Document wKB3oKdwY3gzk832jkVedEbLd

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PAOLI LABORATORY RESEARCH A2JL) DEVELOPMENT REPORT PERIOD OP JANUARY 1963 THROUGH .TUKE 1963 T/J3LE OP COrJTErJTS Page 1................... .... . . .Picture of Test Illustrating Ilow Glass Fibers Improve The Fire Endurance of Gypsum Board Page 2........ ..Forward Page 3........ .Market Performance of Mew Products Patent Information Page 4........ .Projects Completed - Stud Adhesive I; C; D 201 Page 4..................... .... .Projects Completed - Foam Glass Pellets k Ci D 210 Page 5........ .Projects Completed - Acoustical Tile R M D 246 Page 6...............................Projects Completed - Super Firesaop R & D 241 Projects Completed - Laminating ComDound l; C> D 209 Peee 7........ .Projects Completed - Statistical Control ' R 0 D 239 Projects Completed - Blue kanids Dust Collecto. k U D 238 Projects Completed - 2 Hour Fire Rated Par tition R M D 251 ........Page 8 .Projects Completed - 2 Hour Double Solid Partition ROD 252 Projects Completed - Effect of Glass Fiber In Board k o D 210 PC.0G 9 Projects bearing Completion - Thiucoat blaster R 1 D 219 J4 TABLL CF CO?JTiJTS Page 10 ..... . .Projects Hearing - Glass Fiber Reinforcenen*: Completion II E D 210 Projects Hearing - Texture for Cne Day Join-: Completion Compound H E D 243 Projects * tearing - Fire E Sound Tests - Completion R E D 249 Page 11................... .... .Projects Hearing - Grinding Methods - R E D 2:>J Completion Page 12 ...... . Projects Underway - Extrusion Process For Board R a D 21 " Projects Underway - High Expansion Densite R E D 132 Projects Underway - Ran Process Plaster -RED 132 Projects Underway - Tooling Densite - R E D 132 Page 13.............................Projects Underway - Hater Repellant for Sheathi.n RED 203 Projects Underway - Synthetic Joint Compound RED 211 Projects Underway - Texture for Masonry Ceilings RED 211 Projects Underway - Mummer System -RED 209 Page 14.............................Projects Underway - Synthetic Gypsum I. E D 221 Projects Underway - Pre-Fab Panels RED 223 Projects Underway - Trowel Finish Plaster -RE. 228 Projects Underway - 1" Core Board -RED 229 Page 15 ..... . .Projects Underway - Radiant Heating Panels RED 235 Projects Underway - Volumetric Stucco Feeder R E D 240 Projects Underway - Lightweight Rocfdeck Unit RED 242 Page 16 Projects Underway - Grabit - R u D 244 . rojccts Jndcn.'ciy - 1/4" 2 Tx2' Coaling aiie R E i) 246 TARLi- OF CO.TmnS Page 16 . .........................Projects Underway - Continuous Calcination n u D 253 Projects Underway - Imrerforn Paper - r. O D . 254 Projects Underway - Lirjhtweiglit Gypsun hoard K-ii D 255 Page 1T............................ .Projects Underway - One Hour Floor 0. Ceiling L Ci D 256 Projects Underway - Ilof-Hor Panel Fire Test IUD 257 Page 18......................... .Projects Underway - Donn Clip-On Stud - I', u D 258 Projects Underway - Sound Deadening Constructic - I; ti D 260 Pages 19-21 . . . Pictures to Illustrate the Effect of Glass Fibers in a Gypsum U'&llboard Core Pages 22-24 . . . . Pictures Showing Thincoat Plaster Application FORWARD Tills report covers the activities and accomplishments of our research program for the past six months. No basic changes in or ganisation have occurred during this tine, vie have,however, begun to assign projects to a single individual rather than dividing the responsibility between two people. The former approach was being utilized until such time as the new men bad gained sufficient ex perience and had become familiar with our procedures. At least one priority project has been assigned to each man as well as other pro jects of lesser priority. Each man is responsible for maintaining progress in his assigned projects. Assistance is provided where ne cessary by contacting the group leader. A budget was put into effect in January 1963 in order to make available a record of the total expenditure for R&D and the amount spent for each project. The budgeted versus actual expenditures axe being reported quarterly. These will be studied to determine whether our emphasis is being placed in the proper areas and whether our money is being spent wisely. This year's figures should give us a good ba sis for preparing next year's budget. Tlie field testing stage of our development programs was revamped during the past 6 months. There have been a number of instances where we have gained little or no information from trials. Another problem has been the difficulty we have had in obtaining field tests. We have brought this problem to the attention of the Sales Department and solicited their cooperation in planning a more effective field testing program. After several discussions, it has been decided to institute a standard procedure for requesting, conducting and report ing results of field trials. To simplify the reporting, a standard report form and follow-up form have been prepared. We trust that these measures will enable our field testing to be conducted more effi ciently in the future. Included in this report are the market performance of products developed through research, patent information, and some pictures illtis trating the effect of glass fibers in gypsum. The latter are to be used in promotional literature. Hie major portion of the report is, of course, devoted to the progress of the various projects. -2- MAIUCET PERFOrJlAIJCE OF WEVJ PRODUCTS JANUARY THROUGH JUKE 1963 Ip FIRESTOP 120 CEILING TILE Amount Sold -- Dollar Sales Volume - Gross Profit -- 122,000 sq. feet $16,215 $ 5,349 Amount Sold -- Dollar Sales Volume -- Gross Profit -- 9 Tons $ 1,739 $ 1,019 3, ONE DAY JOINT COMPOUND Amount Sold -- Dollar Sales Volume -- 'Gross Profit -- 634 Tons $113,953 $ 33,063 Total Sales Volume of New Products Total Gross Profit of New Products Estimated by Ardmore Cost Department $131,907 $ 39,431 PATENT INFORMATION Patents Issued: None Patents Applied For: Method of Processing Synthetic Gypsum Patent Applications Deing Prepared: One Day Joint Compound Grabit .'-iasonry Adhesive 3 PJl0.r3CTS MEAKI.3G completion 1. Thincoat Plaster - R Ct D 219 Objective: To develop a conpetitive thincoat lath and plaster system. Status of Investigation: Tlie original objective v;as -co have one product tor both smooth and textured surfaces. Such a product was developed and field trials were commenced. It became appar ent during our field testing that smooth finishing properties itfere more important and textured finishes appealed only in cer tain markets. In view of this a second formula was developed in which the texturing properties were sacrificed in order to improve the smooth finish application. This product was found to be much more acceptable for those who desired a smooth surface. The for mer product will be retained for use where textured surfaces are desired. A number of successful field trials have been completed and we have recommended that both products be released for sale in limited markets. Our thincoat plasters have certain advantages over other thincoat products, and can be priced competitively uhi:.e still maintaining a favorable profit margin. Paralleling the thincoat plaster development were our efforts tc impart the proper suction characteristic to our T. C. pinliolath.. This has been resolved to the point where all plants are capable of producing a satisfactory lath to be used with our thincoat nla-* ter. Advertising photographs taken during one of our field trial:, axe included in this report. 2. Ready Mix Joint Compound - R Ct D 211 Objective: To develop a ready nixed or paste type joint compound to be conpetitive with other sinilar products on the market. Status of Investigation: Several field trials of a product con taining a dry binder system have been conducted. Other than a few adverse comments on workability, the performance of the pro duct has been satisfactory. On the basis of the trials, we re ceived orders for 1500 pails of the product. The economics of cu.ready nix are still not completely favorable, and we axe striving to improve this situation. Ue are soneuhat limited in this direc tion because the fixed costs of the container and the freight rep resent a large percentage of the cost cf the product. This leaves the formula and the processing for us to work on. Ufc are even limited here as the improvement in both of these areas is limited since certain possibilities for cost reduction v;ill require lar, e initial expenditures for equipment, judging from tlie emphasis Sales has given this project, it appears imperative that we con tinue to seel: a practical solution to the problem, our present thinking is that if we could install a small operation with mini mum expenditure, it would enable us to effectively assess the mar ket potential as well as possible cost savings. This would roqai : that Management approve a low profit item, even if only on a cevn orary basis. Cased on this experience, the market potential then dictate the wisdom in considering certain equipment expend*., tures necessary to improve the profit margin. -9 I PROJECTS NEARING COMPLETION 3* Glass Fiber for VJallboard Reinfoxcement - R & D 210 Objective? To be able to approve several types of glass fiber, particularly 799 (Muzzy Mix) for use in our wallboard. Status of Investigations Fran this evaluation of fiber types vre found that iypes 710, 804, and 799 all were better than the 863 we were using because of improved dispersion characteristics, and that 799 was a special improvement because it offers greater re inforcing value per lb* of fiber* This evaluation has progressed to the point where all of the glass fiber used in our board is either 710 or 799* This work then became intermeshed with an investigation being conducted by the Manufacturing and Process and Control Departments to evaluate the effect of paper fiber. It was found that the regular amount of 799 glass fiber was equivalent to the standard amounts of paper fiber and 863 glass fiber. Seme trial runs were made at Wilmington, but due to cutting problems with 799 fiber, an increased amount of 710 fiber was used and the paper fiber eliminated. Doing away with the paper fiber appears to permit machine speed increases on the order of 10% without changing the characteristics of the board. This will be carried further at other plants* In the meantime, 799 glass fiber is still a superior fiber and we axe continuing with our effort to enable all plants to use it. Improved quality or further cost savings, or both, are inevitable through the use of the 799 binder glass fiber. 4. One Dav Texture Problem - R & D 243 Objective: To find a means of eliminating the need for a primer over one bay Joint Compound prior to texture application. Status of Investigation: The sale of One Day has been limited because we have bad to "recommend a primer prior to any joint system texture application. National Gypsum has issued a simi lar precaution because of the same drawback to their setting type joint system. Two approaches have been studied. The first is to develop a texture which will do its own priming, and the second is to develop a topping which will alleviate the necessity for priming regardless of the texture used. After considerable experimentation, a texture has been found which we believe will eliminate the need for the primer. The development of a topping for use over One Day has not been completed as yet. lie are pro ceeding with field trials of the texture as quickly as possible, since we feci this will greatly enhance the sale of One Day Joint Compound. 5. Accumulation of Fire and Sound Test Data - R & D 249 Objective; To gather all available fire and sound test data on the various constructions and put it into a usable reference form. - 10