Document mbaqY0MbbKGOoZ5B79dBv9Vw0

Inter OHiee Car Engineering October 12, 1978 To: A. S. Anderson I. J. Burba V, D, Camsbell K. F. Klrcuoff J. L. Maurer J. V. Sprys J. D. Wells C, 7, Bolling Subject: Raybestos-Manhattan Friction Products Non-Asbestos Review A presentation was given to Ford personnel September 27, 1978 at the RaybestosManhattan Corporate Headquarters in Trumbull, Connetisut on the development of non-asbestos products. The following issues ware discussed on the agenda: Regulation Baaed on three reports, the British Parliamentary Committee, consisting of 15 members, will recommend by 1979 a lower standard. British industry is guessing at 1 fiber/cc. The US Government (OSHA) is not expected to take action until next spring on a lower regulation. R-M considers 1 flber/eo as feasible but admits a ,5 flber/cc standard would be legally challenged by industry. Supply Trends . R-M purchases raw asbestos fiber from 5 Canadian mines through annual contacts and competitive bidding. Procurements have been completed for 1979-1980 with a nine month supply on hand. ^lK> . Asbestos is currently net purchased from Russia because of the lack of and the crude consistency of the fiber. ty . Canada la considering the establishment of a cartel to control all marketing of asbestos fiber through the government. On a lover order of magnitude cashew nut shells have been affected politically by a fabricated BUpply and demand condition. Substitute materials have been considered In light of these pressures. Fries Trends Responding to escalating Inflation, price trends began to rise between 197^--6 with a 6.2-7.5$ per annum increase. Since that period prices havs advanced 8-10fC per year. This is projected to continue as a long term trend. 004230 PRODUCED BY FORD 2. Price Trends (continued) , Between 1974-6 the cost of spinning grade fiber increased 30.1$, causing concern for clutch facing fabricators, who are dependant upon this grade for manufacture. Future increases have equalled those established for other fibers. Plant Compliance . It is anticipated OSHA would allow sufficient time to comply with ebv standards. An abatement period would extend time for re-formulation or the implementation of engineering controls. . Each employee is provided with medical attention exceeding $2,000/yr., in addition to workmens compensation and insurance premiums totalling $2 mflllon/yr. Expenditures in this area are subject to increase due to more frequent litigation and further health requirements imposed by the government. , In Ireland, litigation and Irish government interference has resulted in a one year closing of the 2 yr old R-M friction facility. Although samples obtained from the plant are within the 1-2 fiber/cc level the Irish Government requires air samples continually be sent to Irving Selikoff, Mt, Sinai* far analysis. Residents of the area have picketed the plant from inception. Asbestos Elimination Program R-K policy is either to comply with government regulations or eliminate the need for asbestos fiber. Research projects for the last few years have been restricted to tae development of non-asbestos products. An internal non-asbestos target date of 1982 has been chosen to avoid major capital expenditures and the escalating costs of....recordkeeping, medical check-ups, fiber level monitoring, insurance premiums, legal fees and latent liability for R-M employes and customers. In the interim R-M intends to maintain the continuity of supply of asbestos products while reducing asbestos usage in the aftermarket with non-asbestos products. Fifty candidates have been reviewed as potential substitutes on the basis of biological effects, availability, cost, performance and processability. Substitu tion has required complete re-formulation and process modifications due to the larger fiber sizeB (>3u) considered to avoid health affects. Research and Development Programs . Wet Clutch Facings (Automatic Transmission) The 10% asbestos content in vet clutch facings does not present a problem for substitution. The current nonasbestoe paper facing ranks equivalent in cost, - performance, and processing, An eight week lead time is required for production capability. . Dry Clutch Facings (Manual Transmission) Extreme conditions of heat, pressure, and torque in manual systems increase the difficulty in substituting 50-70$ of the asbestos content with a composition that will serve as a suitable reinforcing member and friction modifier. Although a non-asbestos glass facing exists for passenger units, a cost and weight equiva lent will not be available until 1980. Release to the aftermarket at that time will result in an estimated Job 1, 1902 introduction, 004231  -i 3- Research and Development Programs (continued) Brakes R-M Is currently not a supplier to Ford In this area. However, testing is scheduled to be completed the first quarter of 1979 on a fiberglass/sisal composite, followed by aftermarket introduction. Buphasis has not been placed on Bend.-metallic systems due to the weight and noise characteristics of the product. A release date of Job 1, 1983 is planned for passenger components and Job 1, 1964 for heavy duty segments. Conclusion . Ford representatives were generally impressed with the level of funds and effort expended on non-asbestos programs. Given three years, R-M will be in a primary position to offer non-asbestos products to the market, . Concern was expressed by R-M President, Bob Gordon, of a potential shift in asbestos manufacture to the Orient, as a result of future IT. S. regulations and litigation. Such competative firms would prove detrimental to U.S. friction manufacturers. , Although it was emphasized by Ford representatives that the acceptance of a substitute be predicated on acceptable performance, cost and weight, R-M Contends that elimination of asbestos could result in limitations on our criterion. . Extensive litigation re-affirms R-M policy to eliminate asbestos. The company has been named as a defendant in 28 product liability cases brought by asbestos workers and 255 asbestos cases brougnt in other jurisdictions by 448 plaintiffs who seek between $200,000 and $5,000,000 each. JL a C. B. Zelek Vehicle Materials Engineering October 12, 1978 004232