Document MMQqBDNK2nDM66rjwGo6bvqEx

mu F. E. MUELLER INGOT AND POWDER DIVISION PITTSBURGH OFFICE - 23 TO MEMORANDUM August 15, 1973 RE: Ref-: ASBESTOS FREE TROUGH LINING MATERIALS Memorandum, F. E. Mueller to D. R. Barch, Dated W73, Re Same Caption_________________________________________ The reference presented recommendations for the captioned which generally amounted to replacement of asbestos shorts mixtures and sawed Marinite trough linings with Johns-Manville JM375-L. Summarizing the progress made since April, of our thirteen casting plants: 5 have converted to JM375-L ij are evaluating JM375-L 3 are evaluating other non-asbestos materials 1 has converted to another non-asbestos material The table attached to the present memo shows those casting plant locations between the furnace and the mold where asbestos contain ing materials have been used and the specific progress and program to replace these materials. F. E. MUELLER FEM/mj distribution reverse side % Q ALCOA ALCOAO 000009715 ALCOA0000009716 I FROM PITTSBURGH PURCHASING INDUSTRIAL MATERIALS AND CHEMICALS - 19 TO Arc. Mav In, 1973 RE: JOHNS-MAMVILLE 3 ?''! Ocmei'.t INOOlUlRPA .T01INS MATTVIL1.C' __________________ By means of Change Order No. 1, we have added John-Manvilift fs 37^1- Cement to the referenced Agreement-..' This asbestos-free materia] is a recommended substitute ''or asbeoloa-1 nmnite in molten metal operations. The Johns-Man vi lie 375L can bo combir.es with Si;r,--r'. a Moot: shipments out of Waukegan, Illinois; and the material is available in the following packagea: 50 lb. paper bags <* . ?r'/bup FOR Wau'-ngan, Illinois 25 lb. plastic bags @ $.?.3r*/bag FOB Waukegan, Illinois Johns-Manvilie will carry an inventory of IS ton per month for Alcoa releases. This inventory will consist solely of the material packaged in SC lb. paper bags. If > rt-r location prefers plastic bags, we suggest that you irme-'n* notify Johrs- Mariville's Pittsburgh Office (Mia;-. Pat Koeyar) o'' your estimated monthly usage. M. J. CAPRIO j. MJC/lmp Distribution: R. D. Griswold - Alcoa, Tennessee H. A. Barton - Badin J. K. Chambers - Bauxite W. E. King - Cleveland T. B. Weber - Corona * A. E. Gantt - Cressone H. P.. Bruaschke - Davenport R. C. Miessler - Lafayette G. H. Duckworth - Massena 0. E. P rantor - Alcoa. Technical Center J. V. Dri&coll - Mobile J. R. Zokaites - Point Comfort C. G. Shining - Rockdale D. J. Fisher - Vancouver C. A. Ha-lliday - Vernon J. D. Eagan - Warrick C. J. Shank - Wenatchee F. E* Mueller - Pittsburgh 23 D. R. B-rrh - Oliver Flnr.a 8 ALCOA000000971 FRO* R. G. LA BAR - ALCOA TECHNICAL CENTER ( PITTSBURGH PURCHASING INDUSTRIAL MATERIALS AND CHEMICALS - 19 TO MEMORANDUM April 12, 1973 RE: ASBESTOS-FREE TROUGH LINING J~M 379-L __________________________________________ Johns-Manvi 1 le 's J-M 37E?-L (Fiberglass-Lumnite) is an asbestosfree material recommended for the following trough lining appli cations : (a) holding furnace to molten metal treatment process. (b) downstream of molten metal treatment process in both troughs and distribution pans. Today J-M 375-L is available only on specie] manui&cLure orders and is not a warehouse item. However, because of our intent to purchase J-M 375-L, Johns-Manvilie will maintain a stock of this material at their manufacturing site in Waukegan, Illinois, for exclusive use by Alcoa. This site is the shipping point for Superex, and a freight savings may ba realized in combining shipments of Superex and J-M 375-L* To arrive at a satisfactory inventory level for J-M 375>~L at the vendox*'s site-, we request each plant to forward to my attention their estimated monthly usage of this material. All ingot plant personnel have been alerted on the use of this material by Mr. F. E. Mueller's letter of April li, 1973* In order to expedite the availability of J-M 37i?-L, your estimated usage is requested by May 1, 1973 M. J. CAPRI0 MJC/lmp DISTRIBUTION: See Page 2 y.st-i-M ALCOAOOOOOQ9718 1 Memorandum April 12, 1973 Page 2 DISTRIBUTION: R. D. Griawold - Alcoa., Tennessee H. A. Barton. - Badin A. E. Gantt - Cressona. H. P. Bruescbke - Davenport R. G. Miessler - Lafayette G. H. Duckworth - Massena 0. E. Proctor - Alcoa Technical Center J. R. Zokaites - Point Comfort C. G Shiring r- Rockdale D. J. Fisher - Vancouver C. A. Halliday - Vernon J. D. Eagan - Warrick C. J. Shank - Wenatchee H. A. Wolff - Suriname Aluminum Companj D. R. Barch - Pittstorglx, Oliver Plaza 8 C. J, Cox/R. E. Albrecht - Pittsburgh, Oliver Plaza 8 F. E. Mueller - Pittaburgh, 23 J. Z, Nelson - Pittsburgh, Oliver Plaza 7 A. J. Sar-tsehev - Pittsburgh, Oliver Plaza 7 R. G. LaBar - Alcoa Technical Center / / AlCqa ooo0 097l, I MESSRS----T-a onmagy/B. p. CARTER - PITTSBURGH 7 FROM D. R. BARCH PITTSBURGH OFFICE ' T0 MEMORANDUM R. G. LaBAR ALCOA TECHNICAL CENTER April 27, 1973 RE: RECOMMENDATIONS FOR TROUGH LINING INSTALLATION Ref: Memorandum, F. E. Mueller & D. R. Barch, "Asbestos Free Trough Lining Materials," April 4, 1973 This memo provides recommendations for preparation, installation, in-service care, and precautions for asbestos free trough lining materials outlined by Mueller and Barch. Recommendations for Preparation and Installation A. Melter to Holder Castables (2 in. minimum thickness): Alcoa C-l, Wahlcast SJP, Kastolite 30, Alfrax 28A, alternatively fused-silica castables (Glasrock 840, Silfrax ARC, Thermosil 120, H-W Visil). 1. Use manufacturer's recommended water addition for pouring. Mix thoroughly, preferably in a cement mixer. 2. Use plywood forms coated with oil, grease, polyethylene sheet stapled to forms. 3. For best results tack weld expanded metal mesh liner (2.5 diamond mesh lathing) to inside of trough. Liner should be 1/2 to 1 in. from inside of trough surface. 4. Post-casting procedure: a. Cover casting with plastic sheet for 24 hours. b. Dry casting in air for 24 hours. c. Castables should be heated slowly to 600F prior to use, preferably overnight. Caution: Avoid flame impingement and rapid heatup. 5. Coatings are recommended, especially for high Mg alloys. Recommended coatings are: Plistix 900 (add sufficient water for wash coating). Brick: Coral P or Chas. Taylor 12054 a. Use 85% alumina phosphate bonded mortar. b. Standard practice for refractory brick installation a i rnA ALCOA0000009720 SF49C l*CV Memorandum April 27, 1973 Page Two B Holder to Molten Metal Treatment Process Moldables (2 in. minimum thickness): JM-375L, JM-375L + JM-460 (50-50 mixture), alternatively fused-silica castables (refer to A above). 1. Avoid excessive water. Use approximately 75-100% by weight to form a soft ball in hand consistency. 2. May be hand tamped and trowel finished or tamped around a form. 3. For best results use expanded metal mesh liner as in item A-3 above. 4. Post forming procedure: Follow same schedule as outlined in item A-4 above. 5. Coatings recommended: J-M Cerakote Plistix 900 (wash coat) C. Downstream of Filters (both trough and distributor) Moldables (1-2 in. thickness): JM-375L, JM-375L + JM460 (50-50 mixture). 1. Follow same procedure as outlined in B above. Drop-In Liners: Glasrock foam (50 pcf) 1. Follow manufacturer's recommended installation and coating procedures. Alternatively a wash coat of Plistix 900 could be used instead of manufacturer's recommended coating. In Service Care 1. Avoid excessive preheating. If preheating is necessary, apply uniform heat, avoiding hot spots and direct flame impingement. 2. Avoid mechanical abuse. a. Install protective caps over linings near tap spouts. b. Lift skulls by hand, minimize scraping and/or gouging. 3. Extra care is required when installing dams in drop-in liners to avoid breakage. Recommend use of ceramic fiber paper (Fiberfrax, Cerapaper, etc.) gasketing around dams and joints. ALCOAOOOOOQ972 Memorandum April 27, 1973 Page Three 4. A program of scheduled inspection and maintenance should be implemented. It is recognized that individual plant differences exist in trough usage and design, but it has been concluded that these differences can be taken care of if made known and discussed. The ingot plant metallurgists are requested to inform F. E. Mueller of contacts with various vendors and receipt of sample materials. In addition, brief feedback on plant experiences, either pro or con, with the recommended materials are requested. New materials and/or revised procedures for installation and use will be added to the list as they develop. D. R. BARCH R. G LaBAR RGL:sh cc: TID M. J. Caprio - Pittsburgh 19 F. E. Mueller - Pittsburgh J. Z. Nelson/A. J. Sartschev - Pittsburgh Oliver Plaza R. E. Albrecht - Pittsburgh Oliver Plaza C. J. Cox - Pittsburgh Oliver Plaza R. W. Wrenn/J. A. Dunbar - Pittsburgh 23 T. B. Bonney/R. P. Carter - Pittsburgh 7 V. W. Rieke - Pittsburgh 24 J. H. Mudge - Badin R. C. Hinkle - Badin R. L. Givens - Badin J. H. Baugh - Badin C. T. Barger - Badin W. E. Goza - Badin R. C. Ashurst - Cressona B. J. Axelsson - Cressona R. B. Hanson - Cressona N. 0. Kraft - Cressona E. J. Schafer - Cressona D. D. August - Davenport L. D. Dunlap - Davenport R. P. Dieffenbach - Davenport R. J. Reitz - Davenport J. W. Mclntee - Davenport J. D. Yerger - Davenport ALCOA0000009722 Memorandum April 27, 1973 Page Pour cc (Cont.) W. G. Allen - Lafayette W. K. Dalton - Lafayette J.- B. Dolan - Lafayette P. M. Tomalin/J. E. Jacoby - Lafayette F. R. Knox - Lafayette J. J. Hicks - Logans Ferry W. D. Helmick - Logans Ferry G. B. Campbell - Massena R. W. Knapp - Massena G. H. Lantz - Massena B. A. Schafer - Massena J. N. Rumble - Pt. Comfort C. L. Green - Pt. Comfort D. N. Harvey - Pt. Comfort R. A. Molsberger - Pt. Comfort R. M. Rose - Pt. Comfort T. J. Randall - Rockdale B. M. Stamer - Rockdale W. R. Smith - Rockdale G. L. Paolino - Rockdale R. E. Aungst - Tennessee L. L. Held - Tennessee J. C. Vergho - Tennessee J. N. Lehigh - Tennessee R. L. Dearstone - Tennessee D. E. Luckett - Tennessee C. R. Windbigler - Tennessee B. R. Hood/E. L. Rooy - Tennessee H. F. Godges - Vancouver P. F. Woodward - Vancouver L. J. Sullivan - Vancouver A. M. Shanks - Vancouver M. Scherbak - Vancouver W. C. Harvey - Vernon J. R. Jones - Vernon L. F. Hughes - Vernon R. J. Stokwisz - Vernon M. L. West - Warrick R. L. Parsons - Warrick J. A. McCune - Warrick B. Anderson - Warrick M. l. Redhair - Warrick N. L. Lawson - Warrick C. R. Seltzer - Wenatchee J. A. Thompson - Wenatchee K. A. Isaksen - Wenatchee J. L. McKinstry - Wenatchee J. E. Gunn - Wenatchee R. C. Studley - Wenatchee W. P. Helsley - Suriname 0. R. Gonsalves - Suriname N. L. Sundaram - Suriname J. R. Herrick - ATC R. J. Ormesher - ATC C. R. Howie - ATC L. Resch - ATC R. Bachowski/G. Ponzani - AT R. E. Spear/G. K. Turnbull S Div. File 12B10319 !1 / cc: A. F. Malort, Corona & R. H. Allen, Corona (5/29/73) ALCOAOOOOOQ9723 / FROM.Ft E. MUELLER INGOT AND POWDER DIVISION "PITTSBURGH OFFICE - 23 FILE COPY T0 MEMORANDUM April 6, 1973 RE: Ref: ASBESTOS-FREE TROUGH LINING MATERIALS r F. E. Mueller and D. R. Barch to Memorandum, 4/4/73, Re Same Caption The referenced memorandum presented recommendations for asbestos free materials in trough lining applications. These recommen dations were agreed upon at a March 21, meeting of ATC and Pittsburgh personnel wherein plant and ATC development programs were also discussed. Table I reveals the present materials being used at each of our production plants, and it is readily evident that we are presently deeply involved in asbestos usage. Also shown in Table I are the asbestos free materials either already under investigation or being proposed for investigation at the plants. It is encouraging to note that the recommended JM-375L is already being considered by half of the. plants. Unfortunately, Table I also reveals that some plants have: 1) spent "X amount" of time, effort, or money on evaluation of previously known unsuitable materials 2) unsuitably evaluated suitable materials 3) are investigating materials totally unknown to both ATC and Pittsburgh To minimize the possibility of misdirected effort, the review at the above meeting covered those materials either previously or presently being evaluated at ATC. These materials are shown in Table II. These materials fall into the four natural categories as shown. Comparative data are shown, where available, and continuing work at ATC will provide the lacking and additional data from the following areas of investigation: 1) R-340 and R-6l6 - Basic data shown In Table II. These materials show great promise but are presently in the development stage at one plant (Warrick) working with ATC. A small plant will be contacted to simultaneously evaluate these materials under a development program as smaller plants do not have the same service requirements as Warrick. 2) Consolidated Ceramic Products - Moldable Mix #3924 ATC will evaluate this material in cooperation with Vernon Works, but this material is still to be considered in. the research stage. 3) General further refinement of: a) Vacuum formed drop-in trough liners from Foseco and Babcock & Wilcox. b) Various materials such as Kast-O-lite 30, Mandoseal, JM-375L, coatings, mortars, and installation procedures. c) Refractory resistance to salt penetration. H ALCOA ALCOAO 000009724 Memorandum April 6, 1973 Page Two The ingot plant metallurgists are requested to inform this office of contacts with various vendors and receipt of sample materials. In addition, brief feedback on plant experiences, either pro or con, with the recommended materials are requested. F. E. MUELLER FEM/mj cc : M. J. Caprio - Pittsburgh Office (19) J. Z. Nelson/A. J. Sartschev - Pittsburgh, Oliver Plaza C. J. Cox/R. E. Albrecht - Pittsburgh, Oliver Plaza D. R. Barch - Pittsburgh, Oliver Plaza R. E. Spear/G. K. Turnbull - ATC C. R. Howle/R. G. LaBar - ATC R. W. Wrenn/J. A. Dunbar - Pittsburgh Office (23) G. L. Paolino - Rockdale Operations D. E. Luckett - Tennessee Operations C. R. Windbigler - Tennessee Operations M. Scherbak - Vancouver Operations R. J. Stokwisz - Vernon Operations M. L. Redhair - Warrick Operations J. E. Gunn - Wenatchee Operations 0. R. Gonsalves - Suriname Operations C. T. Barger, Jr. - Badin Operations R. P. Dieffenbach - Davenport Operations F. R. Knox - Lafayette Operations G. B. Campbell - Massena Operations R. A. Molsberger - Pt. Comfort Operations R. L. Givens - Badin Operations B. J. Axelsson - Cressona Operations L. D. Dunlap - Davenport Operations W. G. Allen - Lafayette Operations J. R. Herrick - ATC B. A. Schafer - Massena Operations D. N. Harvey - Pt. Comfort Operations W. R. Smith - Rockdale Operations J. N. Lehigh - Tennessee Operations A. M. Shanks - Vancouver Operations L. F. Hughes - Vernon Operations B. Anderson - Warrick Operations K. A. Isaksen - Wenatchee Operations ALCOAO 00000972 PLANT TROUGH LINING MATERIALS ' TABLE I PLANT BADIN PRESENTLY USED MATERIALS Castable before filters Glasrock after filters Some marinite and some asbestos-lumnite PRESENTLY EVALUATING MATERIALS Johns-Manvllle 3751 CRESSONA High-alumina brick, castable and : asbestos-lumnite before filters. Asbestos-lumnite or marinite I after filters i JM-375 and JM-A60 \ on order j j DAVENPORT LAFAYETTE MASSENA ' Brick or castable before filters Glasrock and marinite after ; filters. 1* ' Asbestos-lumnite JM-375 and JM-lf60 Asbestos-lumnite before filters. Marinite after filters. JM-375 and JM-H60 POINT COMFORT ROCKDALE Marinite ; Asbestos-lumnite . converting to JM-375 across the board. Fused silica found unsatisfactory. Evaluated JM-375, JM-460 and Karchrome. Found all equal. TENNESSEE 1 Glasrock NORTH PLANT Thermotec TENNESSEE SOUTH PLANT Marinite R-340 Thermotec material in DC trough. Glasrock failed at tap-hole VANCOUVER : Asbestos-lumnite Glasrock, JM-375 Fibrefrax or Kaowool to replace asbestos filters. VERNON ....... ........ WARRICK Asbestos-lumnite -......... ..............Marinite - -...... -- Consolidated Ceramic products #3921l-Moldable mix i -............................ R-340 and R-616 ........... ... WENATCHEE Asbestos-lumnite Marinite JM-lt60 ^-All plants have been notified to request JM-375L ALCOAO 000009726 ! ! s s a>i s s sa s a 8 s SJ A:TSe -g-m.4 a1Si -mu *m1* u i g sua b be is 15 a5 51 &M 1 e * 5< OM 1 b In 5 S i; TABU I I ALCOAO 000009727 I FROM F. E. MUELLER D. R. BARCH PITTSBURGH OFFICE TO MEMORANDUM April *, 1973 RE: ASBESTOS FREE TROUGH LINING MATERIALS A meeting concerning the captioned was held on March 21, attended by representatives from: Melting and Ingot Casting Division, ATC; Pittsburgh Mechanical Engineering; Pittsburgh Ingot and Powder Division; and Pittsburgh Purchasing Department. The objectives of the meeting were to: 1) Discuss which asbestos-free materials have worked satisfactorily in the plants. 2) Review which asbestos-free materials have been or are being investigated at ATC. 3) Arrive at a recommendation of materials for the plants to replace asbestos-containing material in troughing applications right now. Recognizing that asbestos-containing materials are used in many other Alcoa and Ingot Division applications such as pot linings, furnace linings, and headers, by definition the only concern of the above meeting was related to: a) Troughing between melters and holders. b) Troughing between furnaces and molten metal treatment processes. c) Troughing between molten metal treatment processes and molds--this includes the distributors and FDC pot linings. Elimination of asbestos containing materials for other applications will be covered by related but separate programs. Information on objectives 1) and 2) above will be distributed by separate memorandum, however, summarizing this information, those present at this meeting agreed on the following recommendations for objective 3): A. Melter to holder Recommended: Coated^- castable (Cl or SJP) Brick (coral P or Chas. Taylor 1205*1*2) 3 Preferred alternate: Coated fused silica castable 2 B. Holder to Molten Metal Treatment Process Recommended: Coated-'- JM-375L Preferred alternate: ALCOA Coated^ fused silica castables 2 r4se (av ALCOAOOOOOQ9 728 I Memorandum Page Three April 4, 1973 cc: J. H. Mudge - Badin Operations R. C. Ashurst - Cressona Operations D. D. August - Davenport Operations W. K. Dalton - Lafayette Operations G. H. Lantz - Massena Operations J. N. Rumble - Pt. Comfort Operations T. J. Randall - Rockdale Operations R. E. Aungst - Tennessee Operations L. L. Held - Tennessee Operations H. P. Godges - Vancouver Operations W. C. Harvey - Vernon Operations M. L. West - Warrick Operations C. R. Seltzer - Wenatchee Operations W. P. Helsley - Suriname Operations R. C. Hinkle - Badin Operations N. 0. Kraft - Cressona Operations R. J. Reitz - Davenport Operations J. B. Dolan - Lafayette Operations J. J. Hicks - Logans Perry Operations R. W. Knapp - Massena Operations C. L. Green - Pt. Comfort Operations B. M. Starner - Rockdale Operations J. C. Vergho - Tennessee Operations P. F. Woodward - Vancouver Operations J. R. Jones - Vernon Operations R. L. Parsons - Warrick Operations J. A. Thompson - Wenatchee Operations R. L. Givens - Badin Operations J. H. Baugh - Badin Operations B. J. Axelsson - Cressona Operations R. B. Hanson - Cressona Operations L. D. Dunlap - Davenport Operations J. W. Mclntee - Davenport Operations W. G. Allen - Lafayette Operations J. R. Herrick - ATC R. J. Ormesher - ATC B. A. Schafer - Massena Operations D. N. Harvey - Pt. Comfort Operations W. R. Smith - Rockdale Operations J. N. Lehigh - Tennessee Operations R. L. Dearstone - Tennessee Operations L. J. Sullivan - Vancouver Operations A. M. Shanks - Vancouver Operations L. F. Hughes - Vernon Operations J. A. McCune - Warrick Operations B. Anderson - Warrick Operations K. A. Isaksen - Wenatchee Operations J. L. McKlnstry - Wenatchee Operations C. T. Barger - Badin Operations R. P. Dieffenbach - Davenport Operations F. R. Knox - Lafayette Operations G. B. Campbell - Massena Operations Memorandum April 4, 1973 Page Four cc: R. A. Molsberger - Pt. Comfort Operations G. L. Paolino - Rockdale Operations D. E. Luckett - Tennessee Operations C. R. Wlndbigler - Tennessee Operations M. .Scherbak - Vancouver Operations R. J. Stokwisz - Vernon Operations M. L. Redhair - Warrick Operations J. E. Gunn - Wenatchee Operations O. R. Gonsalves - Suriname Operations B. R. Hood/E. L. Rooy - Tennessee Operations N. L. Lawson - Warrick Operations R. C. Studley - Wenatchee Operations N. L. Sundaram - Suriname Operations W. E. Goza - Badin Operations E. J. Schafer - Cressona Operations J. D. Yerger - Davenport Operations P. M. Tomalin/J. E. Jacoby - Lafayette Operations W. D. Helmick - Logans Ferry Operations R. M. Rose - Pt. Comfort Operations M. J. Caprio - Pittsburgh Office (19) J. Z. Nelson/A. J. Sartschev - Oliver Plaza, Pittsburgh R. E. Albrecht - Pittsburgh, Oliver Plaza C. J. Cox - Pittsburgh, Oliver Plaza R. W. Wrenn/J. A. Dunbar - Pittsburgh Office (23) T. B. Bonnev/R. P. Carter - Pittsburgh Office (7)________ V. W.Rieke - Pittsburgh Office (24) R. E. Spear/G. K. Turnbull - ATC C. R. Howle/R. G. LaBar - ATC ALCOAO 000009730 Memorandum April 4, 1973 Page Two C. Downstream of Filters (Both trough and distributor) Recommended: Coated^ JM-375L Preferred alternate: Coated^ Glasrock foam These recommendations pertain to materials which have been found to be suitable, practical, available, and asbestos free. Shortly following issuance of this memorandum, Pittsburgh Engineering and ATC will issue a Joint memo with recommendations for preparation, installation, in-service care, and precautions for each of the above recommended materials. The ingot plants are to begin programs for orderly replacement of all asbestos containing trough materials with the above recommended materials bearing in mind that on July 1, 1976, the present OSHA asbestos dust exposure limit becomes even tighter. If any plant finds restrictions to their use of these recommended materials for these applications, they are specifically requested to contact any one of the following in this order: D. R. Barch - Pittsburgh Mechanical Engineering F. E. Mueller - Pittsburgh Ingot and Powder Division R. G. LaBar - ATC It is recognized that individual plant differences exist in trough usage and design, but it has been concluded that these differences can be taken care of if made known and discussed. F. E. MUELLER D. R. BARCH FEM/DRB/mJ distribution page three Refractory coating and/or mortar should be Plystix 900. 2Glasrock 820 and 840, Thermosll 120 and TG, or Sllfrax ARC. ALCOAO 000009731