Document B91gLkYvj59Gn0eZDGqo3wQX

FILE NAME Corning OC DATE 1967 Apr 26 DOC OC193 DOCUMENT DESCRIPTION Report RE Kaylo with Confidential Stamp Mr. J. Kirry 1. Y. Stamnca FourHILIARY FourHILIARY FourHILIARY Owens This document document or any parts of it should not be to others wiwithout thcoouptied nornor divulged divulged permission of CCoornrinnging Fiberglas Corporation April 26 2267 Mr. D. Y. Pfeifer Contral Files Iast work you asked us to prepare for you a brief status repart covering the Kyle Product Developoprionprte directed toward replac asi ben stg os in Keylo Dua to a ombination of factfoactrorss factors this program is falling sombat behind sabodule We have attempted to merate vithin the badget I and C allocated to Rs ^ robar of roquarta from I and C and mai^ repairs to the SID gylinder not planted or bagsted for the first quarter cousunod a cobres cobres tial portion of the budget budget We ran maly 310 in the red on Kyle Product Development S4035 during the first quarter 9.399 9.399 in the black for the overall Kayle program including that sponsored by Yanufacturing portion of our I and C 1 obstantial ponsored badget time and varpower res speat on 1 ) the parchice and testing of capotitive insulations requested by Del Ledd 2 various activities related to the production and cortification of the stress corrosion betch defect in February approximately tikdag and block tikdag and program est by fedosky and Kevlia ) melting drying end grinding of over to tous of 2339 glass at Granville f^r um la maxfacturing of stress corrosiva ST3 pipe for the test market program Lovlix 4 plant trials to produce approximately 20,000 pounds of stress corrosion product for test marketing and 5 for expenditures for repairs to the 3D gyliates Swank and Schilling to charge repairs against project project In addition to the probless of ties mumpovar and planned progres and requests from I and C Ferksting va bave also beca dove for ^,st of the last mix vocks due to series of moobasicel breakdowns of the a SI cylinder For the replacemat of adestost progtrheeks ey survival of fibers through the SD cylinder bea the SID is dora so ere vo, At the motrat so hire a mostantial backlog of fibers and Alber treatmts to be evaluated as room es the SID cyli agn aladboe nomr as sparational estimated fyril 27 or 28 b expletion of repairs All calaiza silicate insulations on the market are reinforced t^ Good arbestos Atosios fibars are low cost and resistant is alkali they do not bell ty or braaidova during riding riding they provide unvallart ry informing charestaristics to the cagedte cagedte and have mallet shoda Good to olatum millastes Deir only possible drur book involves a health ^', Karard wevewoald wate wma a Iron 4th all the above advantages of asbestos in Lavay murl t ^o z a colination of grades and fiber lengths to achieve the overall strengths and handlesid required to the long fibored andito arbustes t cy ~~ a 4 oe eh Ate SP wera! Oa Oy bad Ate . - ; aod ata ry * wots POP oo Ba?i:SES i SEbOe ate v* n.ae : a0 cieele it Aa ue s e a 3 ae : - : . . I STENvTevTt . so, ee te ? - Wo. he ant en cate + ARE A SEDAN . one one and aa GB ONES ne ee wae Aes wo Mr. J. Hebry ale April 26 1967 a s _. te el oe on provide provide impet fleural and tensile chart fibered drysstile bestos to strength in the prodort Va top and inorasca mustension of Inarta provide processing la ratios datering during On the batch and to allinto allinto crecking drying in fiber length or years to be found that eva a slight variation characteristics and processing percentage of bed bed of Lyle materially affects strengths glraesasstaably owe 7 J | Mace the first of the ~ . . , priced fiber year va have survomed just ebost we could flod irolating organie every roshvool carinda and . products The first step paremad many of our an textils of our staly has been to dotemdos vhatbor @ fiber is resistant to alkali present in calcium silleata sjected to the pressures and batch ' ww texperatures of the Layo W a het . our standard glass roving products bepaale and saremo fibers failed to rockwool as well as only natal fibers alkali survive autoslaring To date resistant glass 5 fibers leached plaze6 survive the autoelara overal orgando fibers including cotton Yotal fibers rejected ability and favbraircaation fabrriecjateiocntedAlblrosotrgoasnioof their aireras efforts on hands- rejected Fibern umopt prorecjeesctsedbutYansyhrionrkganinic vfiisbeertshusinclating heap and beegxetstsoon svuarrveivealtsohe comporictompoerite providing no relaforsemat to th Tids Leares just four alessee of . of replacing astogios in Kayla fibers which have any probability They inalads sotion aball glassee Lesobed Reframil I glass and redistant ised glass possibly resin trusted or bara problem the momost is all four of the above listed at to be bara som Khiob provide the Peplace the short suitable forreplacinrg eplacing ampsite abertos ocnllyiatmhoaseof strength fibered Ya hors not found to dete boy ^ berte chrysotile arbestos in myle batch suber of attents have bons I atlatl rodistant rodistant delayed delayed fed with made to fabricateinto cation all into pipe and black 8 alkali gets gets all rose the into plass er all losabed Cucks during in products produced bylin Strengths ditaized hairline sofied those fibers which showed vers very lov 15 eart tibestos with a smill parocstage of chrystile point has progress started to bare SID cyllater palms mally in propres actostos was wond to replace the 15-20 d Lyle l's exgarable to standard our Kaylo vore ch^'alond progress has boca ra held dirse rare fe : . eeu ue tt et as ae ms ne Se omy er ot . ( cma nf 0s tel > Voge ae str) -t 3 aos rs sy re Me 2) oo oe oe ~ - Jostewe that ad 2 SS ASAT hoe +t ey i .s : te Ee - ' . . 2 . ; ee ADS tbe Annee ADD Ta NEES BP. et fr. SY TS PE Gas IPTC PPK Le W OL Le PEL ee SEE Ieee CDP SIO SOLS TBS ALLYSoA go ee eee OE a 1 eS eee -{ - | fo 2 barits the status of this progres ve have not found to date a * . mivinual mivinual fiber which can be used to replace both amuita and shrysotile . i arbastos in kayla Es here at least three and possibly four plazone of fibers which chov prosive of repleting andita abestos To nih } stitutes for chrysotile asbestos fobou ca n foud nd La soon is the SID cylinder again becases opal ples containing ome estion alkall rodistant gliss and leschod 3 Fafraal glass in oxblostis vith chrysotile 15estos vill be poured and rudeditted to Product Testing for evaluation Yajor emphasis during the next coveral months vill also be placed on finding a mibstitute for obrysotile dart . wa ee oe oer memes 273/718 nvy 1. Sheznos rw mee el ate ee + Seyqenpe, era eens ens xo OE Be Pre et ate ee 4 t SC the eye E, S olf t. ne g t5 4 | f 1 Ne t t~ Neue ue Following is a short outline and sketchy description important batch changes that favorably and adversely adversely of the end product Improvements were made to years When any changes were made away from the basic density formulation an accompanying loss of impact resulted Naturally a lower density gave lower strengths of cons cons af ected af ected affected affected affected thermal values values values Kaylo of of the the nose thethe the strength strength strength strength strength strength strength 1. 1954 Asbestos changes were made both in percentages of chrysotile : and amosite as well as types of each 1955 1955 1955 1955 No major batch changes . 1956 1956 Increased amounts of amosite asbestos grade particularly particularly particularly AAW W 1957 Introduced various additives to 10 batch to improve improve thermal conductivity curve Finally settlesettledd on limestone aanndd chromite Percentages were as high as 25 percent Finally reduced to 12 percent because of loss of strength Removed clay from batch in a deliberate attempt to make a soft Kaylo similar to 85 percent magnesium Due to low strength increased breakage replaced clay and improved end product quality Asbestos raised to 20 percent and lowered back to 13.5 percent 1958 Began use of Kenite for Celeton and had to discontinue because of uniformity of product Reduced additives in June to 9 percent to improve strength Increased asbestos in October to improve K factor 1959 Tried Kenite again for Celeton and again hahad d to remove it for was analysis variations of too great a second trial of this material for perpecrcentage entage cost cost cost saving This purposes In August cut Plant back to 5 days per weeweekk due to slack business and high inventories 00865 Raised density to 12 pcf for an improvement in strength handleability and offware Introduced Kaylo dust to 10 batch 1961 Few batch changes none major keeping strengstrength th of strength product fairly high due to customer's desire for a product in their manufacturing of fittings Began Plant operation on June 1 end hard hard hard full 1962 1962 Began introduction of coated glass fibers both phenolic and vinyl base for strength improvements and reduction of asbestos fibers Began also the use of liquid sodium silicate and dry milled amosite asbestos Removed coated glass fibers at year end _ 10. 1963 Reduced Reduced Reduced density of K10 to 11 pof Not substitutingsubstiuting changeschangcheangses substituting changes , all minor except for removal ssubsutitbutisngtituting 6D1 also chrysotile too many batch of 47 chrysotile 1964 4 . Reduced density of 10 to 10-3 pcf Experimented with powdered sodium silicate for prevention of stress corrosion along with liquid sodium silicate The latter mad madee for an improvementimprovement in surface visual appearance of pipe insulation 12. + 1965 = Substituted supersil for tripoli to 11 pcf Strengths declined Density remainremaienedd at 10-3 13. 1966 Began use of 50 percent 533 short amositeamosif te or longer fiber W3 amosite Stopped the use of powderedpowdered sodium silicate experiments Substituted 703 chrysotile for 6D chrysotile asbestos Strengths dropped Introduced several bags of 11.3 cement per batch and increased density to 11-1 / to pcf These helped to increase the strength of end product some 255