Document qop7wRr3xvJqRQ49vQ1mEDZx

DATE: SUBJECT: 000? Dr, F, L, Steahly 855-2307-6214 File: 574,000082 Hydrocarbon Resins E 6, Caflisch April 8, 1963 Hydrocarbon Resins - Visit by Mr, Norman Setter to Discuss Coaiinga Asbestos bn April 3, SUMMARY Great interest was indicated in the use of light-colored prepolymers as binders for Coaiinga asbestos, While four factorially designed samples will be sent at a later date, Mr. Setter asked for and will be sent a single sample1 as soon as it can be prepared. Equipment is being prepared to test this and the Prepolymer U-311 which has already been sent, A sample of E Cut of Unsaturate Oil will also be sent to Mr, Setter. DISCUSSION Mr, Norman Setter of Union Carbide Nuclear Company visited with Dr, F, L. Steahly, Mr, W, B. Lanham, Mr, C, W, Schersten and the author on April 3, 1963, Mr, Setter reported that the sample of Prepolymer U-3111*2*3*1* had been received and that a roll mill and an extruder were being obtained to enable them to blend and process the mixtures of prepolymer and Coaiinga asbestos at elevated temperatures (probably below 100C.) Mr. Setter was shown a sample of 1 part Prepolymer U-311 and 2 parts Coaiinga asbestos, which had been blended for the author on a roll mill and then pressed (about 3,000 psi) to a sheet about 0,06 inch thick (both operations at room temperature). He suggested that flexural strength tests, from which the modulus of elasticity could be calculated, would be the most meaningful tests on samples of this material after they had been cured under various conditions. Notched- and unnotched-Izod impact tests would give additional information. Mr. Setter was not sure whether the asbestos served any purpose other than as a filler in the pipe they make. Sufficient work had not been done at Tuxedo to indicate that the viscosity of the Prepolymer U-311 is too high; however, it was suggested that E Cut of Unsaturate Oil (U-300) might be used in place of the prepolymer if a lower viscosity is desirable. A lower initial curing temperature would probably be required because of the lower nonvolatiles content, A five-gallon sample of E Cut will be sent to Tuxedo for testing. Mr, Setter indicated great interest in the light-colored prepolymers, of which four one-gallon samples are to be sent to Tuxedo. These might be used for low-cost light-colored asbestos building materials. While additional work will be required before the factorially designed set of four samples can be prepared, the interest warrants the shipment of a single sample as soon as it can be prepared during the next few weeks, A market survey by Mr. Setter on the use of asbestos in building materials is under way. Eleven sheets of information which he had collected ^Memorandum, February 18, 1963, 2Letter to Mr. H. F, Reichard, February 19, 1963. Memorandum, February 19, 1963. Memorandum March 7, 1963. -2- 6214 are attached to the file copies of this memorandum. The deposit of Coalinga asbestos has an area of 17 square miles and appears to be over 1,000 feet thick At the present world consumption of asbestos this would be a 400-year supply. The structure of asbestos was briefly discussed. Dr. Steahly suggested that Mr. Setter present a EGCssmr ccs Mr. B. M. Fonville Mr. G. w. Harris Mr, R. s. Hovey Mr. R. G, Keister Mr, w. B. Lanham Dr. J. V. Murray, Jr, Mr0 s. E. Parrish Mr, R. J. Rasmussen Mr. R. L. Readshaw Mr, J. B. Reid Mr. C. w. Schersten Mr. C. H. Shields Mr, J. J. Toslosky Mr. G A. Trigaux Mr. Do R. Vredeveld Index: Hydrocarbon Resins Prepolymers -eoaHHga Asbestos 'SSti^2 0 s' i/2 Z' i/7 -(s&O _____________ Type of Pipe_______ bestos Cement i ipe, conduit, `ducts; includes pressure pipe ..trified Clay 'ev;er pipe and fittings 7"st Iron oil pipe and fittings rbon Steel ripe and tubing 11 types "*?. as tic Polyethylene I 7C Type I ) Type II ) Styrene-Rubber ABS Butyrate Polypropylene Polyacetals '."inforced Thennosets Pipes, Tanks, Ducts PIPE MARKET SURVEY 1958 Da ta Value of Quant of Shipments Shipments ($1000) (Tons) 69,750 366,305 Unit Values $/ton 190 C/lb. 9.5 1960 Data Value of Quant, of Shipments Shipments ($1000) (Tons) 1961 Data Value of Quant, ol Shipments Shipments ($1000) (Tons) 86,900 1,723,503 50 2.5 94,800 1,854,000 89,600 1,737,000 119,768 1,382,694 789,000 6,627,000 152 208.7 7.6 127,705 10.4 1,774,306 782,000 135,515 1,822,000 834,000 21,273 19,600 1085 54 22,500 7,500 7,500 6,000 500 N. A. (est.) 800 1961 N.A. est 1962 3,250 Tyne Unit of Measure ; ;ent-Asbestos: Siding Shingles and Clapboard Roofing Shingles Flatsheets and Wallboard Cl/4" thk. basis) Corrugated Sheets (1/4" thk. basis) 1,000 squares It It 1,000 sq. ft. It II It Sheet Metal: Roofing, siding and drainage Wood: Particle Board Softwood Plywood Hardwood plywood Hard Pressed Wood Fiberboard Asphalt: Roofing and siding Floor Tile Plastic: Vinyl-Asbestos Floor Tile Panels and Laminates tons STRUCTURAL MYTERIALSKARKUT SURVEY 1958 Data Value of Quant, of Shipments Shipments ($1000) Unit Value c/f t.2 I960 Data Value of Quant, of Shipments Shipments ($1000) 1961 Data Value of Quant, of Shipments Shipments ($1C00) 45,636 4,566 15,916 4,208 325 84,720 10.8 13.8 18.9 ) ) ) 45,453 ) )] 38,433 ) 4,291 19,869 21.5 185,775 17,345 450.000 146.000 78,331 317,437 77,000 66,591 231,302 88,043 328,325 71,705 99,784 232,145 97,290 334,907 70,299 102,582 i p i 41,500 5 Product Image - UCNC F-100 General Service Pipe Present F-100 Product Characteristics The following measurements were obtained on pipe samples -- 3-1/2" IJ>. x O.325" vail: Lengthwise flexural (psi) Lengthwise flexural modulus (psi) 11,000 Q 2.5 x 10 Crushing Strength (lbs/ft) 2,300 Crushing Modulus (psi) 0.9 - 1.0 x 10 Rupture (instant burst)(psi) 50 Palling Ball Impact (ft. lbs) 5-6 Hie following measurements were made on l/8" thick sheet stock: Flexural Strength (psi) Flexural Modulus (psi) 12,000 ,6 2 x 10 Izod Impact (ft. lbs/in. of notch) Heat Distortion (26k psi) 0.6 to 0.8 Nil to 500 F Coefficient of Linear Thermal Expansion I.05 x 10 3 (-30 C to 60 c) For an in-service test application at UCNC's King City, California asbtotos mill several sizes of pipe will be produced with a somewhat thicker wall to radius ratio to obtain a minimum rupture proof pressure of 500 psi. Specifications for this pipe are as follows: 1. Outside Diameter - To conform to nominal 1-1/2", 2-1/2", and l-i/2" steel pipe sizes. Tolerances are expected to be +.010" i.-. the diameter. 2. Length - Random from 10 feet to 15 feet including coupling. 3 . Service Pressure - 100 psig to 200 F. A 12" section from each length shipped will receive hydrostatic proof testing to 500 psig. 6- - 4. Dimensions: (Approximate).. Outside Diameter (in.) Inside Diameter (in.) Wall Thickness (in.) Wt. per foot (lbs.) 1-1/2" 1.900 1.500 0.200 0.8 2-1/2" 2.875 2.275 0.300 1.8 ?-i/g 4.000 3.180 0.410 3.6 5. Couplings: - A Victaulic "Roust-a-Bout" coupling will be supplied with each ler . of pipe shipped. (The coupling-pipe Joint will be hydrostatically ter -a to 500 psig.) Not*-:: It is obvious from the pipe dimensions specified here crushing strv.- jth, shock impact resistance, and instant burst levels are going to be greater than those listed above. Performance in the field will give valuable data on the general utility of the pipe. Future F-100 Pipe Characteris~w-.?s 1. Smooth interior and exterior, no machining required for Joining. 2. Couplings and fittings to be manufactured from thermoset resins (either phenolic or epoxy) in two design varieties: a. "Ulok'i type - for non-permanent installations b. Cemented - 3*. Sizes: 1" to 6" nominal I.D. (outside diameter to conform to steel pipe standards.) 4. Lengths: 20 to 24 feet. 5* Price range: Difficult to asses3for now. Pricing on 4-1/8" O.D conduit from an engineering cost analysis was 39//ft. or approxi mately 13//lb. As a good figure now use 15//lb. -7- SOCIETY OF PLASTICS INDUSTRY - PIPE STATISTICS FOR THERMOPLASTICS IN 1961 Polyethylene Type 1 and II FVC Styrene - Rubber (Drain and Sewer Uses) ABS Butyrate 45 million lbs. 15 million lbs. 15 million lbs. 12 million lbs. 1+ million lbs. Anticipated increase for 1962 5# across board. Actual Plastics Pipe and Fittings Sales in 1962 - $65 million ASBESTOS - CEMENT PIPE COSTS Asbestos-Cement Service Pipe Size 5-inch 4-inch 6-inch 100 PSI Working Pressure $/ft. Installation Costs, $/ft 0.8l O.98 1.48 O.38 O.39 0.43 Size 3-inch 4-inch 6-inch 150 PSI Working Pressure $/ft. Installation Costs, S/ft- 0.87 O.38 I.05 0.40 I.63 0.44 Growth Market Potential Application Potential Sales million ft/year Gas Distribution Water Services (Municipal, pool, etc.) 107 95 Conduit 58*5 Source: Modern Plastics, April, 1961 9 TRANSITB AND SEWER PIPE Size I.D. Wt/Lineal Ft. Price/Lineal Ft. Ibs/ft F.O.B. Delivered 6 in. 8 10 12 14 16 18 20 24 10.1 14.2 19-9 25.6 32.2 39 A 46.7 54.4 Tl-3 $1.07 1.42 2.07 2.65 3-35 4.10 4.85 5.65 7-42 Sewer Pipe $/Ton Material Crushing Strength per Lineal Ft. 212 2400 lbs. 200 2400 lbs. 208 2400 lbs. 208 2400 lbs. 208 2400 lbs. 208 2400 lbs. 208 2400 lbs. 208 2400 lbs. 208 2400 lbs. Approximai Wt./Cu.Ft 100 lb 100 100 100 100 100 100 100 100 3 inc. 4 6 8 10 12 14 16 18 20 24 8.3 9-9 15.3 21.0 28.9 40.5 54.0 65.6- 0.86 I.03 1-59 2.19 2.99 4.21 5.63 6.94 9.29 11.40 16.28 150 lbs/sq. in Pressure Pipe Carload Price - Delivered 100 lb 100 100 100 100 100 100 100 100 100 100 Source: Letter from A. Q. Lundquist - July 7> 196l - 10 - COMPARATIVE COSTS 5-INCH PIPE (From "Chemical Engineering1*, 5/25/59. ~p. 157) Plain Carbon Steel (Sch. 40) Stainless Steel (Sch. 40) 304 316 Transite (15O PSl) Cast Iron (150 PSl) Bigid PVC ABS Polymer Polyethylene (Virgin) Aluminum Pyrex (0.2n Wall) Karbate (0.5" Wall) Hard Rubber (0.375" Wall) Porcelain Rubber Lined Steel Haveg F-100 Estimated Pricing (150 PSl) $/ft. 1.00 9-12 14.88 0.95 O.95 1.96 I.96 1.28 1.19 4.3O 8.00 4.00 2.90 3*32 4.92 1.00 - 11 "POLYURETHANES MOVE IN ON NEW MARKETS"* Rigid polyurethane foams have a tremendous potential market in the building construction field. These foams have good insulating properties# can be made in large sections# have good heat and solvent resistance# and can be installed in the form of boards# poured in place# or sprayed. Unfortunately the relatively high (16-20 cents/bd ft) cost of urethane foams prohibit their vide application in^place of polystyrene (9-11 cents/bd ft) or nonplastic materials (as lov as 2 cents/bd ft). If this disadvantage could be overcome# a 635 million board feet market is immediately available. POTENTIAL MARKETS FOR RIGID BOARD INSULATION IN CONSTRUCTION Low Temperature Space Insulation Pipe and Equipment Covering Cavity Wall and Insualtion# Plasterbase Perimeter and Floor Slab Insulation Roof Insulation Backerboard for Metal Siding Nonresidential Panels Residential Panels Panels for Lov Temperature Space Insulation Thin Shell Construction Floating Structures Miscellaneous Nov 1966 (Millions of Board Feet) 200 50 60 40 200 40 20 Nil Nil Nil 25 Nil 635 300 100 200 70 600 180 125 125 150 50 80 20 2000 * Chemical and Engineering News# April 3/ 19^1 CONSUMPTION OF PLASTICS IN CONSTRUCTION End Use 1961 (1000 lh.) Flooring 372,000 Surface coatings 398,000 Adhesives 142,000 Electrical Equipment (Mainly insulation) 237,000 Molded Specialties (Wall tiles, fixtures) 74,000 Panels and laminates 83,000 Moisture harrier, thermal and moisture harrier, sealing compounds l4l,000 Piping 75,000 Increase over 1959 (*) 5 6 8 14 19 38 53 103 Source: Modem Plastics, January, 1963 - 13 - NEW NON-FABM HOUSING UNITS STARTED (lOOO's) Year Area__________________ Non Metropolitan Metropolitan _________ Type of Structure______ One- Two- Multi- Family Family Family 1958 1959* I960* 1961* 827 1076 888 936 382 435 386 391 975 1229 987 952 39 59 51 50 195 244 237 325 Total 1209 1531 1274 1327 * Includes Alaska and Hawaii.