Document DGzOZ1kGvL0G1YEnDo53gOZqN

FILE NAME: Pfizer (PFIZ) DATE: 1972 Apr 17 DOC#: PFIZOIO DOCUMENT DESCRIPTION: Memo RE Problems with Donelo Co. Contract because of Asbestos FROM; SUBJECT: J. P. Bartel* R. W. Unmet DONELCO CCMPANT - TORONTO, ONTARIO DON LITTLE, MANAGER CALL 4/11/72 WITH B. K. ROURKB 1972 v w tf The Doneleo Company has a contract to apply acouaelcal material to the tunnel and atation walla of an addition to tha Toronto aubway system. The job consista of a section five allaa long with four stations. The tunnels consists of an inbound and an outbound tunnel constructed of pre-cast concreta or tubular Iron members. 180 tons of Kilnoiae have been applied to data. Tha project will re-* quire approximately 1,100 tons. Once completed, additional extentions are expected. Tha completion data on the current contract la September 1972. Two problems have developed. The first is ralaeed to the asbestos content of Kllnolse. Doneleo has temporarily satisfied the authorities by installing tarpaulin screens at both ends of each section being coated. There does not appear to be a graat deal of pressure on Dontlco to eliminate asbestos from the formulation of Kllnolse. ?or reasons ocher than the asbestos problem, it appears to be necessary to make a formulation adjustment. The Kllnolse is being used to absorb noise in the tunnels end stations. The job specification calla for a "Noise Reduction Coefficient" (NRC) of 50. . Test panels submitted by Doneleo panned tha NCR racing; however, test condi tions and actual conditions probably will not give the same results. Doneleo is concerned that Kllnolse la not performing up to minimum specification* on the job. Kilnoiae la not being applied by Pfizer's recommended procedures. Pfizer procedure ealla for Che use of a bonding agent on tha surface to be coated prior to application of Kilnoiae. No bonding agent Is being used on the job. Kilnoise should be applied to mucal lath. On this job it la applied directly to eonerata or ataal. This procedure does affect noise reduction. To improve tha noise reduction level formulations, baaed on mineral wool as a replacement of aabestos, have been made and tested. The bast effort to dato has not bean successful; however, the teat panels ware not perforated. They ware not perforated because the problem appeared to be the naed to mateh SAMPLE 15799 526 04130 s - 2- a coaoetlfciva material that d m noe require perforation. An additional teat villbe made to determine the acceptability o the minarai wool formulation whan perforated. The cutaway job la being perforated. The competitive product la made by Cafeo (a part of 0. S. Mineral Wool Company). The product la known aa Sound Shield 05. Ihla product. 1 claimed to have a BSC of 85. Doneleo and Pfiser teats indicate It ha* an BSC of 65 or better. The specification on the aubway job call for 50 or better. Sound Shield 85, therefore, ia a batter product then ie required by the aubway apcciflcation. Sound Shield 85 la aold for 8300 oar ton. It ia con sidered the beat produce of lea type on the market and ia auparlor to Kilnoiae. It ia a much let* danae material than Xllnolss. It ia poroua and haa the , appearance of a very low binder system. Kilnoiae hae the appearance of a high binder system as evidenced by a glaaalnesa on the eurfaee when examined by a magnifying glace. The Sound Shield 85 appear* "punfcy" to the touch yet passes a rather mild washability teat. The washablllty tact, which Xllnolse also passes, consists of the ability of the acoustical material to withstand a. high speed wash and rinse cycle twiee annually Co prevent dirt accumulation rad the reeultent fire hataxd. To pace the east, an acoustical produce does not have eo be "herd". A "punky" film will pass if the adhesion is OK. There la no evidence that Kilnoiae suffers adhesion problems. The wall of the tuenmU. coated with Xllnolse was attacked with a l i i without damage. Don*Ice's main business ia the application of firm retardant materials to structural materials. One of their primary suppliers ia V. R. Grace ft Company, W, R. Grace led Donelco to believe they could produce an acoustical product adequate for the Toronto subway job. Donalco bid the subway job on W. R. Grace1 estimate of price for an acoustical product. V. &. Grace could not perform. Oonaleo was loft holding the beg. They either had to uao Sound Shield 83 at $300 par ton and taka a financial loss or find a lass expensive product. Xt was ia search of a replacement that they contacted Harry Rourke. Sound Shield 85 has another disadvantage. Because of its law density it cannot be pumped and applied at the rate desired, (which Xilnoise era be). -A direct match for Sound Shield 85 ie not desirable for tble job. Another contractor working on a section of the aubwey is using Sound Shield 8 9 By about September of 1972 Donelco and tit other contractor will be vorkiagi 'towards each other to finish a section. At that tloa, the Xilnolea section and the Sound Shield section will be joined. It is faared that Che comparison of the two materials will be observed and Donelco will suffer reprisal. in summary Donelco risked bidding baaed on a non-existent produce. They have scrambled to meat chair committment and may not bo performing aa expected. Pfizer ha* supplied standard product and has performed aa expectad. The Pfizer product ie not being used as wa recommended it to ba used so there is no Pfizer exposure to liability. SAMPLE 15800 52i 04131 - 3- ahead, some incremental benefits from producing a product to meet Che .job requirements of the Toronto subway can be expected. Don Little estimates the market for Sound Shield 85 in Canada to be 2.000 tens per year. This would place the United States market at about 20.000 tens. This market Is for non-subway applications. The Canadian business has been developed, but the United States business has not. The reason is marketing strategy. In Canada the sale of Sound Shield 85 is controlled by firms specialising in acoustical application. The contractors supervise the plastering applicators. Sound Shield 85 is not sold directly to applicators. The result is good workmanship and acceptable results. Xn the United States, Sound Shield is available to anyone that wants to buy through a dealer. Application technique is shoddy; performance is un satisfactory and expensive; and repeat business does not develop. Washington, D. C. has a subway project underway. The totel system includes 47 miles of subway and stations. At least two tubes (Inbound and outbound) will be required; so in total over 100 miles will be coated with acoustical material to a thickness of 5/8 inches. This job should require over 10,000 tons of acoustical plaster. Bids have not been Issued on t h e . contract for acoustical application as yet. Barry Rourka is following this job. In view of the foregoing information, the following is recotmaended. Development work continue to formulate a product meeting the Toronto specification. Technical assistance is needed and a modest amount of money to get equipment capable of blending mineral wool and other ingredients. With a satisfactory product, a marketing strategy can be developed and other subway work pursued. It appears to me that a successful product can be developed by exploring the following: 1. Properly dispersing mineral wool in the Xilnoise circut. Xn under stand a "chopper" is required. 2. Seducing the binder (hydrated lias) to a much lower level, than in Kilnoiacfc.'- 3. Adding a hardening agent such as latex or smgnesium based reective chemicals. 4. Exploring air-entraining agenta that produce larger air bubbles to help open up the surface to allow sound absorption. SAMPLE 15801 52C 04132 4. - 4 Because of the success in Toronto of achieving good adhesion and good waahability with 11 materials evaluated, it Is likely that any formula that is lower in dry density, with an open surface and somewhat "punky" in hardness will bs satisfactory. It should be noted that the curing conditions in the Toronto subway ware miserable. The atmosphere ia cold, tha walls and ceilings damp, and the humidity high enoagh to be foggy. At this stage, the development of a 5,000 ton per yeer market appears to be possible. Pricing is not critical. Estimated cost would ba on the order of 50% C.O.G. I'll work with Mr. Stephenson ead Mr. Bailey .on e program to develop ' a product. BHl/esm 0. G. Brant H. E. Rourks W. M. Stephenson Eager w . linnett SAMPLE 15802 526 C4133