Document xzMMnV8gDj6Mx2rNBJaNmMKEQ

OWINS COKNINC. FlBERGLAS to Mr. K. 0. Preston subject K-17 Door Core Production Reouirements F^S 0 PLAINTIFF'S .EXHIBIT 33HQ.0 intra -company correspondence from A. K. Weaver date August 10, 1971 cc: Mr. H. A. Waters Kr. V, 3, Jfuiet Mr. D. C. Koons 1 PLAINTIFFS |i EXHIBIT |1 WV-01080 I. Raw Materials A. Short Term (remainder 1971) For the remainder of 1971, we are planning to use those raw materials currently in the K-17 Berlin product. These are: Raw Material Vendor Cost/lb. Grade S-33 Amosite Asbestos 73 Chrysotile Asbestos iiT Chrysotile Asbestos Quicklime Suoersil North American Asbestos Like or Carey Asbestos Lake or Carey Asbestos Warner Lime Co. Penn. Glass Sand Co. $0.1336 $0.0523 $0.1169 $0.0168 $0.0090 B. Long Term (1972) By 1972, we expect to optimize the formulation by utilizing lower cost raw materials, closer sources of supply (reduced shipping costs) and ingredients currently bought in bulk for the pyrccr product line. The modifications to be investigated are as follows: 1. Substitution of Hydrated Lime for Quicklime. Problems to be overcome - because of the absence of a bulking agent like IS, the Hydrated Lime may have a tendency to settle out of solution. 2. Using cheaper DX asbestos in place of S-31 Amosite. Problem to be overcome - ability to fine mill (to 3/k" to 1" lengths) the DX fiber in our mill. 3. Substitution of Silica Flour for Supersil. Problem to overcome - mixing efficiency and re-formulation to maintain C/S ratio. iw Incorporating Fyrcor dust in the fojmilation. Problems to overcome - evaluation of amounts, formulations, and physical properties? means of capturing sanding dust in usable form. 01 SOI t&31 WV-1080 K-17 Door Core - Production Requirements Page 2 August 10, 1 <?7i II. K1U Based on the saccess of the 7/23 trial, we should plan on using our present mill. III. Mixer Dependent on activity, our current small <180 cu. ft.) mixer nay be used. It is recommended that the rpn of the ribbon blender be increased to obtain increased mixing. Over the long term in the event a new sixer is purchased, the advantages of reported improved mixing should be investigated using Berlin's new cylinder mixer. 17. Pouring A. ftimp A high tbruput/lo* rpn pump is essential in eliminating our problem of air holes. Berlin currently using a <n and White Centrifugal Pump with a Beeves Variable Drive lest. cost$3-hM). This pvnp can. also be used for Fyrcor pouring. Moyno Positive Displacement pumps can also be evaluated as to cost and maintenance savings as long as they can be geared to produce a high thrapat at a low rpa B. fose With a new pump, a 2 Inch I.D, hose^iar rgnwmended to reduce air entrapmeats. A aoaala wit* "separatd^Ao breakup tte flow can also be investigated "" and hose do not eliminate the air holes. C. Location Dependent on activity, the short term location of the pouring operation should be at the west end of the Fyrcor press. The empty molds may be kept on an autoclave truck on the other side of the pit {currently where autoclave plates are stored). The hoist will pick up the empty , place it on the track, and when filled place It on the autoclave cart on the movable track This method will only involve tbe cost of installation of pipe from the pump to the vest end of the press. 01 501 1238 K-17 Door Core - Production Requirements Page 3 August 10, 1571 IV. D. Mold Release Continue to use motor oil/S$ polyethylene and urethane strips. E. Recovery of excess slurry For the short term, the screened off slurry can be captured with sheet metal troughs ecptying into $ gallon buckets. long term, ve should investigate a sump when a new pouring location is found. ?. Pour Kate The estimated pour rate should compare with the Fyrcor rate for a 2 board. Again our pour rate will bo dependent on the mix rate. Berlin rate ParJS/br. V. Molds A. Dimensions 1. Short term - 2*3/16 x 50 x 9& 2. long term - reduce green thickness required to finish at 1-11/16 and investigate possibility of using partitions to reduce module siae. 5. Design and cost C. Number For the short term, one autoclave load of molds should be adequate. (60) 71. Autoclave A. Cycle 1. Short term - 1-12-3 2. long term - reduce time at pressure and install automatic pressure bleed-off controls. B. Capacity - 16 Pans/Cart 5 Carts/Xoad. VH. Drying A. Cycle - 12 boors 3SC ?. B. Capacity - 16 Boards/Cart 5Carts/Oven load. VUI* Finishing Boards are to be finished rough sanded to 1-3A" thickness (per Novak). Finishing rates should compare to Frycor rates. mtif 015611239