Document LKEmEbp5GrBdddvbOremw3nk5

...an economical, highly efficient product to strengthen ami control viscosity of dry and ready-mix ...TAPE-JOINT COMPOUNDS mih4MSBmm>0 SG-210 for TAPE-JOINT COMPOUNDS WATER ANO OH. ASSORPTIOW CAPACITY OF DIFFERENT ASBESTOS FSQOSJCTS USED IN TAPE JOINT AOHES1VE FORMULATIONS The high-purity, finely ground fibers of "Caiidria" asbestos SC-210 offer many advantages compared to other types of asbestos including: MORE EFFICIENT STRENGTHENING "Calidria" asbestos SG-210 fibers are ground to a fine size, with over S5% of the fibers 1ess than 325 mesh. The product therefore has a large surface area and more active sites to interact with the inert fiilers in the compound, Formulators using "Calidria" asbestos therefore need less material to give dimensional strength to the finished joint. MORE EFFICIENT VISCOSITY CONTROL The fibers of "Caiidris" asbestos SG-210 can absorb vast amounts of water - generally about 400 times their weight- As shown by the graph above, this unique asbestos absorbs from 70 to 125% more water and oii than other types of asbestos. Thus, less "Calidria" asbestos is needed to reach a given viscosity. 40% SMALLER ADDITIONS This reduction can be made by most users switching to "Caiidna" asbestos SG-210 from other types of asbestos. Such a reduction allows substantial savings in the amount of asbestos to be handled and stored. To make up for the weight difference, extra lime stone should be added to the system. LESS CRACKING Toe smalier addition needed with "Calidria" asbestos SG-210 reduces shrinkage problems ihat often occur with large asbestos additions. SG-210 users have reported that cracking over r.ailholes and along feathered edges has been minimized. SMOOTHER, WHITER COMPOUNDS The tiny particles of "Calidria" asbestos SG-210 give very smooth compounds when spread and dried. The absence of rock dust and abrasive fillers in this asbestos also contributes to the smoothness. There are no impurities that can discolor the system, so that a whiter compound can also be obtained. CONVINCE YOURSELF To test the effectiveness of "Calidria" asbestos SG-210, make up a small batch of your present formulation. Add .60% of your normal asbestos addition using "Calidria" asbestos SG-210. Then make up for the difference in weight using limestone. Overall water demand should be about the same but sometimes varies according to the ingredients in the formulation. Withhold about 10% of the water tor final viscosity adjustment at the end of mixing. Then test the properties of the formulation made with SC-210 . .. and compare. A.'-'Jf.. va'Xu.Jt vAs UCC 005941 Why is "Calidria" asbestos different? "Caiidria" product' are made from high-purity, short-fiber ehiysocile asbestos obtained front a unique deposit about 360 miles south of San Francisco, California. Unlike conventional deposits that extend through the host rock, this deposit is essentially free of hard, ccnsoiidated rock masses. Further, the ore assays up to 60% asbestos compared to conventional deposits which contain ftotn 6 to 10% asbestos. Special hydraulic beneficiation techniques develop ed by Union Carbide efficiently break down the fiber bundles and remove the rock and impurities from the asbestos fiber. As a result, ail "Calidria" products are over 95% pure asbestos whose fibers are 98% liberated from fiber bunches. SG-210 is finely ground fot use in tape-joint compounds. CANADIAN ASBESTOS - AS-MINED - Individual fiber bundles art straight aw) tightly bonded, surrounded by consolidated rock masses. In lira form, the fibers defy separation from each other and from the host rock. "CALi 08iA" ASBESTOS - AS-MWED - Hsre me fibers are randomly oriented and essentially tree of hard rock meases. Further, the ore essays up to S0S1 asbestos, consider ably mere than ihe Canadian ora. "CALIQRIA" ASBESTOS - IF DRY-PROCESSED - Even the c exacti.tg dry processes .j0 no) completely break down the fiber bundle* into individually liberated fibers. Union Carbide teehnoicov developed a specie! wat process to liberate the fibers. "CALIDRIA" ASBESTOS - UNIQUELY WET-PROCESSED -- Union Carbide's process separates 98% of the fibers from the fiber bundles. The fibers contain virtue'ly no rock dust, abrat-vs fillers- or impurities that can mar tspe-jcint compounds. UCC 005942 Use Xalfdria" Asbestos T-135 in Acoustical and Textyring Compounds Containing high-purity asbestos and TiOj , "Calidria" asbestos T-135 is a low-cost pigment with secondary thickening action. The titanium dioxide particles ate uniformly dispersed along the asbestos fibers and are firmly fixed to the fiber surface by electrostatic attraction. These dispersed Ii02 particles give maxi mum optical efficiency and allow T-I3S to replace TiOj on a pound-foi-pcund basis. The effective thickening ability of the high-purity asbestos fibers also allows removal of asbestos and partial removal of other thickeners. "Calidria" asbestos T-135 therefore provides savings in many spray-ceiiing acoustic and wall-texturing compounds. UNION CARBIDE CORPORATION MINING AND METALS DIVISION 270 PARK AVENUE. NEW YORK, N. Y. 10017 MARKETINQ AND TECHNICAL CENTER: P.d. Boa 579. Nissara Fails. N.Y. 14302 Tat.-' 716-278-3376 PLANT: ?.G. Be* K. King City. California 93930 Tel.: 403-385-5961 F-73-0133 2/74-4M 'Criteria," "UCA#?/1 od *'Uncf Cartsicto'1 ara rtract mark of Union Csrbid* Coroccatioru UCC 005943 Printed frt U.S.A 3RMANCE DATA IN 3 READY-MIX FORMULATIONS BEDDING-COAT TAP-4Q!T CONDOMS GENERAL-PURPOSE TAPE-iomr COSSPOUMD 4D ORDEfJ OF^CDmor' lbs. psr tOO Gal. % by Weight ibs. per 100 Gal. % by Weight -.icSseraea 0 1 SG-210 424.16 4.41 1.72 14.01 90.34 -- 5.23 8.74 39.62 _ 184.34 - 35.04 31.39 0.32 0.13 1.04 6.73 - 0.39 G.85 2.32 _ 13.66 - 2.60 421.67 4.41 1.73 14.01 . 31.35 0.32 0.13 1.04 __ 97.55 - 8.74 _ 7.25 -- 0.65 39.19 2.92 91.60 9?.SO - 21.71 6.81 6.81 ~ 1.62 Mo. 1 whits Ho. 1 writs TIES 3rd Tape esistancs -gallon mixer at 79 r.p.nv 542.17 0.88 - -- " 40.11 0.06 - -- -- - 1351.26 - 100.00 35.1% 700 8.U. 100% 99% Good 4.35 8.77 539.69 1345.C2 - 0.32 0.65 40.13 100.CC 35.1% 800 B.U 100% 95% Good V* S: /u TAP-oo$*rr TOPPING, COMPOUND lbs. per 100 Gal. 399.31 5.S3 1.84 - % by Weight ______________1 28.27 G.49 0.13 -- 80.47 -- 4.62 9.39 42.17 __ 23.36 93.20 9.24 5.89 -- 0.33 0.66 2.97 _ 1.65 6.60 0.66 j 729.53 -- S.24 4.67 - - 1414.50 51.56 _ 0.66 0.33 - " 100.00 30.66% 84Q3.U. 100% 92% Good UCC 005944 TYPICAL PHYSICAL PROPERTIES ReflscarKSffi IG-E- PNotwsitsramr) M'sgnatitft'Coatmt, Alfcsifaftyr ' pH in Water { 535 slurry)! Sarf8ifB8Area(SET> Otfc (OQ^ ... VteBSi&Q&HssSr. (S8KtsiOfeS8fesftS!S:l8't!6*fc | DhfrgislfcDsntakie 63% 2% max. 0.5 to 0,6% of Na^Q 8.5 to S.5 50 to 60 sq. m. per g. 100 to 110 !b. per 100 lb. asbestos 82 to 65 weight % in fitter cake 220 ml. for 10 g. asbestos in 250 ml. container 4 to 5.5 lb. per cu. ft. SIZE DISTRIBUTION Cumulative retained <kt 100 mesh- screen Cumulative retained orr 200 mesh screen CtiiTttitetive retained cm 325 mesh screen | 0.6% | 3 to S% j 10 to 15% PACKAGING AMD AVAILABILITY ?... ............." .................................. ........... .... . One Package--Weight 13-piy paper bag) 301b. One Pallet --Weight-- Dimensions 1,200 !b. approx. 53 in. x 44 in. x 69 in. high Full 50-ft. Carload .......{.a.v..a.i.l.a.b..l.e..f.r.o..m...King City,..C..a..l.if., plant) Full 40-ft. Truckload {available from several iocations nationwide} 52 pallets 62,400 lb. 17 pefiets 20,400 ib. TYPICAL PER smumra SKSB Iff |88|BBi INGREDIENTS Water 'Csrtlcwza" TJC Sacteriastat Anionic Qispers "UCAft" Latex "UCAR" Latex Oibutvi Phthala Sthytan* Glyec "Caliaria'" Asbe Miea.AA Mica. P-30-F Mica, Ser-X Clay, ASP-400 Calcium Carbon PO #1 Defosmt Talcum Powder Water Condition Talc Calcium Carbon ^(|t 1 I TYPICAL PRO! { Water Content Srabender Vises Adhesion to Wa Nailhcie Crackii Sandability "Mixed 1.5 to 2.0 ('.cur UCC 005945 UNION CABBSQE CORPORATION METALS DIVISION P. 0. BOX 573 - NIAGARA. FALLS. N.Y, H332 TEL: 71S-278-337S "CALIDRIA" ASBESTOS SG-2I 0 FOR DRY-M i % yape JOINT COMPOUNDS The present 7-1 sheet F-42258 describes how re substitute CALIDRiA Asbestos for Canadian Grade 7 in ready-mix tape joint compounds. The same general priciples (and cost advantages) also apply to dry-mix compounds but certain precautions are desirable to be sure to arrive at a trouble-free CALAORIA formulation. In the ready-mix system, the correct amount of water is incorporated into the formulation by the manufacturer. For dry mixes, however, the user adds the amount of water which he judges to be right for his conditions of application. Obviously, this can vary over quite a wide range. if too much water should be added, the joint wiii shrink excessively on drying and develop cracks. For this poorly controlled situation, it is clearly desirable to market a product which has as wide a range of acceptable water content as is cons Istnet with its other necessary properties. The solution to this problem is really quite simple. The formulator must only be carefui not to put too much of the "concentrated" CALIDRIA Asbestos and put cut a product with too high a water demand. It is suggested that the ready-mfx rule-of-thumb where one pound of Canadian Grade 7 is replaced by cne-half pound of CALIDRIA Asbestos plus onehalf pound of limestone also be taken as the starting point for drymix formulation. Adjustments should then be made to minimize the amount of asbestos and maximize the amount of Iimestone while still giving a product that has satisfactory properties. It is probably also desirsable to compare the range of usable water content with the manufacturer's older formulation. ' y. yys UCC 005946 UfSiOfi CARBIDE CORPORATION S8ETALS OIVSSSON P.O.BOX 573 . NIA3ARA FALLS, M.Y.'.4382 TEL: 71S-278-337S TYPICAL PRODUCT CHARACTERISTICS FOR STANDARD GRADE 2QC (SG-200') AND STANDARD GRADE 2C0X (SG-2QQX) SG-200 and 5G-200X are wet sheared, moderateiy-Uberated fiber products for use as general purpose fillers. These dust-free pellets, which contain no binder are idea(y suited for bulk handling and economical shifting and storage. SG-200 is approximately i/4" in diameter and SG-200X is 1/8" in diameter for optimum dry blending. Property________ Reflectance (GE Brightness), % Moisture Content, % Magnetite, % pH Surface Area, m^/g AvaNable Fiber Content, jl Ultimate Fiber Content, % Packaged Density, ibs./ft^ Single' Bag Weight, ibs. Single Pallet Weight, ibs. 50! Carload (60 pallets), tbs. 40* Truckfoad (20 pallets), ibs. Typical Value 68 2 1.7 9.5 60 ?} 88 44 50 2,000 120,000 40,000 UCC 005947 7/73 Revised STANDARD GRADES Moderately liberated risers used AS LOW-COST fillers and flow control agents sn ASPHALT ICS, CAULKS, SEALANTS AND SIMILAR APPLICATIONS. AVAILABLE AS EITHER OPEN FIBER OR ESSENTIALLY SUST-FP.EE PELLETS, WHICH ARE ABOUT 1/4-INCH DIAMETER FOR OPTIMUM DRY BLENDING. Her F.O.B.Prices - Cents per ls. - King City, Calif. Punt ~ Sold only in full-pallet multiples | Brace ] $5-130 Coreii fiber) SS-200 (pellets; | St-210 (opes fiber) Carload j 3.7 3.8 12.5 | Truckload j 2.7 3.8 12.5 | Less Than Truckload j 13.0 11.0 18.0 i F.O.B. Warehouses - SG-210 0,-ilt ) Atlanta, GA S Hammond, IS j 22.5 j 28.0 Prices subject to chahse without notice HoTES INDIVIDUAL SAGS ARE SHRINK-FILMED AND PALLETIZED AT !0 EXTRA CHARGE. Ir SPECIAL PACKAGING, SUCH AS PALLET SHRINK-WRAP, IS REQUIRED FOR EX-PLANT SHIPMENTS, ADD 1.04/L3. TO THE PRICES LISTED ABOVE. Grade SG-130 $5-200 $5-210 PACKAGING IHFOSflATIOR Per Sag 40 50 35 SET WEIGHT, LiS. Per Pallet jpfa Trucklcap* Truck-2.000 Raft -1 ,6M 2,000 j 1,400 1 34,000 (17) | 40,000-129) 1 23,800 (17; Per Carload S3,203 (52) 120,000 (60) 72,200 (52) *Ti'ucklcad pricinq is based on these minimum quantities; however, to feci Tits to compliance with DOT remrtations, Union Carbide reserves the right to lead trucks to full volume or weight rapacity and to adjust customer orders accordingly. ) (lumber of pallets TO ORDER ... OB ASX A TECHNICAL QUESTION-call or write the nearest "'Calisria" asbestos office below: Northeast: P.O. Box 573, Niagara Falls, N.Y. 14302 - Tel.: 716-273-3371 South; 17 Executive Park Drive, Atlanta, Ga. 30329 -- Tel.: 404-321-6500 Midwest: P.O. Box 579, Niagara Falls, N.Y. 14302 - Tel.: 716-278-3365 West: TOO Oceangate, Long Beach, Calif. 90S02 -- Tel.: 213-435-3721 Plant: P.O. Box K, King City, Calif. S3930 - Tei.: 408-385-5361 COMBINED SHIPMENTS -- Shipments of one or more pallets of any "Calidria" asbestos product may be combined with one or more pallets of any other "Calidria" product for total quantity price, based on the totai number of pallets ordered. IMPORTANT -- Terms are net cash 30 days from invoice date. Prices apply within continental U.S.A. Union Carbide reserves the right to adjust customer's orders to comply with the ordering quantities shown above, ... -'v*- Vl USIQN CARBIDE CQRPQRATfO* METALS DIVISION 270 PARK AVENUE, NEW YORK, N.Y. 10017 UCC 005948 (/ U 9'2 NION IHTSKISAL fiSRRIIPfiHSiMSS CARBIDE mmmc ahd metals division P 0 BOX 579. Hmm fftUS. KEW YORK 1430? r4W<aW Mr. F. H. Larrison *** Union Carbide Corporation tsextim P.0, BOX K King City, California 33S30 Bel* Oiifflesttag M <8 December 8, 1971 gettarzh and Osvelapment Deportment CALIDRIA Asbestos -- _ Messrs, R. E. Byrne G- L, Dickson B. L, Ingalls R. 0. Marsten d. L. Myers J, W, Rawlings E. Saunders Product Seed ficaticris- SG-130 : Dear Larry: As we have discussed several times recently, Sherwin-Williams has included SG-130 asbestos in a new formulation for exterior texture paint. They have, therefore, asked us to supply purchase specifications for SG-130. In .preparing these specifications, the SG-130 product quality data obtained at King City and Niagara Falls over the past four years have been reviewed. The review showed that the product was generally well within specifications but.that the specifications were so broadly drawn that it could, and sometimes did, vary quite widely in important properties. This letter presents the data and recommends updated product specifications. The data from Niagara Falls "composite" samples are listed in Table I. The corresponding King City quality control data as provided by Dick Marsten in his letter of 10/21/71 are given in Figure 1. It is useful to examine and com pare these results as a background for selecting appropriate specifications. Percent Reflectance (Test 1, Table I) is only run at Niagara Falls on this product. Table I shews that reflectance has always been very constant in the 70-71 range. The magnetics results from Table I and Figure 1 are summarized ion Page 2 for convenience in comparison. Since sore of the samples were marked with dates and sore with lot numbers, Figure 1 has been used to get what appears to be a generally good matchup. The lot designations or dates obtained by matching are shown in parentheses in the Table. .& JL ^ UCC 005949 Hr. F. H. Larrison -2- December 8, 1971 Sample Designation Weight % Magnetics Niaqars Falls King City Di fferenee Nov. 68 (6789) Oct. 69 (7132 and/or 7134) (April 70) 108 (Aug. 70) 193 (Sept. 70} 201 May 71 (304?) (Hoy. 70-July 71) 304 (Sept. 71) 598 1.8 1.8 1.5 1.6 1.6 1.8 1.8 1.4 1,5 +0.3 1.5 K3.3 1.4 +0.1 1.4 +0.2 1.3 +0.3 --1.4 c.o Av. +0.24 It is inmediately evident that the current specification of 2.5% max. is far above the level of any SS-130 product we have ever made. There also is a con sistent bias of +0.2 to 0.3 between the laboratories. It would probably be desirable to determine why this difference exists but as long as it stays this consistent it is hard to justify much effort to this end. Continuing with the results in Table I, the Dry Bulk varies from 5.7 to 10.2. We feel that this Is not a particularly reliable or reproducible test so we will not be concerned with this variation. The two types of Wet Bulk tests. Nos. 4 and 5 in Table I, are related to fiber openness and fineness of grind of the asbestos product after It has been subjected to very low or to high shear, respectively. There has been some drop in these properties in late 1970 and early 1971, particularly in the 2 g./l test. The latest material. Lot 598, is back over 400, however. The Oct. 1969 material also appears to be quite different from any other SG-130 that we have ever made. It is our judgment that these Wet Bulk values should be around 175-18G for the 10 g./250 ml. test and about 400 for the 2 g./l. procedure. We will continue to monitor this property via the Niagara Falls composites but no specification limit will be suggested at this tin. Next comes a key measure of product properties, the two types of wet screen ing. The present specifications require 28-32% on 325 mesh by the tap water technique. There are no "coarse end" requirements. The +325 mesh data from both laboratories and both types of procedure are plotted in Figure 2. The tap water data show a very consistent pattern with the specifications met nicely by the King City data while Niagara Falls results are consistently high by around 4%. This difference between laboratories is generally characteristic and no attempt will be made at this time to resolve it. Note that the tap water screening data from each laboratory in themselves show that the various lots of product are pretty much the same in this property. In contrast, the dispersed screening data, indicate that the Oct. S3 product is much finer than any other material tested. This distinction is borne UCC 005950 Hr. F. H. Larrison -3- Oecen&er 8, 1971 out, but not as sharply, by the screening data at other mesh sizes (see Table I both screening procedures), the high Z g./I. Wet Sulk gf 460 and the higher Available Fiber and Ultimate Fiber results. For other than this sample, however, the results cluster quite closely around the 15* level. Dispersed screening is actually a more reliable method than tap water (flocculated) screening to characterize asbestos. It is our opinion that in the longer run we should switch to this type of screening for quality control but the attendant interlaboratory checking and standardization work is beyond both of our present manpower capabilities. The corresponding +35 mesh data obtained by Niagara Falls are shown in Figure 3. King City does not run a +35 mesh test on this product since it is not now specified. The tap water data show that the material made In 197C had +35 values of 1.5 to 2.5. The amount of the "coarse" has declined steadily over 1971 and is now down to about 0.5%. The dispersed screening results show very similar trends. Over the past year, values have ranged from over 1% to as little as 0.1%. Excessive coarse material can cause problems in tape joint compounds and in certain paints where SG-130 has so far found limited usage and, hopefully, will be much larger in the future. We feel that observed variation is too large and that a "coarse end" specification is needed to ensure that a product with con sistent properties is manufactured. The last tests in Table I, Available and Ultimate Fiber, have in the past been somewhat controversial. Available Fiber is intended to show the amount of fibrous material that is available to the user with very little shearing in his process. The Ultimate Fiber represents fiber availability If the product is sub jected to high shear by the user. It Is ,1n addition, a measure of ^srotMct purity. Although these tests may not be accurately named, it has been our experience that they represent a reproducible and valuable measurement of fundamental product quality. It Is beyond the scope of this letter to argue the point so it should only be noted that the range of values since Aug. 1970 to the present has been only 55-58.6 for Available Fiber and 82.4-84 for Ultimate Fiber. The'68-69 samples differ appreciably. This quite extensive background on product properties makes it a fairly straightforward job to select realistic updated specifications. In essence, it is proposed that we set up Plant Control specifications which the product as now manufactured meets but does not exceed substantially. These would be supplemented with a set of Manufacturing specifications which are more liberal and would be the ones used with customers. Both sets of specifications would be based on the three tests presently run, i.e., moisture, magnetite, and +325 mesh wet screen, plus 35 mash wet screen test and reflectance. The dual specification approach which has been used to a limited extent in the past has several important advantages. It allows for analytical uncertainties UCC 005951 Mr. F. H. Larrison -4- Decenrber 8, 1971 and differences between laboratories. It permits the plant operators to push as close as practical to the Plant Control limits to reduce costs without serious danger of reject product. It also gives us the flexibility to ship material that falls between the'two specification limits at our discretion and under control. It Is our understanding that the present specifications for SO-130 are those given in a 12/3/70 summary by Hr. R. Rivera as listed below. Test frequency is one per 52 ton conposite. There are no "Plant Control" specifications. Determination Specification yTant~~Contro1 Moisture Magnetite (%) Wet Screen +325 H 3% max. 2.5% max. 28-32% Referring first to Moisture Content, Figure 1, since June of 1969 there has been one lot (199) at 1.9%, one lot (598) at 1.6% and everything else has been 1.5% or less. The 3% maximum level is so high it is hardly relevant. It is sug gested, therefore, that we set a Plant Control Specification of 2.0 maximum and a Manufacturing Specification of 2.5% maximum as packaged. The "as packaged" limita tion is not intended to give us a license to store the material under water but does provide negotiating flexibility for an "as delivered" basis, for polyethylene overwrap, and/or for moisture picked up while stored in the customers' plant. The magnetite contents were summarized previously on page 2. The tests at King City over the entire four years show a range of 1.3 to 1.5% while the Niagara Falls are generally 0.2 to 0.3% higher with a range of 1.4 to 1.8. In the present applications for 5G-130ftbe magnetics effect the users product as grittyness and via their effect on product whiteness. The grit is more Important in tape joints while the whiteness Is one of our main advantages over Canadian for paints. Accordingly, It is recommended that we change the present Manufacturing Specification from 2,5% to 2.0% with a corresponding Plant Control of 1.6% At the same time, we should add a reflectance specification. Since the magnetics analysis requires both special standards and interlaboratory standardization we will emphasize "whiteness" when talking to paint customers and if this "sells" we can possibly drop the magnetics testing at King City in a few months. Niagara Falls could continue to monitor it as a precaution. Based on the data in Table I, a Plant Control limit of 70 minimum and a Manufacturing Specification of 69 minimum for Reflectance would appear reasonable. These values will have to be tentative since the only historical data on this product have been obtained at Niagara Falls. Where corrparable data are available, the two laboratories generally check reasonably closely on this property, but occasionally there have been some differences. Adjustments in the values can be made as King City data accumulate. It should be noted, in this connection, that all specifications must obviously be written in terns of King City data. UCC 005952 Mr. F. H. L'arrison "5- December 8, 1971 Finally, we get to one of the most critical measurements of product properties, the wet screen analysis. The present Manufacturing Specifications for 28-322 on +325 mesh by the tap water technique fit the product as manu factured quite well. In view of your consents that there were son prob lens meeting the 282 minimum on the recent run where a low +35 mesh was made, it is suggested that we make these Plant Control Specifications and widen the range slightly to 27-32%. In view of interlaboratory differences a Manufacturing Specification of 25-35% is suggested. The desirability of a +35 mesh specification has been discussed previously. Again, In view of your recent plant experience, a value of 0.7% maximum is sug gested for Plant Control limits. This should give us a typical value around 0.5% which should be satisfactory for this product without pushing you too hard on the +325 end. The corresponding Manufacturing Specification would be 1% maximum. This completes the recommended changes in specifications. For convenience they are sunraarized in Table II attached. There is one additional.area, sample frequency, however, where I would like to make some comments for your conslderar tion. We have discussed several tines the standard procedure of setting a lot size at 52 tons and manufacturing it in several parts often separated by a month or more. Analysis are then run on a mixed composite from the entire lot. It seens to us that a 52 ton lot Is much too large to be reasonably con fident that one composite is representative of the entire lot. This is particularly a concern when parts of the lot are made at different tires separated by a month or more. Our feeling is that it would be much better to reduce the lot size to about 20 pallets (16 tons} or whatever is made in a contiguous or closely related manufacturing run if the latter is less than 15 tons. It Is also suggested, if this is not already your procedure, that a sample be collected for each pallet during the bagging operation and the composite be prepared from these by the man in your laboratory. This would help to assure that representations taken evenly across the lot make up the overall composite. Your comments on the suggestions contained herein are solicited. Regards, HBR/bsn Attach. K. B. Rhodes UCC 005953 TABLE II RECGMCNPED SPECIFICATIONS FOR SS-130 Test Moisture Content (wt. %) (As packaged) Magnetics (wt. %) Reflectance^ % +325 Mesh Wet Screen (Wt. % Retained) +35 Mesh Wet Screen (Wt. % Retained) ^Tentatl ve Manufacturing Sped fi cation 2.5 2.0 tfK' 69 25-35 IS max. Plant Control Spedfi cation 2.0 tf- 1.6 0K. 70 <3i<- 27-32 fX* Q.7% max. UCC 005954 Trace Trace 0 .4 1,1 3.6 7.9 Cz )m run te s t* were sde about one sonih a fte r aanufaeture. Repeat was run on 10/8/71. {^E stim ated froa 1.3 9. saaiple, usual technique uses S grans. ^Its tlfs a te d froa slse distribution curve*. UaS >8 * < <&9r O. *"> *eVvj 5 >*3 aa w *** PttHt g~ *-- y* O MS 10/JCSUS ltj/)* SO 1 SI ii/33$I u0* vs Ki: aj 1 v> 4 I s PM 4* <Qae < ss < S < as << 2E 3 IS ph 03 V" CM rO* s (A rt t-- ift 4J 0 cmph PH *" Ph Srt wJr 8 1 CM - CTl t to 0 O i (A 1A 1 1/3 tn r~ w 8 1 t>j JS P9h VS #* < 3S vr*O w* pA portNM < n f-oi^r ("Wrt &4i& V- a/a *- 9 0*N Orn*ttCrMt*C*O "0 <sS*J OaS O_ ** CMO Np Wfl 9CM V *-\4<7SNOPg* CM <JvTrO* NQOij 3C C 3? < % < 3S < 3S ** *--. gSSi El <3 9 PH. 1 1 > V O*IS*<4> ** (fmc>. 0*F **""p'3** r3?t sa^reso- ,,9 QrttflQCSN < < W O **p*R}> SB 3B <<<PHOQ9CO N XJg^rtOiA VA5 u O rtrttwtp C9h UV%9 3 0*~ m as* L J~ Q f* rt 0 PrHt < C3f*u>pHtft X 0 PM TO SDm3 CaMt S3 V O * << SB 3C C<rttQCQrt Cs O 38S3S OOPJffl On < *io a a> vd **""88 rt ** O <3 .U $ I c s o I =S2 a<0. s6 S i 3 s. > S a S 5- UCC 005955 f/ffc S c r e e n S 'S -Z Z o + 3 S /V < ? s A TECHNICAL SERVICE REPORT by D. H. Resd ^ --* I V A w L' C.V_;C??!A -- TV "A. The Use of Caiidria SG-210 Asbestos in Dry or Ready-Mix Tape Joint Compounds Union Carbide Corporation Chemicals and Plastics Research and Development Department South Charleston, West Virginia July 1?, 1971 UCC 005959 What Asbestos Fibers Do in Tape Joint Compound Asbestos performs a number of functions in commercial ready and drymix tape joint compounds. The primary function is to form the backbone or ''web1' for the inert fillers and film formers to associate with. Upon drying, or film cure, the asbestos adds a significant amount of dimensional strength to the applied materials. The influence of asbestos on other formulated performance properties depends upon the particle size and concentration level with respect to the other inert fillers. Asbestos functions as a secondary bodying and thickening agent, in wet formulations, via the water absorption capacity of the fiber. In this capacity, it contributes to the reduction of product density in relationship to the concentration level employed in the formulation. This comes about as a result of the increased water demand. The water absorption efficiency is a function of the particle size, and other physical properties of the asbestos. Finally, perhaps more than any other filler, asbestos contributes signi ficantly to the formulated compound smoothness, cratering, and "wet edge" properties. This is because of the fibrous nature of asbestos particles. In like manner, both the asbestos particle size and concentration level will determine, to a large extent,, the smoothness of the feathered edges. On the negative side, of the variety of inert fillers employed in a joint compound, asbestos and clays contribute most to the nailhole cracking problems. In the process of water absorption, asbestos particles swell. On drying, these particles shrink with the release of water. Although the swelling is necessary for good product body, asbestos at too high a level can be the single largest con tributor to thick layer joint compound shrinkage cracks. Product particle size uniformity is therefore of utmost importance in regard to reproducible built-in properties of a formulated tape joint compound. Special Properties of "Calidria" Asbestos Most asbestos materials, marketed commercially for use in tape joint compounds, contain rock dust and other abrasive type fillers, that have no specific desirable effects on joint compound performance. ''Calidria" SG-2I0 and SG-130 asbestos are produced by a proprietary manufacturing process that yields essentially a pure asbestos fiber content. The SG-2 10 product is preferred for ready-mix smoothness and water absorption efficiency. Another feature is the unique shape and physical structure of the "Calidria" asbestos fibers. The micro size particles are actually "fibrils" and the respective stems are hollow; hence, the fibers have a.tremendous water absorption capacity. In like manner, there are more "active sites" for other inert fillers to associate with, in formulated film formation. As a result, "Calidria" asbestos generally goes twice as far, on a pound for pound basis, as the Canadian and other commercial types used in tape joint compounds. It is these physical properties that enhance the wet joint compound workability and performance properties mentioned above. How to Use ''Calidria" Asbestos in Tape Joint Compounds "Calidria"' asbestos can be used in dry or ready-mbc compounds, with very little change in formulation parameters. Since "Calidria" SG-210 will go twice as far as similar Canadian types, a good substitution starting point is UCC 005960 2 one-ba.li as much. The formulation weight difference is best made up with mica or calcium carbonate dry filler. The typical product characteristics of "Calidria'1 SG-210 and SG-13 0 are listed in Table I. The SG-130 is shown, because it can be used in formu lations where surface smoothness is not as desirable as that obtained with SG210 asbestos. The relationship of nCalidria!l asbestos fiber physical properties to subsequent oil or water demand characteristics are depicted in Figure 1. In Figure 1, these absorption characteristics are compared to typical commercial grades regularly employed in joint compounds. The data, in Figure 1, shew that a good :iCalidria'' asbestos substitution starting point is at about 50 percent, by weight, less than other typical commercial asbestos, without changing signi ficantly the original formulation water demand (i.e. one-half the amount of other sources). The weight differences can be made up with either additional amounts of calcium carbonate or mica fillers. The latter is preferred with respect to ready-mix water demand and good naiihoie cracking resistance. No other changes are necessary in the formulation. Three suggested tape joint compound ready-mix formulations are listed here to depict the use of Calidria SG-210 asbestos. These are listed in Tables U, III, and IV. These formulations differ in both the ratio and types of additives, to introduce desired formulation end-use properties. For example, the suggested bedding coat material, Table II, does not have as smooth a dry surface, but should fill the primary requirements of good tape adhesion and a minimum amount of thick layer cracking. The general purpose formulation, Table III, should depict good overall working properties and have better wet edge and surface smoothness than the bedding coat material. A topping coat product. Table IV, should exhibit a minimum amount of volume shrinkage,(note the higher density), have exceptional surface smoothness, and wet edge. In addition, a minimum amount of sanding is desirable for topcoat materials. In actual practice, the bedding and top-coat materials are giving away to the general purpose types. If Canadian or other types of asbestos were used in these suggested formulations, it would be at double the concentration level indicated to achieve essentially the same water demand. In like manner, the higher asbestos level dry compound surface smoothness would not be as evident with everything else being equal. The formulations listed here are merely suggested ones. Experienced tape joint compound formulators have their own source of fillers and usually employ other ingredients to fit particular geographic conditions and subsequent end-use requirements. In the case of asbestos, the choice is generally between the Canadian and "Calidria" types. It is a matter of grades employed, efficiency, and effect on compound workability and dry-film cratering. In these important areas, "Calidria" SG-210 asbestos shows extremely good properties in either dry or ready-mix tape joint compounds. V .$L x UCC 005961 TABLE I UNION CARBIDE CALJDRIA ASBESTOS Typical Product Characteristics SC"130 SG-210 Reflectance (G.E. Photovoit) Ceneaincd magnetite Alkalinity (os % of NajO) pH (57. aqueous slurry') Surface ares (B2T) . Oil Adsorption (DO? /1CD# asbestos) Wet Bulk, settled vol. (ml.) lOg/250 dL./1 hr. Dry Bulk, <$/t. 3) Water adsorption (vt. 7, in filter cake) Siza distribution (Cumulative % retained) Wet Screen mesh size 100 200 325 SO-100 200 7-8 55-60 5 17 23-32 68% 2% K&x. 0.0S-Q.06 8.5-9.5 50-60 t*fr. 110-120 220 5-6 62-65 Trace 3 10-15 5wd* '/s> UCC 005962 TABLE II UCAR LATEX WC-130 OR 131 SUGGESTED BEDDING COAT TAPE JOINT COMPOUND (13-DRR-18) 1 !agredxents and Order of Addition(a) 1 . Wa ter 2 . CELLOSTZE TJC Thickener. Union Carbide W'1 . Bac terias ta t "Dowicide" A or similar 4 . Dispersant,. "Daxad"-3G, {25% I), Dewey and Almy 5 . UCAR Latex WC-130, (58% |) r Union Carbide 6 . Dibutyl Phthalate, Union Carbide 7 . Ethylene Glycol, Union Carbide 8 . Calidria Asbestos SC--210, Union Carbide 9 . Mica P-80-F, Western Mica 10 . Clay, ASP-400, Minerals and Chemicals, Phillip 12 . Calcium Carbonate, No. 1 White Thompson-Weinman 12 . NQPCO PD #1 Anti f oam Nopco Chemical Company Pounds Gallons Lbs/100 Gal % bv w 1932 20 232.43 1.72 424.16 4.41 31,39 0.32 8 0.74 1.72 0.13 84 6.53 14.01 1.04 414 44,66 90.94 6.73 24 40 180 2.75 4.30 8.45 5.23 8.74 39.62 0.39 0.65 2.92 840 160 36.68 7.44 184.34 35.04 13.66 2.60 2468 109.20 542.17 40.11 4 0.55 0.88 0.06 8154 455,45 1351.25 100.00 Note (a) Mixed 1.5 to 2.0 hours in a one-gallon Baker-Perkins, Sigma Blade Type Mixer, at 79 r.p.m. Typical Properties Water Content Pounds/Gal ] on Bra bonder Vjsfosily Adhesion lo Wall board Tape Naillioie Cracking Resistance Sandnhi i i tv 35.1% 13.51 7C0 a. U. 100% 99% Good : J&, UCC 005963 m TABLE III UCAR LATES WC-130 OR 131 SUGGESTED GENERAL PURPOSE TAPE JOINT COMPOUND (13-DKR-68) Ingredients and Order of Addition(a) Pounds Gallons Lbs/100 Gal % by wt 1. Wa ter 2, CELLOS1ZE TJC Grade Thickener, Union Carbide 3. "Bowicide" A, or similar bacteriastat 4 . "Daxad'-30, dispersant (25% S) 5. UCAR Latex 131 preplasticized (59% T) , Union Carbide 6. Ethylene Glycol, Union Carbide 7. Caiidria SG-210 Asbestos, Union Carbide 8. Mica, AA, Thompson-Weinman 9. Mica. P-SO-F, Western Mica 10. Clay, ASP-400 11. Calgon, Water Conditioner 12. Talc, Asbestol or A-200 13. No. 1 White Calcium Carbonate 1932 20 8 64 447 40 180 420 420 100 20 40 2472 232.43 1.72 0.74 6.53 48.48 4.30 8.45 18.34 18.34 4.65 3.12 1.69 109.38 421.67 4.41 1.73 14.01 97.55 8.74 39.19 91.60 91.60 - 21.71 4.35 8.77 539.69 31.35 0.32 0.13 1.04 7.25 0.65 2.32 5.81 6.81 1.62 0.32 0.65 40.13 6163 458.17 1345.02 100.00 Note: (a) Mixed 1.5 to 2.0 hours in a one-gallon Baker-Perkins, Sigma Blade Type Vaxer, at 79 r.p.m. Typical Properties Water Content Povjnds/Gallon Adhesion to Wallboard Tape BraLender Viscosity NaiShoie Cracking Resi-tn.'.oe Sandability 35.1% 13.45 100% 600 f 95% Good UCC 005964 TABL. SUGGESTED TAPE JOINT TOPPING COMPOUND (13-DHR-43) Ingredients and, , Order c: Addition' Wat e r CELLQSIZE TJC Grade Dcvnctde "A", 3acteriastat UCAR Latex WC-130 (53% IS) Dibutyi Phthaiate Ethylene Glycol Calidrta SG-210 Asbestos Mica (P-30-F) Mica (Ser-X) Clay, ASP-400 No, 1 White Calcium Carbonate Talcum Powder (MallirScrodt) Calgon, Regular Pounds O&lions 1714 30 o 345 20 40 180 100 400 40 3127 . 40 20 6064 206,21 2.59 0,74 37.26 2.29 4.30 8.45 4.37 17.47 1.S6 138,36 1.69 3. 12 428.71 Lbs/100 Gal. 399.81 6. 96 1.S4 80.47 4.62 9.39 42.17 23,36 93.20 9.24 729.53 9,24 4. 67 1414.50 % bv Wt. 28.27 0.49 0. 13 5.69 0.33 0.66 2,97 1.65 6.60 0.66 51.56 0. 66 0.33 100.00 Water Content Pour.cs/ Gallon. Brabcnder Viscosity Adhesion to Waiiboard Tape Xaiihole Crack Resistance 3a ndabi.lity 30.66% 14, 14 840 3.U. 100% 92% Good NOTE: (a)M,,.ixec ,i. 3. -2, .0. r. .ours ir. a one-gallcn 3a.<er-Perk;ns, Sizma Blade Type Mixur, at 79 r. ?.m. UCC 005965 FIG URE I RELATIONSHIP BETWEEN WATER C. OIL ADSORPTION CAPACITY OF SOME ASBESTOS PRODUCTS FOR TAPE JOINT ADHESIVE FORMULATIONS INTERNAL CORRISPGNDINC2 ETALS DJVISSO UU I - tf 1978 UNION CARSiDE kinq city, ca. P. 0. 30X 573 -4625 ROYAL AVE., NIAGARA FALLS, NSW YDRK 1433 Tc- <mrnei Division l^ocatron Mr. R. E. Byrne!, Jr. UCC-Metals Division Niagara Falls, NY Cooy to Messrs. 6 L. Dickson E ! 5! Kleber T . P. Norris H . B. Rhodes ....... File F . J. Shortsleeve J . t. Walsh Cale Or,igin3tir>9 Dept. October 4, 1978 "Calidria" Asbestos Anssvrirtg letter dale Subject Daubert Chemical I called Bill Houghton in Oak Brock today to check on orders for RG-110-EX for Holland. He advised me that "upper management" decided last week to discontinue all asbestos-filled products, with a target date of 12/31/78. He said this applies to domestic and exoort requirements and was caused primarily by union pressure at their plants and their customers. Their insurance company is also insisting that they stop using asbestos. I told him we had a similar situation at one of his competitors, but that they were at least giving us a chance to present our side to their board of directors. I offered to do the same but he doesn't think Daubert will accept the offer. Bill says they have substitute formulations without asbestos which are lower quality and higher cost. He also indicated their filled asphalt business was declining due to higher use of plastisol corrosion coatings which "don't contain asbestos". I chose not to correct him on this. Daubert has been threatening to stop using asbestos for several years so this may not be the end, but this is the first time I have heard a target date. Jojjfa L. Myers JIM:dal UCC 005967