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# OAR Box 1413 Prepped by Ollie Stewart



## Document

Number: 

# 35 ) 11-1-3 5 Docket Number: 

# A-94-5 2

Printed 7/9/2008 3:11:22 PM

Sheet 35 of 114r 

## Engineerin g &. AAanufacturin g Solution s fo rIndustr y 

## A-94-5 2

September/Octobe r199 5 

# TECHNOLOG Y U-f c
v v v S



# CAS T POLYMER S G O UPTOW N FOR D TEST

S E-GUAS S PREFOR M STRUCTURA L PAR

T FUS E MAKE R GET

S CHARG E OU T OF . BM C - • * » •

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# COMPOSITE S '9 5 SHO W PREVIE W

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# CAS T POLYMER S CAPTUR E SOPHISTICATE D MARKET S Volume , variet y an d technolog y giv e thi s busines s prestig e i n a b environment , fro m bathroom s to bridges

. : • t.'. i •nta •atta. ?* ! riK'',>••' •



## omm- j 

## UEC- 5 199

7 

# ? o experienc e th e benefit s o f cas t poly

me r engineering , jus t

thro w abowlin

g ball , se w o n abutton , repai r

your aut o body , shav e or

cook
. Yo u can eve n take th e famil

y t o se e th e Golde

n Gat e Bridge
. The ball , th e button , repai r putty , vanit y an dkitchen counter

top s ar e prob

abl y made o f cas t polyme r composites
. The approac h to th e Golde

n Gat e Bridge I s afor mo f cas t polyme r engineering called polyme r concrete . ' Cas t polyme r i s anon-reinforcedcom

posit e tha t combine s polymers , fillers an d additive s t o meet ' speciflc^appllcatlo n requirements. Fillers accoun t fo r u p to 9 0 percent o f th e materia

l system . Afte

r th e materia l i s catalyzed , i t

polymerize s an d become s rigid
. Figur e 1 summarize s typica

l cas t poly

me r products , processe s an dmaterials
. Methy l methaayiat e acrylic (MMA ) an d unsaturate dpolyester s resins (UPR) — A AI R DOCKE T 

### bot h orthophthalic;ari dlsophthallc-^-dom

inate'the'gel^coato i cultured'maibl e an d _»U dsuifacwmarkets. " Orthopolyeste

r an dpolyurethan e ar e commonl y use dfo r decorative casting s an dflexible moldings
. Polyester, epox y an dviny l este r ar e th e predominan t matri x resins i n precas t

polyme r concret e fo r product s suc h a s utilit

y vault door s an delectrolytic mining cells
. The y ar e als o use di n fieldapplication s suc h 

## Summar y o f Cas t Polymer Products , Processe s & Material s PRODUC T CATEGORY * TYP E OF , PROCESS/PRODUC T Cas t polyme rsurface s Gel-coate d

Cas t polyme rsurface s Soli d (no t gel-coated ) MOS T COMMO N RESIN S TYPICA L FILLER S

Bod y filler s

Furnitur e parts , statue s & figurine s Bowlin g ball s

Button s

Min e bol t anchors Polyme rconcret e

Polyme rconcret e Spreadabl e filler s (putty ) Spra y filler s Flexibl e Rigi d Highl y fille d inne rcastin g Gea route rshel l Centrifuga l castin g Cel l castin g Ro d castin g Uniqu e on-sit e castin g Pre-cas t

Rei d application s Orthophthali c UP R

MAAA acrylic , Isophthali c UP R
Orthophthali c UP R Modifie d orthophthali c UP R Orthophthali c UP R Castin g urethane s Orthophthali c UP R Isophthali c UP R o rspedalt y Orthophthali c UP R sam e sam e Orthophthali c UP R Caldu m carbonat e (CaCO. ) Aluminun a trihydrat e (ATH ) Acryli c o rUP R granule s Microsphere s AT H

Talc s an d glas s bead s o r othe rmicrosphere s CaCO
_ Glas s bea d microsphere s Glas s bead s o rothe r stron g microsphere s No t filled urethane s Pearlescen t fillers/pigment s sam e sam e Talc s an d speda l filler s an d additive s Orthophthali c UP R Epox y vinyfeste r Als o AAM A acryli c an d polyurethan e Sand , fl y as h an d grave l

Isophthali c UP R Sand , fl y as h an d grave l PRODUC T APPLICATION S & NOTE S Kitche n countertops
. showe rpanels , tubs , sinks , vanit y tops , whirlpoo l spas .
Vertica l an d horizonta l surface s fo rkitche n an d bat h products , commercia l wor k • surfaces , offic e furniture

. Pens , jewelry , ar t specialities , decorativ e architecture

. Meta l finishin g filler s fo raut o bod y repair an d fo rfillin g roug h cas t meta l surfaces

. Flexibl e moulding s fo rbuildin g industry , frames , headboards , signage , spedalt y decorativ e casting

. Bowlin g ball s

Men' s shirt button s Buttons ; speda l shapes , color s Women' s dres s button s Reba ranchor s i n min e shaft s Curbs , drains , gutters , bamer s Utilit y doors/cover s Minin g cell s Highwa y overlays , repladn g cemen t concret e Figur e 1 . Cas tpolyme

r engineerin g combine s polymers , fillers an d additive s a s composite s t o mee tapplicatio n requirement s fro m kitche n counter s to highwa y overlays . COMPOSITE S TECHNOLOG Y SEPTEMBER/OCTOBE R 199 5 1 7

l-fl-P ! •:'j".mjui*.'.uvwija.__j » 

# . 

# z. l^ll »U.JIMlll»iJ...W_yi»J!illJIJ MP. 4

a s th e Golde

n Gat e Bridg e approach
. Shipment s o

f non-reinforce

d compos ite s reached 849. 9 millio

n pound s i n 1994
. That' s 2 2 percen

t o f th e tota l U.S
. compos ite s shipment s fo

r th e year—jus

t belo w th e 945. 6 millio

n pound s shipped fo

r trans
portation , whic

h primaril y use s shee t moldin g compounds
. Transportatio n i s th e larges t reinforced composit

e marke t Non

reinforced composite s ar e expecte d t o con tinu e growin

g throughout

th e 90s
. HOM E I S WHER E TH E HEART I S Gel-coated culture d marbl e an d densifle d (solid ) surface s are th e hear

t o f th e cas t polyme r industr y an d accoun

t fo r half th e total marke t

A health y housin g marke t mean s stron g growt

h i n thi s sector . Th e Intemational Cas t Polyme r Association (ICPA

) (Arlington, Va. ) represent s gel-coa

t an d solid-surfac e materia l produc t manufacturers
. Abou

t 140 ICP A membe r companie s mak e gel-coate d product s an d 6 0 mak

e soli d surfacing
. Som e ar e majo r manufacturers , bu t

mos t ar e small businesse s wit h 2 0 to 3 0 employees
.

Figur e 2
. Culture d marbl e bathroo mwit h Roma n columns
. Stil

l th e larges t applicatio n fo r cas t polyeste r resin, culture

d marbl e ha s agel

coate d surfac e backe d b y castin g resi n chemicall y bonde d wit h marble , ony x o r granit e "dust " (Source

: E l Dorad o Mig. ) ICP A say s hundred s o

f smalle r cas t polyme r caster s nationwid

e servic e loca

l areas . Entrepreneur s ca

n start asmall cast
ing outfi t wit h lo w capita l investmen

t usin g non-automate dequipmen t an d manual operations
. However

, growt h ha s stimulat

e d anee d fo

r automation , an d majo

r equipmen t supplier s ar e responding. Agglomerated Ston e Canad aInc
. (Concord , Ontario) specialize s i n automat
e d castin g machine s manufacture d i n Canad aan d Italy
. The

y recentl y intro

duce danew CN

C grinde r wit h multipl e heads
. Remot

e persona l compute r opera tors can monito

r an dcontro l th e proces s usin g man-machine interfac e software
. Th e compan

y als o offer

s turn-ke y service s fromengineering to installation , trainin g an dtechnolog y transfer
. AD M Nort h Americ a(Springfield

, Va ) supplie s alin e o

f semi-automate d an dautomate d castin g machine s an d equipmen t

Th e AD M Log o castin g machin e offer

s afrequenc y conversio n optio

n wit h analo g control
. Thi s allow s th e proces s to b e compute r controlled
. AD

M manufacture s th e machine s l n Bruggen , Germany
. Anothe r company , Gisc o Technolog y Ltd
. (Willow

brook , 01.) , manufacture s custo mautomate d castin g equipmen t i n th e Unite d States
. Gisc o continuou s castin g machine s automat
icall y fee d proces s informa

tio n to acompute

r fo r oper ato r monitoring an d evalu

ation
. - Cas t polyme r pioneer Grube r System s Inc
. (Valencia , Calif. ) manufac

ture s batc h mixin

g process es , molds , vacuummixers , blenders , conveyors , oven s an d whirlpoo

l jettin g sys tems . I n addition , Grube

r offer s engineering services , customdesign , an d train

ing , an dha s installe d turn
ke y cas t polyme r facilitie s worldwide
. Man y caster s sa

y robotic spra y system s an d auto
mate d fabricatio n equip

men t ar e th e next

technolog y challenge
. Mos t solid surfac e produc t

fabricatio n no w relie s on woo

dcarpentr y technology an d manual equipmen t

Secondar y fabri

catio n operation s aren' t

feasibl e fo r gel

coate d product s becaus e routing o r cut
tin g ruin s th e protective surface
. GEL-COATE D SURFACE S Cas t polyme r marble , ony

x an d granite ar e popula r fo r kitchen countertops , showe r panels , tubs , sinks , vanit y top s an d whirlpoo l spa s (Figur

e 2)
. A home

y influ

enc e base do

n th e us e an d loo

k o f thes e product s ha s tende d to giv

e th e cas t poly

me r industr y afood-oriente

dlanguage
. Manufacturer s spea

k of aresin matri x "the consistenc y o

f pancak e batter " an d com

pare^th e proces s to bakin g acake
. Manufacturin

g begin s wit

h agel-coa

t sprayup int

o a n open mold
. A clea

r ge l coa t allow s th e pattern an d colo r t o sho w throug h th e protective coating
. Coloran t i s adde dto th e ge

l coa t resin fo r soli dsur fac e colors
. Whe

n th e ge l coa t drie s to a tack y consistency , th e resin matri x i s mixe dwit h filler, additive s an dcolo

r pig

men t Colo r veinin g past e can b e adde dto simulate quarrie d marble
.

• • v0 « *
. ippsGast polyme r marbl e i s typicall

y man ufacture d by mixin

g liquidUP

Rresi n wit

h calciumcarbonat

e (CaCOs ) fliler. A chemi

ca l compoun

do r natura l CaCC

h groun d into particulat

e ma y serve a s fliler. CaCO

a i s th e cor e ingredien

t o f real marble
. Whe

n cured , thi s produce s ahar d piec e o f mar bl e "dust " hel dtogethe

r b y aplasti c resin. The primar

y fliler i n cas t polyme r ony x i s alumin atrihydrat e (ATH)
. Karen Shields , marketin g communication s director fo r Hube r EngineeredMineral s (Noreross , Ga. ) say s AT

H l s idea l fo r ony x cas t polyme r sinc e i t offer s th e same refractive inde

x a s th e polyeste

r polymer
. Sh e add s tha t

i t als o "enhance s th e appearanc e o

f dept h an d translucenc e o

f th e onyx. " Hube

r supplie s AT

H an d gran it e texture d pigment s to th e cas t polyme r industry
. Minera l granit e or

asyntheti c fliler tha t simulate s granit e i s use dfo r a granit e appearance . Synthetic s includ e acryli c an d thermose t

resin s tha t

ar e catalyzed , cas t

an d groun dInt o particu

late
. Producer s ca n als o premi x th e syn 1 8 COMPOSITE S TECHNOLOG Y SEPTEMBER/OCTOBE R 199 5 

# 3P. 5

thetlc s wit h ATH

, CaCO a o r othe r fillers (suc h a s microspheres ) an d prepigmen t th e produc ti n a variety o f colors , "Arizon a Cultured'Ston e Product s (Tucson , Ariz.) supplie s granit e an d onyx fillers includin g a lightweigh tmicrospher e calle d Featherlit

e tha tcut s productweigh t i n half . It' s especiall y goo d fo

r bathtub s an d othe r heav y products, " say s Ji m Novak, presiden t"Extremel y ligh thollo w microsphere s ad d strengt h an d bul k with ou taddin g weight " Th e compan y als o manufacture s Dur a Ston e soli d surface products . Takin g a slightl y differentapproach , America n Marbl e (Birmingham , Ala.) use s Dicaperl glas s bead s b y Grefco , Inc . fTorrance, Calif. ) t o mak e lighter-weight ye tstronge r parts . "B

y usin g a hollo w glas s sphere , w e reduce warping an d shrinkag e durin g processing, " say s Bil l Harris , presiden to f

America n Marble. "W

e cu tth e weigh tof

th e partb y abou tone third , makin g i teasie r for th e installe r to handle. " H

e say s th e adde d strengt

h als o reduces crack s an d breaks . Mosto f it s casting s ar e base d o n Isopolyeste r neopenty l glyco l (NPG

) ge l coa tan d orthopofyester resin matrix , both supplie d b y Coo k Composite s & Polymers (Kansa s City , Mo.) . Th e compan y als o make s nat ural pigments i n 6 0 colors , vhic h i tals o supplie s t o othe r manufacturers . Fora top surfac e granite look , particu late s are combine d wit h clea r gel coatan d spraye d into th e mold . Thi s requires dedi cate d spray guns , however , since particu late s may fou

l lines , creatin g cleanu p problem s an d downtime . Special spra y gu n attachment s ca n solv e thi s proble m b y applyin g dr

y an d liqui d material s sep arately withou tpre-mixing . For example , a ne w dr y material syste m developed by Unite d Granule s (M tBethel , Pa. ) add s di y material s suc h a s granules , flakes, microsphere s an d othe r particulate s from a hoppe r attachmen tdirectl y Int o th e gel coa tspray . _....,^-,«..., W v.i..,->..:. - Afte*»ih©ma§ & i s catalyze d an d cast onto th e mold , it' s usuall y vibrated t o allo w ai r bubble s t o escape . "I f yo u imag in e combinin g a liqui d tha ti s th e consis tency o f syru p [th e resi n system ] wit h a di y materia

l tha ti s th e consistenc y o f bab y powder, yo u wil l understan d why a lo to f ai r Is presen tI

n th e mix. " say s Kevi

n Latham , technica l manage r fo r Genera l Marbl e (Iincolnton , N.C) . G

M make s gel coate d cas tpolyme r products fo r retail hom e center s nationwide . FoUowing :;g"4bratlon, th e produc t enter s "exotherm " —th e matrix' s chemica l reaction generate s it s ow n heat—resultin g i n a fina l cure d state . Mos tmanufacturers don' tpost-cur e gel-coate d products , bu t the y sometime s us e a heate d oven t o accelerate cure . Finally , th e gel coatfinish i s buffe d an d polished . . ^ SOLI D SURFACE S Ai r void s ma y b e tolerated I n gel-coate d products , bu tnon-porou s castin g i s criti cal i n densifie d sur face s tha thav e n o protectiv e ge l coat . Ge l coate d produc t densit y i s typicall y 1. 2 to 1. 5 specifi c gravity , compare d to a soli d surfacin g density of 1. 5 to 1. 8 specifi c gravit

y (50 percen tt o 8 0 per cen theavie r tha n wate r a t1. 0 specifi c gravity) . Fo rthi s reason , th e resin matri x for* 5 solid* " surfac e castin g te usuall y blende d with a vacu u m mixer , an d part s ar e cure d unde r vac uu m to remove trappe d air. Densifie d product s ar e ove n cure d (typicall y tw o hour s a t180°F ) to avoi d post-mol d shrinkage . Densifie d (soli d surface ) product s cal l fo r a high-qualit

y resin matrix tha toffer

s a n aestheti c finish an d colo r stability . I t mus tals o b e moisture- , stain - and ultra violet-yellowin g resistant , an d provide mechanica l strength an d therma l shoc k characteristics . Dary

l Francis , nationa

l sale s manage r for th e Silma r Resin s Divisio n o f Interplasti c Corp . (For

tWright , Ky. ) sa y hi s compan y recommends poly este r resin s base d o n NP

G an d isophthal i c acid . "Modificatio

n b y MM A acrylic ca n improve U

V an d stai n resistance. Whil e thes e composition s are mor e expensiv e tha n orthophthali c resins, they achieve th e highe r performanc e level s require d b y soli d surfac e product s i n aesthetic-critical applications, " h e explains . DuPon tCorp . (Wilmington. Del. ) origi nate d soli d surfac e cas tpolymer wit h Corian i n th e lat e 1960 s (Figur e 3) . According t o Tony Rala, commercia l tech nology manager , Coria

n i s abou t4 0 per cent'MM A .pqlymerjand ,60 . perceht»hifih grade ATH, ; ; with smal l amounts. . o f big ments . initiators,an d catalysts . "Durin g th e manufacturin g process , al l chemical s are fully reacted," Raia says . Thi s result s l n a ver

y stabl e and environ mentall y saf

e material. " I

n othe r words , product s won' toutga s o r leach an y chem ical s int o air, wate r o r food .

Figur e 3 . Soli d surfac e product s ar e densified , non-porou

s casting s wit h n o ge l coa tIhe y ca n b e cu tshape

d an d seamlessl y joined . (Source : DuPon t Corian ) While kitche n an d bat h product

s ar e stil l th e larges tCoria

n marke tth e com mercia l secto r i s growing fast. "A s archi tect s an d specifier s becom e mor e knowl edgeabl e abou tth e long-ter m economic s o f soli d surface , the y ar

e mor e incline d to specif y i ti n lie u o

f laminate s and othe r more traditiona

l materials. " Raia says . Ne w application s includ e sculpture , furni ture , offic e an d plan twor

k surfaces , a s well a s ar

tspecialtie s suc h a s writin g instruments , jewelr

y an d lighting fixtures. An ; Importantdifferenc

e betweCTl*^e.l

coate d an d soli d surface s t s tha tsoli d stir face'casting s ca n he

? simd^rseamliessl y joined , cu tfor^inlay

s an d eve n route d t o a beveled ; bul l nos e o r wateffall"edge . Daniel lipper tpresiden to f lipper tCorp . (Menomone e Falls , Wis. ) an d curren t COMPOSITE S TECHNOLOG Y SEPTEMBER/OCTOBE R 199 5 1 0 

# 4P. 6

Figur e 4
. Highwa

y overla y polyme r concret e i s read y fo r traffi c i n thre e hours
. Vie w show s applicatio n b y automate d pre-mi x equipmen t train
. (Source: Reichhol

d Chemicals

) replace s labor-inten

siv e filling, priming an d sanding
. The

y als o make specialt

y fillers wit h fiberglass strand s t o provide additiona l bod y an d asprayabl e polyeste

r fo r soli d surfacing
. POLYME R CONCRET E president ofth e ICPA

, see s thi s a s amajo

r advantage
. " A beautiful , seamles s installatio n ca n b e create d wit

h thi s technology, " h e says . "An y othe r surfacin g ha s visible seams. " I n addition , colo

r inlay s ca n b e changed year s afte

r installatio n to matc h new decors
. lipper t

custo mmanufacture s gel

coated cas t

polyme r product s i n marble , onyx , granit

e an d soli d pattems , a s wel l a s Pris msolid surfac e products
. The compan y make s als o it s ow

n fiberglass molds
. BOD Y FILLER S Fille d polyme r meta l finishing fillers clai

m abou t 2 5 percent

o f th e cas t polyme r mar ke t Aut o bod y putty I s typicall

y apoly

este r resi n filled wit

h microsphere s suc h a s glas s beads
. Th e fille d resi n an d hardene r ar e usuall y mixe

d jus t befor e application
. Fibre Glass-Evercoa t Co
. (Cincinnati) produce s alin e o f aut o bod y puttie s an d othe r

meta l fillers suc h a s coatin g tha t

can b e spraye d onto cas t

iro n machin e tool s an d othe r metals
. Thi s

Figur e 5
. Castin g machin e too l bas e wit h hon-shrln k polyeste r allow s insert s t o b e cas t i n plac e withou t causin g interna l stres s o r fractur e (Souree: Reichhol

d Chemicals)
. Polymerconcret e pre-cas t product s an d field application s mak e u p abou t 5 percent o f th e total cas t

polyme r marke t In polyme

r concrete ; polyme

r replace s Portland cemen

t (Figur e 4)
. Again , unsatu
rated polyeste

r i s th e mos t

typica l matri x bu t epoxy , MM

A an dpolyurethan e ar e als o used
. Sand , fly as h an dgrave l ar e fillers. A typica

l formulation ma

y includ e ston e aggregate , fine sand , granite chips , resin, pigmen

t an d additives
. The ston e aggregat e o r grave l varie s b y location
. Californi acontractor s usuall y us e granite an d beac h san d a s fillers fo r field applications , according to A l Klail , presi

den t o f Kwlc k Bon dPolymer s an d Constructio n (Sa

n Ramon , Calif.)
. Mai

l say s polyme

r concret e i s th e "bes t

highwa y overla y syste mi n th e UnitedState s by far " fo r wea r resistance , protectin g steel from sal t ions , an d returnin g highway s to service quickly
. Klai l say s Califomi aha s installe d abou t 5 0 highwa

y overlay s i n climate s rangin g fromdiy , ho t

deser t to th e Sierra Mountains ' snow an d Ice
. On e suc h field Installatio n l s th e souther n approac h t o Sa n Francisco' s Golde n Gat e Bridge
. Highwa

y engineer s use d afast-curin g polyme r concret e fo r ane w sur fac e overlay
. It s composition i s 8 9 percent

filler an d J 1 percent resi n matri x base d o n Reichhold' s Polylit

e 32-04 3 unsaturate d isopolyester
. The 240,00 0 s q ft

polyme r concret e formulatio n wa s completely cure d an d read y fo

r traffi c In thre e hours
. Conventiona l Portlandcemen

t concret e take s abou t tw o weeks
. Klai l caution s tha t

becaus e delay s ar e common l n infrastructur e construction , resin mus t

hav e along shel

f life
. "Reichhol d ha s develope

d aresin tha t

ha s enoug h shelf lif e to b e contractor/user

friendly—and ha s th e righ t propertie s an d promoter s to allo

w adjustment s i n th e fleld fo r changin g weathe r conditions, " Klai

l says . BALLS , BUTTON S AN D BOLT S Th e remaining 2 0 percent

o f th e market

i s sharedby
. furnitur

e parts,-statue s an d figurines,^bowling s balls;^^fbuttohsi'and^mln e bol t anchors.

- Min

e bol t anchor s ar e cas t

l n plac e to quickl

y ancho r steel reba r l n mine shafts , according to Ji mMaass , director o f marketing fo

r Reichhol dChemical s Inc
. (Researc h Triangle Park , N.C)
. Reba r sta
bilize s th e shaf

t roofs an d walls
. Hole s ar e drilled tw o o r

thre e fee t dee p into th e surroundin g rock an d castin g materia l tube s resembling tw

o halve s o f a ho t dog separate d longitudinall y b y a membran e ar e inserted
. Hal f th e tub e i s resi n matri x an d di e othe r

half i s catalys t paste . Reba

r i s pushe ddow

n th e middle o

f di e polyme

r tub e an drotated, mixin

g th e resin an dcatalys t

The castin g gels , an d cur e occur s i n abou t

3 0 seconds
. Th

e technique l s als o bein g considered fo r infrastructur

e construction
. EXPECT CONTINUIN G GROWT H Expec t ne w development s i n materials , technology an d automate dequipmen t sys tem s to pus h thi s non-reinforcedcompos ite s sector Int o higher-volum

e markets
. A

n exampl e o f thi s potentia

l i s aflllable toolin

g resin systemdevelope

d b y Reichhol

dusin g ne w non-shrink

technolog

y (Figur e 5)
. Maas s say s polyester-base d system s tradi

tionally demonstrate comparativel y hig h shrinkage—abou

t 2 percent

t o 7 percen

t linear
. "W e ar e now abl e to formulat

e non shrinking , roo

mtemperature, polyester

base dpolyme

r concret e system s a t

fa r lowe r cos t tha n epox y systems. " Thi s could ope n majo r market s to polyme

r concret e formerl y dominate db y cas t

iron or othe r meta l castings
. Qt Please circle the appropriate number on the reader

service card

for more information on the foUowing: resins/gelcoats, 200; Jitters. 201; equipment. 202. 2 0 COMPOSITE S TECHNOLOG Y SEPTEMBER/OCTOBE R 199 5 wtasJiutii-^Myj.UMJLimiijijyi i