The Iron Age 1908-01-02: Vol 81 Iss 1

HE IRON AGE maablished every Thursday Morning by David Williams Co. 14-16 Park Place, New York. Vol. 81: No. 1 New York, Thursday, January 2, 1908. See See eo Reading Matter Contents 110 Alphabetical Index to Advertisers ‘‘ 370 Classified List of Advertisers ** 360 REVOLVER AND PIS) Advertising and Subscription Rates ‘“* 126 @ Cc ARTRIDGES Se REED F. BLAIR & CO. HE American Rifle Team selected FRICK BUILDING, PITTSBURG, PA. U MC Cartridges over all others STANDARD CONNELLSVILLE * for use in the international , match against Australia, Canada and C O K E Great Britain. They won with a world’s record score and se- FOUNDRY FURNACE CRUSHED cured the Palma Trophy. For- a an eign and American press prais- ed the ammunition (U M C) , he Ms - which gave the Americans a The AmericansMfg. Co. — ||| | winning advantage. Ropes and Twines UMC Revolver and Pistol Cartridges : _ are of the same high quality as 65 Wall Street, New York i % UM C Military Cartridges. THE UNION METALLIC CARTRIDGE COMPANY oee am 7 Write to M. HARTLEY CoMPANy, Sole 3 BRISTOL'S Steel Belt Lacing 313-315 Broadway, Ne Ww Y rock Cl a 246 wen Crees SAVES | | ; Time, Belts, Money. Greatest Strength with Least Metal Send for Circu- lar QO and Free READY TO APPLY —_ FINISHED JOINT Samples _ THE BRISTOL CO., Waterbury, Conn. __——CSNNEW YORK and CHIicaGco WATER TUBE O6h4e Babcock @ Wilcox Co. SAMSON SPOT CORD BOILERS " 5 85 Liberty Street ec page 7 New York Also Massachusetts and Scores ess WHEN IT’S a QUESTION of PROFITS SAMSON GORDAGE WORKS, Boston, Mass. |] People Are Inclined to be Interested TURNBUCHLES i i q Hardware Dealers find “Capewell” nails the MM most profitable to handle. Horseshoers and Cleveland City Forge and tron Co., - Cleveland, O. i" Horse Owners believe them to be the most eco- TURN BUCH IUAES. nomical to use. - MERRILL BROS., @The great volume of “Capewell” sales p= 465 to 471 Kent Ave., Brooklyn, E. D.. N.Y throughout the country attracts Merchants. The absoe lute reliability and superior qualities IRON pe O N O oN ES. of “‘Capewell’’ nails satisfies Shoers and Owners. Girard Building, Phila. MADE BY Pilling & Grane scree e-r* |! THE CAPEWELL HORSE NAIL CO., Hartford, Conn. UFAIN |. | RULES | * JENKINS BROS. VALVES MADE IN AMERICA do not require constant regrinding. When necessary to repair, a new Disc THE BEST IN THE WORLD will usually make the valve as good as new. /enkins Discs are inexpensive, tel i alk ial and can be readily applied by any one without taking valve from the pipe i. ee ee ten : 3 All parts interchangeable. Write for booklet, All genuine bear Trade Mark as shown in cut, JENKINS BROS., New York, Boston, Philadelphia, Chicago. There may be some sub- stitute for HIGH QUALITY “Swedon” Cold Rolled Steel cet: Drawing ax otamping THE AMERICAN TUBE & STAMPING COMPANY SEB (Water and Rail Delivery) BRIDGEPORT, CONN, i 3 —but so far it has not been discovered. D MAGN OLIA FRICTION METAL See i & The Standard Babbitt of the World AMERICAN 4 Vg We manufacture 7 : everything in the SHEET & TIN PLATE ge, — “Babbitt Line. COMPANY’S - > MAGNOLIAMETAL CO, Ad. on Page 26. New York: 115 Bank St, Chicago: Fisher Building. Montreal: 31 St. Nicholas St. AGE SHEET ROD WIRE THE IRON ‘BRASS| TUBING, BRAZED BRASS AND BRONZE TUBING STEEL SHEETS FOLLANSBEE BROTHERS COMPANY PITTSBURGH & Metal Co. BRIDGEPORT, CONN. Phosphor and Deoxidized Bronze Composition, Yellow Brass and Alumi« num Castings, large and small Matthiessen & Hegeler Zinc Co. La Salle, Illinois. SMELTERS OF SPELTER AND MANUFACTURERS 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. BU SN irre UE aI 105 -109 So, Jefferson St., Chicago. ASTINGS On Short Notice Say Ge SUPA LUI EG ME UC Tie eRe Tier WETHiiD ITIP} ate GERMAN SILVER | NICHE ANoDEs Brass, Bronze, and Copper THE SEYMOUR MFG. CO. SEYMOUR, CONN. HENDRICKS BROTHERS tre Belleville Copper Rolling Mills, of the Manufacturers of Braziers’ Bolt and Sheathing COPPER COPPER WIRE AND RIVETS Importers and Dealers in Ingot Copper, Block Tin, Spelter, Lead, Antimony, etc. 49 CLIFF ST., NEW YORK. OF OUR SHEET SPECIALTIES {| COPPER} IS THE PRODUCTION OF ooo SHEET BRIGH OD | wee SILVER | “wre PLATE §$/.Low BraASS, SHEET BRONZE, AND SEAMLESS BRASS AND COPPER | « | THOMASTON, CONN. FOR | DIFFICULT Waterbury Brass Co. DRAWING WATERBURY, CONN. O PE RATIO N S : 99 John St., New York. Providence, R. 1. Bridgeport Deoxidized Bronze a | and German Silver Wire. The Plume & Atwood Mfg. Co. Manufacturers of Sheet and Roll Brass WIRE Printers’ Brass, Jewelers’ Metal, German Silver and Gilding Metal, Copper Rivets and Burrs Pins, Brass Butt Hinges, Jack Chain Maresene Burners, Lamps, Lamp Trimmings, 279 Broadway, NEW YORK Room 508 Heyworth Building, East Madi- son St., CHICAGO, ILL. Rolling Mill 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: NEW YORK CHICAGO BOSTON HenrySouther Engineering Co. Consulting Chemists, Metallur- gists and Analysts. Complete Physical Testing Laboratory. Expert Testimony in Court and Patent Cases. Arthur T. Rutter d oo. 256 Broadway NEW YORK Small tubing in Brass, Copper, Steel, Aluminum, German Silver, &c. Sheet Brass, Copper and German Silver. Copper, Brass Brazed and Seamless Brass and Copper Tube. Copper and Brass Rod. “PHONO-ELECTRIC” WIRE. “IT'S TOUGH.” TROLLEY, TELEPHONE and TELEGRAPH LINES. BRIDGEPORT BRASS COMPANY, Postal Telegraph Broadway and Murray 8t., ~~ York PHOSPHOR-BRONZE GERMAN SILVER meee Bridgeport Sen THE RIVERSIDE METAL CO. RIVERSIDE, N. J. THE IRON AGE New York, Thursday, January 2, 1908. The Grey Structural Mill at South Bethlehem. Some Important Improvements Upon Its German Prototype. The starting up this month of the Grey structural steel mill of the Bethlehem Steel Company, at South Bethlehem, Pa., is an event not without significance in connection with the widening of the field for steel as a material of construction. In previous issues of The Iron Age* the characteristics of the Grey sections and some of the essential features of the method of rolling them have been touched upon. The present article gives a description and illustration of the Grey sill, as now completed, forming a part of the new Saucon plant at TTT 300 ft. of mill table, this length being necessary when bars are simultaneously passing from each mill in the direction of the other. Fig. 3 is a plan of the blooming mill and Figs. 4 to 9 give details of the Grey mills and their method of rolling. In Figs. 4 and 5 the main hori- zontal rolls are marked M and the supplementary rolls S. Figs. 10 to 12 show the special hot beds and the run- out tables. In the description given in our issue of September 26, 1907, it was explained that the rail mill and the Grey Fig. 1.—One of the Grey Structural Mills at the Bethlehem Steel Company’s Saucon Plant, South Bethlehem, Pa. South Bethlehem, on which all together, including new blast furnace construction, ore handling equipment and additions to the original plant, an outlay of about $12,000,000 has been made. An important departure is made at Bethlehem from the original Grey mill, installed at the Differdingen Iron & Steel Works, Differdingen, Germany. At Differdingen the beams are finished from the blooms by a single Grey mill, but at Bethlehem, by the use of two Grey mills of identical construction, the No. 1 as a roughing or inter- mediate mill and the No. 2 as a finishing mill, a con- siderably larger output will be secured. The Bethlehem mills, moreover, are larger than the one at Differdingen and embody a number of improvements. In Fig. 1 a view of one of the Grey mills at South Bethlehem is given and in Fig. 2 a plan view of the entire structural plant. This shows the relation of the blooming mill and the No. 1 and No. 2 Grey mills. Between the first or interme- diate Grey mill and the second or finishing mill are about * The Iron Age, November 1, 1906, p. 1142; September 26, 1907, po. 831. structural mill, which are arranged on parallel lines, headed by two groups of soaking pit furnaces and gas producers, had each its own blooming mill. The struc- tural steel plant thus consists, first, of vertical pit fur- naces, approach tables, a 46-in. blooming mill, with tables in front and back of the mill, each with a Wellman- Kennedy manipulator, similar to that already described in the rail mill article, and modified so as to handle sat- isfactorily the various sections required from the bloom- ing mill. Then, in order from the rear blooming mill table are the front shear table, an 800-ton.shear with hydraulic intensifier, a back shear table, and following these a No. 1 and a No. 2 Grey structural mill, with hot beds, straighteners and other accessories to which more detailed reference will be made below. All the Grey sections are rolled direct from the ingot in one length. The method pursued in the production of the various sections is as follows: The ingot, which is always of open hearth steel, is delivered to the vertical pit furnaces from the ingot stripper. It is charged, withdrawn and placed in the traveling ingot seat by the OT Te 8 Fr ne ee ee, Re — + oe, <aes ee 2 = nn ee tees z MS + January 2, 1908 AGE THE IRON ‘343}q 84} UO IBEqg 24} 03 3J0] Ay} UO YoBAY, {28ngq ZORU] 04} Woarz ‘soquy, GIT [II Zuyu00[g eq} JO UBIG—s “31 —————— + AVMNAY JO SNM YSLNZO A I OD ° | Hele f n mA Pr berecks liane ihe ir OER CTR ee eT | fH a_t | cE ABE ii Cy 1 i i | H i t rin ty P, eS 7s (Lia ESE EC EEE E REESE ‘2UBId [Binjonayg AVIpH eq} Jo JUOMEZUBIIY ZulMoYyg ‘M2TA UBlq-—"Z “Sia ee || it |p3NVUD NOL OF aNvuo NOS OF | &> | 4 9 <i | ) ' oe 44, 789 ~—< , 022 >< ,Ovz >< £9 >< 7 Ovz 7t0— -> oot ~~ £9- ->* 706 00 »~ “ UINIVELND | : uaENRGNOO INVED NOL OF IN ILHOIVULS) AuVYLOU || | 84991 Ro) | TIT HT] 1} ] |4W [ASM | |) © YINILHDIVEL L4ugsiSngant ovo iB owns a ¥ BVINE TMA SNIWOOTd 1! InvND Nu O08 A a+ ete mie a Lit sauvA| a0vYuOLs sipcnshipieeietce clinainttinieseaey ciciiiaiamer ate a SON TH A340 anvVUD NOL % et _— 4, | vv? NOL OF [inwMO NOA) 4 i non tf ) Py | January 2, 1908 pit crane. The ingot seat is moved up to the approach table and tilted thereon by suitable mechanism. The in- got is carried up to the blooming mill on the roller tables, is squared up and then passed through the beam blank forming passes the number of times necessary to give the blank suitable thickness on web and flanges and a TSS aE 45 ey Figs. 4 and 5.—Plan and Elevation of Grey Mill, predetermined width of the latter. When rolled to the proper proportions the blank is passed on to the shear, in which the ends are cropped so as to secure a blank solid throughout its:entire length. The thickness of the web and flanges of the blank should bear the same pro- portion to each other as will the web and flanges of the desired finished section. The blank is passed on to the first or intermediate Grey mill, where it is gradually re- THE IRON AGE 3 duced in cross section. It should be understood that the beam plank passes first through the supplementary rolls of the intetmediate mill; that it continues on through the main and vertical rolls; that it returns on its backward passage (after the adjustment of all rolls) first through the main and vertical rolls and then through the supple- mentary rolls, repeating these alternations us often as necessary, until it is ready for the finishing mill. Most bars can be finished on the one set of rolls—that is, many sec- tions may, if desirable, be finished on the in- termediate rolls without the use of the finish- ing mill, but for large product and for econ- omy in rolls the two mills are preferable. An examination of the diagrams of the main horizontal, the vertical and the supple- mentary rolls in Figs. 6 and 7, will show that the relation of the main horizontal rolls to each other determines the thickness of the web at each passage through the rolls; that the distance of each vertical roll from the contiguous working side of the main rolls governs the thickness of each flange at each passage of the bar, and that the dis- tance between the working parts of the supplementary rolls (which are horizontal), determines the width of the flanges at each opera- tion of the mill. From these diagrams it will be understood that the thickness of the web and flanges, also the width of the latter—any one or two dimen- sions—can be altered without effecting any change in the third dimension. The reduction in the area of the cross section is made in almost an exact pro- portion; that is to say, the elongation of the bar in each part of the section web and either flange is approx- imately the same. Further, the reduction in area of each part of the section web and either flange is accomplished Showing Main (M) and Supplementary (S) Rolls. for the most part in the same direction; that is, each is proportionately reduced in thickness at each passage through the rolls. Hence it is argued by the designers, as like causes produce like effects, the ultimate strength of the flanges and that of the web will be found more nearly approaching one another than similar parts do on beams rolled by the old collar and groove process. While the number of passes on either the intermediate or fin- 4 THE IRON AGE ishing Grey mill will be determined by the nature of the section it is desired to roll, the whole number of passes will be between 10 and 14. In most cases of beam and girder sections from three to five passes will be made upon the finishing mill, while for column sections of the heavier weights but one pass will be made in the finish- ing mill. The rolling surfaces are also shown in Figs. 6 and 7, and are marked 2. The two mills have a number of interesting minor features, some of which are clearly shown in the illus- trations, including special side guards, top and bottom Fig. 6.— Diagram of Main and Vertical Rolls.—Rolling Surfaces Are Indicated by z. guides, screw mechanism for horizontal and side rolls, indicators, &c., in addition to special scrap handling devices. Between the No. 2 mill and the hot saw there is about 240 ft. of table, as there will be times when bars 200 ft. in length will be delivered to the hot saw. Leaving the saw the bars run out on the ingoing hot bed table, which as well as the outgoing table is about 250 ft. in length, to such a point as may be desirable. The beams are pushed off the ingoing table into such a position on Fig. 7.—Diagram of Supplementary Rolls.—Rolling Surfaces Indicated by r.—No Rolling Action on the Web of the Beam. the hot bed as to be within the radius of the mechanism used for turning them from a horizontal to a vertical position. They are then moved toward the outgoing table and when cold are deposited on it by the rake off mechanism. The hot beds, Figs. 10 and 11, are a radical departure from anything at present used in this country. The rails are of cast iron and are water cooled with the discharge water from the various hydraulic appli- ances at the saws and hot beds. These beds are built January 2, 1908 heavy to resist as far as possible the tendency to buckle which would be very great, as many of the sections rolled on these mills are much heavier than anything heretofore made. The section modulus of the heaviest beam now rolled is 198.4, while the section modulus of the heaviest beam at present designed for the Bethleham plant is 610.3. Thus the carrying capacity of the heay- iest beam to be rolled at these works is more than three times that of the largest rolled beam at present made in this country. Between the outgoing hot bed table and the rotary straightener is placed suitable mechanism for turning the beams on the edges of their flanges, so that they may be in a suitable position to enter and be operated on by the rotary straightener. Only the narrow flanged beams need be edge straightened by the rotary machine. When the mill is working on girder or column sections the ma- chine will be withdrawn from its position and a section of table will be introduced so as to make a continuous passage from the outgoing table of the hot bed to the yard tables. The bars will be delivered on the yard tables. Such as need to go to the gag straightener will be carried on the transfer mechanism to the line of feed rollers working in unison with the machine in which they will be straightened. The material will be dis- tributed, some to the cars for direct shipment and some to the stock piles. That which is to go through the fabri- cation department: will be delivered to the south longi- tudinal runway; that which is to become part of an assorted order and such beams as merely have to be coped or cut to length on the cold saws will be delivered to the north longitudinal runway and shipped from there. It will be appreciated that roll turning is reduced to Fig. 8.—Method of Increasing Area of Column Sections. a minimum by the Grey mill. The finishing rolls when worn out for a certain size can be either turned off so as to make the next smaller profile or a pair of rolls de- signed and used to roll special beams may be altered for girder sections; or either may be used, if put into the roll. lathe, for a section of column steel. The adapta- bility and pliability of this type of mill is great, and the designers believe that time will show that for economy and scope it is a desirable addition to the manufacture of shapes and of much value to the architect and engi- neer. The Bethlehem mills are built for an output of 800 to 1000 tons a day, according to the section produced. As illustrating the scope of the Grey mill, the inte- rior columns of an actual 14-story building with base- ment may be taken as an example. All the columns for this building can be rolled on one set of rolls and with- out any change on main horizontal rolls of the Grey mills,or any change on the blooming mill, although the loads on a single column vary from 345 tons in the base- ment to 32 tons on the fourteenth story. If the beam and girder sections designed for the Bethlehem Steel Company are increased in weight in the same manner as are the column sections, that is, if the thickness of the flanges is increased proportionately to the increased thickness of the web, and the width of flanges increased ay Teens aad m ellis aoa hCE pees, eee e TT ee eit ne eee aes ane January 2, 1908 THE to the same extent as is the thickness of the web, then the increase in the section modulus will be in the same or nearly the same proportion as the increase in weight. Of course, such sections would be special, but the ex- ample is given to show the scope of the mill and its flex- ibility in supplying the wants of the engineer. Such sections with the increased weight added in the manner | a ar ig. 9.—-Side View IRON AGE ; R. Smythe & Co., Pittsburgh, and the cranes serving them by the Alliance Machine Company, Alliance, Ohio. The en- gines used for driving the blooming mill were built by the Wm. Tod Company, Youngstown, Ohio. They are of the twin compound condensing, geared reversing type, 40 x 66 x 54 in., geared 61 to 101. The gears are cut and have 40-in. face. The engines for the Grey mills are of the same PL ot oe Ee ase Pree aia of Grey Mill. Fig. 10.—Hot Beds, with Cast Iron Water-Cooled Rails.—No. 2 Grey Mill in the Distance. described could be furnished without the delay and cost attendant upon providing special rolls, as in the ordinary structural mill. The complete layout and all the various appliances used in connection with the new plant were designed and specified for by the consulting engineers, Henry Grey & Son, 68 William street, New York, who are the patentees of the Grey mill. The vertical furnaces were built by 8. size and design as the above, but differ in that they are direct connected to the mechanism for simul- taneously driving the main and supplementary mills. The condensing plant was built by the Alberger Condenser Company, New York, and is designed to handle the ex- haust from the three engines mentioned. The condenser is of the largest type the above company has turned out It is supplied with necessary circulating water by one THE IRON AGE eS % . Be” h . January 2, 1908 Fig. 11.—Another View of the Hot Beds. 20-in. two-stage water pump, assisted by one 20-in. re- turn water turbine, the return water being supplied by the hot well of the condenser. The two-stage pump is driven by a 350-hp. cross compound vertical engine, which works normally at 225 hp. All the feed tables and hot beds were built by the Wheeling Mold & Foundry Company, with the exception of the blooming mill tables and manipulators, which were furnished by the Mesta Machine Company, Pitts- burgh. These latter tables are driven by Crane engines Fig. 12.—Runout Tables Which Carry Beams from the Hot Beds to the Straighteners and Shipping Yards. 2S SORE Ret RRR REE TR me IRE A RRIRROT St NOME 8 90 YN RR INCRE N REme ee Se hate Bart a ste wade eerie 4 Sai January 2, 1908 controlled by the Ahlen mechanism. All other mill tables are driven by Crocker-Wheeler mill type motors, which are manipulated by the magnetic controllers of the Elec- tric Controller & Supply Company, Cleveland, Ohio. The same types of motors and controllers are used on all the screw-down mechanism on the blooming, intermediate and finishing mills. The 800-ton shear and hydraulic intensi- fier were built by the Mesta Machine Company, Pitts- burgh. All hydraulic valves are of the Henry Aiken type. The blooming mill, both the intermediate and finishing mills, the gag straightener and the indicators for the several mills, all were built by the Bethlehem Steel Company. The rotary straightener was furnished by the United Engineering & Foundry Company, Pitts- burgh, and: the yard tables and transfer by the Wheeling Mold & Foundry Company. These tables are driven by constant speed motors and are reversed and handled by a patented induction drive, supplied by the last men- tioned company. 7 A Record Car and Locomotive Output. The figures compiled by the Railroad Gazette show a record breaking output for the car and locomotive works of the country in 1907. As might be expected, the num- ber of orders on the books late in December, both for ears and locomotives, showed a very great falling off from the figures at the same time in 1906. Many car and locomotive works are running now on orders placed last spring with no new work in prospect. One of the large locomotive building companies reported a falling off of 75 per cent. in orders, as compared with last year. The Canadian car and locomotive builders have not felt the effect of the disturbance in financial and business conditions to any extent. All of the companies in Canada report aS many or more unfilled orders on their books now as they reported last year. Official returns from 36 car building companies in the United States and Canada (estimating two small plants not heard from) give the total number of railroad cars built during 1907 as 284,645, an increase of 19 per cent. over the record breaking output of 1906. This includes subway and elevated cars, but does not include electric street and interurban cars. No estimate has been made of the number of cars, both freight and passenger, built by the railroads in their own shops. Of the total num- ber of cars built by manufacturers, 284,188 were for freight service and 5457 for passenger service; 280,216 were for domestic use and 9429 for export. The number of passenger cars built during the years shows an in- crease of more than 70 per cent. over last year’s output. About 72 per cent. of the freight cars built were of steel or steel underframe construction. Canada built 9159 freight cars and 106 passenger cars, an increase of 30 per cent. over last year’s output; all of these cars were -for domestic use. The one company building cars in Mex- ico retired from business in the year and no returns were received from it. The following is the Railroad Gazette's compilation of the number of cars built in the last nine years: Year. Freight. Passenger. Total. ES atk dee duce Kacgtale 119,886 1,305 121,191 MEL 6 a pias os Oe 115,631 1,636 117,267 BOE oc ales we We're bc eee 136,950 2,055 139,005 Ee eer 162,599 1,948 164,547 i whdd + 4s an er aeeean 153,195 2,007 155,202 a sas asign & os 5% ae tans 60,806 2,14 62,950 Ds cc ten ev aust chee 165,455 2,551 *168,006 WOE. Abas wwe cake 240,503 3,167 *243,670 BOGE 6a > hb os bee < Hsin Se 284,188 5,457 *289,645 * Includes Canadian output. The locomotive output shows a smaller increase over 1906 than the car building output. This is probably due to the fact that the locomotive builders worked their plants practically to their full capacity in 1906. The 12 builders in the United States and Canada built 7362 lo- comotives in 1907, of which 6564 were for domestic use and 798 for export. This is an increase of 6 per cent. in the total output; the export output increased 11 per cent. as against 5 per cent. for domestic output. These figures do not include locomotives built in railroad shops or loco- THE IRON AGE 7 motives rebuilt or repaired. There were 330 electric loco- motives and 240 compound locomotives built, as against 237 and 292 respectively in 1906. The Canadian output of locomotives was 264. The following table shows the number of locomotives built in the last 15 years: No. No. Year. built. Year. built. ais ae ake icaee 6S 2,011 ae a 3,384 6s So eek oe welee ae 695 Bcd ease ceevense’ 4,070 Reals < dain emewere 1,101 Se ttn cewivea eave 5,152 ana 6eX’ éanaie oan 1,175 DRC k tin cenneaw ee 8,441 NE 0 ewes abd 6608 1,251 NR ere re *5,491 MG a acs these ead 1,251 Dee tered exes xeye *6,952 DGS Oh skh wtdewees 2,475 Ses. «si scnweawes *7,362 Pe haeenveees 3,153 * Includes Canadian output. The cost of cars and locomotives has increased slight- ly over 1906, due largely, in the case of locomotives, to the increased average weight. Estimating the average cost of freight cars at $1100, the total spent for freight cars amounts to $312,607,000; for passenger cars at $8500 the cost was $46,384,000, and for locomotives at $16,000. the cost was $117,792,000. The total amount spent by the railroads for new rolling stock and locomotive power ap- proximates $477,000,000 for 1907, an increase of about 25 per cent. over 1906. ——_~+e—_—__ .The American Furnace & Machine Company. During 1907 the American Furnace & Machine Com- pany, Diamond Bank Building, Pittsburgh, did some very successful work in the furnace line. It recently built a new 40-ton open hearth furnace for the United Stee? Company, Canton, Ohio. It has also designed some new and modern sheet and pair furnaces and producer gas fired annealing furnaces, erecting five sheet and pair fur- naces and three producer gas fired sheet annealing fur- naces, and also two of the James H. Swindell patent water seal gas producers at the plant of the Seneca Iron & Steel Company, Blasdell, N. Y. These furnaces are so arranged as to give a soft and uniform heat through- out and are easily operated. The sheet and annealing furnaces are equipped with frictionless charging machines. Three 12 ft. x 12 ft. James H. Swindell patent water seal gas producers were recently installed in the plant of the Jessop Steel Company, Washington, Pa., to oper- ate three 36-pot crucible furnaces, built by the American Furnace & Machine Company some time ago. These pro- ducers are also of a new design and are said to be giving entire satisfaction in every respect. The company has a large number under construction at the present time. The same company builds four types of gas producers, including small gas producers 10 ft. in diameter by 12 ft. high, fed by one bell coal hopper, and a large gas pro- ducer 12 ft. in diameter by 12 ft. high, fed by two belB coal hoppers. These producers are operated by poke holes located on top, and there are no side poke holes, doors or false bars to contend with. These bell coal hoppers are so arranged as to spread the coal evenly around the producer. A third type of gas producer is known as the suction producer and is used for gas en- gine and illuminating purposes. The gas from this pro- ducer is pure and strong and free from dust and carbon, and does not cut valves or clog pipes. A fourth type, which will be found adapted to many purposes, is me chanically poked and mechanically fed. The above company has just completed a new design of copper smelting and refining furnace for the Algoma Custom Copper Smelting & Refining Company, Thessa- lon, Ont. This furnace will be in operation about Aprib 1, 1908, and is of different construction from any smelt- ing furnace now in use. It is said to be constructed so as to obtain all the copper in the ore, without allowing any to escape through the stack. There is no direct connec- tion to the stack, the melting chamber being separate from the draft of the stack, and all metal contained in the ores will be extracted and melted down into the re- ceiving bosh, where it can be either dipped out by ladles or tapped through a spout into a ladle, as desired. This is a 200-ton furnace operated by two James H. Swindell patent water seal gas producers. 8 THE IRON AGE January 2, 1908 The Goulds Manufacturing Company’s New Foundry. An Extensive Plant for the Production of Pump Castings. The Goulds Mfg. Company, Seneca Falls, N. Y., has recently occupied a group of new buildings, consisting of a large foundry and pattern shop, with accessory power plant. Their erection was in progress for nearly 18 months, the new buildings being part of a comprehen- sive plan of construction that was undertaken six years ago and that will require several years for complete rounding out. At the outset the problem presented was that of a long established company that had outgrown the facilities afforded at its original site. Addition after addition had been made, but the old works were hedged in by the Seneca River and the Seneca and Cayuga Canal and the growing up of the town about them. Several came in response to constant expansion in both the large and small pump departments since the first erection on the new site. They will be followed by others in pursu- ance of a plan under which the foundry will be on one side of and at right angles to a series of machine shops, shown in broken lines in Fig. 1. At the other side of the proposed machine shops and heading all of them will be an assembling department. This last named building will receive work from all the shops, and in it and alongside of it will run tracks for shipping out the finished prod- uct. The entire layout of the No. 2 plant has a frontage of 2100 ft. on the New York Central Railroad, and the rectangle marked out by the final group of buildings will | I FOUNDRY ! a ’ a RESERVOIR NGINEDOILE : \ eo’ 200 ROOMIROO 144 x 600 | 4 ; | z2<—_ @—_—_—_"_—<<x«. we S \ SN FOUNORY ' ! ' ! CORE-ROOM J — — . . ...- BLACKSMITH r i Ll sHop | STORAGE [ } = SE | MACHINE SHOP ik | Fig. 1.—Plan of the No. 2 Plant of the Goulds Mfg. Company, the New Buildings Being the Group at the Left. buildings had been erected, indeed, extending over both the canal and river, to such unusual measures was the company driven by the demand for increased facilities. Originally confined to small pumps, the business had de- veloped rapidly in the manufacture of power pumps, which was entered upon in the late eighties. Therefore the natural first step, when another site became a neces- sity, was to provide in the new place sufficient foundry and machine shop capacity to take care of the heavy work. This was done in 1900, when the company ac- quired 10 acres of land in the western part of the city, about a mile from the original plant. A foundry and machine shop were built first, and thereafter the No. 1 plant and the No. 2 plant were distinguished in all the operating records, “ No. 1 work” designating the smaller pumps and “No. 2 work” the large power pumps. The present article deals with the extensive new foun- dry and pattern shops that were under construction in 1906 and 1907, Joseph H. Wallace & Co., industrial engi- neers, New York, being the architects. These buildings be £31 ft. from north to south, as in Fig. 1. Additional property has been acquired since the first purchase in 1900, so that the company now has 66 acres at the new site. The Original No. 2 Plant. Before giving a description of the new plant, which is the group of buildings in the left-hand portion of the sketch in Fig. 1, reference should be made to the ma- chine shop shown on the upper side of the plan drawing. This buiiding, erected in 1900, is 500 x 100 ft., and is equipped throughout with modern tools and labor saving devices, including three 10-ton electric cranes, with run- ways the entire length of the building. Just east of the machine shop are the blacksmith shop and storeroom buildings. On the west side of the machine shop and south of the group of smaller buildings is the men’s building, with complete system of plumbing and equip- ment of lockers, wash trays, &c., for the convenience of employees. The upper floor of this building is devoted exclusively to a large reading room, on the tables of of) Se cn ae 2 ae es re wae piece ga a 9 REARS OT ST OUTER AERIS PIN HT. “OE aan pees Ses: en eee nee January 2, 1908 which are provided trade, technical and other publica- tions. This room is used during the noon hour as a lunch and smoking room, and is in charge of a special janitor. The engine and boiler room of the group of buildings a ° os t —_ —_—_—_—_————— T2T S44 ! ' | w ' 1 | 3} 3 | Fa L ! "| 4 | | ! , | i o } | } | CORE ROOM REINFORCED CONCRETE STEEL @ GLASS [] |) PARTITION wate J CORE STORAGE i4 MASHWAY THE IRON AGE 9 buildings and those provided for cores, sand and flasks have been abandoned, and will be used to supplement the ! 1 i ' \ | | ' ' ' 1 \ 1 | 7 ' | alae 1 | oO! h pe \ : 1 j |) 3 RATTLING ROOM © 1 j 3 | | “a > . § | ° 4 \ I CONE ROOM BRICK WALL , — ! 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Z | u 1 2\\ | | I ee ae | Rae ae ae | Oe.” RR eee aieak ss ie eel i " ' | 1! we o,T Troawra i — j 11 | BLE ce i | i I Ht---- FESS ES 4 ( | } | | Y i! ty 11 ; i] | | Y\- 1° ; | I i] | | ; | | é | | | | | | tI tt Vi + | Hy | | | ; | 1 , } - | | >» | | °o : wt ‘+8 o!| = : lA sr \ tot ' j j | A .- 4 | ' o ’ Yo } aot | | | i oo $ =a i | | ; \ iO ; ' e | BINS ? 1; | | | | ® I | — S || i] 3 14 T | > | } | ' } | | ! : * , ! | | | i ' 1A Lay i 2. } it x* } | | | } | 1 } IV ! | | | ’ 10 | | | | \ | | | t ! | lige | | i ! j ' | | , ' : | | es i i } + -— -— - . \ } a ees ‘ 2 —n ! ! | aa re ate - yp — - —l) ! , f - \ — ——49— — je - —— - - 4 - — - \ . tt - 3 — + -——_» J a 5 L ities os * : \ j a aoa w! | ~~ i ! mek: _ ~ o ty Fig. 2—Plan of the New Foundry and Auxiliary Plant. west of the machine shop have been abandoned, the equip- ment being transferred to the new power house, of which mention will be made later. The foundry and cleaning machine shop. The pattern storage building in the upper central portion of the sketch will continue to be used for the same purpose. , lit Hid ait anise Sa THE The New Plant. The new foundry and the buildings connected with it are shown in plan in Fig. 2, which gives a good idea of their extent and equipment. The foundry is 500 x 144 ft., of steel and brick construction, with monitor roof. From the floor to the ridge is 66 ft. The monitor extends the full-length of the building. There is a complete system IRON AGE January 2, 1908 The roof and ends are of steel frame and reinforced con- crete. The roof is waterproofed with five-ply roofing felt, laid in asphalt, with coating of stag. The flashing is of 14-02. copper. The new foundry building has a standard gauge switch track running into the main span. Another con- nection with the New York Central tracks is the trestle Fig. 3.—View at East End of the New Plant, Showing Foundry Crane Serving the Flask Yar4, iso the Inclined Trackway and the Trestle Crossing the Roof of the Bin Sjstem. of transom windows on both sides, these being opened and closed by devices operated from the foundry floor. Four series of skylights are provided—one on each slope of the main foundry roof and one on each bay, the for- mer being 10 ft. 10 in. wide and the latter 15 ft. 6 in. The skylights are of ribbed glass and extend the full length of the building. The building is fireproof. The foundations are of concrete and the walls are brick. Fig. 4.—Interior View of the Foundry.—‘C” Indicates the Location of Cupolas. Provision for Lighting, Heating and Ventilation. et mot oh | Uo ae The Illustration Shows the Exceptional track shown, running over the coal storage end of the boiler room and thence over the storage bins at the right of the main building in Fig. 2. Another feature to which attention is particularly called is the inclined track shown in Fig. 3, leading from the cupola charging floor and supported by heavy brackets carried on the side of the storage bin building. Fig. 4 gives an interior view of the foundry looking a isda xt Serie ; Si SON i SAREE TI HEN i | ete wd January 2, 1g08 toward the west end. The location of the three cupolas is indicated by the letter C, in the central portion of the right hand side. The iron is distributed by track ladles through the various avenues which were not completed when this view was taken. Tor large castings the heav- ier ladles are transported by a 20-ton crane serving the center bay, which is 64 ft. wide. This crane is of the two trolley, five motor Alliance Machine Company type. The crane runway extends beyond the east end of the building, a distance of 100 ft., to serve the heavy flask storage, and to reach cars on the switch. The swing door in the end of the building, which opens to allow the passage of the crane to the outside, is operated by an electric hoist. Two 5-ton electrically driven jib cranes, as shown in the plan in Fig. 2, and one of which is included in Fig. 4, are provided for handling large castings. They have 19 ft. arms and are arranged to swing entirely around the supporting columns. They were built by the Northern Engineering Works, Detroit, Mich. Fig. 5 gives a view of the western end of the foun- THE IRON AGE II dry, the rattling and grinding building, shown on the left in Fig. 2, and the washroom and locker building, 82 x 42 ft., is located on the south side of the foundry build- ing. An Ingersoll-Sergeant 1644 and 104% by 10-in. air com- pressor is located in a room adjoining the cupola room. From a large air receiver on the north side of the com- pressor room pipes run through the cupola room to the foundry to the molding machines and air hoists. A branch pipe goes to the pattern storage buildings, supply- ing the air valves of the sprinkler system. A line also runs to the No. 2 machine shop for supplying air hoists, chipping tools, &c., and to the cleaning room for sand blast. Core Department, The drying ovens for power pump work are located in the east end of the north bay of the foundry, as shown in Fig. 6. There are five of these, one being 16 x 24 ft. inside measurement for the dry sand molds, and the other four 9 x 16 ft., for drying the large cores. The rooms in which the smaller cores are made are located Fig. 5.— View in the West End of the Foundry, Devoted to Small Pump Work.—The Cross Marks the Entrance to the Small Core Department. dry floor, which is devoted to small pump work. The heating pipes are shown plainly in this view, as also in Fig. 4. The side bays of the main foundry are each served by two small cranes. Those in the north bay, which are Niles electric cranes of 3 tons capacity, can be utilized in handling large cores to and from the core oven cars running on the industrial track. Hoists oper- ated by compressed air are provided in the south bay. The cupola room is 60 by 40 ft., and contains at pres- ent a 92-in. cupola, built by Byram & Co., Detroit, Mich., and used especially for small castings; also a 72-in. cupola built by Byram & Co., which was transferred from the old foundry and serves for the heavier or trip- lex castings, and a 48-in. cupola built by the Northern Engineering Works, Detroit, used for special mixtures. Loaded cars are taken to the charging floor on an hydraulic elevator. The empties are returned to the ground level at the east end of the storage bins by an inclined industrial trackway; thus all interference with the incoming loaded cars is avoided. On the second floor of the blower room is one of the two steam engine driven blowers which supply warm air for heating the foundry. The other blower which heats the south side of the foun- in the west end of the south bay, occupying a space 160 x 40 ft. This department is separated from the foundry by a steel and ribbed glass partition. In the small core rooms are seven tracks, on each of which runs a car. Each track runs into a separate oven. The car runs between the benches, and the coremakers have only to turn around from their benches and place the finished work directly on the shelves of the core cars. In addi- tion to the ovens for the cars five Millet core ovens have been installed, which are used during the day and are arranged so as to use the same stacks as the main ovens. The large core oven doors are counterweighted and thus easily raised, the cables running over ball bearing sheave wheels. The furnaces heating these ovens are located at the rear. The fuel is not carried through the core room, but through a walled passageway at the rear, thus doing away with the handling of coke and ashes through the core room proper. Midway of the small core department is a room 20 by 28 ft., fitted with shelves for storing cores not required for immediate use. The Brass Foundry. The brass foundry, which occupies the northwest cor- ner of the main foundry building, is 120 by 40 ft. It is “SS oe re - I2 THE IRON well equipped for the production of a variety of brass work ranging in weight up to 1500 lb. There is a bank of 16 melting pots. The brass foundry floor is served by two cranes of 2 tons capacity each. The equipment in- cludes two tumblers, two sprue cutters and one grinder. Rattling Room, Connected with the main foundry by an enclosed passageway is the rattling room, 42 by 160 ft., one story high, with truss roof. Skylights 8 ft. wide are provided on each side of the roof, the entire length of the building. Twelve tumbling barrels, driven by Westinghouse motors, were supplied by the W. W. Sly Mfg. Company, Cleveland, Ohio. Nine direct connected grinders were furnished by the Bridgeport Safety Emery Wheel Com- pany, Bridgeport, Conn. The exhaust ducts from the grinders are led under the floor, a Sterling exhaust fan being located on. the north side of the room. It draws ~ See =. TT iF oll ia) : Tr ry re | imi t } : TS AGE of the pattern shop, so that a workman does not have to go far to reach any kind of machine. Storage Bins, It will be seen by reference to Figs. 2 and 3 that the trestle, 22 ft. high, which runs across the coal pocket room, continues over the roof of the storage house, which has a total length of 268 ft. The roof of the storage de- partment is for the most part a series of hatch cover- ings which are removed so that pig iron, sand, coke and other supplies may be dropped into their proper bins. Industrial tracks traverse the stock storage house on either side and a transverse track with turntables is laid in a middle passageway as shown in Fig. 2. The indus- trial railroad, which was furnished by- the Arthur Kop- pel Company, reaches also to pattern storage building No. 2, and to the brass foundry. The industrial cars loaded with pig iron and coke are pushed by hand to Fig. 6.—Northeast Corner of the Foundry, Showing Large Core Department, with Ovens and Racks. the dust and air into the dust separator just outside of the building, the air being discharged back into the room. Pattern Storage Buildings, The two buildings for the storage of patterns are lo- cated to the north of the foundry as shown in Fig. 2. Each is 82 x 42 ft., and they are designated as pattern storage No. 1 and pattern storage No. 2, the former being for small pump patterns and the latter for the patterns for triplex power pumps. The walls of these buildings are without windows, excepting on the north side, or the one remote from the other buildings. Pattern storage No. 2 is 65 ft. high, or four stories, and has a tower 92 ft. high, containing a 33,000 gal. tank. Each of the pat- tern storage buildings has a hydraulic elevator in an outside fireproof stairway tower. These elevators are operated from pressure tanks supplied by triplex power pumps of the Goulds make, which are driven by Crocker- Wheeler 250-volt motors. The pattern storage buildings are equipped with automatic sprinklers having dry pipe valves to control them during the winter months. The pattern making department is located in a two story building west of pattern storage No. 2, 162 ft. x 42 ft. The lathes, band saws, jig saws, surface planers and core box machines are duplicated toward opposite ends the cupola room where an elevator carries them to the charging floor. As indicated above, the empty cars from the charging floor are pushed out upon an inclined in- dustrial track leading to the yard at the east end of the bin storage house. On coming down into the yard the empty cars run up a slight incline from which they re- turn by gravity to either side of the storage house, the switch being set as cars are needed. Washrooms and Lockers, Unusually complete provisions have been made for washrooms and lockers. The large washroom shown at the left in Fig. 2, is reached by an enclosed passageway from the main foundry. It contains 232 lockers, and the rows of washbowls alternate with the lockers. For the small coreroom, 32 lockers are provided, with separate lavatory. The pattern shop has 20 lockers, and the brass foundry 24 lockers. The main washroom is intended for coremakers as well as molders. Heating System. For the American Blower Company’s heating system, already referred to, exhaust steam is carried through a 16-in. pipe leading from the power house, and the distri- bution is through 12, 10, 8 and 6 in. pipes to various por- January 2, 1908 ae ere eS eer f 3 4 a sg a ng Ea January 2, 1908 tions of the plant, including the No. 2 machine shop. There are two fan blowers in the foundry, one in the pattern shop and four in the machine shop. The steam pipe conduit carries the exhaust steam pipe for heating and also the live steam pipe supplying the engines driving the fan blowers and the pumps at the receivers. A third pipe in the conduit returns to the feed water heater in the power house the condensation from the three receiy- ers. The three pipes are carried in a Portland sectional conduit, supplied by the H. W. Johns Manville Company. The steam and exhaust piping and Holly return system were installed by the Walworth Mfg. Company, Boston, Mass. The pipe conduit is about 900 ft. in length. Water Supply. A very complete system of pressure mains has been provided, having two underwriters’ pumps at one end and a connection with the city water supply through an 8-in. pipe at the other end. In addition the com- THE IRON AGE 13 750 gal. capacity per minute. These pumps take suction from the reservoir, and their discharge pipes are con- nected with the complete system of the pressure mains running to 15 hydrants distributed about the plant. A 5-in. connection is made to the city service for use in the boiler room and for drinking. A gate and check valve are provided in this line, and in case the river supply is interfered with the city supply from the 5-in. pipe can be turned into the 6-in. pipe leading to the pattern stor- age tower tank and supplying river water for various purposes about the plant. Power Plant, The power house, Fig. 8, which includes engine room, boiler room and coal storage space, is 128 by 66 ft., and room has been left for an addition to the west. Two engines are at present installed, the larger being a 24 x 36 in. Allis-Chalmers heavy duty engine direct con- nected to a SCO kw. Westinghouse three wire direct cur- 4 Fig. 7.—Small Core Department, with Ovens and Racks. pany has a 6-in. line of its own extending from the pump house at the Seneca River 1700 ft. to a 450,000-gal. res- ervoir at the north of the power house. The reservoir is 60 x 100 ft. and 8 ft. deep. At the river is a Goulds’ electrically driven 8 x 10 triplex pump, designed prima- rily to supply a 33,000-gal. tank in the tower of pattern storage No. 2. There is a by-pass in the pipe located near the power house, so that the river supply can be turned into the reservoir referred to above. The lower half of the tower tank supplies the sprinkler system in case the city pressure becomes lower than the tank pres- sure. Only the upper half of the tan