Document Ozw4ZeenbG5N5a3zj24wGJD5X

TECHNICAL SERVICE REPORT by R. P. Braddicks S. Drap PLAINTIFF'S EXHIBIT FK-211 COMPARATIVE PERFORMANCE PROPERTIES OF VINYL ASBESTOS TILE MADE WITH UCC SC--100 AND "CAREY'1 7TS3 ASBESTOS for THE FLINTKOTE COMPANY los Angeles, California Union Carbide Corporation - Research and Development Department Tarry town Technical Center Tarrytown, New York January 14, 1975 COMPARATIVE PERFORMANCE PROPERTIES OF VINYL ASBESTOS TILE MADE WITH UCO SG-I00 AND "CAREY" 7TS3 ASBESTOS INTRODUCTION i Performance properties of UCC SG-100 asbestos have been compared with those of "Carey" 7TS3 in a low binder level vinyl asbestos tile composi tion. The "Carey" 7TS3 asbestos has been used at a level of 12% of the total batch while SG-1 00 has been formulated at 8. 8 and 9.65%. Binder level for all compositions has been maintained at 19. 5% in accordance with this customer's current formulation objectives. The lower levels of SG-100 evaluated reflect the superior reinforcing value of this fiber and are con sistent with proven commercial practice. As per the advice of Flintkote, critical performance properties receiving special attention in this study include: "fiber value retention" of Banbury mixed tile compositions, fiber binder level requirements, tile hot strength and water sensitivity. Comparative formulation costs are also provided. DISCUSSION J. A. Sweeney of the Los Angeles plant recently reported that VA tile formulations were being revised in order to replace the old standard Hills asbestos with "Carey" 7TS3 fiber. It was suggested that UCC SG-100 CALIDRIA Asbestos be considered as an alternate for the "Carey" fiber. Because of the concerns expressed by the Flintkote Company, the following tile properties were evaluated as a function of SG-100: fiber value retention' during Banbury mixing, processing hot strength, fiber binder requirements and tile water sensitivity. It was also learned that the newly revised formulations will be main tained at 19 1 /2% binder and 1 2 % asbes tos. Using these formula tion constraints, tile performance data have been generated and reported for SG-100 and "Carey" 7TS3 formulations. These formulations, as well as the old Hills asbestos standard proprietary formulation, are detailed in Table I. Table II lists the performance data developed for these tile compositions. Tile pro cessing conditions are shown in the Appendix. RESULTS Comparative impact resistance, hot tensile strength, accelerated oven shrinkage and Bra bender equilibrium torque values shown in Table II indicate that SG-100 fibers do not degrade and lose their reinforcing value when Banbury processed. This confirms reports based upon many years of commer cial tile usage. The lightness and the tinctorial potential of all fibers in vestigated are approximately equivalent based upon the measured Yjqj brightness readings determined for corresponding tile samples. Except for the Hills asbestos containing formulations, the hot tensile strengths of these compositions are roughly equivalent. The superior hot tensile strength of the latter is expected since it contains not only 12% asbestos but, in addition, is reinforced w;ith 9% talc plus 1.6% added binder. 2- - Brabender equilibrium torque valuer '* SG-100 containing stocks are slightly lower than those determined f; e "Carey" 7TS3 counterparts. However, since they contain approximately and 81 % of the asbestos formulated in the "Carey" counterparts, these small differences again reflect the effective reinforcing value of the SG-100 fiber. The 3 day water expansion data listed in Table II represent average values and ranges determined at two reference points using two specimens of each formulation. Within the precision-limits of the test method, all formulations except possibly compound # 6_A show approximately equivalent expansions and are generally within acceptable limits. Although the average expansion value of compound 62A is higher than the other tile formulations tested, its magnitude is considered acceptable and lower than most commer cial tiles tested similarly. Due to its lower delivered cost and reduced required usage level, SG-100 affords a significant raw material savings. For example, compara tive costs provide in Table I result in the following potential savings: Formulation: 1 'Carev" 57B SG-1 00 56D Baas Bulk Cost, $/lb. - . 0705 0.0673 0.0668 Savings, $/lb. vs. "Carey" - 0.0032 0.0037 Savings, $/lb. vs. Hills . 0076 0.0108 0.0113 Hills Asbestos 70B . 0781 - - -Pound cost used rather than square foot cost due to specific gravity discrepancies caused by unavoidable occluded air in prepared laboratory tiles. CONCLUSIONS 1. Banbury processing of tile formulations made with SG-100 asbestos has been shown not to degrade this fiber. This is consistent with commercial tile production experience. 2. SG-100 fiber used at appropriate levels produces tile having hot tensile strengths equivalent to those determined for "Carey" asbestos con taining tile. 3. When properly adjusted for its fiber value, SG-100 formulated tile has binder requirements equivalent to "Carey" 7TS3. -3- 4. The water sensitivity of tile made with SG-100 fiber is about equivalent to that determined for its ''Carey" asbestos counterpart. This is particularly true at the low levels of asbestos used in this evaluation. 5. Adoption of SG-100 asbestos as a replacement for "Carey" 7TS3 fiber has been shown to effect substantial savings in formulation costs. R. P. Braddicks/S. Drap:et File No.: TSR-7S-6 TABLE I FORMULATIONS AND COSTS Notebook 1 555 Page / JM 7R "Carey" 7TS3 SG-100 40 Mesh Limestone Mistron Talc VS JD "Amoco" 18-240 DOP EPO Petroleum Wax Stearic Acid "Mark" 140 Ti02 Total T> Binder % Asbestos $/lb. Determined Sp. Gr. $/ft.1 l/l 6" 57A 57B - 11.97 67. 34 11. 28 2. 99 3. 94 . 37 . 22 . 23 . 66 1. 00 - 11. 97 67. 34 - 11. 39 2. 99 3. 83 . 37 . 22 . 23 . 66 1. 00 100.0 19.5 12 . 0705^ ^ 100. 0 19.5 12 . 0705^ ^ 2.0415 2. 0415 . 0468\1 ) . 0468(1 ) SG-JOO 56D 62A Hills Asbestos 703 - 8. 77 70. 54 11.60 2. 99 3.62 . 37 . 22 . 23 . 66 1. 00 9.65 69.66 # 11.60 2. 99. 3. 62 . 37 . 22 . 23 . 66 1.00 11.92 " 56. 88 9. 04 12. 49 3. 21 3. 88 . 40 . 24 . 23 .71 1.00 100. 0 19.5 8. 77 0673m . 0668^ 2.0340 . 0445T . 0442^3) 100. 0 19.5 9. 65 .0675(3| . 0670^' 2.0535 .0451 "r . 0447") 100.0 21. 11.92 . 0781 2. 012 . 0511 Note: (1) "Carey1 ' delivered in bags $ 112/ton 2) SG - 1 00 delivered in bags $ 74/ton (3) SG -1 00 delivered in bulk $ 64/ton TABLE II TILE PHYSICAL PRODrR TIES Formulation Page Notebook 155: - "Carey " 7TS3 57A 57B SG- 100 56D 6 2A 1 Min. McBurney Average No. Impacts v rICI 1/2 hr. Oven Shrink, 180F^ 22 hr. Oven Shrink, 1 80F^ ^ Tensile Strength, psi, 180F % Elongation, 1 80F 3 Day Water Expansion^ 10. 3 1. 6 46. 3 17. 7 24. 7 21.7 27. 8 9.4 1.6 47. 5 16.0 23. 2 24. 7 29.7 9. 0 1. 3 47. 5 ^27. 5 ^ 35. 2 N 19. 0 29. 9 8. 1 1.6 47. 3 17. 5 26. 5 22.4 21. 8 Simula ted Hills Ashes LOS 70B 8. 0 0. 7 47. 1 14. 5 28. 7 38. 9 1 5. 8 Average Range Brabender Equil. Torque,(3) 1 52C 9. 0 8-25 1175 7. 3 4-9 1210 8. 5 5-11 1100 12. 5 11-14 1140 7.0 5-9 1270 Note: (1 ) Oven Shrinkage 1 80F. mils/6 inch, machine direction (2) Water Expansion, mils/6 inch, across machine direction (3) Brabender Torque - 60 RPM, Bowl 150C, diced tile, 100 gms, # 6 roller head APPENDIX TILE PROCESSING CONDITIONS Banbury - Batch Size Ram Pressure Rotor Cooling Rotor Speed Drop Temperature - 4300 gms 40 psig 40 psig water 56 RPM 1 50C Mix Mill - 8 in. x 16 in. two roll mill Front Roll - 115C, 75 fpm Back Roll - 135C, 65 fpm Sheet Thickness - 0.125 inch Calender - 8 in. x 16 in. inverted L, Calender Speed Top Roll Middle Roll Bottom Roll - four roll 20 fpm 6 5C 55C, Gap for .080 inch sheet 50C, Gap for .065 inch sheet