Document r9dRzDJBVGwbxe9Jy71w2JXq

interoffice MEMORANDUM to: William Longo from: Margaret Manville subject: Eagle Picher Supertemp date: March 21, 2000 y-i50 Eagle Picher Interrogatories show Supertemp Block Insulation contained chiysotile asbestos from 1938 until 1945. One Interrogatory stated the product was manufactured until 1951 but contained asbestos only until 1948 (Exhibit GR 99, attached). The Product Specification Sheets you sent show that some form of Supertemp was manufactured until 1958, however, the company does not address this in any interrogatories. The sales brochures we have for Supertemp and Supertemp PV are not dated and do not state ifthese products contained asbestos. You noted in your letter the service temperature of these products were 1700 but we have an Interrogatory (ACS 246, attached) and a sales brochure for Supertemp PV that list the service temperature to up to 1900. One interesting note, Eagle Picher admits in a 1990 Interrogatory (NAR 168, attached) that even though" ...a small percentage of chrysotile asbestos fiber was charged against a product known as 'Supertemp Block'. However, former plant managers of the Company deny that the product ever contained asbestos fiber." Hope you find this information and the attached documents helpful. ATTORNEY WORK PRODUCT - CONFIDENTIAL March 6, 2000 #MAS 10309.00* 1 8969 Ms. LeAnne Jackson Baron and Budd sutte?iaooUwnAvenUe Dallas, TX 75219 Do c^y^ L oJouvJ -fe/U'i RE: Eagle-Pitcher Non-Asbestos Insulating Block Material Dear LeAnne: Enclosed please find some Eagle-Pitcher manufacturing specification^ for what looks like a non-asbestos containing thermal insulation block material that had a service temperature of up to 1700F. Interesting enough, Ol's and OCF's K^fylo 10 was only good to about 1200F. Also, it looks like at a minimum, this material was manufactured frofn 1946 to 1958. Of course, there may be additional spacifiratinn ^hnnto that 1 Hnn't hs/a- If you have any additional information on this product, I would appreciate it if you could forward a copy to me. William E. Longo, Ph.D. President WEL/mac Raleigh Office: 616 Hutton Street Suite 101 Raleigh, NC 27606 (919) 829-7041 FAX (919) 829-5518 Atlanta Office: 3945 Lakefield Court Suwanee, Georgia 30024 (770) 866-3200 FAX (770) 866-3259 ANSWER: See attached agreement. Respectfully submitted. GRIGSBY, GACA & DAVIES, P.C. Charles S. Warren, Esquire Attorneys for North . ' American Refractories Company, one of the defendants . Respectfully submitted. McARDLE, CAROSELLI, SPAGNOLLI & BEACHLER Bv Edwin H. Beachler Attorney for Plaintiffs tAGLE-L* Insulation Divi at, PICHER PRODUCT SPECmCATION CONFIDENTIAL FOE EMPLOYEES ONLY NOT FOR DISTRIBUTION TMi specification form* the bttn it all Manufacturing Specifications. Fabricating Specifications, Purchasing Specifications, Inspection Procedural, Advertising, Salat Promotion and Product ftaferanca data. No deviation may be made from these requirements accept under emergency conditions in which case the deviation shall be reported promptly to the Intidatien Engineering Department. Revisions mey be requested by written memorandum giving reasons tor the desired change. Until such recommendations have been adopted and Incorporated in a revised issue, the provisions at this Specification thaH gowem.*-- T. C, CARTER. Ho...... E*hctiv.fe*<&.3L..lS*tt Sup#r**di....T.?.r S Betel 12-19-*' 1. VvI*'T`l JUffiMXOHXK WPSMg BLOCK IXSCUTXCK (Oede 4A9) HFIBEKTIAi. 2. Dscsrlutlaat ' . a. Si* product & e dry, daxfc PO* relatively dost free, hosMceaaoos insulating block* eoeposod of Xvle-Xleher Mineral Haul Tiber with suitable blading a^oots, forned late a iwi-iisld or rigid uUrlsl, Slacks ere flat and ; . ractaagalar with square corners and aide* aad ends parallel* Slocks are vatar repellent and shall he sufficiently strong to withstand aomal shipping aad installation without ezeeeslvs breakage* _ V Sav Batarlalt, processing aad/ee fshrloatlon required shall he la aaoordanoe * with Manufacturing Specification dated Daeseber 6* 19*6. 3* Por-raln* or ftildlna .flseclflafttlflnal <u U. 8. Dapertaaat of Conserc* Honaarrinl Btaadard CS 117-hh (Oovsnlag). h. C. 8. Doparteeat of Coaaaroa Goaaereial Standard 08 l3QL-*6 (Oovemiag)* a. Pederal Specification HB-2-36* -(Governing)* . d. SaTj Daparteeant Specification 32-1-3# (Golding)* a. A.8.T.TU 25-18 (Ooldiag). (Sotel SSda A.S.T.R. specification va* eaaealled). Patents, Trade ft-irko end Cotrrlrfitnt a. Trade Kart: So. (Ponding)* 5* frmo9ft for Ho.1 potion! a. Uao of inpropor ingredient* la aaamfaeture. h* Boa-oonpliaaa# with perfonaase properties speifl*d la paragraph* 2 aad 6* a. Preoena* of foreipi materials* d. Bon-unlfornity aa to shape or othw physical proparti##, (Hotel Aay lot or shipment which does not meat with all requirements of this specification shall be rejectad. Ooah products of sub-standard quality *h*H be plainly narked aad stored separately pending disposition)* font 1JS3--1 u---__ t . -2- 6. Platensignal -hunlrmtmtu "d othmr Physical ni Chanlcal PTrocrtlest. _. a. Standard else* arst Length ndth Shidmase 18* 6* rad 12* 1*. 1-1/2*. 2\-2-l/2*. 3% >1/2*. 4*. Speeial aim armilabla within aarima dlaenriaaa f 4* x 12* x 18*. Vidth. Laegth and Thickness tolersaees shall to pins or tinna 1/8*. to Rjyical rad Cheaieal Properties - Performance Eaqulreoente. (Sotot Performance properties liatad "below ahall to toatod at a frequency of every 6 neaths rales* stherwiss specified). Hmrag Breaking L-- (6* Vida Specimen oa 10* Spaa) ' PSSBg&gg 1* Slide - 8 Ito KLa. 2* Shick - 40 Ito Miu 3* Thick -HO lto Kin* 4* Thick -140 lto Kin. Minas sera . ea eb Pmyfrm ** Boater 8our< X-l46a ASTH 0-203 4ST Canpraw&T* Strength. 2000 lto/sq.ft. Kin. at 5^ caapraasioa of original thickaaas or at failure. which ever la lover. Kinaa sere I-12Sa Asrx C-165 Corrosia* (So Steel) Density Tire Saaiatrace Linaeg Shrinkage Shall not ace&erato corrosion ' 18#/eo.f4. Minima* 22&fca~ttm Karlana Material shall to ratod incoabostihls 2$ Kas. after 6 hours 0 1500*1 Hone Mims rare Plus sore leas Plus sare I-130a X-136a 1-1444 I-l68b .cs-131 CS-131 cs-131 HB-I-5& Loaa in Vaight Koiaturs itoorptlaa 25 Kax* ftar 6 hours 1500*7 1/G HaxisBa by weight Plus sere Blue sere 1-1504 1-1044 HB-I-5& CS-131 Taoperetora hailstones Thsnoal Conductivity So failure or change Is. state which will adversely affect its ' use after exposure to 17M7 (caa face) for 96 hours. 42 3tu Kax. O 200*7 Kara T. 51 2ta Max. 4007 Xeaa ?. .81 3ttt Hex. 600oT Kara T. 75 2ta Xjkx 800o7 Kara S. Sacs Plus sere -R SR R 1-1804 1-184*. cs-131 cs-131 or ASTK C-177 3- a. Tactary Control Soots* Qaallty control tests shall bs sade periodically. as called for In the Kaxmfaofcuring Specification to insure continuous ecsspllaace with the perforsaaee property Units specified in paragraphs 2a. , 6a. sad 6b* 7. Inspection Pjrpcsfraa.* a. Usual Incpoetioa shall bo maintained os all aatorial aanafaetarwd* b. Sample* for performance tost purposes shall bo tooted in accordance with paragraph 6b and reported in triplicate to the Insulation Engineering Sopartzas&tt Cincinnati* Such eaaplos shell bo taken at random from material in standard shipping containers which hare boon warsfcooaed for a f two weeks. " c. Before sa^ changes in the product soda a* la purchased ingredients, ' aaanfactnrlne process, packaging, etc., which may affect either the physical properties, performance or appearance of the prodset, sasples shall bs aabaltted to the Insulation Engineering Bspertaeat for approval* Vhen such changes sore aathorised, tests shall be node os covered In paragraph 6b ami. tha rosalts forwarded to Cincinnati* 8* for shlraeat! ( a. Containers shall bs 275? test cartons of detigs adequate to protect products and of proper dlasasians to restrict shifting in transit* Carton shall be aarfcsd with freight classification stanp. Carton sixes bs as follows! Carton alga 1*. 1-1/2*. 2. 3, 2-1/2 3-1/2* 24-l/B0 x 18-1/8- r 12-1/8 30-1/8" r 18-1/8- x 12-1/8" 28-1/8" x 18-1/8" x 12-1/8" b Pending cooplstion of carton study, tha plain cartons shall be stencilled as indicated in paragraph 8s & &. Upon completion of study the cartons *bal 1 bs printed in the type colors end layout as per approved design** a. Cartons shall be clearly stencilled with tsaaber ^ sixe of pieces square foot sad board feet per carton using data, frnn the following table* Thickness 1" 1-1/2* 2* 2-1/2* V. 3-1/2* b* Bd.?t./cta* 36 , 36 ` 36 *5 , 36 # 52 * 36 So.Tt./etzu 36 2418 18 12 12 9 i2" X 48 24 32 16 24 12 24 12 16 8 16 8 12 6 8. i, A 1st nnabsr tha.ll h# stsarpsd cm **ch ooatalaar to psrait cssralsis mo* f*otarin Idsotlfleatiea whan r*qnr*JL Carton* shall bs tl^itljr {lus-*s*ld# the* storsi 1a a Ary, perotsotsf. loottiau fiAStafr lagqlmtlon XoflAaerlas Depertosst % Em Zm LaWiS ) Product Supertemp Block THE EAGLE - PICHEE COMPANY INSULATION DIVISION MANUFACTURING SPECIFICATION PLANT PRODUCTION MUST FOLLOW THIS SPECIFICATION. Emergency Change may be made but shall be promptly reported to the Production Manager and may not extend beyond the Emer gency. Permanent Change must be submitted to and be approved by the Production Manager before tue by any Plant. Plan!____ Joplin....... ............. ....... Pag*_____1of. k Pages _ Efftcfivt November, 1950 Supertedei Spec. Dated 12/6/1x6 ' Ravi,ad Ifarm Entire Fora Contents Prepared By----E._ Young^ Approved: .b J v J ; . Production Mgr. `.'-.-.u .. Dlvition Mgr. * _ -i-.-i-- I. PRODUCT DESCRIPTION (a) Eagle-Picher Supertemp Block is a dark grey, dry, relatively dust free "block composed of Eagle-Picher Mineral 'Wool thoroughly blended with suitable binding.agents. The finished product is semi-rigid and rec tangular in shape with square comers and parallel faces. II. PRODUCT INFORMATION (a) Density (b) Service temperature (c) Fire resistance (d) Corrosion on steel (e) " Performance fe 1700F, one face Volumetric shrinkage Linear shrinkage Loss in weight (f) Compressive strength (10? deformation) (g) Breaking strength (1" sc 6" on 10* span) (h) Thermal conductivity (k) in ETU in/sq.ft/hr/F (i) Block Sizes Length Width Thickness (j) Packages '1 * (k) Ifet Weight, per carton 22-2 lx lbs./cu.ft. Up to 1700F, one face Incombustible None 2% 2% 2% 18 psi 12 lbs. 0.37 200? K.T. 0.53 500F K.T. 0.6U 700F-M.T. 13" and 36" 6n and 12" 1* to lx* in -J" increments Cartons 66, 77, and 32.5 lbs. ) Supertemp Block Page 2 of 1* III. materials * MATERIAL WT. PSR MIX* (a) Tufted Wool (Type B-l in burlap bags) 350 lbs. (b) Ben tonits Clay -200 Me eh, 95$ min. -300 Mesh, 70* min. 50 lbs. (c) Hydrated Lime (High Calqiua) 2.5 lbs. (d) Starch (#126 Buffalo Corn Starch) * 5.5 lbs. bo8.0 lbs. JE58SEHI* 85.6$ 12.3$ 0.6* 1.3$ 100.0* NOTE: Weights and percentages are approximate only. In practice, measurement is "by volume rather than- by weight. if;' PROCESSING (a) The clay, lime, and starch are added to 55 gallon&of water, under agitation, in pre-mix tank. (b) When this slurry is thoroughly "blended, it is heated to aporoximAtely 2007, "being kept under continuous agitation during the heating. (c) The hot slurry is then moved by gravity from the pro-mix tank to the mixing tank. (A) Here, the elurry is again placed under agitation and 10-35 pound bags of wool, plus sufficient water to bring the whole mixture to L50 gallons, are added. (e) Mixing continues, until the wool fibers are thoroughly dispersed and suspended in the slurry. - (f) The resultant slurry is then metered in the mold boxes, allowed to drain and pressed to the desired thickness. . (g) The mold boxes are removed ,and returned for refilling. (h) The pressed, green blocks are sent to the drying ovens on rack cars. The blocks are dried for Approximately k days with in-going gases .to ovens t LOOP. * er drying, the blocks are allowed to cool to a handling temperature IV . PROCESSING (Contd) . Supertemp Block ' Page 3 ol It (k) The cooled blocks are then planed and sawed to the desired dimensions. (l) Acceptable Blocks are packed in cartons which are then closed, marked, and placed in storage or made ready for shipment. See VI-b below for quantities. V. PRODUCT CONTROL (a) Product control tests shall be conducted as often as is necessary to main tain the quality limits set forth in the following table but with no less frequency than indicated. PROPHET! VALUE KIN. TEST FREQUENCY TFST PROCEDURE (1) Dustiness Relatively free , Continuous Visual (2) Waterproofness To be determined 0.25? Production To be determined (3) Density Minimum Maximum ( Breakload l"x6" on 10" span 22 Ib/cu.ft. 2li lb/cu.ft. -- 12 lb. min. 0.25? Production 0.25? Production E-P 1-136* Navy 32-1-3 (5) Dimensional Tolerance -0 / 1/8 incir 0.25$ Production Visual ' (b) Substandard material shall be set aside for disposition as directed by j Plant Manager VI. PACKAGING (a) Packages shall be regular slotted cartons made from 275 lb. test stock. (b) Packages .shall be filled in accordance with the following table: BLOCK - SIZE BLOCK THICKNESS 3D. FT. PIE CARTON CARTON ____ SIZE_______________ APPROX. KIN.NET WT. PER CARTON 6" and 12" x 18" 1, l, 2, 3, It in. 36 2L-1/8" x 18-1/8" x 12-1/8" 66 lbs. 6" and 12" x 18" in. 1*5 30-1/8" x 18-1/8" x 12-1/8" 82J lbs. 6" and 12" x 18" 3 in. 1x2 28-1/8" x 18-1/8" x 12-1/8" 77 lbs. 6" and 12" x 36" 1, lh 2, 3, h in. 36 12-1/8" x 12-1/3" x 36-1/8" 66 lbs. 6" and 12" x 36" 2\ in. 1x5 15-1/8" x 12-1/3" x 36-1/8" 82* lbs. 5" and 12" x 36" 3i in. U2/ lii-l/8" x 12-1/3" x 36-1/8^ 77 lbs. ' SupertempBlock ' Page L of ii ti. jyicnciso- (Cont d) ' (e) Crrtons shall be printed in accordance with X-P Torn layout B-112. (d) Cartons shall he closed by gluing top and bottom. (e) All cartons shall be marked with a code number that will permit complete manufacturing identification. e (f) This product shall be identified on shipping forms as "Mineral Wool Blocks in Cartons". i / V* Product" Supertemp Block THE EAGLE - PICHER COMPANY INSULATION DIVISION MANUFACTURING SPECIFICATION PLANT PRODUCTION MUST FOLLOW THIS SPECIFICATION. Emergency Change may be made but shell be promptly reported to the Production Manager and may not extend beyond the Emer gency. Permanent Change must be submitted to and be approved by the Production Manager before use by eny Plant. ' Plant__ _ Joplin __ Page___ . 1 . . .of Effective _ March 2b, I952 b Supersedes___ November, 195 Revised Items___ VI-- 6_b__ Prepared By____ 0. Ioun Approved: Production Mgr. V.' J iLf - 1 :'P'- Division MgrJ^^cx ,, i.^1. - . I. PRODUCT DESCRIPTION U) Eagle-Picher Supertemp Block 1* a dark grey, dry, relatively duet free block composed of Eagle-Pieher Mineral Wool thoroughly blended with suitable binding: agents. The finished product is semi-rigid and rectangular in shape with square corners and parallel faces. II. PRODUCT INFORMATICS (a) Density 22-2b Ibs/cu.ft. (b) Service temperature Up to 1700P, one face (c) Pire resistance Incombustible (4) Corrosion on steel * None () Performance 1700T. one face Volumetric shrinkage Linear shrinkage Loss in weight 2r" # ' (f) Compressive strength (10^) deformation) 18 psi (g) Breaking strength (1* x 6" on 10" span) 12 lbs. (h) Thermal conductivity (k) in BTU in/sq.ft/hr/ 7 (i) Block Si2s Length' Width Thickness ^ <J> Packages 00 Met Vaight, per carton _ 0.37 0 2007 H.T. 0.53 500? H.T, 0.6b 7007 H.T. 18" and 36" 6" and 12* 1" 4o b" in i" Increments Cartons 66. 77. and 82.5 1**. Supertemp 3 lock i ragt 2 of L PAW KATEBIALS MSSRILL, (a) Tufted Wool (Type H-l in burlap bags) VT. PFp MIX* 350 lbs. 85.8 (b) Bentonite Clay -200 Mesh, 955 min. -300 Mesh, 70$ min. 50 lbs. 12.3* (c) Hydrated Lime (High Calcium) 2.5 lbs O.656 (d) S tareh (#126 Buffalo Corn Starch) 5.5 IBs. 1.356 408.0 lbs. 100.056 *MOT: Weights and percentages are approximate only. In practice, measurement is "by volume rather than by wei^jt. IT. PROCSSSINS (a) The clay, lime, and starch are added to 55 gallons of water, under agitation, in pre-mix tank;. (b) When this slurry is thoroufdily blended, it is heated to approxi mately 200F, being kept under continuous agitation during the heating. (c) The hot slurry Is then moved by'gravity from the pre-mix tank to the mixing tank. (d) Here, the slurry is again placed under agitation and 10-35 pound bags of wool, plus sufficient water to bring the whole mixture to L50 gallons, are added. (e) Mixing continues, 'until the wool fibers are thoroughly disoersed and suspended in the slurry. (f) The resultant slurry is then metered in the mold boxes, allowed to drain and pressed to the desired thickness. (g) The mold boxes are removed and returned for refilling. (h) The nressed, green blocks are sent to the drying ovens on rack cars. l' ' (i) The blocks are.^dried for approximately h days with in-going gases to ovens at hOOF. (j) After drying, the blocks are allowed to cool to a handling temperature. . e Suoertem'o 31ock Page 3 of It IV. PROCESSING (Cont'd) t (k) The cooled blocks are then planed and sawed to the desired dimensions. (l) Acceptable Blocks are packed in cartons which are thpn closed, marked and placed in storage or made ready for shipment. See Vl-h below for quantities. V. PRODUCT CONTROL (a,) Product control tests shall be conducted as often as is necessary to maintain the quality limits set forth in the following table but with no less frequency than indicated. PROPERTY VALUE MIN. TEST FREQUENCY . TEST PROCEDURE (1) Lustiness Relatively free Continuous Visual (2) Waterproofness To be determined 0.25$ Production To be determined (3) Lensity Hininua Maximum 22 lb/cu.ft. 24 lb/cu.ft. 0,25$ Production E--P I--136a (4) Breakload 12 lb. min. l"x 6" on 10 span 0.25$ Production Navy 32-I-3 (5) Dimensional Tolerance -0 -j 1/8" 0.25$ Production Visual (b) Substandard material shall be set aside for disposition as directed by Plant Manager, 71. PACKAGING (a) Packages shall be regular slotted cartons made from 275 lb. test stock. (b) Packages shall be filled in accordance with the following table; BLOCK SIZS BLOCK THICKNESS BE. FT. PER CARTON CARTON SIZS ArPECX. MIN. NEG VT. CARTON 6" and 12" x 18" 1. l, 2, 2h, 3 in. ^5 30-1/8" x 18-1/8" x 12-1/8" 82i lbs. 62 and 12" x 18" 3o- 4 in. , 42 28-1/8" x 18-1/8" x 12-1/8" 77 lbs. 6" and 12" 1 36" 1. lit 2, 3, 4 in. 36 12-1/8" x 12-1/8" x 36-I/8" 66 lbs. 6" and 12" x 36" 6" and 12" x 36" ( Z\ in. ik in. ' ' *5 15-1/8" x 12-1/8" x 36-1/8" 82^ lbs. 42 14-1/8" x 12-1/8" x 36-I/8" 77 lbs. J Supertem> -^lock Page h of h VI. PACKAGING (Coat'd) (c) Cartons shall be printed in accordance with -P layout D-112. (d) Cartons shall be closed by gluing top and bottom. (e) All cartons shall be marked with a code number that will per mit complete manufacturing identification. (f) This product shall be identified on shipping forms as "Mineral Wool Blocks in Cartons". / * THE EAGLE -PICHE8 COMPANY INSULATION DIVISION MANUFACTURING SPECIFICATION PLANT PRODUCTION MUST FOLLOW THIS SPECIFICATION. Emergency Change may be made but shall be promptly reported to the Production Manager and may not extend beyond the Emer gency. Permanent Change must be submitted to and be approved by the Production Manager before use by any Plant. Plant__ JOElitY. Pag,_ 1 . of_______ ______ Effectiv . _ Junt 14, .1252 Supersedes Spec. dated 3"4--5?_______ Revised Items__ .Entire Specification Prepared By,,. ... D. A. Scheal el . . Approved: Production b Division Mgr. I. PRODUCT DESCRIPTION 1.1 Eagle-Plcber PV Superteap Block i* a dark gray mineral wool insulating block composed of Eagle-Picher Mineral Wool and suitable binding agents. The block ia relatively dust free, water repellent and formed into semi-rigid rectangular shapes having square corners and parallel faces. II. PRODUCT INFORMATION 2.1 Density ,, 16 to 18 lbe./cu. ft. , 2.2 Service temperature . Dp to 1900 F, ona face 2.3 Fir* resistance Incombustible 2.4 Corrosion on steel - None 2.5 Performance 9 1900 F, one face Volumetric shrinkage Linear shrinkage Loss in weight 2.6 Compressive strength at 10^ deformation 2* 2* 2* 18 pai 2.7 Breaking strength 1* x 6" on 10" span 23 lbe 2.8 Thermal conductivity (k) in BTU in./sq. ft./hr./deg. F 0.37 200 F M.T. 0.53 500 F K.T. 0.64 700 F K.T. 2.9 Standard Block Sikes: Length Width Thickness 18" and 36" 6" and 12" 1" thru 4" in l/2" increments 2.10 Packages Cartona 2.U Net Weight per carton iair ie~t o* 63.68 and 72 lbs > f" ft Supertemp `Block I u Pag* 2 Of 5 RAW MATERIALS AND FORMULATION 3.1 Eagle-Picher Superteap Granulated Wool . 3.2 Starch (Archer-Daniela-Midland *Adcol 105" Sorghum Starch) 3.3 Bentonite Clay - 95% in. -thru 200 mesh 7ojf min. thru 300 aeah EQgffiL&nPfl M?./gg* PERCENT 180.0 i-- . 90.77 76~% ' 2,02 n.o 5.55 3.* Aluminum^Sulfate, pondered 3.5 Caustic Soda, Flakes ' # ' 2.7 0,6 1.36 .30 ` TOTAL 198.3 100,00 * NOTEi Weights sod percentages are approxinate. Slight deviations are Bade in formulation to secure proper draining of block in the wet molding process. 17. PROCESSING - Pressure - vacuua molding and wet sawing nethod. 4.1 Approximately 35 gallons of water are run into the primary - mix tank. Then the starch is added and cooked until the temperature of the starch solution is approximately 200 F* Constant agitation is maintained during this operation. 4.2 Sufficient water is added to bring level up to 1*4-5 gallons. Clay is added at- the same time. Agitation is continued and - this portion of the nixing cycle consumes approximately 1^ minutes. This permits clay to be adequately dispersed and expanded. .. ` 4.3 One pint of caustic solution is then added. Solution is - made ty adding 75 lbs. of caustic soda to 18i gallons water. Agitation is continued for at least 1-J- minutes to permit ' further expension of clay. ` . 4.4 The aluminum sulfate is then added and agitation is continued for at least two minutes. This flocculates the clay and the mix is ready fcrr transfer to the secondary mix tank. - .. . . - 1 C!.V . > FV 5uparteap Block w Page 3 of 5 PROCE55IHO (Cont'd) - 4.5 The wool la placed in hopper which can tranafwr it* content* into the eeeondary nix tank. Normally, email piaoaa of scrap block and trim from tha wet aawing process are added harm to salvage tha value of material in them. This is equivalent to adding approximately one bag (30 lbs) of wool. The wool and slurry are then transferred into the seoondary mix tank and water is added to bring level up'to 450 gallons of mix. A minimum of agitation is used to disperse the mix and to avoid breaking the wool fibers. 4.6 Once the mix is sufficiently agitated, it is transferred to the surge tank and is ready for the molding operation. The surge tank provides a minimum of agitation and only during the period of drawing off the mix to the scale box. 4.7 The scale box automatically measures the mix. Approximately master blocks are obtained from one mix. 4.8 The pressure vacuum equipment then drains the excess water froa the mix and molds the semi-dry master block. 4.9 Each master block is positioned on s carrier pan and is then automatically moved through the wet sswlng process to be out to the proper width, length and thiakness. (Note j The combina tion of thickness adds up to 5 Inches.) 4.10 The master blocks are eheoked for dimensions and irregularities prior to loading onto drying carts. Substandard pieces are removed and fed back with the wet trim. 4.11 The blocks are dried in ovens at approximately 400 ? for 70 hohrs 4.12 After drying, the blocks are removed from the ovens and permitted to cool. t 4.13 Blocks are removed from the carts and packaged. Final inspection is made Just prior to inserting the blocks into cartons. 4.14 Cartons are identified to show contents and date of packing. They are then ready to ship or be palletised and put into the warehouse. FROEPCT CONTROL " 5.1 Product control tests shall be conducted as often as is necessary to maintain the quality limits set forth in the following table but with no less frequency than indicated. ,Pr 'unertenp Hlock k of5 ' V. FRODOCT CONTROL (Contd) PROFERTT VALUE MIN. TEST FRE00ENCT TEST PROCEDURE 5.1.1 IXistiness 5.1.2 Waterproofneas Relatively free Sheds water Continuous Visual . .55 Production Apply water 5.1.3 5.1.** Density Minimum 16 lbe/ou. ft. .55 Production Maximum 20 lbe/cu. ft. 20 Breaking Strength S* lb. min. ave. .55 Production 1" x 6- on 10" span (None below 18 lb.) E-P 1-136s Navy 32-1-3 5.1.5 Dimensional Tolerance Thickness + l/l6" Lon. A Width * l/8- Continuous Visual and gage 5.2 Substandard material shall be set aside for disposition ss directed by the plant manager. VI. PACKAOINQ joD 6.1 Packages shall be regular slotted carbons made froa-275"lb. test stock with 4'5flute and tape closure. Standard carton sires are as followst - 1t \\ 16- carton - 16-1/8- I 32-1/8- X 36-1/8" ' 'I 15" carton - 15-1/8- X 12-1/8- X 36-1/8 V 14* carton - 14-1/8" X 12-1/8' X 36-1/8 6.2 Cartons shall be printed in accordance with E-P fora layout D-147. The 14- cartons are plain except for "contents panel". Colors are OCMI #21 green and "ATlgSPango. y' 6.3 Cartons shall be filled in accordance with' the following tables* BLOCS . THICKNESS BD. FT. " PER CTN. cm.. SIZE APPROX. GROSS WT. PER CTN. LSS, 1*.2",4-. 48 - 16" - 74 ii\2i".3" 3i* ' BLOCS THICKNESS 1- 22i3* 2t- *5 15* 42 ' 14- PIECES PER CARTON 6 X 18 6 X 36 or 64 40 \ 32 \ .. 24 \ 12JL1S_ 32 20 16 12 20 16 1.6' ' ( 10 \8 -xa ` 69 0< 65 fs ^ 12 x 36 IS 10 0 8 6 5 4 4 A ' 1 Suparterrp Elcefc i i Page 5 of 5 TI. PACEAOIBO (Coat'd) 6,h Cartons shall be closed by gluing top and bottom* 6.5 All cartons shall be marked vith a oode number that will permit couplets manufacturing identification. . 6.6 Cara or trucks shall be inspected and any wire, nails, or other protuberances which might tear oartons shall be removed. Cartons shall be suitably protected, IT such haaarda cannot be removed, to prevent damage in transit or when opening ' doors at destination. 6.7 This product shall be identified on shipping forma as *W^rrr--1 u~'T~f1Tp"h In Tart^na*. \- IS Vc^ q v' o i~c. 'C~. . t I*