Document rBxR0JpJMX6VDj86awO3NJVyq

FILE NAME: WR Grace (WRG) DATE: August 20, 1970 DOC#: WRG119 DOCUMENT DESCRIPTION: 1970 Research and Development program for asbestos-free mono-kote status report. . ZONOLITE D N tT M e n O H PR O D U CT D IV ISIO N TO: See Distribution List FROM: T. F. Egan DATE: August 20, 1970 SUBJECT: Research and Development Program for Asbestos-Free Mono-Kote . The attached program prepared by- Ralph Bragg is to some extent a status report on research efforts outlined from the meeting in Cambridge on July 28th and 29th. . . It is important to note that this report will be revised regularly as our test program develops and the work will be documented and written ' in a comprehensive manner. The research work is involved in the most emotional and controversial area of construction pollution. Remember that not only are the charges unproven, but methods or limit values of control have not been established. Therefore, as the data becomes fact we must be able to adjust or correct our research effort. Recent discussion with Johns-Manville personnel - Dr. Sidney .Spiel andMr. Ed Fenner - confirm my earlier comments that, barring some alarming medical fact to the contrary, the health hazard of asbestos wili require the bah on loose asbestos particles to the atmosphere, and probably within one year. Already we have lost a major project in Philadelphia, and I'm sure others may follow across the country. The asbestos-free product will get the order.. Knowing this, I again want to emphasize the importance of the "Long Range" development program discussed in our July meeting. Reference can be made * to m y letter of August 10th - "Fireproofing Products Research". The market belongs to the film that provides a new "pollution-free" spray cementitious product. . Your attention to this situation, comments and inquiries are expected. Please contact me or others at once on any matter. TFE:dlc Attachment Distribution List R. J. J. N. H. A. J . X. Bragg* Beveridge Brown Chapin, Jr. - Zono/Travelers Rest K. R. Gianker* .., X . C-yRHr"son AuG 271970 T. P. Feit* G. Fulmer - WRC X. IV. Karrison J. IV. Xraus - WRC* . C. C. Legal - WRC- W. R. Payment - Zono/Travelers Rest D. G. Powell R.. E. Rothfelder - Zono/Los Angeles Plant A. F. Schneider - Grace/New York R. W. Sterrett R. M. Vining C. H. Wendel - Zono/Los Angeles Office *These individuals have attachment. D0085C8 CONSTRUCTION PRODUCTS DIVISION RESEARCH & DEVELOPMENT PROGRAM for ASBESTOS-FREE MONO-KOTE U CONSTRUCTION PRODUCTS DIVISION U INDEX SUMMARY PRODUCT REQUIREMENTS . COMPLIANCE WITH REQUIREMENTS ' L . . ORIGINAL R&D PROGRAM (to JULY, 1970) . REVISED R&D PROGRAM (Based on Management Review) FORMULATION AND TEST DATA (limited distribution) APPENDIX Recommended Data Collection - Fiber Pollution Moderate Risk Program Schedule Overall Mono-Xote Program Schedule Formula, Standard Mono-Xote (MK-3) Formula, No. 1165A Formula, MK-4 Direct Manufacturing Costs, MX-3 Direct Manufacturing -Costs, MX-4 . . Yields end Densities, MK-3, plus graphs . Yields and Densities, MX-4, plus graphs D00855Q  7;.*- .. '..v'---. V ' - 'V. -^v : . . . 'V - ;*r; ; ' / . : " > >. . . :'., ' -.: .> ' ' .`i* * '*./'..'.****V1 ^ - r ** P.V-iOVy.- * ... -.* .T*' ` . ' ;. ^ ^ .v;V^**'** ?* ^ '*'* * - .,.vVs**5-* .V.\y.V-W- V. -. , V ;-#- ;v'V - v>;.. * *.* . . ` ' ` '* Vv > '': ** . ' . :' 4.`.,V , JV ^ : ^ - ; *; rv**y^t ^* ' *V'\ 'V* * * ' * '* ",,****' * .* * .-. ...V.... *' ,.< - , ; ;V>lir',Ffc .-. .... _*- .y -%->>>4r : ;'V. . : V-''*.*V'C^ -;: 'V ,iw . ' ; * J.y.A'viii'i -- S ^ ** 'f \ >\-aV*. -&**&* - ' * - ;-,v4 -;*r-vJ'^ *' **' - **k '^VTtAV *t--V , * * ** .' . `V- `;#** ' ' . %/ D 0 0 8 5 51 .*' *.9m+!~/VV? iyiiyr - : . -V-..-X^.*'-v*Vr. : :>-' r CONSTRUCTION PRODUCTS DIVISION SUMMARY Standard Mono-Kote (MK-3) contains 12.5 vt. ^ asbestos fiber which is a potential health hazard. CPD has adopted a bi-directional approach to this problem as: (a) Attempt to quantify the degree of hazard posed by the - Job application of Mono-Kote. This is difficult since presently there are no hazard criteria in existence which are based on epidemiological medical statistical data. There is a level defined as an absolute criteria set in early 1970 by the American Council of C-overmen- tal Hygienists (no more than 5 fibers greater than 5 microns in length per cc of air). This level has also ' been used by one of the larger asbestos producers for "in-plant" control. We have found in limited monitoring of standard Mono Kote on the job that pollution levels at the mixer and spraying areas are in the order of 1 to 2 such fibers/ cc of air. Additional work in this area is planned (see exhibit A, "Recommended Data Collection for Mono Kote Health Safety Program). In addition, the CPD ' Laboratory and Product Managers are attempting to keep .. abreast of the changes in pollution criteria and to work out local problems affecting the sale of Mono-Kote where they arise. (b) Eliminate asbestos from the Mono-Kote formula. This Red) approach is the subject of the bulk of this re- port, as: Formula II65A, an asbestos-free Mono-Kote has failed to match MK-3 in Underwriters1 Laboratories testing, both from a thermal and bond to steel standpoint. These failures are detailed in the sub-section, Orig inal. R&D Program. As a result of these failures, management has asked . ' that we increase R&D efforts toward solution by using necessary talent and broadening our research approach. We report our past R2> program here as well as our revised program. m D008552 CONSTRUCTION PRODUCTS DIVISION 7 1 SUMMARY (continued) Work projects have been assigned to various groups of W.' R. Grace & Co. CPD is handling formulation, testing and U.L. testing of MX-4, a new asbestos-free Mono-Xote. VJRC is involved with determination of bond mechanism of Mono-Xote with a CPD goal of devel oping a "super-bonding". Mono-Xote for future (1571 ?) development. . . . Our projected short term scheduling which is called a "moderate risk" program is shown as Appendix B. The overall Mono-Xote program is Appendix C. Under the moderate risk approach, we will have pre pared UL fire test specimens by August 21. These include a full scale blended deck system comparing MX3 and MX4 on a side by side basis. Also, we will apply MX-4 to a 100# flat plate assembly, using a November 1969 test as performance criterion. Finally MX-3 and MX-4 will be comparison rated for thermal efficiency on a series of six 31 i pilot tes'ts. Still under the moderate risk approach, we have a decision point about September 8, 1970 when we decide whether to proceed with these fire tests. This decision will be based on data obtained up to that time. D008553 CONSTRUCTION PRODUCTS DIVISION PRODUCT REQUIREMENTS (for present sales) Mono-Kote is a "Direet-to-Steel" fireproofing composition, factory blended and packaged, requiring the addition of vat er on the job-stie. This, product must conform to the following characteristics: Requirement Value Compliance Easily Mixed - 3 Minute Period Yes Easily Spray Applied . B y Plaster Pump-Nozzle Yes Resistant to Corrosion % Coatings over 0.5 im Yes y it.a*<u.~c> (A-r ; a w e ) Hard Surface . No Erosion @ 10b mph Yes low Thermal Conductivity Less than .66 K factor Yes Competitive in Yield Min. of 30 3d.Ft./5C Bag Yes Competitive in Cost As Specified by Market - Yes ' Non-injurious to Health Low Pollution Level No" Fire Resistant Provide Protection to Heat Transmission per ASTM E-119 Questionable' See next page detailing negative compliance. DO 0855S CONSTRUCTION PRODUCTS'DIVISION COMPLIANCE WITH REQUIREMENTS Our current Mono-Xote, identified as KX-3, was developed in 1959 and has been successfully marketed since. In two areas of performance, I-2C-3 is questionable. Under the requirement that such a product be Non-Injurious to Health, we are attempting to determine code pollution levels and to rate MX-3 field performance against these levels. We are also, attempting to reformulate the product to completely exclude asbestos. In this latter respect, recent test data confirms there are trace amounts of asbestos associated with some vermiculites, but they are presently judged to be unimportant. In the area of requirement that MX-3 lie Fire Resistant, our standard I-K-3 has borderline performance in its ability, to adhere to a certain configuration of steel deck during a fire test. V.e find that premature bond failure is the rule rather than the exception in those full scale test specimens which contain a large area of flat-plate. The efforts being made to Improve such performance in a r.ev,. Kono-Xote include careful adherence to 'optimum mix w a t e r 1, the possible use of bond promoters and consideration of other methods of application of fireproofing. The latter two categories appear to be means of developing a super-bonding Kono-Xote, and cannot be utilised in our tightly scheduled moderate risk program. D008556 - Vivi''.SftE: i *-V3.kV' .D008557 y:/** .> ' V*rf r'*V . - % / > ; . . . '. *' .?* * r *W 4 ^\ -*.v -'-vvi'1s_.;-.-.. -,r/i>r.*.- .. ""S'.-*tie:-r . ,';'KV<A^ - - .V: ]>* CONSTRUCTION PRODUCTS DIVISION ORIGINAL R&D PROGRAM (thru July, 1970) Attempts to reduce the level of asbestos include: I. Complete Asbestos Elimination for Cost Considerations This work (Zonolite Test Report 1231 of 1965) was requested by the Vermiculite Institute and resulted in a product 21?$ . higher in dry bulk density, % higher in cured density, 1C?$ shorter set time, 18?$ lower water requirement, 10?$ lower RKC, and 5% higher cost in place. These results were of a negative nature, and further efforts to eliminate asbestos . were suspended. . II. Reduction of Asbestos for Patent Purposes In order to escape possible patent infringement against Rational Gypsum Co., we successfully reduced the level of asbestos 7% in 1969. This reduction was approved by Underwriters1 Laboratories, Ir.c., who provides inspection and label service for Mono-Note and all other fireproofing materials. . . III. * Complete Asbestos Elimination for Health Considerations Since June 196, we have attempted to eliminate asbestos by substituting other materials, within a few months we had defined the function of asbestos as primarily a yield increasing additive, also useful in improving the homo geneity and pumpability of the composition. 17e had dis carded the following functions as being insignificant: (a) Necessity that fiber be inorganic and highly resistant to high temperatures. . (b) Contributed to cohesive strength during expos ure to fire. D008558 CONSTRUCTION PRODUCTS DIVISION ORIGINAL R&D PROGRAM (continued) Having reached this decision point, our research program followed three distinct paths to March 1970. These were: (a) Search for an acceptable substitute fiber. This area included worl-c on glass, mineral and ceramic fibers of inorganic origin as well as organic fibers such as cotton, rayon, nylon, cellulose, etc. (b) . Search for non-fibrous'yield promoting materials of an air entraining type. Typical of tr.ese materials is Methocel H. G. which has shown a considerable degree of success. (c) Shot gun approach, used primarily to compress time without reasonable confidence of success. Approximately 25 compositions were investigated, essentially using low density fillers of particu late type. Also we probed a few bond promoters such as starch and polyvinyl acetates, none of which were acceptable on exposure to fire testing. Progress by March 197 directed our RD along a single path approach, using a substitute fiber of cellulcsic origin, specifically a sulfite process fiber. The approach was strongly influenced by what we considered acceptable pilot testing of this product, Formula IlfpA. Another governing factor was the type and scheduling of final performance testing and sample preparation in Underwriters1 laboratories Inc., and by the desire to obtain a new product as soon as Possible. Having committed the program to a single composition, the period of May to June 1970 was devoted to field testing, production testing and sample preparation in Underwriters' Laboratories, Inc. in the Chicago area. D008S59 CONSTRUCTION PRODUCTS DIVISION ORIGINAL K&D PROGRAM (continued) Field Tests pointed up what we had noted In our develop ment phase, i.e. that Formula II65A provided lower yield than standard Mono-Xote. This fact is important from a competitive outlook and in respect to insulative properties of the new material. Fire Hazard Test at U.L. demonstrated that the presence of a combustible fiber in Formula II65A at 4.55 wt. % did not change the surface flammability of the product. It achieved the same rating as standard Mono-Kote containing asbestos. . Column Fire Test at U.L. demonstrated that Formula II65A, at approximately 2 lbs./cu.ft. heavier density than a reference column fireproofed in 1 66 with standard Mono Kote, was a poorer insulator. He are on record with U.L. engineers as stating that the density of the standard Mono-Kote was not typical of the product. He also are aware, that the use of high mix water ratios with these types of compositions will cause reduced density, and therefore we used as much water as practical during the application of Formula II65A to the column. ' Flat Plate Fire Test at U.L., which was conducted July 14, 1970, resulted in loss of bond of Formula II05A to the zinc coated flat plate in less than 10 minutes. Desired perform ance was to maintain bond 2 hours. At the request of Mr. R. Vining on July 1 7 * 1970 we have broadened our R&D approach, and have involved mere personnel in problem solution. 3eyond the strong desire to obtain an acceptable asbestos-free product is the necessity of protect ing standard Mono-Kote from close scrutiny of outside testing groups. He have seen from two recent fire tests at U . L . , as well as from 14 U.L. tests between i 960 and 1970, that our ' standard Mono-Xote has a poor performance record in respect to bond to flat horizontal steel surfaces. This new informa tion mitigates against selection of old test results as a criteria of performance of a new product. ' D008560 C -V'.*'*''/.:''-'V**'*'***"`;jVsi-'*,*'f-vV%*Jj7*'*:;i:*.<v"-*..v*..\ **v'`'< .**.**^*_..,.v*.\*.^*..v.**-**;.- -* .. *-' Vr-i*-/ />,:.?' ,'>:* 'v .''\ *. * v.S-v**'\.*-' ^ V!. :N* ,,../.vi*/*!.*. V**.'*-n"V ...v*}."-?.'V.* *'.' .* . * ; *'. v*v'. >-V:v: l'.O**.'.* -k'**..'rr,* .*. *..1 ->T-i`-.;*-V '"V W ? ;/.*7/ *;...? .* '*'* ' .. ; ` _ v # .'^ : .'/ rV -N ' - -r^ S* - ' .* ./'..y*. V . v`i*;-s<v ^ JV.V . .-*>.*;,, * ';' .'* - V.-'**.V`...' *.*" '! f '' -: . .* " * - CONSTRUCTION PRODUCTS DIVISION REVISED R&D PROGRAM (based on Management decisions) During July 28 and 29, in meetings attended by Construction Products Division personnel from Cambridge, Massachusetts Travelers Rest, South Carolina . and Los Angeles, California, as well as three representatives of Washington Research Center, the following topics were covered in detail. I. Mono-Kote Bond to Steel Because of recent results with Formula II65A, and past history of standard Mono-Kote, we are attempting to define the mechanism of bond of such materials. In this respect the following assign ments have been made and a r e .underway: (a) WRC under direction of CPD personnel " ' .. .. ..... _ will attempt to build a mathematical model of Mono-Xote performance during fire testing. In addition to the thermal and mechanical behavior characteristics of the steel and concrete deck, which WRC will obtain, CPD will provide certain data which characterize Mono-Xote type compositions. In this respect we have prepared specimens in Travelers Rest of standard Mono-Xote (MX-3) and of a new composition which is called MX-**. Six batches of these products have been made, applying each composition at three water levels. Specific data to be obtained and conveyed to WRC include - Compressive strength Modulus of Elasticity Surface hardness Coefficient of expansion Shrinkage characteristics Water requirement Yield . Density Thermal conductivity (b) ' W. R. Payment, working in the T.R. Laboratory, will conduct a series .of bond screening tests on the six compositions in (a) above, as well as on MX-4 containing bond promoting agents. These tests will be done in duplicate, using ambient and high temperature bond determinations. D008562 CONSTRUCTION PRODUCTS DIVISION V REVISED B&D PROGRAM (continued) (c) R. J. 3ragg will prepare a report on standard Kono-Xote applications at U.L., detailing all such work on MX-3 since i 960 with the object to determine optimum water requirement in respect to bond. (d) URC, as a supplemental project,has determined that the 100# flat plate deck at U.L. may be re-used by scraping the Formula H 65A off, and then removing residual traces of gypsum with a 10# solution of sulfuric acid. Three washing steps shall be used, followed by a clear water rinse. Bragg will do this cleaning job. II. Complete Review of MC-*r KK-4 is the new composition which we will test at U.L. It Is a compromise formulation, using sulfite cellulosic fiber. The primary differences between XX-4- and the previously tested. V. II05A are: . (_ (a) KK-4 uses a larger, cleaner, and lower density aggregate. \ . ___ v. t-r- **t (b) It u t i l i z e r s weighted formula^-basis which^oeemits varia . tion of /binder depending on/aggregate weight. Note: See Appendix A, 3, and C, for exact formulation of standard Kono-Xote, Formula II65A and XX~+. Regarding a review of NX-t, it was the consensus of the meeting that a successful new Kono-Xote shall be as light and resilient as possible and that, based, on data presented by R. Rothfeider on field testing and by Vi. Payment on fire testing, that MX-4- provides the most logical candidate for our next approach to U.L. The formula (Appendi:: C) was unanimously approved after . several hours of discussion-considering aggregate properties, availability of fiber and relationship of aggregate density to binder. BOOBS 63 jUi CONSTRUCTION PRODUCTS DIVISION \ REVISED R&D PROGRAM (continued) . Later data obtained at Travelers Rest confirms that has the following performance characteristics comoared to standard ::ono- Kote: ` . (a) requires 11# less mix water (b) is % lower in density (cured) (c) has low K factor (d) is about equal in cost (see Appendix) Also, as a result of negotiations by T. P. Felt at U . L . , we are permitted in MK-4 the free substitution of any vermiculite be tween 4-.5 and 8.0 lbs./cu.ft., regardless of size of the aggregate. Detailed KK-4 mixing and spraying performance is recorded in Appendix D, which indicates performance of KK-3 also. III. Proposed Test Schedule at U.L. During the week of August 17 to 21, the following test specimens will be prepared. This work is to be done by Bragg, Payment a n d ' Rothfelder, based on decisions taken during Eono-Kote meetings .on July 28 and 29, 197? ' (a) Apply KK-3 at 0.75", 1.25", and 2.0" to three 3 x 3'. pilot fire test panels to determine thickness versus heat transfer rate. (bj Apply KK-1* as above. The performance curves obtained from (a) and (b) will constitute base data from which U.L. will determine whether ` I-K-4 is equivalent. (c) Apply EK-Jr to a full scale 14* x 1 7 ' floor . . ceiling, construction comprising concrete-backed - H. H. Robertson Air Cell, supported by,an 8" wide flange beam. MK-4- will be 3 A " thick on the 100# flat plate area, and also 3A " thick on all areas of the beam. The flat plate shall . be cleaned with 10# H 2SO21 prior to fireproofing. ^008564 f k CONSTRUCTION PRODUCTS DIVISION RZ7ISFD ?.&D PROGRAM (continued) (d) In a side by side comparison, 11K-3 and '*X-4 will be applied to a- full scale. 14* x 1 7 1 concrete backed floor ceiling construction. The steel in this case will be alternate sections of fluted and flat plate. Although thicknesses are not yet decided, MX-3 will coat the deck on one side of the bean and ' KK-4 on the other. The 8" wide flange^bean will be protected with 1 1/4" of I-jX-4.* A further decision of the late July meetings was that the blend system (d) deck will be fire tested before the flat plate (c), and that if the blend deck passes the test, the flat plate deck will be tested immediately. 'Conversation with T. Feit on 8/10/70 indicates 'some advantage may be gained in using M-C-4 on all surfaces of this deck. This approach is based on information recently obtained, and we have not fully explored the possibilities. D0Q8565 - / *\V* ;. - ...>**V*v* '-1.- . >.'>. .> - ?:y **-, . K &;. *' 'r'**'* >::.v\*:*.* vr-.v*''K * .`'-V*-.. ;.<-r -r. ''*-.':r;- v*; ' . .-. ' *... 7. .*wV /' Y*. ; *-.. . -. / i"*' '*-. J S y*>,;.>;i/'T K'**:.-.T../'**.^.* 1. ;; i-/S?` ";*Y- -/V"'' ^ '-.v\ - * .. * : ': " +*t\ . ., . ' ,,}.>-. -^J V.-.'4...... ..- ::*?&>; ..." - -f\' 'v^eVW-*5*3*Mi4:-N^` - 'M . V * ~7**+. ' % * jV.?/..O. - ^ -: *..v .*%>v*-/: ' '..'V%' :.y *"-* T'*Ti.> ^ i.-"''Ku /'v. ;'.W-U;.' 7 r : v:*>.- . ^.4 v . .*. '.*...^; r' ' *^ -VVv'V''::/ : ^ -, ^ :!>' .>.. i- . ' ; , . * * - ' . ' . w V : "w./ ;r ; : \;\ ... ''5)008506  ws -A MBM DATS: .-.ur:s` ?. W. Eaton ?. Xostic (!) Cell-.-t d r sar.ples iron plenum areas In buildings in:aula ted vith ' and sprayed fibrous coatings, h'ould recuir: *-- * -- J eight sar.ples: Mcnc-Xote S cr2 .v 0 cl \sh ac^ Plenum 2 . Room Area 2 2 These samples vould then be analyzed by electron ploying Dr. Nicholson's (Kt. Sinai Hospital') tecr (2) Conduct high velocity air test vith Honc-Kote and sprayed- fibrous naterials - analyze accurately (possibly to 1/10,CiO f:r .-.eight loss. If possible it vould be helpful to direct some of the a i r passing over the sar.ple through a r.illipore filter and analyse for asbestos fibers. Scr.e air sar.ples could also bo ar.e.lyzed e'er notes- 'tos by electron nicroscopy as t* ^ On \ -- / c-~ All data to date is on I'cno-Kcte 1 a asb estos sp- J - -- mat erials for co: nil lipore f liter col lection noon.r: ve must col lect simi lar data (dur: on sprayed asbes tos fiber ccatir.g: 'Sir.r; (li) Ucinj electron microscopy vith 2r. rrioholoonrs .echnio.ue, analyze . sar.ples collected in general vicinity (one cr tvo block area' at orooorly enclosed aoplication sites for "cnc-H nous coatings. This vould involve about four (5). C-o to building site vhere some type of der.eliticn is being done on buildings fireore ofod vith sprayed r.o.tsrials and col^rtct ''0 " and electron microscope samples. The kind of data available ..ill depend upon, the 'type of edition or remedeiin.' *"An AA .A OVLGL, / K GHACS CONSTRUCTION PRODUCTS DIVISION APPENDIX A Mono-Xote > standard Ingredients. . Ho. 3 or 4 Vermiculite Gypsum Asbestos Duponal WA Dry * ' ' - Batch 212.5 lbs. U33.O lbs. . 93.0 lbs. 1.0 lb. 729.5 lbs. ^ by vt. 28.73 53.55 12.53 0.1 b ICO.CO Tolerances : Aggregate Gypsum Asbestos Duponal WA Dry - 1+.5 to 8.0 lbs./cu.ft.* ^ - ft* -i-ms ?0.''b, -- = ~ ^ u v/ - ulus or minus 5 lbs. -- v \7 - .75 to 2.75 lbs. 4 * 3I+ cu.ft. @ 6.25 lbs./c m .ft. NOIE Because volute range iron b.5 can range from is constant and aggregate to 8.0 lbs./cu.ft., the $ 22.27 to 33.75. (..l,, l/s-ij density can b y vt. value C'yi1 *A 93 l}r/S .Bragg; al, 8/7/70. D008570 CONSTRUCTION PRODUCTS DIVISION ccssir APPENDIX B Formula 1165A, U.L. Tested Ingredients No. U Veraiculite* Gypsua Cellulose Fiber (P-32) Orvus AB Batch C `( u f L ' ' b y Wt 262.8 lbs. h67,0 lbs. 35.0 lbs. 3.0 lbs. 767.8 lbs. uy.c HiT! !.T 9 1 i- 7* 3^.23 60.82 b.=6 . 0.39 ICO.CO ' ' , Tolerances; 7 None determined. lVc * 36 cu.ft. 7*3 Ihs./cu.it. R. J.Braggrnlr 8/7/70 D008571 CONSTRUCTION PRODUCTS DIVISION CONFIDENTIAL APPENDIX C Mono-Kote (MK-4), Proposed (also called Revised C.F.) Ingredients No. 3 Vermiculite Gypsum Cellulose Fiber (P-20) ASA** 188.8 lbs. 288.3 19.9 1-1 `ii ;ro 497.0 lbs. 33 % \jo L u * ^ / S 53 & ' ] Jcc v I-/.' 'T ''cJZt / 1 \\ H 1 O1 o Tolerances Prooosed: Aggregate - Gypsua - Cellulose Fiber - 4.5 to 8.0 lbs./cu.ft. plus or minus 2 / plus or minus 0.5^ '1U Cc I* `1/JS L-'1'7 /CirTZ. * 36 cu.ffc. @ 5.25 lbs./cu.ft. -be., e* r ( o -ijT AEA as needed (Orvus AB " " 2-3 lbs.) (Duponal WA Dry .75-2 lbs.) (Dupcnal MS Dry .5-1.0 lbs.) i i. t .r" b l'i >5~i- R.J.Bragg: air 8/7/70 D008572 CONSTRUCTION PRODUCTS DIVISION MASTEB FORMULATION1SHEET HO. Wet Mia 2005 PRODUCT: MK-3 . . c ; ' . INGREDIENTS EMC PER L3. $ BY .jpATCH WEIGHT FORMULA T R i #3 *@ 8.'55 pcf .0213 20U ` .0146 Fiber (71-102) .0380 Duponal WA Dry .48oo 29.35 15.730 31 & rf . 3350 58.03 31.ICO * .4540 12.50 ' 6.700 CtS "~ .2412 .12 .C67 1-5*' .0221 100.CO 53.597 . 1.0623- BULK Density RMC/Lb. $ .0198 Lbs./Bag . . 5 0 RMC/3ag .990 Conversion .475 Total Cost/3ag $ 1.465 . " # ' Yield: 20.6 3d.?t./5C# Cost/lCO Bd.Ft.: $4.7875 ' . ' . Calculated "by: W. R. ?ay=snt . on August' 7, 1970 D008573 CONSTRUCTION PRODUCTS DIVISION - . ^MASTER FORMULATION SHEET NO. Wet Mix 2002 PRODUCT: ' MK^l ' . : ! . EMC INGEEDIENTS '__'_______ PER IS. % BY ,ATC2 F02iCLA WEIGHT FORMULA. __ COST Calzoco #3 @ 5.73 pcf u zou .0213 .0116 Fiber (P-20) ' ' .1050 Duponal WA Dry .1800 3.8.08 1 1 .I60 51 .^ CaJ ^ f -.2110 58.15 17.500 `r V t . : .2535 3 .U 9 . 1.C50 .1102 CO cvj ICO.CO .C 03 "> : .0393 30.C93 8 1 9 5 3ULS Density- ' HMC/Lb. $ .0216 Lbs./Sag 50 EiC/Bas 1.080 Conversion .I75 Tote! Cost/s&s $1.555 , * * . Yield: 31.15 3d.?t./50# Cost/lCO 3d.Pt.: $ 1 . 9 3 ' Calculated by: W. P. P a r e n t on Aug. 7, 1970 D008574 CONSTRUCTION PRODUCTS DIVISION CONFIDENTIAL appende; d MK-3 Saaples Sprayed at Travelers Rest, Aug. 6 , 1970 Using Kearney No. 3 @ 6.55 P.C.7. Batch 2003 Batch 200U Batch 2005 Q) Dry Material (See Fonn.#2003) Lbs. CaSOl* . H 2O Chea. iiyd. HgO (S' Total hydrated Wt. lu>r Mix Water Total Wet Batch Cu.Ft./Batch ; (y CU.Pt./5C^ (3; A EBM/50# . . Theor. Dry Dens. Water, Lbs./50 lbs. Water, Gal./50 lbs. < * 2^ Nozzle Dens. Mixer Dens. - R. J. Bragg:alr 9 * ^ Ur>' .8/7/70 - c7fcf 53.597 31.100 5.600 59.197 /. l f 100.08 153.677 2.636 2.U6 29.52 --g*T.UU 93.363 58.3 ^ 5.5 i %.<c 53.597 31.100 5.600 59.197 *.in 116.76 170.357 2 .SU9 2.66 31.92 '----- 108.92^ 13.0 59.8 52.8 7.t 16.L .3L? 10-2G Gl.5 ye-r z2.S' // / 0 & s~ T.V.S [XC'S 53.597 31.100 5.600 59.197 ^ t *--- 108.12 162.017 2.732 2.55 30.60 -- -- 101.1 I 3 1 2 .1 . 59.3 18.1 //. -2- /$ 2- /6 1 . M ui.y i 0.0 xin DG08575 CONSTRUCTION PRODUCTS DIVISION i ROTHFELDERS SAMPLES Sprayed at Travelers Rest - August 5, 6 , 1970 Using Calzoco 5.73 PCF Ho. 3 Batch 2000 Dry Material (See Fora.#2000) Lbs. CaSOjj/-!- H2O ' Cbem. Iyd. H2O Total hydrated Wt. 30.093 17.5 3.15 33.21*3 Mix Water Total Wet Batch Cu.Ft ./Batch Cu.Ft./50# EBM/5 0 # Theor. Dry Dens. Water, Lbs./50 lbs. Water, gali/50 lbs. Nozzle Dens. Mixer A A&,J. 50.0U0 80.133 1.506 2.502 30.02 22.07 83.ll* 10.0 53.2 38.0 ..fa ir-./3 ' C] \\i. tc.VT' R.J.Bragg!!aly 8/7/70 . o1t ,L1tn .m tfc-y 0-1 7 Batch 2C01 30.093 17.5 3.15 33.21*3 60.860 90.973 1.710 2.841 3l*.09 19.38 101.153 1 2 .1 53.2 1*3.2 /i C ic 50 ip 7 3 3atch 2CC2 30.093 17.5 3.15 33.2^3 55.1*60 85.553 - 1.573 2.621 31.1+5 a .c s 92.11*7 11.0 51+.2 1*0.2 /v <- i f .IS 33- T-) 1-7 1 l t -c) J C S / D008576 EFFECT OF MIX WATER ON MIXER DENSITY OF MK-3 AND MK-4 DQ08577 EFFECT OF MIX WATER OX NOZZLE DENSITY OF MK-3 AND MK-4 " -----------!-------------------- 1____________l ____________!____________ -- .52 5^ '56 53 60 . ' . WET DENSITY NOZZLE (P.C.F.) ' D008578 EFFECT OF MIX WATER ON DENSITY OF i-X-3 AND MK--4- THEORETICAL DRY DENSITY (P.C.F.) D008579