ML20198C419

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Requests Approval to Revised GE Drawing 112D1592,rev 15 Ref in Coc for BU-7 Shipping Container.Ref to Phenolic Foam Spec NCI-BU-7 Is Revised from Rev 0 to Rev 2.Description & Explanation of Drawing Changes,Encl
ML20198C419
Person / Time
Site: 07109019
Issue date: 12/16/1998
From: Vaughan C
GENERAL ELECTRIC CO.
To: Chappell C
NRC OFFICE OF NUCLEAR MATERIAL SAFETY & SAFEGUARDS (NMSS)
References
NUDOCS 9812220065
Download: ML20198C419 (67)
v • d • e


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GE Nucicar Energy 1e Gener3!(!xtric Cxwy P0 Bcx 78u Winungton NC?M02 910S!55000 December 16,1998 Mr. Cass R. Chappell, Chief Package Certification Section Spent Fuel Project Office, NMSS US Nuclear Regulatory Commission Washington, DC 20555-0001

Dear Mr. Chappell:

Subject:

Request to Change Callouts on BU-7 Drawing

Reference:

NRC Certificate of Compliance (COC) USA /9019/AF, Docket 71-9019 GE's Nuclear Energy Production (NEP) facility in Wilmington, N.C. hereby requests approval to the revised GE Drawing No. I12D1592, Revision 15 (Attachment 1) referenced in COC for the BU-7 shipping container A description and explanation of the drawing changes are provided (Attaclunent Ia).

. These requested changes involve: (1) an alternate fiberglass size component in the phenolic foam specification,(2) the addition of tolerances to dimensions on the drawing that were previously untoleranced, and (3) the use of stainless steel. None of the changes I

being requested would have an adverse affect on the criticality safety of the package.

j This submittal revises the reference to the phenolic foam specification NCI-BU-7 from Revision 0 to Revision 2. Revision I was never submitted to the NRC. Some of the changes made in Revision 1 are included in Revision 2. These changes include a company name change and clarification for the phenolic resin, the freon and the boric i

anhydride. The other changes made in Revision 2 of the NCI-BU-7 specification are described in the following paragraphs.

Eco-Pak Specialty Packaging (ESP), a manufacturer of the BU-7 Shipping Container, discovered that the Owens Corning No. 405 one quarter inch (1/4") fiberglass roving, referenced in the phenolic foam specificat%n NCI-BU-7, Revision 0 and 1 (See for foam specification NCI-BU-7 Revision 0,1 and 2), had been discontinued. Apparently, Owens Corning had decided to completely switch their i

hp { j products to metric, and now have only the 4mm and 8mm fiberglass rovings available in this product. The Owens Coming replacement product, No. 405D-14C 4mm fiberglass roving, which is described in the enclosed Owens Coming letter dated 1/8/98 (Attachment 3), is requested to replace the original component. Not only is it essentially the same product, except slightly shorter in length, it has comparable physical characteristics, which is shown in the enclosed test results conducted by SGS U.S.

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(,,,ehy['fni 9812220065 981216 PDR ADOCK 07109019 I

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l Mr. Cass R. Chappell L

December 16,1998 l'

Page 2 of 2 l

l Testing Company and Law Engineering (Attachments 4 and 5, respectively). The l

physical characteristics described in Revision 5 of the NCI-PF-1 Phenolic Foam i

l Specification (Attachment 6) are used for the No. 405 one quarter inch (1/4") fiberglass l-roving comparison with the new No. 405D-14C 4mm fiberglass roving component. Also included in Attachment 6 are two letters from ESP to the DOT regarding these changes.

The two physical tests conducted were: (1) compressive strength testing per ASTM D-1621 and (2) thermal conductivity testing per ASTM C-177. The compressive strength values shown in the test results are 42-108 psi for perpendicular to rise samples and 58-l-

147 psi for parallel to rise samples. The values in the NCI-PF-1 foam specification are l

42-81 psi for perpendicular to rise samples and 44-92 psi for parallel to rise samples. The 2

thermal conductivity range for the recent test results is 0.25-0.30 Btu-in/hr-f1 - F and the 2

L range in the NCI-PF-1 foam specification is 0.25-0.30 Btu-in/hr-ft,op, j

L contains a replacement page to Section 5.2.1, inspection Criteria, of the l

application and a description of the change being made. The change updates the foam l

specification document to the latest revision.

I I believe that the only section of the COC that requires changing is Condition (3). The j

drawing reference should be changed to No. I12D1592, Rev.15.

l Six (6) copies of this submittal are being provided for your use.

l Please contact Rick Foleck at (910) 675-6299 if you have questions or would like to l

discuss this matter further.

l l

Sincerely, GE NUCL < R-ENERGY k

Charles M. Vaughan l

Manager i

Facility Licensing i

/zb Attachments (7) cc:

CMV 98-037 8

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'l Mr. Cass R. Chappell -

. December 16,-1998 Page1of1 4.

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41-i Attachment I 1

Replacement Page A for Appendix A Changing the Reference to 4.

GE Drawing No. I12D1592, Revisi en 15, and a Copy of the Drawing 1'

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APPENDIX A Revised GE Licensing Drawing No. I12D1592, Rev.15 l

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I LICENSE SNM-1097 DATE 12/16/98-PAGE

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DOCKET 71-9019 REVISION 2

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i INSULATION PLUG 22-1 it/2* DBA. m 2.75 WDL THIQO4ESS j

FWIE RETARDANT FOAW (20 LB

. FT. ISL DENSITY)

PER AEC MATERIALS AND EQUIPMENT OFICATION P-9 i

f. S AS WCDIFED BY OR@P REPORTS K/IL-729 OR PtENOUC FOAW 2 [

t PER SPECFICAfl0N NO-SU-7.ItEV. 2. TWD UFMNG HOLES, NOT 1 5\\

EXGIDSIG 1* DBA. X 1* DEEP, WAY BE WOLDED NTO DE PLUG TO FACIUTAE NSERTION AND REMOVAL GAGE M MTH 0NE ggg py, hi

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  • 12 GAGE d.0SURE RNG WTH DROP FORGED LUGS, DRILLED AND THREADED FOR j

5/8" DIA. BOLT AND NUT. (SCE NOTE 7)

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1/8" *1/32' THICK SIUCONE RUBOU SPECIFICATION ZZ-R-765 CLASS 10 j

OR Q. ASS 2e OR 2b, ORADE 50. DUI i

AS PURCHASED (SEE DETAIL ZONE C0 3

NNER UD (SEE DETAN, ZONE H-1) g 2

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1 /4'11/16* DIA. VENT NEAR TOP, C0%DtED t.TH WArr

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AEC MATDtlALS AND EQUPIENT

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WTH ROLMD SEAW BOTTOW CG IDENunCAVON PLAM

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(SEE NOTES 5 & 8)

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SEE NOTE 12 INNER DRUM 16 GAL,18 GAGE lmN./14 GA0E WAX.,

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EQ. SPACED ON A 15 3/4*1/4* DIA. 8.C.

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11201592 SHPPING CONTAINER-WODEL D-7 UCDSHQ DRAtee0 NOES:

1. MOOR 10 FWtST UK. LEAM DQH1 NESS 5 %ERFED BY A
7. AFflX TAWDt SAFE EAL 10 M S DIA, SOLT PDt SOAP gugglE TEST AT 15.0 PSG maa TEST M fEQUIRDENTS OF 10 CFIt 71.

(Q PS 00BCUCMD U500 M 910000E M 00NTASGt CASET AS M Of&Y EALDec AGENT BET 1EIN F1ANGE

& TORQLE B00t CONTA8Et BOLTS 10150 900+-POUDOS

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WAXIMUW 10ftQUE NOT 10 m7h

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2. CONW)STT OF 90T10W EADt 3/t* het TO 3/4* WAX.
9. WeeAJW WELD FEET $2E TO K poet DRLad afd.L

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1 CAvlTY DEP1H IEEQUuqED 10 NYYW"A1E PRODUCT DECK ESS. tELD AT 90Tf0W OF 11/2* ANGLE IS

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OPfl0NAL AND WAY BE INTUte#TfD(T OR 380'.

%MW M 10 BE WDM & N Lpt.ESS OTHDtWSE DOICA BOT 10W 00VOLI SEAW.

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& CDd1FICAfl0N PLAW TO BE IthCTED TO M OJTDt

11. $1tEL Cor0ENTS. UILESS OTERWE FEM

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CONTApet WTH 1/B* OIA. STABLESS $1EIL RLMD lthCfS' N BE CMubON SHEL. STASSISS SM MAY SEAli

" ' ("I sE Sues 1nufto r0R ANT CARO 0N STEEL CCedPCNDUS.

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12. OLDER DRUW CAN HAW DMR (2) OR (3) ROLUNG METER HARDNESS 45 TO 75 g pgenugxy,y uAng yy De0RAweso, EToeN4 CR METAL n00Ps s)

STAMP. uSmo 1/2 omaWuW) CHARacTDtS. PeR to CFR 71.Os (c).

11 QPSONAL 30RAL UNDt etstT 10 K UND se ACxx)RDANCE WTH PROWSONS & NRC COnlRCATE.

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14. A MAnaduW OF D4IEE 1/2* WAJeAnd OLAWE10t LFVING HOLII-WTH STASSISS S1tEL ETLETS. TE QMTUtLDE OF TM HOLIS MUST BE 1* WAXhduW F140W THE 10P EDGE OF 1HE DORAL Upst. DE L3et EltlAL Nulsppt idVST SE LOCAltD ON M c 0F TW SMDt STAMLISS STEIL SURFA&

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5/16*-18 WIN./ 7/16*-14 WAX.

4-STL BOLT AND WASHER tsi R. STust X;M til et Suwt 714 atWec slius %

TOR (12 EA. REQ'D.)

Pecm-sae Pt0m-s42 Pem6-7ss PED 6-aan 10/15/n4 D HEX NUT I

121 R. 51 Rose eIA anax 41 AA. apax ko2 BS STEEL)

Pto6-e00 PEme-73e s/te/es PECN-as7 4/34/es OR-s l

11 R. 515ENE 9lA BDAK sIA aDak Pepe-sio Pe > 742 3/so/to PED 6-70s e/30/ss i

14 R.. - E 10] R. sluset e IA anas PED 6-912 PtCN 833 PEDS.73D W

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- Mr. Cass R. Chappell

' December 16,1998 Page1of1 h

Attachment la J

Description and Explanation of the Changes Made to the BU-7 Licensing Drawing 112D1592 from Rev.14 to Rev.15

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/' T l-l Description and Explanation of the Changes Made to the BU-7 Licensing Drawing 112D1592 from Rev.14 to Rev.15 t

Draw.

No.

Zone Description of Change 1

A-3 Changed insulation plug diameter from: 22 - 1/8" to: 22 - 1/8" +/- %.

D-6 Changed phenolic foam specification NCI-BU-7 in two places from: Rev.O to: Rev.2.

2 B-5 Changed silicone rubber gasket thickness from: 1/8" to: 1/8" +/- 1/32.

3 B-7 Changed rubber gasket hardness from: 45 to 75 to: 45 to 75 as purchased.

4 C-1 Changed vent hole diameter from: %" to: %" +/- t/16" 5

H-1 Changed inner lid and gasket OD from: 17" to: 17" +/- %"

H-3 (g

6 H-1 Changed inner lid thickness from: 3/16" to: 3/16" +/- 1/32" 7

H-4 Added after 15-3/4" B.C: "To match lid and flange" 8'

F-2 Changed bolt circle on gasket and flange from: 15-3/4" to: 15-3/4" +/- %"

F-7 The above eight changes are to add tolerances to dimensions which were previously untoleranced and to complete the tolerancing of all dimensions on the licensing drawing. The tolerances reflect new container manufacturing as well as wear and tear on older containers as they are refurbished. Change 1 also reflects the revision to the phenolic foam specification to allow 4.mm fiberglass rovings.

9 B-9 Added the following to drawing note 11: " Stainless steel may be substituted for any carbon steel components" This change will allow stainless steel to be used in those areas of the container subject to wear and high refurbishment costs. Stainless steel has equivalent or better strength compared to mild carbon steel and has better durability and general corrosion resistance. Stainless steel is a better neutron absorber than carbon steel and would lower the reactivity of this fissile l

package.

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Mr. Cass R. Chappell December 16,1998 Page1of1 1

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Foam Sp:cification NCI-BU-7, Revision 0,1 and 2 i

Ata=e h 3.5 NUCLEAR CONTAINERS,INC.

ELIZABETHTON,TN SPECIFICA710N NO.:

NCI-BU-7 PROCEDURETYPE:

MATERIAL AND EQUIPMENT SPECIFICATION DESCRIPTION:

BU-7 PHENOLIC FOAM SPECIFICATION This page is e record ofrevisicas to this procedure. Renmarks huh =v a briefdesadpden of the revision rd am on a part of the pmoedme.

I AFFECTED REVISION DEIE PAGE (s)

REMARKS 0

7/2865 ALL ORIGINAL O

APPROVALS

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b4ti-4,b 11 @

/M QA MANAGER OPERA 710NS MANAOER PRESIDENT

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Page 1 of 3 NCI-DU-7, Rev. 0 Scope This specification shall cover materials and procedures for mixing and app fire resistant phenolic foam with a density range of 7-30 lbs/cu.ft..

Materials All materials used in this phenolic foam shall be as listed below. Any substitution shall require approval of the appropriate authority prior to use in a specification pac Component Wt. %

Material Specification Schenectadh Chemical Company 65.8 0.2
  • Phenolic Resin
  1. HRJ-l1825 Dow Corning DC-193 2.00.1 Surfactant 1,1,2-trichloro-1,2,2-C Cl F 6.6*0.1 2 3 3 trifluoroethane h

Boric anhydride B0 8.0 min.

2 3 Practical grade or better

(-50 mesh size)

Oxalic Acid H C 0.2H O 8.2*0.1 2 2 2

Technical grade or better Fiberglass rovings -

Coated for compatibility 9.60.4

~~

1/4" chopped length with phenolic resin (Owens Coming 405)

Phenolic resins are required to have a chloride content ofless than 300 ppm. Prior

  • NOTE:

to use the chloride content shall be verified by an independent laboratory.

Storace Reauirements Phenolic Resin 1.

Store in airtight storage containers.

2.

Maximum shelflife at an average temperature below 80"F is three months from date of receipt.

O

1 Page 2 0f 3 j

NCI-BU-7, Rev. 0 0

3. '

Maximum shelflife at a temperature of 40oS*F is six months from date of manufacture.

NOTE:

- These dates shall be marked on the storage ecminer or manufacturer's certificates as required.

1 All Other Materials l

1.

All other materials shall be stored at room temperature in properly sealed containers until ready for use in a manner to prevent contact with moisture.

2.

Shelf life should be as recommended by the chemical manufacturer.

Receptacles

/

Receptacles shall be secured and anchored as necessary to prevent distortion by the foam and should have vent holes to prevent voids in the finished foam and to provide gas relief, as defined by the applicable drawings. In the event molds are used, they shall have a mold release applied to the surface or shall be coated with a permanent release coating prior to being filled with foam to facilitate the release of the foam from the mold. Container components in contact with foam components shall have a coating (i.e_.,, zine epoxy primer, etc.*) applied to act as an additional barrier between the foam and the container. This coating shall be applied in not less than 4 mils wet thickness as determined with a paint gauge or less than 1% mils dry thickness as determined

(

by a dry thickness gauge. Surfaces shall be inspected prior to the foaming operation by.

I inspection personnel.

L

  • NOTE:

Zinc epoxy primers are currently being used although other coatings may be used j

if they prove to provide better protection.

Cleanino Before Foamina Receptacles shall be free from foreign particles prior to the foam material being applied.

Temperatures l

1.

Receptacles shall be at room temperature, but not less than 60*F.

2.

Chemicals shall be at a minimum temperature of 60*F when mixed for foaming.

3.

The air temperature shall not be less than 60*F.

Mixino Add liquid components to the mixer tub and stir to a uniform consistency for a minimum l

1.

I of 30 seconds.

Add all other powder components and mix to a uniform consistency for I to 2 minutes.

f.

2.

3.

Add fiberglass and mix no longer than necessary to achieve a uniform consistency.

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Page 3 of 3 NCI BU-7, Rev. 0

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Transfer the mixed raw materials quickly to the receptacle so that the foaming action g

4.

takes place in the receptacle.

PJacing Fonm Material The mixed foam material should be spread evenly over the bottom of the receptacle so th foam expands in relatively level, uniform layers. When multiple pours are required, the layer shall be tamped as necessary to control the height of the foam, thus controlling density. Sequential pours should be sprer.d evenly over the initial layer after foaming the first pour is complete.

Removal of Rracing All bracing, molds or accessories not part of the finished product as defined by the drawings shall be removed after foaming and hardening are complete.

Wnterpronfing Seal all holes in the outer surface where applicable (e.g., vent holes, nail and screw holes, etc.)

with RTV silicone caulking and caplugs as required by the drawings. All molded foam products or exposed foam surfaces shall be sealed using twospats of epoxy primer prior to any finish coat of paint as required.

9 Prior to production of each product Quality Assurance or Engineering shall establish the correct weight of the foam materials required to produce the correct density. Quality Assurance shall verify that the density of the foam installed in each package is that which is required by dividing the difference in package weight before and after the foaming operation by the volume of the foam cavity.

Patching Voids in the finished foam surfaces shall be patched by filling with additiaial fman raw material and allowing the material to expand and cure. Small imperfections may be filled using automotive or other compatible fillers prior to painting.

Records A foaming record must be completed for foaming operations ofindividual packages and shall become a y of the final QA Record. This record shall include at a minimum: foam components, weights before and after foaming, and QA verifications.

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ECO-PAK SPECIALTY PACKAGING ELIZABETHTON, TN PROCEDURE TYPE:

MATERIAL AND EQUIPMENT SPECIFICATION DESCRIPTION:

NCI-BU-7 FOAM SPECIFICATION This page is a record of revisions to this procedure.. Each time a revision is made, ealy the revised pages are reissued. Remarks indicate a brief description of the revision and are not a part of the procepure.

REVISION DATE AFFECTED REMARKS PAGE (s) 0 7/2855 ALL ORIGINAL 4

j 1

5/0157 ALL COMP 4NY NAME CHANGE I

l 4

l' APPROVALS (Alt._ m h LA Mdd/d d-Lilh YWh U

QA MAN GER PRODUCTION MANAGER PRESIDENT I

O

r Page1of3

-l NCl-BU7, Rev.1 Eco-Pak Specialty Packagmg Material and Equipwnt Specification g

NCI-BU7 Fire Resistant Phenolic Foam Scope This specification shaP. cover materials and procedures for mixing and applying foamed-in-p fire resistant phenolic foam with a density range of 7-30 lbs/cu.fl..

Materials All materials used in this phenolic foam shall be as listed below. Any substitutions not listed shall require approval of the appropriate authorit) prior to use in a specification package.

Material Snecification Comnonent WL%

Phenolic Resin

  • Schenectady Chemical Company 65.8*0.2
  1. HRJ-l1825 Surfactant Dow Coming DC-193 2.0*0.1 1,1,2-trichloro-C Cl F 6.6+0.1 2 3 3 1,2,2-trifluoroethane Boric anhydride B0 8.0 min.

2 3 Practical grade or better Mesh size: -50 Oxalic Acid H C 0 2H O 8.2*0.1 2 2 2

Technical grade or better Fiberglass rovings -

Coated for compatibility with 9.6 0.4 1/4" chopped length phenolic resin (Owens Corning 405)

  • Note: Phenolic resins are required to have a chloride content ofless than 300 ppm. Prior to use the chloride content shall be verified by an independent laboratory.

Storage Requirements Phenoliclesm 1.

Store in airtight storage containers.

O

7-Page 2 of 3 NCI-BU-7, Rev. I

' 2.

Maximum shelflife at an average temperature below 80*F is three months from date of receipt.

[

3.

Maximum shelflife at a temperature of 40:i:5*F is six months from date of manufacture.

)

l Note: These dates shall be marked on the storage container or manufacturer's certificates as 4

required.

All Other Materials 1.

.All other materials shall be stored at room temperature in properly sealed containers until l

ready for use in a manner to prevent contact with moisture.

J l

2.

Shelflife should be as manW by the chemical manufacturer.

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ReanenAn

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i Receptacles shall be secumd and anchored as n~+- y to prevent distortion by the foam and

'should have vent holes to prevent voids in the finished foam and to provide gas relief, as defmed j

by the applicable drawings. In the event molds are used, they shall have a mold release applied 4

to the surface or shall be coated with a permanent release coating prior to being filled with foam to facilitate the release of the foam from the mold. Container components in contact with foam

]

components shall have a coating (i.e., zine epoxy primer, etc.*) applied to act as an additional barrier between the foam and the container. ' Ibis coating shall be applied in not less than 4 mils wet thickness as detennined with a paint gauge or less than 1 % mils dry thickness as determined i'

by a dry thickness gauge. Surfaces shall be inspected prior to the foaming operation by

}

inspection personnel, i

j-

  • NOTE:

Zinc epoxy primers are currently being used although other coatings may be used

{'

' if they prove to provide better protection.

}

('lanning Before Fnaming Receptacles shall be free from foreign particles prior to the foam material being applied.

i Temnernhwen 1.

Receptacles shall be at room temperature, but not less than 60*F.

2.

Chemicals shall be at a minimum temperature of 60*F when mixed for foaming.

}

3.

The air temperature shall not be less than 60*F.

I Miring 1.

Add liquid components to the mixer tub and stir to a uniform consistency for a minimum of 30 seconds.

G) 2.

Add all other powder components and mix to a uniform consistency for 1 to 2 minutes.

Page 3 of 3 NCl-BU-7, Rev. I Add fiberglass and mix no longer than necessary to achieve a uniform consistency.

Transfer the mixed raw materials quickly to the receptacle so that the foaming, act g

3.

4.

takes place in the receptacle.

Placing Fnam Material The mixed foam material should be spread evenly over the bottom of the receptacle foam expands in relatively level, uniform layers. When multiple pours are required layer shall be tamped as necessary to contml the heig the first pour is complete.

Remaval of Bracing

/

All bracing, molds or accessories not part of the finished product as defined by the shall be removed after foaming and hardening are complete.

Waternrnnfing Seal all holes in the outer surface where applicable (e.g., vent holes, nail and screw with RTV silicone caulking and caplugs as requin:d by the drawings. All molded foa or exposed foam surfaces shall be scaled using two coats of epoxy primer prio of paint as required.

oi Prior to production of each product Quality Assurance or Engineering shall establis weight of the foam materials required to produce the correct density. Quality verify that the density of the foam installed in each package is that which is re the difference in package weight before and after the foaming operation by the volu foam cavity.

Patching Voids in the finished foam surfaces shall be patched by filling with additional foa and allowing the material to expand and cure. Small imperfections may be filled usin automotive or other compatible fillers prior to painting.

Records A foaming record must be completed for foaming operations ofindividual pack become a part of the final QA Record. This record shall include at a minimum: foam components, weights before and after foaming, and QA verifications.

O l

ECO-PAK SPECIALTY PACKAGING

. ELIZABETHTON, TN SPECIFICATION NO.:

NCI-BU-7 i

PROCEDURE TYPE:

MATERIAL AND EQUIPMENT SPECIFICATION DESCRIPTION:

BU-7 PHENOLIC FOAM SPECIFICATION L

This page is a record of revisions to this procedure. Remarks indicate a brief description of the revision and are not a part of the procedure.

1 AFFECTED l

REVISION DATE PAGE (s)

REMARKS 0

7/28/95 ALL ORIGINAL 1

5/01/97 ALL COMPANY NAME CHANGE 2

12/10/98 COVER,1 TECHNICAL &

ADMINISTRATIVE l

ADJUSTMENTS 1

I l-APPROVALS

]

i REV d W

2 OA MANAGER PRODUCT MANAGER l-I r

_ _ _ _ _ _ _ _ ' ~ ' ' ' ~ ~ ~ ~ - - - - - - - - - _ _ _ _ _ _

Page1of3 NCI-BU-7, Rev. 2 12/10/98 O

Eco-Pak Specialty Packaging Material and Equipment Specification NCI-BU-7 Fire Resistant Phenolic Foam Scope Th9 specification shall cover materials and procedures for mixing and applying foamed-in fire resistant phenolic foam with a density range of 7-30 lbs/cu.ft..

Materials All materials used in this phenolic foam shall be as listed below. Any substitutions not listed shall require approval of the appropriate authority prior to use in a specification package.

Comnonent Wt %

Material Specification Schenectady Chemical Company 65.8 0.2 Phenolic Resin *

  1. HRJ-l1825 g

Dow Corning DC-193 2.0+0.1 Surfactant 6.6*0.1 C Cl F 1,1,2-trichloro-2 3 3 1,2,2-trifluoroethane 8.0 min.

B0 Boric anhydride 2 3 Practical grade or better Mesh size: -50 8.2+0.1 H C 0 2H O Oxalic Acid 2 2 2

Technical grade or better Coated for compatibility with 9.60.4 Fiberglass rovings -

1/4" or 4mm chopped length phenolic resin (Owens Corning 405 or 405D-14C)

  • Note: Phenolic resins are required to have a chloride content ofless than 300 ppm. Prior to u the chlorid-content shall be verified by an independent laboratory.

Storageluquirements Phennlic Resin 1.

Store in airtight storage containers.

,m

~ __

Page 2 of 3 NCI-BU-7, Rev. 2 '

,0 12/10/98

2. '

Maximum shelflife at an average temperature below 80'F is three months from date of j

receipt.

3.

Maximum shelflife at a temperature of 40*S*F is six months from date of manufacture.

Note: These dates shall be marked on the storage container or manufacturer's certificates as required.

All Other Materiale i

1.

All other materials shall be stored at room temperature in properly sealed containers until ready for use in a manner to prevent contact with moisture.

I 2.

Shelflife should be as recommended by the chemical manufacturer.

Receptacles Receptacles shall be secured and anchored as necessary to prevent distortion by the foam and should have vent holes to prevent voids in the finished foam and to provide gas relief, as defined by the applicable drawings. In the event molds are used, they shall have a mold release applied to the surface or shall be coated with a permanent release coating prior to being filled with foam l

to facilitate the release of the foam from the mold. Container components in contact with foam components shall have a coating (i.e., zine epoxy primer, etc.') applied to act as an additional barrier between the foam and the container. This coating shall be applied in not less than 4 mils wet thickness as determined with a paint gauge or less than 1 % mils dry thickness as determined by a dry thickness gauge. Surfaces shall be inspected prior to the foaming operation by

- inspection personnel.

  • NOTE:

Zine epoxy primers are currently being used although other coatings may be used if they prove to provide better protection.

ll Cleaning Refnre Foaming Receptacles shall be free from foreign particles prior to the foam material being applied.

l.

Temneratures I

L 1.

Receptacles shall be at room temperature, but not less than 60'F.

2.

Chemicals shall be at a minimum temperature of 60 F when mixed for foaming.

3.

The air temperature shall not be less than 60 F.

l Mixino l

1.

Add liquid components to the mixer tub and stir to a uniform consistency for a minimum

.v of 30 seconds.

2.

Add all other powder components and mix to a uniform consistency for 1 to 2 minutes.

~-~~

~

Page 3 of 3 NCI-BU-7, Rev. 2 12/10/98 9

Add fiberglass and mix no longer than necessary to achieve a uniform consistency.

3.

Transfer the mixed raw materials quickly to the receptacle so that the foaming action 4.

takes place in the receptacle.

Placing Fnam Material The mixed foam material should be spread evenly over the bottom of the receptacle so that foam expands in relatively level, uniform layers. When multiple pours are required, the fi layer shall be tamped as necessary to control the height of the foam, thus controlling density. Sequential pours should be spread evenly over the initial layer after foaming a the first pour is complete.

Removal of Bracing All bracing, molds or accessories not part of the finished product as defined by the drawi shall be removed after foaming and hardening are complete.

Waternroofing Seal all holes in the outer surface where applicable (e.g., vent holes, nail and screw hole with RTV silicone caulking and caplugs as required by the drawings. All molded foam prod or exposed foam surfaces shall be sealed using two coats of epoxy primer prior to a of paint as required.

QA Prior to production of each product Quality Assurance or Engineering shall establish the weight of the foam materials required to produce the correct density. Quality Assu verify that the density of the foam installed in each package is that which is requi the difference in package weight before and after the foaming operation by the volume foam cavity.

Patching Voids in the finished foam surfaces shall be patched by filling with additional foam ra and allowing the material to expand and cure. Small imperfections may be filled using automotive or other compatible fillers prior to painting.

Records g

A foaming record must be completed for foaming operations ofindividual packag W

become a part of the final QA Record. This record shall include at a minimum: foam components, weights before and after foaming, and QA verifications.

Mr. Cass R. Chappell December 16,1998 Page1of1 qU

\\

5 Owens Corning Letter Dated 1/8/98 A

4

V O

owens conMNG ANoERSON PLANT P.o. box 1367, HIGHWAY 81 SOUTH, STARR ROAo ANoERSON. south CARouNA 29624.8761 064.296 4221 FAX 064 296.1469

/

G January 8,1998 Heather Little Eco-Pak Specialty Packaging 125 lodent Way Elizaoethton, TN 37643

Dear Heather,

Per your request via our phone conversation today, this letter is intended to document the similarities and differences between the now obsoleted Owens Coming Chopped Strand 405AA 1/4" and the new replacement product 405D-14C 4mm. Both the 405AA 1/4" and the 4050-14C 4mm chopped strands were developed specifically for phenotic compatibility. In fact, both products share the same sizing chemistry (chemical coating on the glass) to impart that phenolic compatibility. In addition, both have the same inorganic glass composition (which accounts for about 99% by weight of the product) with filament diameters of approximately 14 microns. The

[]

products differ in the process on which they are chopped and in the chop length. 405AA had a V

chop length of 1/4" while 405D-14C has a chop length of 4mm or 5/32". 405D-14C 4mm was developed and introduced with the specific objective of providing a replacement product with similar performance in phenolic applications to the obsoleted 405AA 1/4".

If you require any additionalinformation regarding Owens Coming's 405D-14C 4mm chopped strand, please don't hesitate to contact me at (864)296-4162.

Yours Truly,

-~

Corey A. Melvin Senior Product Engineer Owens Coming l

O N.

l OWENS CORNING

Mr. Cass R. Chappell December 16,1998 Page1 of1 1

i 4

4 l

1 4

l Test Results Conducted by SGS U.S. Testing Company

..~ -

4

~

SGS U.S. Testing Company Inc.

291 Fairfield Avenue REPORT NUMBER: 103212

' Fairfield, NJ 07004 DATE: January 21,1998 Tel: 201-575-5252 PAGE 1 OF 2 Fax: 201-575-8271 CLIENT:

Eco Pak Specialty Pkg.

125 lodent Way Elizabethtown,TN 37643 Attn: Heather Little

SUBJECT:

Thermal Conductivity b

AUTHORIZATION:

Eco Pak Specialty Pkg. - Purchase Order #4152 1

SAMPLE ID:

Two (2) samples of material were received from the Client on January 6, 1998. The Client identified the samples as:

1)

Eco-Pak #1 2)

Eco-Pak #2 oc TEST PROCEDURE: The submitted samples were tested for Thermal Conductivity in

,O accordance with the procedures outlined in ASTM Test Method C177 85(1993).

L.LJ TEST DATES:

January 16,1998 5

RESULTS:

Continued on Page 2 PREPARED BY:

SIGNED FOR THE COMPANY BY:

SQ

~

Jeffrey Chien, Supervisor Frank Savino, Manager Engineering Physical Properties Engineering Physical Properties dj C\\

V Member of the SGS Group SOS U S. TESTN3 COMPANY MC. REPORTS ARE EXCL CUE 10 WHOM THEY SSE L

ON SUCH REPORTS SHOULD UNDER-TO THE TE TED TEST RESUL MA NOT MDCATr4 OF THE OF THE LO ROM WHICH SA AS N SOSUS ST CO PANY MC

%ll?OT ^l".Oi>Om"b*il",4" =##0R#" T4"JO#m" "t'n"STsl"*A,#' ^?lJi'"' S #~'O #RE"s"x%"ET NFmTA OUTTHE WRITTEN PERhAS*,0N OF THE SGS U.S TESTING COMPANY INC SAMPLES NOT DESTROYED M TESTING ARE DSPOL OF AFTER 30 DAYS.

r REPORT NUMBER: 103212 DATE: January 21,1998,

SGS U.S. Testing Company Inc.

PAGE 2 OF 2 CUENT:

Eco Pak Specialty Pkg.

RESULTS:

Eco-Pak #2 Eco-Pak #1_

5.54 9.75 Sample Density, Lbs./ cubic ft.

2.055 1.999 Thickness, IN.

95.52 95.65 Hot Face Temperature, 'F 54.68 54.82 Cold Face Temperature, *F 75.10 75.24 AverageTestTemperature F 0.305 0.248 Thermal Conductivity, k Btu-inihr.-ft g r

l l

W l

LL O

O h

End of Report O

ct LLI E

O

i Mr. Cass R. Chappell December 16,1998 Page1of1 4

J

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a f

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. Test Results Conducted by Law Engineering 4

4 4

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LAW ANGINEERING INDUSTRIAL SERVICES A DIVISION OF LAW ENG. & ENV. SVCS., INC.

8BA)j 2801 YORKMONT ROAD, SUTTE 200 + CHARLOTrE, N.C. 28208 i Og O

i p)

P.O. BOX ? 9667 + CHARLOTTE, N.C. 28219-9667 4b 1

t 2

PHONE 704-357-8600 FAX 704-357-8637 ECO-PAK SPECIALTY PACKAGING Laboratoly Testing, ASTM D 1621-94 Law Engineering Industrial Services Project 10825-7-7094 January 16,1998 Low Dansity Sample SAMPLE MASS (Ibs)

VOL (ft')

DENSITY PEAK AREA (in*)

COMPRES"YVE 1

ID (lbs/ft')

LOAD (Ibs)

STRENGTiluisi)

A' O.0299 0.0047 6.36 244.%

4.02 60.95 B

0.0275 0.0045 6.11 220.16 3.78 58.20 D

0.0302 0.0047 6.43 254.88 4.06 62.79

~

k E'

O.0302 0.0044 6.86 238.48 3.86 61.76 H*

0.0246 0.0044 5.59 164.45 3.90 42.16 I'

  • 0.0317 0.0044 7.20 230.08 3.95 58.30 i

K*

0.0310 0.0043 7.21 165.98 3.77 44.03 2

4

+ Sampic 1.D. Nos. arbitrarily assigned by LEIS

  • Samples reportedly cut perpendicular (horizontal) to rise of foam. Compressive load applied against the grain All other samples reportedly cut parallel (vertical) to rise of foant Coir pressive load applied with the grain.

Rest ectfully submitted, W

I mkchman Santanam Charlotte Technical Center Manager

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LAW ENGINEERING INDUSTRIAL SERVICES

,; e$l A DIVISION OF LAW ENG. & ENV. SVCS., INC.

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2801 YORKMONf ROAD, SUITE 200

  • CilARLO1TE, N.C. 28208 i

P.O. BOX 19667

  • CilARLOTrE, N.C. 28219-9667 P1IONE 704-357-8600 FAX 704 357 8637 ECO-PAK SPECIALTY PACKAGING Laboratory Testing, ASTM D 1621-94 Law Engineering Industrial Services Project 10825-7-7094 January 16,1998 High Density Sample SAMPLE MASS (Ibs)

VOL (ft')

DENSITY PEAK AREA (in')

COMPRESSIVE ID (Ibs/ft')

LOAD (Ibs)

STRENGTH (psi)

B2 0.0418 0.0048 8.71 585.70 3.99 146.93 Cl 0.0450 0.0047 9.57 359.05 4.00 89.73 D1 0.0350 0.0045 7.78 441.85 3.93 112.33 11 0.0425 0.0045 9.44 344.93 3.%

87.20 N1 0.0390 0.0049 7.96 420.86 4.22 99.66 O

Ql 0.0376 0.0044 8.55 512.06 3.83 133.76

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Fl*

0.0414 0.0051 8.12 265.95 4.01 66.28 Gl*

0.03 %

0.0049 8.08 375.08 4.27 87.7' H1*

0.0376 0.0044 8.55 427.35 3.%

107.93 MI*

0.0412 0.0046 8.%

339.21 3.82 88.76 Pl*

0.0410 0.0049 8.37 265.95 3.93 67.73 Rl*

0.0394 0.0049 8.04 283.88 4.01 70.74

+ Sample I.D. Nos arbitrarily assigned by LEIS

  • Samples reportedly cut perpendicular (honzontal) to rise of foam. Compressive load applied against the grain All other samples reportedly cut parallel (vertical) to rise of foam. Compressive load applied with the grain.

Respectfully submitted, 4C Lakshman Santanam Charlotte Technical Center Manager l

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l Mr. Cass R. Chappell December 16,1998 f~

Page 1 of j l

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l Revision 5 of NCI-PF-1 Phenolic Foam Specification l

l l

l i

1

ECO-PAK SPECIALTY PACKAGING Os ELIZABETHTON, TN SPECIFICATION NO.:

NCI-PF-1 PROCEDURE TYPE:

MATERIAL AND EQUIPMENT SPECIFICATION DESCRIPTION:

NCI-PF-1 PHENOLIC FOAM SPECIFICATION i

This page is a record of revisions to this procedure. Remarks indicate a brief descriotion of the l

revision and are not a part of the procedure.

l AFFECTED REVISION DAIR PAGE (s)

REMARKS 0

6/09/95 ALL ORIGINAL 1

9/27/95 1,4 TECHNICAL ADJUSTMENTS 2

12/08/95 4

TECHNICAL ADJUSTMENTS 3

2/28/97 ALL COC REQUIREMENTS I

4 5/12/97 COVER,1 COMPANY NAME CHANGE l

5 1/16/98-

COVER, TECHNICAL I

1,2,9,10 ADJUSTMENTS l

APPROVALS f

b UDI+bbM 5

e m

O REV QA MANAGER MANAGER of PRESIDENT MANUFACTURING

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NCI-PF-1, Rev. 5 Eco-Pak Specialty Packaging Material and Equipment Specification NCI-PF-1 Fire Resistant Phenolic Foam SLQ99 This specification shall cover materials and procedures for mixing a fire resistant phenolic foam with a density range of 6.5-9.0 lbs/ft'.

Materials h ll All materials used in this phenolic foam shall be as listed below. Any require approval of the competent authority prior to use in a specification C_ omponent Wt. %

Soecification Material 65.8 0.2 Schenectady Chemical Company Phenolic Resin *

  1. HRJ-11825 Chloride Content < 300 ppm O

2.0*0.1 Dow Corning DC-193 Surfactant 6.6+0.1 C ClF 2 3 3 1,1,2-trichloro-(Dupont Freon TF or equivalent) 1,2,2-trifluoroethane minimum 8.0 B0 Boric anhydride Practical grade or better 2 3 Mesh Size: 50 8.2*0.1 H C 0.2H O 2 2 2

Oxalic Acid Technical grade or better 9.6+0.4 Coated for compatibility with Fiberglass Rovings

%" & 4mm chopped length phenolic resin (Owens Corning 405)

Phenolic resins are required to have a chloride content ofless than 30 Prior to use the chloride content shall be verified by an independent

  • Note:

O l

Page 2 of10 NCI-PF-1, Rev. 5 Basic Physical Properties Thermal Conductivity Based on testing performed on samples ranging in density from 6 lbs/ft' to 10 lbs/ft', the thermal conductivity of the foam ranges from 0.25 to 0.30 Btu-in/hr-fi2..F at 75*F. Testing was performed in accordance with ASTM C-177, " Steady-State Heat Flux Measurements and Thermal Transmission Properties by Means of the Guarded-Hot-Plate Apparatus."

Coinsiessive Strennth Testing was performed in accordance with ASTM D-1621 " Compressive Properties of Rigid Cellular Plastics." Testing was performed on April 29,1996, using a 10K Instron Universal Testing Machine. The unit had a range from 0-10,000 pounds (Serial Number: 89872,315,103 Calibration Date: 12/21/95; Calibration Due Date: 12/21/96). Testing was also performed on January 16,1998, using a United Calibration Corporation Universal Testing Machine. The unit

)

had a range from 0-20,000 pounds (Serial Number: QS-4815; Calibration Date: 1/23/97).

The testing was performed on samples ranging in density from 6 lbs/ft' to 10 lbs/ft'. The following compressive strength properties were identified:

Load Direction - Parallel to Rise - 44 psi to 92 psi (4/29/96); 58 to 146 psi (1/16/98)

Load Direction - Perpendicular to Rise - 42 to 81 psi (4/29/96); 44 to 107 psi (1/16/98)

Typical stress strain curves for the phenolic foam at low and high densities are attached as Figures

-1 to 4. The 1/16/98 test results are attached on pages 9 and 10.

Storane Reauirements Phenolic Resin 1.

Store in airtight storage containers.

2.

Maximum shelflife at an average temperature below 80*F is three months from date of receipt.

3.

Maximum shelflife at a temperature of 40*5'F is six months from date of manufacture.

Note: These dates shall be marked on the storage container or manufacturer's certificates as required.

All Other Materials 1.

All other materials shall be stored at room temperature in properly sealed containers until ready for use in a manner to prevent contact with moisture.

A 2.

Shelflife should be as recommended by the chemical manufacturer.

.. - =

Page 3 of10 NCI-PF-1, Rev. 3 Recentacles Receptacles shall be secured and anchored as necessary to prevent distortion by the should have vent holes to prevent voids in the finished foam and to provide gas relief, as de by the applicable drawings. In the event molds are used, they shall have a mold rele the surface or shall be coated with a permanent release coating prior to being filled with foam to facilitate the release of the foam from the mold. Container components in contact with foam components shall have a coating (i.e., zinc epoxy primer, etc.') applied to act as an additiona barrier between the foam and the container. This coating shall be applied in not less than 4 mils wet thickness as detennined with a paint gauge or less than 1% mils dry thickness as determined by a dry thickness gauge. Surfaces shall be inspected prior to the foaming operation by i personnel.

Zinc epoxy primers are currently being used although other coatings may be used if

  • NOTE:

they prove to provide better protection.

t Cleaning Before Foaming Receptacles shall be free from foreign particles prior to the foam material being applied.

h Temocraturn 1.

Receptacles shall be at room temperature, but not less than 60*F.

2.

Chemicals shall be at a minimum temperature of 60'F when mixed for foaming.

3.

The air temperature shall not be less than 60"F.

Mixing 1

Add liquid components to the mixer tub and stir to a uniform consistency for a minimum of 30 seconds.

2.

Add all other powder components and mix to a uniform consistency for 1 to 2 minutes.

3.

Add fiberglass and mix no longer than necessary to achieve a uniform consistency.

4.

Transfer the mixed raw materials quickly to the receptacle so that the foaming action takes place in the receptacle.

Placing Foam Material The mixed foam material should be spread evenly over the bottom of the receptacle so that the foam expands in relatively level, uniform layers. When multiple pours are required, the first layer shall be tamped as necessa;y to control the height of the foam, thus controlling the foam density.

l Sequential pours should be spread evenly over the initial layer after foaming action of the first l

pouris complete.

I

Page 4 of 10 NCI PF-1, Rev. 3 Removal of Bracing 1

All bracing, molds or accessories not part of the finished product as defined by the drawings shall

. be removed after foaming and hardening are complete.

Wateroroofing Seal all holes in the outer surface where applicable (e.g., vent holes, nail and screw holes, etc.)

with RTV silicone caulking and caplugs as required by the drawings. All molded foam products or exposed foam surfaces shall be sealed using two coats of epoxy primer prior to any finish coat of paint as required.

QA Prior to production of each product Quality Assurance or Engineering shall establish the correct weight of the foam materials required to produce the correct density. Quality Assurance shall verify that the density of the foam installed in each package is that which is required by dividing the difference in package weight before and after the foaming operation by the volume of the foam cavity.

Patching l

Voids in the Snished foam surfaces shall be patched by filling with additional foam raw material l

and allowing the material to expand and cure. Small imperfections may be filled using automotive or other compatible fillers prior to painting.

' Records A foaming record must be completed for foaming operations ofindividual packages and l

shall become a part of the final QA Record.

The fabricator will also keep all records from the independent laboratory verifymg the l

chloride content of the phenolic resin. This is for verification that the overall chloride content of the phenolic foam is below 200 ppm.

l l

l

!O

m Page 5 of 10 NCI.PF.1, Revj l}

Figure 1

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Susin Weight Dimensions (inches)

Heicht Length Samole ID Widtli 1.95 2.10 7.95 76.02 TN.1055LDF.3 1.96 2.05 8.05 75.91 TN.1055LDF-9 2.04 2.00 8.00 79.12 TN.1055LDF.10

+m Page 6 of10 s

U NCI.PF.1, Rev. 3

.)

Figure 2 Typical Stress vs Strain, Perpendicular to Risc Low Density Foam Samples Sampic No.16 Sasopic No.15 50...-.

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Page 7 of16' g

NCI.PF-1, Rev: 3 Figure 3 l

R.isc

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/N Page 8 of 10

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NCl-PF-1, Rev. 3

.I Fi8ure4 Typical Stress vs Strain, Parallel to Risc Low Density Foam Samples Sample No.19 Sampic No. Is so eo 3...........................

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4v.-

l

Page 9 of 10 LAW ENGINEERING INDUSTRIAL SERVIdb~

d A DIVISION OF LAW ENG. & ENV. SVCS., INC.

lyb O

2801 YORKMONT ROAD, SUrm 200

  • CHARMTE. N.C. 28208 P.O. BOX 19667 = CHARLOTTE, N.C. 28219-9667 PHONE 704 357-8600 FAX 704-357-8637 ECO-PAK SPECIALTY PACKAGING Laboratory Testing, ASTM D 1621-94 Law Engineering Industrial Services Project 10825-7-7094 January 16,1998 Low Density Sample SAMPLE MASS (Ibs)

VOL (ft')

DENSITY PEAK AREA (in')

COMPRESSIVE l

Obs/ft')

LOAD 0bs)

STRENGTH (psi)

ID A'

O.0299 0.0047 6.36 244.%

4.02 60.95 B'

O.0275 0.0045 6.11 220.16 3.78 58.20 D

0.0302 0.0047 6.43 254.88 4.06 62.79 E'

O.0302 0.0044 6.86 238.48 3.86 61.76 H*

0.0246 0.0044 5.59 164.45 3.90 42.16 1*

0.0317 0.0044 7.20 230.08 3.95 58.30 IC*

0.0310 0.0043 7.21 165.98 3.77 44.03

+ Sample I.D. Nos. arbitrarily assigned by LEIS

  • Samples reportedly cut pernenAim1=r (horizontal) to rise of foam. Compressive load applied against the grain All other samples reportedly cut parallel (vertical) to rise of foam. Compressive load applied with the grain.

I Rest ectfully submitted, I skchman Santanam Charlotte Technical Center Manager

Pags 10 of 10 LAW ENGINEERING INDUSTRIAL SERY[bN- ""'

A DIVISION OF LAW ENG. & ENV. SVCS., INC.

i 2801 YORKMONr ROAD, SUTE 230

  • CilARLOTTE. N.C. 28208 P O. BOX 19667
  • CIIARLOTE, N.C. 28219-9667 PIIONE 704-357-8600 FAX 704 357-8637 ECO-PAK SPECIALTY PACKAGING Laboratory Testing, ASTM D 1621-94 Law Engineering Industrial Services Project 10825-7-7094 January 16,1998 High Density Sample SAMPLE MASS (Ibs)

VOL (ft*)

DENSITY PEAK AREA (in')

COMPRESSIVE ID (Ibs/ft')

LOAD (Ibs)

STRENGTH (psi)

B2 0.0418 0.0048 8.71 585.70 3.99 146.93 Cl 0.0450 0.0047 9.57 359.05 4.00 89.73 D1 0.0350 0.0045 7.78 441.85 3.93 112.33 11 0.0425 0.0045 9.44 344.93 3.%

87.20 N1 0.0390 0.0049 7.%

420.86 4.22 99.66 Ql 0.0376 0.0044 8.55 512.06 3.83 133.76 Fl*

0.0414 0.0051 8.12 265.95 4.01 66.28 Gl*

0.03 %

0.0049 8.08 375.08 4.27 87.77 Hi*

0.0376 0.0044 8.55 427.35 3.%

107.93 Mi*

0.0412 0.0046 8.%

339.21 3.82 88.76 Pl*

0.0410 0.0049 8.37 265.95 3.93 67.73 Rl*

0.0394 0.0049 8.04 283.88 4.01 70.74

+ Sampic I.D. Nos. arbitrarily assigned by LEIS

  • Samples reportedly cut perpendicular (horizontal) to rise of foam. Compressive load applied against the grain All other samples reportedly cut parallel (vertical) to rise of foam. Compressive load applied with the grain.

Respectfully submitted, 4C Iskehman Santanam Charlotte Technical Center Manager

sm_

m.

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m. a l

l Eco-Pak 125 lodent Way, Suite A Slmcialty Packaging Ezdedu n,W 37643 USA Dl vision of CBC Tel:423-543-4211 800-2212465 Fax:423-543-6007

' q I

intermediate Bulk Containersfor Gemicals & Liquids UFgandD0 Packaging 2

January 23,1998 Atta: Mr. Alan I. Roberts, Associate Administrator Office of Hazardous Materials Safety Research and Special Programs Administration United States Department ofTransportation 400 Seventh Avenue, SW Washington, DC 20590-0001:

RE:

Revision to Competent Authority Certificate No. USA /4909/AF

Dear Mr. Roberts,

Eco-Pak Specialty Packaging (ESP), would like to request that the DOT Certificate of Competent hc Authority No. USA /4909/AF be modified to include the following substitution for the phenolic foam in the reissuance of the certificate prior to March 1,1998. This modification will affect Appendix A, Variations From 49 CFR 178.358, for the DOT Specification 21PF-1B overpack, as well as the Safety Analysis Reportfor the DOT-21PF-1B Protective Shipping Package with Vahe Protection Device, Appendix 2.10.2, submitted February 25,1997.

The fiberglass roving component, Owens Corning No. 4051/4", was discontinued approximately 10 months ago, and the suggested replacement is Owens Corning No. 405D-14C 4mm. ESP just discovered the discontinuation last month and immediately made contact with Owens Corning, received a sample of the No. 405D-14C 4mm fiberglass, and had foam samples of the appropriate density range tested for compressive strength per ASTM D-1621 and thermal conductivity per ASTM C-177. The results of this testing are very comparable to the physical characteristics specified in ESP's NCI-PF-1 Phenolic Foam Specification (erielosed).

ESP anticipates a large order of the DOT-21PF-1B packages (specifically 160), which canno; !<

manufactured, and thus transported, without authorization of this substitution to the NCI-PF-1 Phenolic Foam Specification and variation from 49 CFR 178.358. Therefore, we need this change in the upcoming reissuance of the certificate.

l Enclosed are copies of the letter from Owens Corning regarding the discontinuation and replacement of the fiberglass roving component, the NCI-PF-1 Phenolic Foam Specification, Rev.

l [d 4, the NCI-PF-1 phenolic foam specification, Rev. 5 (including the fiberglass component l

Mr. AlanI. Roberts Page2 January 23,1998 substitution), and the recent test results on foam samples containing Owens Corn 14C.

If you need any further information, please contact myself or Heather Little Respectfully yours, t

Q16tA. )\\M William M. Arnold President Mr. Jim O'Steen, Director, OHMT Mr. Rick Boyle, Chief, Radioactive Materials Branch, OHMT cc:

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Eco-Pck 125 lodent Way, Suite A Specialty Packaging Elizabethton,TN 37643 USA r-x Division of CBC Tel:423-543-4211 800-221-2465 Fax:423 543-6007 Intermediate Bulk Containersfor Gemkals & Liquids U andU0 Packaging 2

January 23,1998 Mr. Alan I. Roberts, Associate Administrator Office ofHazardous Materials Safety Research & Special Programs Administration United States Department of Transportation Washington, D.C. 20590-0001 l

RE:

Emergency Modification to Exemption DOT-E 11347

Dear Mr. Roberts:

Eco-Pak Specialty Packaging (ESP) would like to request a modification to the abovementioned exemption, particularly in Paragraph 7(a)(1) regarding the other ingredients to the phenolic foam described in the NCI letter of October 27,1994. This modification is considered an emergency, because ESP anticipates a large order of these exempt packages, specifically 160, that cannot be filled without this modification.

/

s ESP discovered 5 weeks ago that the Owens Corning No. 4051/4" fiberglass roving, an equivalent to the original No. 8321/4", had been discontinued approximately 9 months prior.

Apparently, Owens Corning has decided to completely switch their products to metric, and now have only the 4mm and 8mm fiberglass rovings available in this product. The Owens Corning replacement product, No. 405D-14C 4mm fiberglass roving, which is described in the enclosed Owens Corning letter is requested to replace the product mentioned in the 10/27/94 letter. Not only is it essentially the same product, except slightly shorter in length, it has comparable physical characteristics, which is shown in the enclosed test results (No. 405D-14C 4mm) and current NCI-PF-1 foam specification (No. 4051/4").

The two physical tests conducted were compressive strength testing per ASTM D-1621 and thermal conductivity testing per ASTM.C-177. The compressive strength values show m the test results are 44-107 psi for perpendictdar to rise samples and 58-146 psi for parallel to rise samples. The values in the NCI-PF-1 foam specification are 42-81 psi for perpendicular to rise samples and 44-92 psi for parallel to rise samples. The thermal conductivity range for the recent test results is 0.25-0.30 Btu-in/hr-ft2..F and the range in the foam specification is 0.25-0.30 Btu-in/hr-ft' *F.

Since ESP discovered this change 9 months after the discontinuation, there is not a lot of the former product left av.dable. Again, we anticipate an order to be placed within the next few 3

weeks of 160 of these exempt packages that cannot be filled without this modification.

(V Therefore, we request that this exemption modification be given high priority, so that we may l

l continue to manufacture these packages without delay.

Mr. AlanI. Roberts Page 2 j

January 23,1998 If there are questions concerning our request for this emergency modification, or if there is anything further that we could do to expedite this change, please contact me at (800)

Best regards, 9

A1d eather Little Regulations Specialist Enclosures (5)

Cc:

Suzanne Hedgepeth, Director, OHMEA Rick Boyle, Chief, Radioactive Materials Branch, OHMT O

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Mr. Cass R. Chappell December 16,1998 Page1.of1 Replacement Page and Explanation of the Change Page Section Description of Channe 21-5.2.1 Changed the drum primer thickness specification from NCI-BU-7, Rev. O, to NCI-BU-7, Rev. 2 O

O i.

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Typical Typical e;

Container Inspection

,Q Characteristic Specification

%)

Phenolic Plug 12.2 lbs. Minimum weight of plug Soap bubble pressure test for 15 PSIG minimum the inner container Leak tightness is verified by a soap bubble test at 15.0 PSIG, minimum. Test is conducted using the silicone rubber container gasket as the only sealing agent between flange and cover.

Drum Primer Thickness The primer thickness, per specification NCI-BU-7, Rev. 2, will be verified by one random reading each on the inside of the outer drum and outside of the inner

drum, Verification of container Based on approved dimensions on e

measurements licensing drawing Appearance integrity No visible holes or cracks, and no

]

(Visual) significant absence of paint Boral Liner Verification of dimensions based e

on licensing drawing i

j Visual for physical integrity Visual at tends ofliner for missing Boral material between stainless steellayers Review vendor test result for boron content to assure areal l

density.

Review certification for traceability of Boral to liner serial i

number.

O LICENSE SNM-1997 DATE 12/16/98 PAGE b

DOCKET 71-9019 REVISION 2 l

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