Document a4wOdBezz4njgKJ5D6yXjgnGX
FILE NAME: Mead (MEAD)
DATE: 1974
DOC#: MEAD020
DOCUMENT DESCRIPTION: Memos with Expenditure Estimates for Meeting EPA and OSHA Regs
CEMENT ASBESTOS PRODUCTS COMPANY
Ragland., Alabama *
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TO: Jim Carpenter
FROM* Bob Baker
February 26, 1974
In addition to my memo concerning EPA and OSHA Regulations,
L, Sanders and I have worked up a guesstimate of expenditures
that will be necessary to bring the Ragland Plant in compliance
with the regulations, and an estimate of cost in converting
to a dry mix.
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Fiber Warehouse {see sketch 1) .Add one collector and cyclones for dry lathes .....New-bank Mbve existing finishing line collector to reclaim Tie batch asbestos waste to ' reclaim Clean up vacuum system for warehouse and batch New fiber charging unit
$ 25,000. 4.,.0,00. .3,000. 3,000. 20,000. 4,600.
Batch Area (see sketch 2) Install -live bottom in -fiber...si-lo
$ 59,600. ST $ 4,000.
Enclose silo and conveyor
3,000.
Place kollargang hopper under negative pressure and make minor modifications
3,000.
Rework area over pulper
5,000. s.
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M EADffiENDERSGN00329
Coupling Lathes and Coupling Cut-Off. Ho Estimate
Finishing Line & pry Lathes Clean up vacuum system Hoods and hoppers Piping
(Ref. sketch -1) $ 20, 000, 4.000. 2 .000.
Cut-Off Saw Redesign with wet
;
Change Rooms
Additional Lockers
Miscellaneous Violations
Walking surfaces
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Emergency Lighting
'Jtoisa -..Meter
.Noise Control
Traffic. Lanes'
Machine Guarding
...national Electric Code
$ 26,000.'ST r
$ 6,500. ST
$ 1,000. ST
$ 2,300. ST
$ 4,000. 600. 350,. N/A . 200.
1,000. . K/A
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Liquid Waste {see sketch 3}
Add 2 wastewater pumps helow
, hasins .with ccnt.to.ls
^gridging
"
Piping-to lake
Recycle system
land
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Solid Waste
$ 6,150. ST
* 4,500, - 2/000. 2,000. 4,500. ___
$ 13,000. ST
H/A
TOTAL $129,550.
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MBA/HENBERSONOO330
She $229,550 does not include expenditures for noise abatement, National Electric Code, nor solid waste,- Noise and electric code regulations 'will require- a more- complete study before a cost can be placed on compliance. The solid waste cost would depend on whether or not we could obtain enough land to operate a sanitary land fill operation.
Dry Mix
asbestos Elevator - tfse existing elevator
Fiber Blender
$ 14,920.
Fiber Feed
. 14,880,
Willowmills' Cyclones
17,700.
; 2 ,000.
Seales & Hoppers
19,000.
Batch Mixer
- .22,640.
Batch Feed Mixer
23,080.
Feed Screw
2,000,
Stock Pump
8,500.
Motors for Munsons
1,600,
Steel Structure
-25,000..
Removing "Existing -Equipment
15,000.
Installation
25,000.
Motors for Willow Mills
1,200.
Electrical Equipment
2,000,
$194,520,
Bond Weaver Beasley Sanders Driver
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MEAD/HENDERSON00332
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Mr, H- C . Davis, Mr. G . H. Kettering r
Mr, W. A, Enoufn, U r. W, Q. Kugent
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W.L.B.
M A R I S 1374
CEMEN1 / ASBESTOS PRODUCTS COMPANY Sales Offices,2.W4Highland Avenue, South /Birmingham, Alabama 35205 */%<>25933-7281
W .L.B .
WILLIAM R . BOND
Qtolrrooti rf ths Board
March 12, 1974
Mr. barren L. Batts, President The Mead Corporation Talbott Tower Dayton, Ohio 45402
MED/HENDERSON00320
Dear Warren;
You asked for a "get by" figure on expenditures for CPCO..
Ragland Location (Attached is Baker's and engineers* report relative to OSHA and estimate to handle.)
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Recapitulation of Baker's
and. Engineers* Report
W. R. Bond's Estimate
Fibre Warehouse Batch Area Coupling Lathe & Cut Off Finishing Line & Dry Lathe
Cut Off Saw & Miscellaneous
Liquid Waste
$ 59,600 15,000 SA 26,000
" 15,950 13,000
$ 129,550
Land Dozer
$ 60,000 20,000 20,000 26,000 50,000 25,000
$ 201,000 30,000 (could possibly 50,000 contract out)
$ 80,000
Total
$ 281,000
The above figure takes care of the OSHA requirements at the plant; it does not include the amount of $194,520 for a dry mixing system. Our effort of controlling the cement reaction in the present wet system has proven successful, and I think we should delay any change of systems at this time* Some of the money,. $15 - 20,000, to he spent on OSHA, mainly dust and fibre emission control in the batch area,, will b e expendable should we. later install the dry mixing system. In addition to the above, we should provide the following, money a t .Ragland for -
Mandrels Trays (10 @ $1500.) Mlsc. Replacements
$ 50,000 (addition and replacement items) 15,000
23,000
$. 90,000
Manufacturers o f Cement A sbestos and P, V. C. Pipe with PERMAFLEX Joints
Mr, Warren L. Batts Page Two March 12, 1974
MEAD/HENDIESON0032J
Mandrels - we do not have sufficient mandrels to make a complete run of some sizes of pipe; for instance, when operating on 16" size we must mix 14" and 10" sizes, When making 10" pipe we must run 6" Class 200. This is inefficient, causes opera ting problems, loss of quality, and increased costs (because of the foregoing and increased fibre formulation). There is a long delivery time on mandrels and I ex pect to have them made from ductile iron at Lynchburg in. order to expedite. The Plan set aside $40,000 for this purpose. Presently we have remaining three 16" 150# class mandrels; an impossible situation.
Trays - when manufacturing large diameter pip there is insufficient numbers of trays in which to place the pipe. This pipe must b e s e t aside and handled twice in processing, which results in excessive loss and increased costs.
Miscellaneous Replacement - this is a throw-in figure to take care of conditions and equipment which may be necessary to improve or replace. One example is a stock distribution screw in the pipe machine vat.
The engineers assure me they can do the'job for the figure they have mentioned. My figures are outside estimates, including items they have not mentioned and from which the following comparison is madV
Engineers' ..Estimate
W. R. Bond's Estimate
Grand Total
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$ 299550
$ 371,000
Van Buren Location
OSHA
Solid Waste Disposal . Other
$ 00,000 (could possibly contract out) 25,000
$ 105,000
Additional Autoclave -Additional Trays Miscellaneous
75.000 15, 000 (may need- a- few more) 25.000
Total
$ 115,000
Van Buren manufactures a greater amount'of large diameter pipe than Ragland, Van Buren
has insufficient autoclave and tray capacity, studies are being made to reduce auto
claving. time but it is doubtful if the need for additional .autoclave capacity can be
eliminated based on the present product mix, ' Lack of sufficient tray capacity requires
double handling of the pipe, resulting in damage to the pipe with added cost,
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Miscellaneous is to change and improve some of the conditions which are causing problem!
One example is the installation of stock distributor-screws i n the pipe machine vats. Facilities to blend two types of cemht are desirable.
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Er. Warren L. Batts Page Three March 12, 1974
&E)/HENBERSWro0322
Ragland Van Buren
Grand Total
Ragland Engineers * Estimate
$ 299,550
220,000
$ 119,550
W. R. Bond's Estimate
$ 371,000
220,000
$ 591,000
With the exception of the mandrels, trays, and autoclave, there Is little cost saving as the expenditures are made to meet OSHA requirements. Savings can be made by doing some of this work with the plant people.
Mr. Weaver's recommendation to Mr, Messell of December 24, 1973, amounting to 1*2 million, was designed to provide cos improvements based on quality, production vol ume, and products now being purchased from the outside, such as PVC couplings. Based on the improvement in the operation at Ragland, namely learning to use the cement from Rational, getting the quality and maintenance under control, also, applying this know ledge and assistance from Ideal Cement Company to the cement problems at Van Suren, and assessing the need for the product and the trend towards increased prices in' the marketplace, 1 would suggest proceeding as outlined; holding the cost to the minimum and programming in order to take advantage of any savings in doing most of the work ourselves.
Sincerely,
Enclosures (3) WSBirp