Document emRdLLwR30kbjJy6XNeD2xkvm
FILE NAME Corning OC
DATE 1968 Mar 5
DOC OC456
DOCUMENT DESCRIPTION Feasibility Study - Alternate Process for Manufacture of High Temperature Insulation
cC
7
0
1 _
Mr. B. E. Boyd Toled
R. F. Shannon Granville
FEASIBILITY STUDY - ALTERNATE
PROCESSES FOR MANUFACTURE OF
HIGH TEMPERATURE INSULATION
Dota March 15 1968
.
+
Mr. Mr. Mr. Mr. Mr. Mr.
E. Gay Tolod
R. S. Grant Toled
M. Hardwick Berlin R. J. McEvoy Granville C. Staelin Toledo
R. P. Witschen Toledo
Central Files
,
asked me to take a good hard look at the various processes
Last January you
for the new Southwest Kaylo facility
under consideration
and which summarizes our study of every known
Attached
is
a
copy
of
my
report
I reduced
the
list
to
just
three
processes
which
pmerroictesfsurtAhseryocuonwsiildlerantoitoen for installatiothne new facility They
include pan pouring filter pressing
bonded aggregate
which must be resolved before any final selection
The most important question
of asbestos Silihoff Because of
of process is made relates to the use
of Multi in my report
I also included an evaluation
tAhfitserpraolblleimt is the only asbestos free product available
strictly on a technical
Unfortunately I had to compare thaet vtahreiomuosmepntrocteossmeaske a recommendation
the
basis I am not in the position
we should select for
combination of processes
as to the procesosr
the lack of cost data As soon as cost projections
new facility because of
still under considera-
are completed by Gay and Brooks on all of the processes as to which process
will be able to at least make a recommendation
to come
w teiofneew le offers OCF the best product and gross margins in the years
overload of the advantages and disadvantages of
I am sure you are already aware
has a lot of merit It
Berlin's pan pouring process
Filter pressing
molded
the product is precision
produces a stronger better looking product Bonded aggregate products
and the process itself is highly automated shortcomings They break
as they now exist on the marhkaentdlheadve Wsheyriotuhsen would we still want to consider their breakage
easily in transit and when
ever solves
is if Philip Carey
this process The reason
the market It is precision
problem they will have the best product on repellent higher temperature
molded lends itself to automation is water
but not least is the fact
resistant and is a autoclaved product Last
made asbestos free
The only reasons for
the product
it has the best chance of being
is already available
Multi are the facility
overload
considering
and it could relieve some of the current
is free of asbestos fibers
at Berlin especially in the block market
It is my hope this report and disadvantages of each a much better position of
best for the new facility
gives you a better insight Once we got cost
process
making a recommendation as
and for the 1970+ market
as to the advantages data we will be in
is
to which process
3 PLAINTIFF'S
| EXHIBIT 394x
INTRODUCTION
market for Kaylo pipe and block has made it necessary for OCF
The expanding
the Berlin operation again in 1968 but also to consider
n t only to expand
the Southwest The problem facing Management
building a new facility in
be installed at the new facility
is defining the type of process to
today
one of the more automated processes
Should it be Berlin's pan pouring process
developed by our competitors or a combination of processes Also to be
considered by Management is whether Multi has a place in the high tempera-
ture market of the future
R
decide which process or combination of processes is most
To help Management
at the new Southwest facility Kaylo R & D carried
suitable for installation
for the manufacture of high
out an intensive evaluation of all known processes
insulation products A lack of cost data on competitive processes
temperature
for us to limit this study to strictly a technical comparison
Fade it necessary
rather than a more preferred technical evaluation
d )
SUMMARY
o
The Kaylo R & D study confirmed the fact no other product can compete with
Kaylo block made by the pan pouring process
It is by far the best on the
tends to delaminate bonded
market
Block made by the filter press process
It should also be noted that neither the filter
aggregate block crumbles
can be used to produce structural
press process nor the bonded aggregate process
17 type core for the UL fire rated door market
.
<t
in the block and core markets we must continue t
T maintain our position
must decide
produce such products by the pan pouring process Management
facility
whether block and core products are to be producedwialtlthtehennew havSeouttohwbeest installed
If the answer is yes a pan pouring flatware line
The second decision Management must make relates to the type of process qr
combination of processes to be installed at the Southwest facility for the
production of pipe insulation
If the decision is made to go to a process
will have to be purchased There is not
other than pan pouring technology
and still meet
time to develop from scratch an alternate process
sufficient
the timing for construction of the Southwest facility
has a number of process options to chose from for the production
Maragement
at the new Southwest facility They include 1 a filter
of pipe insulation
to produce all sizes of pipe up to and
pinrcelsusdionrgbo3n0deidnchaggOrDega2 te paropcaensspouring process to produce the smaller piopfe
sizes and a filter press or bonded aggregate process for the production
size sectional pipe and 3 a pan pouring process to produce the smaller
large
located anywhere for the production of
pipe sizes and a Multi Wfiatchiliotuyr current level of technology the pan pouring
large size sectniootnable pciopnesidered for pouring large size sectional pipe at the
process should
new facility
Ms
217
-2-
SUMMARY Cont
technical standpoint no one process
indicates that from a
the manufacture of
The Kaylo R & D study
for
over other known processes
has a
has a distinct advantage
each also Each has its advantages
high
temperature
pipe
insulation
after
a
comprehensive
cost
analysis is
made
on
number of diswaidlvlanwteagbees abOlnelyto decide which process or combination of processes
eiaschmopsrtocseusistable for the new Southyest facility
for the manufacture
intensive technical
evaluation of all
known
processes
are
only
three
processes
Our
insulation products indicates there
the Southwest
of
high
temperature further consideration
for
possible
installation at
Kanville's
filter
worthy of
the Berlin pan pouring process
other
facility
They include
bonded aggregate process
All of the of Multi-
and Philip Carey's
the possible exception
pprreoscsesspreoscecsosnsidered during this study with would not yield a product suitable
Temp were rejected because 1 thewas proncoetsssufficiently developed to meet the
for OCF's needs or 2 the process
new Southwest facility The Crosfield
time schedule for installation in the failed on both accounts
Multi and
sectional pipe
filter press acuotnsoicdleraevdefdorprtohceespsroduction of large size
should onlays baen additional facility for the production of high temperature
possibly
overloaded
block when Berlin becomes
as to the process they will
Before a final decision aits tmhaedeSobuythMwaesntagefmaecnitlity and the product they willremlaartkientg
adopt for installation
must consider a number of basic questions
in the 1970's and 1950's they
need for a product of a higher
need for automation
to rising labor cotshtes asbestos fiber health threat
This report will attempt acted on before the final
quality level and
which must be considered and
for Manage- Manage-
to outline the questions reached This report will also provide
of
decision as to process is
and disadvantages for each
ment's consideration uandleirstcoonfsitdheeraatdivonantfaogresthe new Southwest facility
the processes still
to RECOMMENDATIONS
has already been made to appraise
A visit to Manville's Research Center followed by an OCF prepared
This visit must be
be made to Philip
the filter press process
and a plant visit
A visit should also
should be followed-
cost projection their bonded aggregate process It too
Carey to appraise
and if possible a plant visit
up by a cost projection
bonded aggregato
must be made or updated on the filter press
cost
Cost projections
To achieve a fair comparison
pan
pouring
and
Multi processes
the pan pouring process
more autorated
should be made on a
since
is reasonable request
projections for exists at Berlin The latter a
labor and batch
than now
process
is currently underway to reduce
a major R & plant program
of automation of the pan pouring process
costs and to achieve a higher degree
must be
and bonded aggregate processes
Cost projections on the filter press One cost projection should be based on
at two levels of activity
will be used to
prepared
the filter press or bonded aggregate process
The second cost
the assumption
and including 24 x "
produce the entire line of pipe up
|
215
215
RETOMMENTATIONS RETOMENTATIONS RETOMMENTATIONS Cont )
or bonded aggregate
should
be
based
on
the
assumption
the
filter
press
sectional
pipe
only
projection
limited to the production of large size
covering
process will be
it must be tied in with the cost projection
should
Under these conditions
sizes of pipe The Multi cost projection the
of the smaller
pan pouring
sectional pipe only
It too must be tied in with
be limited to large size
of the smaller sizes of pipe To get
cost projection covering otfhethepanvarpioouursingoptions available to us cost projections
a good economic picture
combinations
should be prepared on the following process
Oction
Block
Pice
ANMEM
Fan poured
Filter pressed
ANMEM Pan poured Bonded aggregate
sizes filter pressed
Small sizes pan poured large
ANMEM
Pan poured
Small sizes pan poured large sizes bonded aggregate
ANMEM
Far poured
Small sizes pan poured large sizes Multi
ANMEM
Fan poured
facility will be limited to the production
It is possible the new Southwest Southwest
Berlin and stockpiled at various
pipe
pipe
Kaylo block would all be produced at
in the Southwest and West
Since Since this is a possible
distribudtisitroibnution distribution centers
projections
should also be made on the five pipe process
Management option cost projections
facility for block
combinations combinations
combinations
listed
above
minus the pan pouring
combinations
be installed in the new Southwest facility
In deciding the type of process to
to the Silikoff
Management Management will have to give serious consideration have on the future growth
health threat
What effect if any will it
of the market
insulation market and our share
of the overall high temperature
decision we face in deciding
in particular It could be the most important
The only asbestos free
to install in the Southwest facility
All three
which procestshe market during the past 5-10 years was Multi
consideration
product on
and bonded aggregate now under
processes pan pouring filter press
asbestos
The probability of removing asbestos
for the
new facility contain
is far greater than it is
bonded aggregate product
or OCF's pan pouring
from the autoclavedeither the Manville filter press
from products made by
and are based on highly alkaline
both of which require autoclaving
process compositions
batch compositions
to install the Berlin pan pouring process for
In the event Mbalnoacgekmeantt tdheecindeews Southwest facility Kaylo R & D still recoamlmseondbso or bonded aggregato
both pipe and
either the filter press
an alternate process
the new facility
This should
that
limited basis either at Berlin or at
at
installed on a
R & D program on the chosen alternate process
be further supported by an
made because it is our opinion
Granville
These recommendations are being
dilemma we
to again face the process
the
company
should not have
If future market
conditions demand
a product made by a process knowhow and experience
are now facing
will have the technology
than pan pouring we
to the new process without delay
other
facilities over
to convert our manufacturing
to be installed at the now South-
of the decision as to the process
to automate
Regardless
facility the
major
R & plant
program currently
underway ahead
especially
west
at Berlin should proceed full speed
the pan pouring process
for the processing of Kaylo block
RESSIMENTATIONS Cont
be installed
this planning
period
many have
suggested two
processes
block
and
smaller
During
facility the pan pouring process for
of sectional
the new Southwest
for the manufacture of larger sizes
XY sites of pipe and filter press
be resolved is will our customers and the
The first question which must
If the answer
pipe
' Marketing Division
accept
two
types of pipe
products
Multi
if
it
and
is would the market also accept
is
the second question
sizes of sectional
pipe limited to the larger
a filter press or bonded aggregate process
the only reason for purchasing the manufacture of large size sectional
competitors is for
must ask whether it
one of our
to 24 inch ID range then we
i.e. sizes in the 13
toward producing large size sectional
be better to direct a majorateffaocrcteptable gross margin levels rather
pipe by the pan pouring process
toward a new process and technolog
thetnhen ddiriect rect such a major major effort and expense
there has been little
of the overall market Actually
such a small portion
toward learning how to pan pour large size
for if any
technical effort directed
such a result changes
sectional pipe with adequate gross
margins To achieve
and handling
well as new techniques of pouring prehardening
in mold design as If Multi pipe is acceptable to the market and gross
must be developed
when limited to large size sectionals
margins are projected as habseiangpraoddeuqcutatea process and a facility available to
only then CCF alresaidzye sectional pipe market -
large
e
Asbestos
as the rein-
which must be resolved is the use of asbestos
The first question
insulations contain asbestos
forcing fiber Today all high temperatur1e0
the only known asbestos
In fact during the past
years
reinforcement
on the market was Multi a product
insulation
free high temperature
OCF To emphasize how important is the
sili for a brief period of time by
I would like to call to your
of asbestos as a fiber reinforcement
problem
1967 to D. M. Barthold concern-
D. W. Ladd's letter dated October 9
I think
attention
and Kaylo expansion
Quoting
from Mr. Ladd's memo to this whole
Ang asbestos
which is of paramount importance
there is no other consideration
will probably blow the whistle
subject As you are well aware the government distant future and before we
relative to the use of asbestos in the not too Berlin and consider putting
expansion program at
have an
erbark upon a substantial
we had better be damn sure that we
facility in the Stouhtrhewaetst Work has been done on this in the past and
answer to the asbestos
successful answer
to date there has been no
fiber's asbestos fibers in calcium silicate products
The
of
probability
replacing
No
solution
to
this
problem has been
found by
is rated at best at 50/50
had no success in getting
OCF Manville told us recently they too haIvfe the decision is to install
to survive the autoclave process
at
glass fibers
the Manville filter press process
or
the Berlin pan pouring process
fact the reinforcement used inll
the Southwest facility we are barcecaekptthirnogugthhe is made by R & D during the next
the autoclaving
probably be asbestos unless a
to survive the alkali and
year or so in modifying glass o
decides the asbestos threat is still with us then careful +
If Management should be given to the bonded aggregate process It does not
consideration
alkaline calcium silicate batch which attacks glass
involve the highly
the use of expensive autoclaves
and does not require as part of the process Philip Carey's bonded aggregate
which dissolve gilnassulsatiAolnthocuognhtaCinasresyotmeempasbestos the probability of develop-
hiinggh a tbeomnpdeerdatuargegregate product reinforced with 100 percent glass fibers remains .
quite high
our recent meeting in Manville New Jersey they
Manville told us during
on our high temperature glass fiber insulation
were
surprised we never followed
Multi By the tone
of the
conversation
they
seemed
to be
product line concerned about this product
it were to be placed back on the market
available If the asbestos threat
it would be the only asbestos free product
is real and is a serious threat to OCF's participation in the high temperature
marker of the fufuture ture , then thew n e should consider directing a major
insulation
R & D effort toward product
or process modifications to raise gross margins
pouring at the new
If a decision decision decision decision decision
is made to install a process other than pan
is not sufficient
Southwest Southwest decison purchased Southwest Southwest Southwest
facility facility
facility technology will have to be
There
and still meet the timing
time devlop time time time to to develop develop develop
from scratch an alternate process
the
of technology will
construction purchase for for for construction construction construction construction construction
construction the new facility
Since
the cost of the license
constructionprobaly probably
mean mean mean taking out a license from a competitor
in the market
probalyprobaly mean on its its
adadvverse eadversre se effect gross margins and competitive position
.
and its mustmust
all all be be carefully considered
already
already already already already
already patent plus
in months be involved mechanizng wwiillll wib ll e be be
and block block
patent patent in involved involved
producedproduced are produced produced produced
or more of technology on pan pouring and several years
years has has
20 20
position
yyeaers ars
position on Multi
strides have been made in recent
Major
costs for licensing
at Berlin No
mechanizing
mechanizing the pan pouring process
both pipe
is chosen for producing
involtvheed n if ewthfeacpialritpyourinTgheprsoacmeessis true if large size sectional pipe
by the Multi process
.
Competitive Competitive Competitive Competitive Processes
and disadvantages for each of the
tabulating the major advantages
in the new facility
Before
still under consideration for installation
processes
I would like to compare briefly each process against the
for Multi
three
and
others
problems
with
products
made
by
the
pan
pouring
process
include
2
The major
made by the filter press process
1 they are not as strong as products to both filter press and bonded aggregate
they have a visual appearance inferior
dimensional and nesting problems
products
3 not being precision molded
made by pan pouring involve
customer complaints and 4 products
of pan
result in
considerable hand labor to produce
Labor costs for the production
cost
constitutes nearly 40 percent of the total manufacturing
be
pWoiutrhedlabpoipre costs rising rapidly pipe rade by the pan pouring process could
.
i
agregate agregaategregate ^'
Competitive
Processes Cont
Comme Competitive Competitive
rade by one of
in the future with pipe
It
disadvantage
placed competitive
with pipe made
placed placed automated processes disadvantage disadvantage in future
or bonded bonded aggregate one of
tre
the
unfortunate
unfortunate processes
processes
such
filter
filter
press
emphasis
during aggregate aggregate
It
ig is
autorating autorating our place same emphasis our competitors competitors the past
possible years
49 to 10
theirs If we had it quite
pouring process as
possible possible possible would
theirs
having to take license quite
of having
over
does does a never of advaniages
+o
Kaylo
made
by
the
pouring
pouring pouring
process
number number advantages advantages over
Kaylo
products
on
market
marmarket ket
process
does
the ability over over
git all products
both light today They include
heavy heavy density of
produce by process
( the tremendous insulation and
daily of
structural
material
flexibility the
structural structural
ability ability expedite flexibility
and thick-
Resses
coupled coupled with
block
( the best desired
various sizes
the
Resses of pipe pipe
service
shipping shipping cycle
of batch composition
thickof
Industry
:
Industry
Industry ) versatility
of
composition composition to achieve lower
batch
foot basis ( production
products products
market market on cubic
pee
of light density heat insulation
core with and production
resistance of 1800 insulation
core maximum temperature
core
developed by Joins-Yanvile
the filter press
As has competitive prinotceersessets from OCF personnel
There by Johns Vanville Vanville Vanville 4
sseSs
bonded doubt has
and
number number of advantages
over both the pan pouring
aggregate processes
Products Products made
have considerably higher flexural compressive compressive compressive
impact strengths strengths process better visual appearance
and like precision
and
the bonded aggregate
It has a
pipe and block products
precision precision
molded molded
filter
press
produces
lends
itself
the
products
production
large
also
process
OD Field production large
size sectional pipe up and including 30 inches
filter filter
pressed products products extremely extremely
now developed
Finally the process
by bonded
Johns ManviMllaenville is extremely low
developed developed
When compared products products
bonded
AI
aggregate
aggregate
process
filter
automated
have two distinct advantages
Geaggregate aggregate
aggregate
and pressed products
physical strengths and lower breakage characteristics
The filter strengins
compared compared directly
process a number of disadvantages disadvantages
delivery directly are
with the pouring process
flexibility include shipping shipping
poor 3 are
considerably considerably considerably longer flexibility flexibility
lend itself daily of goods is
fittings fittings
batch higher , does has itself the fabrication fabrication
moisture
product densities densities higher higher 6
delaminate delaminate moisture tendency
is
will not produce structural structural tendency
produces produces products products
less absorbed
acceptable the
market
and
operating
efficiencies
efficiencies to to
6
products
hour acceptable
mold change
change
are
still
operating
compared
compared operating
operating
efficiencies efficiencies
process still low
for the pouring pouring
hour efficiencies aggregate the process pouren^' process
bonded
advantages
press processes Philip has many advantages Philip
their and filter
problems and when Philip
far far
Carey solves
handleability and breakage
have by
best product their handleability
major advantages will
bonded
the
process market Some
the bonded advantages
aggregate process
include autoclaved low manufacturing manufacturing manufacturing manufacturing
low
use very very low
investment investment cost include
ability
autoclaved autoclaved product product ability
use glass fiber fiber
reinforcement
reinforcement
itself
ability
produce
precision
ability molded investment investment
(6) a
process lends
itself
temperature
high
production
production
rates at
8 water
investment
cOSstS+
-
7
1500
1600
temperature
temperature
resistant
product
and
8
water
repellency
repellency
rocess 1600
resistant product
(7) a 1509 to 1600 F texperature
Frocesses
Competitive
Competitive
Competitive Competitive
Frocesses
Cont
Cont )
When compared directly with filter pressing the bonded aggregate process has
two major disadvantages
It produces a product with lower strengths and one when roughly handled On the other hand it
that is susceptible to breakage
Overall process costs
has a number of advantages over filter pressed products
batch costs are substantially lower the product can be marketed
are lower
applications 1500 vs 1200 F it is water repellent
for
higher temperature fabricated
from the
product
investment
costs are
much
lower
fittings can be
be made free of asbestos The ability to
no autoclaves and it probably can
when combined with the
use glass fibers as reinforcement in this product
it mandatory
tremendous glass fiber knowhow available to OCF personnel rakes
before
our Management give careful consideration to the boansdbeedstoagsgraesgatthee prreoicnefsosrcing
rejecting it in favor of a process which requires
fiber
poured Where does the Multi product and process fit in the overall picture
we currently know it does not yield adequate gross margins to
The product as
board with
filter pressed or bonded aggregate
compete across the
pan
one that
However one must remember it is a glass fiber product
predicts
natural
CCF to market and one that could be produced at any of our
back on the market it would be the only
were to be placed
free product on the market today
process ShouldShould ShouldShouldShould we we go ahead and install the pan pouring process process at the new SouTthhiwsesits
rather
rather facility facility facility facility facilityfacility rather
than the filter press or bonded aggregate aggregate If the filter filter press or bonded aggregate
Management
decison facilty Management a decision decision decision decision which
must make
at the new facility
processprocess process processprocessprocess
is chosen to produce the complete range of products
at this time
If and only if
then thenthen then there there is no need to reconsider Multi would we then want to reconsider
the
the the
asbestos threat reaches the danger point
insulation
asbestos ar ar asbestos
asbestos free product such as Multi for the high temperature
markemtarket market market asbestos market
cost of licensing Management decides to install
for for some reason such as high
will again be facing the problem
If If the panpan pan p uring p uring process in the new facility we
Under such circunstances circunstances
produce of
deciding deciding
deciding deciding deciding deciding deciding deciding
how
to
deciding
large size sectional pipe
to
with the pan
Multi
Multi Management Multi Multi Multi
Temp Temp
Temp
could be the answer
Even if
decides
go
-
production Temp
TempTemp
for all
except large size sectional and choses to
products pouring pouring pouring pouring pouring
process process process process process
process
to
these
produce license
the problems aggregate license license license license license
the
the the
filter
press
or
bonded
process all the
and costs to
licens licens question percentage we
must
must
raise raise raise raise raise the
whether it is worth
for such a small
license license competitors license license license
license license
another
another another
another another
another
process
from one
of our
of of
the the the
market
market
market marketmarket market market
site sectional pipe to remain competitive If we chose
We We
must
must must
must must
market large
would have three choices 1 fabricate
not not to to license another process we
Berlin 2 start up a crash program
large size size sectional pipe as we do now at
the
large large large
how
to
large size sectional pipe at adequate gross margins by
learn to to
learn
how learn
how
pour
or
3
could
market
a
line
of
large
size
sectional
Milti
pouring pouring pouring
process
those conditions where all production except large size
Temp TempTemp pipe pipe . Only under
at the new Southwest
Temp sectional pi e sectional sectional sectional sectional
pipe
is
to
be
made
by
the pan
pouring
process Limited
to
the
production
facilty sectional facility facility facility facility facility would I recommend we reconsider Multi
facilities
large large of of large large large size sectional pipe and to block when Berlin block producing
;
7
Cont Processes
Competitive
in today's
today
Multi
may
have
@
piace
place
in
today's
over taxed as they
Temp have place
today's
become become
may cheaper cheaper today Multi
sectional pipe the
market market It
by current produce sectional
process than
Tenp Temp
our
share current
fabrication technique
total increase our
would increase
1. 2.
3.
&.
.
na row
.
results it
This flexibility
highest
highest
mix
goods
flexibility
inventory
flexibility
flexibility
flexibility
results
results
lowest
workable workable
finished
goods goods high
temperature
the
processes
now in use for manufacture
temperature insulation products The shipping cycle in the high temperature
produced with normal inventories
is the acknowledged Leacer
leader
produced the pan pouring pprroocce es ss s
acknowledged
on acknowledged acknowledged leader
of
high
insulations insulations
ofof of flatware high temperature
at OCF Plant personnel are
trained as established process
working personnel wath
well trained
We have a 20+ year
this process as to process
be this process
permits versatility as to batch composition
composition
5. Various additives conasniddeerxatbelneders can be added to reduce
Yarjous additives
of soluble chloride
extremely
low percentage
6. Meets AEC military
requirements
Meezs AEC and military
|
the same sizes sizes
thicknesses
both
of
pieces
are
procurable
when needed
expediting
expediting
7.
and
any of the and block
shipments
manufacturing processes
shipments
than in any of the competitive
1968
service service cycle
than the service further improve our competitors competitors
E, It already better
service cycle any of
Kaylo Kaylo high better than the
insulation market
and applicators temperature
9. among owners owners ddiissttrriibbuuttoorrs s ane applicators
Pan pouring
UL lends itself the production production
10.
core core Only with
Pan structural
UL
ratings ratings
K pipe block Only one
are
products
can
pan
used
process
are
ses
11,
to
1800
F.
themselves
themselves
Ka20
used
products
at
temperatures
temperatures
tr a 1800 F. Bemse-veS-
complicated 12,
Batch mixing for
Batch
pouring
25 the complicated
Baten required required pat p2=reng
gelling gelling
of vaten required.
cred
FanFan Pouring Pouring Kaylo Cont
Advantages Cont
13
Drying costs are currently lower for pan poured products than f^r
products produced by any other process This advantage will soon be lost since the SID cylinder patent expired in January 1968
Densities
Densities
Densities Densities Densities Densities
of
pan
poured products
are
lower
than
densities
of
filter
pressed
products
products
pressedpressed products
,
15 In general thermal conductivities of pan poured products are lower
than for competitive products
16.
Pan pouring operating efficiencies are considerably higher than they are for filter pressing
17.
Fittings can be cut and fabricated from
yhen press products delaminate
into fittings
attempts
pan
are
poured products
made to fabricate
Filter them
18
No license would be involved if the decision is to install a pan
pouring process at the new Southwest facility
DisadvantaOS DisadvantaOS DisadvantaOS
1. Fhysical strengths of pan poured products are lower than those
obtained from filter pressed products
|
and
bonded
2. Visual appearance of surface is inferior to both filter press and bonded
aggregate products
we . 3. Pan pouring is not a precision process Problems of dimensional stability and nesting of ware show up from time to time in the
field
!
!
4. With current level of technology large size sectional pipe cannot
be poured with adequate gross margins by the pan pouring process
5. Like filter pressed products pan poured products are reinforced with asbestos fibers With current level of technology glass fibers
cannot be used in either process
6. Pan pouring requires the use of expensive autoclaves SID's and
r
Contherm units
7. Pan poured 10 products have a maximum temperature application of 1200 F vs 1500 to 15000 F for bonded aggregate products
8 Pan poured products have higher breakage losses while in transit and when handled at the job site than filter pressed products
Se
o
-10-
Kawls Cont
Disadvantages Disadvantages Cont )
hand labor Labor costs to produce
involves considerable
of total manufacturing costs
Pan
pouring currently
averaging
40
percent
pLiepveelaroef autoration at Berlin is still very low
Process job efficiencies for the those for competitive processes
pan pouring process
because of the high
are lower
degree of
than
handling in the plant
Pan Pan poured
products
products
are
products and Multi
not
are
water water
repellent Only repellent today
bonded
aggregated
Manville
ManviMalnvillle MeanMvanviillle le Manville
and
and
have higher physical strengths in all three
Filter pressed products
and impact strengths
categories R compressive
smooth and free of air holes Has an excellent
surfaces are
.
appearance
developed by Manville
as
of total
costs as a percentage
is a highly autorated autorated
manufacturing cost
The filter press process sectional pipe up to and and
including
itself to the
including 24 x "
molding
of large
i
no amosite asbestos only
The ManvillManeville product contains
percent chrystile
little in transit and job
Filter pressed products suffer very
size 7 site
extremely high percent for the
Process job efficiencies are
Manville
as developed by
filter press process
ware is greater for filter
Cylinder capacity for induration of green
This is because filter
pressed products tbheanstfroirpppeadn fprooumretdheprmooldducptrsior to autoclaving .
pressed ware can
have fewer broken corner problems during
9
pressed products
material in the Manville process
10. Very little waste
,
legs of pipe are trimmed
Only
-
wf
--
A
on TT
-
LY
those for pan poured cycles considerably longer longer Shipping Shipping
products
flexibility
in daily mix mix of goods
2 flexibility flexibility
Wof ith current level of tochnology
contain asbestos fibers
Products
asbestos fibers current
fibers cannot cannot
glass
Tend to desamanate
are not water repellent
Filter pressed products
because of high do not meet Mil Specs
Manville probably
9. 19.
involves the use of expensive autoclaves
6. "4 vu Process of
maxmaximium mum temperature applications
products
have
bonded
aggregate
applications
1200 pressed 1200 F 1500-1600 for
is substantially 4nferior
to poured by the IandteIhrtaesr paretsesndpernoccyestso delaminate
to par poured block and
Structural cannot be made by the filter press process
fire rated products
Xo UL fire rated products
press
moisture moisture
have a tendency to delaminate
is absorbed products
isa
percent for efficiencies still remain low percent
hours required
over
Satch are for mold change
costs process
concerning higher than
Not flexible
use additives
Sot flexible concerning
those the
additives
to 5 to 6 6
pan pouring pouring
lower batch pouring
,
Densities
densities densities pan pan
products higher higher
poured products products pressed
very inventory
because
be maintained maintained
the rix goods limited range the rix goods goods
of the
Production Production rates of of
usually usually per hour hour
than for pouring pouring .
filter press are far required pouring
Skilled craftsmen craftsmen
mold equipment equipment
fabricated fabricated to changsa precision precision
Fittings cannot
35
-- problem problem
delamination fabricated from pressed ware
Fittings delamination
one of delamination.
Ne
"
-12-
.
nied
nied
nied
Amcreate
Philic
Philic
Carey Carey
Carey
.
praodd 1 No autoclave required to produce bonded aggregate products
2. Low investment costs
/
- good dimensional stability - nests well 3. Precision molded product
4. 4.
SmootShmooth Smooth Smooth Smooth Smooth surface surface - no air holes
5. Can be reinforced with glass
6. Product is water repellent
Careytemp limitations for bonded aggregate
products
7. Temperature
300
400
higher
than
than
for
pan
poured
and
are
1500
1500
to
1600
1600
F
300
to 400
F higher
filter pressed products
--
8. Bonded aggregate offers potential of being a highly automated process
potential low labor cost process
lower than those for the filter press process
9. Batch costs are
aggregate process is capable of producing large size
11. Pipe fittings can be fabricated from bonded aggregate products products
Disadvantages Disadvantages
'
1. Bonded aggregate products are
2. Has lower physical properties
quite fragile break easily when handled than calcium silicate type products
3.
40 5.
6.
7.
Flexibility in the daily mix of goods is rather p r
would be much longer than
Like filter press products shipping cycles those for the pan pouring process
block is inferior to Kaylo block Bonded aggregate
Crumbles when
handled
will not yield structural Bonded aggregate process makes it unsuitable for for the product to crumble rated door applications
core
use in
The tendency
UL fire
must be maintained because of Large inventories of finished goods the limited range of the mix of goods
from do not fabricate as well as pan poured
8. Bonded aggregate products from
breakage
sawing and cutting
i
products due to
a i
-23-
Advantages
the basic product of 1 Multi is a product made from Fiberglas
It is free of asbestos fibers the Corporation
-- 2 It lends itself to decentralized operations adapitnasbulleattioonany General
Products plant capable of making Fiberglas pipe
and snow resistant and water repellent in that
3. The product is rain
capacity
capacity capacity
one to operate efficiently
4 The saturation process is not a complicated
5. Multi pipe has an acceptable K value
6. Multi pipe can be applied to 1000 F surfaces
7. Large size sectional pipe can be produced by the Multi process
due to rough handling would be nominal 8. Breakage
9. Easy to cut good fabrication characteristics
margins 33 percent projected for block
10. Excellent gross
1.
2.
3. 4.
5.
of the product was 1000 F rather
The maximum temperature resistance than 1200 F for 10 Kayl
to in transit and handling damage
The ends and edges were susceptible
dusty than competitive competitive materials Multi products were more
were lower than those
Projected gross margins for Multi pipe :
projected for Kaylo pipe
efficiencies were very low
In the Newark pilot plant facility job of offware were excessive
due to excessive offware
Major causes
in
operation of process and burn ware
and rough handling improper
the oven
car ying
inventories of two different types
6.
Distributors
objected
to
carrying
which
called
for
additional
warehouse
of high temperature insulation
space
calcium silicate and bonded aggregate type 7. Softer product than the
products
32