Document e1Ejab4313rEEXRdpRBvODQg

I PLAINTIFF'S EXHIBIT CEMENT ASBESTOS PRODUCTS COMPANY Birmingham, Alabama April 27, 1976 Page 1 of 3 Revised 4-27-76 Revised 4-D 7-9-76 TO: Bruce Klomfas, Jim Carpenter FROM: SUBJECT: A. E. Alpine QUALITY CONTROL PROCEDURE - Operating Bulletin #4 C Revised 4-27-7 COPY TO: W. R. Bond, S. D. Weaver, W. H. Beasley, I. L. Tavlor, Lynn Roberts, Buddy Swafford, Cecil Clark, Gerald Fox, Wayne Limbaugh, Jim Wright,Paul Cooper, Roy Jackson,Lamar Sanders In reviewing past and current claims, it is obvious that our Quality Control program needs an up-date. As quickly as the procedure can be modified for our operations a copy will be forwarded for plant use. In the meantime, please note the following - As of this date, each and every pipe going into a unit will be hydro-tested 5 seconds at the required AWWA pressure test, and all pipe requiring flex testing will be flexed for 5 seconds at the specified loading and hydro-tested for 5 seconds at the AWWA requirement. As explained verbally, whenever F.T.T. (first time through) rejects down the finishing line exceed 107. for pipe 4" through 10" and 7% for pipe 12" through 24" a decision must be made. The decision may consist of one of the following alternatives. A. If excess "flex" breaks are evident it is practical to cut the pipe into half-lengths and quarter-lengths. This salvaged pipe must meet the required hydro-test after being machined to 3'3" and 6'6" without deviation. B. If "hydro" breaks exceed the percentage figure, a decision must be made as to "wetting down" and "double autoclaving" in order to gain strength, but in any event a decision must be made on the line whenever the percentage figures is reached. C. After random sampling of pipe (made close to the date of the pipe being run) and the pipe is within 50 lbs. of meeting test-example: a run of 16" Class 150 that is breaking at 480 lbs, a decision can be made to roll the unmachined pipe through and unitize it with red, "hold" tags on each corner. . A complete wetting down for one weeks duration using a rainbird sprinkler and double autoclaving may achieve sufficient strength the second time. If not, declassify (but we cannot afford it.) r\ V CAPCO JEN 0019645 -2QUALITY CONTROL PROCEDURE Page 2 Of 3 Note It is proposed that we equip one autoclave with the sprinkler heads and associated equipment in order to provide induced moisture during the cure cycle, and especially during the "bring-up" cycle. This method will usually provide an 8 to 14% pickup in hydro strength. It is asked that the "bring-up" of an autoclave be not less than 45 to 50 minutes and the "blow-down" be 50 to 60 minutes. If this format isn't being used now, please incorporate it. On all class 200 pipe it is customary to use "rain bird" sprinklers for several hours before autoclaving. Any written or verbal deviations to AWWA testing are waived as of this bulletin. AEA:dp A. E. Alpine Vice President of Operations Important Note - Added 4/28/75 - Revision A Pipe, at a raised temperature out of the autoclave is not to be machined and tested while in the expanded condition. All pipe must be sufficiently cool prior to machining so that machining tolerances and contraction stress through interior surface area cooling does not become 'factors. The rough rule-of-thumb is - If the human hand can be placed and remain on the pipe without discomfort the pipe may be run down the line. Note that this is the maximum allowable temperature. Cooling by water hose while the pipe is in the tray isn't permitted as this cellular material must have the wall cooled uniformly. Important Note - Added 4/27/76 - Revision C - SUBJECT; RECORDER CHARTS All hydrotester charts, flextester charts, crush tester charts (or daily "crush" records) must be reviewed daily for date, shift, signature, and any pertinent notes. The preferred method is to arrange the charts on pegs on the wall in the Q, C. office for the month and after the month's end closing by accounting the charts are stapled together and filed. AWWA requires that the charts be maintained one year and the usual format is to put the charts into dead storage for 3 years. In the event that a claim should become a lawsuit and the charts are required as proof of adequate testing of the pipe in question, we will adopt industry practice and keep the charts 3 years. A. E. Alpine CAPCO JEN 0019646 OPERATIONS BULLETIN -4~n SUBJECT: OUALITY CONTROL PROCEDURES Sr ~ -- Page 3 of 3 Original 2/10/75 Revised '7_.9l.76 W~ 2O'Vo Of Circumference Of D3.-Mfgr's- toler^^AS^ p>,p> Size 4" 6" 6" 10" 12" 14" 14," IS" 20" 24" W 3* INSPECTOR'S CHECK SHEET 43/9* 5^4" 7^<S" 8 W~ 10 '4" tl5/s" lS'/4" MSss" STRAIGHTNESS TOLERANCE 'Bow' or concavity shall not exceed 1/2" in a 13ft. length of pipe. B. D3 DIAMETER 20% of the D3 circumference may have a shoulder less than .070". When checking D3 shoulder use step gauge and scribe lines where shoulder falls below .070". The measured area is then compared to 'W' in chart above. 1746" Step Gauge To construct use 1/8" x 1" CR flat stock. Drill 1/8" relief hole at step and 5/16" hole D3 5tep GaxwE. o to allow gauge to be hung up. MINIMUM WALL DIMENSIONS Ref. AWWA C-400 -3,6 Use calipers,, or constuct "go"and "no go" horseshoe gauges. / Cl.ass Pipe Size 4 G 8 10 12 14 1 (d l> 20 24 00 k X- 150 X 200 .240 .340 .340 .330 .4S0 .54 0 .450 .550 .750 .530 j>S0 .420 .640 .380 i.oao .&60 1.010 I.22D .75 0 1.130 1.330 310 1.370 I.S40 3 (oO 1.540 2230 1,14 0 i.aso 2.710 Note: Q. C. Bulletin, for in-plant use. Approved 4* CAPCO JEN 0019647