# Presentation: 656498

## Raising Expectations for Performance and Stewardship

**Advantex®  Glass Fiber****A New Era in Composites Technology**

**Scott E. Colangelo**

## Founded 1938

**Founded 1938**

**New Corporate Brand 1996**

**Notes:**
Company Profile
Owens Corning pioneered the science of glass fiberization and has led the industry ever since.  The Owens Corning Fiberglas Corporation was formed in 1938 as an equal-partner joint venture between the Owens-Illinois Glass Company of Toledo, Ohio, and Corning Glass Works in Corning, New York.  In its first year, the fledgling company introduced fiberglass insulation and furnace filters, manufactured in a converted glass bottle plant in Newark, Ohio.  In the 1940s, the company developed glass fiber materials as reinforcements for plastics, creating the glass fiber composites industry.

## Global Facilities

**Global Facilities**

**20,000 employees, 135 locations, 30 countries...**

## Corporate Organization

**Business Units**
**North American Building Materials Systems**
**Insulating Systems, Roofing Systems, Exterior Systems**
**Composite Systems**** **
**International Building Materials Systems**
**Integrex**
**Litigation Management Systems**
**Testing Systems**

## Composites  Systems Business

- Composites  Systems Business

**Notes:**
Glass fiber composites have become a material of choice for added performance because of their design flexibility, higher strength, lighter weight, corrosion resistance, electrical properties and cost reduction benefits.  They are used in more than 40,000 end-use products -- from complete hulls of power boats and bridge deck structures, to printed circuit boards and fiber-optic cable reinforcements, as well as body panels and structural components for cars and trucks.  Owens Corning has built a core competence in solving advanced material needs in these markets and virtually every major industry.

## Composites is a Global Business

**Key facts:**
**$1 Billion in Revenue**
**Number 1 in Global Market Share**
**20 Production Sites - 750,000 Tons ****of Composites**
**Increasing demand for Global Consistency**

## Definition of Glass

_**ASTM**_**:      An inorganic product of fusion which has cooled to a rigid condition without crystallizing.**
_**General**_**:  Glass is a liquid which can be cooled without crystallizing and is so viscous at room temperature that for all practical purposes it is a solid.****Glass is amorphous, i.e., it does not have an ordered atomic structure.**

## Advantex® Glass Fiber is a Reinvention of E-Glass

**“****E-glass” was developed in 1937 by OC and OSU**
**The goal was to develop a glass with excellent**
**electrical insulation properties (E)**
**water durability**
**tensile strength**
**E-glass is primarily CaO, SiO****2**** and Al****2****O****3**
**E-glass contains alkali level less than 2%**

## Boron Was Added to Lower Liquidus and Viscosity

**Most E-glass formulations are variations of the original composition**

## The Role of Boron in 

**E-Glass Melting**

## Typical Glass Composition

**                            **_**E-Glass**_**	**_**Container/**__**	**__**	**__**	**__**Flat Glass**_
**SiO****2****	****54****	****	****73**
**CaO****	****22****	****	****6**
**MgO****	****---****	****	****5**
**Al****2****O****3****	****14 ****	****	****1**
**B****2****O****3****	****8****	****	****	****---**
**Na****2****O****	****0.5****	****	****15**

## Driving Forces for Change

**Extended Performance**
**Increasingly complex product design demands for physical, mechanical, chemical & electrical criteria**
** **
**Global Consistency**
**Manufacturers need to source materials with     uniform properties around the globe**
**Environmental Stewardship**** **
**Increasing demand for materials to be produced         in environmentally responsible processes **

**Notes:**
Extended Performance
Today’s complex product designs demand materials that provide high-performance across the full range of physical, mechanical, chemical and electrical criteria.
OEMs and their end-use customers expect a high level of long-term reliability. Therefore, the life of products being designed today will extend far into the future. So must the materials from which they are made.
Global Consistency
Just offering good materials is no longer enough to provide high value in a global marketplace. It’s not unusual for a product to be designed on one continent, manufactured on another continent, and sold on yet another. So, it has become increasingly important that manufacturers be able to source materials with uniform properties and consistent availability around the world.
Stewardship
An added element of the demands for long-term reliability and a global perspective is the need for materials to be produced in an environmentally responsible process. Stewardship to reduce impact on the environment is essential during initial materials manufacturing, product fabrication and throughout the product’s life cycle.

## Glass Melting Based Upon 

**Glass Melting Based Upon **
**Fossil Fuel Consumption **

**Batch**

**Furnace**

**Forehearth**

**Forming**

**Channel**

**Raw Materials**

**Emissions from Melting Process**

## Major Emissions to the Air:

**CO****2**
**combustion of hydrocarbon fuels**
**decomposition of carbonate batch material**
**SO****x**
**sulfate from salt cake or gypsum**
**sulfur in fuel**
**NO****x**
**high temperature required to produce glass efficiency and oxidizing atmosphere**
**Particulate**
**volatile components of the glass condense in the stack**
**primarily boron compounds**

## Composites Glass Fiber Manufacturing Locations

**GUELPH, **
**ONTARIO**

**BIRKELAND, **
**NORWAY**

**JACKSON, TN**
**AMARILLO, TX**

**RIO CLARO, **
**BRAZIL**

**BRUSSELS, **
**BELGIUM**

**WREXHAM, **
**WALES**

**JOHANNESBURG, **
**SOUTH AFRICA**

**TALOJA, **
**INDIA**

**SEOUL, KOREA**

**MEXICO CITY, MEXICO**

**ANDERSON, SC**
**AIKEN, SC**

**Composites Glass Fiber Manufacturing Locations**

**L' ARDOISE, **
**FRANCE**

## Glass Composition Development

_**Manufacturing **_
_**Constraints**__**	**_
**Batching****	**
**Melting**** **
**Fiberization**** **
**Health, Safety & Environmental**

_**Limitations**_**	**
**Raw Material Availability**
**Raw Material Quality**
**Cost**** **
**Refractory Life**
**Foam**
**Fuel Cost**** **
**Glass Crystallization**
**Precious Metal Creep Rate**** **
**Meet or Exceed All Regulations**

## Composition Ranges

_**Oxide**__**	**__**E-glass**__**	**__**Advantex®**_
_**	**__**	**__**	**__**Glass Fiber**_
**SiO****2****	****52.0 - 56.0****	****59.0 - 61.0**
**CaO****	****16.0 - 25.0****	****21.5 - 22.5**
**Al****2****O****3****	****12.0 - 16.0****	****12.7 - 14.0**
**MgO****	****  0.0 -   1.0****	****  2.5 -   3.3**
**Na****2****O + K****2****O ****	****  0.0 -   2.0****	****  0.0 -   2.0**
**B****2****O****3****	****  5.0 - 10.0****	****     0.00**

## Shift in Mineral Requirements with Advantex ® 

_**Annual Usage**_
_**Mineral**__**	**_
**Silica****	****	****18% increase**
**Clay****	**** ****	****  6% decrease**
**Limestone****	**** ****	****    no change**
**Burnt Lime****	****   ****	**** 18% increase**
**B Dolomite****	****          need 70 M metric tonnes**
**Borate****	****              no longer needed**
**Fluorspar****	****              no longer needed**
**Rutile****	****              no longer needed**
**Zinc****	****              no longer needed**
_**Assumes 100% Conversion for Composites Division**_

## Glass Property Comparison

**Glass Property Comparison**

**Notes:**
The chart below shows a comparison of Advantex® glass fiber physical properties with those of traditional E-glass and E-CR glass.  Advantex exhibits a higher softening point than either E- or E-CR glass which may be of advantage for some applications. 
Even though the ultimate properties achieved in the laboratory with single filament measurements are not normally achieved in field applications, they provide a way to compare the properties of glasses prior to field processing. 
One of the key features of E- and E-CR glasses is their durability in water.  The chart below demonstrates that Advantex® glass fiber maintains the high standards of these types of glasses. 
Advantex® glass fiber has excellent resistance to acids. 
Although Advantex® glass fiber does not contain boron as do traditional E-glasses, it exhibits comparable electrical properties.  The data below shows how the critical electrical properties of volume resistivity and dielectric breakdown strength compare with currently available E-glass products.
Volume resistivity is a measure of the insulating properties of glass.
Breakdown strength is a measure of the voltage which can be withstood before arcing through the material occurs.

## New Technology Enabled Launchingof Advantex® Glass Fiber

** ****Melting Technology**
** ****Furnace Design**
** ****Fiber Forming**
** ****Size Formulation**

## Environmental Results(Particulate) 

**   **_**Particulate emissions in lb./hour**_
_**Plant Location**__**	**__**E-Glass**__**	**__**Advantex® **_
_**	**__**	**__**	**__**	**__**	**__**	**__**Glass Fiber**_
**Battice, Belgium****	****   11.3****	****	****      0.4**
**L’Ardoise, France****	****   12.1****	****	****      0.2**
**Approximately 97% reduction in particulate emissions**

## Environmental Results(NOx) 

_**NOx Emissions in Kg./hr**_
** **_**Plant Location**__**	**_** **_**Gas/Air**__**	**__**Gas/Oxygen**_
**Guelph, Ontario****	****    7.1 ****	****	****     1.5**
**Wrexham, Wales****	****   18.9****	****(1)****	****      4.0**
**Reduction in particulate and volatile components helps enable conversion  to oxygen combustion   **
**Approximately a 5X reduction in NOx **
**      **
**(1)  Estimated Value for Wrexham base NOx level**

## Global  Consistency with Advantex® 

**Finished glass chemistries less variable across Global facilities**
**Simplification of raw materials  **
**Elimination of volatile components**
**Minimize impact  from various Global melting processes**

## Composites Glass Fiber Manufacturing Locations

**GUELPH, **
**ONTARIO**

**BIRKELAND, **
**NORWAY**

**JACKSON, TN**
**AMARILLO, TX**

**RIO CLARO, **
**BRAZIL**

**BRUSSELS, **
**BELGIUM**

**WREXHAM, **
**WALES**

**JOHANNESBURG, **
**SOUTH AFRICA**

**TALOJA, **
**INDIA**

**SEOUL, KOREA**

**MEXICO CITY, MEXICO**

**AIKEN, SC****ANDERSON, SC**

**Composites Glass Fiber Manufacturing Locations**

**L' ARDOISE, **
**FRANCE**

**Converted  to Advantex®**

## Increased Performance with Advantex®

**Properties of E-glass with  higher corrosion resistance**
**Higher softening point improves service life or temperature**
**Providing New Solutions or Applications**
**Automotive exhaust systems**
**  **
**Compact and Lighter**
**Lower System Cost**
**Improve Corrosion Properties**
**Eliminate Particulate Blow-out**
**Meet Tighter Noise Requirements**

## Conclusions

**Introduction of Advantex® glass fiber marks an important milestone for Owens Corning**
**Advantex® glass fiber is one of many solutions Owens Corning is providing to create new value for our customers**
**Owens Corning’s consumption of silica and dolomite will increase**
**Owens Corning will need new sources of the mineral dolomite**

## Conclusions (continued)

**Advantex® will help meet customer demands for Global consistency**
**Advantex® has electrical and mechanical properties of boron containing E-glass**
**Advantex® glass fiber provides higher temperature applications and corrosion resistance compared to boron containing E-glass**

## Conclusions (continued)

**Advantex® will have a significant impact upon reducing amount of particulate emissions with elimination of added boron and fluorine **
**Advantex® helps enable conversion  to oxygen combustion and therefore obtain reductions in NOx emissions**

**GLASS**

**CRYSTAL**

**Glass Structure**

## Global Composites Materials Use

**Transportation**

**Infrastructure**

**Consumer**

**Electrical / Electronics**

**Construction**

**Notes:**
Market Data
Demand for aesthetically pleasing, easily manufactured, reduced-weight, high-strength and lower-cost structural parts is driving growth in the glass fiber composites industry worldwide.  The total market for parts made of composite materials is approximately $25 billion and is expected to grow at an annual rate between 3 and 5 percent for the next few years.  In recent years, Owens Corning has participated in about 20 percent of this total market as a raw materials supplier.

**In 1992 Owens Corning Fiberglas produced just under $3 billion in sales, and ****glass fibers**** ****made up**** ****over 80%**** ****of its material base.**

**Expertise Beyond Fiberglass...**

**By 1998 Owens Corning became a**** ****multi-material based**** ****company with sales over $5 billion and glass fibers constituting**** ****less than 50%**** ****of its material base.**

**Notes:**
Building on the company’s leadership position and brand strength in the glass fiber and roofing industries, Owens Corning diversified into complementary material markets such as foam and mineral wool insulation, vinyl siding and accessories, manufactured stone products and rainware (i.e., gutters and downspouts).  In most instances, Owens Corning is now the leader in these arenas.

## Composites is a Global Business

**Key facts:**
**$1 Billion in Revenue**
**Income From Operations Above 15%**
**Number 1 in Global Market Share**
**20 Production Sites - 750,000 Tons ****of Composites**
**Technology Leader - Expanding Patent Portfolio **

## Global Market Share - Glass Fiber Reinforcements

**2 million metric tons = Global market estimate**