Document dnbE9XKQgnkp2KOonnVvQ5gYb

FA3LI LABCRATCP.Y r>::sEAJ.CK' urr develophe?!!- repcct : = 'led of July 1962 through December 1962 TABLE OF POrTENTS Page 1 * ................................... R & D Organization Page 2 . .......... Market Perfornance of Hew Products July 1962 - December 1962 Page 3.................... .... Projects Completed Page 7.......... Projects Nearing Completion Page 9.., Projects On Which Work Is Underway Page 16 ; ........ Photographs of Rib Pans! Fabricate:in n & D ORGANIZATION In August of 1962, a recent graduate chemical engineer v;as hired. Our Research Group now consists of six men: Messrs. Lehnert, Schnabel, Sundberg, Hinlcel, Green and Smith. Initially, the new men were assigned to work with one of the other members of the group, in order to gain experience. Another reason for this grouping is that certain projects require the efforts of more than one person. Specific projects have been assigned to each individual or pair of individuals. A monthly research group meeting is held, in which each member gives an oral reporting on nis assigned projects. The purpose of these monthly meetings is three-fold: 1. The meetings serve to inform each member of what the others are doing. 2. We receive the benefit of the thinking of the entire group on a given project, even though the project may only be assigned to one man. 3. First-hand guidance in project investigation and planning is provided by Messrs. Hoggatt and Shuttleworth. A Research and Development budget has been prepared fcr the year 1963 and an accounting procedure has been set up, which is intended to provide the cost or each R & D project. These costs include salaries, materials, special equipment, plant runs, fees for outside testing, travel expense, etc. Heretofore ouch detailed cost informa tion has not been available. This report covers the accomplishments of our research efforts for the past six months. During this period, much time has been devoted to training the new men. We feel that this tiue has been well spent and will pay off in the future contributions of these iaer.. Also included in this report are the past six months' market perfor mance of products which were developed through research since this group was organised in June 1961. 1 MARKET PERFORMANCE OP NEW PRODUCTS - JULY 1962 - DECEMBER 19C2 Fires top-X-TiO Ceiling Tile 1. Amount sold - 741100 square feet 2. Dollar sales volume - $13,303 * 3. Gross Profit - $4,398 E * Grabit Masonry Adhesive .- 1. Amount sold - 7 tons 2. Dollar sales volume - $1,39S * 3. Gross Profit - $766 C. One Day Joint System (Limited sale to Philadelphia and Washington sales districts and a few selected customers) 1. Amount sold - 90 tons 2, Dollar sales volume - $15,616 * 3. Gross Profit - $7,619 Gross Profit estimated by Ardmore Cost Department 1 } 1i o i !VH -2 - PROJECTS COMPLETED Hew Products 1. On* Day Joint Compound - R &D 243 Objective: Develop a setting type (gypsum base) joint compound. Result: For the past six months, we have been market testing this product in the Philadelphia and Washington sales districts, as well as with selected customers in Indianapolis, Indiana; Omaha, Nebraska; and Columbus, Ohio. Our Acme, Texas and Wilmington, Delaware plants have been manufacturing this One Day Joint Compound. About 75 tons of One Day Joint Compound were sold during this period, most of it in the Philadelphia and Washington sales districts. This was a follow-up from our field testing program, which indicated we had a product with great potential. The market tests confirmed our field trials and gave us quite a lot more experience with the product. Only two minor complaints were received during this time, and in neither case has the customer stopped usieg the product or requested an adjustment. Zn November, we were informed that National Gypsum Company and United States Gypsum Company were field testing products similar to ours. A sample of National's product was obtained and our examination of their material indi cates they are not too far behind us. Based on the six months of fa\'orable market testing, and the fact that National and probably U.S.G. are field testing similar products, we made a decision on December 4th to release our One Day Joint Compound nationally. About 30 to 50 days will be required for us to receive the necessary bags and raw materials at Acme to begin stocking our plants. Wilmington will continue to manu facture and supply One Day Joint Compound for the area they service. it will be some time after the first of the year before we have all plants stocked and ready for general distribution of One Day Joint Compound. The advantages we expect to gain from this product are: a. Increased sale of joint system materials b. Greater profit margin from One Day Joint Compound as compared to other joint system products. c. Prestige of being the first company to market a product which improves the quality and economy of Drywail joint treatment operations. di A competitive edge over companiest such as Synkoloid, Proko, Reardon, and many others which manufacture joint compounds but are not gypsum manufacturers. These manufac turers would have to purchase gypsum from one of the gypsum companies in order to manufacture a product like our One Day Joint Compound. e. An increase in the sale of our gypsum board products is possible, at least until National and U.S.G. have setting type joint compounds of their own. We have seen evidence of the One Day Joint Compound helping board sales in the Philadelphia sales district. f. At such time as the demand warrants. One Day Joint Compound can be manufactured at other plants, such as Sigurd and Blue Rapids, with very little capital investment. This would enable us to realize some savings in freight. 2. Gypsum Board Surfaced with Wood Veneer - R & D 215 Objective: To find a satisfactory means to laminate Purnaflex wood veneer to gypsum board. Result: Although we were able to accomplish our ob jective, the project was dropped because of the unfavorable economics of this product. Improved Products 1. Super Firestop - R & D 241 Objective: To develop a 5/S'* Firestop board which will permit i/2 and 2 hour fire ratings when it is used on the underside of concrete and bar joist floor and ceiling constructions. Result: Our laboratory testing indicated that a 5/S" "Firestop with twice as much glass fiber would provide the additional fire endurance we were seeking for this construction. A fire endurance test at Underwriters* fell 8 minutes short of making two hours, so we received a 1-1/2 hour rating. This makes us competitive with U.S.G., vrho also have a 1-1/2 hour fire rating for this construction. The additional glass fiber in the special s/s" Firestop will cost us $1.12/M sc. ft. 5. Water Repellent Treatment for Sheathing Paper Objective: To find a lower cost material than the Quilon we now use, which will apply easier and offer better repellency. Status: The wax emulsion treatment* after several raodifications and retrials* proved to be unsatisfactory. We are now evaluating a two component material which has looked very encouraging on a small scale. We are planning to make a full scale trial at Pryor* as soon as it can be arranged. 6. Owens-Corning Foam Glass Pellets - R & P 210 Objective: To make a 1" insulation board and/or a 1/2" one hour fire rated board by incorporating Owens-Corning*s foam glass pellets into these products. An additional advantage sought is to make a lighter weight board. Status: We finally settled on a 5.6 lb. apparent density pellet and an extensive investigation was launched. Our conclusions were: a 1" pellet board* having sufficient low thermal conductivity to be sold as an insulation board* would have much too weak a core. We were unable to achieve good enough fire resistant qualities to make a l/2" fire rated ^ pellet board. We were* however* able to reduce the weight of 5/8" Firestop and regular l/2" board. Based on a pellet cost of 10$ to 12$ per lb.* as furnished by Owens-Corning* the savings in freight and stucco displaced do not offset the total pellet cost. We have requested that Owens-Corning de velop a lighter weight pellet so that the freight savings and stucco reduction per pound of pellets will be greater* there fore improving the economica. 7. Resin Base Topping Compound - R & D 211 Objective: To develop a synthetic base* dry powder joint .finishing material which will have longer pot life and lower shrinkage than present casein base products. Status: Two field trials have been made with two different formulas but* in each case* we were unable to satisfy all the requirements. In addition to this* a problem of the plasti cizer leaching into and discoloring the bag has developed. A revised formula has been found which should overcome all previous problems. We have instructed the plant to make a trial batch of this revised formula and* if it is satisfactory* another field trial will be arranged. 8. Resin Base Joint System Texture - R & D 211 Objective: To formulate a dry texture which can be mixed with perlite and sprayed onto masonry surfaces as a one coat decor ation. - 10 Status: Die chief problem here was to impart sufficient rust inhibitive properties to prevent steel members from rhsting through the texture. We have arrived at a formula which ' appears to satisfy all the necessary requirements. We have instructed the plant to make a batch of this texture for field testing. 9. Ready Mix Joint System - R & D 211 Objective: To develop a ready-mixed or paste type joint compound to be competitive with U.S.G.'s Ready Mix and other similar products on the market. Status: We previously developed and successfully field tested a paste joint compound, but cost studies indicated that the product should be mads at Acme to avoid freight for dry fillers. Unfortunately the area serviced by Acme is not a large ready mix market. In view of these factors, this project was tabled. The subject of ready mix was brought up again recently to reconsider furnishing the West Coast, which is one of the largest markets for ready mix, out of Acme. In the meantime, we have been developing a ready mix with a dry resin binder in lieu of the liquid resin used in the previous formula. We have arranged to have some of this material made at Acme and shipped to Paoli. We will mix the product here, put it in pails, and arrange for field testing. If this revised product is satisfactory, it will prevent us from having to store large quantities of liquid emulsion and from requiring equipment to handle the emulsion. While this will not affect the cost studies previously made, it will simplify the facilities we would need and reduce the expenditure for equipment, if it is decided to market a ready mix joint compound. 10. Thincoat Plaster - R & D 219 Objective: To develop a one coat thincoat lath and plaster system which will be suitable for both textiued and smooth finished surfaces. Status: The original ;product we developed and field tested was not suitable for smooth finished surfaces. A second experimental product has been developed to be used in con junction with a fast suction lath, and this system appears to be very satisfactory. The new formula has much higher compressive strength, is adaptable to smooth and texture finishes, and costs less to make than our first formula. Our first field trial of this thincoat formula was quite encouraging. Mere field trials will be conducted as soon as possible in order to more completely evaluate this new product. 11 ft?/*? Products containing asbestos banned as cancer-cause suspects WASHINGTON (UP!) -- Tht Con The commission voted 4-0. with one sumer Product Safety Commission commissioner absent, to eceept e banned speckling compounds and recommendation from the Natural Re otbar wall patching mixtures contain- sources Defense Council to ban speck- kt tag aabastos Thuredtj- as pamtbl*' .ll&( pOSpOttfiAS ttd SlBllAT UJCTUTM causes of cancer. _ . with asbestos. The council said-mll- Agbaftexontalnlng Imitation logs Uans of consumers were being exposed ami alls "Used In gas-burning fireplaces to needleee heard when such materi also came under tbe ban and a list of als are installed, sanded or removed. other-materials, such as vinyl tiles, Tbe commtemoners tlso banned wffiboafd. brake linings and modeling speckling compounds containing a clay was named for investigation form of asbestos called tremolluc talc. This (asbestos) is probably one of The NPCD followed op by asking the the most well-documented toxic sub commission to consider banning stances around." Commissioner David modeling clay, textured paints, brake Ptttle said. "You don't have to look at shoes end linings, wallboard and other the rats, just look at the people " products containing asbestos. The agency left open tbe question of It also said there was s potential whether consumers will be able to get problem with vinyl floor Ole because refunds for banned products now in lbs adbesivt used with it contains thmr poetsetion.____________________ asbestos. ii Ji O PLAINTIFF'S EXHIBIT 6>P-I23 14 A Balia* iflornmg XftD* Friday. April 29. 1977 3 German guer Exppnsii p tluinmics Seme o' tbe 50 test dummies at the General Motors proving grounds m Milford, Mich , are restrained by shoulder belts while being stored on wheelcarts The dummies cost between $10,000 and SI2 000 and arc- made to government specs by a private contractor. Trio found guilty of Amcri STUTTGART, West Germany (API -- Urban guerrilla Andreas Baader and two companions were sentenced to life imprisonment Thursday for the terrorbomb murders of four O.S. soldiers dur ing the Vietnam war, Basder. 33, bis girl friend Gudrun Ennslin. 36. and Jan-Carl Raspe. 37. were fouDd guilty of bombing Army posts in Frankfurt and Heidelberg in 197? and buildings m four other Ger man cities. "Not everyone can declare himself a subject of international law and de clare war on his own." chief Judge Eberbard Fotb declared in rejecting defense claims tbe bombings were legi timate protests against U S military ac tions in Vietnam. Tbe three terrorists also were con victed by the 5-judge trtbunal of 34 counts of attempted murder and of forming a criminal conspiracy They are on a hunger strike in their jail cells and refused to come to court to bear the verdict. ^ m s- THE 23-MONTH tnal in a special se- m curny courthouse built for the case at Stuttgart's Stammheim Prison was w. punctuated bv tbe same outbreaks of antistate violence that made the q_ Baader-Memhof gang West Germany s q "Public Enemy No. 1" from 1970 to 197: Three weeks ago. chief federal . prosecutor Siegfried Buback, S', who u led the state's case against the terror ists. was assassinated in Karlsruhe by a c; group calling itself "Commando Ulnke Metnhof." a Mrs Meinbof. 41. the gang's accused cochief along with Baader. was found n, HIND TAILORED SUITS TM" HONGKONG MilMUl Mm Sv e^mia-rmim ije um - Afe c5? Eafeft Red n*4 Sett 14m tiM w BB IU IfHii TrMsd Use* leH 1U-M excluding import du*t IipWHTwHUH ItAM 1M.M k**TA<w MODES. I\C. CUSTOM TAILORS lilt Oak lawn Call Hr. Badlirani l TtLf 521-8850 tmi &* , OPENING RON BURNETT'S M0T0I RECREATIONAL STORAGE--Ct: SERVICE RE: Also Open Beat CORRECTION! (FOR YOU DO-TT-YC WASH UTS EQUIPPED F An orror wm mod* in the Chts-lM advertrse- WASTE IISPflSAL ment which ran in the Trend ction of The Doiiot News on Thursday, April 28. Tho price of the Key- i SERVICE PtT FOR OIL CK AHt L0IRICATI0R Finder should have been $3.50 ck CALL NOW TO Ches*Lee. Hiiisiae Village MOCSingtXC <V AD'.ims I STORAGE I 214-238- Products containing asbestos banned as cancer-cause suspects WASHINGTON UP!; -- The Con sumer Product Saler. Commission banned speckling compounds and other wall patching mixtures contain ing asbestos Thursd.r. a- poss!b;i. causec of cancer Asbes-Ovcontai: in, lmito'ior Inc- and asn used in ga^-huming fircniacc- also came under -fie ban and a .is* o' other materials suer. as vjny: waliboard brake !.nines and modeling clav was named for investigation "Top usDestr"- is probably one ->f the most well-documented toxic sub stance- around ' Commissioner Done Pittie sa:c You don - have u.ok the rav-. tun' look c the people The agency k-f: -iper the hues1.-,.r. uht-thc- nr'iimp' v. tv- ,('>!( - refund- bunrv , "r*]u<.'- n<iw : i he: r posst ssior. The commission voted 4-0. with one ! commissioner absent, to accept a j recommendation from the Natural Re- : sources Defence Council to ban spackline compound'- and similar mixtures wilt: asbestos The council said mil lions of consumers were being exposed to. ii noediess hazard when such mutcria.t- are installed. sanded or removed The commissioners also banned spacklmg com pound'- containing a form o! asbestos called tremol'tic talc The NRCD followed up by asking the commission to consider banning modeling clay, textured points, brake shoes and itntngs wa.'board and other products containing asbestos I' also said 'here w.i` a potential problem Witt, \;nv: floor 1:1c because ' DELTA'S! TOCALIT 12 NON ENJOY dioJJj* 7ftA***J Products containing asbestos banned as cancer-cause suspects WASHINGTON (UPI) -- The Con The commission voted 4-0. with one sumer Product Safety Commission commissioner absent. to eccept banned speckling compounds and recommendation from the Naturtl Re other wall patching mixturas contain- sources Defense CouucU to ben speck- ^itlag aabaatoa Thundaj. aa paanblai ]lB| pQBpOUBdi **l*r &UCTUTM cium* of cancer. with esbesttm The council laid-mil Aqbestoe-contiliilni Imitation lop lions of consumers were being exposed tad aih Used In gae-bumlng fireplaces to e needues baiard when such materi also came under the ban and a list of als are Installed, sanded or removed. other-materials, such es vinyl tiles, The commisnoners also benned wciboafd. brake linings and modeling speckling compounds containing a clay was named for investigation form of asbestos celled trcmolltic talc. 'This (asbestos! is probably ont of The NFCD followed up by asking the tba most well-documented toxic sub commission to consider banning stances around." Commisaioner David modeling clay, taxturad paints, brake Pirile said. "You don't have to look at shoes end linings, wallboard and othtr the rats, just look at the people." products containing asbestos. The agency left open the question of It also said there was a potential whether consumers will be eble to get problem with vinyl floor tile because refunds for benned products now m the adhesive used with it contains their preaeeiioa. . asbestos NiJ in rN xNi j.