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PLAINTIFF'S EXHIBIT K-1560 Johns-Manville Insulating Fire Brick... for Unsurpassed Heat-control Effectiveness to 3000F Johns-Manville provides industry with the most complete line of insulating fire brick, insulating brick and light weight refractory aggregates, fills and castables for temperatures through 3000F. With six types of top-quality insulating fire brick. Johns-Manville offers operators and builders of fur naces and other high-temperature equipment the opportunity to use the one insulating fire brick that is right for a given service. Every J-M insulating fire brick has the correct balance of thermal, chemical and physical properties for its recommended use. In addition, J-M insulating fire brick have high purity (low reducible oxides), making them adaptable for use in prepared atmosphere furnaces and special ceramic kilns that use salt glazing processes. All six types have light weight, low conductivity and high structural strength for the efficient and economical control of heat. New Production Method Improves Quality of J-M Insulating Fire Brick Recently, the combined skills of Johns-Manville research, engineering and production developed a new, improved method of making insulating fire brick which is radically different than the old accepted process. The main difference is the fact that the brick are cut out of fired slabs. In J-M's extensive facilities at Zelienople. Pa., these slabs are molded, fired rapidly through tunnel kilns and then cut into standard brick and special shapes. Han dling of the slabs throughout the process is easier, a more stable load is possible on the kiln cars with better spacing to permit removal of the burnout and to obtain !T' temperatures throughout the kiln car.'. Many ,'haj.t-' tan be produced directly from slabs. v r,:tr normally would hat e to be molded and processed a- -I'eti.b items Tne slab> are formed m processes almost foreign to the clay product- industry. The 1600. 2000 and 2300 orick slabs are formed in a casting' operation, the 2600. 2*"0 and 3ono brick slabs are molded by a slinger type machine. In addition to the high quality obtained, this -treamlmed t'peration provides the flexibility and basis or giving quick shipment of standard and special -hapes to J-M customers. Sil-O-Cel Insulating Brick... (or Back-up Insulation Through 2 5 OOF S.l-O-fel insulating brick are made in Johns-Manville's Lompoc. California pian: using selective blends of diamataceous silica. This material is composed of millions f microscopic cells that offer maximum resistance to v.e riou of heat. Consequently, tnese high load-bearing i k are ideal tor u.-e bertind fire brick at temperature .-ugh 25opF. Three types of Sil-O-Cel insulating brick, are avail able for varying temperature requirements encountered in back-up insulation service. The new Sil-O-Cell 16L brick may also be used for exposed as well as back-up service. Used as back-up insulation. Sil-O-Cel insulating brick make it possible to reduce the necessary thickness of the exposed refractory as much -as one-third. This results in a considerable saving in furnace wall con struction for all type.- of high temperature equipment. Sil-O-Cel insulating brick are made by pressing according to conventional industry practices and are dried and fired in tunnel kiln.-. They are pressed to size, no; ,-ized after firing a- is the case with J-M insulating fire brick. 3 i I DESCRIPTION: Johns-Manville produces six types of Insulating- Fire Brick to provide operators and builders of high temperature equipment six opportunities to get the one insulating fire brick that 's right for a given service. Each type of J-M Insulating Fire Brick has the correct balance of thermal and physical properties for its recommended service. All six types offer light weight, low conductivity, high purity and high structural strength. Made from high quality refractory clays (plus alumina in the case of JM-3000 and JM-28), these insulating fire brick contain a carefully graded organic filler which is burned out during manufac ture to give a uniform, controlled pore structure. AVAILABLE TYPES: JM-3000-for temperatures to 3000F exposed. JM-28-for temperatures to 2800F exposed. JM-2o-for temperatures to 2600F exposed. JM-23-for temperatures to 2300F exposed. JM-20-for temperatures to 2000F exposed. JM-1620-for temperatures to 1600F exposed: to 2W0F back-up. USES: Recommended for use as refractory lin ing or a- back-up insulation behind other refrac 4 tory protection in domestic oil burning equipment, kilns, furnaces, flues, refining vessels, regenerators, gas producers and mains, soaking pits, stressrelieving furnaces, reactor chambers and similar high temperature industrial equipment. The improved JM-23 and JM-20 are made espe cially for use in prepared-atmosphere furnaces. Designed for direct exposure or back-up insulating, they are resistant to gases such as CO, HL.. and CH,. They have the perfect balance of chemical and physical properties for effective heat control in prepared atmospheres. ADVANTAGES: High Insulating Value The light weight and high insulating value of J-M Insulating Fire Brick make possible thinner furnace walls, improved efficiency and lower operating cost.-. Quick Heal Up Furnace- can be brought up to operating temperature- with unu-ual speed, resulting in increased production. High Purity All J-M Insulating Fire Brick have high purity with )ou iron content which provides high re-istance to the deleteriou- effect- of prepared atmos phere- The;, are a!-" recommended fur u-e in ceramic kiin- v. here -alt giazmg proce-e- are employed. INSULATING FIRE BRICK PHYSICAL PROPERTIES* Temperature Limit JM-3000 JM-28 3000F** 2800F-* JM-26 2600F- JM-23 2300F" JM-20 JM-1620 2000F** 2000F*** HOOF" Approximate Density, pcf 65 58 51 31 29 27 Transverse Strength, psi 200 175 140 140 105 95 Cold Crushing Strength, psi 400 300 210 210 155 145 Linear Shrinkage, percent +0.8 at 3000F 1.4 at 2750F 1.0 at 2600F 0.1 at 2300F 0.0 at 2000F 0.0 at 2000F Reversible Thermal Expansion, percent 0.65 0.75 0.65-0.75 0.65-0.75 0.5 0.6 0.5-0.6 0.5-0.6 at 2000F at 2000F at 2000F at 2000F at 2000F at 2000F 'The figures given m this tabic sre avenge values attained in accordance with accepted test methods. "Back-up or exposed "'Back-up only. r?4-hr Simulative Service Panel Test; all others 24-hr soaking period. PACKAGING Type JM-3000 No. of Brick per Carton ' 20 JM-28 JM-26 JM-23 JM-20 JM-1620 COMPLIANCE WITH GOVERNMENT SPECS THERMAL CONDUCTIVITY CONDUCTIVITY: BTU IN. PER SQ FT PER F |R HR JM-20 complies with MIL-B-16305A. Class A jm-tQ curriyucs wi ill FVUL-D-iOJUJM. L-ldii 0 MEAN TEMPERATURE. F 500 1000 1500 2000 STANDARD SIZES JM-3000 JM-28 3.22 3.30 1 3.37 1 2.55 1 2.80 3.06 3.46 3.32 Type Size JM-26 2.22 1 2 44 : 2.68 *1 2.93 JM-3000 JM-26 JM-26 JM-23 JM-20 JM-1620 Accurately sized in all standard 9 in shapes of the 2\t JM-23 JM-20 1 1 01 1.18 ,1 1.34 1.50 | 0.90 I1 1.08 2.27 ; _ and 3 m series. as well as JM-1620 1 0 77 i1 i 1.02 1.27 1 _ special shapes i ) J-M SIL-O-CEL' INSULATING BRICK : ESC RIPTION: Madefromdiatomaceoussilica. a material composed of millions of microscopic cells that offer maximum resistance to heat flow, Sil-O-Cel Insulating- Brick are particularly useful where high load-bearing characteristics are required. Sil-O-Cel Insulating Brick are furnished in three types for use as back-up insulation behind refractory fire brick linings or behind insulating fire brick linings. The new Sil-O-Cel 16L brick may also be used for exposed as well as back-up service. AVAILABLE TYPES: Sil-O-Cel Insulating Brick are furnished in three different types as follows: Sil-O-Cel Super-for temperatures to 2500F back up only. Sil-O-Cel C-22-for temperatures to 2000F back up only. Sil-O-Cel 16L-for temperatures to 1600F back-up or exposed. USES: Sil-O-Cel Insulating Brick are recom mended for use as back-up insulation in furnaces, kilns, hot blast stoves, soaking pits, boiler walls, oil heaters, regenerators, and similar high tempera ture equipment in the steel, chemicil, ceramic, power, petroleum and glass industries. ADVANTAGES Good Insulating Value Used as back-up insulalion, Sil-O-Cel Insulating Brick make it possible to reduce the necessary thickness of the exposed refractory as much as one-third. This results in substantial savings in furnace wall construction for all the types of high temperature equipment for which these brick are recommended. High Load Bearing Strength Sil-O-Cel Insu lating Brick are made from diatomaceous silica, a natural fossilized material which imparts to the finished brick great strength. The Sil-O-Cel C-22 brick, for example, has a cold crushing strength of 700 lbs per square inch. 6 i tJ j ] I SIL-O-CEL INSULATING BRICK PHYSICAL PROPERTIES THERMAL CONDUCTIVITY CONDUCTIVITY: STU IN. PER SQ FT PER F PER HR Temperature Limit Approximate Density Transverse Strength Cold Crushing Strength linear Shrinkage Reversible Thermal Expansion 90 psi 300 psi 2.0% at 2500F 1.3% at 2000F MEAN TEMPERATURE. F 115 psi ! 60 pst | 700 psi ! 350 psi I 500 1000 1500 1 Super 1.70 1.95 2.19 0.8% at 0.7% at 2000F j 1600F 1 C 22 1.67 1.88 2.08 I 161 0.92 1.07 1.22 0.7% at less than 0.1% 1 2000F 1 at1B00F I 'Thp figures fiven m this tide are average values obtained m accordance with accepted test methods **6jc-up only "'Backup or exposed COMPLIANCE WITH GOVERNMENT SPECS Sil-0-Cel Super complies with M1L-B16182S PACKAGING INFORMATION All Sil-O-Cel Insulating Brick are packaged 25 to a carte" ST A NDARD SiZES Type Sii-D-Ce! SuDr Si-O-Ce: C 22 S':-0-Ce! 15. Size Furmshec m ail stanoard 5 m shapes c' ire 2:: anc S ir. senes, as well as soecia snapes OB S C R I PTION: Johns-Manville produces nine types of castable refractories to meet practically every castable requirement for temperatures through 3000F. Each of these refractories is eco nomical and efficient in the service range for which it is recommended. All harden rapidly and are highly resistant to spalling. AVAILABLE TYPES: 3X Firecrete -- For service to 3000F. Composed principally of high aluminous materials calcined at high temperatures. Recommended for casting thicknesses of 2 inches or more. H. T. Firecrete - For service to 2800F. Recom mended for casting thicknesses 2 inches or more. Standard Firecrete - For service to. 2500F. De velops exceptional strength on air curing. Can be used to cast thicknesses as thin as 1 inch. L. tV. Firecrete - A light weight, insulating re fractory concrete for service to 2400F. 75 lbs of dry material required for one cubic foot. CA Insulating Firecrete-Alight weight, low iron content refractory for use in controlled atmos pheres. For service to 2600F. No. 20 Firecrete - Similar to L. \V. Firecrete but lighter. 58 lbs of dry material required for one cubic foot. Service to 2000F. 2200CA Insulating Firecrete-A light weight, low iron content refractory for use in controlled atmos pheres. For service to 2200F. Lo-D Firecrete - Designed primarily for use as a back-up insulating refractory in naval boilers. Service to 2500F. C-31 M Refractory Cement-A chrome base castable refractory for service to 3000F. USES: Firecrete is used extensively for mono lithic furnaces and linings and is recommended for such special shapes as those required for burner rings, baffle tile, header protection tile, pipe linings, furnace bottoms and similar installations. ADVANTAGES: Hardens Rapidly Firecrete permits casting and use of any desired shape within 24 hours. Resists Spalling All nine types are highly resist ant to spalling. Negligible Shrinkage Firecrete has no drying shrinkage and only negligible fire shrinkage at recom mended temperatures. Easy and Economical to Use The adaptabil ity of Firecrete makes possible the easy construction of monolithic furnaces, linings and she like which would otherwise require the use of special shapes or involve costly cutting and fitting of brick. 8 FIRECRETE PHYSICAL PROPERTIES' Highest Recommended Service Temperature 3X 3000F H.T. 2800F STD. 2500F L.W. 2400F CA Insulating No. 20 2600F 200F C-31 M Refractory 3000F 2200 CA Insulating Firecrete 2200F Le-D 2500F Pyrometric Cone Equivalent 33 !3173F) 30 (3002F) 16 (2669F) 15 (2615F) 321-j (3135F) 14 (2552F) Weight 36 (3290F1 16-17 (2740F) As Placed 148 pet Oven Dried at 220F 134 pcf After 5-Hr Firing at 1750F 130 pcf 131 pcf 113 pcf 110 pcf 130 pcf 116 pcf 110 pcf 109 pcf 80 pcf 75 pcf 109 pcf 80 pcf 75 pcf 96 pel 62 pcf 58 pcf 193 pet 183 pcf 177 pcf 97 pcf 66 pcf 57 pcf 100 pcf 48 pcf 44 pcf Crushing Strengths After 5-Hr Firing at: 220F 1200F 3750F 22OOF 2400F 3500 psi 2680 psi 2350 psi 2490 psi 2950 psi 700 psi 560 psi 300 psi 580 psi 1500 psi 1310 psi 1190 ps. 780 psi 1190 psi 2130 psi 630 psi 595 psi 490 psi 690 psi 1690 psi 580 psi 475 psi 595 psi 650 psi 840 psi 500 psi 490 psi 410 psi 365 psi - 2920 psi 1780 psi 1300 psi 1690 psi 3850 psi 310 psi 320 psi 375_psi Linear Change After 5-Hr Firing at: 1200F 1750F 2200F 24 OOF 2800F 3000F * -0.2% -0.1% -0.2% -0.7% -0.9% -0.1% -0.2% -0.1 % -0.6% -0.9% - 0.0% -0.2% -0.6% -1.6% _ - -0.2% -0.3% -0.5% -1.2% - -01% -0.2% -0.3% -0._8% - -0.4% -0.4% _ - -0.2% -0.2% -0.3% -0.5% -1.9% -3.1% -0.1% -0.1% _ _ 'The fi*ur liven in !hi< table ere aetriie values obtainca in accordance with accepted tail methods. THERMAL CONDUCTIVITY CONDUCTIVITY: BTU IN. PER SO FT PER F PER NR MEAN TEMPERATURE, F 800 1000 1200 1400 1600 3X Firecrete - 7.0 7.2 7.5 7.8 H.T. Firecrete - 4 45 4.76 5.08 5 41 Standard Firecrete 4.16 4.34 4.59 4.88 5.19 L.W. Firecrete 1.99 2.09 2.21 2.36 2.56 CA Insulating Firecrete - 2.57 2.70 2.90 3.12 No. 20 Firecrete 1.43 1.54 1.65 1.76 1.87 C-31 M Refractory Cement - 6.0 6.1 6.3 6.5 COMPLIANCE WITH GOVERNMENT SPECS Lo-D Firecrete complies witn MIL-C-I9794A 1800 2000 8.4 9.4 5.74 5.52 2.82 3.33 3.65 1.98 -- 6.7 6.9 PACKAGING INFORMATION Packaging 100-lb bags 100-lb bags 50 or 100-lb bags 100-lb bags 100-lb bags 50-lb bags 100-lb bags Lo-D Firecrete 50-lb bags 2200 CA Insulating 50-lb bags Firecrete -M Firecrete ... Application Instructions Mixing: Firecrete hardens rapidly, therefore water should not be added until the job is ready for application. Only clean, fresh water should be used. The amount of water will vary depending upon the size, shape and type of installation. Mix thoroughly after addition of water and adjust to proper percentage. Avoid an excess of water in order to obtain maximum structural strength in the refractory concrete. If cast against a porous material it is necessary to waterproof, or thor oughly wet, the surface to prevent water being taken from the refractory mixture. Casting: Forms for casting shapes can be made of either wood or metal. Wooden forms should be coated with shellac to prevent the absorption of water. If necessary, wooden forms can be burned away without damage to the refractory. If more than one shape is to be cast, heavy metal forms are more satisfactory. They should be smooth and coated with oil or grease to permit the easy removal of shapes. The refractory mixture should be "rodded" with a blunt-end tool until all corners are filled and air pockets eliminated. The use of vibrating equipment is recommended. Curing and Firing: Firecrete air-hardens suffi ciently in six hours to permit the removal of forms if necessary. For linings or large shapes, it is pref erable to air cure for 12 hours or longer before firing. In firing, apply heat slowly and without interruption until temperature is brought above service-operating conditions. Preparation o! Door Frames: A door which is less than 4 sq ft in area generally requires no reinforcing to hold the refractory in place. On larger doors, however, it is necessary to provide the refractory with some means of anchorage. Rods with bent ends or bolts with washers and nuts are generally used. Although such anchorage is necessary, best practice suggests that it be kept at a minimum, both in thickness and number. All bolts or rods, spaced on about 24" centers, should extend through approximately one-half the thickness of the refractory and, where possible, be placed in a staggered construction. The maximum diameter of the bolts or rods generally used is Vs". Anchors should not be placed at the corners of the door. Wrap rods with friction tape to permit expan sion. Storage: Firecrete should be stored in a cool, dry place as exposure to moisture will cause the mate rial to harden. $ % I s 4 1 JFai i . i!'1' iil '"W >''V. \ %, "< n sTr^^ ESTIMATED POUNDS OF DRY MATERIAL REQUIRED PER CU FT OF CONSTRUCTION (no allowance made lor waste) Type of Firecrete Lbs/cu It 3X Firecrete H T. Firecrete Standard Firecrete L W. Firecrete CA Insulating Firecrete No. 20 Firecrete 2200 CA Insulating Firecrete Lo-D Firecrete C-31 V Refractory Cement 130 no no 75 75 58 57 44 175 ESTIMATED POUNDS OF WATER REQUIREO PER 100 LBS OF CEMENT Type of Firecrete Lbs water/ 100 lbs of Cement 3X Firecrete H. T. Firecrete Std Firecrete L W Firecrete CA Insulating Firecrete No. 20 Firecrete Lo-D Firecrete C-31 M Refractory Cement 2200 CA Insulating Firecrete 12 18 17 45 DESCRIPTION-: Four types of dry monolithic, hydraulic setting refractories have been developed and produced by Johns-Manville for gunning and slap-troweling applications. These four refractories are especially adaptable forjrun application in building new refractory lin ings and repairing old ones. They adhere readily with a minimum of loss when "shot" in place. Mixed with water at the gun nozzle, they are pneu matically projected with great force, resulting in a dense, homogeneous lining. Blazecrete is equally effective for heavy patching by troweling, especially where brickwork has eroded deeply. It eliminates the laborious ramming or tamping required with "plastics", and patches need not be prefired. AVAILABLE TYPES: 3X Blazecrete - For service to 300.0F. High alu mina content. Particularly adaptable for gun appli cators and for heavy patching by slap-troweling. Standard Elazecrete - For service to 2400F. Alu mina silicate base. L. \V. Blazecrete-For service to 2000F. Light weight, alumina silicate base refractory. Used ex tensively for stack linings, heaters and other appli cations where gunning mix with low rebound loss is required. t-2 Refractory Cement - For service to 2300F. Used to advantage in making a protective abrasionresistant refractory surface over L. W. Blazecrete. USES: Recommended for lining or patching forge furnaces, ashpits, cyclones, heaters, boilers, oil refining equipment, furnace bottoms, ladles and similar applications. L. W. Blazecrete is extensively used on tanks, structural steel and skirts for fire protection purposes. ADVANTAGES: Hardens Rapidly Application* ready for use with in 24 hour* of punning or -lap-troweling. Resists Spalling All four types are highly resis tant to spalling. Easy to Use Can be applied by gunning or slaptroweling. BLAZECRETE PHYSICAL PROPERTIES* Highest Recommended Service Temperature 3X 3000F STO. 2400F Pyrometrie Cone Equivalent Weight Slap Troweled: As Placed Oven Dried at 220F After 5-Hr Firing at 1750F 33 (3173F! 148 pCf 133 pcf 130 pcf 16 12669F) 132 pcf 116 pcf 110 pcf Weight Gunned: As Placed Oven Dried at 220F After 5-Hr Firing at 1750F 153 pcf 142 pcf 140 pcf 134 pcf 124 pcf 118 pcf Crushing Strengths After 5 Hours Firing at: 220F 1200F 1750F 2200F 24 OOF Linear Change After 5 Hours Firing at: 1200F 1750F 2200F 24 OOF 570 psi 700 psi 790 psi 1040 psi 2390 psi 0.0% 0.0% -0.2% -0.2% 1350 psi 1070 psi 1130 psi 1480 psi 2870 psi -0.1% -0 4% -0.6% -0 4% *Tne figures given >n trns table are average values obtained in accordance witn accepted test methods L.W. 2000F 14 (2552 F) 104 pcf 69 pcf 65 pcf 117 pel 76 pcf 73 pcf 275 psi 338 psi 400_psi - -0.3% -0.6__% C-2 Cement 2300F 1512608F) 140 pcf 126 pcf 120 pcf 142 pcf 134 pcf 128 pcf 6200 psi 4700 psi 2600_psi - -0.2% -0.2% THERMAL CONDUCTIVITY CONDUCTIVITY: BTU IN. PER SQ FT PER F PER HR 3X Bfazecrete Standard Blazecrete L W. Blazecrete C-2 Refractory Cement MEAN TEMPERATURE. F 600 800 1000 1200 1400 1600 1800 - - 4.10 4.30 4.68 5 40 6 35 - 3.89 3.95 4.05 4.24 4.57 5.09 1.42 ' 1.52 1.64 1.76 1 89 2 0! - _ __ 3 40 3.50 3 80 4.30 5 :c 5 93 J-M Blazecrete... Application Instructions Preparation of Surface All surfaces should be clean and free of loose scale or other foreign mate rial. When Blazecrete is applied to worn brickwork or other refractories, the surface should be chipped to expose raw solid material. Metal should be cleaned by wire brushing, steam, or sandblasting to provide a satisfactory surface. Reinforcement As a general rule, reinforce ment is not required when Blazecrete is gunned on a sloping or flat surface because gravity will hold it in place. However, on vertical walls or overhead areas, except for patching, reinforcement should be used to hold the refractory in place. Where continuous reinforcing is unnecessary, rods with bent ends or bolts with washers and nuts should be used. All bolts or rods, spaced on about 24" centers, should extend through approximately one-half the thickness of the refractory and where possible be placed in a staggered arrangement. Use bolts or rods with a maximum diameter of Vz"Friction tape wrapped around the bolts or rods will permit expansion of the metal under heat. For continuous reinforcement, welded wire fab ric or hexagonal steel grating is recommended. A wire fabric should be spaced midway in the refrac tory and held in place with suitable studs, lag bolts, or other means. When more than one type material is to be applied, include a reinforcing mesh in each layer. For thin linings, hexagonal steel grating V' or 1" thick with openings approximately IV x IV x 14 gauge should be tack welded to the equipment and the refractory applied flush to the surface of the hexagonal mesh. Ounnlng Follow the standard methods of gun ning as recommended by gun manufacturers. It is helpful to pre-moisten Blazecrete before placing it in the gun hopper. This can be done by first put ting the Blazecrete in a concrete mixer and adding a small amount of water. After thorough mixing, the Blazecrete should be just slightly damp, but not enough to ball up. Pre-moistened Blazecrete tends to take on additional water at the gun nozzle more readily and the amount of dust and rebound is kept to a minimum. Some guns premix water with the cement before reaching the gun nozzle. Do not apply refractory through grating or mesh with openings of less than 4" if the shell of the vessel or the insulating surface is more than 1" from the underside of the mesh or grating. A given area should be finished if there is to be a lapse of time before the entire job is completed. When work is resumed, the contact surface of the material which has already been applied should be rough ened, cleaned and wet. When Blazecrete is used in double layers, the first layer should still be wet when applying the second layer. Do not use rebound material. Troweling Mix Blazecrete thoroughly with clean, fresh water until a stiff consistency is obtained so that it can be readily placed by slap-troweling. Curing and Firing It is preferable to air cure Blazecrete for 12 hours or longer before firing. Heat slowly and without interruption, bringing temperature above the service operating condi tions. miiin: 3X Blazecrete Standard Blazecrete L.W. Blazecrete C2 Refractory Cement 14 Pounds ef Refractory Required for 1 Cubic Foot 130 (slap-troweling) 140 (gunning, 110 islap-troweling118 (gunnings 65 (slap-troweling! 73 (gunning) 120 (slap-troweling 140 (gunning! Estimated Pounds of Water Required tor 100 Ids of Cement 14 16 53 15 1 J-M LIGHT WEIGHT REFRACTORY AGGREGATES AND FILLS DESCRIPTION: Johns-Manville light weight aggregates and tills are available in a wide selec tion for temperatures through 2400F. JM Zelie L.W. and JM-2400 L.W. Aggregates may be mixed with calcium aluminate cement to form an insulating refractory concrete for various operating conditions. Sil-O-Cel C-3 maj be mixed with calcium aluminate or Portland cement for lower temperature conditions. By selection of the aggregate, an insulating refractory concrete can be made with the characteristics desired for con structing core, japanning and enameling ovens, foundations and bases of heated equipment, fur nace doors, and many special shapes. In addition, all materials listed below may be used as fills for insulating irregular spaces in high temperature equipment, making it possible to conserve heat where other forms of insulation cannot be eco nomically installed. ------ AVAILABLE TYPES Name Csmpositien JM-24000 L.W. Aggregate Zelie L.W. Aggregate Sil-O-Cel C-3 Sil-O-Cel Insulating Powder Sil-O-Cel Coarse Grade al. silicate al. silicate calcined, coarse-graded diatomaceous silica ^ finely ground diatomaceous silica similar to Sil-O-Cel Insulating Powder, but coarsely ground Temperature limit, F Approx density to whichfills are normally packed, lbs per cu ft 2400 2400 2000 50 31 31 1600 17 1600 .. 22 Packaging 65-lb bags 50-lb bags 50-lb bags 50-lb bags 50-lb bags 16 DESCRIPTION: J-M Refractory Bonding Mor tars are recommended for bonding together many relatively small units into a stable, strong, and gas- tight structure. The use of refractory mortars reduces slag or gas penetration and cuts down heat loss caused by open joints. There are two general classifications.of bonding mortars: heat setting and air setting. Heat setting mortars will develop a bond only with the application of heat. Air setting mortars develop a strong bond without the applica tion of heat. J-M Bonding Mortars have been scientifically formulated to insure good workability, low shrink age. and long shelf life. AVAILABLE TYPES' Mortar Type Biamte* atr setting Temperature Limit F 3200 Super Blakite* air setting 3000 No. 2986 air setting 3200 Hellite* No. 20 No 26 No. 31 No 32 air setting air setting air setting (coarse) heat setting (fine) heat setting 3000 2700 2600 3100 3100 Uses laying insulating fire brick or refractory brick; shallow patching hot or cold surfaces for coating over vertical industrial boiler tubes, shallow patching, laying brick laying insulating fire brick or refractory brick; shallow patching hot or cold surfaces laying fire brick; shallow patching laying fire brick laying lire brick; patching laying fire brick laying fire brick Packaging 220,100, 50, 25,10 and 5-lb containers 220,100, 50. 25,10 and 5-lb containers 220,100, 50. 25.10 and 5-lb containers 220,100. 50. 25.10 and 5-lb containers 220,100, 50, 25.10 and 5-lb containers 100-lb bags 100-lb bags 100-lb bags 17 J-M CERAFELT0 D ESCR I PTION : J-M Cerafelt is a lightweight, refractory-fiber insulation notable for its excellent thermal and chemical stability. Made predomi nantly "f alumina and silica, it combines lightness, heat re-i-iance. low conductivity and high sound;:b~"niti"n qualities. -v'A u. a E L E FORMS: Furnished in densities ranging from 3 to 24 lbs per cu ft. Also available i".i<irm (J-M CERAFIBER) in 25-lb bags. z s Recommended for a great variety of high mnerailire industrial applications such as insula- in-.-tection in repairing open hearth roofs: on cover-type annealers to fill openings for electrical access: expansion joints in kilns, furnaces and boiler walls. ADVANTAGES: ss.gr Heat Resistance Will withstand continu expo-ure to a full 2"'X>F. w- Thermal Conductivity Unusually low conc.olivny a: high temperature- due to opacity of basic "e!' to infra-red rariiatior. w i c r i Weight Weigh* a* little a> 1 -10th equal vol ume of hard fire brick. Cherr.ically Stable Non-aikalme and chemically -...''it. ' "naiii' no con-'.i-ioii-promoting agent.-. IB TYPICAL CHEMICAL ANALYSIS -- INSULATING FIRE BRICK Material Composition New JM-20 j and JM-23 j No. 26 No. 28 JM 3000 SIL-C CEL 16L C 22 Super s.c. 44 2 57 4 35 0 29 4 90 2 90 0 TiO. 1-29 1 7 2.25 1.0 02 Fe.C 0 46 8 .5 .7] 1.6 :o5 A!. 0 38.0 33 7 59 0 65 6 49 43 CaO 25.2 0.2 - 0.3 0.8 3.4 MgO .06 ; - 05 0.6 .75 Na.O .02 .29 0.1 06 - K.O 27 , .06 0 2 o: ~ P.C 0.16 - - - 04 - mi' Meta' Corrected lor - - 3.6 e Quipmesl ei At Me111 preient - CALCULATED CHEMICAL ANALYSIS- WET CEMENTS' Material Composition -2986 -20 Super Cement Cement Nellite fireite Blakite Blakite SiO. 478 90S 49.6 85 4 47 4 48.1 A:. 0 44.3 52 37.8 64 4S-7 43.1 Fe.O 1.6 2.5 0.1 1.4 1.6 TiO. 25 - 22 - 14 1.4 CaO 0.2 - 0.6 - 0.1 0.3 MgO _ _ 0.1 -- K ; 0 0.9 1.4 ~ 0.5 0.9 Na 0 3.3 1.8 6.1 1.9 2.7 Misc 01 0.8 04 - - - ig loss 2.2 _ 'Anetytii it on e dry 'bill*. 3.6 2.0 1.6 1.7 CALCULATED CHEMICAL ANALYSIS-FIRECRETES CALCULATED CHEMICAL ANALYSIS -BLAZECRETES I 2200 Material 3X H.T. [Standard L.W JM 20 ! C-2 CA Int. I CA Ins. CompositionlFirecretelFirecretelFireeretelFireeretelFirecretelCementlFireeretelFirecretel SiO. 38.9 ; 39.3 j 30.2 46.2 | 28 4 1 40.0 40.1 i 27.0 Al;0 55.0 50.3 I 52.7 36.0 | 39.9 I 33 4 51.0 1 53.9 1 Fe:0 1 1 40 64 5.6 ' 6.9 7.9 .8 04 TiO; 2.1 2.0 2.1 1.5 16 - 1 2 0.8 CaO t*o* r 40 7.8 89 21.2 13.6 4 7 158 MgO K;0 Na;0 - -- - 0.2 - .1 1 0.2 ___ _ - - - i' - -- 1.1 .2 : j! ir04 - 1 Misc Ig Loss - 04 C.5 0.9 - _ ; _ 03 * *3 11 1 1 ,i I 1 1.0 j Material Com- 3X j Standard L.W. position j Blazecrete Blazecrete 1 Blazecrete JSiO. 38.0 j 34.5 AI-0 1I Fer0 ` 53.9 | 51.3 | 39.9 i 1.7 . 5.3 | 5.5 TlO: 2.6 2.1 1.5 CaO 2.0 68 16.2 MgO - - 0.2 K 0 ; } 0.3 Na 0 trace j - Misc trace ' 0.1 - Ig Loss. i1.3 1.6 ; 1.6 HEAT LOSSES, HEAT STORAGE AND OUTSl J-M INSULATING FIRE BRICK AND SUPE Wall Thickness Construction 1000 HI JT ST HS HS 4H' JM 1620 4>/;' JM20 4>/r' JM 23 4VT 4W* JM 26 4>/;- JM 28 41/;' JM 3000 4`/;- FIRECLAY BRICK 243 2500 260 2850 285 3300 387 6300 4-JM 1620-r IVJ'SX 44' JM 20- IV;' SX 44' JM 23 -- 14' SX 44' JM 26- 14" SX 44" JM 28 -- 14'SX 44 "JM 3000- 14'SX 116 398 137 126 423 142 134 444 145 202 615 175 214 645 180 230 684 187 1850 1790 2070 3660 4260 4880 150 485 153 2350 159 508 157 2350 168 531 161 2550 252 735 196 4700 267 771 202 5540 285 812 208 6250 9' JM 1620 9' JM 20 9' JM 23 9' JM 26 9' JM 28 9' JM 3000 9' FIRECLAY BRICK - 119 2550 - 125 2800 - 130 2900 - 177 4700 - 189 5300 - 208 6100 - 295 1)400 - 333 14600 9" JM 1620 - 3' SX 59.6 379 110 3650 76.7 462 119 4630 9" JM 20 - 3' SX 64.6 403 113 3480 81.6 485 121 4345 12' 9" JM 23- 3' SX 69.0 425 115 4010 86.6 508 123 5090 9' JM 26- 3' SX 106 596 133 7250 132 713 144 9350 9" JM 28 -- 3' SX 112 627 136 8480 140 750 148 10600 9' JM 3000 -- 3' SX 121 667 140 9720 150 792 153 12200 134' JM 1620 -- 34' SX 42.5 327 102 4870 54.7 396 108 6310 134' JM 20 - 34' SX 46.5 350 104 4900 58.8 418 110 6030 17' 134' JM 23 - 34' SX 50.0 369 106 5530 62.8 440 112 7100 134' JM26- 34'SX 80.5 536 121 10000 100 640 130 12800 134' JM28 - 34'SX 86 4 568 123 11800 107 678 133 15300 134'JM 3000- 34'SX 944 610 127 13700 116 723 137 17400 HOT FACE TEMf 1400 1600 1800 JT ST HS HL JT ST HS HL JT -- 193 2000 300 -- 214 2350 -- -- -- 202 1900 322 -- 222 2200 379 -- - 212 2200 345 - 232 2550 407 - 303 3700 688 - 329 4400 800 -- 322 4170 779 - 349 5100 906 - 347 5000 i 900 -- 372 5750 1036 -- - 468 9400 1933 - 510 10800 2259 - 575 168 2850 225 670 185 3400 -- -- 595 172 2740 231 686 187 3450 271 779 620 176 3150 242 712 192 3800 282 805 855 216 5770 359 975 235 6730 416 1096 897 222 6600 381 1022 243 7860 441 1148 938 229 7620 400 1063 249 8900 461 1186 -- 142 3800 154 -- 155 4580 -- -- - 148 4080 167 - 160 4900 195 -- 154 4100 181 -- 166 4940 211 -- -- 218 6800 365 -- 237 8100 422 -- - 233 8000 415 - 254 9600 480 -- 255 9000 484 - 276 10600 553 - 366 17600 1047 - 395 21000 1238 - 549 128 5620 569 130 5335 594 132 6250 830 156 11000 873 161 13100 916 165 14700 115 640 137 6690 119 656 139 6310 125 682 141 7340 186 948 169 13200 198 997 174 15400 209 1039 178 17600 ---- 139 746 145 772 216 1067 229 1121 240 1161 469 115 7730 489 116 7310 513 118 8690 745 139 15600 789 143 18700 836 148 21100 82.4 547 121 9170 85.6 564 123 8890 90.3 589 125 10200 142 85) 149 18500 152 901 154 21800 162 947 158 24610 ---- 100 641 105 666 164 958 176 1013 185 1058 HI - Heat Loss at Steady State Condition. BTU SQ FT HR JT - Junction Temperature between Brick and Backup Insulation. F. * Ambient - 80 F. Still Air. Outside Surface Temperature. F Heat Storage. BTU 'SQ FT. ^)DE SURFACE TEMPERATURES OF WALLS REX COMPARED TO FIRECLAY BRICK PERATURE*--F 1800 ST HS 2000 HL JT ST HS 2200 HL JT ST HS 2400 HL JT ST HS 2600 HI JT ST HS 2800 HL JT ST HS 242 2550 438 261 2900 252 2950 469 - 271 3350 533 - 290 3800 353 5000 917 - 374 5700 1040 - 394 6400 1168 - 411 7000 1300 - 427 7600 373 5850 1040 - 394 6600 1179 - 413 7400 1324 - 430 8200 1474 -- 447 8800 394 6600 1175 -- 414 7400 1317 - 431 8400 1462 - 448 9200 1607 -- 465 10000 570 12700 2670 - 586 14100 3070 - 619 15500 3510 - 642 17200 3990 - 658 18700 465 9600 482 11000 703 20500 203 3800 207 4350 254 7710 263 9030 268 10300 312 873 219 4180 324 899 223 5000 476 1216 273 8770 505 1273 282 10300 523 1308 287 11600 368 994 238 5550 538 1336 291 9650 572 1398 300 11400 588 1428 304 12700 604 1455 308 10700 642 1522 318 12700 656 1546 321 14200 673 1574 325 11800 716 1645 335 13800 726 1662 336 15300 793 1766 350 14900 798 1775 351 16400 172 5700 226 185 6400 179 5700 242 - 192 6400 275 - 205 7200 257 9400 482 - 275 10600 543 - 292 12000 607 - 309 13600 673 -- 325 14600 274 11000 547 - 293 12600 617 - 312 14000 689 - 329 15600 764 -- 345 16800 295 12400 623 - 314 14000 694 - 330 16000 767 - 346 17600 840 - 361 19200 421 23400 1440 - 445 26000 1653 - 469 29000 1871 - 497 33000 2090 - 533 35000 360 18400 374 21000 584 39000 148 7400 151 8410 181 15300 187 17700 191 20200 160 838 157 8290 166 864 160 9920 246 1186 193 17200 262 1245 199 20100 272 1282 203 23100 189 957 170 10800 278 1305 206 19300 296 1369 212 22200 304 1401 216 25200 311 1424 218 21300 331 1493 225 24300 338 1518 228 27400 345 1543 231 23400 368 1616 238 26500 373 1634 240 30500 406 1738 251 29700 409 1749 252 32600 130 10100 132 11600 159 21600 164 25000 168 28600 116 720 137 11700 121 746 139 13200 187 1065 169 24400 200 1126 174 28100 209 1167 178 32600 137 826 147 15100 210 1173 179 27500 226 1239 185 31200 234 1276 188 35800 235 1281 189 30100 252 1352 196 35000 259 1383 198 39500 261 1389 199 32900 280 1465 206 38100 285 1489 208 43500 308 1578 217 41200 312 1593 218 46600 - itf: < ^9" TYPICAL CONSTRUCTION OF chord': w . 9 JOHNS-MANVItlE PR.ODU CTS REFERENCE FILE FOR NEW LITERATURE ON A J-M INSULATING FIRE BRICK ^ AND RELATED PRODUCTS A Johns-Manville General Headquarters: 22 East 40th Street, New York 16, Offices in all large cities