Document rek4v2E1q9aJOVxG0k8yp2Nv7

UL i/4U| INTERNAL CORRESPONDENCE PLAINTIFF'S EXHIBIT UC-364 UNION CARBIDE CORPORATION 100 OCEANGATE, LONG BEACH. CALIFORNIA ? to (Name) Division Location R. E. Byrne, Jr. Metals Division Niagara Falls, NY Copy to w. C. Thurber, Danbury G. M. Lincoln, Pittsburgh D. F. Kapral, Niagara Falls G. L. Dickson, Niagara Falls J. E. Walsh, Atlanta B. L. Ingalls, Niagara Falls J. L. Myers, King City Date originating Dept. December 17, 1982 Market Development Answering letter date subject PRODUCTION TRIAL INTERNATIONAL BUILDING PRODUCTS NEW ORLEANS, LOUISIANA / /? / iv p On November 18th, a trial was conducted at International Building Products using 7 drums SG-100 Filter Cake in asbestos/cement sheet. The attempt was to replace a 10% asbestos formulation of 2/3's Grade-6, and 1/3 Grade-7, with 14% SG-100 Filter Cake. This replacement formulation was based on the results provided by the Ontario Research Foundation, Ontario, Canada. Their results on Bauer McNett testing of Filter Cake indicated a UCC Canadian equivalent of 6-D or 5-R. However, the production trial indicated that the results of that test were not applicable to our fiber. The production trial was made on a 1/4", 4' x 10' asbestos/cement sheet. Under normal production conditions (2/3's Grade-6, 1/3 Grade-7) the sheet is released from an accumulator roll every 12 & 1/2 seconds onto a moving screen. In our evaluations, more often than not, the sheet did not remain together once it left the accumulator roll. The inability to successfully form a sheet is called poor Wet-Strength or Green-Strength. This is caused by the asbestos fiber having insufficient length to hold the sheet together. To overcome our poor Wet-Strength and to produce an acceptable sheet, machine speed was decreased and a sheet was then formed every 25 seconds vs. the norm of 12 & 1/2 seconds. International Building Products. This is not acceptable to Although we had failed the production evaluation there was still some optimism that on the product successfully produced the strength test would indicate a high modulus because of our higher than average surface area of 29,000 cm^/g. However, on December 9th, the results of the strength test became available, and the results parallel the data from Ontario Research Foundation. 2 These results indicate that the data from Ontario Research Foundation and the actual testing of finished product at International Building Products that the SG-100 Filter Cake produces an A/C sheet with a strength value of less than a Canadian 7D. This indicates that we cannot be the sole asbestos in this large volume application. We could be a source for the Canadian 7D, but according to International Building Products they are purchasing that grade at a delivered price of $238.00/ton. That price shows the result of heavy discounting, because of high inventories, as the 1981 published price of 7D is $250.00/ton, F.O.B., Canada. A second trial is to be held in mid-January using the balance of 3 drums Filter Cake and one ton SG-103. This production trial will be made on "Monolithic Board". Machine speeds are slower, sheets are thicker and several are laminated together to form a finished product 1" thick. End use is laboratory counter tops. Normally, Canadian 7D is used in this formulation. However, International Building Products does not anticipate the previous production problems. The volume of asbestos used in this application is much smaller than that used in the A/C sheet. The continuing research work currently under investigation in Niagara Falls on Overburden, Ore & Tailings could prove to be applicable in this market area. Its use could be as a low cost filler to compete with Canadian 7D. Of course, this would all have to .be proved in both Ontario Research Foundation and actual successful production trials. TPN;vc -0108B- T. P. Norris CM ca CEMENT