Document DDreDMzep9a0YqMkzM6mXjgp5

i \ l L r1 Mr. J. H. Thomas, Toledo R. ?. Shannon, Granville gAYLO PRODUCT DE7EL0PKE2JT October 23. 1967 , Hr* K. J. McEvoy, Granville PI Pfeifer sent ns word last week you wanted to talk about the 'replacement of asbestos* program. I atteispted to oontaet you several tines last week, plus on Monday of this week, without suooess* As you know, I was in Berlin all of last week working on in-plant process problems* To follow-up on your request to move promptly en the evaluation ef epoxy coated PVberglas yarns, ?i Pfeifer asked Bob Wong -for help in getting for us a supply of sueh yarns for our evaluation in aylo. As soon as the Chemistry Lab produces the yarns for us, we will evaluate in Kaylo and send you the results* /. - . 1, . The epoxy coated yams reported recently as being uaad to good advantage in cement are in reality 12 end rovings coated with eposy resin to form miniature 'fishing1 rods. They are quite stiff, about the else of tooth picks and about 1-1/2 to 3 Inches long. Hr, McEvoy agreed to qy aooompany- tng Hr. Potts, of FIM Division in Hew York, to Rensselaer Polyteohnio Institute on Wednesday, October 25,. to discuss the concept with Professor ELiok, the inventor. _ . .. . " . .. .. ........._ The program directed toward replacing asbestos in Keylo is complicated by (l) the huge investment we have in the SID cylinder pen pouring process et Berlin, (2; the need for additional plant capacity and (3) problems which oust be answered as to type of process to use in the new facilitybefore mansion Is undertaken. Questions to be answered include * U do ve expand Berlin .(901 now in Toledo) or do we build a new plant awi \Z) if we build a new plant, do we Install the SID cylinder pan pouring process or another prooeas yet to be determined? I cannot say at tha moment with any assurance we will be suooessful In developing another type of reinforcement, preferably glass, whioh can be adapted to the SID cylinder pan pouring process* The best odds I can project at the moment are 50/50* In any case, the problem won't be solved in a week or month. In fact, we will be lucky to carry the .program to a plant trial stage after a year's effort. ' . In view of the feat the probability of finding another reinforcement, which can be used in our present process, is at the best 50/50, do we also direct some of our effort toward a new prooess and if so, what process? At the moment there are go high temperature insulations on the market whioh do not contain at least seme asbestos. To the best of our knowledge, the only asbestos free product en the market in recent years was OCF's Multitemp. Do we attempt to improve Multitemp? ify answer would be no. The Multitemp eoneept of post impregnating a prebonded product wasiill conceived. It does not land Itself to adequate profit margins. PLAINTIFF'S EXHIBIT 01 022 1468 Mr. J. H- Thoi -2- Oetober 23, 1967 Instead, if the decision is to develop & produet booed on glass fibers, I would recommend we work on on inorganic bonded gloss fiber composite, which eon be produced is o one-atep operation, possibly via o modified Torsion of the filter press proas##. - .' * *' / r* * V# must not forgot the bonded aggregate type product. Carqyteoy is o - bonded perlite reinforced with glass ond asbestos fibers. If Philip Carey could solve their breakage problem, Coreyteap would become the best high temperature product on the market/ X believe an OCF version of such a product containing 100 percent glass reinforpeaent would have a high prob ability of success. As you know, this is the program which Marketing canceled on us year after year in the past. How that I have given you a brief insight as to my thoughts as to where we go from here, X would like to suggest for your consideration the follow ing program. Initiate a hard hitting Intensive search for a fiber substitute for asbestos. The effort should be directed mainly toward glass fibers. We should not, however, dose our eyep to other oeramio fibers, which become commercially available in the/meantime. We should also initiate an exploratory program directed toward checking the feasibility of develops ing a glass reinforced bonded aggregate or an inorganic bonded high temperature glass fiber product (Multitemp via a different process). Tour first thoughts to the above may be we are spreading our activity too much. We should instead decide on one program. Under ordinary circumstances X would agree with the idea of concentrating on one approach. However, ve must recognize the fact that if we direct all our efforts toward finding a substitute for asbestos snd if not successful, we could find ourselves with two plants (Berlin snd tbs new one to be built) equipped with s prooess requiring asbestos. On the other hand, If the decision is not to continue looking for a substitute for asbestos, but start to develop a bonded aggregate or high temperature glass fiber (a la Multitemp) product, we are giving a death eentenee to Berlin, the SID cylinder prooess and tbs hugs invsstmsnt in the pan pouring process. A.so, ve will faee an eutlay of 6 to 10 million Just to revamp Berlin to the new process. What are the chanoes of technical success* X would guesstimate 50/50 of replacing asbestos in the pan pouring prooess, 90 percent for a glass reinforced bonded aggregate product and about 80 percent for a one-step prooess Multitemp type product having a 30+ percent gross margin. What really bothers as is timing. To oarry out any type of progxmm ve will need manpower and facilities. At the moment I am down to two technicians and about 1/2 the space allocated to Kaylo prior to 1964, when all research on Kaylo was term!nsted at Granville. Two of our three available autoclaves are in storage for lack of space. 01 022 i469 Mr. J. H. Thomas -3- Octobsr 23, 196? At the momant wo ars attoa^ting to tiro la on tho laprorsd stross corrosion formulations to bo pourod aftor Hovoabor 13 An a Supply of 2399 glass bocomas arailablo and prorido aa *uoh toohnl nal sorrioo to Borlin at tint cad manpower will'permit. Our manpower situation is becoming critical. Tho rocruiting program for new people is batting taro.- As for additional spaos* no arc working with Trod Swank and Xko 1{]r*rs ' A 901 will probably bo roquirod to prorido tho space *e need, - If you haro tho timo arailaHe Thursday when you ease to Granrille, I would liko to haro tho opportunity of discussing this program with you. HFS/rie R. ? Shannon