The Iron Age 1907-09-26: Vol 80 Iss 13

THE IRON AGE Published every Thursday Moraing by David Williams Co. 14-16 Park Place, New York. 4 $00 a Year. includir Poste a. Vol. 80: .No. 13. New York, Thursday, September 26, 1907 0.0) a, Tors. trctotion Ramage Reading Matter Contents...... page 886 Alphabetical Index to Advertisers ‘‘ 193 Classified List of Advertisers “* 183 Advertising and Subscription Rates‘‘ 192 Reed F. Blair & Co. Frick Building, Pittsburg, Pa. COKE, PIG IRON CHROME ORE FERRO MANGANESE SILICON SPIEGEL, ETC. __ The- American Mfg. Ropes and Twines EU Street, New York Co: E sano waee BRISTOL'S Steel Belt Lacing SAW -4 ——— Time, Belts, ae a 5 Greatest Strength va 7) with Least Metal » SS a Send for Circu- lar Q and Free FINISHED JOINT Samples THE BRISTOL CO., Waterbury, Conn. NEW YorK and CHICAGO SAMSON SPOT CORD READY TO APPLY Also Massachusetts and Phoenix Brands. SAMSON GORDAGE WORKS, Boston, Mass. - TURNBUCKLES — Cleveland City Forge and Iron Co., TORN BV CHEUEE Ss. =e FORGINGS Brooklyn, E. D., N.Y, enge Girard Building, Phila. Pilling & Cran - Cleveland, O. Machesney Bldg., Pitts’g Empire Bldg., New York There may be some sub- stitute for HIGH QUALITY —but so far it has not been discovered. See AMERICAN SHEET & TIN PLATE COMPANY’S Ad. on Page 16. AUTOLOADING SHOTGUN Powerful Penetration The Remington Autoloading Shot Gun has plenty of penetration. One sportsman writes, ‘‘I killed a goose at 90 yards and a Mallard at 76 yards with my Remington Autoloading Gun.’’ An deal wild-fowl gun which loads itself, shoots hard and increases the pleasure by lack™of recoi!. The only gun of its kind on the market. don't overlook’this salable Kemington, List Price $40, within=the reach of all. Dealers REMINGTON ARMS CO.,_ .« Ilion, ™N. Y. 315 Broadway, New York City. “Agency, WATER TUBE OGhe Babcock @ [Wilcox Co. BOILERS See"page54 85 Liberty Street New York ‘* Capewell ’’ Horse Nails Yield Dealers The Largest Annual Profits Considerably more than half of all the nails sold in the United States are ‘‘ Capewell.”’ Dealers who always keep this brand of nail in stock secure the largest volume of the horse nail business annually. IT PAYS TO CARRY ‘‘ THE BEST ’’ NAIL Made By The Capewell Horse Nail Co., 22"v%,. THE LARGEST MANUFACTURERS OF HORSE NAILS IN THE WORLD JENKINS °96 SHEET PACKING Flexible enough to bend easily without cracking, soft enough to fill up any slight unevenness of surfaces, but sufficiently strong and tough to resist all pressures of steam. Has been used for years under all conditions, and has proved its merits in thousands of plants. All genuine bears¥he Trade Mark,‘and i{guaranteed- JENKINS BROS., New York, Boston, enunenanaes nega Lenten London. “<cwedah” Gold Rolled Steet '.%, Drawing x Sanping THE AMERICAN TUBE & STAMPING COMPANY SEEK Water and Rail Delivery) BRIDGEPORT, CONN. PAGE MAGNOLIA ereaitcrios METAL The Standard Babbitt of the World everything in the Babbitt Line. > MAGNOLIA METAL CO. 115 Bank St. Chicago: Fisher Building. New York: Montreal: 31 St. Nicholas St. THE IRON AGE ( SHEET DICKEY PLANISHED SHEET STEEL WATERBURY, CONN. 99 John St.. New York. Providence, R. I. A ' FOLLANSBEE BROTHERS COMPANY . A > KEES y & Metal Co. ." ya \% oS BRIDGEPORT, CONN. LY PITTSBURGH aN ’ ron . . y Louisville Memphis Cleveland oN Phosphor and Deoxidized nv Milwaukee Norfolk tochester Ve pate pacientes Soskerilte aw Bronze 4 A= ra PA os Oe oe Oe ek Oe uS.s y) Pa Saree" P77 die ia a )a/apa/a num Castings, large and small Matthiessen & Hegeler Zinc Co., LA SALLE, ILLINOIS. SMELTERS OF SPELTER AND MANU *ACTURERS SHEET ZINC AND SULPHURIC ACID. Special Sizes of Zinc cut to order. Rolled Battery Plates. Selected Plates for Etchers’ and Lithographers’ use. Selected Sheets for Paper and Card Makers’ use. Stove and Washboard Blanks. ZINCS FOR LECLANCHE BATTERY. a gL ook rer) So, Jefferson ia Chicago. . Best Bronze, Babbitt Metals, Brass and Aluminum CASTINGS On Short Nottee Brass, Bronze, and Copper THE SEYMOUR MFG. CO. - - SEYMOUR, CONN. HENDRICKS BROTHERS PROPRIETORS OF THE Belleville Copper Rolling Mills, MANUFACTURERS OF Braziers’ Boit and Sheathing COPPERNR COPPER WIRE AND HRIVETS, Importers and Dealers in Ingot Copper, Block Tin, Spelter, Lead, Antimony, etc 49 CLIFF ST., NEW YORK. RR E RE REAI ROD ¢ Y THE SEASON A BRASS. yi WHEN RK | ay | y mpi nett A COPPER: ROD Y | WIRE y IS NOW HERE i | SHEET WE CARRY A GERMAN ROD AFuLL stock A! SILVER WIRE OF Bridgeport Deoxidized Bronze ~ Plume & Atwood Mfg. Co. Manufacturers of (wme| Sheet and Roll Brass and Printers’ Brass, Jewelers’ Metal, German Silver and Gilding Metal, Copper Rivets and Burrs Pins, Brass Butt Hinges, Jack Chain, Kerosene Burners, Lamps, Lamp Trimmings, &c. 279 Broadway, NEW YORK LOW BRASS, SHEET BRONZE, Room 508 Heyworth Building, East Madi- SEAMLESS BRASS AND COPPER TUBING, BRAZED BRASS AND BRONZE TUBING : + : : : WATERBURY BRASS CO., son St., CHICAGO, ILL. Rolling Mill THOMASTON, CONN. Factories WATERBURY, CONN. SCOVILL MFG. CO. MANUFACTURERS OF BRASS, GERMAN SILVER, Sheets, Rolls, Wire Rods, Bolts and Tubes, Brass Shells, Cups, Hinges, Buttons, Lamp Goods. Special Brass Goods to Order. FACTORIES: WATERBURY, CONN. DEPOTS: CHICAGO NEW YORK BOSTON Henry Souther Engineering Co. HARTFORD, CONN. Composition, Yellow Bra. and Alumi-| Consulting Chemists, Metallur- gists and Analysts. Complete Pnysical Testing Laboratory. Expert Testimony in Court and Patent Cases. ArthurT. Rutter’ Co. 256 Broadway NEW YORK Small tubing in Brass, Copper, Steel, Aluminum, German Silver, &c. Sheet Brass, Copper and German Silver. Copper, Brass and German Silver Wire. Brazed and Seamless Brass and Copper Tube. Copper and Brass Rod. “ Search-Light’’ GAS Bicycle Lanterns Send for Circulars and Electrotypes. The BRIDGEPORT BRASS CO. BRIDGEPORT, CONN. Postal Telegraph Building, Broadway and Murray Street, NEW YORK GeO, PHOSPHOR-BRONZE aval g 4 GERMAN SILVER i THE RIVERSIDE METAL CoO. DRADE MARK * RIVERSIDE N. J. x t N \M ETAAOD?: WLS, SUPPLEMENT TO THE IRON AGE, SEPTEMBER 26, Py ry oo LE OMAN .s HE TE by in + oo of Th POURING SIDE OF THE OPEN HEARTH FURNA( CHARGING SIDE OF THE OPEN HEARTH FURNACES THE NEW SAUCON PLANT OF THE BETHLEHEM STEEL COMPANY, SOUTH BETHLEHEM, PA. ROUGHING, INTERMEDIATE AND FINISHING STANDS OF THE 28-INCH RAIL MILL. Sere ey aera eT Tee ee ee te THE SHIPPING AND STORAGE YARDS. THE NEW SAUCON PLANT OF THE BETHLEHEM STEEL COMPANY. ceeemrenieie. lisaany ef CONGHF Ss i [wo Copies Receives CLASS KXc,, THE IRON AGE jo" New York, Thursday, September 26, 1907. COPy 3 3. aici The Bethlehem Steel Company’s New Plant. A Description of the 28-in. Rail Mill and the 28-in. Structural Mill at South Bethlehem, Pa. In The Iron Age of November 1, 1906, an outline was given of the improvements planned by the Bethlehem Steel Company at its Saucon plant, South Bethlehem, Pa., involving, together with blast furnace erection at the old plant, the provision of new ore handling equipment and other important additions, an expenditure of about $12,000,000, The new plant is now in partial operation, the rail mill having started recently and five of the 10 open hearth furnaces. The original plans called for basic open hearth furnaces, blooming mills, rail mill and strue tural mills. These were to be in a group about 1 mile east of the blast furnaces of the company. ‘The starting of the rail mill will be followed next month by the be ginning of operations with the 48-in. Grey universal beam mill, and a third unit, a 2S-in. structural mill, will start early in 1908. The present article deals chiefly with the rail mill and the 2S8-in. structural mill, with some refer ence also to the open hearth plant and the 40-in, bloom ing mill. Besides there is under erection a 46-in. bloom ing mill, which will serve the Grey universal mill. With the building of its new Saucon plant the Beth lehem Steel Company returns to the manufacture of rails, which was carried on at the old plant for about 25 years, though no rails have been rolled since the late nineties, The structural mills represent the first operations of the company in the manufacture of steel shapes, though for a number of years under the old régime it was a manu- facturer of plates. Formerly Bessemer steel rails were rolled at South Bethlehem. The output of the new rail mill will be low phosphorus open hearth rails. Besides the company will pay special attention to the production of nickel, nickel chrome, vanadium and other special alloy steel rails The Open Hearth Furnaces, The original plans for the new Saucon open hearth plant called for two units, each composed of 12 50-ton furnaces. Thus far. as shown in plan view, Fig. 1, 10 furnaces have been erected, This number will be filled out by the addition of two furnaces when increased ca pacity is demanded, and later the 12 furnaces of the second unit will be erected. The open hearth building is 158 x 891 ft. As appears in the views given in the ac- companying supplement, the layout is on a liberal scale, both in ground and air space, Sixty ft. clearance was allowed on the pouring. or pit side and 70 ft. on the charging side, Two 60-ton electric ladle cranes will ban- dle hot metal over the charging floor. A 250-ton hot metal mixer is now being installed at the west end of the building and directly in line with the furnaces, The mixer will be supplied with metal from the blast fur naces by 35-ton ladle cars. For the charging of scrap or cold pig iron into the open hearth furnaces two Morgan low type electric charging machines are provided, built by the Morgan Engineering Company, Alliance, Ohio, On the pouring floor 70-ton ladles are used, and are handled by three 100-ton ladle cranes built by the Alliance Ma- chine Company, Alliance, Ohio. The provision of an elec- tric hoist for each furnace to handle the spout is a fea- ture. Gas for the open hearth furnaces is supplied by 45 Laughlin gas producers, 10 ft. 3 in. in diameter by 14 ft. high, with 13%-in. lining. The gas producer building is 253 x 844 ft. These producers and the 20 supplying the soaking pits of the finishing mills are equipped with Heyl & Patterson overhead coal bins and coal convey- ing and ash handling apparatus. The company experi- mented with its gas producers, operating some of the open hearth furnaces with gas from four producers and others with gas from five producers It has been de cided that the latter plan is the more economical in fuel. as the producers need to be forced where only four serve a furnace. The scrap storage vard, 909 ft. long and 84 ft. wide, is south of the producer house and is commanded by 10-ton electric cranes. When the plans are fully car ried out by the erection of the 14 additional open hearth furnaces, two additional parallel scrap storage yards will be provided. The ingot mold storage space three is to the north of the open hearth building, and between it the boiler house. and It is traversed by narrow gauge tracks and overhead is an electric crane of ample capacity fer Perl handling all sizes of ingots and ingot molds. The ingots are taken over $-ft. gauge tracks from the pouring pit of the open hearth building to the stripper building, which. as the plan view shows, is at the head of the buildings containing the two blooming mills and the rail and stru fural mills. The ingots are stripped of the molds by a crane of 100 tons capacity and are taken to the pit fur nace building, containing six four-hole soaking pits, three on each side of the narrow gauge ingot track. The soak ing pits are served by two 10-ton electric cranes, a 5-ton electric crane traversing the runway over the gas valves. Electric buggies convey the ingots to the blooming mill tables, The 40-inch Blooming Mill, In the article of November 1, 1906, the general facts concerning the blooming mills and the rail. standard Befcre passing to the description of the rail mill some additional details may be given of the 40-in. blooming mill and its structural and Grey universal mills were given equipment. This mill serves the 28-in, rail mill and the 28-in, structural mill. It was built complete by the Mesta Machine Company, Pittsburgh, Pa., the installation con sisting of approach tables, runout tables, an S00-ton hy draulic bloom shear and a three-cylinder hydraulic billet shear, with shear tables, shear delivery and weighing tables complete with loader and pushoff, together with scrap handling devices. The Mesta Machine Company also furnished the accumulators and intensifiers required for the equipment of this mill. The blooming mill hous ings weigh 105,000 Ib. each, The 40-in, blooming mill, of which a general plan is given in Fig. 2, is driven by a horizontal twin tandem compound geared reversing engine, built by the William Tod Company, Youngstown, Ohio, The cylinders are 40 and 66 in. in diameter, and the stroke 54 in. Both eylin- ders are separately attached to the bed plate, so as to allow free expansion. All valves are of tubular form, to relieve the unbalanced pressure of exhaust. The low pressure cylinders are fitted with twin valves. The links are so supported as to balance and are controlled by a floating gear connected to the pulpit, the operator being thus able to place them in a position to give an early cut off and maintain steam expansion. The engine is fitted with three throttle valves operated by a common floating steam gear. There is also a device for auto- matically maintaining steam pressure in the receiver be tween the cylinders when the engine is not in operation. All shafts are of nickel steel. The jack shaft is equipped with crabs on both ends. The Manipulator, The blooming mill tables are commanded overhead by a 10-ton crane on the approach side and by a 25-ton crane on the finishing side. A modified Wellman-Ken- —— on — an hee ‘ a aes “ oe Set a N~ — as rn lacs a ’ = ne a +++ +--+ -------- EEE eet Bq ‘Meqe/qIq Qynog ‘AuvduloyD jsveIg Weayelqiey ’ ss . wo aq JO JUBIq WOONeS MON 0g} JO JUsMEZUBIIW [BIBDUaH— "| ‘41,1 aiiwovoa v : = = a a — - — - Ee __ ~ —- = as —— — —- = _ = —_—_- + —_—— —- — — ——-— -- - - ~ 8 v anvuo anvuo | ! anvyo “ 2 arnt san of BOVUOLS dvuoS g ce ae ek oy v SOV 3ONVD MOYYYN S3LVOIGNI “O°N —— eae : i ; e as eZ s2a—> Y WOVEL JONVO GUVONVLE SILVOIGNI “9°S ae os ——5-9 ‘ *3LON eee ae : ; 00 Osyadridodd |sv92 0000000 2 : + Fe s . _7 —— : t o> f - ‘o's . ° ° aninoww |\/ : BuIOve 78 SNOISN31X3 03S0d0ud DN IDUWHO | J Oniouy _ : H:0"4.09 204-08 won oort| HLYV3H N3dO . ow J e ns —\ O'N ‘o's \ ea) * o) eee aa sny7 cwmoene “9 eoerett — 2. senesced i hd bg ; $f pt npn ttt ttt tt tt tt ttt ttt ttt ttt e a“ i ie 21° ' § = ow! a {> —-———- y o's! o- dOHe mg a r e ‘ ¢ > INIHSINIG ° ‘ {- - Oot = > . - o's! z 13 Iwunionuis 214 ./- - im > ‘ nr 3 — > > ms ale > an a ae We Copan ee mate. Ae —— Se iba - es one-- —rb—29—> Ons £99 — - —09T— - +89 — 06 ~ 89 - { ‘ : mi oO re j Sf | | ' | | ia * ° Y % - apse 4 : 2 arom Dian aie Lorena pe ; _JaNIONS 7 N be | BINTLHOIWeLS)™ L om s 4 $038 LOH & f& TA l 4 & sive "o°O ave BNVUO "40! Bavigawesini BNVUO TTIW DNIWOON8 9 ‘ Q ba +8 ——- t maxttoatn sesersursese fb G Ott mons ESTE SEH g}° ° iL 69) xx Aaud uD 5 8 6 | T gt? |s| ° ] 4 u » j = + z ae = : — - * re) > 21 ues 8 oz - 5 GVA SNiddIHS ANY 39vHOIS : —. : : x lo ols | *% ; RR *® re--Ol ou Ls = aNVuO NOL Ol 2 Oj? 5 4 anvuo a 6 tt tr ) anvuo omg ~ +—# |} t¢ BNvBO NO4 04 BNVUO “1 01 “wef Ce] tS anvuo = NOs Ub auvuo $038 LOH ge ° 3 L one , : ( t u . wOu OF wool OF WHNsoNsls & 2 | 10/9 seeius® | | dest ~= S12 — anvud 7 — : | = + ee BINILNVI VEILS —- — a 2 Yio £ 3NVuO i anve : aNvuO moa ol anvud iS 5 * g wos Ch wos ° ave, US NUd Ub o'N ° o|? aOvsOi18 437118 et aie . MVS MVS, & mvs es anveo Ne ‘ ives | <BNIHOVN yz | anvOna Q) waswacnog | } | I Oninaeny } anvuo L i é L 4 | | 2 a ; | *1d30 ONIHSINIA anvuo 5 anvuo | WOL OF * WOOL OF : cere t vt "9's + —| WHOdLV1d ONIGVO? - eae i a Toa Shaintedatenhaieienmmmnenstiiiee — ae — - = > ee 2 — — — — oe a —— Se] tember 26, 109¢ 7 nedy manipulator is provided. The two pusher bars on each the mill 21% ft. high and 24 ft. long. They are steel castings, carrying on their faces heavy side of are steel wearing plates. The mechanism, located under- neath and at the side of the tables and actuating the pusher bars, consists of transverse racks working in opposite directions, which derive their motion from two pairs of hydraulic cylinders on each side of the mill The manipulators on the approach and finishing sides of ACCUMULATOR 3 a MANIPULATOR CYL'S THE IRON AGE 833: The S00-Ton Shear, The blooming mill is equipped with an 800-ton shear, after a new design proposed by Henry Grey & Son, New York, and built by the Mesta Machine Company. With its intensifier it is shown in elevation in Fig. 3. It has a stroke of 18 in., and the width of the knife holder is ® ft. The shear is of the up-cut type and has one operat- ing cylinder fitted with a plunger of 40 in. diameter. The line pressure of 509 Ib, may be used or 1500 Ib. pres- | i. ree Oa 11) sacor TER So a ich oo a aaa ur W | TH ceed Pree eee | as i — oo ee ie \ j = f NARROW St AGE } he . a | | : ; : t = = Ser 1 | ra | | ' | | Fig. 2. INTENSIFIER ol. | | | | | | \ccessories. Fig. 3.—The 800-Ton Bloom Shear with Intensifier the mill respectively are connected by large shafts, so that they work in unison. The turning of the piece is accomplished by a tumbler, of which the principal ele- ment is a square rocker shaft connected to a lever arm and actuated by a hydraulic cylinder. The tumbler bars, sliding with the manipulator bars, are always next to the latter on the engine side of the mill and work through guides in the manipulator bars, a vertical motion being imparted to them as the square shaft rocks. sure secured through the intensifier. The top knife is supported by the working cylinder, and this is carried by two side cylinders, to which water is admitted for raising or lowering the working cylinder, and with it the top knife. The stroke of the side cylinders is regulated by two screws operated by an electric motor, but there is this difference from the usual construction, that the screws are not subjected to any of the pressure of shear- ing. The use of the floating top knife economizes water 834 and secures rapidity of action, as the top and bottom knives are never separated by a greater distance than the thickness of amount the piece being sheared, plus a small fer clearance. ‘The bottom knife holder is con- nected to the upper cross head by two 14-in. bolts, and the upper cross head is an integral part of the plunger of the working cylinder. The Bloom Transfer. From the shear the rail blooms are carried on the roller table until they come within the space conmanded by the bloom transfer crane. This is of 10 tons capacity and travels at right angles to the tables, so that it can take blooms either to the rail mill or the structural mill. Three vertical for the hoisting operation, and these carry heavy hooks for picking up the blooms. The latter are elevated above the table by aprou plates between the roflers, as shown in Figs. 4 and 5. mounted on hydraulic jacks operated from the same pulpit from which the As the bloom is held above the roller the crane hooks pick it off the aprons. Ordinarily it is taken direct to the approach table of the rail mill rough- ing train. If, racks on the crane frame are provided The plates are shear is operated. however, the specifications call for its re- THE IRON AGE September 26, 1907 ing, being operated by floated gears, giving an early cut off. The shaft is of nickel steel, in two similar pieces. There are four bearings on the shaft, with provision on the outside bearings for lining whem up with the inside bearings, insuring the carrying of the shaft by all. The bed plates are of the bored guide type. The double bear- ing frame of the engine weighs 210,000 Ib. and the single bearing frame 165,000 Ib. The traveling crane which transfers the blooms from the blooming mill shear table drops them upon table A, Fig. 6. This connects with the table B, which delivers the bloom to the roughing stand. On the latter there are The piece is handled on either side of the roughing mill by hydraulic manipu- lators, attached to and forming part of tables B and C. The plungers of the cylinders operating the manipulators carry racks and have a stroke of 2 ft. The racks on their upper side engage pinions, and through these and racks five passes, as shown in Fig, 7. with which they mesh the manipulator bars are actuated. Rail Mill Passes and Transfers, In line with the table C, on the delivery side of the is the table D, from which the rail is transferred to the table E by the use of hydraulie cylin roughing stand, ft ‘s Cc j z } 5 ; c ‘ | oo —— | . —_———— = ———————— = ie \ S c Ve # z f f f 1. ; , t ' tigen ae = | ele 4} paleo at TH oH z ke) I rn | \ Figs. 4 and 5.—Top Plan heating, or if for any reason the rail mill cannot directly take the pieces as fast as they come from the blooming mill, the transfer crane drops the bloom on a table run ning in front of a Laughlin continuous furnace, which is 17 x 40 ft. An electric pusher introduces it into the furnace, and through the gravity discharge at the outlet end of the furnace it is dropped upon the roller table leading to the stand of the rail mill. Two Laughlin covtinuous furnaces are provided for between the rail mill, but only one roughing the 40-in. blooming mut! and has been built as yet. The 28-inch Rail Mill. The 28-in. rail mill is unique in that the roughing, in termediate and finishing traius are lined up on the same As is well known, the usual plan places the fin- ishing rolls some distance from the roughing rolls, with tables intervening. There are turee stands of three-high rolls, with two stands of three-high pinions, this arrange- ment allowing of the rolling of three-length or four-length rails or of structural desired. The three tables, C, F and K, on the delivery side of the mill are made tilting for the same reascn, The roughing stand was designed to be three high, though at present it is operated two high. It is driven by a 32 and 56 x 50 in. Mesta twin tandem compound piston valve reversing en- gine. The valves are tubular and the links self-balanc- shoes shapes, as ind Partial Elevation of the Lifting | | | | | | | | € C.L—-800—T,0 N—SHEAR——_——+-—__ | | + | + been -——- t Jacks for the Bloom Shear Table. ders and racks actuating a 5-in. shaft. The shaft carries at intervals of 9 ft. 40-in. spur wheels, and the latter mesh with racks with a stroke of 11 ft. working in guides. The piece is pushed by triggers carried on the In line with the table E is the table F, leading to the intermediate stand, on which there are five passes. This intermediate stand and the finishing stand are three high and two high respectively, a dummy roll being used in the top of the finishing stand. Driving the interme- diate and finishing rolls is a 44 and 76 x 60 in, compound automatic piston valve engine, Mesta Machine Company, Pittsburgh, Pa. as the roughing operated nickel steel shaft has three bearings. of the bored guide type. running constantly at weighs 200,000 Ib. The table F is arranged to handle the piece auto- matically by means of levers and collared rollers. On the first pass in the intermediate stand, which is No. 6, the piece enters the middle and top, being delivered to the table G and turned over to enter No. 7 pass by an angle chute. By means of collared double rollers and levers operated automatically by the rising of the table the piece is turned up to enter No. 8 pass, from which it falls to the table G, the end nearest the mill being pushed racks, cross built by the This, as well condensing. Its The bed plate is There is a special governor for The fly engine, is varying speeds. wheel September 26, 1907 THE IRON AGE , nishing Department. Tables, Hot Beds and Fi Rail Mill, 28-In. > Plan of the Diagrammatic 6 st ~ Ke w Ji ever as it falls by means of a guide on the table to ent No. 9 pass, No. 10 pass brings it back from the table F to the table G. As usual, two No. 11 or leading passes are provided, automatic pushover levers being arranged so as to be easily adjusted to deliver to either pass The table G is extended by the idler table Hl. as is the table J by the idler table I Between G and H and J and I is a hydraulic transfer similar to the one between D and EB, except that it has two cylinders, The shaft of the transfer mechanism on this side is S° ft. long, instead of 40 ft., as the length of the piece has been practically doubled by the passes on the intermediate mill From the table K, on the delivery side of the tinishing stand, rails pass to the saw table L. which is provided with grooved rollers on the side next to the saws, The rails are guided into these by adjustable switches, which can be set to throw structural shapes to the opposite side of the table. It should be said here that the rail mill can be changed for operation either as a structural mill or as a billet mill, Five rail saws are provided, so that if desired four-length rails can be taken care of though usually four saws are used for three-length rails The saws are of the drop type, motor driven, and are fed to the work by hydraulic cylinders operating a hollow shaft and sliding on shees to cut either SO or 35 ft lengths of rail The crop ends drop into a east iren chute and thence into a box placed in a pit at the side of table L. These boxes when full are picked up by a crane for loading on to a car on an outside track. A 54 in. sliding frame motor driven hot saw operated by hydraulie cylinders is provided for structural shapes, and beyond it is placed the machine for stamping the heat numbers on rails, The motor driven cambering machine is mounted on shoes and is movable by means of a hydraulic cylinder It is attached to a double roller with a short section of side shaft, which when the cambering machine is pulled out of line forms an extension to the table L for use on structural shapes. The table M is made of extra width to accommodate cambered rails Lhe hot bed, table N, is immediately connected with the table M. Leading off from it are the six hot beds The pull-on for each of the hot beds consists of a 15-in channel, each pull-on being operated by a 50-hp. motor driven and 7-in. shaft. This driving shaft is arranged with clutches, so that the drums for three pull-on ropes may be operated together where structural material o« cupies three hot beds. The pull-off consists of two bug gies to each section of hot bed, the buggies traveling on depressed tracks and carrying triggers which engage the rails. The pull-off is driven in the same manner as the pull-on, and is also arranged to be operated either sepa rately or in sections of three. Rails are delivered from the hot beds to run out table P, at the end of which is the rail collecting table R. provided with a stop. Rall Transfer and Distributing Crane, Irom the table R the rails are taken by a special traveling crane, which with its load is conveyed from the hot bed buiiding to the finishing building by a transfer bridge, as illustrated in Fig. 8S. The bridge has a span of 36 ft. 6 in. and commands the loading skids in the end of the hot bed building. It is operated by means of a line shaft driven by a 7ts-hp, motor and by vertical shafts and bevel gears. Its speed, as well as that of the rail distributing crane it carries, is 300 ft. per minute The rail distributing crane has a span of 10 ft. 6 in. and an extreme length of 36 ft. Its frame has for its main members two V4-in, I-beams resting on wheels and the frame work carries the hoisting mechanism, consisting of three vertical racks carrying six arms or rail hooks The racks are operated from a line shaft driven through gears by a 24-hp. motor. The speed of the hoist is 30 ft per minute. Both the bridge and the distributing crane “ure operated by one man, the cage being carried by the rail distributing crane, Suitable counterweights are pro vided to carry the dead load of the hoisting mechanism The transfer bridge is equipped with an automatic con troller holding it in place, in line with the runway of the distributing crane while the latter is carrying rails and depositing them on the skidways adjoining the various straightening presses. The finishing department is - Gi —E. ESR ' ; Pe me Y a &26 x equipped with 12 motor driven straightening presses, an equal number of drill presses, and @& motor driven cold saw, with the necessary beds and a conveyor table, which delivers rails to any point on the shipping platform. At present there are seven straightening beds; eventually this number will be increased to nine. Each has a capacity for handling 200 tons of rails in 24 hours when operating double turn. The machinery in the rail mill, except the engines, drill presses and cranes, was ) FINISHING se 7 , 1 PASS a ) INTERMEDIATE eoTtow TT \ PASSES Lor a put Tux —— ( ROUGHING ) 5 PASSES FURNACE SIDE Fig. 7._Diagram of 11 Passes in the Three Rail Mill Stands. furnished by the United Engineering & pany, Pittsburgh, Pa. Since the rail mill was started up, on August 30, it has been rolling 75-lb. rails for the Union Pacific Rail- road. The ingots are 19 x 23 in. at bottom, and 72 in. high, and weigh about 6500 lb. After blooming down the piece is sheared into three blooms. The first of these is 13 ft, 8 in. in length, and the other two 9 ft. 2 in. long. The first rolls into three 33-ft. rail lengths, and the others into two rail lengths each, making seven rails Foundry Com- 5 COLUMN OF RAIL STRAIGHTENING BUILDING SHOWING POSITION OF HOOK READY TO RECEIVE RAILS FROM TABLES, AS Me ‘ \ Fig. 8.- from the ingot. Experience with the features of the rail mill has been quite satisfactory, and has indi- hew cated to the designers and builders that their expecta- tions will be fully realized, when the stage of smooth working is reached. The 28-inch Structural Mill, With reference to the blooming mill, the layout of the -28-in. structural. mill with that of the ‘Fail mill... That is, the approach table of the roughing , train-of the structural mill -is.the same distance on one + fide.of-the shear -table of the blooming mill as is the is. symmetrical THE IRON AGE er \ / \ jo September 26, 1907 approach table of the roughing train of the rail mill on the other side. The 28-in. structural mill consists of three rolls and one stand of three-high pinions, driven by a 32 and 56-in. by 50 in. Mesta twin tandem compound piston reversing engine. The mill has top and bottom screws on all housings Its arrangement is shown in Fig. 9. The same bloom trans- fer crane referred to in the description of the rail mill blooms for the structural mill from the 40-in. blooming mill shear table and drops them on a table in front of two Laughlin continuous furnaces, from which they are pushed into either furnace. In coming out they fall on the table in line with the first stand of the mill. Table B connected with table A delivers the piece to the roughing stand, and it is handled on either side by hydraulic manipulators attached to the tables B and C, which are both tilting. In line with the table C on the delivery side of this stand is table D, from which the piece is transferred by a hydraulic transfer similar to that in the rail mill, to the table E, which has an extension marked E’, The latter is formed of apron plates only, no rollers being used, and it takes care of the long pieces on the last pass of the intermediate stand. The tilting table F is in line with the table E. On the opposite side of the intermediate stand is the table G, of which H, an idler table, is an extension. From tables G and H the piece is transferred by a hydraulic transfer to the tables I and J, of which I is an idler table, and J a driven table, entering the piece in the finishing stand. The table K on the delivery side of the finishing stand \ 4 stands of three-high valve takes RAILS BENT AS SHOWN T FORM INCLINE FOR RAILS TO RUN DOWN ON AFTER DELIVERY SHOWING POSITION OF {| ] | HOOK DELIVERING RAILS | | Hot Bed Transfer.—On the Left Is the Transfer Bridge in the Hot Bed Building, Carrying the Rail Distributing Crane, Which Is Shown on the Right Delivering Rails on the Straightening 3eds. is a tilting table. On tables F, G. J, and K, hydraulic pushers are provided to bring the piece in line with the different passes, The saw table L, in line with the table K, leads the piece to a 54-in. sliding frame motor-driven hot saw, fed by hydraulic cylinders. Connecting with table L is the hot bed table M. There are two hot beds eath 90 ft. long. The arrangement of pull-ons and pull-offs is simi- lar to that in the rail mill. The material is delivered from the hot beds to the run-out table P, at the end of which is a double eight-roll straightening machine. The September 26, 1907 R ROTARY STRA Tae 3 — GHTENER Q ott C.t. OF ENGINE | nl Hot Beds and Finishing Department. Tables, Structural Mill, 8-In. 9 -Diagrammatic Plan of the Fig. 9.- THE IRON AGE 837 rolls in one machine are provided with grooves for ubngles and in the other machine with grooves for beams and channels. A short section of table is placed between these machines, the whole being arranged to slide on shoes by means of a hydraulic cylinder, so that either machine may be used, or material may be run on the table R without straightening. The shapes are handled off the table R by traveling cranes to the storage and shipping vard. All the machinery in this mill. except the engines and cranes, was furnished by the United Engineering & Foundry Company. Storage and Ship Yards. The structural mill storage and shipping yards, of which a view is given in an accompanying illustration, are a noteworthy feature of the new Saucon plant. They contain every facility for the quick and economical hand ling of material from the 28-in. structural mill and the Grey universal beam mill. Roller tables from these mills deliver the material through and under all of the crane runways, and eventually into a structural shop at the east end of the yard, where the Grey beam mill products will be prepared for fabrication. This storage and ship- ping yard is 750 x S00 ft., and is equipped with nine par allel 84-ft. storage crane runways, with a transverse run way across each side, intersecting with the others. The tract upon which the yards are located contains 14 acres, and is equipped with 13 double trolley 10-ton cranes built by Pawling & Harnischfeger, Milwaukee. Wis., com- pletely covering the yards. The structural finishing shop will be 120 x 480 ft., and will contain an equipment of punches, multiple drills of notable capacity and construc- tion, and facing machines for finishing beams and col umns. The Gray Universal Beam Mill, In the general article of November 1, 1906, dealing with the Saucon plant, extended reference was made to the shapes produced on the Grey universal mill and to the considerations on which their introduction into the United States is based. Details of the construction of this por tion of the new South Bethlehem plant are not available, but reference may be made briefly to the work that is now nearing completion. The 46-in. blooming mill and the two 48-in. Grey beam mills, as shown on the general plan view, Fig. 1, are arranged tandem for continuous production from the ingot to the finished shape without reheating. A 40 x 66 x 54 in. twin tandem compound revers- ing engine with geared connection drives the bloom ing mill. The blooms pass a hydraulic shear where the ends are cropped and are then delivered to the first or intermediate Grey mill, and then to the second or finish- ing mill. At Differdingen the beams are finished from the blooms by a single Grey mill, but at Bethlehem the use of two mills, one for roughing and the other for fin- ishing, will give an increased capacity, an output of 1000 tons a day being expected. Each of these mills is driven by twin tandem compound reversing engines, exact dupli- cates of the 46-in. blooming mill engine, except that they are direct connected to the mills. All parts of the Grey mill works are commanded by overhead electric travel- ing cranes. After being hot sawed to length the beams pass to a water cooled hot bed of liberal area. A driven roller table from the straightener extends the full width of the storage yard for finished shapes, and later will be extended for delivering beams direct from the mill to the fabricating shop. The mills and mill equipment of the Grey works were built by the company in its own shops except the three engines. which were furnished by the William Tod Company, Youngstown, Ohio. These mills are now practically completed with the exception of the electric wiring, hydraulic piping and a few other ininor details. In construction the Grey mills are somewhat similar to a universal plate mill. with separate sets of horizontal and vertical rolls. These sets of rolls form the web and flanges by combined rolling operations acting at right angles. Both web and flanges are produced in a manner similar to the rolling of universal mill plates. The Grey mills at Bethlehem are like that at Differdingen, (rer- many, also built by Henry Grey & Son, except that the Bethlehem mills are larger and embody many improve RATE A Nh SENET in ee | | : : S38 THE IRON nents and modifications that have been suggested by the five years of operation of the mill in Germany, which has been prvuducing beams up to 30-in. in depth with flanges 12 in. wide ln the ordinary beam mill the web is the only part of the shape which is formed by an actual rolling operation, the flanges being produced by crowding and dragging the metal through the flange grooves where no rolling action is possible, owing to the construction of the rolls. In the production of a beam by the ordinary mill the outer edges of the flanges are churned by the upper and lower rolls and the points of contact with the shape are acting with a large difference in linear speed. 24-in. with usual beam mill, the middle roll at its point of contact In the case of a beam, flanges 7T-in. wide, rolled in a 2S8-in with the outer edge of the beam flange is 21 in. in diam eter, while the upper or lower rolls at their points of contact with the same outer edge of the beam flange are As both rolls have the same angular contact in diameter. velocity, their linear with the outer edge of the beam flange are in proportion oo in. velocity at the points of in other words, one roll is moving with a speed of one and two thirds times the velocity of the other roll. The effect of this, especially on the larger sizes of beams rolled by the to their diameters at such points of contact, or, large variation in quality of the material in the webs and flanges. By means of the Grey method of usual method, causes a the physical rolling beams, the sections can be designed to give economical distribution of the metal, larger beams can be rolled and the flanges can be made very much wider than it is possible to pro. duce in the usual mill. The rolled by the Grey mill in Germany are ployed in bridge and building construction in England. Canada and other foreign countries. smaller used for beam wide flange beams extensively eim- Europe, The and the deeper sections are used to take the place of riveted gir- Sizes are column purposes ders. The operation of the Grey mills at Bethlehem will make the advantages of such sections available to engi- neers and constructors for the first time in this country. The Grey mill produces beams by the same method as is used in the rolling of mill plates with a practically uniform amount of reduction in the rolling for universal all parts of the shape. Beams of all sizes and shapes rolled by the Grey mill in Germany have shown great uni formity in physical quality of material throughout the section, thus indicating equal reduction work in the roll- ing process and the absence of internal stresses. Such sections, it is claimed, are more reliable than beams rolled in the old way, especially when they are to be used in places subject to impact and vibration. In the production of the larger sizes it is intended to use ingots up to 10 tons in weight, so that the work of reduction in rolling the shapes will be sufficient to de velop proper ductility of the metal. For the design and construction of the entire Saucon plant. Henry Grey & Son, 6S William street, New York, were consulting engineers —_——+—-e—_—____—_. The Diamond Belt Shifter. The only positive lock belt shifter is claimed to be the one illustrated, which is made by the Diamond Clamp & Flask Company. Richmond, Ind. In the form shown it board in any way that is may be bolted to a hanger or most convenient. It is made in three styles, to be oper- ated directly by pulling the pendant handle. or by a cord attached any point, or to the top and carried over guiding pulleys to in connection with a floor stand. to be oper ated by the pressure of the hand on the knob at the top or the foot on a treadle at the bottom. pressure of the The parts are few and consist of a frame in which the cam plate carrying the shifting fork slides laterally, and a rod, carrying a pivoted shoe engaging the grooves in the eam plate. slides vertically. <A holds the latter at the upper limit of its strike. When the rod is pulled downward the shoe working in the groove slant spring normally ing downward to the left moves the plate and with it the fork to the right, and the shoe rides over into the vertical groove at the left. As the spring returns the rod, the shoe follows this groove and rides over a himp into the vertical other diagonal this portion of the groove. In September 26, 1907 AGE position the shifter is locked until another pull on the rod causes the shoe to follow the groove slanting down back to its ward to the right and the fork is drawn first position. The return of the rod by the spring leads the shoe up a right hand vertical groove, hidden in the engraving, locking the shifter as before. The reduction in the depths of the grooves, at the ends where the shoe leaves them, forms the switches that insure a continuous cycle of operations in the same direction. It will be seen that there is no time in the operation of the shifter that it is not locked and under perfect control of the operator. The shifters are made in five sizes, each adaptable to in, increasing by quarter nches; for fitted with four plates for 1144, 14, 1% and 2 in.. respec- a range in width of belt of 1 example, the smallest may be either of tively, and the largest for 54 to 6 in. belts by similar e el CO \ Positive Lock Belt Shifter Made by the Diamond Clamp & Flask Company, Richmond, Ind The fork rods for various widths of belt, and the fork rods in the steps. prongs may be adjusted on the fork cam frames for various distances from the belt to the shifter frame, but the throw of variable, so that a different one is necessary for each dif- ferent width of belt. Presumably the average dealer would have to carry an prohibitive amount of stock to cover even the most usual requirements. By a thoughtful selection of parts, however, the manufacturer has considerably simplified the problem in what is recom- each cam plate is in almost imended as a dealer’s stock. From this a shifter may be assembled for any of the widths of belt between 1% and tf in. in any of the three styles. This stock comprises three sizes complete. each equipped for a different style of manipulating. and the nec The Diamond belt shifter ‘ssary extra plates, 11 in all. is applicable to all kinds of countershafts and hangers If the countershaft is al- ready up, the shifter may be bolted to a board and the board nailed to a joist, or by casting a lug on the hanger any size shifter may be attached to it. The company fur- nishes two sizes of complete countershatts equipped with this shifter, one carrying 2 x 6 in. tight and a 3 x 12 in. driving pulley, and the other 4 x 10 in. tight and loose pulleys and a 6 x 16 in vend loose pulleys driving pulley. Hangers are also furnished separately. sc that a mill- wright may make up his own countershaft. September 26, 1907 New Massachusetts Boiler Rules. ‘The new Massachusetts Board of Boiler Inspectors, established under an act of legislature early this year has promulgated the first sections of its rules, covering Lain pressure on boilers, shearing strength of rivets, factors of safety and fusible plugs. Under the rules the maxim pressure allowed on any steam boiler con strected whelly of cast iron shall not be greater than 25 lb. per square inch, and on any steam boiler, the tubes of which are secured to cast fron headers, not greater than 160 Ibo ner square inch, The maximum pressure al lowed on uwuy steam boiler constructed of iron or steel shells or drums shall be caleutated from the inside diam eter of the outside course, the percentage of strength of the longitudinal joint, and the minimum thickness of the shell plates, the tensile strength of shell plates to be taken as 55,000 lb. per square inch for steel and 45,000 1b per square inch for iron, when the tensile strength is not known. The maximum shearing strength of rivets per square inch of cross sectional area to be taken as follows: Tron rivets in single shear, 38,000 Ib.; iron rivets in double shear, 70,000 lb.; steel rivets in single shear, 42,000 Ib. ; steel rivets in double shear, 78.000 Ib. The lowest factors of safety used for steam boilers, the shells or drums of which are directly exposed to the products of combustion, and the longitudinal joints of which are lap riveted construction, shall be as follows: Five for boilers not over 10 vears old; 5.5 for boilers over 10 and not over 15 years old; 5.75 for boilers over 15 and not over 20 vears old; 6 for boilers over 20 years old; 5 on steam boilers, the longitudinal joints of which are of lap riveted construction, and the shells or drums of Which are not directly exposed to the products of com bustion: 4.5 on steam boilers, the longitudinal joints of Which are of butt and strap construction. fusible plugs shall be filled with pure tin. The least diameter of fusible metal shall not be less than 1 in., ex- cept for working pressures of over 175 lb. gauge, or when it is necessary to place a fusible plug in a tube, in which eases the least diameter of fusible metal shall not be less than ®. in. The location of fusible plugs shall be as follows: In horizontal return tubular boilers, in the back head, not less than 2 in. above the upper row of tubes and pro- jecting through the sheet not less than 1 in. In horizontal flue boilers, in the back head, on a line with the highest part of the boiler exposed to the prod- ucts of combustion and projecting through the sheet not less than 1 in. In iocomotive type or star water tube boilers, in the highest part of the crown sheet and projecting through the sheet not less than 1 in. In vertical fire tube boilers, in an outside tube placed not less than one-third the length of the tube above the lower tube sheet. In vertical submerged tube boilers, in the upper tube sheet. : In water tube boilers, horizontal drums, Babcock & Wilcox type, in the upper drum, not less than 6 in. above the bettom of the drum and over the first pass of the preducts of combustion, projecting through the sheet not less than 1 in In Sterling boilers, standard type, in the front side of the middle drum, not less than 6 in. above the bottom of the drum and projecting through the sheet not less than 1 in In Sterling boilers, superheated type, in the front drum, not less than 6 in. above the bottom of the drum and exposed to the products of combustion, projecting threugh the sheet not less than 1 in. In water tube boilers. Heine type, in the front course of the drum, not less than 6 in. from the bottom of the drum and projecting through the sheet not less than 1 in. : In Robb-Mumford boilers, standard type. in the bot- tom of the steam and water drum, 24 in. from the center of the rear neck and projecting through the sheet no! less than 1 in. THE IRON AGE S39 In water tube boilers, Aliny type, in a tube directly ‘Xposed to the produc ts of Combustion In vertical boilers, Climax or Hazelton type, in a tube or center drum not less than one-half the hight of the shell, measuring from the lowest circumferential eum. In Cahall vertical water tube boilers, in the inner sheet of the top drum, not less than 6 in. above the upper tube sheet In Scoteh marine type boilers, in combustion chamber yoamd projecting through the sheet not less than 1 in In dry back Scotch type boilers, in rear head, not less than 2 in. above the top row of tubes and projecting throuch the sheet not less than 1 in In Economic type boilers, in the rear head above the upper row of tubes In enst iron sectional beating boilers, in a section ove and in direct contact with the products of combustion in the primary combustion chrmber For other types and new desigus fusible plugs shall he placed at the lowest permissible water level, in the direct path of the products of combustion, as near the primary combustion chamber as possible An Elevator Suggestion for Preventing Accidents. A well-known architect of Worcester, Mass,, impelled by a series of fatal elevator accidents in one building, has been working out the suggestion for a remedy of a certain class of accidents against which there is at present no safeguard. In writing to a local newspaper, he says: J In view of the recent second fatal accident in the passenger elevator of a local building, and the fact that nearly parallel cases are of almost daily occurrence throughout the country, should not seme further means for protection be devised * Consider, for a moment, the vast number of people who enter and leave the elevators of the office buildings, stores, &¢., of our own comparatively small city and realize that, for one reason or another, each passage from the solid floor of a building to the movable