Republic Ultra Coat Face
We are taking the lead in producing a product that is less dependent on diminishing white fiber sources. This new sheet can replace standard gypsum face paper and will produce a more uniform color with an improved surface.
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Republic Ultra Coat Properties:
- More uniform color from run to run
- Smoother
- Less standing fiber on sanding
- Similar surface to fiber for painting and taping
- Good performance in humid conditons
- Reduced damage/delamination of painted walls with tape peel
- Less effect of fiber swelling when wetted
- Quickly approaches maximum whiteness with fewer coats
- More closely matches the swatch color even with difficult colors
- Coating the sheet leads to higher porosity which still runs well on board machines
- Coating goes translucent when wet but re-turns to white when dry
Description
Many of the fiber sources that were once used to produce gypsum face paper have diminished due to the electronic age with less use of newspaper and lower availability of unprinted white fiber. Republic saw the future and started investingating alternatives and options. A newer type coater was gaining ground in the U.S., the curtain coater. The curtain coater has defined advantages over standard blade, air-knife and rod coating that looked like a viable option for Republic. After approximately five years of research and development, Republic finalized a coating formulation that works in the gypsum board process. Board was produced using the coated paper, evaluated and tested and found to run well in the board plant. Finished gypsum board was then installed on various jobs from office to commercial buildings and performed well.
GENERAL SPECIFICATIONS
| Critical Properties | UOM | Min | Target | Max | Test Method | Method Comments |
|---|---|---|---|---|---|---|
| Basis Weight | lbs/msf | -2.0 | as ordered | +2.00 | ABB Scanner | |
| Moisture | weight % | 7.5 | 9.00 | 10.5 | ABB Scanner | |
| Porosity | sec/100cc | Grade Dependent | Autoline | Gurley; 5-min 300°F cure | ||
| Face Cobb | g/100cm^2 | 0.30 | 0.80 | 1.50 | T-441 | 10-min 250°F cure; 3-min 120°F water |
| Bond Cobb | g/100cm^2 | 0.50 | 0.70 | 1.2 | T-441 | 10-min 250°F cure; 3-min 120°F water |
| ZDT | psi | -20 | BW dependent* | ----- | T-541 | Uncured |
| MD Tensile | lbs/in | -10 | BW dependent* | ----- | Autoline | 5-min 300°F cure |
| CD Tensile | lbs/in | -4 | BW dependent* | ----- | Autoline | 5-min 300°F cure |
| Smoothness Sheffield | SU | 350 | Autoline | 5-min 300°F cure | ||
| Coefficient of Friction | degrees | Grade Dependent | T-815 | Uncured; test 3x, record 3rd value | ||
| Expansion 180 sec | % | -0.30 | BW dependent* | +.30 | CD Wet | Uncured; 10” strip |
*BW Dependent Targets:
| BW | 38/42 | 48 | 54 |
|---|---|---|---|
| MD Tensile | 83 | 90 | 95 |
| CD Tensile | 28 | 32 | 35 |
| ZDT | 80 | 75 | 73 |
| Expansion | 1.15 | 1.0 | 0.80 |
Additional Requirements:
Surface Quality – Paper shall be uniform in appearance and formation. Examples of defects include, but are not limited to: orange peel, discoloration, tiger striping, streaking, spotting (dirty face), fuzzing, fish hooks, cockles, excessive wire, felt, press roll, or other marking.
Flatness – Paper shall lie flat - free of cockles, edge warp, curling, and grooves.
Holes – Paper shall be reasonably free from holes (no repetitive MD holes). Holes smaller than 3" may be patched (no more than 2 per roll).
Roll Quality – Rolls shall be tightly wound. No telescoping. No wrinkles. No crushed or damaged cores. Splices shall be clearly marked. No splices 1" from the top. Core diameter: 4".
Physical Damage – Paper shall be free from physical defects including, but not limited to tears, edge nicks, excess moisture.
Packaging – Rolls shall be packaged to prevent damage during transport (ex: plastic wrapped). Rolls shall be marked to indicate bond side and labeled with roll number, basis weight, MD & CD tensile strength, top & bond cobb, and porosity.
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Established in 1999, Republic Paperboard Company occupies a 70 acre site in the industrial park in Lawton, Oklahoma. All Manufacturing, Marketing, Sales and Service personnel are based in Lawton.
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