Document KR5e04N5w11JnmeBEJ7dvboKK

*<980* ' I .j . e || Product 1 _ (W Super-temp Block THE EAGLE-PICHER COMPANY INSULATION DIVISION MANUFACTURING SPECIFICATION PLANT PRODUCTION MUST FOLLOW THIS SPECIFICATION. Emergency Change may be made but shall be promptly reported to the Production Manager and may not extend beyond the Emer gency. Permanent Change must be submitted to and be approved by the Production Manager before use by any Plant. Plant__ . JO&Iin________________ Pag._ 1 . . of-----------5 tffactrv# . _ June 14. .1956 Supericdes .Spec. dated 3*^**5?_______ Revised Items__ Jhtire gpe.cificatian. Prepared By._. . A, SchJUlal . Approved: Production Mgr. PJffiiFiSSsfi'iiVi Division Mgr. I. PRODUCT DESCRIPTION 1.1 Eagle-Picber P7 Superteap Block is s dark gray mineral wool insulating block composed of Eagle-Picher Mineral Wool and suitable binding agents* The block is relatively dust free, water repellant and formed into semi-rigid rectangular shapes haring square comers and parallel faces. , PRODUCT INFORMATION ' 2.1 Density . 16 to 18 lbe./cu. ft. 2.2 Service temperature . Up to 1900 F, one face -2.3 Fire resistance Incombustible 2.4 Corrosion on steel * None 2.5 Performance 9 1900 F, one face Volumetric shrinkage Linear shrinkage Loss in weight 2.6 Compressive strength at 10? deformation 2i 2* 2!% 18 pel 2.7 Breaking strength 1* x 6* on 10* span ` 23 lbs _ 2.8 Thermal conductivity (k) in BTU in./aq. ft./hr./deg. F. 0.37 200 F M.T. 0.53 500 F M.T. 0.64 700 F M.T. 2.9 Standard Block Sites: Length f Width ` Thickness 18* and 36* ' 6* and 12* 1* thru 4* in 1/2" increments 2.10 Packages '' Cartons 2.U Net Weight per carton 63,68 and 72. lbs I y sV Supertoap 'Block' I 11 Page 2 of 5 RAW MATERIALS AND FORMULATION 3.1 Eagle-Picher Superteap Qranulated Wool . 3.2 Starch (Archer-Daniels-Midland *Adcol 105" Sorghum Starch) 3.3 Bentonite Clay - 95% min. thru 200 mesh 7ojf min. thru 300 sash FORMULATION Hff./Kg* PERCENT 180.0 1. 90.77 TT6' 2.02 11.0 5.55 3.4 Aluminum^Sulfate, powdered 3.5 Caustic Soda. Flakes - $ 2.7 1.3$ 0.6 .30 ' TOTAL 198.3 100.00 * NOTE: Weights end percentages are approximate. Slight deviations are Bade in formulation to secure proper draining of block in the vet aolding process. IV _ PROCESSING - Pressure - vacuus aolding and vet saving aethod, ' 4.1 Approrinatuly 35 gallons of water are run into the primary nix tank. Then the starch is added and cooked until the temperature of the starch solution is approximately 200 F. Constant agitation is maintained during this operation. 4.2 Sufficient water is added to bring level up to 145 gallons, day is added at- the saae tiae. Agitation is continued and ' - this portion of the nixing cycle consume approximately 1$ ainutas. This pemita clay to be adequately dispersed and * expanded. .. 4.3 One pint of caustic solution is then added. Solution is - . aade by adding 75 lbs. of caustic soda to 18$ gallons vater. Agitation is continued for at least 1$ minutes to pernit ' further expansion of clay. '. 4.4 The aluainua sulfate is then added and agitation ia continued for at least two minutes. This flocculates the clay and the six is ready for transfer to the secondary x tank. - > PV Suparteap Eloct v< Pa** 3 of 5 PROCE35IHO (Cont'd) - 4.5 Th* wool ia placed in a bopp*r which can transfer ita contents into th* eeoondary six tank. Nor*ally, small pi*o*a of acrap block and trim froa th* vat saving process are added her* to salvage the value of aaterial in them. This ia equivalent to adding approximately on* bag (30 lba) of wool. The wool and altxrry are then traniferred into th* aeoondary mix tank and water ia added to bring level up to 450 gallon* of six. A minimum of agitation ia uaed to diapers# th* six and to avoid breaking the wool fibers. 4.6 Once the six ia sufficiently agitated, it is transferred to the surge tank and is ready for the Bolding operation. The surge tank provides a ainisua of agitation and only during th* period of drawing off th* six to th* seal* box. 4.7 Th* scale box autoaatlcally Measures the adx. Apprcxiaately sister blocks are obtained froa on* xix. 4.8 Th* pressure vacuum equipment then drains th* excess water froa th* aix and molds the leai-dry master block. 4.9 Each master block is positioned on a carrier pan and is then automatically moved through th* wet sawing process to be cut to the proper width, length and thickness (Hotel The combina tion of thickness adds up to 5 indies.) 4.10 The master blocks are oheoked for diaensions and irregularities prior to loading onto drying carta. Substandard pieces are removed and fed back with the vet trim. 4.11 The blocks are dried in ovens at approximately 400 7 for 70 hohrs 4.12 After drying, the blocks are removed from the ovens and permitted to cool. t 4.13 Blocks are removed froa the carts and packaged. Pinal inspection is made just prior to inserting the blocks-into cartons. 4.14 Cartons are identified to show contents and date of packing. They are then ready to ship or be palletized and put into the warehouse. PROroCT CONTROL ' 5.1 Product control tests shall be conducted as often as is necessary to maintain the quality limits set forth in the following table but with no less* frequency than indicated. 1 ,Fr 'upertaap Block t ^ of- 5 V,. PRODOCr CONTROL (Cont*d) PROFERTT___ VALUE KIN. TEST PRE00ENCT TEST PROCEDURE 5.1.1 IXistiness Relatively free Continuous 5.1.2 Waterproofness Sheds water ,55* Production 5.1.3 5.1.^ Density - Minimum 16 lbe/cru. ft. ,5jf Production Maximum 20 lbs/cu. ft. Breaking Strength 20 9 lb. min. ave. 5% Production 1" x 6* on 10" span (None below 18 lb.) Visual . Apply water E-P 1-136a Nary 32-1-3 5.1.5 Diaenaional Tolerance Thickness + l/l6* Len. & Width * l/8" Continuous Visual and gage 5*2 Substandard material shall be set aside for disposition as directed by the plant manager* VI PACKAQINQ . t/oO 6*1 Packages shall be regular slotted cartons made froa-275"lb* test stock vlth * flute and tape closure* Standard carton sites are as follows* - , W 16" carton - 16-1/8" I 12-1/8* I 36-1/8" \ 15" carton - 15-1/8" I 12-1/8" X 36-1/8* V lk carton - 14-1/8" X 12-1/8* X 36-1/8" 6.2 Cartons shall be printed in accordance with E-P form layout D-147. The 14* cartons are plain except for "contents panel*. Colors are GCMI #21 green and. ATH-denge. 6.3 Cartons shall be filled in accordance with' the following tables* / BLOCK . - THICKNESS BD. FT. * PER CTO. CTN., SIZE APPRCH. GROSS WT. PER CTO. rtf 1",2".4*. 48 ' 16" - 74 i'2i",3" 3i" ' HLOCX thickness l1i"* 2* 21" 3" if *5 15" 42 1 14* - PIECES PER CARTON / 6 I 18 6 X 36 or A ... 64 12 X 18 32 40 \ 32 \V .. 24 \X 20 - 16 12 "VS 20 16 . -16' X8 ' 69 0( . 65 r 12 X 36 16 10 8 6 5 1 414 \ \ o'L \\ * \/1 1 f Supartesp Hook 4 J Ptp 5 5 TI. fACKAOIHO (Coat'd) Cartons shall bs elossd by gluing top and bottoau 6*5 All cartons shall bs warksd vlth a oods nuwbsr that will psrait coaplata Manufacturing idantiflcation. . 6m6 Cara or tracks shall bs lnspsctsd and any virs, nails* or other protuberances which wight tsar cartons shall be rsnorsd* Cartons shall bs suitably protected, if such haiards cannot ' bs reBored, to prevent dawi^a in transit or when opening doors at destination. - 6m7 Ibis product shall bs identified on shipping forms as "Mineral WooUttoaka in Gartnna". .. \ ^ 'j r fprod^cT . k* 5ttpqrt*ttp Block THE EAGLE -PICHER COMPANY INSULATION DIVISION MANUFACTURING SPECIFICATION PLANT PRODUCTION MUST FOLLOW THIS SPECIFICATION. Emergency Change may be made but shall be promptly reported to the Production Manager and may not extend beyond the Emer gency. Permanent Change must be submitted to and be approved by the Production Manager before use by any Plant. Plant__ . Joclin____ Page._ 1 .. of_ Effective . _ Jun* 14, ..5........ .. Supersedes Spaa, dated 3-4*52. Revised Items Jntire Specif Prepared By._. D. A. Schaaltl . _ Approved: Production Mgr. DNFjBBD'lAt ' Division I. PRODUCT DESCRIPTION 1.1 Eagle-Picber P7 Superteap Block la a dark gray Mineral wool Insulating block couponed of Eagle-Picher Kinaral Wool and suitable binding agents. The block la relatively dust free, water repellent and formed into semi-rigid rectangular shapes having square corners and parallel faces. FRODOCT INFORMATION 2.1 Density . 16 to 18 lbs./cu. ft. 2.2 Service temperature ,2.3 Fire resistance 2.4 Corrosion on steel Up to 1900 F, one face Incombustible * None 2.5 Performance 3 1900 F, one face Volumetric shrinkage Linear shrinkage Loss in weight 2.6 Compressive strength at 10jS deformation 2.7 Breaking strength 1" x 6" on 10" span ' zi 2* 2J* 18 pai 23 lb# 2.8 Thermal conductivity (k) in BTU in./aq. ft./hr./deg. F. 0.37 200 F K.T. 0.53 500 F K.T. 0.64 700 F K.T. 2.9 Standard Block Sikes: Length * Width ' Thlcknees 18" and %' 6" and 12" 1* thru 4" in 1/2" increments I f /7 Superteap 'Block I li Page 2 of 5 RAW MATERIALS AND FORMULATION MATERIAL 3.1 Eagle-Picher Supertemp Granulated Wool . 3.2 Starch (Arch*r-Dani*ls-Midiand *Adcol 105" Sorghum Stareh) 3.3 Bentonite Clay - 95% min. thru 200 mesh 70% min. thru 300 mesh fOTOATM ,/mi PERCENT 180.0 . i. 90.77 2.02 11.0 5.55 3.* Aluminua^Sulfate, powdered 3.5 Caustic Soda, Flakes - 9 2.7 ` 1.36 0.6 .30 ' ` TOTAL 198.3 100*00 * NOTE: Weights and percentages are approximate. Slight deviations ara aad* in formulation to secure proper draining of block in the wet adding process. T7.^ PROCESSING - Pressure - vacua Holding and wet sawing aethod* ' 4.1 ApproxLuatoly 35 gallons of water are run into the primary mix tank. Then the starch is added and cooked until the temperature of the starch solution is approximately 200 F. Constant agitation Is maintained during this operation. 4.2 Sufficient water is added to bring level up to 145 gallons. Clay is added at- the same time. Agitation is continued and - this portion of the mixing cycle consumes approximately 1$ minutes. This permits clay to be adequately dispersed and ' expanded. .. 4.3 One pint of caustic solution is then added. Solution is made by adding 75 lbs. of oaustic soda to 18$ gallons water. Agitation is continued for at least 1$ minutes to permit ' _ further expension of clay. ' . - 4.4 The aluminum sulfate is then added and agitation la continued for at least two minutes. This flocculates the clay and the nix is ready for transfer to the secondary mix tank. - > FT Suparteap Slock VJ Page 3 of ^ PROCESSIMP (Contd) '- 4,5 The wool is placed in a hopper which can transfer ita contents into tha saoondarj mix tank. Normally, small piaoaa of scrap block and trim from tha vat savin* procsss ara addad harm to salvage tha value of matarlal in them, This is equivalent to addin* appcroximataly ona bag (30 lbs) of wool* The wool and slurry ara than transferred into tha saoondary mix tank and water is addad to bring level up'to 450 gallons of mix, A minimum of agitation is used to disperse tha mix and to avoid breaking the wool fibers. 4*6 Once tha mix is sufficiently agitated, it is transferred to the surge tank and is ready for the molding operation. The surge tank provides a minimum of agitation and only during the period of drawing off tha mix to tha scale box* 4*7 The scale box automatically measures tha mix. Approximately 8 master blocks ara obtained from one mix* 4.8 The pressure vacuum equipment then drains the excess water from the mix and molds the semi-dry master block. 4.9 Each master block is positioned on a carrier pan and is then automatically moved through the wet sawing prooeaa to be cut to the proper width, length and thiokness, (Hotet The combina tion of thickness adds up to 5 Inches.) 4*10 The master blocks are cheoked for dimensions and irregularities prior to loading onto drying carts. Substandard pieces are removed and fed back with the wet trim. 4.11 The blocks are dried in ovens at approximately 4oo 7 for 70 hohrs 4.12 After drying, the blocks are removed from the ovens and pemdttsd to cool. 4.13 Blocks are removed from the carts and packaged, final inspection is made Just prior to inserting the blocks into cartons. 4.14 Cartons are identified to show contents and date of packing. They are then ready to ship or be palletised and put into the warehouse. PROIXTCT CONTROL , ' 51 Product control tbsta shall be conducted as often as is necessary to maintain the quality limits set forth in the following table but with no less frequency than indicated. > 1 i ' ,Pr "trportaop Block k of- 5 V. PRODUCT CONTROL (Cont*d) ( MIR. TEST TEST PROPERTY . VALUE ... FREOUENCT PROCEDURE 5.1.1 Dustiness 5.1.2 Waterproofness Relatively free Sheds water Continuous Visual . 5 Production Apply water 5.1.3 5.1.* Density MiniauB 16 lba/cu. ft. ' ,5% Production MaxiBUB 20 lbs/cu. ft. 20 Breaking Strength 2$ lb. Bin. ave. . 5Jf Production 1" x 6" on 10" span (None below 18 lb.) E-P I-136a Navy 32-1-3 5.1.5 Dimensional Tolerance Thickness * l/l6" Lon. & Width * l/8" Continuous Viaual and gage 5.2 Substandard material shall be set aside for disposition as directed by the plant nanager. VI. PACKAGING y/oO 6.1 Packages shall be regular slotted cartons Bade froaJS?5^1b. test stock with jrflute and tape closure. Standard carton sizes are as followst - , \f 16- carton - 16-1/8" X 12-1/8" X 36-1/8" \ 15" carton - 15-1/8" X 12-1/8" X 36-1/8" V 14" carton - 14-1/8" X 12-1/8" X 36-1/8" 6.2 Cartons shall be printed in accordance with E-P fora layout D-147. The 14" cartons are plain except for "contents panel". Colors are GCHI #21 green and' 17^-tf^eRge. y' 6.3 Cartons shall be filled in accordance with' the following tables: /% BLOCK - THICKNESS BD. FT. PER CTO. CTR.. APPROX. GROSS WT. PER CTO. LBS. 1".2".4". 48 16m - 74 li\2*\3" ^5 05V ' 69 o< 3i" 42 ' 14" 65 HLPCg THICKNESS 6 X 18 PIECES PER CARTON 6 X 36 or 12 X 36 1" 2" 2i" r 3" it C' IS 10 0 8 6 5 4 4 ' r Supartsnp ELpefc 4 * Page 5 of 5 YI. fACKAOIBO (Cost'd) 6.4 Cartons shall bo closod by gluing top and bottoa. 6.5 All cartons shall bo marked vith a oodo number that will poralt coaploto manufacturing identification. . 6.6 Cars or trucks shall bo inspoctod and any wire, nails, or othor protuberances which sight tsar cartons shall bo removed. Cartons shall bo suitably protootod, if such haaards cannot ' bo removed, to prevent damage in transit or whoa opening ` doors at destination. 6.7 This product shall bo identified on shipping forms as IS Dc*J Q'*' C't'C-'C'- . . t s: