Document RaB7LX6a57gem9BgLD5vj98yv

FILE NAME: WR Grace (WRG) DATE: 1973 DOC#: WRG066 DOCUMENT DESCRIPTION: 1973 MK workshop lecture MK - Workshop - Lecture Arnold Rosenberg Paul Cornberg - research - purpose of mtg. - learn about MK-5; also to learn about MK in general; to solve problems in field instantly; patent situation not clear on MK-5; will not tell us what the substitute for asbestos is; April *71 - began working on MK-5; committed $500,000 - and about 12-15 research people; 6-9,000/tes.t at UL and about 9 nos. 4" x 12" furnace 0 Cambridge -.4' x 4' at TR - made 120 sample panels; 8' x 6' deck ? USG and Ohio State; went to UL Feb. '72 w/2 materials May we tested.MK-5; deck fireproofing can't be too hard -- due to expansion of the steel ; ^ / Ivan Odler function - filler and to provide low density for MK; elasticity - important during the pumping; also during fire test - MK is bent by steel; plaster of paris - for the binder; Gypsum setting - p l a s t e r of paris - partly soluble in water - fast set - possible in presence of external particles - eg. - dirty equip. only Use it quickly; depends on humidity - 30 days in Ea. Region - About 90 days in W. Coast; submit sample - for testing (if stored in trailer) ck - mix in cup - stirring of mixer promotes set time (mix by hand -is easiest way to, mix MK). Massive crystallization -60-65 Heat m generated - will get harder la m K - +2 # H?0 ,004535 m - ; " Gypsum is calcined - 1^0 taken out; (retarders and accs1er a:: - s built in to MK to stabilize Free water - RH of ambient air + moving of air - important ) .j / When MK is heated - results in loss of strength - MK is decomoosed MK is unhydrated 21% H^O is last in fire test Gypsum sticks well - (MK must be low density - we must entrain air in system) we use air entraining agent - to get density.1ower - air bubbles are formed - evenly distributed - throughout - bubbles are negatively charged which results in even distribution; Strength - (tensile strength - resists to pulling) we need high tensile - strength during attack of fire - most important; steel used in concrete to increase tensile strength; asbestos - was originally used - reolac emenis not identical to asbestos - (it is better than MK-3) * Supersat. state - (longer mix time decreases set time) run - MK thru 3 min. mix - 3 hr. set * thru nozzle - 50 min. - more gases to solution Di-Hydrate (solution) (Dirty or set MK speeds up set) squirt around edge of mixer or sides of mixes; wide soatu1a - t1ade . to clean off sides; (Calcium Sulfate - Di Hydrate) will set off flush out hoses and save water for re-using; - will set off fast set; wet baos - will set off fast set; retarder used in clean-up' and at beginning of day; wet MK_or dirty equip, will .not be he! ped by Mixing and Proper Mi x Consistency - Rosenberg 12 ft.^ - Mixer - 40 RPM - quick fill - frown on guy who uses nose; good close fitting blades; make sure mixer clean - flush thru w/ a sponge; flush w/ retarder in morning; 1.) water 1st 2.) break open bags - keep dust down - some will say - it looks like feathers introduce it as looking like feathers; pumps better How much water - 9.5 - 13.5 gallons water - MK-3 more demanding for water than MK-4 or MK-5; 11-11-1/2 gallons - ideal; MK-3 mixed 5 mm. MK-4, MK-5 - mix.for 2 minutes; (pumpability and hanging - depends on mix; (Density - dry mixing is critical for MK-4, MK-5; we are controlling the density) Mixer density is what to look for when problems occur; Pancake batter - good; run finger down thru - makes wake which slowly closes; this is good - if closes immed. - or doesn't close - not right; 48-50 lbs. ft.^ - ideal mixer density; low density looked at good yields - not good for pumping; lighter because - more of a problem in pumping - ck. density -^probably too low - (piston pushes ball 1300 PSI more back pressure - will get away on low rise When cleaning - out - must reduce pumping speed; overwatering leads to low yields - (62.4 lbs./ft. water) - not true Overwatering - d isaster 'in spraying; dryer mix - better it hangs; Painted surface - not as easy as spraying regular steel; tendency is for water to be repelled. - should be paint mfgr. responsibility to give data about paint being an integral part of fireproofing system. Cheaper to shop coat steel in factory than to clean up mill scale - we don't have tests at UL showing painted steel; (if it d o e s n 't say paint - then we shouldn't advise) bond strength Negotiations now w/ _ Organic materials burn at 3-4CQ3 r* E-119 goes to 2000 - MK doesn't burn - in between we slip an organic material - paint - flakes off - (what happens to MK) Small granular rusting - doesn't hurt; loose mill scale bad - N.Y. - air blasting - 90S of jobs - not shop coated; nobody knows whether ' MK will fail - (columns - beams get painted 2-3 yrs. - should be shop coated; don't get in a position of guaranteeing the paint - decks are being tested now; and decks are being painted now; things are unclear - Oxygen source needed for paint - to burn; (Weathering - type steel we are not talking about) Cost not that much more 2-3c/lb.; Pumping -hanging - slides - yields - can be traced to mixes; MK-5 has dryer feel (don't add more water) - tendency will be to cverwater; if we overwater - we will experience slides; - water will bleed out of MK to back of steel - reason looks dry (reinforcing fiber - will see lumps - will interpret as lumps of MK; 2-3 min. can easily go by; then complains about pumpability - put water in - then material - . li .*N = m i n . - t o o C r. c OH MK-: * 4 2 3 at 5 m i n 52-48 - takes long ti r,e - can nix 13"m i M <-4 , v <-5 - to 2 mi we ars too long 1- 1/2 - 2 min. - tur off mixer 8* . m <_4 MK-5 better pumcing ac septa ole at 4 min. 2 min. - dens. MK-5 is 50# - MK-4 is 52# at 2 minutes; Turn c^f mixer; . don't go below 48# for MK-4 - don't co below 40 - for MK-5; Density is important - more than mix-time; figures at 40 RPM too 1ittle densi ty rpuemspuiltns5 in . poor think of MK as sponge pillow - must have water & ; %j r. 50# dens. MK-3 takes lots norewa Ter; graph shows this relation i, 11 *` '7 i.: * %l water + air bubbles make for fluidity; - too much water fluidity - " won't hang; air bubbles will be broken due to air pressure MK-5 won't look runny- like MK-3; within 2-5 m:s. - we will standardize weights - and will eventually standardize the water. Hard to accurately put in 7 full buckets (1/4" off on buckets - result in bad MK) Quick fill - are too slow (doesn't fill up in time) might need larger hose. 30 secs, for quick fill tank to empty; automatic float valves - slowly close; water gage - anything that measures height of tank; we have problems measuring. Mono-Kote - Cracking . 25d/ft. 2 - to go back and correct problem - 3 types; mud or map cracking dry river bed ' ' This is most serious crack . Why does this happen? Fine particles - stick together - attract one another law of physics; water evaporates from mud samp!e;*water leaves - particles draw closer together - whole mass loses volume - grows smaller; surface tension phenomenon - actually shrinks. Differential shrinkage: adhes ive force - holds sample - 2 pnen. adhesive force keeps MK stuck to steel; water leaves top before bottom and cracks Gyp. sets - forms crystals - which attach to each other; gypsum Evap. - leads to tendency to crack (air voids left by evaporating) Strength of oypsum resists tendency to crack; if MK not up to strength then shrinkage will win out; evap. - cause cohes iveness of m a s s ; Crystal act as reinforcing steel (steel binder resists cracking) ' Whv cracking - set up MK - or dirty m k - set takes place in. line - set already occurred - broke up crystals as you spray; lost strength - will crack Old MK - np binder; improperly made binder; could be a cause; (pre-hydrated material) - causes cracks - no binder Wash slow down - leaves mixer running; Retarders - cculd cause cracking - 8-10 hrs. - 90 - 0 RH 0 MPH - t .A . area - could d-v 2 hrs. Unusual delays - (high water ratio) 6" MK in corner Corner Crackino MK-5 tendency to crack will be less; but MK not designed to hanole that much stress - Won't have an effect on the fire rating - (binder not that strong) Poor Ventilation MK remains wet 90 RH; never dries; strength gain depends on coed drying ' ' Gypsum - (few big crystals instead of lots of small ones) Use fresh MK - good ventilation - put up quickly - to avoid problems - Prolonged Cracking Wet Conditions What about #3 vs. if4 agg.; Cracking has no bearing on change in aggregates - UL fire tests on both aggregates; No change in yields; (Amt. of water - depends.on surface area) - poorly expanded are? Does this cause any problems- less water will be absorbed - most of water is located between spaces of aggregates; Not dependent on changes in aggregates; pumping is dependent on density; Retarders . . eggs, glues, gelatin, case in (milk) orange juice, tea Accelerators gypsum, cement, table.salt, sodium silicate; retarders - coat the crystals which stops growth; (have - spacings which link together molecules) hasten (U.S.G. - retarder) - we don't charge for it. Red top: - (Gold Seal - National Gypsum) . ' Karenbero - Pumps " MK-5 - back pressure less - Mayno - Thompson - Essich - 3 types of pumps Moyno - is small - rarely used; plug to wall . Essich - good for hi rise bldgs. (Never say Thompson is bac pumDj Stator - sqeezes M K - direct draw - no back pressure - will oump low . density material - - T h . - 12 cyl. mach. - piston pump; good to 30 floors - 300 bags/day 7 hr. day Essich ? 1000 Mixer 12 ft."* TM 30 pump var. speed pump speecs AO to 140 stroke's/mi n .. - 70-90 strokes/min. look at piston shaft - (oiler) count strokes - (pump PPM) only - 150-250 bags 7 hr. day 350-400 bags (48-50 MK-4,3) (46*/ft.3 - MK-5) densities deliv. rate - (can increase deliv. rate by increasing water) 1 coat -.spray man 150 bags - 1.8 water ratio - dense mat. no overspray. G1enBrosr-soup - less than 1/2" 2 coats over 300 bags/day -White balls distort - (black neoprene ball rips apart) * seats tear up ball; (K-ball) lasts 4 hrs. on Glen Bros, job w/1000# back pressure :eel balls - rip apart seat 90 RPM - 150 bags/day MK-4 .an MK-5 - rate up to 300 bags/day balls deformation or cracked Check Valve Orifice size - 5/8" don't work w/MK-5 OK w/ MK-4 uneven application - co to 1/2" orifice ' (Air pressure over 20 PSI hurts air) not stripping out the air - w/ 15-20 PSI Auxiliary Compressor . 1) dirty equip. 2) poor stor. 3) insuff. mix 4) overmix 5) cold temp. - 6) hi temp. 7) hi humidity Summary acc. set - nozz. clog. - hi pump press. clean ea. day - acc. set - crackina dry MK use bags in 1 no. low yr. hi dens, plug due to lump ` slow pump - low dens. - use clutch on mixer to stoo mixer 40-450 - acc. set - slides drop port. heaters -.tarps above 95 retarded set don't add more retarder inadequate vent vr - <n too much water slow crack shrink - stiffer mix - 1ar too hi pressure at overspray - rebounding low yield nozzle need rioht orifice - . stream - poor pattern Pump malfunction slow pump Check ball valves avoid air plucs Undersized riser hi press . in pump piping blowouts in pump - fast wear Use larger piping tapered reducers - radius elbows leaky connect, slug dirty steel slides fall out - clean steel - remove oil, peel patch dirty water accelerator set - use clean water (set MK - spray) c r a c k - f a l l off no set - demand water Waste the material Keep mixes clean. (Meet at 7:00 in lot) Genets 1 Session: M < - Manual? (job procedure - set up and estimating) Most contractors don't take yield checks; take typical Pay - cale.- scale - 28-32 bd. ft./ b'ag - check jobs - on floor basis - p-ea^dowr on estimate per floor 20% waste factor 30 b d . ft. (28-27 Pc. ft.) 300 bags/day - sacrifice .yields Doyle Nigh - 175 baos per day beams vs. deck and beams one nozzle some days 240-250 15 horse - 150-1 60 bags/day secret of volurae" procuctic ns is no.down time; 5 min. batch - 36 baos per hour - 252 bacs/dav (315 bags/day - 4 min. mix) 3 man crew from scaffold; (Fla. - 4 man crew - 180 bags) (6 hrs. - work out of 8 hr. day)- (push hare on open floors to average 175) Br. Columbia - 150 bags/day is a good day - with 3 man crew - starts early - mixer - shut down for lunch - wash up early; * ' What 0 mechanical contractor getting there early - L.A. What about clean-up - 1/2 - li/bd. ft. for cleanup - 15c/Pag fer cleanup $95/day - spray man $90 - hod carrier cleanup results in 1 extra man per day - in 5a. Rec 1cn Patching - w/MK vs. cost of patching of fibers - MK w/ trowel is . cheaper - but if we have to bring back in ecu ioment - we are mere expensive - EC's in N.Y.C. are getting lump sum prices - seme leave bags behind; L.A.' general - would rather do himse1f , cleanup on floors - (wire scrape them - L.Z.) Canada broom cleans drywall - knife blade; made wider to cut off floor - Painted - 'Paint Mfgrs. - selling sir. to pair.-, beams, :::s; hand 1/4" (dirty the steel) then cone back; UL bea~s are tested unoa inted- sheet of MIC - keeps oxygen away from steel (linseed oil base paint) after two weeks drying - no difference about bond but watch out about spraying before 2 weeks dry (Chicago - can hang 1-1/4" on beams - even on edge of beams) Surface Hardness Hard-hi density - usable for exterior applications - (smoke generation re: albi-clad-) re: (oversoray - in hi speed elevator shafts) - PVC Cast $200/ton 80 bags per day - ori ce~ is delivered to the job 5212/Ton - 75 bags/day (90-100 baos per day) - - 1 I f ' -V . 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M 1 1 1 * I. t i l j 1 III l/l *1 vi r - 3 O 1 O '.y # 3 ri 1 i o i * 1 * f -* o I - * q o . U M * o ;i K O M /l 1 j 1" 1 c, M -> i 1 i / /. O : i i~ I:oiI u f ti O r/i m : v Vil n i o > C J. i j vi . li c vi M il i -* O i/ M M* * I I oO M 1 c 1 1 '* i i J o n i O O M> O 1 OM O O l-l 1 0 i vn 1 f t O I * . * 1 * f ;i ; 1 i !-* i (H * : t M i * e l i n i h i/i # x i 11 J* * i < . o ti ' ' N O1 1 M f / l 10 1 1 e l I- .-- > m j i 1 ( i 1 ' *i i 1 ;* o X i1 o x --<' 1 1 1 . V ^ o :: i i i * t*> i io u i ( / i *i i i i/> O o i - : i , ti I 'M o < i o l `> t 1 1 C i o f\> vInJ MF- ;oi; H vii f\Vi r- : VO di V it Oo 'cnn D \ --I v /l O O O O V I o o o o u :; * tl i V *< V II \ iI n J ()\ mI- oo o m <n I I- 0\ oi\lni\ ci i` n i I ii . i  I. Direct Ccso Kar.ocver Classiflcaoicn Heir * 3 a Principal Tr.vestiraocr (lari) Senior Scientist (Stanly) Senior Cheuist (Turin) Cher.ists Aralvoi^*1 Cher.ist Project Cccriir.aocr (nice) -c: i 3CC SCO iSo 175 e Tota"1 Profession! Technicians 13CC Totals 2155* t;.- Prcvis-.cn .-cr ca.ary _r.crease a. Salaries b. vaceriale C .U.t- 1. T-=- 'O- 2. Subsister.: d. Other 1. Sheovcrk Criers ` ^otaT ni'^on II. Iniirect Coses a. Overhead (13Of: x b. G1A (lUjJ x*37,5-:c)** * )** Subtotal Tota.l Coso 51-,7-0 3== c = : ow III. Pee (BfO ' . Total Cost l Pee (TP.C) * ~C.Cj w 5 ;T,3:C 3,23C 5 ->7;3 >*C--mw "Jr*"*-~?Cj These are Cross hours. Tec hours are 2333- Ciffsrer.ce of 2-2 hours a. for Vacations, Holidays, Sickness, etc. Cverheai t CA Rates are Provisional P.ates, sub.jeco to audio ieoern. Direct Cost Manoo'.'er Classification Principal Investiratcr (larc) Senior Scisr.cist (Stahly) Senior Cneicist (Purc..) Cherists . Analytical Cher.ist * Project Cccriine.icr (PicO Total Professional Techr.iciar.s . Totals Hours 120 120 to to - =0 3 SO 2t0 20 3, 57 a. Salaries b. viteriil c. Travel 1 * 2. Sut- d. Other 1. Shot "C 3 CO Totau Direct II. Is^irsct Ccsts a. Overhead (IJCf; :: * v r j . '."Lei vt *0 V i* Suotcta: Total Cost III. Jee. (i> Total Cost 1 Pee (;.P;C) v L ;r-'-i . ' "s n: 12 ,Cc2 S5 2 IlI~It.1l1i1 IIt)* vO.l- IO-* \(IIII These are Cress hours. Pet hours are 5te cf 3t heurs are for Vacations, Moll cays, Sic'/.r.ess, etc. **Cverhead C-IA Rates are Provisional Pates, subject to audit eterr.ina.ticn 1 -o 9 -- 'tprve co pos Tono : S9;-2- XB-OISTAOO<1 5 - 3 S 3 p V f 'C ? pcSV .Ja/.Q *.* dos '353U>;37S '/.3?" o;-; 'suo-prso-s;. foj JO 50--S--SJJOJ '**2 5--? ^203^ .P-*,, `S.'T.OO 2 2 0 --j 3 o 2 rV - - r .o _ 'y =j S -...O X -ooitcojpsst'O 2020p 009--* 0. : O * I i i -> ' t ( Provisional rat? , li i i (M .st e:--- erier.ee er. 2-cveiT_~.fr.'; ;c :n atcut 1Cl cf direct salaries