mechanical Engineering Division--Furnace Section's and AL Ingot Casting Division's program to better design and construct furnaces and metal transfer equipment, a study was made to find acceptable asbestos-free insulating backup materials to refractories in contact with molten aluminum. Since each application must be considered individually as to the proper amount and type of insulation, this report points out the advantages and limitations of nine commercially available products. Introduction Refractory insulating materials offer significant advantages in the construction and operation of furnaces and refractory-lined vessels. Proper selection and application of insulation result in important savings of fuel, time, space and weight. In addition, insulation helps maintain close temperature control and contributes to more comfortable working conditions for operators. Savings of fuel is one of the most important reasons for insulating. Heat flows through a wall or roof from an inner hot face to the outer cold face where it is dissipated and lost by radiation and convection. The amount of heat lost often constitutes a consider able portion of the total heat input required to maintain the desired operating temperature. Such losses would be greatly minimized by building the walls partly or entirely out of hightemperature insulation, either as backing to denser refractories, or when conditions permit, as an inner lining exposed directly to furnace atmospheres. When desirable, the use of insulation also allows economy of space, weight and time. If used in place of part of an existing dense refractory wall insulation, it may permit thinner walls and the weight of the refractory structure could be significantly reduced. This would permit both a lighter foundation and a lighter furnace superstructure. At a given rate of heat input with available burner capacity, the time required to bring a cold refractory unit to operating temperature depends on the heating capacity of the refractory lining and upon the heat penetrating it. Through the use of insulation, the heat storage capacity is substantially reduced and the time required to bring the unit to temperature could be considerably, decreased. /7r .A a r-JHi A XL*.,; /9kf /P v - Memorandum 1979-11-08 Page 2 * i , `''l j, \ A When selecting high-temperature insulation, manyyfactois must be ; considered. One determining factor when insulation is used as a backing for a more refractory lining naterialA^ ' > ' temperature. The insulation obviously must be chosen such that it is refractory enough at the interface to withstand ttie temperature.. In addition, one must consider thermal conductiyity,r weight, and heat capacity of the working refractory as wellyas .destructive' factors such as duration of heating, nature of fuel, refractory expansion and growth, and for lower walls, moltenmetal attack. When choosing an insulation for a melting or bolding furnace which operates semicontinuously, high-heat storage in the refractories is a definite benefit because of its cushioning-effect against excessive fluctuations in tenqpereteux;e'^\ -The ' Be^tyicons-b-rdetiOh-vfor . these furnaces is with composite walls and.roof,;consisting of dense refractories backed with compressible insulation.: With a high furnace temperature and a high degree '''ipsul^tipn/jy ihowever ' the mean temperature may become higher than that which the refrac tory can withstand. Hence, adding insulation may result in needing a material with higher refractoriness and., r^quirj:^.;%red]esi<gh:'rtp:. '.7. : reduce deformation. Therefore, heat savings and other benefits of 1 insulation must be carefully balanced againsttkepossibleincreased costs associated with more rapid refractory degradation or in upgrading the working lining to high quality refractories. If this type of problem is approached in a ;8ysteiratlVf;iu^n|3r4thrpugh: ' ; computerized calculations and selection of proper materials, a ; ' refractory system can be designed which will give .optimum heat ";`i\ savings and service life. .; V , . ^ - Insulation Materials ,, ,. Listed below are the asbestos-free insulations materials examined and a brief description of each: Eagle-Picher PV Supertemp block is composed of mineral ' wood , fibers with specially prepared inorganic binders which has ' been one of Alcoa' s recommended backup insulations for years. Temperature limit is 1040C (1900F). i- v Keene Mono-Block, also a mineral wool insulation, has fibers which have been specially interlocked to form a lightweight and rigid, yet resilient block. Temperature like PV, Supertemp is 1040C (1900F). ':v, ; J Keene Delta-T is a felted, spun ceramic clay fibers bonded with i inorganic binders. Temperature limitation is higher\than mineral wool at 1260C (2300F) . 5'f;^ ? \';V J Rim Products 410-03, a ceramic fiber product, isymade,by bonding ; alumina-silica fibers with high purity al'\^iba^'^~Te.mperaturd' rating is 1300C (2372F) . -This insulation was reported to be nonwetting to molten metal, making this insulation;v . particularly attractive. * ;V , . V Memorandum 1979-11-08 Page 3 International Vermiculite IV-19 block insulation is manufactured from vermiculite granules and high-temperature bonding inorganics; like the mineral wool insulations, it is good to 1037C (1900F). International Vermiculite IV-20 block insulation is asbestos-free as are all of these other insulations. IV-20 consists of diatomaceous silica with a hydraulic binder for service to 1093C (2000F). Johns-Manvilie Superex products have been used in combination with Eagle-Picher's PV Supertemp for reverberatory furnaces. A combination of silica, lime, clay and fibers make up these products. Superex 2000, a high-density, low-calcium oxide content block, was designed for low shrinkage and top performance up to 1100C (2000F). Superex 1600, on the other hand, has a high-calcium oxide content and lower density than Superex 2000. This formulation gives better strength and insulating properties for situations where temperatures do not exceed 870C(1600F). Skamol Skamolex PM-10 (formerly Skamolex GX 1000) is also a white calcium-silicate material. This product is distributed by Dolomite Brick Corp. in the United States but manufactured in Denmark. See attached manufacturer sheets for more details. In Table I are the chemical analysis and X-ray diffraction data collected for the nine products studied. The purest material is the Rim 410-03 which contains the highest alumina content and is essentially all amorphous. Three insulations--PV Supertemp, Mono-Block, and Delta-T--are montmorillonite (CaMgSiO.) based. Delta-T has the lowest impurities, whereas Feo3' MgO and alkali are high for both PV Sumpertemp and Mono-Block. IV-19, as characterized as X-ray diffraction, is largely comprised of talc and silica. IV-20, on the other hand, is identified as a diatomaceous earth composition which has silica and calcite. Cristobalite and alpha quartz forms of silica make up Superex 2000. Superex 1600 and Skamolex PM-10 both are calcium-silicate hydrates. Evaluation and Test Procedure Outside of the compressibility testing, all physical property data were determined using ASTM methods. Bulk Density, linear change, and loss on ignition were all examined. Compression tests were accomplished with a Dillon dynameter. Square samples measuring 50.8 mm (2 inches) were aligned in the Dillon machine and compressed initially to 90% of its original height. (Fibrous materials were positioned so their fibers were perpendicular to the pressing Memorandum 1979-11-08 Page 4 direction.) The load was then recorded; Compression measurements . were continued for every 10% deformation up to a reduction of 40%. Any fracture or unusual behavior was noted. : Corrosion resistance to molten aluminum was determined by Alcoa's modified B-Immersion test. Simply, this'-test4consist;sio,preheating the sample to 540C (1000F), then immersing^ ttree^fdurths; bf its : length into 7075 alloy at 760C (1400F) for 24 hours. After ^ being cleaned, the percent sample weight retained is recorded. 1 If ,,!, possible and results are warranted, a second cycle is'performed^ Again, precent sample weight retained is determined'. ' Please refer to Table II for physical property data. ...Maximum recommended service temperatures are recorded first. As seen, the higher the temperature the fewer materials are available. ; The major drop-off points were at 875C (1603F), 986C (1800F), and 1320C (2400F). Rim 410-03 had the highest rating at 1300*C (2372F); Delta-T followed at 1275*0 (2:3qOF) the other !; \ insulations are suggested for less than 1000C, Superex 1600 which is only rated at 870CV (lS'd^0.!;') 1^- ; Other properties which determine allowable exposure temperatures include linear firing shrinkages and loss 'On'S ignition;-^Fd'r'--these' \ measurements, 2.5 X 2.5 X 15-cm (1 X 1 X 6-in.) samples were : ' exposed to temperatures of 540C (1000F) and il00C (2000F) after which they were measured and weighed. ' Photographs -of; Iscxne ,* of the.specimens after exposure are given in Figuresl-8.At 540C (1000E) only slight dimensional changes were apparent; but loss on ignitions were high for IV-19, Superex 2000, and Skamolex PM-10. (Loss on ignition measurements give an indication of the weight of chemically bonded water and organic materials.) Therefore these three materials show structural hydrate -changes even at this low temperature. At a temperature of 1100C (2000F)> very few - insulations retain their structural integrity. Only Rim 410-03 and Delta-T materials remain relatively' unaffected.^; Crushing strengths were performed up to a deformation percentage . ,; of 60%. For most backup insulations the material should, be rigid enough to install but have a crushing strength to meet refractory' . expansion without overstressing and deformingthe fxirnace'i'outside shell. Eagle-Pichers's PV Supertemp has been theperferred material in melting and holding furnace construction;! It congresses' steadily up to 50% before its Strength suddenly doubles. At-;-hov*timei':duri.ng",' the testing did the sample fracture. Other insulations!:(Mono- ' Block, Delta-T, and Rim 410-03) behaved similarly. Rim4T0-03, ; ,, although exhibiting an initial lower strength more clo,sesiy resembles the compressibility of f*V Supertemp than any other i/ . 4' ; : insulation. IV-19, IV-20, and Skamolex PM-10 all fractured at ; Memorandum 1979-11-08 Page 5 approximately 34.5 MPa (5,000 psi). The Superex products, although not showing a brittle fracture, had exceedingly high strenghs up to 345.0 MPa (50,000 psi) after only 40% compression, the highest of all insulations. The apparent thermal conductivity of mass insulations is a combination of the following heat transfer mechanisms: thermal conductivity of air, thermal conductivity of the solid components of the insulating structure, the convective heat transfer within the pore structure, the radiation heat transfer within the structure, and the interactions of these mechanisms. The thermal conductivity term itself refers to an intrinsic property of a homogeneous material, but because of these many heat transfer mechanisms it is subject to much theorectical questioning when referring to insulations. For comparison purposes however, the manufacturer's thermal data are given. As shown, the thermal conductivities of all the insulations evaluated are nearly the same. The greatest difference is between IV-20 and PV Supertemp, 0.13 W/m-K (0.89 ^tu-in/h*ftzF) compared to 0.10 W/m*K (0.69 Btu*in/h*ft F), respectively. In this regard, the choice of which insulation to use will be dependent upon other factors discussed. In many circumstances, molten aluminum may come in contact with the insulation. Molten metal may penetrate to the insulation through lower wall refractories which crack during installation, dryout or other reasons. To evaluate those conditions, the modified B-Immersion test was used. Results are found in Table III and Figures 1-8. Although all the insulations showed good to excellent to molten aluminum resistance as indicated by the high weight retention, the mineral wool products, PV Supertemp and Mono-Block, did shrink and bowed excessively upon metal contact. In actual service conditions, this type of behavior may leave gaps in the lining allowing further metal penetration. For fibrous products, Rim 410-03 and Delta-T, metal resistance was good; both materials remained intact even though some penetration was seen in the Delta-T. The other materials (IV-19, IV-20, Superex 2000, Superex 1600, and Skamolex PM-10) performed excellently; the metal skull retained could be easily removed. Safety Statement Although these materials do not contain asbestos, some are composed of free crystalline silica (see Table I for analyses). It is the uncombined silicon dioxide (SiC>2) in these insulations which may lead to lung disease. Of primary concern is silicosis, a noncancerous disease of the lungs. Silicates, although consisting of silicon and oxygen, combined with other elements in a complex molecules. With the exception of asbestos and some talcs, silicate dusts should not ordinarily cause-disabling lung conditions such as produced by free silica. It is uncombined or free silica " t Memorandum 1979-11-08 Page 6 1 \V`r * ' Tfr V:- . - however that is most important ih industrial;dust exposure.. To deteqt an exposure properly, the percentage of uncorabined silica must be determined by petrographic analysis, preferably by X-ray diffraction or infrared techniques. i It is generally Stated that the size of the offending dust particles is of extreme importance in determining, the concentration of particles that may be- suspended in the air. - The size of particles also determines the depth to which these particles penetrate into the lung along with the quantity that may become deposited and retained. Particulates less than 10 microns in size are potentially the most harmful. Generally, when airborne- particles are larger than 10 microns, they are not of concern because they are unable to penetrate into.the lung where;they could be damaging. Instead they are removed and collected by the nasal passages or upper respiratory system. . ,f |J, f k Also, it has been generally stated that the duration of dust inhalation is of extreme importance. Persons who for many years have continuously inhaled free silica .dust have a great likelihood of contracting!a silica-related disease. Those who only intermit tently inhale the dust have less risk of injury. In addition, those persons who. smoke will increase the risk which otherwise exists. vl; ' It is important to be aware that exposure to silica dust can occur during the installation of some of these products that contain free silica as!well as during tear-out and repair of facilities where these products were previously installed. It is recommended that personnel working with these insulations wear respirator and . eye protection, and that the area be properly ventilated. Periodic safety monitoring of the free' silica should be scheduled also* Conclusions . ? i ' -i . 1. Major insulation materials in the high temperature range are (listed in ascending order of temperature resistance): a. Mineral. Fiber, 540 to 1040C (1000 to 1900F)~ PV Supertemp and Mono-Block. . b. Calcium Silicate and Silica, 870 to 1100C . (1600 to 2000F)--IV-19, IV-20, Superex 2000, Superex 1600, and Skamolex PM-10. - rr c. Ceramic Fibdts Based on the AllO.,--SiO Systems, 1100 to 1260l.C (200.0 to 2300F)--Delta-T^ and 6Rijm 410-03. 2. High compression strengths were found for IV-19, IV-20, Superex 2000, Superex 1600, and Skamolex PM-10, whereas fibrous materials" (PV Supertemp, Mono-Block, Delta-T, and Memorandum 1979-11-08 Page 7 Rim 410-03) show the least resistance to deformation or high compressibility. 3. Thermal conductivity values did not vary significantly between the insulation types examined. 4. Although exhibiting nonwettability, mineral wool insulations (PV Supertemp and Mono-Block) do shrink excessively in contact with molten aluminum. Other products (calcium silicate, silica or ceramic fiber materials) all have good-to-excellent resistance. 5. Products IV-19, IV-20, Superex 2000, Superex 1600, and Skamolex PM-10 have been identified as containing free crystal line silica. Largest contents were found in Superex 2000, IV-20 and IV-19. Recommendations Again, each application must be considered individually when recommending insulation. One must consider the thermal conditions imposed by service along with each particular insulation's qualities of mechanical strength, chemical compatibility, weight, compactness, heat flow resistance, and so forth. In many cases it must be recognized that local availablility and delivery will at times necessitate the use of a product'in a specific class. For ingot melting and holding furnaces, one of the most important developments by Pittsburgh Mechanical Engineering in the past year was the development of a computer program to investigate temperature profiles. On the basis of a computer study and this present work, lower furnace walls are now being backed up with 50.8 cm (2 in.) of Rim 410-03 or Delta-T insulation in place of 50.8 cm of PV Supertemp and 50.8 cm of Superex 2000. This design has established a more realistic metal freeze plane with insulations that are both compressible and molten metal resistant. This construction should prevent frequency of furnace bleedouts and conserve energy. Other ingot applications such as troughing, filter units, etc., are being reviewed, and better materials and designs are being plant tried. With proper design and material selection, improved service life and more comfortable working conditions should be realized. Finally, in handling some of these products studied, particularly Superex 2000 and IV-20, special precautions must be taken to minimize dusting. Without adequate ventilation and respirators, a safety problem does exist. E. HINES Memorandum 1979-11-08 Page 8 JEH:bls Attachments - 18 cc: ID - ATC, D G. L. Baker - Pittsburgh 3 WPH M. J. Caprio - Pittsburgh 3 WPH C. J. Cox - Pittsburgh 3 WPH C. F. Hartley - Pittsburgh 3 WPH R. C. Holtz - Pittsburgh 3 WPH W. A. Keith - Pittsburgh 3 WPH A. J. Magnussen - Pittsburgh 3 WPH J. W. Mclntee - Pittsburgh 3 WPH E. L. Rooy/H. G. Reavis - Pittsburgh 23 H. G. Sakoian - Pittsburgh 7 A. J. Sartschev - Pittsburgh 3 WPH D. L. Schaffer - Pittsburgh 23 L. D. Tannis - Davenport Wks. J. Damiano - ATC, C M. B. Thomas/D. J. St. Jacques, Jr. - ATC, C M. B. Dell - ATC, C R. K. Dawless/F. N. Smith - AL, NK-44 S. K. Das/P. A. Fyala/A. L. LaCamera - AL, NK-44 M. J. McMonigle - AL, NK-44 R. E. Miller/V. L. Hammersmith - ATC, B R. G. LaBar/R. E. Spear/File: 10.160 - ATC, B 7Q3> M <c c oe ao c9 nccaor a Xo. e CO CO Xo CM O r CO H 6 to N 4J * a ao aa a u CO a OM oH a o k <*N HN 8 to P CaoO* xa o. Ha CM o co a CO o 1X a a. -( Hc 88 to a ^>7 a 4H rt O 8 H a X *-% oN a aa a H cr V) a . a a cr a a y--% o ac 4J U fe a oa 4J a a jj a CM o* X H X rH X X<MI8 X C oc o 4o8J eo8 a oa M 4ie- MO 48J oc W a o a00 4 Xa* toM l-0J0 Xo <8 a. CM H a X --> CM oo o CO "3 t O CO CO a 60 X ao aH 60 X H p. a aH a Xao o Xo. CM U oo o to 1 a CM OH H 8 CO CO aa > X a a o c a *aH X Ha a CO X o H 3aO Nam' a a CM o rH H 8 CO CO 73 a > X sr a x X CL OH X 7-1 ' CO *>-N o oX H to t *o a o a rteHo 60 3 o H to X a o a60 i-3 -4I* X CM -3 MANUFACTURER'S DATA-- ANALYSES OF ASBESTOS-FREE INSULATIONS ) a0 r--I (C9 < CO o 1V*4CM CM O CO CO o CM H < CO *3 -3 o oI CM H r-* CM nt CM CO *3 *3 1 Os o rH X CO SO sA *3 r- rH SO 1 CO O 3 *3 rH rH -3 SO CM CO c o o H H *3 *3 in CM OS CO CO CO x o Os r- OV CO U au *4 o aa u *o uo a Wt S4H 04 a a 7j ae Xa Vj Cl ae xa O AH H >4 CL, O n. aa rH X CO n> c> cu a o rH CO a1 pO ac ao XX H l aa cu a rH aa XQ CO 4-1 o* a 73 O CuL, coo B <i H| 04 <T rH a a c H o rH H a 4J u a rl cE w Lt Cs a a rl 4J p > 1 -H t-H rH a a 4H p -rl o rH "rH a 4H o a tH p fs u Lo a a CM 4-1 > | P s> MM CO CM co (aOa4 oH o co so CM co o SO N n CO CO X CM *3 Os r*. 3 -3 CO ^3 a rH rH o v4 o >o c CM >: Va (0 U pa X cu oa o to CM H a rH rH o -H o >X c rH a X1 X a <0 u ca X o. oa --) to 3 H o rH t X CL* X a rH rH ofi o aE X r* XX CO oI 1 os rOs rH a a c rl X LxJ *o TABLE I o o oo- o o ooC to w+ta1 < 4J TM0oJ .o cVqoL> , Oua> o. l Xfl HBO X e aV *4oJ V >aB4 uo u. u, ooo ooo oo CcO o ooo ooo o No oou oooo u1*4u *H W, u3 *c-f ooo o^oo oooo o O O SO o c c C ou oo oou 1 j PROPERTIES OF ASBESTOS-FREE IN S U IA TIO N S Mu0 O O O 30e5 KO t1o o> XC G:T O 0J *H O HO vt O ~ 5 mI c X9 O Vi 00 OC fM *0HJ H03 MOI G rC > t g~ 4i 0 C> 00 e *j O *H *-t U0 30 HI C -H > U 6M J0J U0 c> 9 CO o o COUU Io e '* H 0I 0C i0) U0, X 0 0o 0C CO 0I *i Xo. uoa H O o o Hy o CO oo oo ~l o o o rco- OOot o os0 O to CM Os *3" CM CO CM O o oo CO CM I to CM o> Oo Oo Oo oO oQ oO *4 r>- srs *j rx o oo oo CO o t/1 Os Oo O t0 o O V0 go r- \O0 o tHo o*ot o O *9 CO CM O o lO H to O o> o tM oo OO CO CM -I CM CO tO N0^ CM CO o o o oow GO M 00 M CM to cm sr to O CM CO m dodo O-- 0BO to to O 'T II o I o o 0 1 OI ' HI 0 1 O co II l 0k GO I CO I 0 1 N H CM II o to I ICM (0.28) 0.05 (0.36) 0.06 (0.43) 0.04 (0.26) 0.08 (0.56) 0.08 (0.57) 0.08 (0.58) 0.07 (0.46) 0.C6 (0.15) (0.38) 0.06 (0.42) 0.08 (0.52) 0.05 (0.36) 0.09 (0.64) 0.09 (0.65)' 0.09 (0.62) 0.07 (0.48) 0.07 (0.45) (0.49) 0.07 (0.51) 0.09 (0.60) 0.07 (0.46) 0.10 (0.72) 0.10 (0.70) 0.09 (0.65) 0.08 (0.55) 0.09 (0.65) (0.59) 0.09 (0.62) 0.11 (0.74) 0.Q8 (0.57) 0.12 (0.80) 0.11 (0.77) 0.10 (0.70) 0.10 (0.63) 0.10 (0.70) (0 69) 0.11 (0.75) . 0.13 (0.84) 0.10 (0.67) 0.13 (0.88 0.13 (0.89) 0.12 (0.80) 0.13 (0.87) 0.12 (0 .6 0 3 r--1 a) 3 O 3 i*H 4J a, <u O i--1 ae) Ea o cd cd rH -- (--1 s os rH O <U iH 01 43 CO 4J 3 CM 43 O CU e CO CO o rl 33 > cu o EO 4) > O 3 c c 43 44 a -a -u o 4-> 3 T3 Vi T3 4) U O H o H o H uCO* 44 n 33 cr 3 a) 44 4J u s <-> >o H 00 >1 n > O 3 CO a c 3 a) o rH 3 o V4 Ui H 4> vi s E *3 'O H H 43 6 44 4J 4J P 43 0) a> a> 0) 3 -H 4) >v 3 4) a> 01 cu MS u* o 3 4H Ui CO 3 C c o o CO 4J 3 CO 3 <u 4) a >, *--i rH >43 rH M 4J CO 3 rH E >* H 4) CU CU a a 4J H *3 a) a> rH O iH >* 3 4) 4) at 4J CO 3 co 33 CO J-i t--l rH rH 43 -rl H 33 3 0) <0 CU u 44 3 Vi CO a) a 43 ofi HO > iH *r! H 0) 44 4J 3 3 CO CO rH rH 3 H rH > r-i H H H co zCU 3 cSd i3-l 33 4H VI 3 43 3S 44 O 3M 33 44 S 3O CO 4J 4) ucO 4) > O > O > O (O rH X <44 43 s X % 55 zoM <3 J s co Z i-l Vi 00 o O c oO 44 4J u 44 4J 4J 3 O3 c 4J 0 4) 3 3 4a) c o iH PH Pi 44 rH H rH rH rH rH 4J rH H rH rH rH rH CO f>1 Si a 3 3 4) 4) 3 4) 4) p4 M VI o OU a O O a CJ ai 3 o OX X X X X X > > o uw W w W wW K3 44 3a 43 iH 60 3 iH 44 33 z e4 ITS rH o rH o vO cn CM r*. oo CoO\ CoM\ rH a\ o o> Hf o CD vO CO CO a) u 43J cd c 3 6<u00 JS u0) ft H i--HI 3O 3O O <u 3O oo o I *o cu vi >3 > * i--i r3H 3 4C rH o rH CO cd 3 O rH O rH 1 o 43 0) oI\ r-- C S3 4- c 3 O -H O iH 14 ON M M M W hJ CQ C H cO rH CO rl Ui 4) 4J co X 3 43 44 a H -H 3 Pi CU 1 33 CO rH 60 >3 Cn w 44 CJ o rH P3 13 O3 33 O3 64 EH 1 434 3 3 rH 3 33 a 64 O D d o co Vi O fe 1 o rH tH <r eS o H 4J CO C a> M rH 4) 1 t! >c HM O iH 44 3 3 0O4 Vi 3 1 44 >3 HW o> 04 c 3 X 31 VI Cl) 33 CU 4= 3O CO r-j vO > rH 3 3 X 31 Vi 3 33 a 4= 3O CO *1 Pi X 3 rH rH oo EE 33 44 44 co co o 3 3 4O4 O 43 HPe i co a) c SB w *3 EAGLE PICHER J. P. AUSTIN FIGURE 1 MONO - BLOCK KEENE CORPORATION FIGURE 2 DELTA T KEENE CORPORATION FIGURE 4 " i IVJ 9 INTERNATIONAL VERMICULITE CO. JTV/9 <1, IVI 9 V^tcul.tc) I1NTERNAHONAL VERMICULITEl MODIFIED B IMMERSION' 2 CYCLES! . Ws- :;<-, - . *- * JA.S'IS < --r . * *:. ' >4 ' 'v-^" .'r. FIGURE 5 INTERNATIONAL VERMICULITE CO. mmsmm v-i* -'-- <".* - ::* i.;:*. -4 " '. - ' -'*! ; ria*1li .^r** *' ~ jSUPEREX 2000 ! JOHNS AAANV1LLE Co. - *-' l 14 4 C f iWtX a<_'.* liSUPEREX 1600 :{JOT tjvT-'f-x.-L -gu.r- :>:V..r. >''>VT ,.--,*.. ..." ., k.X-':" FIGURE 8 TYPE: Block TEMPERATURE: to 1900F Description: Eagle-Picher "PV" Supertemp. Block is composed of high temperature mineral fibers bonded with specially prepared binders to form a block insulation having optimum properties during both installation and service. Fibers are oriented to insure maximum strength and thermal efficiency. The blocks are "wet-sawed" by a patented process to provide precise dimensional tolerances and freedom from dust. Uses: Recommended for direct application or refractory back-up insulation in petroleum and process units, power generation equipment, ovens, furnaces, kilns and other related equipment requiring an Insulation that is economical, efficient and dimensionally stable. Advantages: Durability: Strong yet resilient, processed to maintain structural integrity during field application. Absorption: Allows placement - of castable refractories in direct contact with the block without degradation. lnstallation:Can be impaled on pins without predrilling. Easily field fabricated with knife or saw. Standard sizes up to 24" x 36" permit rapid installation. Physical Properties: Service Temperature.......................to 1900F. Density............................. 16-18 lbs./cu. ft. Moisture Absorption................................... Nil Fire Resistance ................. Incombustible Corrosion............ Does not cause or accelerate V. Physical Properties' (cont'd): Linear Shrinkage at 1600F........................................... 2.0% 1800F............................................. 2.2% Modulus of Rupture................40.0 Ibs./sq. in. Compressive Strength............. 2,600 Ibs./sq. ft. at 10% Deformation Thermal Conductivity: Mean Temperature F. "K" (Btu-in./hr./ sq. ft./F.) 200 400 600 800 1000 0.28 0.38 0.49 0.59 0.69 Page 1.1.2 "PV" SUPERTEMP BLOCK Standard Sizes; -. Thickness: Width: Length: 1" to 414" in 44" increments 6", 12", 18" and 24" 18" and 36" Special sizes and shapes are available and are quoted on request. Heat Loss Chart Applicable Specifications: Commercial Standard CS-l 17 ASTM C612-67T, Class D Federal HH-1-55S, Form A. Class 5 Packaging: Board Feet per Carton 1" 144" 2" 244" 3" 344" 4" 444" 6 X 18 12 X 18 6 X 36 12 X 36 18 X 36 24 X 36 48 45 48 45 45 42 48 40.5 48 45 48 45 45 42 48 40.5 48 45 48 45 45 42 48 40.5 48 45 48 45 45 42 48 40.5 54 54 54 45 54 47.25 54 40.5 48 54 48 45 54 42 48 54 Since 1843 Manufactured by EAGLE-PJCHEX INDUSTRIES, Fibers Department American Ruilrfino rinrinna** j.NJC. /-s;*>r>*> MOMO-BLOCK Mineral Wool Insulation-For Service to 1900 F-Asbestos Free DESCRIPTION: MONO-BLOCK is composed of spun mineral fibers and inorganic binders especially formulated for resistance to high temperatures. A patented process interlocks the long mineral fibers to form a lightweight and rigid, yet resilient block which is shaped and fitted. TYPICAL USES: Heat Treating Ovens Boilers Incinerators Chemical Treating Tanks Refinery Equipment Ducts and Breechings Feed Water Heaters Wind Tunnels' Jet Silencers' Fan Housings' 'Acoustical Applications PHYSICAL PROPERTIES: Density-- 12 Ibs./cu. ft. miniumum Compressive Strength -- 10 lbs./ sq. in. @ 10% deformation Flexural Strength -- 40 tbs./sq. in. Linear Shrinkage after heating 24 hrs. at1900*F Soaking Heat -- Less than 5% Single Face -- Less than 5% THERMAL CONDUCTIVITY: Mean Temp. *F 200 400 600 800 1000 1200 K .36 .42 .51 .62 .75 .90 STANDARD SIZES AVAILABLE: Length -- 18, 36 inches Width -- 6,12, 24 inches Thickness -- 1 -4 inches in % inch increments SPECIFICATION COMPLIANCE: Military: MIL-I-24244A* Federal: HH-l-558BFormACIass5 ASTM: C612-70 Class 5 * Indicate on order when specification compliance is required. Easy to Apply -- Easily cut with a knife. Conforms to slight curvatures or projections such as rivet heads, pro viding a snug fit without cracking or breaking. Can be impaled over welded studs without predrilling holes. High Strength -- Strong because of long mineral fibers and unique manu facturing process which uses inorganic binders. This extra strength guards against breakage loss. Low Chloride/Moisture Resistant -- Acceptable for use on austenitic stain less steel. Effective Acoustical Properties -- High sound absorption efficiency makes this product applicable where acoustical treatment is required at elevated temperatures. cot ' u ft A T I O N INSULATION mirin'.) r.mECI. KALAMAZOO. MICHIGAN 29003 m w n m iooo 1200 moo noo isoo 2000 TEMPERATURE or HOT FACE -- 0EGREE3 FAHRENHEIT C006> ucbiqoivM 'oozcuicicx lanjis pio^nj Qtji uojSjAiQ sjonpojd 6uipima Noiivaoddoo 3N33X - <n TJ 3 r to* ui to CM .t - ,* cq . in mjt co cm cm ^ rr m -:o(s0 co O /s= .X 2 -o` ; *2 . to w - >- 5to CD ^ xi >- CO CM + 0) C rf* . 'i V-W-.T is ` . *- - :s \ w o O' c -. . * .' U. 0 o o o CM u. , SI ri -] ai X o -- u CL Ui - OnOQ^O -- 2 TO 05 O O) < W O u. (- 2 ,' - ; #*"< V. x . ../ - c . O- ''* *. c' . o> C . o to to .o -J. - O'' 0) to 40 05 X TJ So 1c0 X o 2 X o c I < 10 c 0c E<0 2 Xo cc oI g 1 i ~ t > <gU 5<.(o*OT Of<^o lL.5T r 5 o re o o & a - C-X5- ca ; -.Q.^ & ' u> o o ;o): tj E-- : <d- x: tj --c .o $ J0 JZ 5 r.r.*, . - . 'v ' V'. * ** * K in to to .'y/N CO S; C9 T7-.V**.T-. . ViA/*'-OvOo;Jo .^'O o o :jV^<0 ^ CM ^Vi W CM CO CO in co w - .0fc). . JC o. 10 -o E c S<2 Ei rz o c JQO "5 `5 > <0 > W N (0 "S <0 O N aSo- 5C J^= jc " *55 ? g o c 2 - EO oc H-c J> >S(- T2XJ WO OWN o co in CM CM TT 05 o> in o t- o re O V_- o Q. w o w Q eO OO o CO cm X co co O. wa. aw. E o o o It 3 go r EI ~ *-"JJ OC r*e' -- C.O =2 a. w s c Oc) ^o c o c o o. 3 tc c~o oE E o E o 2 <0 T TO T3 S s? ^ ^ o_tn in in Oo o> c U. U. U. > o cG) " o ooo VJ oID oO oCO CM CM </) c E@@@ *V) O (}()() aX Q <J CC Thermal Conductivity Mean Temp. F 200 400 600 800 1000 1200 1400 1600 / CERAMIC FIBER INSULATION Contains No Asbestos Type AH-50 For 1500 C (2732 F) Type AH-30 For 1400C (2552 F) Type 410 For 1300C (2372F) Hi-ALUMINA ceramic fiber products are made by bonding alumina-silica fibers with high purity alumina. No starch, silica, clays or asbestos are used. As a result, lowdensity insulating products are obtained with high alumina contents. These Hi-ALUMINA products outperform conventional silicabonded products. Three products are offerred for three tem perature ranges with three markedly differ ent costs. In this way, users are able to obtain the most economical insulation for any particular temperature range. Also available for the 3000F range areour ALL-ALUMINA products described in a separate bulletin (AA-320). PRODUCTS AVAILABLE Type AH-50 77%A1203 For 1500C (2732F) Type AH-30 61%A1203 For 1400C(2552F) Type 410 54% A1203 For 1300C (2372F) All of the above products are available in the form of boards, tubes, cylinders or special shapes. The products can be varied in size, thickness, degree of hardness and surface finish. APPLICATIONS The principal use for these products is as a rigid form of a low density, high temperature insulation. The alumina-insula tion requires 50% less insulation than conventional brick insulation. Fast heat-ip, fast cool down and low heat storage make this insulation ideal because of today's energy shortage. Among the insulation uses are furnace linings, back-up insulation, heat shielding, induction coil liners, combustion chambers, stack insulation and high temperature pipe insulation. The non-wetting characteristics of alumina binderand alumina-silica fibers to molten metal makes these products desir able for many molten metal applications. Among these are riser sleeves, hot top linings, trough linings and tap out cones. The low sodium content and high surface area of the alumina binder makes these products ideal catalyt supports for the flameless heater. The low sodium content makes these products ideal for electrical heating element holders and radiant heater pads. Other uses include burner blocks, expansion joints, kiln furniture, gaskets, peep hole plugs and seals. -- . .. rim products corporation PRINTED IN U.S.A. IQ7Q illM 1605 east ayre street newport, delaware 19804 phone (302) 995-7194 791377H-100 PROPERTIES Chemical Composition A1203 (%) Si02 (%) Density (Ibs./cu. ft.) Modulus of rupture (psi) Loss on Ignition (%) (Absorbed Water) Linear shrinkage (%)* 1300C (2372F) 1400C (2552F) 1500C (2732F) Thermal Conductivity (BTU-in./sq. ft. hr. F) 1300C (2372F) 1400C (2552F) 1500C (2732F) Melting Point Fibers Binder Recommended upper use temperature Thermal shock resistance Two-hour soak AH-50 77 23 11 -12 60 2.3 1.2 2.0 2.5 AH-30 61 39 14-16 75 2.3 2.6 3.1 -- 410 54 46 16-18 80 2.3 3.6 -- 1.5 1.4 1.7 1.6 1.8 Above 3200F 3700F 1500C . 2732F Excellent Above 3200F 3700F 1400C 2552F Excel lent 1.4 -- 3200F 3700F 1300C 2372F Excellent The above information is intended for use by persons having technical skill, at their own discretion and risk. It should not be taken-as a warranty nor as a license to operate under, or recommendation to infringe any patent. Some of the above values are averages obtained on developmental material and are subject to change. They should not be used for specifi cation purposes. IV 19 Block Insulation Product Data Sheet IV-19 Block Insulation is an asbestosfree insulation, manufactured from vermiculite granules and high temperature bonding materials. It is a versatile product available in a wide range of sizes. Because of its low conductivity, IV-19 is an economical, energy saving insulation. It exhibits minima! shrinkage at top temperature limits, and will not decompose even when exposed directly to flame at or beyond maximum service temperature. IV-19 is an excellent back-up insulation as well as a highly efficient hot-face insulation for temperatures at or below 1900 F (1037 C). It's unique composition and hard surface helps insure strong adhesion of cement finishes, and provides superior handling qualities. IV-19 can be manufactured with either straight or beveled edges to meet customer specifications. Standard sizes and weights are listed on the price sheet. Prices for custom size blocks will be quoted upon request. Asbestos-free 5 Product Data Sheet IV 19 Block Insulation Physical Properties: Temperature 1900 F 1037 C Conductivity 0.56 "k" at 200. F (.0808 W/mK at 93 C) 0.64 "k" at 400 F (.0923 W/mK at 204 C) 0.72 "k" at 600F (.1038 W/m*K at 315.6 C) 0.80 "k" at 800 F (.1154 W/mK at 425.7 C) 0.88 "k" at 1000 F (.1269 W/nrK at 537.8 C) Linear Shrinkage At 1900 F (1037 C): 2.25% Chemical Analysis Vermiculite, the basic component of IV-19, is a magnesium, aluminum> iron silicae. It contains no free oxides. Al20, 9.19 CaO 11.51 SiOj 54.38 KjO 3.72 As Silicate Cr202, Ti02 Fe2 02 5.35 NaA Mn204 0.86 Mg 0 13.16 Combined Hrf 1.84 Shipping: Carton IV-19 is available in standard block thicknesses of 1" to 6" in Vi" increments with the other dimensions measuring 6" x 18", 6" x 36", 12" x 18" or 12" x 36". Special sizes available on request. Density Cold: 20.5 Ib/ft* (328.4 kg/m*) At 1900 F/1037 C: 19 Ib/ft* (304.4 kg/m*) Crushing Strength Cold: 125 PSI (.0878 kg/mm*) At 1900 F (1037 C): 51 PSI (.0359 kg /mm*) Area of Application: End/Sidewalls Bn IV-19 has a wide variety Q of uses in high I 1 temperature industrial furnaces including end and side walls of various heating furnaces ... soaking pits, reheat furnaces, carbonizing furnaces and other annealing furnaces. IV-19 is applied as backup insulation as well as hot face material at temperatures of 1900 F (1037 C) and below, for example IV-19 could be used in duct or flue linings and cyclones. Modulus of Rupture Cold: 73.5 PSI (.0517 kg/mm*) At 1900 F (1037 C): 51.5 PSI (.0362 kg/mm*) Method of Application: Block Construction Install, using standard procedures for block construction. 6 International Vermiculite Company/ Post Office Box 66/ Girard, Illinois 62640/ Telephone 217-627-2193 18477-06 -W IV-20 Block Insulation Product Data Sheet IV-20 Block Insulation,'made from diatomaceous silica with a hydraulic binder, is a superior high temperature insulation for service to 2000 F (1093 C). According to ASTM testing procedures, IV-20 exhibits extremely high resistance to breakage at 2000 F (1093 C). Long maintenance-free service arid maximum operating efficiency Is assured by IV-20's unique combination of low conductivity and high stability. IV-20 is also very low in sulfur and iron, making it highly resistant to attack from atmospheric conditions and greatly reducing the possibility of product contamination. Like other International Vermiculite products, IV-20 is produced In a wide range of standard block sizes, available with either beveled or straight edges. This product can also be manufactured in special shapes to fit customer specifications, saving money on both installation and energy costs. Asbestos-free Temperature Area Method Shipping 7 `Product Data Sheet IV-20 Block Insulation Physical Properties: Temperature 2000 F 1093 C r Conductivity .65 "k" at 400F (.0938 W/mK at 204.4C) - .70 Mk" at 600F (.1009 W/m-K at 315.6C) .77 "k" at 800F (.1111 W/mK at 426.7C) .89 "k" at 1000F (.1284 W/m*K at 537.8C) Density Cold: 24.5 Jb/fP (392.2 kg/m1) At 2000 F (1093 C): 23.5 tb/ft1 (376.4 kg/m1) Crushing Strength Cold: 176 PSI (.1237 kg /mm1) At 2000 F (1093 C): 150 PSI (.1055 kg/mm*) Modulus of Rupture Cold: 55 PSI (.03867 kg/mm1) At 2000 F (1093 C): 90 PSI (.0633 kg/mm1) Si02 Al20, CaO *1 Linear Shrinkage J at 2000 F I (1093 C): 2.8% J Chemical Analysis IV-20 is made from diatomaceous silica with hydraulic binder. 79.0% MgO 3.8% 3.9% FejO, 1.3% 6.8% Ignition loss 5.1% Shipping: Carton IV-20 is available in standard block thicknesses of 1" to 6" in Vi" increments with the other dimensions measuring 6" x 18", 6" x 36", 12" x 18" and 12" x 36". Special sizes available on request Area of Application: End or Side Walls 0cs IV-20 is primarily a side Ej wall and end wall | ' " | insulating material. Whether it's used as a hot face or a backup depends upon customer requirements and the IV-20's 2000 F (1093 C) service range. The wide range of uses includes such diverse applications as, soaking pits, reheat and pusher furnaces, copper reverbatory furnaces, petroleum reactor vessels and oil fired water tube boilers. Method of Application: Block Construction Install using standard procedures for block construction. 8 International Vermiculite Company/ Post Office Box 66/ Girard, Illinois 62640/ Telephone 217-627-2193 18477-08 Johns-Manville Refractory Ml Products SuperexTM Biock Insulation Type: Block Temp. Limit: 2000F Description Superex block insulation products are manufactured from carefully selected combinations of silica, lime, clays, and fibers for reinforcement purposes. These products are characterized by high strength, both cold and at elevated temperatures, and high refractoriness. They can be used right up to their temperature use limits -- and in some conditions even beyond -- should upset conditions occur. They uniquely combine low thermal conductivity and high stability at elevated temperatures to provide efficiency of construction and thermal performance, and long maintenance-free service. Superex Block products contain no asbestos fibers and are not soluble in water. Repeated wettings have no effect on this insulation. Superex products are not recommended as a furnace lining material exposed to combustion conditions unless a great deal of past experience shows the product to be satisfactory in a particular application. Typical Applications Superex block is designed as a backup insulation for all refractory constructions; i.e., insulating firebrick, dense fireclay brick, castables, plastic refractories and also ceramic fiber felts and blankets. All Superex block performs well at high temperatures and efficient designing of a refractory system with Superex as the backup insulation will reduce the amount of hot face refractories required. The most thermally efficient and cost effective system is obtained when the lowest thermal conductivity materials are placed in the hottest possible location. The excellent heat resistance of Superex block allows this. The most thermally efficient systems utilize Superex 1600 as backup to Superex 2000. Superex block is good insurance, too. Any refractory construction can be expected to crack in service and allow full furnace temperatures into the back-up insulation. Its high refractoriness will help to prevent catastrophic failure of important equipment and allow operation until a more convenient rebuild or repair time is reached. Uses Ovens Soaking Pits High Temperature Mains and Flues Industrial Boilers Marine Boilers Regenerators Kilns Roasters Reverberatory Furnaces Reheat Furnaces Annealing Furnaces Heat Treating Furnaces Combustion Air Piping Bustle Pipes Blast Furnace Stoves Glass Lehrs Car Tops Forge Furnaces Laboratory Furnaces Cooking Equipment Advantages Exceptional Heat Resistance. Superex Block can be used to its full temperature use limit. Its high refractoriness also offers some insurance against immediate failure should these temperatures be exceeded. Excellent Strength. Easy to install; resists damage both in installation and in operation. Lightweight. Reduces structural steel requirements; ideal for insulating movable equipment. Special Shapes. Good strength properties make Superex block ideal for cutting and grinding special shapes. J-M can supply these to your specific requirements. Sect. 140 Part 10 Date: 4-78 Cancels: 10-77 Specification Data Available Forms Superex 2000 -- A high-density, low-calcium oxide content block, designed for low shrinkage and top performance at temperatures up to 2000F. Superex 1600 -- Has a higher calcium oxide content and lower density than Superex 2000. This formulation gives better strength and insulating properties for use in situations where temperature will not exceed 1600F. Superex 2000 SG -- Composite insulation block made up of Superex and a layer of spun-attenuated glass fiber, bonded together at the factory. The fiber glass layer, consisting of 1000 Series Spin Glas, increase the insulation effectiveness of the Superex block and also serves as a mechanical "cushion" between the block and the steel shell of a furnace Normal Service Temperature, F, (oxidizing atmosphere) Superex 2000 2000 Superex 1600 16000 Marking None Green strip on end Density, Ibs/cu ft 24 14 Modulus of Rupture, Ibs/sq in 45 65 Compressive Strength Ibs/sq in to produce 5% deformation (2" thickness) 130 165 Linear shrinkage, % after 24 hours soaking heat 2.7 @ 2000F 1.4 @ 1600F Chemical composition, % Silica, Si02 Alumina, AI2O3 Calcium Oxide CaO Ferric Oxide, Fe203 Titan ia, Ti02 Magnesia, MgO Alkalies, as NaaO & K20 Sulphur Trioxide, S03 Others Loss on Ignition 74.8 4.3 6.0 2.0 0.3 0.8 2.7 0.0 -- 9.1 49.6 1.2 37.6 0.3 Trace 0.2 0.0 Trace 0.2 10.9 Superex Block Insulation Compressive Data on Superex 2000 SG (2V4" Superex 2000 plus %" 1000 Series Spin-Glas) Compressive Strength of 3" Superex 2000 SG______ CompressedAs Thickness Received (in.) 3.00 0 2.90 1.4 2.75 3.5 2.50 22.6 2.25 66.0 Load to Compress, psi Hot Face of Superex (24-hr test) 1600'F 1800'F 1900'F 00 0.6 0.4 2.4 1.5 21.1 12.5 29.0 70.0 0 0.4 1.6 13.5 73.0 Recovery of 3" Superex 2000 SG After Compression Compressed Thickness of Superex 2000 SG after release Thickness (Percent of original thickness) Hot Face of Superex As (24 hour test) Inch % Received 1600'F 1800'F 1900*F 2.90 97 99 99 99 99 2.75 92 99 97 97 97 2.50 83 95 93 93 93 Standard Sizes All dimensions in inches Thicknesses in Vz inch Superex 2000 Superex 1600 increments 1 to 5 1 to 4 Superex 2000 SG iy2to6 Widths and Lengths 12x36 18x36 6x36 12x36 12x18 6x36 18x18 Beveled blocks are tapered to specific requirements. Outside diameter of circle is to be specified on order. Johns Manville Ken-Caryl Ranch Denver, Colorado 80217 For information on other J-M Thermal Insulations and Systems, write the Johns-Manville Insulation Center,-Drawer 17L. Denver,. Colorado 80217 or call (303) 979-1000. The physical properties of Johns-Manville Superex block insulation represent typical, average values obtained in accordance with accepted test methods and are subject to normal manufacturing variations. They are supplied as a technical service and are subject to change without notice. Check the Johns-Manville district office to assure current information. IND-3009 4' 78 LifNj (J$* SKAMOLEX PM-10 Asbestosfree Calcium Silicate Slab Insulation. An extremely lightweight calcium silicate slab, fibre reinforced but completely free of any asbestos and crystalline silica. It is designed as a final back-up in sulation between refractory linings and furnace casing for interface temperatu res up to 1000C. A low density product - 250 kg/m3 - of good strength and low thermal conductivity throughout its temperature range of service. Excellent resistance to carbon monoxide and a number of other gases, and good perfor mance in contact with molten aluminium. The large sized slabs - standard size 1000 x 610 mm - of accurate shape and clean edges speed construction and improve insulation efficiency. The slabs are easy and clean to handle because of a negligible dust emission. Due to their porous structure the slabs are easily shaped on site by ordinary woodworking tools - fixing can be made with nails or screws. A specially de veloped adhesive is also available. SKAMOLEX PM-10 Asbestosfree Calcium Silicate Slab Insulation Bulk density (dry).................................. 250 kg/m3 Porosity.................................................. 89% Cold crushing strength......................... 2.0 MN/m2 (20 kp/cm2) Compressive strength at 5% deformation 1.7 MN/m2 (17 kp/cm2) Modulus of rupture............................... 0.6 MN/m2 (6 kp/cm2) Recommended service temperature (back-up)................................................ 1000C Linear reheat shrinkage DIN 51066 BL.2(12 h950aC)............. <1.5% Specific heat........................... .............. 0.75 kJ/kg K (0.18 kcal./kgC) Thermal conductivity at mean temp. W/m K 10C.... .. 0.054 200C___ .. 0.065 400C___ .. 0.087 600C.... .. 0.109 800C.... .. 0.132 Kcal./m.h.C 0.046 0.056 0.075 0.094 0.114 Pyrometric cone equivalent................. 1400 C Thermal expansion coefficient 20-730C............................................ 0.74x106/K The above properties represent average test values. They are given in good faith but no guarantee is im plied. SiOa................................................... ......... CaO................................................... ......... FezOz........................................................... AI2O3 ............................................ .......... Ignition loss...................................... .......... (mainlv H?0 and CO2) 41 % 42 % 0.5 % 1.2 % 13 % Skamolex PM-10 is available as flat boards of stan dard size 1000x610 mm with thicknesses of 2530-40-50-60-75-100 mm. Other sizes or shapes, e.g. with bevelled edges, can be supplied to suit spe cific design requirements. For agglutination of slabs, or for adhering Skamolex PM-10 to refractory and metallic surfaces, we recom mend the use of SKAM0L FL-06 Mortar. This adhe sive is supplied as a dry mix in 25 kg bags, ready for use after addition of water. Adhesive thickness should not exceed 5 mm. Skamolex PM-10 in standard size 1000 x 610 mm is offered in shrink film wrapped packs holding be tween 1.8 3 and 6.10 m2 of board depending on thicknessi Packs are palletised for shipment on nonreturnable pallets, secured with nylon strapping. One pallet unit comprises 2.25 m3 shipping volume. PACKING SPECIFICATION Thickness mm 25 30 40 50 60 75 100 Content per pack slabs m* 10 6.10 10 5 5. 5 3 3 6.10 3.05 3.05 3.05 1.83 1.83 Content per pallet packs m* 14 85.4 12 73.2 18 54.9 . 14 42.7 12 36.6 16 29.3 12 22.0 Packing in wooden crates or cases quoted upon re quest. DK-7900 NYK0BING MORS . DENMARK . TEL. INTERN. 45-7-72 15 33 . TELEX 66680 C FROMM. J. CAPRIO PITTSBURGH PURCHASING - 19 1 S DR. R. G. LABAR CCD INGOT CASTING DIVISION nn ALCOA TECHNICAL CENTER - B MJV 1979 OCTOBER 22 RE: ASBESTOS-FREE MARINITE On 1979 October 18, Jim Hines and the writer met with the following Johns-Manville (J-M) personnel for an update on their program to replace asbestos in molten metal grade Marinite. Howard Konrad: V.P. and General Mkt. Manager Refractory Prod. Joe Campbell: Sales Manager - Eastern U.S. Miss Pat Keegan: Sr. Sales Rep. - Pittsburgh J-M's Corporate objective is to replace asbestos in Molten Metal Marinite by the end of 1980. Although they are making what they call an all out effort to achieve this objective, the results todate are few and not too promising. The latest formulation of asbestos-free molten metal board designated Marinite-C was run at the Billerica, Mass, plant on 1979 October 08; this run, like the others which preceeded it, was discouraging in that it did not produce sound, crack-free boards. Although the Marinite-C formulations have allegedly produced acceptable boards at J-M's Research LAB, they have bombed-out under commercial production facilities. We will not elaborate on the problems associated with the Marinite-C formulations except to say that they forced J-M to add additional Research back-up to Walter Pusch, J-M's perennial group leader for Marinite projects. In addition to the increased input from Research, J-M will also utilize the press facilities at their Nashua, N.H. plant to accelerate the commercial production runs. During this development period it was agreed that Jim Hines will be in direct contact with Walter Pusch in evaluating product and in determing the optimum heat treat temperature. If J-M's asbestos-free Marinite-C goal is not achieved, we were assured that Molten Metal Marinite with asbestos will be available for as long as it is requested by the aluminum industry. J-M has a stronger incentive to get rid of asbestos than Alcoa and on that note we are convinced that some how and some way J-M will stumble on to an acceptable Marinite-C material. M. J. CAPRIO \ ALCOA FROM JAMES E- HINES INGOT CASTING DIVISION at HygieInde ALCOA TECHNICAL CENTER - B BDD crc--nn VILF JD '123 i nO PHS -<3" CCD rH DB CD ZD <S.("EDS MJV. RE: ASBESTOS-FREE MARINITE I. PLANT METALLURGICAL ENGINEERS 1979-08-13 Based on limited plant triaflSi^^^he most promising asbestos-free candidate for replacing asbestos Marinite has been Marinite I. Although it cannot be used as headers, preliminary results have indicated that, if the board is heat treated to 290C (550F), it can be successfully employed in less critical molten metal contact applications such as troughing, basins, dams, and feedboards. These areas would require 50.8-mm (2-in.) thick boards. A 25.4-mm (1-in.) Marinite I has also performed well as D.C. distributors or floats. In this case, no special heat treatment is needed outside of removing atmospheric moisture by a low preheat. In order to substantiate these results and limit the usage of asbestos, a large scale evaluation of Marinite I is requested at Badin, Cleveland, Corona, Davenport, Lafayette, Massena, Rockdale, Tennessee, Vancouver, Vernon, and Warrick ingot plants. Before boards can be made available however, a list of each plant's requirements are needed since heat treating Marinite I at 290C (550F) requires special runs by Johns-Manville. Please try to give an estimate of the number of 50.8 mm (2 in.) and 25.4 mm (1 in.) to either Mario Caprio at the Pittsburgh Office (X4332) or myself (X2815), so that an order can be placed in the very near future. Once the boards have been processed and are available, another letter will be issued. Only through the cooperative effort of all the plants can Alcoa completely replace asbestos. JAMES E. HINES JEHrbls (Distribution List - Page 2) ALCOA Sr-4303 Plant Metallurgical Engineers 1979-08-13 Page 2 LETTER TO Plant Metallurgical Engineers: C. T. Barger, Jr. - Badin Wks. T. F. Arnold - Cleveland Wks. A. F. Maloit - Corona Wks. R. J. Stokwisz - Davenport Wks. D. 0. Collins - Lafayette Wks. D. E. Scott - Lafayette Wks. M. Scherbak - Massena Oprs. G. G. Owens - Rockdale Wks. G. K. Reichelt - Tennessee Oprs. J. M. Ekenes - Vancouver Oprs. W. C. Harvey - Vernon Wks. D. Fleener - Warrick Oprs. J. B. Gorss - Warrick Oprs. P. C. Scheble - Warrick Oprs. INFORMATION COPIES TO: J. E. Gunn - Wenatchee Wks. Plant Superintendents J. N. Rumble - Badin Wks. M. A. Gambill - Davenport Wks. W. K. Dalton - Lafayette Wks. G. L. McCullough - Massena Oprs. G. L. Williams - Pt. Comfort Wks. T. J. Randall - Rockdale Wks. D. W. Freeman - Tennessee Oprs.-S D. F. Simonic - Tennessee Oprs.-N D. E. Luckett - Vancouver Oprs. M. L. Redhair - Vernon Wks. A. Pearson - Xtfarrick Oprs. R. S. Grundhoefer - Warrick Oprs (Can Reclamation) E. T. Vanderheyden - Wenatchee Wks. M. J. Caprio - Pittsburgh 19 C. J. Cox - Pittsburgh 3 WPH J. W. Mclntee - Pittsburgh 3 WPH H. G. Reavis - Pittsburgh 23 E. L. Rooy - Pittsburgh 23 \ H. G. Sakoian - Pittsburgh^7___ A. J. Sartschev - Pittsburgh 3" WPH D. L. Schaffer - Pittsburgh 23 R. E. Spear - ATC, C R. E. Miller/R. G. LaBar/File: 10.320 - ATC, B ID - ATC, D A PLANT ATC Davenport Lafayette Massena Pt. Comfort Rockdale Tennessee Tifton Vancouver file MOLTEN METAL MARINITE USES IN ALCOA PLANTS INGOT CASTING 1313 -05-03 SPECIFIC APPLICATION AS REPORTED FROM PLANTS -Ingot casting items - Manufacturing Section --Variable-head distributor -float #2 -DC -pit -Float -'18X50 and 18X60-DC-molds -Float --12X48, -16X50,-16X43 DC molds -Float -- Flow - control -iDC --casting -unit -Float --J 24X72 -ingots J#9 -DC -'pit ^-Trough-Plug - pouring troughs --Support - DC pits --Trough dam - pouring troughs -Trough dam - 503 and 528 filter boxes -Skim stick - DC pits --Float - DC pits '-Float support - DC pits -Blinder - DC pits -(Marinite board) Doorframe insulation on melting holding furnaces and -Casting tools -Insulator - part for chip melter, side bay -Headers (sanding of Marinite headers in mold shop) -Float used for HDC sheet ingot tooling, 30 complex, level flow control, cast units -Miscellaneous Marinite: Spare parts for 30 complex; insulators; inserts; bearing housings; couplings; covers; etc. -Basins for HDC casting -Pre-cut Marinite for molten metal casting -HDC headers - South Plant -DC casting floats and spouts -Headers (Note: ceramic molds replace 2/3 of Marinite heads at present time.) PLANT Vernon Warrick Wenatchee Page 2 SPECIFIC APPLICATION AS REPORTED FROM PLANTS -Marinite board (Non-asbestos Marinite now being substituted on trial basis) -Also use asbestos rope for door seals (being replaced with ceramic) -Also use asbestos-containing block or brick -Trough liners; headers (partial substitution of plastic trough lining continues) NO REPORT HAIG G. SAKOIAN 1979 May 04/eds Second Day AGENDA 8:00 - 9:00 9:00 9:15 9:15 10:00 10:00 - 12:00 12:00 - 1:00 1:00 - 3:00 Asbestos Replacement Program J. Damiano, H.G. Sakoian, J.E. Hines Coffee Break R-680 Program J.E. Hines, W.G. Truckner, T. Fujioka, J.E Jacoby, R. Bachowski Metal Treatment Program: Objectives and Goals - R.E. Miller Status of Specific ATC Programs: - Formation and Interaction of Salts - R.D. Blackburn - Precoalescer/Coalescer - H. Yu - Freon - C.E. Eckert - Selee Ceramic Foam Filter - C.E. Ecker Lunch Metal Treatment Program (continued) and Joint Alcoa/Drexel Filtration Study R.D. Blackburn J. E. Hines n>Bw<nnui - ^r""t">ivt,^rTifci,>,yinnr; -t;~ -- PROPERTY REQUIREMENTS NOT WETTED BY MOLTEN ALUMINUM "SKULL" EASILY REMOVED NO METAL CONTAMINATION READILY MACHINED AND FABRICATED HOLDS METALS AT UNIFORM TEMPERATURE NO PREHEATING REQUIRED MAINTAINS STRENGTH AT HIGH TEMPERATURES RESISTANT TO LUBRICATING OILS ASBESTOS-FREE REFRACTORY BOARD PRODUCTS MARINITE I PYROTHERM B-2 INSURAL MARINITE C GRC PRODUCTS MARJNITE I -- THERMAL. AND PHYSICAL. PROPERTIES Physical Properties: ' 3 BuUc Density -- 736 kg/a (46 pc) Properties After Firing To: M.O. R. MPa (psi) 590*C 650*C 705C ai5*c ^290*0 (110DTP) (120D*F) (1300*F) (1500*F) ( 550*F) L- 4-52 .1655) 3-54 (513) 3-15 (456) 4-43 (643) 4.72 (685) Shrinkage V Height 4 : * Loss 4 *0-35 0-37 0.54 3.9 0.35 . 2.9 3.2 4.3 5.3 10.5 Modified "B* Immersion: Excellent PYROTHERM B-l THERMAL. AND PHYSICAL. PROPERTIES Physical Properties : Balk Density = 960 kg/in'* (60 pcf) Properties After Pirinq To: M. O.R. MPa (psi) # Shrinkage -% Weight Loss % 590*C 650*C 705*C 815C 551C (1100*F) (1200*P) (1300*F) (1500-F) (1025*F) 2.48 '-- 2.97 - 0.83 3.78 (360) (430) (120) (548) 0.02 0.02 0.00 0.00 0.53 2.9 3.5 4.1 5.5 12^1 Modified "B" Immersion: Excellent: ASBESTOS-FREE PRODUCTS Density, Kg/m3 pcf MARINITE I 736 46 MOR Rm Temp MPa Psi 705CQ300F) MPa Psi Shrinkage, 705C(1300F), % L.O.I., 705C(1300F), % 4.93 715 3.15 456 0.89 13.8 Corrosion E Handability (X103) (Strength at Heat Treatment/ Density) 4.72 736 6.4 Price/Board Ft $2.48 PYROTHERM B-2 960 60 5.93 860 3.17 460 0.04 6.4 E 3.78 960 3.9 $5.32 G Good E Excellent INSURAL 1134 70 MOLTEN METAL MARINITE contains asbestos 609 38 3.93 570 -- -- 6.44 933 2.21 320 0.32 0.43 -- 6.1 E 3.93 1134 3.5 G to E 6.44 609 10.6 $6.00 $3.69 $7.38 (header grade) EVALUATION LOCATIONS MARINITE I - ATC VERNON WENATCHEE LAFAYETTE DAVENPORT MASSENA TENNESSEE WARRICK PYROTHERM B-2 - ATC ROCKDALE BADIN DAVENPORT WENATCHEE MASSENA WARRICK TENNESSEE COMPARATIVE DATA ON CHEMFIL GRC 125/S & JOHNS-MANVILLE'S FLAT TRANSITE Technical Data Max. Service Temperature 3 Density, Kg/m Pcf Water Absorption % of Dry Weight Modulus of Rupture, MPa Psi Compressive Strength, MPa Psi Shear Strength, MPa Psi Thermal Expansion cm/cm/K in/in/F Thermal Conductivity, W/mK Btu in/hr Ft^ CHEMFIL GRC-125/S 320C(600F) 2000 125 Max. 16% 27.6 4000 69.0 10,000 2.4 Interlaminar 9.7 In-plane 350 Interlaminar 1400 In-plane 7xl0"6 12xl0~6 1 5 JOHNS-MANVILLE FLAT TRANSITS 320C(600F) 1600 100 Max. 22% 27.6 4000 82.8 12,000 24.1 3500 5xl0-6 8.6xl0-6 .9 4.5 R-680 PROGRAM INTRODUCTION PROPERTIES LAB RESEARCH a) ALLOY CHANGES b) SHEET INGOT c) WENATCHEE-BADIN 6" & 7" d) PROPER INSTALLATION & USAGE e) CLAMPING PRESSURES f) THERMAL PROFILES R-680 - IS A REFRACTORY COMPOSED PRIMIARILY OF FUSED SILICA AGGREGATE BONDED TOGETHER by a Combination of cement phases (Ca02Al203, Ca0*Al203) AND AN EXTREMELY CORROSION RESISTANT GLASS COMPRISING OXIDES OF Zn, B, Si, Ca, AND MINOR IMPURITIES. f PHYSICAL S, CHEMICAL PROPERTIES OF R-680 CERAMICS CHEMICAL ANALYSES sio2 A123 CaO B23 ZnO Na20 WT% 68.4 23.1 4.5 1.0 2.9 .24 PHYSICAL PROPERTIES Specific Gravity Bulk Density Apparent Porosity Modulus of Rupture Cold Crushing Strength SI UNITS 2480 Kg/m3 1299 Kg/m3 23% 14.5 MPa 67.6 MPa Coefficient of Linear Thermal Expansion (50C/Hr) (20-860C) in .'/in .'/C (70-1700F) in./in./F Thermal Conductivity C Room Temperature ,, on Watts -88 M-K NJ 4* XX V-*o o 1l Cl BRITISH (120 pcf) (2100 psi) (9800 psi) 6,1 hr-ft2F