Document NjNDe83ogO67wJg7bj5XJbxE
FILE NAME Corning OC
DATE 1968 Mar 15
DOC OC381
DOCUMENT DESCRIPTION Internal Memo- Feasibility Study - Alternate
Processes for Manufacture of High Temperature Insulation - with Report
COMPANY CORRESPONDENCE
Produced in camere under seal by orderorder
Judges
Paul
Paul
Riley
and
Gordon
Maag
Jamison , October 16 1989 in at al 87-61230
V
von
Sarre
3
fee
Po
peer
-
Mr. Mr. BB. . E. BoByodyd Teledu Teledu
R. F. Shannon Granville
FEASIBILITY STUDY - ALTERNATE PROCESSES FOR MANUFACTURE OF
HIGH TENGERATURE TENGERATURE INSULATION
.
vA
- March 1155 1968
Mr. E. Gay Toledo
o
Mr. R. S. Grant Toledo
Mr. M. Hardwick Berlin
Mr. R. J. McEvoy
Granville
.
Mr. C. G. Staelin Toledo
Mr. R. P. Witschen Toledo
Central Files
,
PLAINTIFF'S
EXHIBIT
K423K423
. :
,
-
,
'
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_
2,
Last January you asked me to take a good hard look at the various processes under consideration for the new Southwest Kaylo facility
Attached is a copy of my report which summarizes our study of every kn
at process As you will note I reduced the list to just three processes
merit further consideration for installation the new facility They
include pan pouring filter pressing and bonded aggregate
wn which
The most important question which must be resolved before any final selection of process is made relates to the use of asbestos Silihoff Because of this problem I also included an evaluation of Multi in my report After all it is the only asbestos free product available
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 of combination of processes we should select for the
new facility because of the lack of cast date As soon as cost projections are completed by Gay and Brooks on all of the processes still under considers-
tion we will be able to at least make a recommendation as to which process
we feel offers OCF the best product and gross margins in the years to come
I am sure you are already aware of the advantages and disadvantages of Berlin's pan pouring process Filter pressing has a lot of merit It
produces a stronger better l skingproduct the product is precision molded and the process itself is highly automated Bonded aggregate products as they now exist on the market have serious shortcomings They break asily in transit and when handled Why then would we still want to consider this process The reason is if Philip Carey over solves their breakage problem they will have the best product on the market It is precision Balded 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 asbestes free The only reasons for
considering Multi are the facility is already available the product is free of asbestos fibers and it could relieve some of the current overload
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 & recommendation as and for the 1970+ market
as to the advantages data we will be in to which process is
76
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wt Se. te
ecbie Coat neo e!e
Produced 1 cam34 YUE CeGl VF VESEY Judges Paul Riley and Gordon Maag 1 October 16 1989 in Jamison v
tal 07-61230
INTRODUCTION INTRODUCTION
INTRODUCTION
The expanding market for Kaylo pipe and block has made n t nly t expand the Berlin operation again in 1968
building a new facility in the Southwest The problem
it necessary for OCF but also to consider facing Management 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 tempera-
ture 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 Rade it necessary for us to limit this study to strictly a technical comparison
rather than a more preferred technical evaluation
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The Ka520 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 the
Parket 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
To maintain our position in the block and core markets we must continue to produce such products by the pan pouring process Management must decide whether block and care 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 elates to the type of process or combination of processes to be instaled it the Southwest facility for the
production
other than
sufficient
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
the timing 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 process should not be considered for pouring large size sectional pipe at the
new facility
|
42 002 0148
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020
coe 18 CAMBIA under seal by order e
Judges Paul Riley and Gordon Mang
1 October 16 1989 et al 87-61230
10 Camison v
Mang Py
-
2.
SUNVARY Cont
The Kaylo R & D study indicates that from a technical standpoint no one process
has a distinct advantage over other known processes for the manufacture of
high temperature pipe insulation Each has its advantages each also has a
number of disadvantages Only after comprehensive cost analysis is made or
each process will we be able to decide which process or combination of processes
is most suitable for the new Southwest facility
Our intensive technical evaluation of all known processes for the manufacture
of high temperature insulation products indicates there are only three processes worthy of further consideration for possible installation at the Southwest facility They include the Berlin pan pouring process Manville's filter press process and Philip Carey's bonded aggregate process All of the other processes considered during this study with the possible exception of MultiTemp were rejected because 1 the process would not yield a product suitable for OCF's needs or 2 the process was not sufficiently developed to meet the time schedule for installation in the new Southwest facility The Crosfield
filter press autoclaved process failed on both accounts Multi
should only be considered for the production of large size sectional pipe and possibly as an additional facility for the production of high temperature
block when Berlin becomes overloaded
Before a final decision is made by Management as to the process they will adopt for installation at the Southwest facility and the product they will market in the 1970's and 1980's they must consider a number of basic questions relating
to rising labor costs need for automation need for a product of a higher
final quality level and the asbestos fiber health threat This report will attempt
to outline the questions which must be considered and acted on before the decision as to process is reached This report will also provide f^r Management's consideration a list of the advantages and disadvantages for each of the processes still under consideration for the new Southwest facility
REGAGNATIONS
A visit to Manville's Research Center has already been made to appraise
the filter press process This visit must be followed by an OCF prepared cost projection and a plant visit A visit should also be made to Philip
Carey to appraise their bonded aggregate process It too should be followed-
up by a cost projection and if possible a plant visit
Cost projections must be made or updated on the filter press bonded aggregate pan pouring and Multi processes To achieve a fair comparison c st projections for the pan pouring process should be made on a more automated process than now exists at Berlin The latter is a reasonable request since a major R & plant program is currently underway to reduce labor and batch costs and to achieve a higher degree of automation of the pan pouring process
Cost projections on the filter press and bonded aggregate processes must be prepared at two levels of activity One cost projection should be based on the assumption the filter press or bonded aggregate process will be used to
produce the entire line of pipe up to and including 24 3 The second cost
wee
Y
He
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ee
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Produced La caneca under seal by order
Judges Paul Riley and Gordon Maaq ' October 16 1989 in Jamison v AL Po 3
at al 87-61230
RREESSISENSTAITIEONNS TATRIEOSSNISENTATIRONES SSIENTATIONS Cont
projection should be based on the assumption the filter press or bonded aggregato
process will be limited to the production of large size sectional pipe only
projection Under these conditions it must be tied in with the cost
covering
pan pouring of the smaller sizes of pipe The Multi cost projection should
be limited to large size sectional pipe only It too must be tied in with the
cast projection covering the pan pauring of the smaller sizes of pipe To ge
a good economic picture of the various options available to us cost projections
should be prepared on the following process combinations
1 2
3
5
Pan Pan Par Par Pan
poured poured poured poured poured
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
It is possible the new Southwest facility will be limited to the production
of pipe Kayis 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 cast 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 It could be the most important decision we face in deciding which process to install in the Southwest facility The only asbestos free product on the market during the past 5-10 years was Multi All three processes pan pouring filter press and bonded aggregate now under consideration for the new facility contain asbestos The probability of removing asbest s 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
In the event Management decides to install the Berlin pan pouring process for both pipe and block at the new Southwest facility Kaylo D still recommends that an alternate process wither the filter press or bonded aggregate also be installed on a limited basis either at Berlin or at the new facility This should be further supported by an R & D program on the chosen alternate process at Granville These recommendations are being made because it is our opinion the company should not have to again face the process dilemma we are now facing If future market conditions demand a product made by a process other than pan pouring we will have the technology knowhow and experience
to convert our manufacturing facilities over to the new process without delay
Regardless of the decision as to the process to be installed at the new South-
west facility the major R & plant program currently underway to automate the pan pouring process at Berlin should proceed full speed ahead especially
for the processing of Kaylo block
4
42 002 0150
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Produced in camaca under sesi sesi by order
October Paul 1
October
16
Alley 1989.
and Gordon
in Jamison
Mag
et al 87-61230
RESIDENTATIONS Cont RESIDENTATIONS
be installed
this planning period
many have
suggested two processes
for block
and
smaller
During
Southwest facility the pan pouring process
sizes of sectional
an the new
for the manufacture of larger
sizes of pipe and a filter press
be resolved is will our customers and the
which must
If the answer
pipe The first quDeisvtiisoinon accept two types of pipe products
if it
and O Marketing
is would the market also accept Multi
the second question
sectional is yes
larger sizes of
pipe
were limited to the
a filter press or bonded aggregate process
If
the
only
reason
for purchasing
for
the
manufacture
of
large
size
sectional
from one of our compettihteor1s3 itso 24 inch ID range then we must ask whether it
sectional size
pipe i.e. sizestoindirect a major effort toward producing large
would be better
at acceptable gross margin levels rather
pipe by the pan pouring process and
toward a new process and technology
than direct such a major effort overeaxlplenmsaerket Actually there has been little
for such a small portion of the effort directed
learning how to pan pour large size such a result changes
if any technical
toward sectional pipe with adequate gr ss
matgins To achieve
and handling
well as new techniques of pouring prehardening
in mold design as
Multi pipe is acceptable to the market and gross
must be developed If
when limited to large size sectionals
margins are projected as being adequate
and a facility available to
then OCF already has a product a process
osenrlvyice the large size sectional pipe market .
res SSION
res
-
Asbestos
must be resolved is the use of asbestos as the rein-
The first question which
insulations contain asbestos
forcing fiber TIon dfaayctallduhriignhg ttehmepepraasttur1e0 years the only known asbest s
reinforcement
insulation on the market was Multi a product
free high temperature of time by OCF To emphasize how important is the
sold for a brief period
reinforcement I would like to call to your
problem of asbestos as a fiber
October 9 1967 to D. M. Barthold concern-
attention D. W. Ladd's letter dated
I think
T asbestos and Kaylo expansion Quoting from Mr. Ladd's memo to this whole
ing
consideration which is of paramount importance
whistle whistle there is no other
well aware the government will probably blow the
[ subject As you are
in the not too distant future and bef rewe
relative to the use of asbestos
at Berlin and consider putting
embark upon a substantial expansion program
be damn sure that we have an
and [
a new facility in the Southwest we had better
this in the past
asbestos threat Work has been done on
1
answer to the
t date there has been no successful answer
a
asbestos fibers in calcium silicate products
The probability of replacing No
solution
to
this problem has been found
by
is rated at best at 50/50
too have had no success in getting
OCF Manville told us recently they
If the decision is to install
glass
fibers
to
survive
the
autoclave
process
Manville
filter
press
process
at
Berlin pan pouring process or the
fact the reinforcement used will
the
the Southwest facility we are accepting the
the next
probably be
asbestos
unless
a
breakthrough
fibers
is
made
by R
&
D during
and the autoclaving
year so in modifying glass fibers to survive the alkali
process fibers
320
|
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42 002 0151
Produced in camera under seal by order o Judges Paul Riley and Gordon Maaq | October 16 1989 la Mantson v PAT
et al 67-61230
Asbestos CoCnt ont
decides the asbestos threat is still with us then careful -
If Management
It does not
consideration should be given to the bonded aggregate process
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 dissolve glass Although Careytemp Philip Carey's bonded aggregato
insulation contains some asbestos the probability of develop-
hinigghatbeomnpdeerdatuargegregate product reinforced with 100 percent glass fibers remains
quite high
margins Manville told us during our recent meeting in Manville New Jersey they
we never followed on our high temperature glass fiber insulation
were surprised
line Multi
By the tone of the conversation they seemed to be
the market
product concerned about this product
If it were to be placed back on
.d would be the only asbestos free .d .d If the .d threat
is real and is a serious threat to OCF's participation in the high temperature
insulation market of the future then we should consider directing a maj r
R & D effort toward product and process modifications to raise gross
t adequate levels
If a decision is made to install a process other than pan pouring at the new Southwest facility technology will have to be purchased There is not sufficient time to develop from scratch an alternate process and still meet the timing for construction of the new facility Since the purchase of technology will probably mean taking out a license from a competitor the cost of the license and its adverse effect on gross margins and competitive position in the market must all be carefully considered
DCF already has 20 years or more of technology on pan pouring and several years plus a patent position on Multi Major strides have been made in recent months in mechanizing the pan pouring process at Berlin No costs for licensing will be involved if the pan pouring process is chosen for producing both pipe and block at the new facility The same is true if large size sectional pipe are produced by the Multi process
Competitive Processes
disadvantages three Before tabulating the major advantages and
processes still under consideration for installation
for Multi I would like to compare briefly each
for each of the
in the new facility process against the
and others
The major problems with products made by the pan pouring process include 1 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 made by the pan pouring process could be
.
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.
Produced in camera under seal by order order
Judges
Heeq Riley and Gordon
Judges Paul |
October 16 1969 la Zamiann v
& how
et al 87-61230
:
V
c
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Competitive Processes Cont
pouring in the future with pipe made by one of
placed at a competitive disadvantage
or bonded aggregate It
the more automated prOoCcFesdsieds nostuchpla as cefitlhteersapmreesesmphasis during the past 5
is quite unfortunate
as our competitors have on
to 13 years on automating our pan
process would not be today in the position
If we had it is quite possible we
theirs
of having to take a license from one of our competitors
does have a number of advantages over
Kavio made by the pan pouring process on the market today
They include 1 the ability to density
all other products
both light density heat insulation and heavy
produse by one process
of the daily mix of
structural core material 2 the tremendous flexibility
and thick-
with the ability to expedite desired various sizes
goods coupled
and block 3 the best service shipping cycle in the
nesses of bothtphiepeversatility of batch composition to achieve lower costs of
on the
Industry 4 cubic foot basis 5 production of the best block products
bmaatrckhetonanda 6 production of light density beat insulation and structural
core with maximum temperature resistance of 1800 F.
the filter press developed by Yanville
As to competitive processes interest from OCF personnel
There is no doubt it has a
has drawn the most
and bonded aggregate processes
number of advantages over both the pan pouring have considerably higher flexural compressive
Products rade by this process
It has
better visual appearance than Kaylo and like
and impact strengths
a
and block products which are precision
the
bonded
aggregate
process
produces
also
pipe lends
itself
to
the
production
of
large
molded The filter press process
sectional pipe up to and including 30 inches OD
Field breakage of filter
now developed by
size
pressed pr
duatsis extremely low
Finally the process as
made by the bonded
anville is highly automated
When compared to products have two distinct advantages higher
aggregate process filter pressed products
physical strengths and lower breakage characteristics
has number of disadvantages when compared directly
The filter press process
a
include 1 shipping delivery cycles are
with the par pouring process They in the daily mix of goods is poor 3
considerably longer 2 flexibility
itself to the fabrication of fittings
batch costs are higher 4 does not lend
to delaminate when moisture
5 product densities are higher
6 has a tendency
structural
8 produces block products
is absorbed 7 will not produce
core
due to 5 to 6
less acceptable to the market and 9 operating efficiencies
hour period for mold change over are still very low compared to operating
efficiencies for the pan pouring proc688
major The bonded aggregate process as developed by Philip Carey has many advantages
over both the pan pouring and filter press processes
If and when Philip they will have by far
Carey solves theironhathnedlmeaabrikleitty aSnodmebroefaktahgee prmaojobr laedmvsantages of the bonded
the best product include 1 a very low manufacturing cost 2 a very low
aggregate process
cost 3 a autoclaved product
4 ability to use glass fiber
investment reinforcement
5 ability to produce a precision molded product
6 a
as
which lends itself to high production rates at low investment costs .
process
7 a 1500 to
1600 F temperature
resistant
product
and
8 water
repellency
i
&
42 002 0153
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: Produced in camera under seal by order Judges Paul Riley and Gordon Maeg October 16 1989 in Jamison v
et al 87-61230
Competitive Processes Cont
with filter pressing the bonded aggregate process has
When compared directly
with lower strengths and one
two major disadvantages It produces a product
On the other hand it
that is susceptible to breakage when roughly handled filter pressed products
Overall
process costs
has a number of advantages over
be marketed
substantially lower the product can
are lower batch costs are
1500 vs 1200 F it is water repellent
higher temperature applications
costs are much lower
for
can be fabricated from the product investment
to
fittings
can be made free of asbestos The ability
autoclaves and it probably
when combined with the
no use glass fibers as reinforcement in this product
makes it mandatory
tremendous glass fiber knowhow available to OCF personnel
before
careful consideration to the bonded aggregate process
roeujrecMtainanggemietntingifvaevor of a process which requires asbestos as the reinforcing
fiber
poured does the Multi product and process fit in the overall picture
Where
we currently know it does not yield adequate gross margins to
The product as
the board with pan
filter pressed or bonded aggregate
compete across
must remember it is a glass fiber product one that
products However one
and one that could be produced at any of our
is a natural for OCF to market
the market it would be the only
GP plants If it were to be placed back on
asbestos free product on the market today
.
ahead and install the pan pouring process at the new Southwest
Should we go
process This is
facility rather than the filtmeurstprmeaskse orIbfontdheedfaiglgtreergaptreess or bonded aggregate
a decision which Management the complete range of products at the new facility
process is chosen to produce
at this time If and only if
then there is no need to reconsider Multi
then want to reconsider
the asbestos threat reaches the danger point would we
an asbestos free product such as Multi for the high temperature insulation
Zarket
reason such # high cost of 1. unsing Management decides to install
If for some
in the new facility we will again be facing the problem
the pan pouring process how to produce large size sectional pipe
Under such circumstances
of deciding could be the answer
Even if Management decides to go with the pan
Multi
for all production except large size sectional and choses to
pouring
process the filter
press
or
bonded
aggregate
process
to
produce
these
products
license
all the problems and costs to
we must raise the question whether it is worth
for such a small percentage
license another process from one of our competitors
of the market
to We must market large size sectional pipe to remain competitive If we chose
not to license another process we would have three choices 1 fabricate
large size sectional pipe as we d
now at Berlin 2 start up a crash program at adequate gross margins by the
t learn how to pourolrar3 ge wsei.zceousledctimoarnkaeltpiapeline of large size sectional Multi-
pan pouring
process under
those
conditions
where
all
production except
large
size
Temp pipe
Only
is to be made by the pan pouring process at the new Southwest
sectional pipe I recommend we reconsider Multi - Limited to the production
facility would
Berlin block producing facilities
of large size sectional pipe and block when
i
a
42 002 0154
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:
order 1 Produced in comer under seal seal by order
of
Paul
| Judge Paul Riley and Gordon
j October 18 1989. in famison
'
& 2. 35
et al 87-61730
02-
Competitive Processes Cont
total are today Multi may have a place in today's
over taxed as they
size sectional pipe by the Multi-
become market
It may be cheaper to produce large
used at Berlin It
than by the current fabrication technique
Temp process
our share of the
market immediately
would increase
a
Pan Pousine Kavis
e
.
1
.
]
|
'
{i
Advantares Advantares
workable.finished mix of goods flexibility This flexibility results in
1. The highest
workable.finished workable.finished goods inventory for any of the processes
tnhoew lionweusste for the manufacture of high temperature insulation products
2. The best shipping cycle in the high temperature insulation industry \
.
with normal inventories
the pan pouring process is the acknowledged leader market today
3. Shock produced by
insulations on the
of all natware high temperature
is an established process at OCF Plant personnel are 4. Pwealnlpoturraiinnged as to process We have a 20+ year working background with
this process
considerable versatility as to batch composition
5. Process permits
be added to reduce costs
Various additives and extenders can
6. Kayle contains an extremely low percentage of soluble chloride
Meets AEC and military spec requirements
7. Higher daily production of pieces are procurable in the same sizes
and thicknesses for both pipe and block when needed for expediting shipments than in any of the competitive manufacturing proc: esses
/
8. The 1968 expansion at Berlin will further improve the service cycle
It is already better than the service cycle of any of our competitors
9. Kaylo has high acceptance inthe high temperature insulation market anong outers distributors and applicators
10.
.
Pan pouring is the only process which lends itself to the production
of structural core Only one with UL fire ratings
11. 12.
20 pipe and black products produced by the pan pouring process are
in a class by themselves 20 products can be used at temperatures
up to 1800 F.
a
Batch mixing for pan pouring is the least complicated
No gelling
of batch required
o
Se
*
s
.
42 002 0155
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crew ab BEES Ss
Use ele
|
| st Judges Paul Riley October 16 1989 et al 87-61230
and Gordon is Zamison
Mesq
.
bok
1
1
[
Le
[
Fan Fousine Kaylo Cont) Advantares Cont)
13. Drying costs are currently lower for pan poured products than for
ony
products produced by any other process This advantage will sooT
be lost since the SID cylinder patent expired in January 1962
14. Densities of pan poured products are lower than densities of filter
pressed products 5
15. In general thermal conductivities of pan poured products are lover than for competitive products
26. Pan pouring operating efficiencies are considerably higher than they
are for filter pressing
17.
Fittings can be cut and fabricated from
when press products delaminate
inte fittings
attempts
pan
are
poured products
made to fabricate
Filter them
18. No license would be involved if the decision is to install a pan
pouring process at the new Southwest facility
sadvantages
1. Physical strengths of pan poured products are lower than those obtained from filter pressed products
2. Visual appearance of surface is inferior to both filter press and bonded
aggregate products
3. Pan pouring is not a precision process Problems of dimensional
fstiaeblidlity and nesting of ware show up from time to time in the
4. With current level of technology large size sectional pipe cannot be poured with adequateadequate gross margins by the pan pouring process
5. 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
6. Pan pouring requires the use of expensive autoclaves SID's and
Douchern units
7.
Ne
a
Pan poured 10 products have maximum temperature
of 1200 & vs 1500 to 1630 F for bonded aggregate ategmgpreergaattuereparpopdluicctastion
breakage Pan poured products have higher
and wher handled at the
losses while in transit
job site than filter pressed products
6
42 002 002 0156
a
Lee
325
-10-
z
Gordon order i Produced in canaza under
Judges Paul Riley and
.
October 16 1989 in Jamison v && Pic
et al 07-61230
a
manufacturing considerable hand labor Labor costs to produce
9.
Pan
pouring
involves
averaging
40
percent
of
total
or
pipe are currently
Berlin is still very low
costs
*
Level of autoration at
efficiencies 20.
Process job those for competitive
for the
processes
pan pouring process because of the high
are lower
degree of
than
handling in the plant
are not water repellent Only bonded aggregated
PparordpuocutrsedanpdroMduuctlsti are water repellent today
Filter pressed products have higher physical strengths in all three
categories R compressive and impact strengths
D and ID surfaces are smooth and free of air holes Has an excellent
visual appearance
as developed by Yanville is a highly autonated
3. Filter pressing
of total manufacturing cost
process Labor costs as a percentage
.
are quite low
lends itself to the molding of large size 4. The filter press process
sectional pipe up to and including 24 x "
5. The Manville product contains no amosite asbestos only 7
percent chrysatile
6. Filter pressed products suffer very little in transit and job site .
breakage
7. Process job efficiencies are extremely high percent for the filter press process as developed by Manville
for induration of green ware is greater for filter
Cylinder capacity
This is because filter
pressed products tbheanstfroirpppeadnfprooumretdheprmooldducptrsior to autoclaving .
pressed ware can
Filter pressed products have fewer broken corner problems during
processing
Very little
waste
material
in
the Manville
Manville
process
lets of pipe are trimmed
Only
i
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.
. 42 002 0157
326
Pa
wg ne
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: Produced in camera under seal by order
Maag and Gordon
Judges October Paul Riley 1989 ,
in
Janison
Janison
v .
a
la
L1230
al
Filter Press ^s.zt
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Disadvantages Disadvantages
pan ? 1 Shipping cycles are considerably longer than those for
poured
products
2 Poor flexibility in the daily mix of goods
Products contain asbestos fibers With current level of technology
3.
cannot be used as reinforcement
glass fibers
are not water repellent Tand to delaminate 4. Filter pressed products
waen vet
Vanville probably do not meet Mil Specs because of high
5.
chloride content
.
6. Process involves the use of expensive autoclaves
Filter pressed products have maximum temperature applications applications of 7. 1200 F vs 1500-1600 F for bonded aggregate products
is substantially inferior
8. Block produced by the alter press process to pan poured block and has a tendency to delaminat
9. Structural core products cannot be made by the filter press process N UL fire rated products
10. 11.
12.
13.
14.
Filter press products have a tendency to delaminate when moisture
is absorbed
efficiencies still remain low 65 percent due to 5 to 6
Operating hours required for mold change over
Batch costs are considerably higher than those for tthoelpoawnerpobuarticnhg
Not flexible concerning use of additives
process
costs
pan Densities of filter pressed products are higher than densities of
poured products
A very large inventory of finished goods must be maintained because of the limited range of the mix of goods
15. Production rates of same sizes of ware is usually less per bour for filter press than for pan pouring
16. Skilled craftsmen are required to change the precision sold equipment
17. Fittings cannot be fabricated from filter pressed ware - problem is
one of delamination
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PS
42 002 0158
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Fev Judges 2s BAER YT
een. VF Vives '
Judges Paul Riley and Gordon Maaq
October 16 1989 et al 7-61230
in Janison v
P &u ua
'
Bonded
Amerate
Philip Carey
Advantsmes
1. products No autoclave required to produce bonded aggregate
2. Low investment costs
/
3. Precision molded product - good dimensional stability - nests well
4 Smooth surface - no air holes
5. Can be reinforced with glass
6. Product is water repellent
407 limitations for bonded aggregate Careytamp products
7. Temperature
are 1550 to 1600 F 300 to 4007
F higher than for pan poured and
filter pressed products
6. Bonded aggregate offers potential of being a highly automated process o-
potential low labor cost process
9. Batch costs are lower than those for the filter press process
10. The bonded aggregate process is capable of producing large size
sectional pipe
11. Pipe fittings can be fabricated from bonded aggregate products
Disadvantages
1. Bonded aggregate products are quite fragile break easily when handled
2. Has lower physical properties than calcium silicate type products
3. Flexibility in the daily mix of goods is rather poor
4. Like filter press products shipping cycles would be much longer than these for the pan pouring process
Bonded 5.
aggregate block is inferior to Layle block
handled
Crumbles when
6. Bonded aggregate process will not yield structural core The tendency
for the product to crumble makes it unsuitable for use in UL fire rated door applications
7. 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
products due to breakage from sawing and cutting
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Judges Paul October 16
Riley 1989
and Gordon in Jamison
Maaq
v
et 61. 87-61230
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Advantares
AdvaAdn vantarestaAdr vane tars es
the basic product of
1. Multi is a product made from Fiberglfaisbers
the Corporation It is free of asbestos
decentralized It lends itself to
operations adaptable to any General
insulation
Products plant capable of making Fiberglas pipe
The product is rain and snow resistant and water repellent in that
capacity
is not a complicated one to operate efficiently
The saturation process
Maiti pipe has an acceptable K value
Multi pipe can Large size sectional
be applied to 1000 F
pipe can be produced
surfaces by the Multi
process
Breakage due to rough handling would be nominal
Easy to cut good fabrication characteristics 10. Excellent gross margins 33 percent projected for block
.
Disadvantares
resistance of the product was 1000 F rather
1. The maximum temperature than 1200 F for 10 Kayle
The ends and edges were suscentible to in transit and handling damage
3. Multi products were more dusty than competitive materials
4. Projected gross margins for Multi pipe were lower than. those projected for Kayl pipe
In the Newark pilot plant facility job officiencies were very low
5.
causes of offware were excessive
due to excessive offuare Kajor
of
and burn ware in
and rough handling improper operation
process
the oven
inventories of two different types
6. Doifsthriigbhuttoermspeorbajteucrteedintsoulcaatriroyninwghich called for additional warehouse
space
Sefter product than the calcium silicate and bonded aggregate type
products
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ivos te Be
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