Document gqJVd7wnJE4yn2jGegV4gGp9

PAOLI LABORATORY PERIOD OF JANUARY 1963 THROUGH JUKE 1963 TABLE OP COLTSPITS Pace oPicture of Test Illustrating How Glass Fibers Improve The Fire Endurance of Gypsum Board Page 2... .^Forward Page 3 Market Performance of iJew Products Patent Information Page 4 Projects Completed - Stud Adhesive R Page 4 Projects Completed - Foam Glass Pellets 11 e D 210 Page oProjects Completed - Acoustical Tile R L D 246 Page 6, .Projects Completed - Super Firestop R & D 241 Projects Completed - Laminating Compoucd K Cs D 209 Pe^c 7. ...* .Projects Completed - Statistical Control R 'a D 239 Projects Completed - Blue Hamids Dust Collecto;. k L D 238 Projects Completed - 2 Hour Fire Rated Par tition R U D 251 Page 8 Projects Completed - 2 Hour Double Solid Partition R C: D 252 Projects Completed - Effect of Glass Fiber in Board R L D 210 Projects Hearing Completion Thincoat Plaster R L D 319 SGP 0014824 TABLE OF COUTIRJTS Page 10 Projects Hearing - Glass Fiber Reinforcement Completion II Ci D 210 Projects Hearing - Texture for One Day Joint Completion Compound R i D 243 Projects Hearing - Fire R Sound Tests - Completion R Ez D 249 Page 11 o a .Projects Hearing - Grinding Methods - R a D 250 Completion Page 12 .... . ,, Projects Underway - Extrusion Process For Board R Ez D 21 Projects Underway - High Expansion Densite R Ez D 132 Projects Underway - Ran Process Plaster - R & D 132 Projects Underway - Tooling Densite - R d D 132 Page 13 . . o . . . * Projects Underway - VJaler Repellant for She athin< R Ez D 203 Projects Underway - Synthetic Joint Compound R c: D 211 Projects Underway - Texture for -Masonry Ceilings R St D 211 Projects Underway - Hummer System - R Ez D 209 Page 24o c . Projects Underway Synthetic Gypsum L Ez D 221 Projects Underway Pre-Fab Panels R Ez D 223 Projects Underway Trowel Finish Plaster - R R l 22S Projects Underway 1" Core Board - R Ci D 229 Page 15 .... . . .Projects Underway Radiant Heating Panels ~ R a D 235 Projects Underway Volumetric Stucco Feeder R a D 240 Projects Underway Lightweight Roofdeck Unit R C: D 242 Page 16 d rejects Underway Grabit - R w D 244 t. -- o jca 1 s Underway 1/4" 2'x2' Cerliug rile R R D 246 SGP 0014825 TABLE OF COiJTEiJTS Page 16 ,, ....................... .Projects Underway - Continuous Calcination R D 253 Projects Underway - Inverforn Paper - r. C: D 254 Projects Underway - Lightweight Gypsun Board 11 -Ci D 255 Page l*7 ,, . .......................Projects Underway - One Hour Floor U. Ceiling R Ci D 256 Projects Underway - Ilof-iCor Panel Fire Test L & D 257 Pace 18 o ooo... .Projects Underway - Donn Clip-On Stud - L v.c D 253 Projects Underway - Sound Deadening Constructio - L & D 260 Pages 19- 21 .... . Pictures to Illustrate the Effect of Glass Fibers in a Gypsum VJallboard Core Pages 22- 24 . . . Pictures Showing Thincoat Plaster Application SGP 0014826 1800 F. BURNER FLAME ENDURANCE |N0 GLASS FIBER - 15 MIN. TO COLLAPSE GLASS FIBER - 8 HRS., NO FAILURE (REGULAR AND FIRESTOP AMT.) SGP 0014827 i FORWARD This report covers the activities and accomplishments of our research program for the past six months. No basic changes in or ganization have occurred during this time. We have,however, begun to assign projects to a single individual rather than dividing the responsibility between two people. The former approach liras being utilized until such time as the new men had gained sufficient ex perience and had become familiar with our procedures. At least one priority project has been assigned to each man as well as other pro jects of lesser priority. Bach man is responsible for maintaining progress in his assigned projects. Assistance is provided where ne cessary by contacting the group leader. A budget was put into effect in January 1963 in order to make available a record of the total expenditure for R&D and the amount spent for each project. The budgeted versus actual expenditures are being reported quarterly. These will be studied to determine whether our emphasis is being placed in the proper areas and whether our money is being spent wisely. This year's figures should give us a good ba sis for preparing next year's budget. The field testing stage of our development programs was revamped during the past 6 months. There have been a number of instances where we have gained little or no information from trials. Another problem has been the difficulty we have had in obtaining field tests. We have brought this problem to the attention of the Sales Department and solicited their cooperation in planning a more effective field testing program. After several discussions, it has been decided to institute a standard procedure for requesting, conducting and report ing results of field trials. To simplify the reporting, a standard report form and follow-up form have been prepared. We trust that these measures will enable our field testing to be conducted more effi ciently in the future. Included in this report are the market performance of products developed through research, patent information, and some pictures illus trating the effect of glass fibers in gypsum. The latter are to be used in promotional literature. The major portion of the report is, of course, devoted to the progress of the various projects. * 2 SGP 0014828 MARKET PERFORMANCE OF NEW PRODUCTS JANUARY THROUGH JUNE 1963 1* FIRESTOP 120 CEILING TILE Amount Sold Dollar Sales Volume -~ Gross Profit 122,000 sq,, feet $16,215 $ 5,349 2. GRABIT MASONRY ADIESIVE Amount Sold Dollar Sales Volume Gross Profit 9 Tons $ 1,739 $ 1,019 3* ONE DAY JOINT COMPOUND Amount Sold -- Dollar Sales Volume -- *Gross Profit -- 634 Tons $113,953 $ 33,063 Total Sales Volume of Mew Products $131,907 Total Gross Profit of New Products -- $ 39,431 Estimated by Ardmore Cost Department PATENT INF0RI.1ATI0H Patents Issued: None Patents Applied For: Method of Processing Synthetic Gypsum Patent Applications Deing Prepared: One Day Joint Compound Grabit Masonry Adhesive -3- SGP 0014829 PROJECTS COMPLETED NEW PRODUCTS A* Stud Adhesive - R iit D 201 Objective: Develop a satisfactory source for an adhesive for attaching gypsum wallboard to wood or steel framing* Investigation: Over a dozen different candidates were tested in the Lab before a product manufactured by the Borden Co* was finally selected for field performance evaluation. The Borden adhesive was selected because - 1) it passed all the tentative Gypsum Association Specifications 2) it is satisfactory for both wood and metal framing 3) it is a water thinned adhesive thereby reducing or eliminating toxicity, fire hazard, and clean-up prob lems of competitive stud adhesives 4) it is priced in the $1.50 per gallon range which is the price objective given to us by Sales This Borden Stud Adhesive was field tested with favorable results in every instance. In some cases the contractor offered to buy the product from us as soon as we had it available. Result: The request for this new product was first approveSPEEen revoked. It was decided that there was not suffi cient profit in the product in view of low priced competi tive stud adhesives appearing on the market. Prices of stud adhesive products being furnished to our competitors are be ing explored. This is now in the hands of Sales and Pur chasing and no further work on our part is contemplated, B, Foam Glass Pellets From Owens Corning - R & D 210 Objective: This has been a joint venture with Owens Corning to develop Cl) a 1" insulating gypsum wallboard - (2) a onehour fire-rated 1/2" gypsum board, or (3) a lighter weight gypsum board by incorporating Owens Coming's foam glass pellets in the core of gypsum board. Investigation: After a series of boards were made and testec1 it was found"that the pellets did not impart the insulation value that Owens Corning had anticipated. This ruled out the possibility of an insulation board or a one-hour fire rated board. The economics of the lightweight board were -4- SGP 0014830 PROJECTS COMPLETED unfavorable as the cost of the pellets we were using could not be counter-balanced by savings in stucco and freight. This information was presented to Owens Corning along with the suggestion that they develop a lighter weight pellet. Our reasoning was that the lighter weight pellet would displace more stucco and increase the weight reduction for each pound of pellets used. This would have improved the economics. Owens Corning accepted the sugges tion and indicated that they could develop a lighter weight pelleto We continued to inquire about their progress on the devel opment of lightweight pellets and each time we were advised that they had encountered one problem or another. Result; We finally heard that Owens Coming's pellet pro ject had been halted for the time being and we could not expect to receive anymore pellets in the near future. After some months have passed, we have heard nothing further and some statements have been made by their representatives which indicate to us that their pellet program has been com pletely discontinued. In view of this turn of events, the project has been inactivated. Acoustical Tile - R St b 246 Objective; Develop a 1/2" - 2*x4* acoustical tile. Investigation: Three approaches were taken to find a means of inhibiting the sagging tendencies of this acoustical pro duct. They irere: (1) increase the weight of the tile, (2) increase the glass fiber content of the tile, and (3) to in corporate a small amount of Portland cement into the core of the tile. Neither of the first two methods showed a signi ficant reduction in the amount of sag. The third method showed some promise in the Laboratory but tire plant runs with various amounts of Portland cement in the core failed to dup licate the Laboratory results. Result* No means has been found to overcome the excessive sag of the l/2n - 2*x4* acoustical tile, so at the present time, we do not know liow to accomplish this. No further work is planned. -5- SGP 0014831 PRO.TECTS COMPLETED IMPROVED PRODUCTS AND PROCESSES A* Super Firestop - R & D 241 Objective: To develop a 5/8" Firestop board which will pe'rmV ff and 2 hour* fire ratings when used on the under side of concrete and bar joist, (incombustible), floor and ceiling constructions. The l|- hour rating was pre viously achieved so the 2 hour rating was our remaining objective* Investigations A board with twice the normal amount of glass fiber achieved the if- hour rating and missed 2 hours by only 8 minutes* According to the Portland Cement Asso ciation, each 1/2" of concrete would increase the rating by 20-30 minutes* On this basis, v;e constructed the same assembly previously tested at Underwriters except the con crete deck thickness liras increased from 2" to 2f", Resultt The construction lasted 2 hours - 20 minutes, which easily gave us the 2 hour rating* The Gypsum Association also lists a 2 hour rating for 5/8" type X board over a 2" concrete and bar joist construction, but we still have a distinct advantage. Their construction requires 40% more supporting members, (furring channels), and over 50% more screw fasteners* This difference gives us a competitive edge over all other companies in promoting and selling this construction* In view of this successful result, it has been decided to make all of our Firestop with the increased amount of glass fiber* This gives us a board of outstanding strength in addition to the fire rating and will enable us to capital ize on this in our advertising and promotion* we expect to offset the additional cost of the glass fiber in Fire stop by savings in other board products which is discussed under "Glass Fiber Reinforcing" on page 10* B* Laminating Compound - R & D 209 Objective; Modify our present laminating compound formula so that it will dry faster and bridge areas between lamin ated boards even though they are not in perfect contact* Investigation: A formula xras developed which satisfied the above requirements and also resulted in a 50$ per bag cost reduction* The new formula was field tested and found to be satisfactory in all respects* -6- SGP 0014832 Result: Hie new formula lias been substituted for the old product in our line* Sales has seen fit to use the cost savings realized to reduce the price of the product,^ This makes our laminating compound more competitive with joint compounds which competitors sell for laminating. In the period covered by the report we sold 5107 bags of Laminat ing Compound as compared to 3517 bags in the comparable period in 1962, This indicates that the price reduction and product improvement are favorably affecting the sale of Laminating Compound, C, Applying Statistical Quality Control to Our Operations R & D 239 Objective: To determine whether our operations can be im proved through statistical quality control methods. Investigation: A survey by Battelle Institute showed that statistical analysis might be most effective in determining our board weight and kettle batch setting time variations. All plants have been instructed in preparing their own sta tistical reports. Result: This statistical analysis of board weights and kettle batch setting times has been adopted and is providing in formation which will help us pinpoint problems in these im portant areas. It is also a means to compare the operation of one plant against another. This project has been handled by the Process and Control Department, D, Dust Collector for Kettle and Hot Pit at Blue Rapids R& D 238 Objective: To enable the kettle to be vented so that moisture can be removed without creating a dust problem. Investigation: A VJheelabrator bag type dust collector was installed and some minor modifications made. Result: This equipment is performing as intended and Ardmore has been advised that the expenditure can be transferred from -R Ci D to the Blue Rapids plant, IH SALES AIDS A, Two Hour Fire Rated Solid Uon-Load Bearing Partition R & D 251------------------------- ------------------------------------------- ------------------------------- Objective: Test a partition consisting of 3 layers of 5/3" Firestop" to achieve an inexpensive 2 hour fire rated con struction for use around pipe chases and elevator shafts. Investigation: The partition was designed and 2 fire tests were conducted at Ohio State, The first partition lasted 97 minutes and a second partition with One Day Joint Compound over the joints failed at 90 minutes. * t -- SGP 0014833 Result; Any means we could devise to extend the rating to 2 hours would make the partition prohibitive in cost* This was requested by Sales and it was suggested that a 2n solid partition which the Gypsum Association lists at 2 hours be promoted for use around pipe chases and eleva tor shafts Our suggestion was accepted and the project has been dropped* Bo Two Hour Fire Rated Double Solid Hon-Load Bearing Partition - rsnrssa----------------------------- ------------------------------- -------------------- Objective; Develop a 2 hour fire rating for a partition con sisting of a layer of 1" core board and a layer of l/2M face board on each side of a 3" core space. Investigation; The partition was designed and tested. It lasted for 2Thours 15 minutes, so the desired 2 hour rating was achieved. Result: This was requested by Sales for a high rise job in betroito This gives us the 2 hour fire rated partition for this job as well as for future high rise jobs, C, Effect of Glass Fibers in Gypsum VJallboard - R & D 210 Objective: Develop data and information to be used in Bestwall's and Owens Corning*s advertising to promote the advantages of glass fiber in gypsum wallboard products* Investigation; This project was brought about through a requesi that"we produce some information to be used in Owens Coming's promotional campaign and another request from our Sales Department that similar information be prepared for Bestwall's advertising literature, Hie latter is specific ally intended to assist in the promotion of our improves Firestop, It was decided that demonstration type tests, which could be photographed, would be the most effective for ad vertising use. We first took Polaroid photographs of our test methods, then arranged for the Advertising Dept, to have their photographers take professional pictures of these test set-ups. Some of these photographs accompany this re port. Result; We believe that the resulting pictures dramatically reveal the advantage of glass fibers in enabling a gypsum VJallboard core to withstand various forms of abuse from im pact, shock, nailing, and fire, Owens Coming is using some of our information in their campaign and we have the photo graphs to incorporate in our own literature. We trust that this information wiII implement our efforts to increase board sales. --a -- SGP 0014834 P310.15CT5 ISARIMG COMPLETION lo Thincoat Plaster - R & D 219 Objective: To develop a competitive tiiiacoat lath and plaster system* Status of Investigation: The original objective was to have one product "ior both smooth and textured surfaces* Such a product was- developed and field trials were commenced* It became appar ent during our field testing that smooth finishing properties were more important and textured finishes appealed only in cer tain markets* In view of this a second formula was developed in which the texturing properties were sacrificed in order to improve the smooth finish application* This product was found to be muck more acceptable for those who desired a smooth surface* The for mer product will be retained for use where textured surfaces are desired* A number of successful field trials have beau completed ana we have recommended that both products be released for sale in limited markets. Our thincoat plasters have certain advantages over other thincoat products, and can be priced competitively whi.'ie still maintaining a favorable profit margin* Paralleling the thincoat plaster development were our efforts to impart the proper suction characteristic to our T. C* pinholath* Tills has been resolved to the point where all plants are capable of producing a satisfactory lath to be used with our thincoat plan ter* Advertising photographs taken during one of our field trial.', axe included in this report0 2* Ready Mix Joint Compound - II & P 211 Objective: To develop a ready mixed or paste type joint compound to be competitive with other similar products on the .market* Status of Investigation: Several field trials of a product con taining a dry binder 'system have been conducted* Other than a few adverse comments on workability, the performance of the pro duct has been satisfactory* On the basis of the trials, we re ceived orders for 1500 pails of the product* The economics of cu; ready nix are still not completely favorable, and we are striving to improve this situation. le are sonewhat limited in this direc tion because the fixed costs of the container and the freight rep resent a large percentage of the cost cf the product* This Xeaves the formula and the processing for us to work on. U'c arc even limited here as the improvement in k-oth of these areas is iir.-tcd since certain possibilities for cost reduction will require lai-e initial expenditures for equipment, judging from the emphasis Sales has given this project, it appears imperative that we cen time to seek a practical solution to the problem. Our present thinking is that if we could install a small operation with mini mum expenditure, it would enable us to effectively assess rue mar ket potential as well as possible cost savings* This would eq J. that Management approve a low profit item, even if only on ;:e\:p orary basis* Cased on this experience, the market potential ;,\r .Id then dictate the wisdom in considering certain equipment 'expend tures necessary to improve the profit margin* 9 - SGP 0014835 PROJECTS HEARING COMPLETION 3* Glass Fiber for Wallboard Reinforcement - R & D 210 Objective? To be able to approve several types of glass fiber, particularly 799 (Muzzy Mix) for use in our vrallboard. Status of Investigation; From this evaluation of fiber types vie `found 'fhat iypes ^04? and 799 all were better than the 863 we were using because of improved dispersion characteristics, and that 799 was a special improvement because it offers greater re inforcing value per lb, of fiber. This evaluation has progressed to the point where all of the glass fiber used in our board is either 710 or 799, This work then became intermeshed with an investigation being conducted by the Manufacturing and Process and Control Departments to evaluate the effect of paper fiber. It was found that the regular amount of 799 glass fiber was equivalent to the standard amounts of paper fiber and 863 glass fiber. Seme trial runs were made at Wilmington, but due to cutting problems with 799 fiber, an increased amount of 710 fiber was used and the paper fiber eliminated. Doing away with the paper fiber appears to permit machine speed increases on the order of 3.0% without changing the characteristics of the board. This will be carried further at other plants. In the meantime, 799 glass fiber is still a superior fiber and we are continuing with our effort to enable all plants to use it. Improved quality or further cost savings, or both, are inevitable through the use of the 799 binder glass fiber. 4. One Day Texture Problem - R & D 243 Objective: To find a means of eliminating the need for a primer over One bay Joint Compound prior to texture application. Status of Investigation: The sale of One Day has been limited because we have had To~ recommend a primer prior to any joint system texture application. National Gypsum lias issued a simi lar precaution because of the same drawback to their setting type joint system. Two approaches have been studied. The first is to develop a texture which will do its own priming, and the second is to develop a topping which will alleviate the necessity for priming regardless of the texture used. After considerable experimentation, a texture has been found which we believe will eliminate the need for the primer. The development of a topping for use over One Day has not been completed as yet. VJe are pro ceeding with field trials of the texture as quickly as possible, since we feel this will greatly enhance the sale of One Day Joint Compound 5 a Accumulation cf Fire and. Sound Test Data - R & D 249 Objective: To gather all available fire and sound test data on the various constructions and put it into a usable reference form. - 10 - SGP 0014836 PROJECTS NEARIUG COMPLETION Status of Investigation; This information has been gathered from various sources and sorted into categorical form. We are now having a card file prepared and xnay put the information into book let form as well. This will provide a single file that we can refer to for locating competitive tests, as well as gathering information for fire or sound tests we are considering. To Evaluate Methods of Grinding Molding fa Industrial Plasters - R & D 250 Objective; To find a method to overcome dusting and mixing problems of industrial plasters made at Wilmington, and to grind other industrial plasters at Blue Rapids. Status of Investigation; A trial of the Entoleter grinding equip ment indicated that it would impart the desired characteristics to the molding plaster. Based on our trial and previous use of the Entoleter in the gypsum industry, this piece of equipment was ordered for the Wilmington plant. The equipment has Just been received, installed and put into operation. Test runs will be conducted and followed to determine xdiether this will enable us to manufacture a satisfactory molding plaster at the Wilmington plant. If the expected improvements are realised, the purchase of an Entoleter will be recommended for the Blue Rapids plant. - 11 - SGP 0014837 PROJECTS ON UIF.ai WORK IS UNDERWAY lo Extrusion Method for Jogging Gypsum Board Products - R & D 21 Objectives To evaluate this process as a means to manufacture a gypsum "board of more consistently uniform weight and caliper. Status of investigation: The extrusion process was tried at New Orleans, fee unifoa^lsalipex was achieved but the operation gave too many problems ,, particularly with 1/4" and 3/8" board. The chief problem was keeping build.*ups off the extrusion equipment. Since this equipment Is stationary, it is difficult to keep clean and slurry build-ups occur which cause paper breaks. Another approach,, also disclosed in our patent, consists of forming beard between moving belts on short pulley centers. The next step is the design of equipment to permit tiie evaluation of this alternate method of extrusion. 2. High Expansion Densite for Patterns - R & D 132 Objective; To develop a high expansion Densite suitable for use as a casting plaster for Kirksite Dies used in forming automobile bodies. Status of Investigation: A reasonably satisfactory formula was developed and a new rest method developed to give comparable re sults with the shop-test method used by customers. Aging tests are in progress and are favorable thus far. One refinement desired is to maintain an upper limit of- expansion of 1/8" per foot. This is not critical for some customers, but is for others. 3. Special Densite for Pam Process Pottery Mold - R & D 132 Objective: To develop a special pottery plaster to be suitable for use an the ram pottery making process. Status of Investigations The formulation of this product involves Increasing the"porosity of the product while maintaining suf ficient compressive strength and a smooth, hard surface. Several formulas have been considered and each time they have been found to be inadequate for one reason or another. We are continuing to seek a satisfactory pettery plaster formula for this use. 4. Densite Tooling Plaster - R & D 132 Objective: To improve on K-71 tooling plaster to meet the re quirements of the aircraft industry. Status of Investigations Hie reformulation has been completed ancTTieid testing is underway. The various security regulations of the aircraft industry have prevented us from keeping in close touch with the trials but, thus far. Indications are that the product is receiving good acceptance. 12 -- SGP 0014838 PROJECTS CN VH1SCH WORK IS UNDERWAY 5. Water Repellent Treatment for Sheathing Paper - R & D 203 Objective: To find a lower cost repellent than the Quilon we now use, one which will apply easier, and cne which will offer better repellency. Status of investigation; We tried a two-ccapcnent water repellent whicii gave excellent laboratory results but poor plant results. Tuo silicone types have been tried, one of which offers sane encouragement. This productt which is Dow Corrdng5 s Syl Off-22, will be evaltiated more extensively. 6. Synthetic Resin Base Joint Compound - R & D 211 Objective; To develop synthetic binder joint compounds which will Tiave longer pot life, better shelf life and lower shzinltage than our present casein binder products. Status of Investigation; An additional areasop for our interest In this product is taaT the synthetic binder formulas are far less complicated than their casein counterparts and synthetic binder is inherently of more consistent quality than can be obtained with casein. The result would be a reduction in inven tory required, a ^implication of the manufacturing process,, and possibly fewer problems that continue to occur in our present operation. Two factors are delaying a successful outcome of our efforts to come up with a satisfactory synthetic binder, dry powder joint compound. One is the difficulty in obtaining satisfactory bond at low temperatures, and the other is the somewhat higher cost of the synthetic resin formulations. We will continue to seek means of overcoming these problems. 7. Resin Base Joint System Texture - P, Si D 211 Objective: To formulate a dry texture which can be mixed with perllti^and sprayed onto masonry ceilings as a one coat decora tion. ~ Status of Investigations All of oux tests in the Laboratory Ttfere successfully concluded"6 months ago. A batch of this product was manufactured, but we have been unable to have any field trials arranged. This is being taken up with Sales to see whether the project should be dropped, or if there is still interest, to have the field trials arranged. The project was originally requested by Sales. 8. Accessories for Hummer System R & D 209 Objective: Develop a 2-1/2" thick laminated gypsum rib that can be used with 1/2" face boards in order to compete with metal stud systemso - 13 - SGP 0014839 PROJECTS ON WHICH WORK IS UNDERWAY Status of Investigation: We have undertaken this development to further the acceptance of Hummer Systems and to displace metal studs where possible, so toe can sell both the ribs and the face board. A 3" wide x 2-1/2" thick rib has been found to give a completely satisfactory partition. 50 of these ribs have been fabricated at Ft. Dodge and we have requested that field trials be arranged. 9. Synthetic Gypsum RD 221 Objective; To find a means for utilizing synthetic gypsum for plaster and wallboard manufacture. Status of Investigation: Approval has been received to proceed with the pilot plant installation to thoroughly evaluate synthetic gypsum at New Orleans. The details for the equipment have been worked up and the orders for this equipment have been placed. 10. Prefabricated Panels with Gypsum Ribs - R a D 223 Objective: To develop a prefabricated sandwich panel unit to be used in non-load bearing partition construction. Status of Investigation: Our pre-fab panels fabricated at Ft. Dodge were installed m each of two houses at Bettendorf, la. and Sioux Falls, S. D.. In each case, the installation proceeded smoothly and the finished partitions were considered quite satis factory. Both contractors were interested in the panels and ex pressed a particular desire for us to furnish the components from which they would build the panels. We have requested that a coramerical job be found where vie can install a long run of panels as all of the previous installations have been confined to short par titions. Sales has indicated a desire to delay action on this pro ject until the results of U.S.G.!s and National's promotion of their prefabricated panels are known. 11. Smooth Trowel Finish - R & D 228 Objective: To develop a one material finish to be used as a sub stitute for line-putty/gauging plaster white coat over basecoat plaster. Status of Investigation: Only a smattering of exploratory work has been done on this product due to its low priority and the backlog of other work* 12. 1" Core Board - R Cz D 229 Objective: Tills project was reactivated by Sales with their re quest tor prescored core board with a special taper edge. 14 - SGP 0014840 PROJECTS ON IJHICH WORK IS UNDERWAY Status of Investigation: Some special equipment was ordered for Acme and subsequently, the desired specifications for the board were changed. The proposed trial of this special 1" core board is unsettled at the present time* 13o Radiant Heating Panels - R & D 235 Objective: To develop a gypsum board panel with radiant heating propertieso Status of Investigation: After examining the radiant cable type and conductive coated i'ype panels we have concluded that the con ductive coated panels offer the best possibility because of their greater versatility* We set out to expand our evaluation of the conductive coated panels with Electronics Discovery Corp., a manu facturer of the conductive coating. As soon as we requested some material to work with, they advised that \ue would have to sign a disclosure which they prepared. The disclosure was forwarded to the Ardmore Legal Dept, and subsequently to Synnesvedt & Leclaner. This disclosure was too limiting for us to sign and Synnesvedt is to rewrite the disclosure and re-submit it to Electronics Discovexy Another company, Cliemelex Corp., makes a conductive coating mater ial and lias a number of patents covering the product and its usel However, Chemelex has signed an exclusive agreement with U.S.G., and are not free to work with anyone else. This project will be held up until we can get some expression from the Legal Dept, as to how we can proceed. 14. Volumetric Stucco Feeder For Grand Rapids - R & D 240 Objective: To purchase equipment to feed stucco volumetrically to the board machine pin mixer in an effort to make board weights mare uniform. Status of Investigation: A number of problems have developed in attempting to use this equipment. The manufacturer of the stucco feeding equipment has now offered to make certain modifications designed to improve the performance. Grand Rapids has been asked to make some modifications in their own equipment. Following this the stucco feeding equipment, with modifications, vrilll be reinstall and retested. 15* Dry Lightweight Roofdeck Unit - R u D 242 Objective: To develop a lightweight roofdeck unit which will have good insulating properties and be competitive xvith Tectum & Insulrock. Status of investigation: A laminated unit consisting of polyure- tlir,,ne and gypsum board was our first effort. This proved to be too costly because of the high price of the urethane required. A number of other ideas were discussed and some of them explored. All except one has been discarded. The remaining approach con sists of a foamed gypsum slab reinforced with synthetic resin and glass fiber and having a paper covering. Quite a bit of work needs to be done to fully explore this idea. - 15 - SGP 0014841 ro.tccts o;: unci i work is uiderway 16. Further Uses For "Grabit" - R i!i D 244 Objective: To determine whether Grabit can be used successfully to adhere gypsum board to expanded polystyrene insulation slabs- Status of Investigation; We have determined that, properly applied, Grabit will bond gypsum board to polystyrene.. Vie have prepared a tentative specification and recommended a field test* 17. Ceiling Tile - II C P 246 Objective: Determine whether 1/4" 2fx2* ceiling tile has sufficient resistance to sagging to be sold as an addition to this tile linc0 Status of Investigation: We have started sagging tests comparing 1/4" tile with 3/s'J ceiling tile and 3/3" acoustical tile. 13. Continuous Calcination - R & D 353 Objective: To investigate a means of continuous calcination which caii be accomplished merely by converting our present kettles. The aims are increased tonnage and lower fuel consumption. Status of investigation: The necessary modifications were made on the #1 kettle at Blue Rapids to permit us to explore this method of continuous calcination. The kettle has been put into operation and initial indications are that both objectives will be achieved and a more uniform stucco will result. This operation is being continued and board is being manufactured from the output. Fur ther studies of the process will be made before any definite con clusions are drawn. 19. Inverform Paper - R St D 254 Objective: To determine xdiether any advantages in cost or quality can be derived from the use of this paper. Status of Investigation: Specifications have been submitted to St. Anne*s Board Mill in England and arrangements have been com pleted for 15 tons of paper to be shipped to our Wilmington plant. This paper will weigh 62-65 Ibs./M sq. feet and conform to our specifications for cross directional tensile strength. A trial run of this paper is tentatively scheduled to be made at Wilmington ill July. 20. Lightweight Gypsum Wallboard - R C: D 255 Objective: To find a practical means to reduce the weight of our board without sacrificing quality. - 16 SGP 0014842 PROJECTS Oh WHICH UOI^IC IS UIDERWAY Status of Investigation: Competitive board., somewhat lighter than standard weight, has appeared in certain areas from tine to tine. In addition, we were told that U. S. G. had been using boric acid as a means to make a lightweight board,, A thorough investigation of boric acid has resulted in a negative conclu sion. We also have previously done some work with pellets, per lite, and other lightweight aggregates, but none of these methods has proved practical. The cost or the aggregate cannot be offset by the savings derived Larger quantities of foam is another possi bility but this invariably produces boards vrfiich are too wealt We theorized that if we could reinforce the cell walls of the voids, they would act like an aggregate and permit weight reduc tion without significantly reducing the strength. It was finally found that certain polyvinyl acetate resins added to the foam did increase the strength of foamed gypsum. The increase in strength is commensurate with the amount of resin used. We are presently in the process of determining whether an economical amount of res in will provide sufficient strength to permit a significant xreight reduction to be achieved. This work involves determining foam efficiencies, fineness of cell structure, and evaluation of various resins. It is believed that this investigation is extremely worth while. Even if the lightweight board should be found to be imprac tical, the reinforced foam idea can be applied in other areas where larger quantities of resin can be justified economically. Two possibilities are a lightweight roofdeck unit or a gypsum acous tical tile. 21 1 Hour Fire Rated Wood Ploor i Ceiling - R & D 256 Objective; To develop a 1 hour rating over combustible floor and celling construction using our new 1/2" Firestop, Status of Investigation: This construction failed under load at 48 minutes due to the l/2" Firestop boards falling earlier in the test than we had anticipated. VJe will not re-test this construc tion unless we are able to devise some changes which would signi ficantly enhance our chances of achieving the one hour rating If accomplished, we would have a substantial competitive advantage. A similar test on incombustible construction should be more easily attainable so the relative importance of this construction will be discussed with Sales 22. Cooperative One Hour Fire Test Of IIof-Kor Panels - R St D 257 Objective: To test a partition of Hof-Kor use-fab panels consisting of a paper honeycomb core faced with 5/S" Firestop Eternawall to achieve a one hour rating Union Bag Co., the manufacturer of the honeycomb, is sharing in the cost of this test - 17 - SGP 0014843 PROJECTS OIJ WHICH WORK IS UMDERWAY Status of Investigation: The first partition tested lacked fast eners at the bevel edge joints and lasted only 34 minutes because the joints opened prematurely, Kolorpin fasteners were used 8" o,c, at the bevel joints in a second partition and this time the partition endured for 72 minutes. Another partition will be con structed for the hose stream test to complete the one hour test requirement, 23, Cooperative Test on Donn Products Clip-On Metal Stud Partition 11 Ci D 258 Objective: To achieve a one hour rating on this non-load bearing partition consisting of Donn's D-405 stud and 5/8" Pirestop. Status of Investigation: On the basis of an exploratory fire test bonn had made and the potential of this partition, participation in this test was recommended. Hie first test barely failed to reach the hour failing at 58 minutes. An early failure occurred in the second partition when a board cracked prematurely, Donn Products conducted another test based on a modification we sugges ted but without our financial participation. This time the rating iras achieved, VJe expect to recommend the promotion of this par tition after certain installation problems are corrected, 24, Sound Deadening Wall Construction - R & D 260 Objective: To develop information as required for reducing sound transmission by facing a partition with a base layer of insulation board and a outer layer of gypsum board. Status of Investigations Some manufacturers are already promoting a wood stud partiti__with a layer of l/2" insulation board and a facing of 1/2" or 5/8" gypsum board. Some work has been done so that we will be able to recommend our ovra specifications for this installation. We are also making some small scale fire tests to study this aspect of the construction, VJe are thinking of this development as a means to improve the sound transmission proper ties of Hummer B System, In the meantime, the Insulation Board Institute in conjunction with the Gypsum Association have a number of sound and fire tests under consideration. We are awaiting the results of these tests before we consider any testing of our own. -- 18 -- SGP 0014844 vVi^v**1' :*?v .''L.LL'rv-'-f AMOUNT OF NO. 710 GLASS FIBER IN IMPROVED FIRESTOP SGP 0014845 .,-............ - - -_____ .- V -' ' ' --*' " ''i-Zr . - PROCEDURE * \'K' .ANNULAR RING NAILS DRIVEN THROUGH -' SAMPLE ;3/aw FROM EDGE AND ^A"APART *V;,** >* ;.. ~g /*? NO CLASS FIBER '."-'C-.l/'T-a 3v.' - .'';'^'iy-i *-.*t-': v^ > -" <"."? l* ''!" ' "; "\`yrJeJ? -'^CTAT'E' 'AHiT, ' ''.-.- .., ,. A..`> . * * 'T * "{* T'' it*! /*t- ; ',' ' ,*it>.*4*& '**/-...- .-S`i AMOUNT OF NO.799 / CLASS FIBER IN /R ECULA RS BOARDi ;*/ '* 'J&tsil. 1 PROCEDURE : ' SAMPLE',ST RUCK ' BY FLAT END ' : OF A 1 LB., 15/16" DIA. . CYLINDRICAL -- /'WEIGHT'T|-'- FREE/FALLING FROM '; A HEIGHT OF 2. FT. : ,T./' AMOUNT OF NO. 710 CLASS FIBER IN IMPROVED FIRESTOP SGP 0014846 IMF^GTlBVlROIii:INGi;STEElMBALl#t#^IT/ O-V *** ^ liri'VL.t.inv.pv 1. 1_U.U? unu-i-i*"^ >Y|g<:'*''*&?{'''''-?H;` ' -- <`. * - '" *"' ^' --?---------- " ''" '" ' br~*" *r*'-.- ** ' * " 4 ~ ~r * ~ 4at --4 ^IPIS^SgRAW STEEiSf BALL 3:0^NGL^f^ROM HORIZONTAL - DROP a; i;.. '^:^./'^-:V`vL .-' .' '. i . ^iwsMhw fcv"Vp^ISv- FROM 3 ETSWEIGHT \L ?'L:rZ.-- -:^; / . \ .T 'V'T'V;^" J-. ,'' - *' SPLiL^k",^aSgfMr%P *"> i yv;'t|Jk:Vr ;Vj ifc^J 'A * GLASS FIBER NO GLASS FIBER REGULAR" AMT. NO:799, SAMPLE CRACKED FIRESTOP AMT. NO-7101 NO DAMAGE SGP 0014847 PROCEDURE: SAMPLES HELD HORIZONTALLY AND DROPPED FROM HEIGHT OF 3 FT. FOR A FLATWISE IMPACT ONTO A L t A r> r\ fi if^r * r r~* A < .* ) THINCOAT BASS # * :$* s-. t it l; Jo t [ Wallsp i | And f Otherwise Prepared I i i SGP 0014848 > >> THINCOAT PIBKH GLASS TAPE * l . a.-ri . ri t:x_i .r. T: lrl:zrirz:iniz. jr.-x^iLtinr']' rii irr1 lrrrrrri trri irri:jri Is Imbedded 1I I In Plat Joints and in Angles K *r SGP 0014849 3LJ? i THINCOAT PLASTER > Is Applied, J rr--=t Troweled Smooth On Ceilings, And Walls, V i` " T. -v , Job Complete1 A </ SGP 0014850