Polyurethane RIM System From Bayer MaterialScience Helps U.S. Foundry & Manufacturing Corp. Think 'Outside The Box'

Revolutionary Valve Box Formed From Bayer's Bayflex 110-50 RIM System is Lightweight, Yet Strong

Pittsburgh - By thinking "outside the box," U.S. Foundry & Manufacturing Corp. has developed a revolutionary new valve box that is as strong as equivalent boxes made of cast iron, but at a fraction of the weight. The valve box was on display at Bayer's booth (#1101) at Composites 2005, Sept. 28-30, in Columbus, Ohio.

The USF-7636 lightweight valve boxes, which incorporate gray cast iron covers, provide access to valves on municipal or residential water lines. They are primarily used in areas experiencing light vehicle traffic or pedestrian traffic such as parking lots, driveways and lawn areas. Florida-based U.S. Foundry forms the innovative valve boxes from the Bayflex® 110-50 polyurethane RIM (reaction injection molding) system from Bayer MaterialScience LLC. The Bayflex 110-50 RIM system offers the physical properties – excellent impact and chemical resistance, stiffness, good surface quality, temperature and dimensional stability and excellent aesthetics – this demanding application required. But what really sets this line of valve boxes apart is its weight … or lack thereof.

Utilizing Bayer's RIM technology, U.S. Foundry is able to produce a 15-inch-tall, 20-inch-diameter valve box that meets medium-duty load rating requirements, yet weighs in at just 16 pounds, compared with the hefty 166 pounds of traditional cast iron valve boxes.

"This adds up to a strong, lightweight product that is easy to handle and transport," said Richard Purvis, product engineering manager, tooling supervisor, for U.S. Foundry. "For municipalities, this translates into reduced labor cost."

In fact, Purvis expects the housing boom – particularly in U.S. Foundry's home state of Florida – to create a strong market for the new line. "The durability, aesthetics and reduced weight these valve covers offer make them the product of choice for this application," said Purvis.

According to Purvis, Bayer's polyurethane RIM system also enabled U.S. Foundry designers to reduce the clearance between the two mating parts. This, in turn, results in less infiltration of foreign materials and allows the polyurethane to act as a gasket, reducing or eliminating water infiltration. "The RIM molding process makes it possible to achieve an excellent fit of the cast iron cover into the valve box seat," explained Purvis.

Just as the Bayflex 110-50 RIM system's combination of properties sets it apart from other material options, so too, does Bayer's combination of technical expertise and excellent customer service set the company apart from other material suppliers, according to Purvis.

"I've had 10 years of experience working with Bayer and I wouldn't work with anybody but Bayer," he explained.

SOURCE: Bayer MaterialScience LLC