Document 91bgjrXEr39ZzY96B10w6mKB6

mu F. E. MUELLER INGOT AND POWDER DIVISION PITTSBURGH OFFICE - 23 TO MEMORANDUM August 15, 1973 RE: Ref-: ASBESTOS FREE TROUGH LINING MATERIALS Memorandum, F. E. Mueller to D. R. Barch, Dated W73, Re Same Caption_________________________________________ The reference presented recommendations for the captioned which generally amounted to replacement of asbestos shorts mixtures and sawed Marinite trough linings with Johns-Manville JM375-L. Summarizing the progress made since April, of our thirteen casting plants: 5 have converted to JM375-L ij are evaluating JM375-L 3 are evaluating other non-asbestos materials 1 has converted to another non-asbestos material The table attached to the present memo shows those casting plant locations between the furnace and the mold where asbestos contain ing materials have been used and the specific progress and program to replace these materials. F. E. MUELLER FEM/mj distribution reverse side % Q ALCOA ALCOAO 000009715 ALCOA0000009716 PLANT REFRACTORY POSITION PREVIOUS ASBESTOS TYPE MATERIAL BADIN [B/T Pllter and Basin HOC Basin PDC Pots Marlnlte (contains asbestos) CRESSONA DAVENPORT B/T Furnaces B/T Furnace and filter B/T Filter and Distribution basin Distribution basin and pots [Brick and Asbestos-lumnlte ISJP or asbestos-lumnlte lAsbestos-lumnlte Asbestos-lumnlte and Marlnlte B/T Furnaces B/T Filter and basin Basin Brick and asbestos-lumnlte Olasrock and Marlnlte Olasrock and Marlnlte LAFAYETTE Ib/T Furnaces IB/T furnaoe and filter ]ta/T filter and basin Basins and FDC pots MASSENA POINT COMFORT Ib/T furnaces Ib/T furnace and filter p/T filter and basin main and. PDC._-ontt i/T furnace and filter t/T filter and basin as in ROCKDALE ROCKDALE PDR. B/T furnace and filter IPUter l/aTsi,nfsilter and basins B/T furnace and nozzles Asbestos-lumnlte and Marlnlte Asbestos-lumnlte Marlnlte Asbestos-lumnlte Marlnlte Marlnlte TENNESSEE NP None No asbestos type linings used. TENNESSEE SP VANCOUVER ;B/T furnaces and filter B/T filter and basin Basins m kmssiFilters and filter B/T filters and basin Basin and pots VERNON B/T furnaces B/T furnace and filter /T filters and basin asln and pots WARRICK WENATCHEE B/T furnaces B/T furnace and filters B/T filters and basins Basins_______________ |S-?65Uf!f!tIr and mteps (B/T filter and basin Basin Marlnlte Asbestosfflunmlte Asbestos-lumnlte H it Olasrock and asbestos-lumnlte Marlnlte Asbestos-lumnlte Marlnlte PROGRESS PROGRAM JM375-L evaluated satisfactorily at HOC drop-ins. Will evaluate JM375L In casting troughs and then PDC pots JM375-L now a stores Item. JM375-L now a stores Item Will use JM375-L as trough linings replacing asbestos shorts (JM-352) need replacement. JM375-L being used routinely with no problems. FDC pots still Marlnlte. Evaluating B/T furnace and filter. JM375-L now a stores Item replac ing asbestos shorts. Expect to go to B/T furnaces and B/T furnace and filter. Will go to Olasrock In basin and B/T filter and basin. Will substitute JM375-L for asbestos-lumnlte as trough linings need replacement. JM375 evaluated satisfactorily. JM375-L FDC pot lining being evaluated. JM375-L on order for evaluation Will use JM375-L as trough linings need replacements. Expect evaluation to approve JM375-L for PDC pot lining. Evaluate JM375-L. Filters are all brick now. Will convert remaining 50% of JM375-L evaluated, approved for trough linings to JM375-L. all lining applications Including 1DC basins. About half converted. - Will convert to JM375-L. Evaluating Thermotec Castable non-asbestos) Evaluating Thermotec Castable In Complete Thermotec Castable 1C trough. evsluatIon. Obtain and evaluate JM375-L. Obtain and evaluate R-3^0 and - R-616 for short term PDC operation. - Obtain and evaluate JM375-L R--3*0 and R-616 drop-ln trough sections Installed B/T holder and Complete R-3^0 and R-616 evaluation filter undergoing long term HDC evaluation Tried JM375-L and had some cracks Will convert to JM375-L as trough jut felt this due to water conten . linings sre replaced. V FROM PITTSBURGH PURCHASING INDUSTRIAL MATERIALS AND CHEMICALS - 19 TO Arc. Mav In, 1973 ' RE: JOHNS-MAMVILLE 3 V'\- Cement INOOlUlRPA -TOURS MANVIL1.C' - By means of Change Order No. 1, we have added John-Manvilift fs 37^1- Cement to the referenced Agreement-. ' This asbestos-free materia] is a recommended substitute ''or asbeoloa-1 nmnite in molten metal operations. . . The Johns-Man vi lie 375L can bo combir.es with Sup'-r'. a Moot: shipments out of Waukegan, Illinois; and the material is available in the following packagea: 50 lb. paper bags <* $1 .?r'/bup FOR Waii'igun, Illinois 25 lb. plastic bags @ $.?.3r*/bag FOB Waukegan, Illinois Johns-Manvilie will carry an inventory of IS ton per month for Alcoa releases. This inventory will consist solely of the material packaged in SC lb. paper bags. If > rt-r location prefers plastic bags, we suggest that you irme-'n* notify Johns- Mariville's Pittsburgh Office (Mia;-. Pat Koeyan) o'' your estimated monthly usage. M. J. CAPRIO j. MJC/lmp Distribution: R. D. Griswold - Alcoa, Tennessee H. A. Barton - Badin J. K. Chambers - Bauxite W. E. King - Cleveland T. B. Weber - Corona * A. E. Gantt - Cresaona H. P.. Bruaschke - Davenport R. C. Miessler - Lafayette G. H. Duckworth - Massena 0. E. Prontor - Alcoa. Technical Center J. V. Dri&coll - Mobile J. R. Zokaites - Point Comfort C. G. Shiring - Rockdale D. J. Fisher - Vancouver C. A. Ha-lliday - Vernon J. D. Eagan - Warrick C. J. Shank - Wenatchee F. E Mueller - Pittsburgh 23 D. R. B- rcti - Oliver Flnr.a 8 ALCOA000000971 FRO* R. G. LA BAR - ALCOA TECHNICAL CENTER ( PITTSBURGH PURCHASING INDUSTRIAL MATERIALS AND CHEMICALS - 19 TO MEMORANDUM April 12, 1973 RE: ASBESTOS-FREE TROUGH LINING J~M 379-L __________________________________________ Johns-Manvi 1 le 's J-M 37E?-L (Fiberglass-Lumnite) is an asbestosfree material recommended for the following trough lining appli cations : (a) holding furnace to molten metal treatment process. (b) downstream of molten metal treatment process in both troughs and distribution pans. Today J-M 375-L is available only on specie] manui&cLure orders and is not a warehouse item. However, because of our intent to purchase J-M 375-L, Johns-Manvilie will maintain a stock of this material at their manufacturing site in Waukegan, Illinois, for exclusive use by Alcoa. This site is the shipping point for Superex, and a freight savings may ba realized in combining shipments of Superex and J-M 375-L* To arrive at a satisfactory inventory level for J-M 375>~L at the vendox*'s site-, we request each plant to forward to my attention their estimated monthly usage of this material. All ingot plant personnel have been alerted on the use of this material by Mr. F. E. Mueller's letter of April li, 1973* In order to expedite the availability of J-M 37i?-L, your estimated usage is requested by May 1, 1973 M. J. CAPRI0 MJC/lmp DISTRIBUTION: See Page 2 y.st-i-M ALCOAOOOOOQ9718 1 Memorandum April 12, 1973 Page 2 DISTRIBUTION: R. D. Griawold - Alcoa., Tennessee H. A. Barton. - Badin A. E. Gantt - Cressona. H. P. Bruescbke - Davenport R. G. Miessler - Lafayette . G. H. Duckworth - Massena ' 0. E. Proctor - Alcoa Technical Center J. R. Zokaites - foint Comfort ' C. G Shiring r- Rockdale D. J. Fisher - Vancouver C. A. Halliday - Vernon J. D. Eagan - Warrick. C. J. Shank - Men&tchee H. A. Wolff - Suriname Aluminum Comp&nj . D. R. Barch - Pittstorglx, Oliver Plaza 8 C. J, Cox/R. E. Albrecht - Pittsburgh, Oliver Plaza 8 F. E. Mueller - Pittaburgh, 23 J. Z, Nelson - Pittsburgh, Oliver Plaza 7 A. J. Sar-tsehev - Pittsburgh, Oliver Plaza 7 R. G. LaBar - Alcoa Technical Center / / AlCqa ooo0 097l, I MESSRS----T-a onmagy/B. p. CARTER - PITTSBURGH 7 FROM D. R. BARCH ' PITTSBURGH OFFICE R. G. LaBAR ALCOA TECHNICAL CENTER ' T0 MEMORANDUM April 27, 1973 RE: RECOMMENDATIONS FOR TROUGH LINING INSTALLATION Ref: Memorandum, F. E. Mueller & D. R. Barch, "Asbestos Free Trough Lining Materials," April 4, 1973 This memo provides recommendations for preparation, installation, in-service care, and precautions for asbestos free trough lining materials outlined by Mueller and Barch. Recommendations for Preparation and Installation A. Melter to Holder Castables (2 in. minimum thickness): Alcoa C-l, Wahlcast SJP, Kastolite 30, Alfrax 28A, alternatively fused-silica castables (Glasrock 840, Silfrax ARC, Thermosil 120, H-W Visil). 1. Use manufacturer's recommended water addition for pouring. Mix thoroughly, preferably in a cement mixer. 2. Use plywood forms coated with oil, grease, polyethylene sheet stapled to forms. 3. For best results tack weld expanded metal mesh liner (2.5 diamond mesh lathing) to inside of trough. Liner should be 1/2 to 1 in. from inside of trough surface. 4. Post-casting procedure: a. Cover casting with plastic sheet for 24 hours. b. Dry casting in air for 24 hours. c. Castables should be heated slowly to 600F prior to use, preferably overnight. Caution: Avoid flame impingement and rapid heatup. 5. Coatings are recommended, especially for high Mg alloys. Recommended coatings are: Plistix 900 (add sufficient water for wash coating). Brick: Coral P or Chas. Taylor 12054 a. Use 85% alumina phosphate bonded mortar. b. Standard practice for refractory brick installation a i rnA ALCOA0000009720 SF49C l*CV Memorandum April 27, 1973 Page Two B Holder to Molten Metal Treatment Process Moldables (2 in. minimum thickness): JM-375L, JM-375L + JM-460 (50-50 mixture), alternatively fused-silica castables (refer to A above). 1. Avoid excessive water. Use approximately 75-100% by weight to form a soft ball in hand consistency. 2. May be hand tamped and trowel finished or tamped around a form. 3. For best results use expanded metal mesh liner as in item A-3 above. 4. Post forming procedure: Follow same schedule as outlined in item A-4 above. 5. Coatings recommended: J-M Cerakote Plistix 900 (wash coat) C. Downstream of Filters (both trough and distributor) Moldables (1-2 in. thickness): JM-375L, JM-375L + JM460 (50-50 mixture). 1. Follow same procedure as outlined in B above. Drop-In Liners: Glasrock foam (50 pcf) 1. Follow manufacturer's recommended installation and coating procedures. Alternatively a wash coat of Plistix 900 could be used instead of manufacturer's recommended coating. In Service Care 1. Avoid excessive preheating. If preheating is necessary, apply uniform heat, avoiding hot spots and direct flame impingement. 2. Avoid mechanical abuse. a. Install protective caps over linings near tap spouts. b. Lift skulls by hand, minimize scraping and/or gouging. 3. Extra care is required when installing dams in drop-in liners to avoid breakage. Recommend use of ceramic fiber paper (Fiberfrax, Cerapaper, etc.) gasketing around dams and joints. ALCOAOOOOOQ972 Memorandum April 27, 1973 Page Three 4. A program of scheduled inspection and maintenance should be implemented. It is recognized that individual plant differences exist in trough usage and design, but it has been concluded that these differences can be taken care of if made known and discussed. The ingot plant metallurgists are requested to inform F. E. Mueller of contacts with various vendors and receipt of sample materials. In addition, brief feedback on plant experiences, either pro or con, with the recommended materials are requested. New materials and/or revised procedures for installation and use will be added to the list as they develop. D. R. BARCH R. G LaBAR RGL:sh cc: TID M. J. Caprio - Pittsburgh 19 F. E. Mueller - Pittsburgh J. Z. Nelson/A. J. Sartschev - Pittsburgh Oliver Plaza R. E. Albrecht - Pittsburgh Oliver Plaza C. J. Cox - Pittsburgh Oliver Plaza R. W. Wrenn/J. A. Dunbar - Pittsburgh 23 T. B. Bonney/R. P. Carter - Pittsburgh 7 V. W. Rieke - Pittsburgh 24 J. H. Mudge - Badin R. C. Hinkle - Badin R. L. Givens - Badin J. H. Baugh - Badin C. T. Barger - Badin W. E. Goza - Badin R. C. Ashurst - Cressona B. J. Axelsson - Cressona R. B. Hanson - Cressona N. 0. Kraft - Cressona E. J. Schafer - Cressona D. D. August - Davenport L. D. Dunlap - Davenport R. P. Dieffenbach - Davenport R. J. Reitz - Davenport J. W. Mclntee - Davenport J. D. Yerger - Davenport ALCOA0000009722 Memorandum April 27, 1973 Page Pour cc (Cont.) W. G. Allen - Lafayette W. K. Dalton - Lafayette J.- B. Dolan - Lafayette P. M. Tomalin/J. E. Jacoby - Lafayette F. R. Knox - Lafayette J. J. Hicks - Logans Ferry W. D. Helmick - Logans Ferry G. B. Campbell - Massena R. W. Knapp - Massena G. H. Lantz - Massena B. A. Schafer - Massena J. N. Rumble - Pt. Comfort C. L. Green - Pt. Comfort D. N. Harvey - Pt. Comfort R. A. Molsberger - Pt. Comfort R. M. Rose - Pt. Comfort T. J. Randall - Rockdale B. M. Stamer - Rockdale W. R. Smith - Rockdale G. L. Paolino - Rockdale R. E. Aungst - Tennessee L. L. Held - Tennessee J. C. Vergho - Tennessee J. N. Lehigh - Tennessee R. L. Dearstone - Tennessee D. E. Luckett - Tennessee C. R. Windbigler - Tennessee B. R. Hood/E. L. Rooy - Tennessee H. F. Godges - Vancouver P. F. Woodward - Vancouver L. J. Sullivan - Vancouver A. M. Shanks - Vancouver M. Scherbak - Vancouver W. C. Harvey - Vernon J. R. Jones - Vernon L. F. Hughes - Vernon R. J. Stokwisz - Vernon M. L. West - Warrick R. L. Parsons - Warrick J. A. McCune - Warrick B. Anderson - Warrick M. l. Redhair - Warrick N. L. Lawson - Warrick C. R. Seltzer - Wenatchee J. A. Thompson - Wenatchee K. A. Isaksen - Wenatchee J. L. McKinstry - Wenatchee J. E. Gunn - Wenatchee R. C. Studley - Wenatchee W. P. Helsley - Suriname 0. R. Gonsalves - Suriname N. L. Sundaram - Suriname J. R. Herrick - ATC R. J. Ormesher - ATC C. R. Howie - ATC L. Resch - ATC R. Bachowski/G. Ponzani - AT R. E. Spear/G. K. Turnbull S Div. File 12B10319 !1 / cc: A. F. Malort, Corona & R. H. Allen, Corona (5/29/73) ALCOAOOOOOQ9723 / FROM.Ft E. MUELLER ' INGOT AND POWDER DIVISION "PITTSBURGH OFFICE - 23 FILE COPY T0 MEMORANDUM April 6, 1973 RE: Ref: ASBESTOS-FREE TROUGH LINING MATERIALS r F. E. Mueller and D. R. Barch to Memorandum, 4/4/73, Re Same Caption The referenced memorandum presented recommendations for asbestos free materials in trough lining applications. These recommen dations were agreed upon at a March 21, meeting of ATC and Pittsburgh personnel wherein plant and ATC development programs were also discussed. Table I reveals the present materials being used at each of our production plants, and it is readily evident that we are presently deeply involved in asbestos usage. Also shown in Table I are the asbestos free materials either already under investigation or being proposed for investigation at the plants. It is encouraging to note that the recommended JM-375L is already being considered by half of the. plants. Unfortunately, Table I also reveals that some plants have: 1) spent "X amount" of time, effort, or money on evaluation of previously known unsuitable materials 2) unsuitably evaluated suitable materials 3) are investigating materials totally unknown to both ATC and Pittsburgh To minimize the possibility of misdirected effort, the review at the above meeting covered those materials either previously or presently being evaluated at ATC. These materials are shown in Table II. These materials fall into the four natural categories as shown. Comparative data are shown, where available, and continuing work at ATC will provide the lacking and additional data from the following areas of investigation: 1) R-340 and R-6l6 - Basic data shown In Table II. These materials show great promise but are presently in the development stage at one plant (Warrick) working with ATC. A small plant will be contacted to simultaneously evaluate these materials under a development program as smaller plants do not have the same service requirements as Warrick. 2) Consolidated Ceramic Products - Moldable Mix #3924 ATC will evaluate this material in cooperation with Vernon Works, but this material is still to be considered in. the research stage. 3) General further refinement of: a) Vacuum formed drop-in trough liners from Foseco and Babcock & Wilcox. b) Various materials such as Kast-O-lite 30, Mandoseal, JM-375L, coatings, mortars, and installation procedures. c) Refractory resistance to salt penetration. H ALCOA ALCOAO 000009724 Memorandum April 6, 1973 Page Two The ingot plant metallurgists are requested to inform this office of contacts with various vendors and receipt of sample materials. In addition, brief feedback on plant experiences, either pro or con, with the recommended materials are requested. F. E. MUELLER FEM/mj cc : M. J. Caprio - Pittsburgh Office (19) J. Z. Nelson/A. J. Sartschev - Pittsburgh, Oliver Plaza C. J. Cox/R. E. Albrecht - Pittsburgh, Oliver Plaza D. R. Barch - Pittsburgh, Oliver Plaza R. E. Spear/G. K. Turnbull - ATC C. R. Howle/R. G. LaBar - ATC R. W. Wrenn/J. A. Dunbar - Pittsburgh Office (23) G. L. Paolino - Rockdale Operations D. E. Luckett - Tennessee Operations C. R. Windbigler - Tennessee Operations M. Scherbak - Vancouver Operations R. J. Stokwisz - Vernon Operations M. L. Redhair - Warrick Operations J. E. Gunn - Wenatchee Operations 0. R. Gonsalves - Suriname Operations C. T. Barger, Jr. - Badin Operations R. P. Dieffenbach - Davenport Operations F. R. Knox - Lafayette Operations G. B. Campbell - Massena Operations R. A. Molsberger - Pt. Comfort Operations R. L. Givens - Badin Operations B. J. Axelsson - Cressona Operations L. D. Dunlap - Davenport Operations W. G. Allen - Lafayette Operations J. R. Herrick - ATC B. A. Schafer - Massena Operations D. N. Harvey - Pt. Comfort Operations W. R. Smith - Rockdale Operations J. N. Lehigh - Tennessee Operations A. M. Shanks - Vancouver Operations L. F. Hughes - Vernon Operations B. Anderson - Warrick Operations K. A. Isaksen - Wenatchee Operations ALCOAO 00000972 PLANT TROUGH LINING MATERIALS ' TABLE I PLANT BADIN PRESENTLY USED MATERIALS Castable before filters Glasrock after filters Some marinite and some asbestos-lumnite PRESENTLY EVALUATING MATERIALS Johns-Manvllle 3751 CRESSONA High-alumina brick, castable and : asbestos-lumnite before filters. ' Asbestos-lumnite or marinite I after filters i JM-375 and JM-A60 \ on order j j DAVENPORT LAFAYETTE MASSENA ' Brick or castable before filters 1 Glasrock and marinite after ; filters. ' Asbestos-lumnite 11 * JM-375 and JM-lf60 ' Asbestos-lumnite before filters. ; Marinite after filters. JM-375 and JM-H60 .' POINT COMFORT ROCKDALE : Marinite ; Asbestos-lumnite . converting to JM-375 across . the board. Fused silica found unsatisfactory. Evaluated JM-375, JM-460 and Karchrome. Found all equal. TENNESSEE 1 Glasrock NORTH PLANT Thermotec TENNESSEE ' Marinite SOUTH PLANT R-340 Thermotec material in DC trough. Glasrock failed at tap-hole VANCOUVER : Asbestos-lumnite Glasrock, JM-375 Fibrefrax or Kaowool to replace asbestos filters. VERNON ....... ........ WARRICK Asbestos-lumnite Consolidated Ceramic products #3921l-Moldable mix -......... ..............- - -...... -- i - -............................ ........... - - Marinite R-340 and R-616 WENATCHEE Asbestos-lumnite Marinite JM-lt60 ^-All plants have been notified to request JM-375L ALCOAO 000009726 /' TABU II \'j ^ TYPE Pre-Cast Drop In " flAJ^RIAL R-340 (REG.) R-340 (Poaa) AIL TEST RESULTS 72 HR 8 CUP 7071 IMMERSION Exc Exc (not teated) R-616 (Puaed Sue ExC Slllca-CA2S) " Glaarock Poan Ca'e table Mix Eest-o-llta 30 Good *' Holdablea Glaarock 840 (Coarae Puaed Silica CA25) Glaarock 620 (Fine Puaed Sllica-CA29) Lo-X (Tool Grade) Cood Good Cood 811 Prax ARC**** JM-460 (Hlnaral wool eodluu-ellleate binder) Exc. Good Cood Cood DENSITY 95 60 88 60 m 110 ns (34) dry ASMsros-fwe tkouch him SERVICE TEST RESULTS prisevt qm UNIT UNN OR PER LB Holten natal contact axe, strength-fair No. 4 trough $22.48/ft. In uaa at ATC, Arnold Holten natal contact axe, strength-fair No 4 trough $14.20/ft.** ' Molten meal contact exc, etrength-good No. 4 trough $15.00/ft. (met ba coated) In uaa at Tannaaaao etrength-good No. 4 trough $22.S0/rt. Llnlted experience eo data. 1.1875/lb. Molten natal contact - good etrength-exc. Molten meet contact-good etrength-exc. $.157/lb. Holten mtal contact-good etrength-exc. $.244/lb. Molten mtal contact-good etrength-exc. .57/lb. . Holten netal contact-good atrangth-axc. .325/lb. High ehrlnkage on curing $.125/lb. 1 JM-375 (Hl-teup glaaa flbara Portland cenent Bentonite) Exc. (40) dry $.12S/lb. " JM-375L (Hl-ttap glaaa Exc. flbara - luamlte cenent) Satlafactory $.123/lb. ** Vacuun Formd Drop In Trough Secttone LDS (Flberfrax colloidal Poor alllca) Piberfrex - colloidal alllca Poor Poor wear raalacanee etrength-poor $1. 50-2.00/lb. (Originally for nonalualnuB applications. Moleen mtal contact-OK If coated acrength-poor Available aa pre-cast trough llnera In 18 or 24 In. lengtha ceat to Alcoa i tandard apeclflcatlona. "Internally calculated on bull of denelty not aunufacturer'# quota. **Approxlmtely equal to $l900/ft for No. 4 trough. "Equivalent to G*iarock 620 or 04O. I COHHtHClAl. 5CWC5 Therno-Matarlala* Atlanta Georgia 811 Baaa Co.* Hunhall, Pa. Glaarock Producta A. P. Groan Glaarock Produeto Atlanta, Georgia Glaarock Producta Atlanta, Georgia Pryor-Glggy Co. Carborundun Johns-Manvl1la Johnsonvilla Johna-Manvl1la Thenaotec BP6oWaoco . * REMARKS In dav. taata at Warrick In roe. taata at ATC In dav. taata at Warrick In uaa at Tannaaaaa So roe. taata at ATC Coaraa aggragata should not ba uaad downetraao of flitore. Raqulraa a Plyatlx >00 or Cere-coat coating. Expensive Equivalent ta Glaarock 820 Expensive Curing shrinkage la unaeceptably large Portland cauant laaa affective chan llMlt*. Beat all around non-eebestoa trough lining naterlal at thla tine. Price la for a noo-eluntnun application Under rea. teata at ATC. ALCOAO 0 0 0 0 0 9 7 2 7 FROM F. E. MUELLER D. R. BARCH PITTSBURGH OFFICE TO MEMORANDUM April *, 1973 RE: ASBESTOS FREE TROUGH LINING MATERIALS A meeting concerning the captioned was held on March 21, attended by representatives from: Melting and Ingot Casting Division, ATC; Pittsburgh Mechanical Engineering; Pittsburgh Ingot and Powder Division; and Pittsburgh Purchasing Department. The objectives of the meeting were to: 1) Discuss which asbestos-free materials have worked satisfactorily in the plants. 2) Review which asbestos-free materials have been or are being investigated at ATC. 3) Arrive at a recommendation of materials for the plants to replace asbestos-containing material in troughing applications right now. Recognizing that asbestos-containing materials are used in many other Alcoa and Ingot Division applications such as pot linings, furnace linings, and headers, by definition the only concern of the above meeting was related to: a) Troughing between melters and holders. b) Troughing between furnaces and molten metal treatment processes. c) Troughing between molten metal treatment processes and molds--this includes the distributors and FDC pot linings. 'J Elimination of asbestos containing materials for other applications will be covered by related but separate programs. Information on objectives 1) and 2) above will be distributed by separate memorandum, however, summarizing this information, those present at this meeting agreed on the following recommendations . for objective 3): A. Melter to holder Recommended: Coated^- castable (Cl or SJP) Brick (coral P or Chas. Taylor 1205*1*2) 3 Preferred alternate: Coated fused silica castable 2 B. Holder to Molten Metal Treatment Process Recommended: Coated^ JM-375L Preferred alternate: ALCOA Coated^ fused silica castables 2 r4se (av ALCOAOOOOOQ9 728 I Memorandum Page Three April 4, 1973 cc: J. H. Mudge - Badin Operations R. C. Ashurst - Cressona Operations D. D. August - Davenport Operations W. K. Dalton - Lafayette Operations G. H. Lantz - Massena Operations J. N. Rumble - Pt. Comfort Operations T. J. Randall - Rockdale Operations R. E. Aungst - Tennessee Operations L. L. Held - Tennessee Operations H. P. Godges - Vancouver Operations W. C. Harvey - Vernon Operations M. L. West - Warrick Operations C. R. Seltzer - Wenatchee Operations W. P. Helsley - Suriname Operations R. C. Hinkle - Badin Operations N. 0. Kraft - Cressona Operations R. J. Reitz - Davenport Operations J. B. Dolan - Lafayette Operations J. J. Hicks - Logans Perry Operations R. W. Knapp - Massena Operations C. L. Green - Pt. Comfort Operations B. M. Starner - Rockdale Operations J. C. Vergho - Tennessee Operations P. F. Woodward - Vancouver Operations J. R. Jones - Vernon Operations R. L. Parsons - Warrick Operations J. A. Thompson - Wenatchee Operations R. L. Givens - Badin Operations J. H. Baugh - Badin Operations B. J. Axelsson - Cressona Operations R. B. Hanson - Cressona Operations L. D. Dunlap - Davenport Operations J. W. Mclntee - Davenport Operations W. G. Allen - Lafayette Operations J. R. Herrick - ATC R. J. Ormesher - ATC B. A. Schafer - Massena Operations D. N. Harvey - Pt. Comfort Operations W. R. Smith - Rockdale Operations J. N. Lehigh - Tennessee Operations R. L. Dearstone - Tennessee Operations L. J. Sullivan - Vancouver Operations A. M. Shanks - Vancouver Operations L. F. Hughes - Vernon Operations J. A. McCune - Warrick Operations B. Anderson - Warrick Operations K. A. Isaksen - Wenatchee Operations J. L. McKlnstry - Wenatchee Operations C. T. Barger - Badin Operations R. P. Dieffenbach - Davenport Operations F. R. Knox - Lafayette Operations G. B. Campbell - Massena Operations Memorandum April 4, 1973 Page Four cc: R. A. Molsberger - Pt. Comfort Operations G. L. Paolino - Rockdale Operations D. E. Luckett - Tennessee Operations C. R. Wlndbigler - Tennessee Operations M. .Scherbak - Vancouver Operations R. J. Stokwisz - Vernon Operations M. L. Redhair - Warrick Operations J. E. Gunn - Wenatchee Operations O. R. Gonsalves - Suriname Operations B. R. Hood/E. L. Rooy - Tennessee Operations N. L. Lawson - Warrick Operations R. C. Studley - Wenatchee Operations . N. L. Sundaram - Suriname Operations . W. E. Goza - Badin Operations ' E. J. Schafer - Cressona Operations J. D. Yerger - Davenport Operations P. M. Tomalin/J. E. Jacoby - Lafayette Operations W. D. Helmick - Logans Ferry Operations R. M. Rose - Pt. Comfort Operations M. J. Caprio - Pittsburgh Office (19) J. Z. Nelson/A. J. Sartschev - Oliver Plaza, Pittsburgh R. E. Albrecht - Pittsburgh, Oliver Plaza C. J. Cox - Pittsburgh, Oliver Plaza R. W. Wrenn/J. A. Dunbar - Pittsburgh Office (23) T. B. Bonnev/R. P. Carter - Pittsburgh Office (7)________ V. W. Rieke - Pittsburgh Office (24) R. E. Spear/G. K. Turnbull - ATC C. R. Howle/R. G. LaBar - ATC ALCOAO 000009730 Memorandum April 4, 1973 Page Two C. Downstream of Filters (Both trough and distributor) Recommended: Coated^ JM-375L Preferred alternate: Coated^ Glasrock foam These recommendations pertain to materials which have been found to be suitable, practical, available, and asbestos free. Shortly following issuance of this memorandum, Pittsburgh Engineering and ATC will issue a Joint memo with recommendations for preparation, installation, in-service care, and precautions for each of the above recommended materials. The ingot plants are to begin programs for orderly replacement of all asbestos containing trough materials with the above recommended materials bearing in mind that on July 1, 1976, the present OSHA asbestos dust exposure limit becomes even tighter. If any plant finds restrictions to their use of these recommended materials for these applications, they are specifically requested to contact any one of the following in this order: D. R. Barch - Pittsburgh Mechanical Engineering F. E. Mueller - Pittsburgh Ingot and Powder Division R. G. LaBar - ATC It is recognized that individual plant differences exist in trough usage and design, but it has been concluded that these differences can be taken care of if made known and discussed. F. E. MUELLER D. R. BARCH FEM/DRB/mJ distribution page three Refractory coating and/or mortar should be Plystix 900. 2Glasrock 820 and 840, Thermosll 120 and TG, or Sllfrax ARC. ALCOAO 000009731