Document rxj3jEZ72kw5YnkMno0NRJZEv

' N l FACTS AND FIGUHES ON ASBESTOS (INCLUDING FRICTION PRODUCTS) c c HFM - 003371 Vahlale BcgUmr!TM August 1977 ^ SCF-ALLF-06640 SO01 1600 I CONTENTS Description friotion Materials Gaskets and Packing Asbestos Industry Raw Material Fabricators Supply/^)eoand U.S. Supply and Demand Forecasts . ' Long Tens Soares of Supply C Friction Materials Use Plants Future Projections Materials Alternatives &nisalons Attachment I Fiber Grades Automotive Applications Distribution by Grade Cost HFM - 003372 8001 J.601 I I asscRiPTian The varieties of asbestos most used commercially are ohryBotile, amosite, croci- dolite and anthrophyllite. Chrysotile accounts for approximately 95? of all asbestos consumed ootmerotally and is of the serpentine group of fibers. Other varieties are of the amphibole group of fibers. While varieties differ in chsmioal oexpositions, they share a similar structure of linear chains of sili cate tetrahedra* The following represents the approximate chemical formula for each variety) Chrysotile Croeldollte Amoslte Anthrophyllite 3MgO 2S10& 2H20 HagO FegC>3 3Fe 0 83102 HgO 1.5 HsO 5.5 FeO 8Si02 H2O 7MgO BSiOg H2O The properties of asbestos that give it commercial value are its fibrous struc ture , the great strength of its fibers, its resistance to high temperatures and to certain types of chemical attaok and electrical conductance. Thermal stability is limited by asbestos metamorphosis, at specific fusion points, to other mineral forms. Asbestos is graded by fiber length in nine groups. Group 1 and 2 are a longer, unmilled crude form. Group 3 thru 9 are progressively shorter and constitute "milled asbestos". Price decreases from long to short lengths or grades (Attachment 1) The lover limit for economical asbestos production is 4$ asbestos containing ore. Canadian reserves presently average 6g asbestos. As mine age increases, the per cent of fiber recovery decreases. Friotion Materials The properties for vhioh asbestos is used in friotion materials include its capa city for tharmei stability, its ability to act as a reinforcing agent, as a filler, for the regulation or inhibition of resin flow, its lover abrasion than other fillers of its prioe range, and its dispersion of metal chips and other particu lates. Fiber lengths of #4 to 7 dominate the friotion materials. P"fv*ng Chrysotile use in gaskets and packing is accounted for by its strength, resiliency, durability, toughness and thermal stability. Fiber length ranges from grades #4 to 7. I ASBESTOS INDUSTRY I Bay Material ITom 1971 to 1975 between 80-85? of the asbestos consumed domestioally was imported. Of the imported asbestos nearly 96? orginated la Canada. The segment of the industry is usually located geographically next to the mine. The mines and 8001 1602 HFM- 003373 2, Bay Material (continued) mills are owned and operated by the same parent corporation. Four corporations (Johns-Manville, RaybeatoB-Manhattan, Jim Valker and Asaroo) not only eontrol large mining interests In Canada, but also nearly 35$ of the American asbestos products market. Asbestos fiber mined in California (8o asbestos) is generally too short to be utilised in friction and related formulations. Ford suppliers for the most pert purchase fiber from Johns-Manville, Quebec. As of 1975., 835000 short tons/yr. of fiber produolng oapaolty existed at this location. In manufacturing, six firms control 50$ of the market. (Economio Information Systems, 1976) Estimated 1975 Company____________ Johns-Manville Corporation Asbeatos-Produot gaJdtfJiimsB). 2$o Approximate % Baybestos-Manbattan 140 10.5 GAF 114 8.5 Bendlx Jim Valker (Celotax) Armstrong Cork 72.5 71 60 Asbestos products manufacturing plants are characterised by a high degree of specialisation. The typical plant is apt to be a single-product operation C whose product is geared to a specific Industry. The U.S. Bureau of Census identified 23 establishments manufacturing friotion materials. Twenty-one of these constituted 73% or more specialisation. A survey of asbestos manu facturing facilities reveals most plants employ over 100 workers. Differences in plant oapaoities are therefore determined by installed machines, automation eto. U.S. Supply and Demand U. S. asbestos supply Is a combination of Imports, domestic mine production. Industry stockpiles and government stockpile releases. The importance of such is illustrated by data from the U. S. Department of the Interior, Clifton, 1975. Thousand Short Tons - 1974 Components of U.S. Supply Domestic Mines Government Release Imports, Chrysotlle Imports, Crooldolite Imports, Amosite Industry Stocks Jan 1 TOTAL 113 29 747 11 8 103 ion 803-1 1603 HFM - 003374 (Continued) ______________________ Thousand Shcrt Tone - 1974 Distribution of P.3. Supply Government Acquisition Industry Stock Deo 31 Exports . Industry Demand S. Demand Pattern Friction Produots Packing and Gaskets Total U.S. Demand (inoludes all asbestos produots) - 103 62 846 80 29 846 Forecasts D.S. Departnent of Interior, Clifton, 1975* projections to year 2000 for friotlon and gasket materials are given in thousand short tones Friction Produots Gaskets and Packing 2m 79 26 Forecast Base _ 150 75 FCreoaat Ranee leu Mek 0baUg 110 144 75 75 118 66 bong Term Source of Supply - 1976 Data Canada U.S.S.R. So. Afrioa So. America An Other 1,700,000 Tons 3,000,000 Tons 400.000 Tons 80,000 Tons 800.000 Tons Presently identified sources for future growth (over the next 10 years) ares U.S.S.R. So. Amerloa Afrioa Mexioo Europe 500.000 Tons 60.000 Tbns 100.000 Tons 50.000 Tons 100,000 Tons Worldwide production of asbestos fiber has Inoreased from 4,330,000 tons per year in 1965 to 5,960,000 tons per year in 1976 (3$ par year). Duo to the maturity of the asbestos industry the yearly growth in supply and demand is estimated to be 2.5-351. HFM - 003375 8001 1604 4, tPRICTION MATERIALS! Friction materials are used in practically all industries as a key component in dutches for transmitting torque, brakes for slowing down or stopping motion, or as torque limiters. Asbestos is an important Ingredient in friction material products because it imparts strength, good friction properties, can withstand high temperatures and is a good Insulator* Iss - U.s. demand far asbestos In friction products has ranged from 65-80 thousand short tons from 19&-1974. This amounts to approximately 9% of the total U.S. asbestos consumption. U.S* Bureau of Census figures Indicate during the five year period from 1967-1972 the shipment value of asbestos friction materials increased by 49%, compared to the 23% increase for the four year period from 1963-67. Asbestos brake materials aooount for 69*6% of the total value of asbestos friction materials. Plants Eight manufacturers accounted for nearly 75-80% of the total estimated sales of asbestos friction products in 197? (Beanomic Information Systems, 1976, Margolin and Xgwe). Company Raybestoa Plant Location Conn., Pa., Ind., Calif. 1975 Estimated Sales ( $ Million) 110 Bendlx H.X., Venn. 72.9 ibex Chlo, Mich., Va. 60.1 GM. Chio 30 H.K. Porter Ind., . 26 Chrysler Mich. -- Borg Warner Illinois -- World Bestoe Indiana 18.8 As would be expected for a mature industry, most of the plants aid equipment are old, usually over forty years of age. Production processes have changed only marginally over the years, and labor rather than capital Intensity appears to the norm in most of the older, plants (Margolin and Xgwe, 1975)* Future Projections Asbestos demand for friction products is projected to year 2000 at an annual growth rate of 1.9%. Based on the forecasted number of vehicles to be produced in the year 2000 (approximately double 1973 production) and on the assumption that the use of asbestos per vehicle will remain at present levels, asbestos demand in vehicles is 8001 *605 HFM - 003376 5 projected to 118,000 tons. In addition to using asbestos In brake liningb, oars equipped with automatic tranaolsalons get their drive from metal transmission dlses which are covered with a super-tough asbestos paper. The average vehicle contains 8-12 of these. Output of over o million automatic transmissions require asbestos disc paper production In hundreds of tons. Materials The average composition of a typical automotive brake lining Incorporates asbestos, phenolic resin, cashew-nut shell, graphite products (to lower the friction coefficient or reduce noise), aluminas or silicas (to Improve wear), and metal dr metal oxides (Improved performance). A typioal formulation would incorporate the following: Asbestos Basins Oxides Metals Carbon 55 28 9 3 5 Uterafttarag ia AateaSse Possible asbestos alternatives for friction materials include the following: glass fiber Overall strength is lower but strong enough for friction materials. At temperatures during braking operations glass fiber melts, even below the operating surface. steel wool Overall strength is lower and the cost is higher. In addition, the material hardness of steel wool damages the brake drums. mineral wool Overall strength is very low and brittle to the extent of limiting mixing processes. carbon fiber Main properties are good, but somewhat inferior to asbestos. A major consideration is cost, which is more than asbestos. sintered metals and cermets Presently used to manufacture brake linings for aircraft. Wear properties are not good enough ar automotive applications and the cost is higher. Asbestos Balssloas The major effect of braking appears to be in separating bunches of fibers and reducing their average length. Brake lining debris contains a high percentage of fiber shorter than 2 urn, with a substantial portion shorter than .5 urn. Asbestos remaining In the brake lining is converted by thermal or other physical processes Into , magnesium silicates or other re-crystallised magneaium silicate structures differmt from asbestos. a Pool 1606 HFM - 003377 (SSI <V ASBESTOS FIBER nninw mm tv ai ATTACHMENT 1 rE APPLICATIONS Product Asbestos Fitor-Maa Approximate Asbestos Content figflKftte "Sbeeter" "Beater Ad" 4t, 5K PB #5 (Similar to 7D Fiber Grade) 70-75* 80-85* Mks& Linings DiSCfl Clutch PaeinH Woven 7F, 7, 7M 5K, 5R 3T Transmission Banda Asbestos Paper 52, 7R PlaBtlo Fillers 7K, 7T, nr Sealants ( BQd9rfi.gayjiga 7R, 7TF 7RF 50-65* 45-^0* 65-70* 80-90* Dp to 40% 5-10* 15-25* Asbestos Distribution (Short Tong) hr Grade Grade 1 2 3 4 5 6 Chryflotlle Crocidolite Amosite Anthrophyllite Total Asbestos Frlotlon Produote ` tm 5600 1300 29,500 6300 36600 79300 200 79,600 . PAMfflLJWdJteflfcat.ff, 100 1900 7500 7500 1400 10,300 28,700 100 28,800 D 8001 1.0 7 HFM - 003378  attachmist i ASBESTOS FIBRE PRICE INCREASES SINCE 1970 Asbestos Grade Lang Fiber_ ( V Short Fiber 3T 4T 5K 5R PB #5 7F 7H 7K TH 7R 7T 7RF 7TF flwnwrr IWQ 425.50 216.00 184.00 156.50 83.50 85.00 72.60 59.70 53.60 50.50 48.40 52.00 52.00 Average Annual Compound Percentage Increase fegflflBfe 1,093 561 ' 434 368 14* 14# 1356 12# 178 . 168 11# 10$ 139 10$ 117 10$ 106 10$ 99 10$ 97 10# 98 9# 98 nrsllt*f During the siztiee there were virtually no prioe inoreaees. The price, during that baaed upon oonotant dollars, aotually vent down. f. Information in Attachment 1 supplied by Johna-Kanville HFM- 003379 8001 160-9