Document 70KjdogGL6QGYozon0v1egnNe
FILE NAME Corning OC
DATE 1962 Mar
DOC OC184
DOCUMENT DESCRIPTION Internal Report - Kaylo Improvement Program Progress Report - Pgs 7,9,13,15
KAYLe O e IMPaROIMVPROVEMEENT IMPMROVEMENET NTPROGRAM JANUARY - FEBRUARY - MARCH 1962
PITdEuston
38
CONTENTS
Glass Fibers
2. Stresa Corrosion
3 Formulation Studies
Core Material
5. Bonded Aggregates 6 Raw Materials
7. Impact Machine
8. 9
10 - 11 - 120 -130
140
36 Pouring Devics
Increase Opening Between Core and Shell - " Molds Kaylo Alumimun
Two Layer High Temperature Pipe Insulation Reduce or Eliminate Dust on Kaylo Elook
Boiler Insulation
Process Shrinkage
OTe eee
39
1. GLASS FIBERS
a Coatings
for glass fibers
proce s Some of
of various types have been tried for a protective covering to reduce or eliminate attrition through the autoclave these tried by General Research are
1 VinylChloridPleasticol -a Excellent but is high in chlorideandis cocstlyostly
2
- VinylVinyl
Acetate
er eee
55 Coating disappeared during process -
fiber attack
3
Urea Formaldehyde - Urac 180 - Coating disappeared but
fiber appeared to be in good condition No adhesion to
Kayloo
4 Shell Expory 828 - Trace of ooating left after processing
Fiber appeared in good condition High cost
5 6
DoDwow Polyetene - PS2 - Resin disappeared
may havebeen absorbed by the Kaylo
Being thermoplastic
*
Melenine Melmac 405- Same results no 3 formaldehyde
7 HiSlightlyPhenolic PhenPheo nPolhil ceni olc icMMonsanto oMonnssanatonto1013 - Excellent results
8
475 Novolak Type Phenolic
Novolak compcaomparedrTeyped to Phen Tybon o Tybl on Pi henolic c 5418
5418 compared to Tybon
Acme
- Poor results when
compared 5418 Dick .
9
- Phenolic Copolymer - Newark Plant - Poor results when
with with
Tyben Tyben
with Tyben
10
Melamine - Phenolic
Copolymer - Newark Flast - Poor results when compared with
Tybon 16 .
11
General
Mille
Folvasid Hot Folvasid Hot Folvasid
Melt
-
Resin
absorbed
away
fiberintoKaylo matmrix atrix durinpgrocess Fiber appeared
good condition
from
in from
The following specification was set for a coating that gave the best results and which was low in chloride content It was Tybon 5418 Phenolic Resin American < Marlatta at 62 solids It was used on K75 1/0 yarn at
636 size with 40 nominal ignition loss with 35-45 rango There are approximately four 4 beads of length
There were various runs cade with variations in percent of coating ranging from 38.5 to 57 chopped lengths at 1-1 to "
~~ce
The main reasons for using Tybon 5418 Phenolic Resin are
1 2 3 4 5
Lower cost
Survival of autoclaving process
Low chloride content
Beading ability Good adherence to Kaylo body
b Teet runs were made with various formulations that are designed for different percentages of coated fibers which gave a similar variance in glass percentages different types of fiberal multiple lengths of fiberst pouring method variances In the January tests the vinyl chloride coated fibers gave superior test results to any of the phenolic fibers Some of the fibers coatings etc. used are
1 2 3 4 5 6
7
Vinyl chloride - 2 length Phenolic 1-3 length Phenolic - 1-1 length Combinations of 2 and 3 Haldron opened W3 amosite astestos Continations of vinyl chloride and Waldron W3 asbestoso
Continations of Phenolic Resin and Waldron
W3 amonite
opened opened
Runs using above variations of coated glass fibers and dry milled opened W3 amosite were made using different designs of the 36 pouring device The presence of air holes and slip planes formed by clogging of the nozzle at too frequent intervals was the main defect and was the technical problem to be overc033
.
A combination of %% opened amosite % chrysotile and % vinyl coated
glass fiber for a total of 21 of fiber gave maximum of eight 8 drops
an average of 5.8 and 6.8 drops The orientation of the fiber was good
The 36 Bauer Mill was redesigned for a dry mill basis for opening
W3 and other anosite and chrysotile grades of asbestos Various types of coated fibers were used both phenolic and vinyl The vinyl coating gave a more pliable glass fiber which resulted in less clogging of the pouring nozzles than was experienced from the stiff phenolic covering Vinyl coated glass fibers were used in many of the February and early Maroh test
trials These results are summarized
1 It was found that a
least 15 based on batch weight
plus coated glass fiber produced
results
fiber content of 18 to 20 of which at was dry rilled opened amosite or atosite a significant increase in the drop test
2 Although resistance to breakage in the drop test was markedly increased by the inclusion of 5 to 73 of phenolic coated fiber these amounts of the stiff fiber contributed to forming difficulties that resulted in a
poorly consolidated body and low modulus of rupture values The ware was
generally unacceptable in spite of rather high drop test ralms
/
3 The inclusion of 0.5 vinyl coated
noticeable effect on the drop test values
was easily observed in the
This
product
fiber resulted in no
amount of vinyl fiber
arosite 4 Bauer Milled opened amosite
proved satisfactory as arosite opened by Waldron
to be as
Newark
equipment or by the shredder at
5 The inclusion of % of sodium
millify the effect of chloride
silicate in the batch to
resulted in no advereo
ion resulting from the vinyl coated
effects process or product vica
fiber
6 Cores out method of
drops than similar ware
pouring gave on an average of 1.3 more
poured with the cores in '
c
and Grand cent used
Shipments of various test runs
Rapids The New
were made to Granville
in these shipmenteOrlwaesatna ware was returned to Berlin
New The
Orleans equip-
1 2 3 4
Granville - Commercial LTL truck
Freight New Orleans - Car load
Return to Berlin -
R.R.
Acme
Fast
Commercial LTL truck
Grand Rapids - Commercial LTL truck
Abuce in transit varied in manner of equipment rather than distance
1 Granville Sone abuse - horizontal loading of some cartons
/
ovidence of other material loaded on cartons
C
C
C
C
C
2 New Orleans Not too much
no evidence of
damage - R.R. Car condition good -
by droppingo horizontal loading - some end damage to cartone
3
New Orleans 2 return to Berlint Terrific
shipment - cartons on side other
abuse on LTL
top - cartons palletized and
heavy material loaded on
cutting into cartons and
metal straps pulled tight
cracking ware
4
_
large Grand Rapids Cartons loaded
had considerable damage LTL
on side -
shipment
size 12 x 1-1
In the Granville New Orleans and
were damaged out of 1134 pieces
return to Berlin
for a total 52.8
shipped which included
The results ware
shipments 599 pieces
competitors ware
1 2 3 4 5
Carey = Highest damage
Kaylo standard production second highest damage Hansville Glass fiber reinforcements in all Sprout Waldron opened W3 amosite pfeirbceerntages and
variables
81.5 81.5
60.8
56.5 *
47.15 47.15
5.6 5.6
|
76.5 On these shipments there was
damaged 15.5 to New Orleans
% of total ware shipped to
return from New Orleans
To size defective
Granville to Berlin
x
x x
1-1
12 x 1-1
153
211
187
24
24
-- ----
4 0 n "
25.5 35.35
31.29
400x
400 %
599 pcso
100
.
Total pieces shipped were 1134
The ware shipped to Grand Rapids was loaded
horizontally at some
trucking terminal after leaving Berlin
year marks
The cartons
on both sides of cartons
very definitely showed
the later formulation in
use
Improvement was noted This ware had 36 Bauer Hill breakagevise on
asbestos in the formulation and phenolic coated
opened dry w
vare after inspection out of the total size shippgeldass fibers Damaged
6^ 1
1705X 1705X
..
Following was the percentage of defective half
related to the total of all half
sections by size as
sections damaged
1-1 68.15
8 x 1-1
8.5
6x2
14.9
.
4x1
8.5
This last table records the
of
total
half
sections
damaged inspected
half
sections
as
related
to
size
12 x 1-1 x 1-1 x
4x1 4x1 4x1
25.0 3,1 5.5 3.1
This LTL shipment to Grand
exceptionally heavy abuse
Rapide eventhough most of the ware suffered
by being borizontally loaded some place
reflected the improvement made formulation
enroute
ments were made
wise since the first three
to Granville New Orleans and Berlin
ship-
UIE
A d A Kaylo Product Improvement
York Tuesday March 20 1962. It
Committee Meeting was held in New
formulation would be placed in
was agreed there that the improved
1962 and it was
The
production at
36 Bauer Mill
the
Berlin
Plant
on March 21
y
dry milled anoeite and other asbestos was moved into position for dumping
Sufficient vinyl coated glass 1/25 in formulation W3
fiber
directly into the hydropulper
was recured from Anderson to place
10.5 pcf
The dust amountopened acosite was included The donsity was
was temporarily designated at 500
set at
amount could be had and maintained from
lbs if this
has continued in production with the
present finishing lines The plant
Some problems were encountered
least to the point where
but
tahobsoevehaovuetlibneeend first phase formulation
mostly overcome at
the vinyl coated
they are not in a major classification classification
glass fibers were secured to
Cutters for
length first used
chop the fiber to the 1-1
e The General Research
committee to proceed
Laboratory personnel were
glass fibers that woulads quickly as possible to discover
instructed by a coating for
the
1 2 3
4
Be less costly than vinyl chloride
Have the same or additional flexibilciotayting
Contain less chloride
Have a rapid drying rate
f The objectives of the
Kaylo batch are
program of using coated glass fibers in
are
for
1 Discontinue the use of screening purposes replacing
the present coated glass them with glass waste
fibers
which
2 Reduce the
general product's waste present glass fiber cost by utilizing textile or
;
.
3 glass waste to
4 by 3 and dry
in Through a
where it
series
of choppers
cutters
shredders
is sized suitable for inclusion
process
Kaylo slurry
Design equipment necessary to coat glass fibers
for immediate use
as prepared
5 3 and 4
Utilize the glass fiber waste at Barrington
Plant
for use at Berlin If more tonnage needed
through
to
source with lowest freight cost for shipment to Bgeorlin next
use of
Fiberglas
6 Determine the
gives the highest number
optimum length of coated glass fibers which
most handling abuse
of drops
before
greatest
impact resistance results
takes
cracking or breaking
7 Ascertain improvements in K
coated glass fibers affect this
factor if varied percentages of
property
44
20 STRESS CORROSION a:
a
Sales has need for a calcium silicate
product with a lower than
competitors measurable chloride
sulation for use in
content to be the leader in beat in-
combating stress corrosion
or vessele when such attack is
on stainless steel pipe
particularly sea water
aggravated by the presence of moisture
b Sales Research and
Testing groupe had a
personnel regarding acceptance of OCF's
meeting with DuPont
of Dr. Fontana of Ohio State
measurements together with these
end
products
regarding ppm
particularly pipe
of chloride
present in Xaylo
these measurements as
covering DuPont's poeple did not accept
would be acceptable
such However DuPont personnel did state that Kaylo
in
the
form
of
as
sodium
a
heat
insulation
for
stainless
steel
if an inhibitor
silicate were present
c It is an academic
follow along with Duport
question whether or not other custocers would
thought
that
they
would
representatives stand of Kaylo acceptance It is
which would include Carbide Chemicals Monsanto
Dow Shell and other It would at least give Sales an
present strong argumente in favor of low
opportunity to
chloride content of Kaylo
d There are two
DuPont people insisted
ways to add be added
the
inhibitor
sodium silicate
that
1 Introduce it into the batch at
through the process There will
this can be a
probably be
measurable variable is not yet
of
the misting stage and follow
some attrition result known
Whether
2 It can be added as a
by either spraying or
dipping
coating
before
to ID - OD - Ends and side
edges
slight overtrin to preserve the
wrapping If applied as a coating a
Also a study on drying needs
dimensional stability may need to be made
for coated material before must determine the method and equipment needed
canvas is applied if such is
necessary
e Some companies Carbide
Placite 7122 on all stainless stCeheelmibceaflosreincluded use a material called
including Kaylo The
insulating with materials
it costs 0.50 a
upper temperature limit is only 482 degreed F and
sq ft applied and R bond which is now
as X Bond has a temperature limit of 2000
designated
application cost of less than
degrees F. It should have an
of 18-20 minutes We
0.50 per sq ft However it has a pot life
that
feel this OCF distributed K Bond material has
is tooubetwemiadgeh wthheethdeirsadavaGnutnangiete of the relatively short pot life
advantagee
A study
spray may be used with the 20 minute pot life
f Salee will want all material sent to these
chloride content This whether
customers to be of a low
stainless steel
they the customers intend to use it on
be
or other applications It is reasoned that there
to abenyplqauceesdtio on n osftahiunmlaenssfailure if only one type of insulation iscanpnroetsent
as a batch
Therefore it is planned to include sodium silicate
component so as to have this inhibitor in all Kaylo end products
_
.
.
: ;
.
;
45
g The Navy specifications call for
with Benjasin Foster 57
covering all stainless steel
coating before insulation is applied Here
again samples of OC K Bond should be submitted for trial
along with Keylo insulation after sodium silicate has
purposes
cessfully in the batch as a stress
been placed suc
corrosion inhibitor
h content
A different grade of chrysotile asbestor has been adopted as a standard batch
of lower
chloride
lovers the overall chloride contoat of Kaylo hemaatteirnisaullatTihoins naturally
1 Arrangements have been cade with the
chlorido tests in their their
Barrington Plant to conduct
end
laboratory of Berlin's Berlin's production
product chloride determination and the
This is an
chloride content
purpose is to check daily
The
stability once it is established established at the lowest
sampling method is to be devised and set
ppx possible
Laboratories
up by General Research and Testing
j Dufont currently approves the
steel applications and
following insulations for
causing stress - corrosisotnatecsratchkaitngthese products are relatively
stainless
free of
1 2 3 4
Unibeatos - 1200 .
Carcy Temp - 275 max Foam Glass - 300 mas Rigid urethane foam - 150
max
ae
k In a report issund 3/2/62 N. A. Lotz stated
the insulation and maintenance
Mr. J. Roy Allen i
Services Department and is
painting consultant in DuPont's Engineering
Practices
also chairman of DuPont's DuPont's Thermal Insulation
Committeso Mr. Allen told us that the
cators do not like to work with
majority of DuPont's appli-
Cares Temp is limited to
Unibestos due to its poor handleability
starts to lose its
275 because the silicone treatment treatment in Carey Temp
water repellency characteristic at
Fosa glasa le limited to
F
F
It is
approximately 275
applications
but
Mr.
Allen
stated
primarily used on low temperature
that his experience has shown that urethane
lia less expensive on an applied basis
Wishes
Mr. Allen in W. A. Lotz's raport
to get approval for Kaylo we could
stated that
if Oveno Corning
solium silicate by weight This
probably probably do so by adding %
approach This approach approach would undoubtedly
aporate without tests undoubtedly usimmediate without
requirior
approach would would would
Mr. Allen
undoubtedly undoubtedly undoubtedly undoubtedly get
ust a sodium silicate inhibitor rather rather
strongly recommendoi that we
water rapellent
than attempt to make our product
Ee also ggested that we consider
of the stainless steel and the
dripping water on the interface
be is concerned that
Carey Carey Temp to simulate field conditions as
this test procedure procedure as used
applicable to penwicking materials such
by DuPont is not completely
as Carey Temp
1 Sodium silicate glass "rr powdered can be
solution # in batch 10L 1 x 7 without without
substituted for sodium silicate
on the mixing floor or
adverse effect on consistency either
on the pouring line Laboratory tests indicate
that
a significant reduction in consistency can be
sodium silicate will remain an inactive inactive
expeted since the powdered
to autoclaving
ingredient in the batch until subject
46 07-
C
4
(:
ot
DuPont charges as much as 3:58 cents core per pound solids for the
powder delivered to Berlin Sodium silicate solution delivered to Berlin
<3.60 centa per lb Sodium silicate powder delivered to Berlin is 7.18 cents per pound Above from R. F. Shannon's letter to R. C. Amos dated
3/27/620
a The basic sodium silicate is produced at Grasselli New Jersoy
by Dufout General Research Laboratory is to conduct a test to determine whether or not these basic sodium silicate chunks can be run through a
Bauer Mill and ground sufficiently fine for incorporation into the Kaylo batch This should produce even lover delivery costs to Berlin
n Tests are to be run at Berlin to produce samples for DuPont to check test and appraise the week of April 2 1962
o It is reported that Mr. Allen has retracted his inference that if % codium silicate were placed in Kaylo batch that immediate approval could be secured without testing These samples are to be subcitted but will have to undergo a six months testing application period before acceptance is forthcoming as an approved ingulation meterial relatively
free from chlorides that cause corrosion cracking on stainless steel
3. FORMULATION FORMULATION ee STUDIES
a Fast standard 10 light density batch was geared to 300 Various problems of dust delivery have been overcome Formulation have made it possible to use additional amounts of dust
of dust changes
This dust amount was increased to 500 per batch on March 26
which is the maximum the system can continuously deliver and there are
times when no dust at all is available the weigh hopper is to be increased
to 750 capacity An additional blower is to be procured for the increased
dust capacity in the 15 mimite delivery cycle required installation should be completed after blower delivery
The equipment
the week of May 1962
b It is probable at 500-600 dust per batch that this amount will not be available continuously from scalping kerfing and trim operations It may then be necessary to install grinding equipment which would reduce all Kaylo processed offware to dust for inclusion in batch
c Sharples Corporation recommends their model P2000 Horizontal Seeper Center for conversion of 70,000 Ibs of slurry per day having a solids ratio of about 20 to one having a constant and definite colids ratio of about 6. An experiment of this treatment of waste alurry will be made by the Sharples Corporation on April 18 1952. This equipment will handle all of the waste alurry and remove the variability of solids now encountered when placed in batch This test will be followed with diligence for favorable
result
B
wes
ee
a
7
| :
47
--
~
.
we vee
ce
EB
ee gen - net ag rte
oo . d Read Standard a Division of Capital Products Incorporated located at York Pennsylvania had a representative call at the plant and we discussed various projects with him One that they expressed immediate interest in was concentration control of waste slurry for water solids They produce a device for thickening sludge and upgrading alurries A sample was sent to thes of waste slurry at a water solids ratio of 4313. They will attempt to reduce it to a 7-10 to 1 ratio
e The grinding of dust through the wet process of the 18 Bauer Mill on a .025 setting was set as a standard procedure Where and when nec-
essary this is coupled with the wat milling of asbestos fibers at the same plate settings
f Dry Milling of amoeite asbestos has been successfully dry mill plates of devil tooth
fibers - W3 and AW as well accomplished The plant is design The W3 amosite and
as 47-3 Lake using the 36
other acosite
and chrysotile fibers are being successfully opened without length attrition Some changes in physical location of the Bauer Mill were made for direct
introduction of opened asbestos fibers into hydropulper An unloading of asbestos bag equipment and a subsequent feeding conveyor into charge aide of Pauer Mill are now being designed by General Engineering Increased strength and resistance to impact was secured by this dry willing method It was adopted as the standard procedure of milling of asbestos fibers on
March 21 1952
g The dry milling of asbestos makes it mandatory that all Retestond
C Retsond be stored under roof crowded raw material
and kept dry
space but it
This poses a problem in an already
must be done to secure the benefite
C of the procedure at
. h x factor tests are to be run at General Testing Laboratory on
present production which has additives still incorporated for a lover K
,
factor result Tests will also be made on samples with additives removed
If K factor holds on non additive specimens the additives will be removed
for K factor is now competitively stable This will result in a lower cost
per batch and increased strength as reflected in the modulus of rupture
1 The production formulation as of March 21 1962 is at 10.5 pcf The / for this brief period seems to be satisfactory well above minimum in Kaylo CAS for 10 light density After a at bilizing period it is
planned to reduce density still further without any deteriorating effects
on 10 light density product quality
5 Quicklime was sistency in 17 core
standard formulation KEH
substituted for hydrated lime giving a higher conmaterial After some trials it was adopted as the It reduced the drip loss damage and the offvare for
The prehardening of 17 core material is to be tried during week of April 16 at Berlin using the colloidal oilica made at the Granville
Research Laboratory Conmercial Ludor purchased from Dupont has been tried
and the results were successful The 17 core material was
}
preburdened
f
me
a
-
amern
-
emny
Fae
tar
2?
mete
The cost was far too high The cost of the prehardening agent made at Granville is much less However the present plant 17 core formulation using quickline in giving the plant improved operating results and lover offware Unless this formulation is directly responsible for proved blows in Roddia door manufacturing procesess the 17 core material will not be prehardened with the agent necessary to speed up the chemical reaction being added This will keep the cost of producing 17 core material at
a lower bass
The results of this prehardening test run will be kept for future use if needed the same with the procesa procedures for making as developed by the General Research group
1 The present production formulation has been subjected to a temperature of 1200 degrees F. for 96 hours on the hot pipe tester at Berlin This contains 0.5 of coated vinyl glass fiber Further tests are to be conducted at once to determine whether the maxious temperature of serviceability for 10 light density can be increased to 1500 degrees Fo
4. CORE MATERIAL
a A meeting was held January 245 with Roddis Division personnel of the Weyerhaeuser Company and General Research and Sales regarding possibilities of mutually developing a 1-1 hour rated fire door Another desire vas to
bave a low cost door with a 3/4 hour fire rating About 100 degrees increase
in temperature on cold side of door would be needed At one hour presentincrease
rating the temperature is from 1700 to 1750 degrees F. The weakness in present
one hour fire doors is the salts impregnated wood rails To reach 1-1 hours
advancement in fire resistance of this wood must be securedo
,
b The R and R bond fire retarding agent has
resistance This work of
oocent which is now known as K Bond a good chance of increasing the range development is to continue as rapidly
being a good
of fire
as possible
c It should be the concern of all interested OCF parties to make any improvements resulting in a 1-1 fire rated door a proprietary process or product rather than one mutually ahared with one customer only
d Roddis Division of Weyerhaeuser Company has been granted permission by Underwriters Laboratory to substitute 17 for 20 core material for
use in one hour B label doors 17 core material has been sent to Roddis
for their 20 core
trials Roddia is still in stock for
now receiving 17 core
them at Berlin
material
except
for
0 Curtis Companies Inc. saw a fire test at Forest Products Lab at Madison Wisconsin that was successful Kopper's treated styles and rails with salts impregnation to 3 to 4 lbs were used A change from standard Kaylo door assembly vas made Two pieces nominal 24 x 36 were used on top rather than standard 12 x 18 and 18 x 36 However temperature on cold side 8 30 minutes was 190 For Roddis at Underwriters it was 156
49
-10-
Curtis Companies made up five doors
February 6 7 and 8 for tests
at New London
on glue wheel with hand
at Underwriters Lab in
glued by hand
placed clampe and one 1 assembled
placed clamps in horizontal
vare made under inspection of Underwriters
positions on table
These
to Chicago on February 9 1962
Underwriters inspector They were shipped
Curtis Companies had a fire test
March 8 1962. It failed
at Underwriters
the door and
to pass because the fire somehow
ignited the cold side
stood up perfectly The stiles and
From Jin Bearons
woll At
rails however did
the
door
approximately
knob
40
minutes
fazes
started
about
and the top of the door
half way between
of the door ignited This was the
Slowly but surely the whole face
minutes the face started to burn
north door On the south door at 45
It worked its way down the
at the upper right hand door know
bour At the end
whole side The test continued
corner
burned off
of the hour the face cold side
through the
the north door and the face
was almost completely
door When they hit it with the
was burned half way off the south
Kaylo and the door north
30 lb. pressure of the fire hose the
half of the
door
completely disappeared disappeared
the
south door about
This was a disappointment to
first test at Madison was very successful
ran
into
everyone everyone concerned Although the some problem with fire the second
Curtis
test
Curtis intends to
test made in the near
go back
future
through
Underwriters
Lab again and
have
another
f Young Door Company at Sunbury
intent to mamifacture a one hour
Fennsylvania have the desire and
using 17 as March 1 1962
the
and
mineral 17
core
rated Class B wood
material
They set a
face fire door
target date of
Sunbury Plant
where
core material was shipped from Berlin to experimental door manufacture was to
their
plan to test these doors at an eastern
begin They
acceptance test at Underwriters Lab in lCahbiocraatgoory before going for an
has g General
rejection at
Research been asked by the Plant on the
Roddis to try to develop a sonic device
basis of alab
for
leading to blowa in bot
Research
press wood fire door manufacturing
detection of defoots
people are evaluating the sonic
manufacturing processes The
mont
This report
is
set
for
April 30
concept 1962
for
practicality
for
develop-
h It is planned to make porating coated glass fibers in s1 oc7 e eaxnpderiemveanltuaatle trial runs in April incor-
results
war his
5. BONDED AGGREXATES AGGREXATES
a United Clay Hines Corporation in February stated
that they had developed a high temperature bonded aggregate does not crack on drying with 12 x 12 samples They had values in excess of 110 pai at 13.5 lb. density They have
to R. F. Shannon product that secured /
submitted these
samples to OCF for evaluation They are filing patenta on this product I and C Division have indicated they are interested in following this develop-
pent J. B. Dennis of United Clay has stated that if we do not take the
product they will go to JM tho have indicated they want it
b
mixture
It was proposed several of Kaylo dust and Ludox
months It is
ago
now
that trials be made on a pressed
proposed that such a mixture
be strengthened by the addition of coated glass fibers of randoa lengths
if necessaryo
c A combination of Zeosil which is an ultra fins precipitated silicoaluminate compound with lime asbestos and water has on small lab semple tests given good strengths when dried at 8 hours at 150 Zecsil is very
reactive with Cab It is manufactured by the J. M. Haber Corporation
Grace Maryland It is planned to try tests of our own during the week of April 92 at Granville This offers another lead for a autoclaved
product .
d The necessity for a autoclaved high temperature heat insulation
product is post pronounced for the foreign markets such as Nexico South Africa and Australia The autoclaved product if strengthened with noncoated glass fibers particularly of waste derivative would be of inmense
value to foreign subsidiaries of Corning The cost of remixing pressing and drying equipment with as few molds as necessary would greatly reduce the investment cost for getting into production A good top grade product could give Carey Teap real competition If the cost can be lowered and this
passed on to the custoser this has all of the ear marks of a
leador General
We intent to keep pressing on
Research group at Granville
this development
work
real with
industry
the
6. RAW MATERIALS
a Rice sized 34 pebble lime produced by National Gypsum is yet to be evaluated at General Research Laboratory
and
b
the
Zoosil has prospects as a prehardening agent for 17
possible source of silica for a autoclaved calcium
material This is a J.M. Huber product Tests are to be made
core material silicate
in April
a Caddo Tripoli of Glenwood Arkansas produced by Collinson is in production on 200 and 325 och material
a cource for a second supply vendor if caterial and price
Baker and This may afford
are assfactory
-12-
a
|
51
lon
d Manville expects to be in production of a new type for them of diatomaceous earth sometime in the fourth quarter of 1962. There is reason to believe that the deposit is in New Mexico This material may be satisfactory as a second source of diatomaceous earth and cost and freight will probably be competitive to other suppliers such as Picher
Long fibered amosite particularly 43 has been opened by dry Bauer Hilling on the 36 mill Trial formulation runs have indicated that a
superior product results giving added strength and increased resistance to impact and abuse
There is not sufficient W3 anosite available in the now required tonnages since it was substituted for like amounts of chrysotile asbestos The AW on band will be used but this grade is in short supply also A k3 grade of amosite is to be trial teated at the Ganeral Research Laboratory and if successful trial tested in several production runs in the plant It is anticipated that this grade of amogite will be acceptable for mbstitution since it was 80 successfully tested several years ago This should be completed by April 20 and General Purchasing then can contract for the X3 grade of cosite
7. IMPACT MACHINE
The General Testing Laboratory has completed the development building calibrating in foot pounds and testing of the requested impact machine
As soon as the test data has been analyzed and the machine declared
by the General Testing Laboratory to be ready for plant Quality Control
tests for impact measurements it will upon request from the planbte
Bont to Berlin Another machine is to be built and kept in the General Testing Lab for correlation of results with Barlin Quality Control Department This detail should be handled in April
Z
8. 36 POURING DEVICE
a Additional changes have been made to the 36 pouring device The pouring technique has demonstrated that a successful operation can be expected on 1-1 minimum thickness sizes where the opening is sufficient to allow coated glass fiber to pass through the mold filling alot without clogging and causing slip planes and air holes Design must be secured to allow the filling of the device to be in proportion to the size of the nozzle opening and this to be variable and controllable Engineering and Design application is to be followed closely to successfully complete this device Preliminary tests have indicated that slip planes air holes and pouring folds can be oliminated if the nozzle velocity is not too great and no
,
clogging is had
9. INCREASE OF OPENING BETWEEN CORE AND SHELL ON " HOLDS
a The use of dry milled opmed asbestos fibers as well as coated
glass Mibers has resulted in more clogging roping and balling of these
fibers in the transmission lines valves and pouring nozzles Opened
Sew amosite clogging is nozzle in areas of regulating valves
glass fibers particularly the hard coated phenolic ones have a to clog at the pouring nozzle
Coated
tendency
It is an advantage to have the pouring nozzle to reduce such clogging to a minimum This point experienced on the limited use of the trials with
as large as possible is true also as a 36 pouring device
b Costs are to be procured from an outside shop for the trimming
of cores on the 1 thickness colds of pipe covering to a minimum of 1/8
This will increase the opening in the hand pouring nozzles By utilizing
a thinner but stronger metal for nozzle fabrication additional opening
can be secured over and above this 1/8
.
o The plant is to proceed as soon as possible to open this slot on several flights of x 1 molde These are to be placed into production to see if the 8th remaining lip is sufficient to secure good stripping Based upon these and other trial results the decision will be made whether
or not to trim back the 1 cor860
100
KAYLO
nPe e ,
a Alumimm
A sample from Coustics presently furnished aluminum entoased jacket for Kaylo was reported by them to be full hard Alcoa Aluminum This statement was suspect upon examination of the material
The sample was sent for checking to the metallurgist at Alcoa Tennessee Laboratory for Alcoa and the result wass
1 2 3 4
3003 alloy H154 temper
Hardness between 1/2 114 and 3/4 Was not 18 or full bard tempar
116
The present alusimm Jacket is oomewhat harder than the first stacks of aluminum from which the first months of Kaylo Jackets were supplied It is not as hard as M's plain aluminum jacket It does not have the spring that 4's alumimum jacket has
It will be determined at once whether or not the embossing can be done on 818 or full temper It will further be determined what degree of embossing penetration can be had from Alcoa
It was stated some months ago that the H14 full bard temper could
not be embossed This statement will be checked for accuracy
-14
53
11. TWO LAYER HIGH TEMPERATURE PIPE INSULATIO
if a Work will be done at once to determin
a layer high
tseecmtpieornatuorfe pipe insulation can be developed by placing an " or 1-1
Kaylo inside a similar thickness of Fiberglas oesented into
place and producing good handling results with correct nesting and fit
12. REDUCE ORELIMINADTUSET ON KAYLO BLOCK
a The Kaylo audit held on that the light density block have reduced or eliminated
January 23 1962 carried the the dustiness of the packaged
recommendation
product
b The material to do this is Ludox This can be diluted with water
and a light spray be directed on one or both sides This with one side
sprayed greatly reduces the dust With both sides sprayed the dust is
practically eliminated General Engineering and Research are
efforts to design the equipment needed for
combining
application and drying after
application if tests prove this is necessary to avoid mildew attack in
high humidity and temperature conditions particularly in storage before
field application
13. BOILER INSULATION
a Sales is desirous also of having an insulation that could be applied to boilers by impaling upon fastened sharp points in a manner similar to mineral wool We will explore the possibilities of developing
such a product and make trial tests of those formulations showing promiss promiss b Product Testing Laboratories issued on February 12"a report
stating that there was no apparent degradation of any samples returned
from field service
- 1 Kaylo block 30 months on 630 outdoor Dowthern tank at
Monsanto at Nitro water stained
-
2 Kaylo curved block - 10 years at 550 - A cylinder at
OCP Plant Berlin
Erie Michigan between
3 Kaylo block - double layer = 10 years at 600 on duct economizer inlet header on & W Boiler - Justin R. Whiting Plant
4
air duct test
R. B. boiler
Kaylo poured
block - double layer - 1-1 years at at Segoo Wilsonville 2 unit - & Wooal
600 on secondary
Wooal fired
54