The Iron Age 1909-05-06: Vol 83 Iss 18

THE IRON AGE Published every Thursday Morning by David Williams Co. 14-16 Park Place, New York. Vol. 83: No. 78. New York, Thursday, May 6, 1909. $5.00 = Yenr. including a Reading Matter Contents........ 1.8 SSS Seen Alphabetical Index to Advertisers ‘“* 292 || Classified List of Advertisers “ 281 | Advertising and Subscription Rates “‘ 1486 | REED F. BLAIR & CO.) ( a PRICK BUILDING, PITTSBURG, PA. STANDARD CONNELSVILLE}S COKE FOUNDRY FURNACE CRUSHED The original and only Genuine ‘*STILLSON WRENCH °° Are ‘you loading up with UMC Ammunition? Our tremendous adver- tising campaign wil, w/oad your shelves in rapid fire time. We are going to send customers up to your counter primed with preference for UMC Steel Lined SHot ShelJg.and UMC Cartridges Load up for the game season and meet the. demapd! wich we are creating. Order UMC Ammunition zow. is manufactured by WALWORTH } MFG. CO., Besten, U. S$. A. And bears their registered Trade-Mark The Bristol Company OMC Ammunition makes a hit with your customers. MANUFACTURERS OF ath ; THE UNION METALLIC CARTRIDGE CO., Bridgeport, Conn. Bristol’s Recording Instruments z for Pressure, Temperature and Electricity THE BRISTOL CO. lwWATER TUBE Ghe Babcock @ Wilcox Co., N SP BOILERS See page 61 8S ee , amso OT Co ' = New FP eens THE MOST SERVICEABLE HORSESHOE NAIL PHOBNIX CORD Send for Samples Samson Cordage Works, Boston, Mass. TURNBUCKLES No matter how severe the cénditions ‘* Capewell ”’ i mm nails can always be relied upon to HOLD THE Cleveland City Forge and Iron Co., Cleveland, 0 SHOE and SAVE ne EXPENSE. a et sso “The Capewell” Nail is Always the Best Maspeth, ‘New York, N.Y. MADE BY Low Phosphorous Pig.) tHE CAPEWELLHORSE NAIL COMPANY Pilling & Crane **” “ins; rnis Hartford, Conn., U. S. A. a ee ee se Building, New York. [UFKIN eH ws ee JENKINS ’96 PACKING RULES | pennant cos nee conte. . wpe joint has once een made it will last for yea t IN AMERICA and m years witbout further attention, rHt ADE I IN THE WORLD saving owner loss of steam, engineers trouble and vexation, Made in sheets and also in gaskets. THE LUFKIN RULE OO., Saginaw, Mich., U.8.A. | New York London, Eng. | Windsor, Can. | The genuine bears our Trade Mark. JENKINS BROS., New York, Boston, Philadelphia, Chicage “Swedoh” Cold Rolled Steel cus wm Drawing « Stamping THE AMERICAN TUBE & STAMPING COMPANY SEE 28 (Water and Rail Delivery) BRipesPort, Conn. PAGB MAGNOLIA peicron METAL Better a little more attention to the roof if the structure it covers is to be properly protected. MF 32 Pounds Coating ROOFING TIN is the kind that iusures permanent protection against water, wind and fire. AMERICAN The Standard Babbitt of the World SHEET AND TIN PLATE We manufacture COMPANY Babbitt Line / | Frick Building, Pittsburgh, Pa, MAGNOLIA METAL CO. See our ad 19 emnaaon New York: 11§ Bank St, Chicago) Fisher Building, Montreal: 31 St. Nicholas St. AGE SHEET ROD WIRE ( SHEET ROT WIRE THE IRON SOFT BRASS} STEEL COPPER: SHEETS |cernan SILVER LOW BRASS, SHEET BRONZE, SEAMLESS BRASS and COPPER TUBING, BRAZED BRASS and BRONZE TUBING : : : :: 3 SHEET WIRE We can make prompt shipment of one, two or three pass Cold Rolled Steel Sheets SEND US YOUR INQUIRIES FOLLANSBEE BROTHERS COMPANY, PITTSBURGH Matthiessen & Hegeler Zinc Co. LA SALLE, ILLINOIS SMELTERS OF SPELTER AND MANUFACTURERS Waterbury Brass Co. WATERBURY, CONN. 99 John St., New York Providence, B.4. Bridgeport Deoxidized Bronze & Metal Co. BRIDGEPORT, CONN. Phosphor and Deoxidized Bronze Composition, Yellow Brass and Alumi- num Castings, large and small 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 Oard Makers’ use. Stove and Washboard Blanks. ZINCS FOR LECLANCHE BATTERY “GERMAN SILVER \ In Sheet, Wire, Rods, Tubing and Blanks NICKEL ANODES BRASS, BRONZE, COPPER in all forms THE SEYMOUR MFG.CO., Seymour, Conn HENDRICKS BROTHERS Manufacturers of Sheetand Bar Copper, Copper Fire BoxPlates | "Jf The Plume & Atwood Mtg. Co, Manufacturers of Sheet and Roll Brass, Wire, Rods, German Silver and Brass Goods In great variety Rolling Mill Thomaston, Conn. Factories Waterbury, Conn. Branch Offices New York Chicago St. Louis and San Francisco A SERVICEABLE BOOK LAYING OUT FOR BOILER MAKERS A pupaiion? tre atioe on the layout of boilers, stacks tanks, . Pipe elbo send t ris eiloaes yus sheet metal wo rk; with er 42! 5 ‘illus wate a A nate =. Volume a 191° Pages, ble Co a $4.00, DAVID WILLIAMS CoO. - SCOVILL MFG. CO. Manufacturers of DE. ‘y Vi = R ED. 14-16 Park Place, New York BRASS, GERMAN SILVER, Sheets, Rolls, Wire and Brass Shells, Cups, Hinges, Buttons, Lamp Goods. Special Brass Goods to Order Factories WATERBURY, CONN. Depo NEW YORK CHICAGO BOSTON Henry Souther Engineering Co. HARTFORD, CONN. Consulting Chemists, Metallurgists and Analysts. Complete Physical Testing Laboratory. Expert Testimony in Court and Patent Cases. Arthur T. Rutter & Go. 256 Broadway, NEW YORK. Small tubing in Brass, Copper, Steel, Aluminum, German Silver, &c. Sheet Brass, Copper and Ger- man Silver. Copper, Brass and German Silver Wire. Braxzed and Seamless Brass and Copper Tube. Copper and Brass Rod. THE BRIDGEPORT BRASS C0. BRIDGEPORT, CONN. Postal Telegraph Building, Sreateey and Murray St., New York 85-87 Pearl St., Bosto 17 N. 7th St., Philadetphia Manufacturers of BRASS SHEET AND TUBING COPPER | WIRE Metal Goods made to order from Sheet, Rod, Wire and Tubing and Staybolts, Wire and Braziers Rivets PHOSPHOR-BRONZE Ingot er, Block, Ti Spelter, ee Akay Decne Nien eae THE RIVERSIDE 49 CLIFF STREET ~ - NEW YORK|™™”= RIVERSIDE, N J. THE IRON AGE New York, Thursday, May 6, 1909. The Greatest Steel Plant in the World.—lyV. The Shops at the Gary Works of the Indiana Steel Company, Subsidiary of the United States Steel Corporation. Considered as a unit apart from the overshadowing greatness of the plant which they serve, the shops con- stituting the maintenance department of the Gary Works comprise a group that would anywhere be regarded as of commanding industrial importance, not only on ac- count of its imposing size, but because of the extent, capacity and completeness of its equipment. Although relatively inconspicuous in comparison with the vast proportions of the steel works proper, these shops several- ly and collectively play an important part in the general scheme of operations; they are, in fact, an indispensable adjunct to the plant. The leading members of the group, such as the ma- ——_ = — ————s,:—S—CSOt F ; PATTERN | stores ! ple" WATER PIPE | The General Arrangement of the Buildings, With the exception of the roll shop and the “ square” round house, as the locomotive shop is called, the entire group is ranged on either side of the main avenue lead- ing into the plant, which is an extension and the northern terminus of Broadway, the principal north and south street of the town of Gary. On one side of the street, at the entrance of the plant proper, are the machine shop, foundry, storehouse, paint shop and brick shed; on the other, the boiler shop, blacksmith shop, electric repair shop, pattern shop, pattern storage house and clock house, all ranged from north to south in the order named. The switch tracks connecting the shop with the main ea a” —400'— Fig. 1.—Location Plan of the Shops, Stores and Foundry of the Indiana Steel Company. chine, blacksmith and boiler shops, were the first of all the buildings erected and equipped, having. been com- pleted and running for over a year. In the meantime these and the others since built have greatly facilitated the work of construction, their capacity being not only equal to the handling of ordinary repair work, but suffi- cient even for the incidental rebuilding of equipment. While not much of radical departure from usual mod- ern practice is to be found in the design and construc- tion of these shops or in the tools and machinery com- prising their equipment, they offer an interesting exam- ple of a comprehensive adaptation to a given end. The probable need of future extension was a factor duly con- sidered in the original plan for all of the shops, and they were accordingly laid out to meet this requirement with- out disarrangement of the present co-relation of the sev- eral units. In the outline plan drawing of the plant as a whole, shown in the issue of The Iron Age of January 7, 1909, the locations of the various shops are indicated. A portion of this plan, on @ little larger scale, is here- with given in Fig. 1. yard system are arranged to afford convenient facilities for handling material in and out and between the shops, all of them being paralleled on either side by continuous tracks connected at either end with the main east and west trunk lines of the plant system. In addition to these, switch tracks enter the machine shop, boiler shop, foundry, electric repair shop and storehouses, in the former two of which the line is continuous through the center of both shops. The handling and transfer of heavy material are fur- ther facilitated by tram tracks leading from the shops to the outside switch line. These trams are al] the more convenient and effective, since the intervening spaces between the principal members of the group are covered by electric traveling cranes mounted on yard runways. Between the machine and boiler shops and foundry and blacksmith shop the runway is continuous, extending across the street, thus supplementing the means of trans- fer between all four shops. It would be difficult to de- vise an intertransit system for shop traffic purposes more complete than is here laid out. ~ URI i a a eS . eas aaa | ar THE : mn er —] ee eae antihige « cnntas «mentee 2 Gh. emcee emanes antique» anf§i:imme ” et) zl ag® 27 25 IRON AGE May 6, 1909 —_— ee —— => TEx See eS ee 21[} 20 19 .18 1 60 [PP TOOL Roos, plata se c a : PIPE, SHOP be -— 844-9" IL 66 i! MANS OFFICE * eS ——E— SS ' ' —z20 Bays @ 20’ = 400! -— a ~—— ---- he MASTER i] MECH. | | OFFICE | = ee ee ol SSS ee Fig. 2.—Ground Plan of the Machine Shop.—The Tools as Numbered Are as Follows: . Screw machine. 20. 14 in. by 5 ft. engine 35. 6-ft. boring mill. 54. 48 x 48 in. planer. Bet -in. cutting off machine. eentering machine. 4-in. centering machine. 2-in. twin bolt threader. 3-in. bolt threader. - 24 in. by 25 ft. lathe. 30 in. by 11 ft. lathe. 21, 24 x 24 in. planer. 22. 10 x 19 x 36 in. universal miller. 23. 12 x 20 x 36 in. universal miller. 24. 72-in. gear cutter. 36. 10 to 16 ft. boring mill. 37. Pipe threader. 38. Pipe threader. 39. Double axle lathe. 40. 300-ton wheel press. 41. 24-in. slotter, 42. Vertical key seater. 55. 36 x 36 in. planer. 56. 36 x 36 in. planer. 57. 26 in. by 10 ft. traveling shaper. 58. 16-in, shaper. 59. 16-in. shaper. 60. 72-in. Gleason gear planer. eenerenty 24-in. turret lathe. 25. Emery grinder. 10. 24 in. by 20 ft. lathe. 26. 20-in. drill press. 11. 30 in. ne 12 ft. lathe. 27. 15-in. shaper. 12. 21-in, turret lathe. 28. 10 in. by 5 ft. 13. 18 in. by 10 ft. lathe. lathe. 14. 30 in, by 20 ft. lathe, 29. Milling cutter grinder. engine 15. 36 in. by 15 ft. lathe. 30. 42 in. by 15 ft. lathe 16. 36 in. by 15 ft. lathe. 31. 48 in. by 20 ft. lathe. 17. er grinder. 32. 72 in. by 31 ft. lathe. 18. a. in. by 10 ft. engine 33. 80-in. horizontal boring lat machine. 19. Te in. by 5 ft. engine 34. Horizontal boring, drilling lathe. and milling machine. The Machine Shop. The machine shop, shown in plan and section in Figs. 2 and 3, is housed in a building 147 x 400 ft., of steel frame construction, with brick siding and tile roofing. All of the buildings in the main group are of similar con- struction with the exception of the brick storehouse, which is sheathed with corrugated iron. The central bay of the machine shop, of which a view is shown in Fig. 4, is 77 ft. wide, and is flanked on either side by lean-tos, each 35 ft. in width. - A systematic arrangement of the tools comprising the shop equipment includes their grouping in such a man- ner as to assemble as nearly as possible all work of like character in the same section of the floor. With this object in view, beginning at the east end of the shop, the lathes are arranged on the right of the central bay, and are followed in order by the heavy boring mills. On the opposite side of the bay, in like position, are located the planers and shapers, the drill presses, key setting and slotting machines, axle lathes and pipe threading machines. This arrangement affords a wide, clear space through the entire length of the shop for erecting, loading and handling, which work is facilitated by a 25-ton traveling crane with a 5-ton auxiliary commanding the main floor. The space in the side bays is occupied by smaller tools for lighter work. + “2-WHITING CRANES MAIN HOISTS 25 TONS AUX. ‘“ 5 “ Fig. 3—Transverse Section of the Machine Shop. 61. 48-in. Gleason gear planer. 62. Horizontal boring and drilling machine with 8-ft. 43. 36-in. vertical boring mill. 44. 12 in. by 5 ft. keyway cut- ter. 45. 6-ft. heavy radial drill. table. 46. 6-ft. universal radial drill. 63. 4-ft. plain radial drill 47. 30-in. drill press. press. 48. 30-in. drill press. 64. 5-ft. plain radial drill 49. 30-in. drill press. press. 50. 20-in. drill press. 65. 4 to 12 in. pipe cutting 51. Emery grinder. and threading machine. 52. 84 x 84 in. planer. 66. % to 4 in. pipe cutting 53. 48 x 48 in. planer. and threading machine. All of the fitted with independent motors, are group driven by four 75-hp. motors connected to line shafts hung from the girders of the side bays. The shop is heated and ven- tilated by a hot air heating and ventilating system op- erated by two sets of steam coils and fans located mid- way of the building and on either side. A fair idea of the shop capacity is indicated by its tool equipment, which includes lathes up to 72 in. by 42 ft.: planers up to 84 in. by 18 ft.; 6-ft. plain and uni- versal drills; 6-ft. and 10-ft. turning and boring mills; a 96 in., 300-ton, hydraulic press; an 80-in horizontal boring and drilling machine, besides the usual complement of smaller tools. The principal part of the machine tool equipment was furnished by the Niles-Bement Pond Com- pany. tools, except a few of the larger machines The Boller Shop. Facing the machine shop, on the opposite side of the street, is the boiler shop, 133 x 160 ft., with a hight of 43 ft. 4 in. from floor to the roof chords in the main sec- tion, which is 638 ft. wide. The plan and section are shown in Figs. 5 and 6. In addition to a 15-ton traveling crane covering the center bay, of which a view is given in Fig. 7, there are a number of wall cranes serving the principal machines. The tool arrangement is designed to promote a con- tinuous order of operations. Entering the shop at the east end over the switch track, or brought in on the tram car from the stock yard on the south side. material passes first to the shears and thence to the punches on one side, and from there is carried over by crane to the bending rolls and forming machines on the other side. A clearance of 25 to 30 ft. between the swing of the jib cranes affords space through the center of the shop for riveting and erecting work. The side bays, each 35 ft. wide, are utilized for laying out and fitting and for lighter work. Compressed air for the operation of pneumatic tools is supplied by an Ingersoll-Rand twin compressor, driven apr Penne May 6, 1909 THE IRON AGE 1405 Fig. 4.—View in the Main Bay of the Machine Shop Looking Westward. by a 120-hp, Westinghouse synchronous motor. A heat- ing and ventilating system similar to that in the machine shop provides an even and comfortable temperature throughout the shop. The term boiler shop as applied to this department is somewhat of a misnomer, since the boiler work re- quired about the plant is relatively small. Gas super- seding steam, as a means of generating power, limits the use of boilers to auxiliary power service, heating and other miscellaneous requirements, so that there are com- paratively few boiler units in actual operation. Of these the yard locomotive boilers comprise the greater number. All of the stationary boilers about the plant are of the water tube type, and the repair work incident to their maintenance calls for but little boiler work in this shop which is now more commonly referred to as the structu- ral shop. Prior to the starting of the blast furnaces, and later the open hearth furnaces and rail mill, it was chiefly employed in getting out miscellaneous structural jobs in connection with construction of the various plant RIVET ROLLS , < yO od * ~ ——— a oar Cl / se yoIna - . ; ; é5 “. BENDING BENDING : MACHINES ROLLS \ \ STANDARD GAUGE RR. jenny ee PUNCH AND? ~ \2o"" SHEAR \ Fig. 5.---Ground Plan of the Boiler Shop. 1406 hm 60° — 15 TON CRANE P, ZZ fe = £0 r Sy | sam ae le I L piethteeenneniineinnees sonenranncengN a = = 85 - —— - ope —- —— - —— - —_ 934 — - — - is Fig. 6.-—_Transverse Section of the Boiler Shop Through A A on Fig. 5. buildings. It will, however, as plant operations extend, be largely employed in the repair of ladles. Its tool equipment is adequate for a wide range of heavy work in plates and structural construction, being equal to any demands likely to be imposed upon it either in repairs or new construction. Extraordinary care has been exercised in providing safeguards against accidents likely to result in personal injury to workmen through contact with machinery. Gear wheels and other moving parts of all tools are, as far as possible, completely in- closed in metal shields. There are no line shafts in the shop, each tool being driven by an independent motor mounted upon the machine itself. The Blacksmith Shop. Opposite the boiler shop is the blacksmith shop, 62 x 160 ft. in its main section, with an ell 31% x 60 ft. It is shown in plan and section in Figs. 8 and 9. The stock yard between the blacksmith and boiler shops is spanned by a traveling crane, and connection between the two is provided by a tram track extending to the center of each shop. From the switch track traversing the yard, mate- rial is unloaded on either side or picked up at any point in the yard by cranes and deposited on the tram car for transfer into the shop. The forges, of which there are z Peedi eli. rat ts THE IRON AGE May 6, 1909 11 ranged along the sides of the shop, are of the down-draft type, which do away with the smoke and gas arising from ordinary open forges. They are operated by two motor driven fans, one for blast and one for exhaust, the pipes being all run under the floor. the Occupying middle of the shop Ss. from front to rear, Fig. 10, are the heavy tools, which include two steam hammers of 1 and 3 tons capacity each, with pro- vision for a third of 2 tons capacity, a large double end punch and shear and two single punches. Liberal space is provided between each of these machines for the handling of work. An electric crane with 20 ft. headroom spans the floor from end to end. In the east end of the building are installed a bolt cutter and two bolt headers, and a bulldozer, all motor driven, and a bolt heating furnace. A battery of two Sterling boilers, housed in the ell portion of the building, produces steam for driving the steam hammers—the only steam driven tools in all the group—and for supplying steam heat to other shops. A large heating furnace for the heavier work is located partly in the main shop and partly in the boiler room; the furnace doors open into the former, and it is fired on the other side from the boiler room firing floor. The coal bin is conveniently accessible to both the boilers and furnace, and is filled direct from cars on a coal track outside. The Foundry. No unit of the shops is better designed or more fully equipped for the service required than is the foundry plant. The foundry building, which in design and con- struction is similar to the machine shop, and which it parallels on the south, is 137 x 400 ft. It is shown in plan and section in Figs. 11 and 12. The molding floor, Fig. 13, occupies the entire middle bay, 61 ft. in width, and is served by three overhead electric cranes of 25, 40 Fig. 7.—View from the Side Bay of the Boiler Shop Looking Into the Central Bay on the Right. May 6, 1909 J 4000-LB. STEAM HAMMER , Fig. 8.—Ground Plan of the Blacksmith Shop. and 50 tons capacity. The foundry is divided into three sections, the east end being equipped for iron molding, the west end for steel castings and the middie for cast- ing air furnace iron rolls. In the iron foundry section, Fig. 14, there are installed one 72-in. and one 46-in. cupola to which blast is deliv- ered by two electric driven blowers. In this section is also a 750-lb. Schwartz furnace, used for aluminum and brass castings. Oil fuel is used for this furnace and is fed from a tank on an elevated steel platform outside the building. In the brick inclosed room to the west of the cupolas in the same bay, provision is made for the in- stallation of two 15-ton air iron furnaces for roll cast- ings, which have not yet been put in. In the meantime this room serves as a flask repair room. At the extreme west end of this bay is located a 25-ton acid open hearth steel furnace, Fig. 15, for the making of steel castings; a Morgan gas producer plant installed in an adjoining building on the outside supplies gas for the operation of this furnace. In the northern bay, and near the middle of the building, are four 18 x 24 ft. brick core ovens, Fig. 16. These are furnished with rolling steel curtains, and each accommodates two truck mounted A\ dee ee AN Pa | \ = =) [4 pouBle PUNCH AND HEAR 1H05 10 it UE LLL THE IRON AGE 1407 HEATING FURNACE BOLT | eka BULLDOZER _ ae — =r a] HI — tr] i} tpt ‘ ee eae Dooce pt _) --4 on { coo FEED PUM | = | [=m fer). fo=- FEET PUMP eesti COAL BIN | ey ee ean steel core racks. Permanent casting pits for cylindrical work are located at each end of the molding floor con- venient to the steel furnace at one end and the cupolas at the other. Owing to the sandy character of the soil these are first lined with steel casing. One in the iron foundry, just being installed, is 11 ft. in diameter by 10 ft. deep. ‘ Supplementing the overhead cranes and mounted on a runway beneath them on the north side of the molding floor are two 5-ton Morgan traveling wall cranes with a reach of 17 ft. Two 5-ton cranes span the north bay with sufficient head room to clear the core ovens over which they pass. Charging material for the cupolas is hoisted from the stock yard on the south side of the foundry te an outside steel platform on a level with the charging SSS] i RSSSSSSS SSNS NNT : anes SSSA] ee SSS NAY) BEE Fig. 9.—Transverse Section of the Blacksmith Shop Through A A on Fig. 8. tnt —j¥——, THE IRON AGE “lay 6, 1909 Fig. 10.—View in the Blacksmith Shop Looking Westward. Fig. 15.—View in the Foundry Looking Westward from the Main Entrance. May 6, 1909 37 = 3914430 Fag ty; ee SFORMER i| S g| Li ! oo 1 +3¢, All ttt n “\LO ‘ sve 99 4 40 “S840 LE ~SUWH,S8 JO “SHLD OF | eLEcTmC_) | FOUNDRY STOR SCHWARTZ | BRASS FURNACE! PLATFORM if} MACHINERY —irrihinttitth — TTT @ we oO < z c > aw - = A _| “4 i : TT D|_N3AO 3800 | fa dus sa tone be | nen ETT ¢ ra Ms # com - ot & a 2 w z z= - 3 I I seer ere ere T “rt. EEL FURNACE) | a ye ee ee gas y 7 t 1! 125 TON O.H.: || 8" — FUERA REEE REE UUEESTAEE we @o > of 3: z x = 2 oa room by a 25-ton yard crane spanning the yard switch track the full length of the building. Auxiliary to this service is a 10-ton Otis electric elevator within the build- ing, on the yard side, running to the charging floor. Owing to the probable extension of the foundry building, the sand bins and mixing and screening machines are located in a temporary structure of corrugated iron at the west end of the foundry which can easily be removed. The Electrical Repair Shop. The electrical repair shop, though not as large as some of the others, is by no means one of minor impor- tance. The use of electricity as the almost universal mo- THE IRON 1 ‘ ai ‘ OPERATOR AGE 1409 ONE 25-TON CRANE Fig. 11.—Ground Plan of the Foundry. Fig. 12.—Transverse Section of the Foundry. ONE 15-TON MORGAN CRANE tive power of the steel plant naturally increases the scope of work in this department, which is charged with the responsibility of keeping the transmission system and motive machinery in order. In the shop group alone there is 2440 hp. of electric motor equipment, in which ‘is included that of 15 cranes, one of which, with 24 ft. overhead clearance and 10 tons capacity, spans the floor of this shop, which is atahee between the blacksmith and pattern shops. The electrical repair shop is shown in pian and sec- tion in Figs. 17.and 18. It is 60 x 120 ft., with a 14-ft. gallery on one side, the latter. being also served by the traveling. crane. The plan of the gallery is shown in Fig. 19. The machinery equipment on the main floor, of which a view is given in Fig: 20, includes three lathes— one single, one three-spindle and one radial drill—amill- ing machine, shaper, two grinders and an open forge. All are group motor driven. A line of work benches set end- wise against the north wall occupies part of the space underneath the gallery. While at present some repair parts are purchased, it is the intention ultimately to do all the repair work in this shop. It is fitted to rewind all motors, and to do practically any kind of work outside of new construction of motors and generators. Light work, such as winding, testing and repairing lamps, is done in the gallery in which are installed a winding machine, paper cutter and IRON AGE Fig. 14.—View in the Foundry, Showing the Cupolas. work benches. Machinery and material are brought into the shop on a stub switch track, which enters the east end of the building. The Pattern Shop and Pattern Storage House, The pattern shop is a two-story structure, 51 x 99 ft., shown in plan and section in Figs. 21, 22 and 23. It is furnished with a complete equipment of standard wood- working machines adapted to the making of patterns for light and heavy castings, many of the latter being called for to repiace breakages in massive machinery parts. All of the tools are belt driven from a single overhead line shaft on each floor run by motors mounted on wall brack- ets. As a provision against fire loss, the floors and ceil- ings are of concrete, there being no openings in the upper floor. The second story is reached by an outside stairway; 2 similar provision marks the construction of the pattern storage house, the second floor of which is connected with that of the pattern shop by a steel bridge. This house, Fig. 15.—The Pouring Side of the 25-Ton Acid Open Hearth Steel Furnace in the Foundry. May 6, 1909 Fig. 16.—View in the Foundry Looking Eastward, the Core Ovens Being on the Left. 50 x 120 ft., shown in plan and section in Figs. 24 and 25, has four floors covered with pattern storage racks. A 6 x 10 ft. electric elevator, running in a shaft outside of the building, reaches each floor, besides which there is an outside steel stairway of four flights. The only openings in the building, aside from the fireproof doors at the stair and elevator landings, are 18 in. square ventilator ports covered by top hinged cast iron plates, all of which can be closed from the ground. The lighting system is similar to that used in vaults, whereby all lights are automatic- ally turned off by closing the doors. As a further protec- tion against fire, it is intended to install a complete auto- matic sprinkler system in both the pattern shop and stor- THE IRON AGE 1411 The Roll and Locomotive Repair Shops, At a distance of 150 yd. west of the machine shop and foundry are placed the roll shop and locomotive repair shop. The former occupies a one-story building, which at present is 200 ft. long by 60 ft. wide, but when the finishing mills are in operation it will doubtless be en- larged to double its present capacity. It is shown in plan and section in Figs. 26 and 27. The roll shop equipment consists of two 60, four 44 and three 34 in. independent motor driven roll lathes made by the United Foundry & Engineering Company. They occupy the northern side of the building, where they are set at right angles with its length, spaced 7 to 8 age house. ft. apart. About one-third of the floor space is used for ke - ——— -- ———— - — _ —_—— - - —— - ———_ - 120° Sess) es ee Pe o> ' 1 7 | == : i i SENSITIVE i | Q OFFICE 7 DRILL F lad i SS) I SS = —_ i OFFICE | i | | LL —i TT i) EMERY = H a t HT i] WHEEL LATHE 3 SPINDLE DRILL i ee ce chat - | ee 7 1 3 . x 5 z : : } @ o Mi / tanver RAD. ORAL | E <—— LATHE LATHE 0] O10) TOKET jen eD ! 26" UPRIGHT DRILL PUNCH PRESS MILLING MACHINE __MAIN SHAFT Fig. 17.—Plan of the Main Floor of the Electrical Repair Shop. 1412 roll storage. Rolls are switched into the building over a stub track entering the building at the west end, and are lifted from the car.by a 15-ton crane which spans the entire floor with 20 ft. clear- ance and are deposited in the roll racks or carried to the lathes. a Instead of the usual round house con- Q— ae Fig. 19.—Plan of the Gallery of the Electrical Repair Shop. struction, a shop rectangular in shape, 104 x 259 ft. in dimensions, has been provided for the repair of locomotives. The shop lies within and is paralleled by the tracks of a switch loop == ee a ; Ww \, F FS iavtinnilie ’ Chey — SPAN—60 - 6&- eae eee = Le ___ ALLIANCE 10 TON E O.T. CRANE HH ofa ee Fig. 18.—Transverse Section of the Electrical Repair Shop. connected at either end with the main yard system. It is traversed diagonally by seven tracks, all of which are covered by a 50-ton crane of 50-ft. span. Passing through THE IRON AGE May 6, 1909 7 Ty sencn [BENCH - BENCH | 7 [eenon | - [pencn | — | BENCH y ' COIL WINDING | | MACHINE } ee —r _ ARM. LATHE ) | oi3G Sore L_S—<s | | Other buildings in the shop section include the store- house, brick shed and clock house, all of which are built to fit in and conform to the general scheme of arrange- ment as laid out in the plan embracing the maintenance department group. The New Brown & Sharpe Catalogue. The Brown & Sharpe Mfg. Company, Providence, R. I., has issued its 1909 catalogue in the usual handbook form and containing full information concerning the company’s comprehensive line of products. The volume contains 551 pages. General speaking, its contents may be divided into two sections, machinery and tools. In the former are set forth with copious illustrations the line of milling ma- chines and attachments and appurtenances; that of grind- ing machines and attachments; the gear cutters, screw machines, automatic turret forming machines, automatic cutting off machines; and the several tools and attach- ments which go to make the scope of the different ma- chines complete. Various semi-special machines are shown, and annealing and case hardening furnaces, pumps, &c. The Brown & Sharpe cutters and gears are too well known to receive more than passing mention; the catalogue goes into them in much detail. The last section of the book is given over to the small tools. A colored insert is devoted to the new machines and Fig. 20.—View in the Electrical Repair Shop Looking Westward. the buildings these tracks connect with the loop tracks on either side. The northern end of the shop is tem- porarily sheeted with corrugated iron, it being the in- tention to extend it to accommodate at least five more tracks. This form of construction, it will be observed, does away with the necessity for turntables. tools which have been brought out since the issue of the last catalogue. The machines comprise the No, 2 A heavy universal milling machine, No. 00 hand milling machine, No. 2 B heavy plain milling machine, Nos. 18 and 24 plain milling machines, No. 12 plain grinding machine, No. 23 gear cutter grinding machine; No. 12 automatic gear cutting machine and No. 2 G automatic screw ma- May 6, 1909 chine. The new features include a large number of ma- chine attachments, reamers and machinists’ tools. As usual, the catalogue is a textbook of useful information, containing much that must be helpful to engineers and mechanics. a The city of Brazil, Ind., with 12,000 population, and situated in the heart of the coal district of the State, has amen — a a poet Wendaiemeney E 1 E + E J THE IRON AGE 1413 The Mortality Rate in Dusty Trades. Frederick L. Hoffman, statistician of the Prudential Insurance Company, Newark, N. J., has contributed an article to the bulletin of the Department of Commerce and Labor on the mortality from consumption in dusty trades. The number of occupations considered is 42, divided into four groups, according to the exposure of the C 3 ~ atin WORK BENCHES Seal | G } CIRCULAR SAW gh pe omaad ] ° | SAW gi yr I GRIND STONE Se ‘ rc SURFACE mp ___MORTISING a 1 \/ | MACHINE MAIN SHAFT Hy f rf ST pa ft — —_— : | f Llanes enater t : 4" FAY & SCOTT LATHE OTOT]| * | [Joona MACHINE TENONING MACHINE EMERY WHEEL || TOULET O H 7 u Sr eS Fig. 21.—Plan of the First WORK BENCHES BAND SAW FILER AND SETTER Te | ——$_ _-—_7j -— Story of the Pattern Shop. BAND SAW 12 LATHE ‘ | ' PLANER AND JOINER FACING CORE BOX MACHINE LATHE BAND SAW -— 61-3" “" J 42 FAY & SCOTT LATHE | 24 FAY & SCOTT LATHE | Fig. 22.—Plan of the Second JOINER Zi=: PLANER WORK BENCHES CIRCULAR SAW Ligown | | MAIN SHAFT Story of the Pattern Shop. 6 PANELS @ 20/==120/ } } ' 7 [ | 4 J | | i | | x Fig. 23.—Transverse Section of the Pattern Shop. set out to increase its population to 25,000, and has en- gauged Charles S. Hernly to lead the movement. Mr. Hernly had much to do with building up Newcastle, Ind., where he lives, as one of the chief industrial centers of the State. His plan is the location of factories. The city bas raised in a few weeks $45,000 of a contemplated factory fund of $150,000. all | — — — } | | . ‘ “ t e iw & [i] = | a B 8 2 Lo i} a — q | WT BRIDGE TO CARPENTER AN@ PATTERN SHOP Fig. 24.—Ground Plan of the Pattern Storage Building. workers from metallic, mineral, vegetable fiber or animal and mixed fiber dust. The article states that of the deaths from all causes among males 15 years old and more in the United States 14.8 per cent. were from consumption. According to in- dustrial insurance experience, the ratios were 36.9 per cent. for occupations exposed to metallic dust, 28.6 per 1414 cent. for those exposed to mineral dust, 24.8 per cent. among those exposed to vegetable fiber dust, and 32.1 per cent. for those exposed to animal or mixed fiber dust. The occupation showing the highest percentage of mortality was that of grinders, among whom 49.2 per cent. were from consumption. In each occupation group the highest mortality from consumption was among per- sons between the ages of 25 and 34, the proportion of deaths between those years being 57.2 per cent. in occupa- tions exposed to metallic dust, 47.6 per cent. in those ex- Fig. 2 posed to mineral dust, 53.9 per cent. in those exposed to vegetable fiber dust, and 53.3 per cent. in those exposed to animal and mixed fiber dust, as compared with 31.3 per cent. for all males in the registration area. It is the opinion of the author that by intelligent methods of ventilation and dust removal the consumption l ee I oO OS oo OO OO + o-oo © - o i ae ae ae ae ae oe ee S ee Oe 34 LATHES ro oo So OO -o ©. -O- 4 be oe D> + oe Be ee rt oe oo ee et ee te ee OD- 1 C.L. TRACK i » SE SS = THE IRON 10 BAYS OF 20 FT. SS SS ee rr EE TT SS tt ee er ee er er AGE May 6, 1909 15.4 years of life for every death from consumption avoided by rational conditions of industrial life. Such a gain would represent a total of 342,465 years of addi- tional lifetime, and by just so much the industrial effi- ciency of the American nation would be increased. am le a ne The Smokeless Combustion of Coal. A bulletin on the smokeless combustion of coal in boiler plants, with a chapter on central heating plants, —-North Elevation of the Pattern Storage Building. will soon be issued by the United States Geological Sur- ver, Technologic Branch, giving in detail a study of the conditions found in industrial establishments in 13 of the largest cities of Indiana, Illinois, Kentucky, Mary- land, Michigan, Missouri, New York, Ohio and Pennsy]- vania, between 400 and 500 plants having been inspected. 200 FT. - - — - = picasa i i 44'LATHES © Od w os “© “ w = ‘3 *o | © 60 LATHE 30°8ED GRINO-STONE ToD. SO rows . a mS EMERY WHCELY ao or — ———! th it = Fig. 26.—Ground Plan of the Roll Shop. death rate among wage earners can be reduced from 2.2 per 1000, the rate based on the number of deaths among . gainfully employed persons 10 years of age and over in the registration States in 1900, to 1.5 per 1000, the aver- Fig. 27.—Transverse Section of the Roll Shop. age rate for 200 small cities, as shown in the mortality statistics of the United States census for 1901 to 1905. Such a reduction, the author estimates, would result in an annual saving of 22,238 human lives and would add Sufficient information was collected to make the data from 284 plants of value for this report. The bulletin, prepared by D. T. Randall and H. W. Weeks, not only shows that bituminous coals high in volatile matter can be burned without smoke, but also that large plants carrying loads that fluctuate widely, where boilers over banked fires must be put into service quickly and fires forced to the capacity of their units, can be operated without producing smoke that is objection- able. Proper equipment, efficient labor and intelligent supervision are the necessary factors. os The Interstate Railway Company, a Missouri corpora- tion organized for the purpose of building an electric interurban road between Kansas City and St. Joseph, has taken active steps to perfect its right of way, and is preparing to begin construction. The company re- ports that it is to build a standard gauge, modern elec- tric railroad on a seven-tenths of 1 per cent. grade and with no curve sharper than 3 degrees. The Chandler & Taylor Company, Indianapolis, Ind., manufacturer of engines, boilers and saw mill machinery, has taken out permits for a machine shop and carriage shop to cover an acre. They will be mainly of steel and gla&s; the larger building, the machine shop, having a saw tooth roof. Two other buildings, for offices and stor- age room for plans, will be erected within a short time. May 6, 1909 The General Electric Company’s Report. The General Electric Company has issued its seven- teenth annual report, which covers the operations of the fiscal year ending January 31, 1909. The following in- come showing is made in comparison with the preceding year: 1909. 1908. POs 20MM. TS. aN $47,168,469 $72,484,988 Expenses, interest, &c........c000. 42,366,217 65,898,335 DC epdet laces ctoestt ied hsent $4,802,252 $6,586,653 SMD > Fics S856 hs Pa RW e ahs 5,214,026 5,183,614 SR on a ieee $411,774 *$1,403,039 PROTIGGE WEPBIOEE isc ccc eves se 16,513,836 15,110,797 ME INES ob 60 65K 0d eens $16,162,062 $16,513,836 * Surplus, For the past six years the sales billed have been as follows: Sales billed. Sales billed. BPO 06. 850.605 60 $41,699,617 PT Bou ROG vi ias Deacon 39,231,328 BOOB eee cc cece 70,977,168 SI Siege ss wcclvun 43,146,902 | 44,540,676 Unfilled orders as of January 31, 1909, were approx- imately $13,000,000 as compared with $14,500,000 at the close of the previous year. The balance sheet given below includes the assets and liabilities as of January 31, 1909, of the Edison General Electric, Thomson-Houston Electric and Stanley-G. I. Electric manufacturing companies which (for the con- venience of bookkeeping) are consolidated with those of the General Electric Company : Assets, Patenis, franchises and good-will.............. $1.00 COW Sin). ca s:0s5 « REE CM eNeUe Ss os ceric gas 22,233,671.29 Stoths aed bandas. os5s 5k ica vice $21,922,189.21 Real estate (other than factory SRUGE) * si tesnusdethsdiceeoiee 85,124.66 Notes and accounts receivable..... 18,873,057.63 Werk ie: DROMONR i665 65.04 00 isos 607,276.59 $41,487,648.09 Merchandise inventories : At factories........ $15,682,255.88 At general and local NONE ecb eixev ide < 2,547,326.08 Consignments ...... 164,317.44 18,393,899.40 ——_——_——— 59, 881,547.49 Factory plants (including all lands, buildings and machinery).......$13,900,000.00 Copper mining investment........ 3,174,580.76 ————__———- 17 ,07 4,5 80.76 a oe ee Net eg kd gk $99,189,800.54 Liabilities. . 5 per cent. debentures of 1892..............0.- $41,000.00 eh MN OE Eas bbc nbG owe dev esdecesceas 2,047,000.00 5 per cent. debentures of 1907..........c.c000. 12,875,000.00 Accrued interest on debentures................ 107,633.36 A SS kg Se SW alee koa 64 vo 00% ba. 2,836,834.51 LRNCRRNOR: = CICA 0 sc Cece ei eee The beN 1,469.86 $17,908,937.73 Cympttnl GtoGk TANG a 8 ois 4A xen Cis ewes os es 65,178,800.00 WE BOTS iia Ee cy dthca es Be Rte a tetas 16,102,062.81 ES 5 ie MOA Ck See de ees CEES Ake cows $99,189,800.54 During the year there was expended in acquiring sundry patents, for licenses under patents, and in patent litigation, $929,109.08. This amount has been charged to profit and loss, leaving the company’s patents, franchises and good will standing at a nominal valuation of $1, the same as at January 31, 1908. The company has no note payable, nor is there any paper outstanding bearing the company’s indorsement. Vice-President J. R. Lovejoy makes an interesting statement regarding the sales of the year, which, al- though the smallest since 1906, included a number of important contracts. Regarding Curtis steam turbines, he states that “more than 500 central distributing sta- tions and industrial power plants have adopted these tur- bines as their generating units, and many are replacing old and inefficient types of prime movers with our turbine generators. The Commonwealth Edison Company, Chi- cago, has in its Fisk street and Quarry street stations 12 Curtis turbines, having a total generating capacity of 200,000 hp. The New York Edison Company has in its Waterside Station 12 Curtis turbines, having a total ca- THE IRON AGE 1415 pacity of 170,000 hp. The central stations of Boston, Philadelphia, Baltimore, Washington, Minneapolis, St. Louis, San Francisco and most of the other important cities are equipped with Curtis turbines and generators of our manufacture.” Manufacturing and Engineering. Vice-President E. W. Rice, in charge of manufacturing and engineering, states that expenditures aggregating $2,524,295.382 were made for the completion of buildings and extensions previously commenced and additional ma- chinery, patterns, special tools, fixtures, &c. The follow- ing table shows approximately the number of employees as of January 31 during the last five years, including the Pittsfield Works (formerly the Stanley-G. I. Company) for the last two years: Employees. Employees. SO rae ick eens n8¥a 18.000 eer ey er ere 20,000 PUR ac hie Kens 0c eee SEs centetcveseen 23,300 ROGU Us sab hohe ences 28,000 The total land area of all of the works is about 515 acres. From that part relating to engineering, the following extracts are taken: “Experience in the use of the high electric pressures of from 60,000 to 100,000 volts, needed for the economical distribution of electricity over very long distances, has been so satisfactory that higher pressures up to 150,000 volts are being considered in pending propositions. In this connection it is an interesting fact that the sales of transformers of €0,000 volts and over in 1908 were nearly double those in 1907. “Our engineers have completed the design of a num- ber of turbine generators for operation by low pressure or exhaust steam. The economic value of these machines is based upon the fact that steam turbines are much more efficient than steam engines in the lower range of steam pressures between atmospheric pressure and a good vacuum. Important turbines of this character have been designed up to 5000-kw. capacity. It is expected that they will, by utilizing the exhaust steam from one of the existing engines, increase the capacity of the com- bined unit more than 40 per cent. with a substantial re- duction in coal consumption. “We have adapted our steam turbine to the driving of centrifugal pumps and have sold to the city of San Francisco eight 750-hp. and four 600-hp. turbine pumps for a high pressure water system. This is the first im- portant application of steam turbines to this class of service.” The President's Comments, President C. A. Coffin says: “The year 190S was marked by severe and continued depression in the busi- ness of the company. During the period very few new enterprises requiring apparatus for the generation and distribution of electricity were brought out, and in con- sequence the business of the company since the last re- port has largely depended upon current renewals and supplies, with occasional additions to plant on the part of the older and more prosperous companies. The result has been that the orders received during the year were only 70 per cent. of those received for each of the two previous years, and the shipments to customers were only 63 per cent. of the shipments for 1907. This great and sudden shrinkage in the business of the company has, because of difficulty in ratably reducing expenses, re- sulted in a great increase in the ratio of cost to selling prices, with a corresponding decrease in the percentage of profit. “The capacity of the factories is now far in excess of existing demands upon them and is sufficient to pro- vide for a considerably greater output than has ever been reached in the history of the company. “Business conditions are slowly improving, and, with a resumption of normal activity throughout the country, the present unemployed factory facilities of the company and its large accumulation of cash will, it is hoped, be profitably used.” ———————_~»--___ The Cleveland office of the Allis-Chalmers Company has been moved from the New England Building to more commodious quarters at 1411 Schofield Building. ; { on a 1410 The Latest Ingersoll Combined Knee Type Millers. Since the description in The Iron Age, June 4, 1908, of the first of the knee type combined vertical and hori- zontal milling machines built by the Ingersoll Milling Machine Company, Rockford, Ill, several important changes have been made in the design. Those apparent on the exterior of the machine will readily be noticed by comparing the illustrations of the Nos. 3 and 5 sizes, illus- trated herewith, with that shown in the earlier issue of The Iron Age. Principal among these are a more com- pact arrangement of the parts, some additional levers which have to do with the control, a substitution of hand wheels for the crank handles used in manipulating the table, and the doing away with the chain drive for the feeding mechanism, this being driven now by a ver- tical shaft and bevel gears on the interior of the column, Poe. 2. Two Views of the No. 5 Combined Vertical THE IRON and Horizontal AGE May 6, 1909 doubling of the speed range is obtained, giving the 16 total possible speeds of the vertical spindle. Similarly the horizontal spindle is driven from a pinion on the shaft i, Fig. 4, through an intermediate spur gear on the shaft k to two gears on the horizontal spindle quill, which may be selectively engaged by the lateral movement of a clutch sleeve controlled by the lever E, Fig. 1. Each spindle quill has an axial adjustment of 6 in. through the crank holds shown at F and G in Fig. 1, which operate pinions engaging racks on the spindle quills. The feed mechanism is driven from the main driving shaft through bevel gears and the vertical shaft I, Fig. 4. By the new arrangement of the feed box it has been possible to bring it in more on the side of the column, with less overhang at the rear than in the old design. The bevel gear on the shaft m, like the sprocket formerly used to drive the feed box, is yieldingly secured on its shaft by friction cones under a regulatable spring tension and provides a safety point in the feed train guarding 9 Fig. Miller Built by the Ingersoll Milling Machine Company, Rockford, Ill. as shown in Fig. 4. Most of the changes are to be seen in the interior of the machine, which is exposed in the latter illustration. Whereas Figs. 1,2 and 3 show the ma- chine as driven by a single belt pulley, Fig. 4 shows a motor mounted on the top of the column and connected through gears with a gear on the driving shaft which replaces the belt pulley. Without stopping the motor, the drive of the machine may be disengaged by manipulating the friction clutch a, Fig. 4. The main driving shaft, which was formerly above, is now placed to one side and a little below the first intermediate shaft. The handle controlling the driving clutch is shown at A, Fig. 1. The gears B, c, d and e, Fig. 4, keyed on the main driving shaft, are in con- stant mesh with their mating gears on the shaft f, which are loose on this shaft except when they are individually engaged by projecting lugs on the shaft f when the latter is shifted longitudinally through the lever B, Fig. 1, operating a pinion engaging rack teeth on the end of the shaft f. Through the mechanism so far described four of the 16 speeds of the vertical and horizontal spindles are obtained. By manipulating the lever C, Fig. 1, either of the gears g or h, Fig. 4. may be engaged with the corre- sponding gears on the shaft i, doubling the speed range. From the shaft i through bevel gears the shaft j transmits power to the vertical spindle through either of the spur gears it carries, and which may be shifted through the iever D, Fig. 1, to alternately engage the corresponding gears on the vertical spindle quill, whereby another Fig. 3.—The No. 3 Ingersoll Combined Knee Type Miller. May 6, 1909 against carelessness in the operation of the tool or an attempt to take too great a fe