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BESTWALL GYPSUM COMPANY SEMI-ANNUAL RESEARCH AND DEVELOPMENT REPORT JULY 1, 1963 TO DECEMBER 31, 1963 Table of Contents Page 1 .................................. Foreword Page 2 ........ Market performance of new products, patent information Page 3 ..................................Projects Completed - Thincoat Plaster - R & D 219 Page 4-5............................. .... Dens-Cote Pictures Page 6 ... ....<> Pre-Fab Panels - R & D 223 Acoustical & Ceiling Tile Products R & D 246 Page 7 .................................. One Hour Rated Wood Floor & Ceiling R & D 256 Page 8 .................................. Predecorated Wallboard - R & D 215 Owens Corning Projects - R & D 210 Page 9 ........ Grinding Industrial Plaster - R & D 250 Page 10 .................................. Accumulation of Fire & Sound Test Data R & D 249 Page 11 ......o Projects Nearing Completion - Joint System Textures - R & D 261 Page 12-13 ........ Texture Pictures Page 14 .................................. Ready Mix Joint Compound - R & D 211 Hof-Kor Panel Fire Tests - R & D 257 Page 15 .................................. New Ribs for Hummer Systems - R & D 209 Projects with Donn Products Fire Rated Columns - R & D 270 Page 16 ............................. .... One hour rated concrete floor & ceiling SGP 0015306 TABLE OP CONTENTS (CONT'D) Page 17 . Projects Underway Extrusion Method of Porming Board R & D 21 Tooling Densite - R & D 132 High Expansion Densite - R & D 132 Ram Process Plaster - R & D 132 Page 18 , Owens Corning Projects - R & D 210 Synthetic Gypsum - R & D 221 Page 19 . Radiant Heating Panel - R & D 235 Strong-Scott Calciner - R & D 236 Page 20 .. Volumetric Stucco Feeder ~ R & D 240 Continuous Calcination - R & D 253 Inverfora Paper - R & D 254 Page 21 ... Lightweight Gypsua Board - R & D 255 Insulation Board & Gypsum Board R & D 260 Page 22 Density Gauge - R & D 262 Calcination & particle size studies R & D 263 Water Resistant Board - R & D 264 Page 23 Moisture Recorder - R & D 265 Pirestop 120 Ceiling with openings R & D 266 Wood Grain Paper - R & D 268 Page 23-24 ........ Plastic Coated Wallboard - R & D 269 Page 25 . Summary SGP 0015307 > - FOREWORD This report covers the activities and accomplishments of our research program for the last six months in 1963. Our personnel was changed somewhat when Mr. E. A. Smith left the Company in August to attend medical school. Mr. N. F. Mbrrone was transferred from the Quality Department, bringing the Research Division back to six men including the writer. We believe that Mr. Morrone's talents can be put to broader use in the Research Division. On the basis of the record of last year's R&D expenditures, projects presently underway and future projects being contemplated, a budget for 1961; was prepared and submitted to Management. * The purpose of the budget is to have a record of the expenses, and to see that our money is wisely spent. Our total 1964 Research expendi ture is expected to approximate $15?0,000. Included in this report ris the market performance of products which have been developed through research. The fire ratings and other technical information developed for Sales and certain product improvements cannot be elearly assessed. However, we trust that these accomplishments have made us more competitive and therefore have favorably affected our Sales. The major portion of the report is devoted to the progress of the various projects. For clarification, it is separated into three sections: (1) Projects Co*"pleted (2) Projects Nearing Completion (3) Projects Underway -1- SGP 0015308 MARKET PERFORMANCE OP NEW PRODUCTS JULY TBRU DF.CE**BER 1963 PRODUCT 1. FIrestoo 120 Tile 2. Grabit Adhesive 3. One Day Joint Compound 4. Ready Mix Joint Compound 5 Dena-Cote Plaster 6* Dens-Cote Tape 7a Dens-Cote Base (T.C,Lath)* 8. l" #8 Drywall Screws SALES VOLUME MILL BASE SALES 95,000 sqft. $ 13,572 37 tons 6,899 388 tons 61;, ?01 482 palls 2,136 67 tons 3.891; H;52 rolls 1,452 214.0,000 sq.ft* 9,720 372 boxes 1.098 $103,272 ESTIM GROSS V $ 4,37 3,97 18,29 6 1,22 59 3,62 28 $32,41 *Arnount of Dens-Cote Base which normally would be sold with 67 ton of Dens-Cote Plaster0 Actually, increase in volume of Dens-Cote Base over the first half of 1963 was 220,000 sq. ft* PATENT INFORMATION Patents Issued - None Patent Applications Submitted (Method of Processing Synthetic Gypsuri (One Day Joint Compound (Grabit Adhesive Patent Applications Being Prepared: Synthetic Gypsum (Canadian) Continuous Calcination (2) -2- SGP 0015309 rwoau^j nannuacr o wnriLiiyriUfl JOINT STSTEM 3PKAY TFXTtTRES - R & D 261 Objectivet To develop pre-aggregated textures far addition t o our line of Joint System products* Another objective Is to eliminate the necessity for a primer over surfaces whore One Day Joint Compound is used prior to texture applications. Three new products and one improved product are our goal. The new products are: 1. Simulated Acoustic Texture 2. Sand Finish Texture 3. Masonry Spray Texture Our standard texture is to be improved so that it will hide One Day Joint Compound and Topping Compound and can be hand or spray applied. Investigation: All four products have been formulated and appear to give the desired finish. In addition* Laboratory tests show that all of these products will hide applications of One Day where a final coat of topping compound is used in conformance with sped fications* In addition, all of these textures will be whiter than competitive products and have excellent application properties. The plain texture, in particular, has been tremendously Improved to the extent that it hides as well as paint and has versatility in making a variety of textures possible from the one product. The type of surfaces possible with this texture, as well as those from the simulated acoustic and sand finish products, are shown in the attached photographs. The masonry spray texture also requires that It have rust inhibitive properties. There is no similar co^oetitive uroduct, so this will be a first for Bestwall, If this texture Is successful in actual use. Thus far, very few trials have been made. A number of trials whic were scheduled were either postponed or cancelled during the re organization of the Sales Department. A limited release for the plain, sand finish, and simulated acoustic textures is being considered, in order to exoedits the field performance evaluation. Texture produota represent only of our Joint System s3.es, and it is felt that this figure should be as high as 10$. We believe these new textures will help bolster our Joint System sales. - 11 SGP 0015310 PLAIN TEXTURE (Ho Aggregate) RdUer Stipple Finish Brash Swirl Finish Spray Orange Peel Finish SGP 0015311 AGGREGATED TEXTURES Spray Application Sand Finish r. SGP 0015312 13 2. Ready Mix Joint Compound - R & p 211 Objective: To develop a ready mix or paste type joint compound to be competitive wifchoetSsr similar products on the raarketo Investigation: A formula utilizing a dry binder was developed and field tested. The field reports were favorable* Even thoug! the economics were not completely favorable, a small facility In Akron was approved to furnish the requirements of a large Detrol job. Unfortunately the contractor ultimately decided to use dry joint system on this job* As a result, only about 500 pails of ready mix were sold from Akron, whereas preparations had been made to furnish 3000 pails. We did not gain much from this United experience, but It did tell us that there is very little potential for ready mix In the area served by the Akron plant. The purpose of the dry binder as opposed to an emulsion binder was to eliminate the necessity for purchasing tanks, pumps, etc* to handle the emulsion. Other means have been found to purchase and handle emulsion which do not require the large Investment for equipment formerly required. The emulsion formula offers a possible saving of 30j per pall. Costa using this formula have been worked out, and the economic picture is Improved but still is not too favorable* Some of the poorest areas economics! (Atlanta, Chicago, and Vest Coast) have the best potential markc wise, according to field surveys. On the other hand, the best areas economically (Akron and Acme) are the poorest market-wise. However, every year ready mix makes more Impact on the joint system market and becomes more of a competitive factor. This competition Is important insofar as joint system sales are con cerned, hut even more important Is its Influence on board sales. The future course of this project Is undecided at present, but It Is felt that it will be only a question of time before we are forced to meet this competition. 3. Cooperative Tests on Sof-Kor Honeycomb Panels - R & D 257 Objective: To test n partition of Hof-Kor prefab panels consist fng of a paper honeycomb core faced with 5/8" Pirestoo Eternawal! to achieve one hour rating. Union Bag-Camp Corporation, the man? facturer of the honeycomb, is sharing in the cost of this test. Investigations On the second try, the fire endurance test was passed. However, two hose stream tests have failed due to inabi of the fasteners to hold the board in place. The probable cause are: the small heads of the Kolorpin fasteners, and the trappln of moisture in the board core by the vinyl facing, and the limit number of fasteners. Larger headed Kolorpin fasteners have been located, hut It has not yet been determined whether there is cufl'itjient Interest to make another try to pass the hose stream test. The Sales Department is to advise us of their further interest. -- Tli -- SGP 0015313 PAOLJ LABORATORY RESEARCH AMD DEVELOPMIilJT REPORT PERIOD OP JANUARY 1963 THROUGH .JUNE 1963 TABLE OP CO.'JTENIS Pane 1 Page 2 Page 3 Page 4 Page 4 Page 5 Page 6 Page 7 Page S Page 9 ,, . . .Picture of Test Illustrating Ilow Glass Fibers Improve The Fire Endurance of Gypsum Board <. . .Forward . . . .Market Performance of iJew Products Patent Information . . . .Projects Completed - Stud Adhesive IiiD 201 . . . .Projects Completed - Foam Glass Pellets K & D 210 . .Projects Completed - Acoustical Tile F; A D 246 ,, . . .Projects Completed - Super Firestop R t D 241 Projects Completed - Laminating Compound li & D 209 .Projects Completed - Statistical Control R & D 239 Projects Completed - Blue R&nids Dust Collectc K u D 238 Projects Completed - 2 Hour Fire F.ated Par tition Ti h D 251 . . .Projects Completed - 2 Hour Double Solid Partition R 11: D 252 Projects Completed - Effect of Glass Fiber In Board R P: D 210 . . . .Projects bearing Completion - Thincoat Plaster R R D 219 SGP 0015314 TABLli OF COHTEiJTS Page 10 ..... . .Projects Hearing - Glass Fiber Reinforcenen-; Completion R E D 210 Projects Hearing - Texture for Cne Day Joiiri Completion Compound R Ci D 243 Projects Hearing - Fire E Sound Tests - Completion R li D 249 Page 11 . . . . .Projects Hearing - Grinding Methods -RED 2:5 Completion Page 12 ..... .. Projects Underway - Extrusion Process For Board R a D 21 Projects Underway - High Rxpansion Densite R a D 132 Projects Underway - Iian Process Plaster -RED 132 Projects Underway - Tooling Densite - U E D 132 Page 13............................. Projects Underway - Water Repellant for Sheath; R E D 203 Projects Underway - Synthetic Joint Compound R E D 211 Projects Underway - Texture for Masonry Ceiling R & D 211 Projects Underway - Mummer System -RED 209 Page 14....... Projects Underway - Synthetic Gypsum RED 221 Projects Underway - Pre-Fab Panels RED 223 Projects Underway - Trowel Finish Plaster - RE. 22S Projects Underway - 1" Core Board -RED 229 Page 15............................. Projects Underway - Radiant Heating Panels RED 235 Projects Underway - Volumetric Stucco Feeder R ci D 240 projects Underway - Lightweight Rocfdeck Unit RED 242 Page 16............................. l-rojects Underway - Grabit - R ci D 244 .rojccts Underway - 1/4" 2rx2' Cerliug rile R E ) 246 SGP 0015315 TABLE OF COilTEHTS Pa^e 16 ............................. .Projects Underway - Continuous Calcination R D 253 Projects Unden/ay - Inverforn Paper - E. C: D 254 Projects Underway - Lightweight Gypsun hoard L Ci D 255 Par*e l? ,, ......................Projects Underway - One Hour Floor C: Ceiling Ps Ci D 256 Projects Underway - Ilof-uor Panel Fire Test L D 257 Page 18 ...........................Projects Underway - Donn Clip-On Stud - 11 D 258 Projects Underway - Sound Deadening Construct! - E & D 260 Pages 19-21 . . . Pictures to Illustrate the Effect of Glass Fibers in a Gypsun Uallboard Core Pages 22-24 Pictures Showing Thincoat Plaster Application SGP 0015316 FORWARD Tliis report covers the activities and accomplishments of our research program for the past six months. No basic changes in or ganization have occurred during tills time* We have .however, begun to assign projects to a single individual rather than dividing the responsibility between two people. The former approach liras being utilized until such time as the new men had 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. Bach 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 are 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. The 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. Vie 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 illu trating the effect of glass fibers in gypsum. The latter are to be used in promotional literature. The major portion of the report is, of course, devoted to the progress of the various projects. -2- SGP 0015317 MARKET PERFORMANCE OF NEW PRODUCTS JANUARY THROUGH JUNE 1963 lo FIRESTOP 120 CEILING TILE Amount Sold Dollar Sales 7olume *Gross Profit 122,000 sq. feet $16,215 $ 5,349 20 GRAD1T MASONRY ADHESIVE 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 -- $131,907 Total Gross Profit of New Products -- $ 39,431 ^Estimated by Ardmore Cost Department PATENT I INFORMATION Patents Issued: None Patents Applied For: Method of Processing Synthetic Gypsum Patent Applications Deing Prepared: One Day Joint Compound Grabit Masonry Adhesive -3- SGP 0015318 PROJECTS HEARING COMPLETION Thincoat Plaster - R C: D 219 Objective: To develop a competitive tiiincoat lath and plaster system. Status of Investigation: The original objective v;as to have oue product for 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 were 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 i: limited markets. Our thincoat plasters have certain advantages over other thincoat products, and can be priced competitively uhi. still maintaining a favorable profit margin. Paralleling the tiiincoat 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 pla; ter. Advertising photographs taken during one of our field trial.' axe included in this report. Ready Mix Joint Compound - II & P 211 Objective: To develop a ready nixed or paste type joint compound to be competitive with other similar products on the market. Status of Investigation: Several field trials of a product containing 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. Hie economics of ou. ready nix are still not completely favorabie, and we are striving to improve this situation. We are somewhat limited in this diroc tion because the fixed costs of the container and the freight rep resent a large percentage of the cost cf the product. This leave the formula and the processing for us to worl: on. We are even limited here as the improvement in b-oth of these areas is limited since certain possibilities for cost reduction i/ill require lai; e initial expenditures for equipment. Judging from the emphasis Sales has given this project, it appears imperative that we con tinue to seek 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 m;:r ket potential as well as possible cost savings. This would roq-J. that Management approve a low profit item, even if only on a La ,:n orary basis. Cased on this experience, the market potential mumi then dictate the wisdom in considering certain equipment expendi tures necessary to improve the profit margin. 9 SGP 0015319 PROJECTS HEARING COMPLETION 3* Glass Fiber fog Wallboard Reinforcement - R & D 210 Objective; To be able to aoprove several types of glass fiber, particularly 799 (Muzzy Mix) for use in our wallboard. Status of Investigation; From this evaluation of fiber types we "found that types 7i5,&04, 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 intenoeshed 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 Taras equivalent to the standard amounts of paper fiber and 863 glass fiber. Some trial runs were made at liiIslington, 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 are 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 Day Texture Problem - R & D 243 Objective; To find a means of eliminating the need for a primer over dine Day Joint Compound prior to texture application. Status of Investigation; The sale of One Day has been limited because we have had '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. We are pro ceeding with field trials of the texture as quickly as possible, since we feel this will greatly enhance the sale of One Day Joint Compound. 5, Accumulation of Fire and Sound Test Data - R & D 349 Objective: To gather all available fire and sound test data on the various constructions and put it into a usable reference form. - 10 - SGP 0015320