Document Mgpm99jyDJeKZxOwgy378J9M
FILE NAME Owens Corning OC
DATE 1968 Mar 15
DOC OC406
DOCUMENT DESCRIPTION Internal Report - Alternate Processes for Manufacture of High Temperature Insulation
INIKA LUMPANT
{
ea .
-
Mr. B. E. Boyd Toleds
R. F. Shannon Granville
PEASIBILITY STUDY - ALTERNATE PROCESSES FOR MANUFACTURE OF HIGH TEPERATURE INSULATION
Deto March 1968
fo
tc
;
. .
Mr. E. Gay Tolod
Mr. R. S. Grant Toled Mr. M. Hardwick Berlin Mr. R. J. McEvoy Granville Mr. C. G. Staslin Toled Mr. R. P. Witschen Toledo
Central Files
,
Last January you asked me to take a good hard look at the various processes under consideration for the new Southwest Kaylo facility
N
a
:
our Attached is a copy of my report which summarizes study of every known
process As you will note I reduced the list to just three processes which
at merit further consideration for installation the new facility They
include pan pouring filter pressing
bonded aggregate
and ;
Silihoff The most important question which must be resolved before any final selection
of process is made relates to the use of asbestos
Because of
-
this problem I also included an evaluation of Multi in my report
After all it is the only asbestos free product available
-
-_ -
-
or Unfortunately I had to compare the various processes strictly on a technical
basis I am not in the position at the moment to make a recommendation
as to the process combination of processes we should select for the
new facility because of the lack of cost data As soon as cost projections are completed by Gay and Brooks on all of the processes still under considera-
tion we will be able to at least take a recommendation as to which process
we feel offers OCF the best product and gross margins in the years to come
overload I am sure are already aware of the advantages and disadvantages of
Berlin's pan p uring process Filter pressing has a lot of merit It
a stronger better looking product the product is precision molded
produces
Bonded aggregate products
and the process itself is highly automated as they now exist on the market have serious
shortcomings They break still want to considor
easily in transit and when handled Why then would we
this process The reason is if Philip Carey ever solves their breakage
problem they will have the best product on the market It is precision
molded lends itself to automation is water repellent higher temperature
resistant and is a autoclaved product Last but not least is the fact
it has the best chance of being made asbestos free The only reasons for
considering Multi are the facility is already avaofiltahbelecutrhreentproodvuecrtload
is free of asbestos fibers and it could relieve some
at Berlin especially in the block market
It is my hope this report and disadvantages of each a much better position of best for the new facility
gives you a better insight process Once we get cost making a recommendation as
and for the 1970+ market
as to the advantages data we will be in to which process is
* -
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N. PLAINTIFF'S
Bayone
EXHIBIT
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INTRODUCTION
The expanding market for Kaylo pipe and block has made it necessary for OCF not only to expand the Berlin operation again in 1968 but also to consider building a new facility in the Southwest The problem facing Management
today is defining the type of process to be installed at the new facility Should it be Berlin's pan pouring process one of the more automated processes developed by our competitors or a combination of processes Also to be considered by Management is whether Multi has a place in the high temperature market of the future ,
To help Management decide which process or combination of processes is most suitable for installation at the new Southwest facility Kaylo R & D carried out an intensive evaluation of all known processes for the manufacture of high temperature insulation products A lack of cost data on competitive processes made it necessary for us to limit this study to strictly a technical comparison rather than a more preferred technical evaluation
SUMMARY
oe
d
The Kaylo R & D study confirmed the fact no other product can compete with Kayl block made by the pan pouring process It is by far the best on the
market Block made by the filter press process tends to delaminate bonded aggregate block crumbles It should also be noted that neither the filter press process nor the bonded aggregate process can be used to produce structural 17 type core for the UL fire rated door market
af
To maintain our position in the block and core markets we must continue to
by produce such products the pan pouring process Management must decide
whether block and core products are to be produced at the new Southwest facility If the answer is yes a pan pouring flatware line will then have to be installed
The second decision Management must make relates to the type of process qr
combination of processes to be installed at the Southwest facility for the
production
other than
sufficient
the timing
of pipe insulation If the decision is made to go to a process pan pouring technology will have to be purchased There is not time to develop from scratch an alternate process and still meet
for construction of the Southwest facility
Management has a number of process options to chose from for the production of pipe insulation at the new Southwest facility They include 1 a filter press or bonded aggregate process to produce all sizes of pipe up to and including 30 inch OD 2 a pan pouring process to produce the smaller pipe sizes and a filter press or bonded aggregate process for the production of
large size sectional pipe and 3 a pan pouring process to produce the smaller
pipe sizes and a Multi facility located anywhere for the production of
large size sectional pipe With our current level of technology the pan pouring should not be considered for pouring large size sectional pipe at the
process
new facility
-2-
SUMMARY Cont)
for indicates that from a technical standpoint no one process
The Kaylo R & D study
for the manufacture of
has a distinct advantage over other known processes
each also has a
-/
high temperature pipe insulation
Each has its advantages
cost analysis is made on
~^' number of disadvantagbees ablOenlytoafdteecridea wchoimcphrehpernoscievses or combination of processes
each process will we
is most suitable the new Southwest facility
technical evaluation of all known processes for the manufacture
Our intensive
insulation products indicates there are only three processos
the Southwest
of high temperature
installation at
of further consideration for possible
filter
worthy
Kanville's
facility They include the Berlin pan pouring process
All of the other
press
process
and
Philip
Carey's bonded
aggregate
process
exception
of
Multi-
considered during this study with the possible
suitable
processes
because 1 the process would not yield a product
Temp were rejected
not sufficiently developed to meet the
for OCF's needs or 2 the process was
The Crosfield
schedule for installation in the new Southwest facility
time
autoclaved process failed on both accounts Multi
filter press considered for the production of large size sectional pipe and
should only be additional facility for the production of high temperaturetemperature
possibly as an
block when Berlin becomes overloaded
decision is made by Management as to the process they will market
Before a final
and the product they will
adopt for installation at the Southwest facilitynumber of basic questions relating
in the 1970's and 1950's they must consider a
of a higher
need for automation need for a product
to rising labor costs the asbestos fiber health threat
This report will attempt
quality level and
and acted on before the final
to outline the questions which must be consideredwill also provide for Manage-
decision as to process is reached
This report
for each of
and disadvantages
ment's consideration uandleirstconofsidteherataidovnantfaogresthe new Southwest facility
the processes still
RECOMMENDATIONS
Research Center has already been made to appraise
A visit to Manville's This visit must be followed by an OCF prepared
the filter press process
visit A visit should also be made t Philip
cost projection and a plant
It too should be followed-
Carey to appraise their bonded aggregate process visit
up by a cost projection and if possible a plant
the filter press bonded aggregate
Cost projections must be made or updated on
fair comparison cost
pan pouring and Multi processes
To achieve a
made
a more automated
for the pan pouring process should be
on
since
projections
exists at Barlin The latter is a reasonable request
process than now
to reduce labor and batch
major & plant proghriagmheris dceugrrreeentolfy auuntdoemrawtaiyon of the pan pouring process
costs and to achieve a
to must be
on the filter press and bonded aggregate processes
Cost projections
of activity One cost projection should be based on
prepared at two levels
will be used to
the assumption the filter press or bondaendd aigngcrleugdaitneg p2r4ocexss" The second cost
produce the entire line of pipe up
REICHNENTATIONS REICHNETAIONS REICHNENTATIONS Cont ) |
pouring should be based on the assumption the filter press or bonded aggregate
pprroocjesesctiwoinll be limited to the production of large size sectional pipe only
these conditions it must be tied in with the cost projection covering
Under
of the smaller sizes of pipe The Multi cost projection should
pan pouring
be
limited
to large size sectional pipe only
It too must be tied in with the
projection covering the pan
of the smaller sizes of pipe To get
economic
picture
of
the
various
options available to
us
cost projections :
should be prepared on the following process combinations
Oction
ANMEM ANMEM
ANMEM
ANMEM
ANMEM
Block
Fan Pan Pan Far Fan
poured poured
poured poured poured
Pire
Filter pressed.
Bonded aggregate Small sizes pan poured Small sizes pan poured
Small sizes pan poured
large large large
sizes sizes sizes
filter pressed bonded aggregate
Multi
facility It is possible the new Southwest
will be limited to the production
of pipe Kayls block would all be produced at Berlin and stockpiled at various
distribution centers in the Southwest and West Since this is a possible
Management option cost projections should also be made on the five pipe process combinations listed above minus the pan pouring facility for block
In deciding the type of process to be installed in the new Southwest facility
Management will have to give serious consideration to the asbestos
health threat What effect if any will it have on the future growth
of the overall high temperature insulation market and our share of the market
in
particular
particular
particular particular
particular
It could be the
most important decision we face in deciding
which process to install in the Southwest facility
The only asbestos free Multi All three
product on the market during the past 5-10 years was
consideration consideration
pan
pouring
filter
filter
press
and
and
bonded
bonded
aggregate
now
under
consideration
for
proceses processes pan pouring
contain
the new facility contain
asbestos
The probability of removing asbestos
from the autoclaved bonded aggregate product is far greater than it is
from products made by either the Manville filter press or OCF's pan pouring
process both of which require autoclaving and are based on highly alkaline
batch compositions
a In the event Management decides to install the Berlin pan pouring process for
and block at the new Southwest facility Kaylo R & D still recommends
both pipe
either the filter press or bonded aggregate also be
that an alternate process
This should
installed on
limited basis either at Berlin or at the new facility
be further supported by an & D program on the chosen alternate process at
These recommendations are being made because it is our opinion
Granville
to
face the process dilemma we
the company should not have
again
demand a product made by a process
are now facing If future market conditions
we will have the technology knowhow and experience
other than pan pouring
to the new
without delay
to convert our manufacturing facilities over
process
.
1
Regardless of the decision west facility the major R
the pan pouring process at
as to the process to be installed at the now South-
& plant program currently underway to automate Berlin should proceed full speed ahead especially
for the processing of Kaylo block
a
SIENTATIONS
SIENTATIONS SIENTATIONS SIENTATIONS
SIENTATIONS
am my SIENTATIONS Pee SIENTATIONS SIENTATIONS
Cont
Cont
Cont
Cont
.
Nv During this planning period many have suggested two profcoerssbelosckbe aindnstsamlallelder
the new Southwest facility the panthepoumrainnugfapcrtourceessof larger sizes of sectional
sizes of pipe and a filter press for
and the
which must be resolved is will our customers
pipe The first question
If the answer
and C Marketing Division accept two types of pipe products
if it
is yes the second question is would the market also accept Multi
were limited to the larger sizes of sectional pipe
If the only reason for purchasing a filter press or bonded aggregate process
is for the manufacture of large size sectional
from one of our competitors
i.e. sizes in the 13 to 24 inch ID range
then we must ask whether it
size sectional
wpoiupled be better to direct a major effort toward producing large
at acceptable gross margin levels rather
pipe by the pan pouring process
and technology
than direct such a major effort and expense toward a new process
been little
for such a small portion of the overall market Actually there has
technical effort directed directed toward learning how to pan pour large size
any
To achieve such a result changes
sectional pipe with adequate gross margins
and handling
in mold design as well as new techniques of pouring prefardening
be developed If Multi pipe is acceptable to the market and gross
must
when limited to large size sectionals
margins are projected as being adequatea process and a facility available to
only then CCF already has a product
service the large size sectional pipe market
DISCUSSION DISCUSSION
DISCUSSION
DISCUSSION
DISCUSSION
-0f
Asbestos
which must be resolved is the use of asbestos as the rein-
The firstfiqbueerstioTnoday all high temperature insulations contain asbestos
asbestos
forcing
In fact during the past 10 years the only known
reinforcement
the market was Multi a product
free high temperature insulation on
is the
stli for a brief period of time by OCF To emphasize how important
fiber reinforcement I would like to call to your
problem of asbestos as a
dated October 9 1967 to D. M. Barthold concern-
attention D. W. Ladd's letter
Quoting from Mr. Ladd's memo I think
ing asbestos and Kaylo expansion
to this whole
other consideration which is of paramount importance
there is no
well aware the government will probably blow the whistle
subject As tyhoeu ua se re of asbestos in the not too distant future and before we
relative to
at Berlin and consider putting
embark upon a substantial expansion program
that we have an
Southwest we had better be damn sure
facility in the
Work has been done on this in the past and
answer to the asbestos threat
to date there has been no successful answer
asbestos fibers in calcium silicate products
probability of replacing
has been found by
50/50 problem rated
at best at
No solution to this
Manville told us recently they too have had no success in getting
OCF survive the autoclave process If the decision is to install
at
glass glass fiters to
procespsrocess
process
process process process
or or
the the
Manville
filter
press
process
the Berlin Berlin pan pouring the
Berlin Berlin
Berlin Berlin
Berlin
pan pan
pouringpouring pouring pouringpouring process process process
pouring process
Berlin
the fact the reinforcement used will
thethe Southwest facility we are accepting
the next
modifying probably probably be
asbestos
unless
a breakthrough is made by R & fiber's to survive the alkali
D during
and the autoclaving
probably in
modifying
modifying class
Asbestos
Asbestos
Asbestos
Cont Cont
Cont
,
If Management decides the asbestos threat is still with us then careful -
consideration should be given to the bonded aggregate process It does not
involve the highly alkaline calcium silicate batch which attacks glass
and does not require as part of the process the use of expensive autoclaves
which
which
which which
which which
which
which which
dissolve
glass
Although Careytemp Philip Carey's bonded aggregate
Anghigh
high
high
temperature insulation
contains some asbestos the probability of develop-
high
Ang
a bonded aggregate product reinforced with 100 percent glass fibers remains
Ang
Ang
quite quite
quite quite
high
high high
JohnsJohns Johns Johns Johns G ManvilMaenville Manville Manville Manvile Manville told us during our recent meeting in Manville New Jersey they
surprised were were
were
surprised
we never followed on our high temperature glass fiber insulation
product productproduct product
concerned concerned concerned
conerd line would
concerned concerned concerned
would
would would
and real
is insulation and insulation insulation
& insulationD effort
eeffortort to adequate adequate adequate
Temp By the tone of the conversation they seemed to be
this product If it were to be placed back on the market bebe the only asbestos free product available If the astestos threat
a serious threat to OCF's participation in the high temperature
market
market
future then should consider directing a major
effort effort effort
or process modifications to raise gross margins
adequate
adequate
Alternate Alternate Alternate Alternate Alternate Alternate Alternate Alternate Alternate
If If a decision
decision decision decision decision decision
Southwest Southwest Southwest
Southwest
Southwest Southwest Southwest Southwest
Southwest
facility facility
facility
devlop devlop time
time time timetime to to
develop develop develop
for for construction construction construction construction construction construction construction construction construction
probaly probably probablyprobably probably probably probably probably
and and and its its
its must must must must all all all
mean mean mean mean
adverse adverse adverse
adverseadverse carefully carefully
is made to install a process other than pan pouring at the new
facility technology will have to be purchased There is not sufficient
from scratch an alternate process and still meet the timing
the new facility Since the purchase of technology will
taking out a license from a competitor the cost of the license
effect on gross margins and competitive position in the market .
carefully considered
.
OCF already
plus a patent
months in mechanizing
will
will will
be
be
block and
block block at block
has
the
yearsyears or more of technology on pan pouring and several years on Multi Major strides have been made in recent
mechanizing the pan pouring process at Berlin No costs for licensing
the par pouring process is chosen for producing both pipe
new facility
The same is true if large size sectional pipe
are produced produced produced by the Multi process
Competitive
Competitive Competi ve Competitive
Processes
Before tabulating the major advantages and disadvantages for each of the
processes still
for Multi
under consideration for I would like to compare
installation briefly each
in the new facility process against the
three
and others
major problems with products made by the pan pouring process include they are not as strong as products made by the filter press process 2
they have a visual appearance inferior to both filter press and bonded aggregate
products 3 not being precision molded dimensional and nesting problems result in customer complaints and 4 products made by pan pouring involve
considerable hand labor to produce Labor costs for the production of pan
poured pipe constitutes nearly 40 percent of the total manufacturing cost With labor costs rising rapidly pipe rade by the pan pouring process could bo
i
.
(
ae
Compet
Processes
Cont
at in the future with pipe made by one of
placed a competitive disadvantage
bonded aggrogate It
automated processes such as filter press or
the past 5
the more unfortunate OCF did not place the same emphasis during
is quite
as our competitors competitors
10 years on automating our panpopsosuirbilengwe prwoocuelsds not be today in the
theirs If we had it is quite
having to take a license from one of our competitors
does have a number of advantages over
Kaylo made by the pan pouring process
include 1 the ability to
aii other products on the market today They
and heavy density
one
both light density heat insulation
produse by
process material
2 the tremendous flexibility of the daily mix of
structural core
desired various sizes and thick-
goods
coupled
with
the
ability
to
expedite
best
service
shipping
cycle
in
the
of both pipe and block 3 the
costs of
resses
industry
4 the versatility of batch composition to achieve lower
the
bbaatcthch on cubic foot basis
5 production of the best block products on
insulation and structural
Market and 6 production of light density heat
core with maximum temperature resistance of 1800 F.
the filter press developed by Kanville
As to competitive processes interest from OCF personnel
There is no doubt it has a
has drawn the most
over both the pan pouring and bonded aggregate processes
nicer of advantages
have considerably higher flexural compressive
Products made by this process better visual appearance than Kaylo and like
and impact strengths It has a
pipe and block products
which are precision of large
the bonded aggregate process produaclesso lends itself to the production
molded The filter press process
OD Field breakage of filter
size sectional pipe up to and including 30 inches
now developed by
pressed products is extremely low Finally the process as
made by the bonded
Manville
is highly automated When compared to products products have two distinct advantages
higher
aggregate process filter pressed
characteristics
physical strengths and lower breakage
has number of disadvantages when compared directly
The filter press process
a
include 1 shipping delivery cycles are
with the pan pouring process They
mix of goods is poor 3
2 flexibility in the daily
of fittings
fabrication
considerably longer batch costs are higher
4 does not lend itself to the
when moisture
5 product densities are higher
6 has a tendency to delaminate structural core 8 produces block products
is absorbed 7 will not produce
efficiencies due to a 5 to
less
acceptable
to the
market
and
9
operating
low
compared
to
operating
hour period for mold change over are still very
efficiencies for the pan pouring process
as developed by Philip Carey has many advantages
The bonded agagregate gregate process
If and when Philip
over both the the pan pouring and filter press processes
will have by far
solves their handleability and breakage problems they
the bonded
Carey
Some of the major advantages of
the best product on the market
low manufacturing cost 2 a very low
aggregate process include 1 a very
4 ability to use glass fiber
investment cost
3 a autoclaved product
molded product 6 a
5 ability to produce a precision
investment costs
as reinforcement
rates at low
which lends itself to high production
p7 roceass1500 to 1600 F temperature resistant product and 8 water repellency
Competitive
Competitive
Processes
Processes
Cont
Cont
When
compared
directly
directly with
filter
pressing
the bonded
aggregate
process
has
t major disadvantages It produces a product with lower strengths and one that is susceptible to breakage when roughly handled On the other hand it
has a number of advantages over filter pressed products Overall process costs
are lower batch costs are substantially lower the product can be marketed
for higher temperature applications 1500 vs 1200 F it is water repellent fittings can be fabricated from the product investment costs are much lower no autoclaves and it probably can be made free of asbestos The ability to
use glass fibers as reinforcement in this product when combined with the tremendous glass fiber knowhow available to OCF personnel makes it mandatory mandatory
our Management give careful consideration to the bonded aggregate process before
rejecting it in favor of a process which requires asbestos as the reinforcing .
fiber
Where does the Multi product and process fit in the overall picture
The product as we currently know it does not yield adequate gross margins to
compete across the board with pan poured filter pressed or bonded aggregate
products
products However one must remember it is a glass fiber product one that
is for OCF to market and one that could be produced at any of our were to be placed back on the market it would be the only
product on the market today
ShouldShould ShouldShould Should wewe go
install
install
the
the
pan
pouring
process
at
the
new
Southwest
proces to process facilityfacility facility facility facility facility facility ratherrather rather
the filter press or bonded bonded
aggregate
This is
facility
facility
a decision decision decision decision
decision decision decision which which which which
Management Management Management must make If the filter press or bonded aggregate
processprocess process process process process
is is
Management chosen
produce
the
complete
range
of
products
at
the
new
facility
then
then
then
then
there
there is is no need to reconsider Multi at this time
If and only if
asbestos asbetos asbetos thethe the asbestos asbestos asbestos asbestos
asbestos asbestos asbestos threat reaches the danger point would asbestos asbestos free free product such as Multi for the
ar market
market
market market
market market
we
then
want
to
reconsider reconsider reconsider
high temperature insulation
If
for for for some some
reason such high cost of licensing Management decides to install
the the
pan
the decidngdeciding deciding
of Multi
decidng decidng MultiMulti Multi -
pouring
deciding pouring
Temp Temp
pouring process in the new facility we will again be facing the problem
how to produce large size sectional pipe Under such circumstances could be the answer Even if Management decides to go with the pan
pouringpouring
pouring
pouring
pouring
pouring
pouring
license license
license license license license license license license
procesproces process process for all production
the the filter press or bonded
except large size aggregate process
sectional and choses to
to produce these products
we must must must
license license license license license license license
raise raise raise raise raise the question whether it is worth all the problems and costs to
another
another another another another another
process
from
one
of
our
competitors
for
such a
small percentage
of of
the the
market
market
market market market market .
We must market large site sectional pipe to remain competitive competitive not to license another process we would have three choices ; 1
size sectional pipe as we do now at Berlin 2 start up a
If we chose fabricate crash program
learn how to pour large size sectional pipe at
pouring process or 3 could market a line
pipe Only under those conditions where all
adequate of Large size sectional
production except large
Multisize
sectional pipe is to be made by the pan pouring process at the new Southwest
Berlin facility would I recommend we reconsider Multi Limited to the production to of large size sectional pipe and block when Berlin block producing facilities
.
@.
.
oh a rae
-8-
Competitive Processes Cont
total become over taxed as they are
today
Multi may have a place in today's
sectional pipe by the Multi-
market It may be cheaper to produce large size
used at Berlin It
Temp process than by the current fabrication technique
would
increase
our
share
share
of the
market immediately
Pan Pouring Havi
1 The highest mix of goods flexibility This flexibility results in the lowest workable finished goods inventory for any of the processes now in use for the manufacture of high temperature insulation products
2 The best shipping cycle in the high temperature insulation industry
with normal inventories
acknowledged
is the acknowledged leader
3. Block produced by the pan p uringprocess
the market today
of all flatware high temperature insulations on
is an established process at OCF Plant personnel are
&. Pan pouring
20+
working background with
year
well trained as to process We have a
this process
Various
t
permits considerable versatility as to batch composition
additives and extenders can be added to reduce costs
6. Kayl contains an extremely extremely low percentage of soluble chloride
Meets AEC and military
spec requirements
daily production of pieces are procurable in the the same sizes
7. Higher
and block when needed for for expediting
and thicknesses for both pipe
shipments than in any of the competitive manufacturing manufacturing processes
/
improve the service cycle
The 1968 expansion at Berlin will further further It is already better than the service cycle of any of our competitors
9. 10
11 11
11
12.
Kaylo has high acceptance
among owners distributors
Pan pouring is the only process which lends itself to of structural core Only one with UL fire ratings
the
production
products 20 pipe and block products
produced produced by the pan pouring proprocess cess are
can be used at temperatures temperatures
ir class by themselves K 20 products
up to 1800 F.
4
Batch mixing for pan pouring is the least complicated No gelling
of batch required .
Fan Pouring Pouring Way20 Cont)
Advantages Cont)
13.
Drying costs are currently lower for pan poured products than for products produced by any other process This advantage will soon be lost since the SID cylinder patent expired in January 1968
Densities of par poured products are lower than densities of filter
pressed products 4
In general thermal conductivities of pan poured products are lower than for competitive products
Pan
pouring operating efficiencies are considerably higher than they
are for filter pressing
.
Fittings can be cut and fabricated from
ipnrteossfpirtotdiuncgtss delaminate yhen attempts
pan
are
poured products
made to fabricate
Filter them
No license would be involved if the decision is to install a pan
pouring process at the new Southwest facility
Disadvantages
Disadvantages
Disadvantages Disadvantages Disadvantages
Disadvantages
1. Physical strengths of pan poured products are lower than those
obtained from filter pressed products
|
Visual appearance of surface is inferior to both aggregate products
filter
press
and
and
bonded
bonded
Pan pouring is not a precision process Problems of dimensional
stability and field
nesting
of ware
show
up
from
time
to
time
in
the
field
field field
sume With current level of technology large size sectional pipe cannot be poured with adequate gross margins by the pan pouring process
] Like filter pressed products pan poured products are reinforced with asbestos fibers With current level of technology glass fibers
! cannot be used in either process .
aa 6. Pan pouring requires the use of expensive autoclaves SID's and
Dowtherm units
1
1 7. Pan poured 10 products have a maximum temperature application of 1200 F vs 1500 to 15000 F for bonded aggregate products
8. Pan poured products have higher breakage losses while in transit and when handled at the job site than filter pressed products
Ne
-10-
Fan Pouring Male Cont
Disadvantages Disadvantages Cont )
considerable hand labor Labor costs to produce
*.
9. Pan pouring involvesaveraging 40 percent of total manufacturing costs
.
pipe are currently
low
Level of automation at Berlin is still very
13
Process job efficiencies for the
those for competitive processes handling in the plant
pan pouring process because of the high
are lower
degree of
than
11 Pan poured products are not water repellent Only bonded aggregated
products and Multi are water repellent today
Filter Press Manville and Rubers
.
e
|
a
a
Advantages Advantages
d
have higher physical strengths in all three
1 Filter pressed products
and impact strengths
categories B compressive
2. OD and ID
surfaces are smooth and free of air holes
.
Has an excellent
.
visual appearance
Manville is a highly automated
3. Filter pressing as developed by
of total manufacturing cost
Labor costs as a percentage
.
process
are
are
quite
quite
low low low
lends itself to the The filter press process
sectional pipe up to and including 24 x 3
molding
of large
size
\ product contains no amosite asbestos only 7 5. The Manville
percent chrysotile
little in transit and job site
6. Filter pressed products suffer very
,
breakage
percent Process job efficiencies efficiencies efficiencies are extremely high
7.
developed by Manville
filter press process as
for the
induration of green ware is greater for filter
8. Cylinder capacity for
This is because filter
pressed products than for pan fprooumretdheprmooldducptrsior to autoclaving
pressed ware can be stripped
have fewer broken corner problems during
9 Filter pressed products
,
processing
10. Very little waste material in the Manvil, le process legs of pipe are trimmed
Only
-_
-1-
Disadvantares
}
1. Shipping cycles are considerably longer than those for pan poured
products
flexibility in the daily mix of goods
Products Products contain asbestos fibers
With
With current level of technology
fibers fibers cannot be used as reinforcement
pressed pressed products are not water repellent
wet
Tend to delaminate
Manville probably do
chloride content
not meet
Mil
Specs
because
of high
Process involves the use of expensive autoclaves
*
of
Filter
Filter
pressed
products
have
maximum
temperature
applications
1200 F vs 1500-1600 F for bonded aggregate products
Iter
Block produced by the Iter to pan poured block andand has
press process process a tendency to
is substantially
delaminate
inferior
StructuralStructural
Structural
No UL fire
core core products cannot
rated
rated rated
pprroodduuctcsts products
be
made
by
the
filter
press
process process
to delaminate when moisture
Filter press products have a tendency
Operating efeffficieinciecs iencies efficiencies still remain low 65 percent due to 5 to 6
i
hours required for mold change over
Batch costs are considerably higher than
process Not flexible concerning use of
costs
those for additives
the pan pouring
to lower batch
Densities of filter pressed products are higher than densities of pan
poured products products
aes" A very large inventory of finished of the llimitied mlimitied ted range of the mix of
goods must be goods
maintained
because
Production rates of same sizes of ware is usually less per hour
for
filter
press
than
for
pan
pan pan
pouring
-
Skilled craftsmen are required to change the precision mold equipment
Fittings cannot be fabricated from filter pressed ware -~ problem is
one of delamination
i
Philio Carey
-12-
No autoclave required to produce bonded aggregate products
Low investment costs
/ Precision molded product - good dimensional stability - nests well
Smooth surface - no air holes
Can be reinforced with glass
Product is water repellent
Temperature
1500 1500
are 15 150000 to
limitations for
161600 00
F
300
33000 0
to
filter pressed products
bonded aggregate Careytemp products
400
400
higher
F higher higher
than
than
for
pan
poured and
Bonded aggregate offers potential of being a highly automated process --
potential potential
potential
l looww labor
cost
cost
process
process
Batch costs are lower than those for the filter press process
aggregate process is capable of producing large size
Pipe fittings can be fabricated from bonded aggregate products
Disadvantages
Bonded aggregate products are quite fragile break easily when handled Has lower physical properties than calcium silicate type products
Flexibility in the daily mix of goods is rather p
r
Like filter press products shipping cycles would be much longer than those for the pan pouring process
Bonded aggregate block is inferior to Kaylo block
handled
Crumbles when
Borded agaggreggateregaggregateate process will not yield structural for the product to crumble makes it unsuitable for
rated door applications
core
use
in
in
The tendency
fire
UL fire
Large inventories of finished goods must be maintained because of the limited range of the mix of goods
Bonded aggregate products do not fabricate as well as pan poured
products due to breakage from sawing and cutting
,
- .
t
-23-
Multi Temp OCF
Advantages
1. Multi is a product made from Fiberglas the basic product of
It is free of asbestos fibers
the Corporation
1
to decentralized operations adaptable to any General
2 It lends itselitfself
insulation
Products plant capable of making Fiberglas pipe
aed and snow resistant and water repellent in that
'
3. The product is rain
capacity
4 The saturation process is not a complicated one to operate efficiently
5. Multi pipe has an acceptable K value
6. Multi pipe can be applied to 1000 F surfaces
7. Large size sectional sectional pipe can be produced by the Multi process 8. Breakage due to rough handling would be nominal
9. 10 10
Easy to cut good fabrication characteristics Excelent Excellent Excelent Excellent EExcexlenctellent Excellent ExcellentExcelent grossgross margins 33 percent projected
for
block
was 1000 F rather
1. The maximum temperature resistance of the product
;
- than 1200 F for 10 Kaylo
2. The ends and edges were susceptible to in transit and handling damage
more dusty than competitive materials 3 Multi products were
were lower than those
4. Projected gross margins for Multi pipe
projected for Kaylo pipe
facility job efficiencies efficiencies were very low
5 In the Newark pilot plant
of offware were excessive
due to excessive offware Major causes
and burn ware in
and rough handling improper operation of process
the oven
to carrying inventories of two different types
6. Distributors objected
called for additional warehouse
of high temperature insulation which
space
7 Softer product than the calcium silicate and bonded aggregate type products
22