p.1 

OAR Box 1384 

Prepped by Charmelle Mathews 

. Document Number: 

) ll-E-157 

Docket Number: 

A-94-52 

Printed 7/2/2008 8:42:10 AM Sheet 198 of 264 
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06/22/1998 09:32 2192699242 PAGE 02 

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From: 

Date: 

Contact: 

Company: 

Contact Report 

Robert Jemison, Pacific Environmental Services, Inc. (PES) 

June 10,1998 

Mr. Rick Farley 

Marble Creations, Inc. (formerly Foreman Industries! IncV) 

Telephone Number (219)269-7242 

Fax Number: (219)269-9242 

Contact Summary: 

Mr. Rick Farley was contacted on behalf of the U.S. EPA to update information provided in 

the 1993 EPA Reinforced Plastic Composites Screening Survey submitted by Marble Creations, Inc. 

for their facility located in Warsaw, Indiana. In response to my questions Mr. Farley indicated the 

following: 

The facility uses polymer casting and atomized spray lay-up (gel coats only) to produce bath 

tubs, shower bases, shower stalls, and counter tops. 

The facility prepares die resin-fillet mixture used in its polymer casting operations by mixing 

a polyester resin, filler, and catalyst in a mixing vessel. The mixing vessel is open (not covered or 

closed) while the mixing process is conducted. The facility actively vents emissions from the mixer 

to the atmosphere to reduce worker exposure. Once the mixing process is completed, the mixture 

is poured into an open mold (or molds). 

The polyester resin used by the facility for its polymer casting operations contains 35.0% 

HAP by weight as supplied (35.0% styrene) and does not contain a vapor suppressant. No additional 

HAP is added to the polyester resin during or prior to the polymer casting process with the exception 

of small amounts of HAP that may (or may not) be present in initiators, promoters and/or catalysts 

added to the resin. 

The facility uses atomized spray lay-up (via an air-assisted airless spray gun) to apply both 

clear and pigmented (off-white) production gel coats in the fabrication of the products listed above. 

The clear gel coat used by the facility contains 46.0% HAP by weight as supplied (46.0% styrene 

and 0.0% methyl methacrylate). The pigmented (off-white) gel coat used by the facility contains 

33.0% HAP by weight as supplied (33.0% styrene and 0.0% methyl methacrylate). 

INFORMATION IS ACCURATE ulfaJCl CT^^L 
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06/22/1998 09:32 2192699242 PAGE 03 

Mr. Rick Farley - Marble Creations, Inc. 

June 10,1998 

Page Two 

The facility uses atomized spray lay-up to apply ah unfilled polyester tooling resin in the 

manufacture of molds. This unfilled polyester resin contains 47.0% HAP by weight (47.0% styrene) 

and does not contain a vapor suppressant 

No additional HAP is added to unfilled polyester tooling resin during or prior to the 

fabrication process with the exception of small amounts of HAP that may (or may not) be present 

in initiators, promoters and/or catalysts added to the gel coats. 

The facility uses atomized spray lay-up (via an air-assisted airless spray gun) to apply a 

pigmented (orange) tooling gel coat in the manufacture of molds used at tha facility. The pigmented 

(orange) tooling gel coat used by the facility contains 38.0% HAP by weight as supplied (38.0% 

styrene and 0.0% methyl methacrylate). 

No additional HAP is added to either die clear, pigmented or tooling gel coats during or prior 

to the fabrication process with the exception of small amounts of HAP that may (or may not) be 

present in initiators, promoters and/or catalysts added to the gel coats. 

INFORMATION IS ACCURATE 

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