1.0 Purpose of Meltable Specification Manual

This document is intended to serve as a guideline for purchasers, suppliers and receivers of meltables for Logan. It will cover specifications, documentation, qualification, delivery and rejection of incoming meltables. Not all aspects of scrap receiving and requirements may be covered in this document. If there are any questions concerning the acceptability of scrap please contact the purchaser or Logan.

2.0 Confidentiality Notice

This document must not be shared with, loaned, sold, or given to another company, person or plant. The person/company who receives this document from Logan or one of its owners is responsible for its confidentiality.

3.0 Meltable Performance Rating System (MPRS)

Logan has developed a Meltable Performance Rating System for the manufacturers and suppliers of some meltables. The purpose of the MPRS is to provide Logan, Logan's Owners, Meltable Manufacturers and Suppliers with data on the performance of manufacturers, suppliers and their products. When issues with manufacturers and/or suppliers occur Logan can assist in solving the issue. Currently the following materials are being rated:

• RSI
• primary aluminum

4.0 General Meltable Specification – Prime and RSI (For more details see following sections)

• Safety will not be compromised for any reason. Personal injury, environmental destruction and equipment damage will not be tolerated.
• All scrap must be clean and free of dross, excessive mold release agents, pot room bath, salts, corrosion, dirt, gravel, aluminum "fines", un-melted scrap, nitrates, sulfates, oxidizers, fertilizers, unknown powders or residues, volatile substances, non-aluminum contaminants, closed containers, crimped tubing, PCB's, radioactive materials and aluminum-lithium alloys.
• Double poured Prime or RSI sow or sow with rough edges will be rejected.
• Residual lubricant must be less than 1% on all scrap, unless otherwise agreed upon.
• Painted, lacquered or coated scrap is not acceptable.
• Paper interleaved or wrapped scrap is not acceptable. This includes coils.
• Physically unloading the scrap and releasing the delivering carrier does not imply acceptance of the load or the shipped weights. Logan has the right to reject all or part of a load if the specifications described in this manual are not met.
• The mixing of alloys is not acceptable
• Each RSI sow must have the heat number marked on both lifting ends.  The heat number must be centered and near the top of the ingot lifting ends. Heat marking on sow must be consistent with data listed on COA sheet. Numbering must be legible. Numbering must be approximately 2-1/2 to 3 inches in height.

• Each sheet ingot or coils must be marked legibly and permanently with manufacturers heat number and the 4 digit AA alloy code. 
• Each bundle of standard ingots must be marked legibly and permanently with manufacturer's heat number. 

• Ingots more than 300" long or more then 85,000 lbs. must be cut before charging. Any ingots over 10,000 lbs must be able to be lifted by the ingot grab. The grab can grip ingots up to 88" wide but not less than 50". The minimum ingot length for the grab is 90".
• Unskimmed RSI or primary aluminum sows are not acceptable.
• Coils must not be more than 86" wide and must not weigh more than 58,000 lbs.
• Certificates of analysis must accompany all shipments. Representative chemical samples must accompany all RSI shipments. Material outside of chemical composition as stated on the purchase order will be rejected.
• No double or multiple pour sows are acceptable. Logan has a zero tolerance and this metal will be rejected immediately.
• Low profile sows by the Aluminum Association description are preferred. See section 5.0 for low profile sow dimensional calculation.
• Sows are to be free of excessive shrinkage cavities and large cracks. See the detailed specification 6.0, which follows.
• Lips or edges must be less than 1" to allow for stacking and safety
• Ideal low profile ingot and small ingot bundles are pictured below:

5.0 Low Profile Sow Determination



To determine if a sow is low profile, take the width of the sow and divide it by the average depth. To be considered a low profile sow this value should be greater than or equal to 4

6.0 RSI (Recycled Scrap Ingot), Sow, Prime sow

RSI and primary aluminum comes in many forms. Some basic rules apply to all forms supplied to Logan. Low profile sows are preferred for RSI. Low profile sows and T-ingot are the preferred forms for prime aluminum. Certificates of analysis must accompany all shipments. Representative chemical samples must accompany all RSI shipments. Material outside of chemical composition as stated on the purchase order will be rejected.

6.1 Foreign Materials, Contamination

Safety is Logan’s core value. There is zero tolerance for foreign materials and contaminants.

Definition: : Foreign materials are defined as dross, pot room bath, salts, corrosion, dirt, gravel, aluminum "fines", un-melted scrap, nitrates, sulfates, oxidizers, fertilizers, unknown powders or residues, volatile substances, non-aluminum contaminants, closed containers, crimped tubing, PCB's, radioactive materials (2 times Background radiation), aluminum-lithium alloys, any non-aluminum materials contained inside, on the surface of or protruding from the ingot. Foreign materials are not permitted. Affected ingots may be rejected.

Suppliers agree to indemnify and hold Logan Aluminum, its Associates (ARCO and Novelis), and its tollers harmless from any claims, demands, cost and expenses (including reasonable attorney's fees), resulting from or arising under, in whole or in part, a breach of the foregoing warranty that their product is not contaminated with foreign materials whether caused or contributed to in whole or in part by the negligence of Logan Aluminum, its Associates (ARCO and Novelis), or its tollers.

Figure 6.1.1 Steel lift pin left in corner of low profile RSI sow.




Figure 6.1.2 Potroom bath imbedded in primary sow




Figure 6.1.3 Rotary Furnace Flux Salt Contamination



Figure 6.1.4 Dirt and Gravel





Figure 6.1.5 Severely corroded / oxidized sow

Figure 6.2a Bottom of low profile RSI sow showing evidence of worn mold and large amounts of bone ash adhering.




Figure 6.2b Example of bone ash contamination on RSI sows.

6.3 Rough Edges



Definition: Flashing: Rough sharp edges protruding 1" or greater from the ingot edge. This type of defect is not acceptable and poses a safety hazard for anyone walking close to this material. There is zero tolerance and the metal will be rejected. The appropriate Associate will be informed and the issue documented.

6.4 Dross and Skimming (Dross Contamination, Inclusions)

All ingots must be skimmed. Unskimmed ingots are unacceptable. A photo of a well-skimmed ingot is shown below in Figure 6.4a. Figure 6.4b shows an poorly skimmed ingot. Also see Figure 4a for a well-skimmed ingot example.

Figure 6.4a Shows ideally skimmed ingot above

Figure 6.4b Ingot showing dross not skimmed off.

6.5 Shrinkage Cavities




Do not top cool sows with water which are not 100% solidified. Top cooling produces larger shrinkage cavities making it more difficult to drive off trapped moisture. Cooling from the bottom and sides of an ingot helps reduce the size of shrinkage cavities. See the Aluminum Association Guidelines for Aluminum Sow Casting and Charging. The Aluminum Association website is www.aluminum.org

6.6 Double (or multiple) Poured Sows – Zero Tolerance

Double poured sows will be rejected. Double poured sows must never be shipped to Logan. Some examples of double poured sows follow:

7.0 Coils

Coils melted at Logan include coils purchased from outside sources, Logan scrap coils and coils returned from the customer. Logan Remelt will not melt coated coils in its round top furnaces. Environmental permits do not permit the melting of coated coils or other coated scrap. There are recycling opportunities for the coated coils.

1. Maximum coil weight is 58,000 lbs.
2. Maximum coil width is 86 inches.
3. Coils from outside Logan must have 4 digit AA alloy designation and weight legibly and permanently marked.
4. Coils from inside Logan must have 6 digit alloy code and weight legibly and permanently marked.
5. Coils must be banded so the tail is kept under control.
6. Purchased coils must have a chemistry certification with shipping documents and must meet purchase specification
7. Paper interleaved in wraps is unacceptable. See Figure 7.1 below.
8. Coated coils cannot be charged in our round top furnaces. There are recycling opportunities for coated coil.
9. No steel sleeves permitted.
10. Fiber cores of up to 1" wall thickness are permitted.

Figure 7.1 Unacceptable coil showing paper interleaved in coil.

8.0 Ingots and Ingot Butts

Ingots and ingot butts melted at Logan Remelt may be internal scrap or purchased scrap from outside Logan.

1. Maximum ingot / ingot butt weight is 10,000 lbs. for charging directly into buckets.
2. Ingots greater than 10,000 must be put into melting furnace using the ingot grab. The maximum ingot weight is 85,000lbs. The grab can grip ingots up to 88" wide but not less than 50". The minimum ingot length for the grab is 90". The maximum ingot length is 300".
3. Ingots and ingot butts from outside Logan must have 4 digit AA alloy designation and weight legibly and permanently marked.
4. Ingots and ingot butts from inside Logan must have 6 digit alloy code, ingot number, heat number or cast number and weight legibly and permanently marked.
5. Ingots and ingot butts purchased from outside Logan must have a chemistry certification with shipping documents and must meet purchase specification.

9.0 Tub Scrap

Tub scrap originates in business units downstream of Logan Remelt.

1. Blue scrap tubs are for hot mill 6-inch shear scrap ONLY.
2. Yellow tubs are used for all scrap other than hot mill 6-inch shear. The only time yellow tubs may be used for 6-inch shear is when no blue tubs are available.
3. Maximum tub gross weight (tub and contents) is 10,000 lbs.
4. Tubs must be filled with as much scrap as possible without going over the 10,000 lb limit.
5. Mixed scrap in tubs is NOT acceptable. Scrap must be segregated by 6 digit alloy.
6. Coated scrap must not be mixed in with uncoated scrap.
7. Tubs must have the proper identification ticket on both sides of the tub.
8. The material in the tub must match what is on the identification ticket.
9. Tubs must not be filled above the top of the tub. Filling above the top of the tub will prevent Remelt from stacking tubs and making efficient use of high bay storage areas.
10. Tubs must contain only aluminum scrap. No trash permitted. (Steel, banding, cups, oily pit cleanings, etc.)
11. Closed containers in scrap are not permitted.

10.0 Plate Scrap

Plate scrap typically originates from business units downstream of Logan Remelt but could be supplied from outside Logan. The following shall apply to plate scrap.

1. Mixed alloy scrap is unacceptable.
2. Plates must be banded together with the total weight not exceeding 12,000 lbs.
3. Length must not exceed 180 inches.
4. Bundled plate must not exceed 36 inches high.
5. Plate scrap from outside Logan must have 4 digit AA alloy designation legibly and permanently marked.
6. Plate scrap from inside Logan must have 6 digit alloy code legibly and permanently marked.
7. Must have total bundle weight marked legibly and permanently.

11.0 Coated Coils / Coated Scrap

Coated coils and other coated scrap is not to be melted in Logan’s round top furnaces due to environmental, melt rate and melt loss issues. This applies to purchased material and material from other business units within Logan. There are recycling opportunities for coated coil.

12.0 Baled Automotive Scrap (Remelt Round Top Furnaces)

Currently no baled automotive scrap is approved for use in Logan’s round top furnaces. There are recycling opportunities for coated coil.

13.0 Baled Scrap (Remelt Furnaces)

Class I
Class I scrap shall consist of 3000 series alloys used in the production of can bodies. Scrap must not be lacquered, painted or in any way contaminated with gaskets, sealants, oils, etc. Residual lubricant levels of up to 1.5% by weight are acceptable. Other oils or lubricants are not acceptable, for example: hydraulic oil. Recycling of baled scrap is also permitted. (See the ISRI Scrap Specifications Circular at www.isri.org)

1. Scrap must have been always stored inside and kept dry. Scrap must be protected from moisture during shipment.
2. Scrap must be briquetted and securely banded to a sturdy wooden pallet. Plastic pallets are unacceptable.
3. Each pallet must be tagged with scrap origin and alloy.
4. Non-aluminum contaminants such as steel, plastic, dirt, etc, are unacceptable.
5. Gross weight for each pallet must not exceed 8000 lbs.
6. Dimensions of briquette stack on pallet are as follows:
   
   • Width = 5 feet (60 inches)
   • Length = 5 feet (60 inches)
   • Height = 5 feet (60 inches)
   The width and length restrictions are due to width of class I scrap charging chute.
7. Pallet dimensions may exceed dimensions of briquette stack.

14.0 Head and Tail Scrap (from can plants)

1. Scrap must be marked or tagged with correct 4 digit AA alloy code (3004, 5182, etc).
2. Must be marked or tagged with gross and net weight.
3. Mixed alloy scrap is unacceptable.
4. Plastic or steel pallets are unacceptable.
5. Non-aluminum contaminants such as steel, plastic, dirt, etc, are unacceptable.
6. Closed containers made of any material are unacceptable.
7. Scrap must be securely banded to pallet.

15.0 Meltable Qualification Process

Logan must evaluate Meltables before they are approved for the process. Quality planning for new meltables includes some of the following aspects:

• Consider blending/alloying issues.
• Consider metal cleanliness and recovery issues.
• Review manufacturing technique.
• Review geometry relative to preheating requirements.
• Review Preheat requirements if applicable.
• Perform chemistry crosscheck evaluation as needed.
• Consider the Logan or Vendor chemical analysis system capability for the chemistry in question.
• Review blending/alloying, packaging, handling and storage logistics.
• Evaluate compatibility with current process and/or machine capability (ingot size, shape, bundle weights, etc.).
• Assess environmental, safety and health risks with consultation of Environmental as needed.
• Perform trials as needed and document using the Process Practice Change System.