Document OEywbMpvgv4n9Qb9Ygg2wqGXM
MEMORANDUM
cc: Mr. D. Suva - BBM Mr. J. Arnold - BBT
Mr.. W. Kimball - BT Mr. K. Col"4" ur
To From Dote Subject
Mr. 0. Laid!aw - RCC Mr. K. Sutton - RBH March 4, 1982 MINERAL FELT COST ANALYSIS
The mineral felt project for Shreveport has progressed to the point where a current cost analysis is required. The project itself has expanded to include mineral felt for saturated rolls as well as for shingles. The formulation for mineral felt is 60% mineral filler, 36% corrugated fiber and 4% Dow latex (XD 30374.33} solids. Betz 1260 polymeric flocculant is used at a rate of 2.5 pounds per ton of felt produced. This formula will be used for shingles and roll goods. Mr. Kimball has given me the latest costs of raw materials needed for mineral felt and these will be found in Table 1.
The cost analysis for shingles should be developed under the same assumptions that were used in'your August 18, 1981 cost analysis with the exception that the mineral felt will be produced on DSPM #2 instead of OSPM #1. The material formula for a standard weight, flat shingle using saturated mineral felt (at 70% saturation) in place of saturated organic felt (at 175% saturation) is presented in Table 2. The costs generated for this shingle should be compar ed to standard current costs at Shreveport for a standard weight, flat, glass mat shingle.
The analysis for roll goods will require separate costs for a 15# saturated felt and 30# saturated felt. Raw material specification for these products will be found in Tables 3 and 4 respectively. The manufacturing assumptions used above also apply. The final mineral felt roll good costs should be com pared to current costs for 15# and 30# saturated organic felt products at FS.
If there are any questions or additional information you require for this work, please feel free to call and we can discuss them.
KS/cem
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TABLE 1
Bulk Raw Material Prices - 3/2/82 FOB Shreveport
Item
Dow Latex XD 30374.33
Corrugated
1
Mineral Filler (ground limestone)
Betz 1260
$ 0.73/pound $47.60/ton $38.80/ton $326.59/cwt
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TABLE 2 Wind Seal Raw Material Specification
Item Mineral Felt, 55# Saturant, 70% Coating Filler, 53% Back Surfacing Talc #11 Granules, Natural #11 Granules, Colored Wind Seal Adhesive Anti Stick Total (Cut outs, 2.07 sq ft) Net Weight per square Finishing Materials
Net weight/square 27.0# (240 ft2)
18.9 38.8 43.9 2.0 52.6 22.5
1.8 0.2 207.7# - 1.8# 205.9# 1.0#
Final shipping weight per square
206.9#
12" x 36" shingle 5" x 1/4" cutouts 80 shingles per square Standard FS production rate
f
TABLE 3
15# Felt Raw Material Specification 4 Square Roll
Item
Mineral Felt, 39# Saturant, 70% Total Finishing Materials Final Weight per roll
Net weiqht per roll
35.3# (432 ft2) 24.7 60.0#
0.1# 60.1#
Standard FS production rate
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TABLE 4
30# Felt Raw Material Specification 2 Square Roll
Item
Net weight per rol 1
Mineral Felt, 78# Saturant, 70%
Total Finishing Materials
Final shipping weight
35.3# 24.7
60.0# 0.1#
60.1#
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MEMORANDUM
cc: J. W. Jackson - BBH/
D. R. Suva
- BBM
F. W. Wood - BBP
J. Zilfi - RCA
J. K. Colvin - MS 0. A. Laid!aw - RCC W* May 19, 1982 ubjtct MINERAL FELT SHINGLE COST ANALYSIS - SHREVEPORT
Shown below is a cost comparison for a Firescreen shingle and a Mineral Felt shingle:
WEB ASPHALTS
FILLER ALL OTHER
ffaunH.
Fiberglass 1 Base
^l. 'V/iu.ff'1-- $ 4.34
% -- /,*& ?
5.63 .61
3.26
Mineral Felt Base
3.09
5.46
.33
3.26
Glass Over (Under)
Mineral Base
$ 1.25
.17
.28
--
SUB-TOTAL MATERIAL LABOR OVERHEAD
TOTAL COST
$13.84 .67
2.37 $16.88
$12.14 .75
2.63 $15.52.
$ 1.70 (-08) (.26)
$ 1.36
RCD SPEED
428 384
The following formula and assumptions have been provided by Mr. F. W. Wood and J.-W. Jackson:
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MINERAL FELT SHINGLE COST ANALYSIS - SHREVEPORT May 19, 1982 Page 2
1. Standard Shingle Formulation:
Mat Saturant Coating Filler All Other
Shingle Weight 2. Mineral Mat Formulation - 55# Mat
Corrugated Filler Dow Latex XD 30374.33 Betz 1260 floculant 3. Raw Material Costs:
Mineral Felt Base
Net Gross
; 27.0 18.9
28.9 19.4
38.8
39.9
43.9
45.2
78.3
84.6
206.9
218.0
Net 720 1Z00 80 2.5
Gross 792
1236 84
2.5
Corrugated
Latex
FilTer"'(.Marble Falls, Texas) VitA'^f
Floculant
^^
Asphalt Colored Slate Base Slate
$ 47.60/ton
$ .73/lb
f /$ 37.15/ton UL l bo/tc cMr FS at
^ $3267597cw^ "
*Tc , iV
" S!,ftz'
$152.50/ton $ 74.00/ton $ 29.59/ton
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4. Felt Mill Assumptions 1. No estimates -included for capital improvements 2. Mineral Felt produced on DSPM #1 using a seven day schedule. (DSPM #2 producing corrugated medium on seven day schedule). 3. DSPM #1 steam consumption would be reduced by 35% while manu facturing a mineral felt versus organic felt. 4. The web speed.for mineral felt production is equivalent to organic felt.
5. Roofing Mill Assumptions 1. No estimates included for capital improvements. 2. Mineral felt shingle speeds would be equivalent to organic base shingles. 3. Standard labor and overhead rates used on the #10 shingle machine. 4. Mineral Felt "broke" can be recycled similar to organic.
nms
;1* ----
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