The Iron Age 1916-03-23: Vol 97 Iss 12

New York, March 23, 1916 BLISHED 1855 LOGE. egg ey UD OLLIE TMM Pay wikis = _ VOL. 97: No. 12 f Mie Continuous Melting in a Small Foundry How This System -Worked Out in a Gray-Iron Jobbing Shop—How the Change Was Made—The Advantages BY G. idea is generally prevalent that continu- nelting is applicable only to foundries pro- a single or very similar product—and then n ease of a large daily output. This is erroneous conception, as often this system be of special benefit to strictly jobbing foun- with a comparatively small daily tonnage. Continuous melting es not necessarily re- suire an elaborate or ex-~ pensive outlay of special equipment. However, with this system, special ma- nervy such as_ special molding machines, sana tempering and handling machinery, sand and mold conveyors and the like, when properly selected for the particular line of vork, prove to be paying vestments. Such equip- it tends toward in- reasing the output. per are foot of floor area, reasing the production man, decreasing cost mproving the quality the output. How a small gray-iron ng foundry was red from the usual rnoon heat to continu- melting with the con- ent results is told in article. (he foundry in ques- Ss. Lanes sensi iSSiSa iad aiiiantacienesindeasioal EVANS the management decided to try continuous melting, also to add additional molding machines and other equipment with a view to increasing the capacity of the shop and with the hope of increasing its earning capacity as well—which was not in vain. The only new equipment added before the sys tem was changed consisted of a small cupola (lined to 30 in. inside of the lining) with the neces sary blower and other equipment incident to the operation of the cupola. This was built along side of the old cupola, the two being served by the same ele vator, charging buggies, etc. When the cupola was in readiness, the shak ing-out and sand-cutting crews, which had been accustomed to do theic work after the heat was off in the evenings, were ordered to come in for work at the regular morning hour. A pour ing crew, consisting of one experienced man and two helpers, was organ- ized to do the pouring The melter was ordered to have the metal ready to pour at 8 a. m. in stead of 2.30 p. m. as was the usual custom. ; operated in connec- Fig. 1—Drop Bottom Sand Handling Bucket for Conveying With these exceptions with a chilled car- foundry. Though the same roof the two foundries are operated separate; the former produces only 33-in. rd car wheels and has a daily output of 300 the latter produces railroad and general gray-iron castings, varying in weight from unces to several tons. At the time of the the daily output was approximately ten hich was considered the maximum capacity shop on this class of work. Orders were months ahead of production and the foundry ng operated at a loss. eemed impossible to better conditions under system and, being of a progressive nature, Sand from the Tempering Floor to the Molders everything went on in the usual order without any interruptions whatever resulting from the change. The shaking-out and sand-cutting crews shake out any molds left over from the previous heat, temper the sand and clean up the shop generally until the pouring starts, after which they follow up the pouring crew, shaking out the molds, loading the castings into iron baskets to be delivered to the cleaning room, and tempering over the sand again. The molders begin work at 6 a. m., which gives two hours molding in advance of the pouring; this is sufficient time for the snap and light floor molders to produce several flasks each on certain patterns 709 satis ak et ieee 5 ‘ j SeEEeteEnnEEeE ee 710 THE and gives the heavy molders a good lead on the pouring crew. This is necessary in order to take care of the first iron and to allow of variations in the rate of melting of the cupola. This also takes care of any variation in the rate of produc- tion, which will vary slightly from day to day on account of changes in the class of work going into the sand. Again this is necessary to prevent the pouring crew following up the molders too closely and interfering with them in their work. The molding floors are arranged in double straight rows, so that while one row is being put up the other is being poured and the sand retem- pered again. This same system is carried out with the molding machines, the sand being divided into two piles one on each side of the machine, so that first one and then the other is being used. This arrangement applies to light work only, where it is possible to use the sand over two or more times during the day, as the heavy molders are supplied with sufficient sand to put up their entire day’s work. The only material difference between this and the old system consisted in pouring the molds with a special pouring crew as they were being put up, using the same flasks and other special rigging over two or more times during the day and increasing the molding time from 2.30 to 4.30 p. m.—approxi- mately 25 per cent. This made it possible to get out a large number of castings of any one pattern with a limited number of flasks, which is an especially desirable feature in jobbing shops, where it often happens that a number of castings off of one pat- tern are wanted on a hurry-up job wherein the prices at which the castings were sold will not jus- tify the equipment of more than one or two flasks and other special rigging that may be necessary to do the job. The increased hours for the molders at their regular labor of molding, would appear, on the face of it, as a hardship on them, but when you con- sider that the actual energy expended by a molder in pouring off and shaking out his day’s work is often equal and sometimes much greater than the IRON AGE March 23, 191¢ ig. 2—Electric Jolt Roll-Over and Plain Air Jolt Molding Machines with Conveyors Arranged Between the Twi Machines total energy expended in putting it up, it would ap- pear that this is in the molder’s favor, and it is. However, it was hard to convince the molders of this fact in the beginning, but now after two years of trial they would not willingly consent to go back to the old system. While the increased output per molder was not in proportion to the increase in mold- ing time at first, due largely to their unwillingness to take to the system, however, as they became rec- onciled to the changed conditions, the output grad- ually increased until it reached a gain of approxi- mately 35 per cent per molder over the old system. This resulted from the continuous system rather than from any new or special equipment, as later, by the addition of more molding machines and spe- cial equipment, as will be described, the output per molder and also per man in the shop was increased still greater, as was the daily output of the shop. The foregoing describes the system in its begin- ning and without any special equipment other than a small cupola, which was necessary to deliver metal at the rate of production of the molds. Acting on the principle that special machinery, when properly selected, forms an economical investment even with the old system, and that it would be still more valu- able with continuous melting, additional equipment including sand handling buckets, power riddles, ad- ditional molding machines, mold conveyors, jib cranes and an automatic sand tempering and han- dling machine, some of which are shown in Figs. |! to 4, were installed, and proved very valuable ad- juncts to the general equipment. The sand handling buckets, illustrated in Fig. 1, are used for conveying sand from the shaking- out or sand-tempering floor to the molders.) As will be noted, they are of very simple construction and inexpensive but serve the purpose for which they were designed in a satisfactory manner. The roller conveyors, illustrated in Figs. 2 and 4, are especially designed for handling lumber in plat- ing mills and like establishments (from which the idea was borrowed) ; and have proved very efficien' for conveying medium and light molds. They are built in 12-ft. sections interlocking one with another shown in Fig. 2. , 2 3, 1916 y be extended, by adding on sections, to any d length. A special feature of this conveyor it is portable and may be removed from place or changed at a minimum cost to suit ar jobs as conditions may require. They rranged convenient to the molding machines eying the molds from the machines to they can be poured and shaken out without ring with the molder. These are especially le to snap molding but are used with suc- r molds having a gross weight of 450 lb. e sand handling machine, illustrated in Fig. 4, modates four plain air squeezers. Conveyors arranged on two sides of the machine each ¢ two molders. Here the molder places his on the conveyor and gives it a shove to where poured, after which the molds are rolled out end of the conveyors where they are shaken the casting placed in an iron basket and the tempered and shoveled into the hopper. A onveyor carries it up and dumps onto a riddle h which it falls into the hoppers serving lding machines and is again ready for use ; designed especially for very light castings, when shaken out at the proper temperature overheat the sand, so that by the time it has | through the different stages and back to the t is ready for use again. However, if the should be slightly off temper, as sometimes ns, cold sand, a pile of which is left con- to the molder, is added next to the pattern serves to overcome this difficulty. | arrangement of the roller conveyors between electric roll-over jolt and a plain air jolt mold- machine, operating or Jasks of 250 Ib. and less, W.th this arrangement there THE IRON AGE m1 is only one operator to a machine, one making the cope and the other the drag halves of molds on their respective machines, and assisting eac} other in lifting and closing the molds. The ope ators clamp the molds and roll them out to wher they are poured with an overhead electric crane After being poured they are rolled out to the e1 of the conveyor and shaken out by the laborers the castings being placed in an iron basket and sent to the cleaning room. The sand is tempered hand and after cooling sufficiently for use loaded into the sand handling buckets : back to the machines. This arrangement does not operate the molding machines at their maximum capacity, yet it has its advantages; particularly, in requiring a mini mum of flasks and other equipment for each par } : again 1s nd « mveved ticular job or jobs, especially on small orders where the quantity does not justify the expense of elab orate equipment; again, by not overcrowding the conveyor it allows of some flexibility for pouring and shaking out the molds; furthermore, it in creases the production per molder. Heavy machine and floor molding is arranged together in one half of the foundry which is served with a 10-ton electric traveling crane. The molds are poured on the molding floor and after setting are conveyed, by the traveling crane, to the shak ing-out floor where they are shaken out and the sand, after being tempered and allowed to cool is conveyed back to the molding floor, using the sand handling buckets illustrated in Fig. 1. At the beginning some difficulty was experienced in operating the small cupola for so long a period (8 hr.), and especially in melting fast or slow to conform to the rate of molding. However, after some experimenting these difficulties were finally Re eh ee eh i 712 THE IRON AGE » March 23, 1 16 a es Soe ae ae _ Se emata Te | ~ “~ Fig. 4—Automatic Sand Handling Machine Serving Four Plain Air Squeezers overcome, and it was found possible to extend the heat even several hours longer and to vary the rate of melting over 100 per cent by changing the coke and blast, etc., and without injury to the metal. Special mixtures, sometimes carrying as high as 40 per cent steel, are often melted during the heat, for use in special castings, which by using blank coke charges and taking other necessary pre- cautions-is accomplished without interfering with the regular heat in any way. Summarizing the results obtained. by this sys- tem, as shown by the foregoing description, the fol- lowing—which is computed from data taken over a three-months’ period—shows the advantages ob- tained by this method: Per Cent Increase in daily output ‘ ead : 79.0 Increased output per molder...... sie 68 Increased output per man (including pattern makers and all other laborers connected with this department) .-51.0 Decrease in cost of production, labor (including all direct and indirect labor and supervision) «ab Decrease in defective castings ; 16.7 increase in molders’ earnings 13.0 As will be seen from the above figures, although the labor cost for production was decreased 35.4 per cent, the earnings of the molders increased still greater so that this system, as it has been worked out in this instance, has proved very bene- ficial both to the company and to its employees. Exports of Swedish Lapland iron ore for 1915 had been estimated by the Kiirunavara-Luossavara Com- pany at 5,050,000 tons, of which 3,300,000 tons was to come from Kiirunavara, but as the war is expected to last through 1916 the company reduces its estimate to 2,000,000 tons from Kiirunavara and 500,000 tons from Gellivara. Exports for 1917 are estimated at 5,350,000 tons. Aluminum from Clay A process of obtaining aluminum from clay has been patented (U. S. 1,160,431) by Grenville Mellen, of East Orange, N. J. The clay or kaolin is fused with sodium sulphate and sulphuric acid, or with its equiva lent of sodium bisulphate in proportion to form alumi- num sulphate and free silica. After the reaction is com- pleted the mass is cooled and dissolved in hot water or in a hot dilute solution of sodium sulphate containing a small quantity of aluminum salts from a prior reac tion. The hot solution thus obtained is filtered and concentrated if necessary. A concentrated solution of sodium fluoride is added, precipitating aluminum fluoride, which is separated by filtration. This is fused with sodium chloride and electrolyzed, producing alun num. The sodium sulphate filtrate is concentrated to crystallize the contained salt, which is used again. By- products are pure silica, chlorine and sodium sulphate and the process is cyclic. The American Foundry Equipment Company, the consolidation of which with the Sand Mixing Machine Company was announced in THE IRON AGE, Dec. 39, 1915, is occupying its new plant at 1111 Power Avenue, Cleveland, Ohio. The factory, which is a new struc- ture, provides increased facilities for developing and manufacturing foundry equipment and affords room for future growth. A stock of repair parts for the sand blast apparatus of the American Foundry Equipment Company and the automatic sand mixing machine of the Sand Mixing Machine Company will be carried 10 stock to give better service in the future to the cus- tomers of both companies, which are still operating under their individual names. H. L. Wadsworth, the inventor and designer of the sand blast apparatus of the company, is factory manager in charge of all the mechanical departments and will be assisted by Charles L. Benham of the Sand Mixing Machine Company, who has been appointed factory superintendent. 23, 1916 AT TREATMENT OF CHAINS V is Methods Used and Their Advantages— Overstrain and Fatigue recognized importance of the strength and con- of chains in steel mills and foundries, especially the “safety first” point of view, lends importance following report of a “Memorandum on Chains ‘ther Lifting Apparatus” by G. S. Taylor, an in- spector of factories in England, which discusses the question of heat treatment: ' It is well known that the metal of a chain deterio- rates with use and that its tenacity can be restored by annealing. Bad accidents do occur now and again owing to neglect in annealing chains periodically, and such ac- cidents are entirely unavoidable. Mr. Taylor does a vood service in giving an account of the various ways in which the annealing is done in different works. CLOSE-ANNEALING PROCESS The close-annealing process is considered the best, and is employed by such firms as have the necessary plant. The chain or article to be annealed is placed in a gas or oil-fired muffle furnace, heated to redness out f contact with the air, and then allowed to cool slowly either in the furnace or covered with dry sand or ashes after removal. Close-annealing prevents oxidation and subsequent sealing of the surface of the metal, and the hain is heated more uniformly than other types of fur- naces. Coal or coke may also be used for a close-anneal- ing furnace and a fire-clay gas retort is said to make a good muffle for these furnaces. Where close-annealing is not employed the chains are annealed in an ordinary reverberatory furnace, as used for heating plates, or in a small furnace of the same kind specially built for the purpose. The chain should not come into contact with the fuel, which should be as free as possible from sulphur or phosphorus. Where an ordinary plate furnace is used the chains are often placed in the hot furnace on Saturday and removed on the following Monday when quite cold. In special an- nealing furnaces the chains are maintained at a uniform red heat for some time; after removal they are either allowed to cool in a mass on the shop floor or covered with sand or ashes and cooled slowly. It is contended by some that cooling in sand or ashes is unnecessary for wrought-iron articles containing little or any carbon while these precautions are considered essential by thers. Possibly the cooling en masse is almost as effec- tive for practical purposes, especially if the articles are vered with plates to prevent the chilling effect of cold air. Several chain users, however, have demonstrated y experiment the advantage of slow-cooling. TREATMENT IN A SMITH’S FIRE A method of annealing, chiefly followed in one dis- ct, consists in passing a chain link by link through rdinary smith’s fire. Each link is heated to redness, n removed from the fire and examined carefully while Cracks or flaws can then be more readily de- ted. The chain is allowed to cool in the open air. Al- igh for examination purposes this open-fire method nnealing is advantageous it is not to be recom- i. In some works the chains are merely placed in © on a smith’s fire, covered over with fuel and heated ‘th the air blast. This method is faulty, in so far ‘links are overheated, while others are not raised temperature sufficient to have any useful effect, refore the chains cannot be considered as “effec- ftened,” although this is difficult of proof. ther method of annealing is used frequently wood is readily obtainable. The chains are either n a grid, supported above the ground, or hung var supported by the sides of a specially con- | pit or by uprights. A wood pile is built over ns, Oakwood being preferred, the chains are the wood fire and allowed to remain in posi- | the ashes are cold. Satisfactory results are ‘or this method of annealing, as wood is free phur and phosphorus and does not affect the THE IRON AGE 713 metal injuriously, while the temperature of a wood fire is comparatively low and the metal is not over-heated and rendered brittle. OVERSTRAIN AND FATIGUE A differentiation is made in the memordandum be- tween hardness in the metal of a chain resulting from overstrain, due to stresses exceeding the elastic limit bing set up by jerking or overloading, and the deteri- oration known as “fatigue,” caused by repeated load- ings, which may all be well within the elastic limit. The former alters the physical properties of the metal, with gradual development of greater hardness and a consequent decrease in the power of elongation, changes attributed by Unwin to the slow accumulation of per- manent set. What happens in the case of fatigue is much less certain. Recent research has shown that it is not, as commonly supposed, accompanied by crystalliza- tion of the metal. An explanation of the fatigue phe- nomenon advanced a short time ago is that in prolonged working incipient cracks are set up in the metal which gradually extend until fracture occurs, and that what annealing really does is to weld up these undeveloped cracks while the ruptured articles are still clean and un oxidized. American Electrolytic Zinc Commenting, in his statement to shareholders, on what is believed to be one of the most important metal- lurgical accomplishments of the many that have made the last five years the most important period in the history of mining, John D. Ryan, president Anaconda Copper Company, said: In many of the mining districts of the West, particularly those which are producers of either silver-lead or copper ores, zinc in varying quantities forms an important and hitherto very objectionable constituent. Found usually in quantities insufficient to justify working the ores for the recovery of this metal, its presence occasioned the metallurgist numerous diffi- culties in the endeavor to eliminate it while saving the valu- able metals associated with it in the ore. These difficulties compelled the smelters to impose heavy penalties on the zin« content in excess of certain percentages. The presence of such refractory ores in sotnme of the mines of the Anaconda Company led to a careful study of the prob- lem by its research department. Gratifying success has resulted from this study. An electrolytic process has been evolved and patented to the company which makes it possible at a satisfactory cost to extract a high percentage of the zine content of such ores, while the other valuable metals are precipitated in the form of an easily reducible residue. Fol- lowing experiments sufficiently long continued to demonstrate the success of the method, a plant capable of producing 20,000 lb. of electrolytic zinc per day was built at Anaconda and has been in successful operation for several months. The product is very pure, its zinc content being about 99.9 per cent. The brand, which has been trademarked Anaconda Electric, finds ready sale at a considerable premium among manufac- turers whose requirernents demand zinc of the highest grade This operation has been so successful that the company is now enlarging the plant at Anaconda sufficiently to make an output of 50,000 lb. of zinc per day. The product of this plant has been sold for a full year from the time when it will be in complete operation, at an estimated profit of over $4,000,000, and construction has been started upon a plant at Great Falls capable of making an output of 70,000,000 Ib. of zinc per an- num, which we hope to have in operation in the early autumn of this year. Another chapter in the unfortunate history of the bridge shop originally operated by George W. Jackson, Inc., in Chicago, passed with its sale recently in fore closure proceedings in behalf of the bondholders. Fol. lowing the failure of the original owner, the plant was operated under a temporary arrangement by the Vier- ling Steel Company. A period of idleness followed, after which the Chicago Steel Products Company, an or- ganization in which a number of the creditors of George W. Jackson, Inc., were interested, was formed, and oper- ated the plant for about a year. Unable to break even in its operations, this company liquidated after a brief existence, and since that time this capacious and lib- erally equipped plant has been continuously idle. Its future presents an interesting problem. a= = eo) pantera ee ~ . . +e a aes Z ae em a verre ses Say Pent i ea ai no lt Rage aro “Safety First” in The welfare work of the H. C. Frick Coke Com- pany, Pittsburgh, as practiced at practically all of its forty or more coke plants in the Connellsville region, was described in THE IRON AGE, Jan. 7, 1915. The Frick Company has spent thousands of dollars and has used every means in its power to advance the social and working conditions of its many employees. It has also spent as much time, é t ‘ 0 Ss properl I articles before entering mine §. The be effort and money as it judiciously could in order to make working conditions in its coal mines and at its coke plants as safe as is humanly possible. For some years the slogan, “Safety, the First Considera- tion,” has been kept prominently before the em- ployees. SAFETY COMMITTEE The work done in the interests of safety by the Frick Coke Company has been stupendous. At the present time the company maintains a general 714 Coal Mine and Coke Plant The H. C. Frick Coke Company Has Expended Much Money, Time and Effort to Make Its Plants Safe and to Educate Its Employees Away from Dangerous Methods of Work irk the place safety committee and special inspectors co: of fifteen men. It has an inside workmen’s committee of 315 men, an outside workmen’s committee of 163 men, and a permanent safet mittee of 580 men. The Hostetter-Conn« ill Coke Company, an identified interest, also has ap inside workmen’s safety committee of nine mem- bers, an outside workmen’s safety committee MINES COAL ding to instructions 2. Miners are where additional props are timberman to make searched for matches to be set. 4. A wear the place safe. 6. A safe method « teen members and a permanent safety committee 0 twenty-one members. This is a total for both com- panies of 1109 men, who devote their efforts an¢ thought to the general advancement of safety wor. The inside committee serves in the coal mines, 2n¢ the committee for each mine consists of three em ployees who can read and write. They are 4P pointed by the superintendent, and one is a miner, one a driver and the third comes from the gener work force of the mine. This committee serves for one year, and during that period makes three '™ ; and reports one in each of the months of \ugust and November. After each inspec- senior member is replaced by a new man, there are always two men on the committee nade at least one inspection. itside committee serves at the coke plants, plant committee also makes three inspec- ‘reports per year. Each outside commit- nposed of a coke drawer, or leveler, one the shop forces or boiler house and a in from the miscellaneous men at the plant. kmen‘s safety committees attend the regu- y safety meeting held at each coke plant. mmittees in all cases make their own re- thout any interference, dictation or assist- m anyone. The reports are signed personally member. The original reports are sent to the offices of the Frick Coke Company at Scott- where steps are taken at once to remedy rect any defects found in the equipment or es at any of the coal mines or coke plants. e company also has what is known as a “Per- t Safety Committee” at each of its coal mines. omposed of the superintendent, mine fore- sistant mine foreman, fire bosses and rib There is also a “Safety Committee” at each composed entirely of workmen. The safety nittee of workmen is appointed by the superin- nt, and it examines the mine at least once three months and makes written recommen- lations for bettering its condition. This committee has from three to five members, according to the size of the mine, and the term of office is usually a year. The term is made short with the idea of ing as large a number of men as possible serve n it, and they are paid for the time spent in the service of the committee at the same rate as when they are at their regular duties. FIRST-AID CORPS \lthough the Frick Coke Company has adopted known device for the safety of its employees, prevention of accidents and for the improve- mining conditions, it has also provided, nst the event of accident, a first-aid corps at its large plants. Each corps consists of five These men are carefully selected and are des- Wrong Way to Place a Danger Sign THE IRON AGE 715 Correct Method of Placing a Danger Sign The entrar the dangerous area should be feneed off and the on the fence ignated, after they have passed an examination as to their fitness for rescue and first-aid work, by wearing a red, white and blue button with the words “First Aid and Rescue Corps” engraved thereon. They are also required to pass a medical and physical examination, after whith they are in structed in first-aid treatment by doctors paid by the company. They also receive twelve lessons in rescue work at one of the company’s training stations. There are three of these training and rescue stations centrally located to all of the company’s operations throughout the Connellsville and lower Connellsville regions. Each one is completely fitted with Draeger oxygen apparatus, a pulmotor and other apparatus necessary to the carrying on of rescue work. After passing the examinations for service on the rescue corps, the men of the first aid and rescue corps'report at intervals of four months at, the training station for additional instruction, so they may be kept fully informed on the best modern methods of performing their duties. In case of injury to, or death of, an employee, the Frick Coke Company has a plan of voluntary accident relief, and the entire amount of money required to carry out the plan is provided by the company, without contributions from the employees. INSTRUCTION OF EMPLOYEES The company a few years ago employed men for the especial purpose of instructing miners who are employed in the extracting of ribs and pillars, how to properly timber a working place and how to “draw” the timber when it is safe to do so. Such a man is called a “rib boss” in the Connellsville re gion, and the number employed in each mine varies from one to six, depending on the number of miners engaged in that class of work. Their duties require them to keep moving from place to place, giving instructions in safe mining methods, drawing and often assisting to set up timbers, or withdrawing men if the condition of the top seems to render it too dangerous to work in the mine. The company also maintains fire-fighting ap- paratus, located in convenient places, both in its coal mines and around its towns where the em- er A GE CA AE tt i ae Na et a he Olas po nF merits a ee tae ae te fog 716 THE IRON AGE March 23, 51 oe ployees live. This apparatus is regularly inspected ner. These latter are board signs about 5 f by persons delegated for that work, as are also all and 10 in. wide, so placed as to warn pers mine buildings, houses, outbuildings, fences, sewers proaching electric power lines. A sign | and drains. “This way out” in white letters on a black k. rround, and i re la ages, is s ‘ DANGER SIGNS ground, and in five languages, is posted | junctions in the traveling ways of the mine In addition to various printed and illuminated The company goes further in the mat signs, the company also uses the danger signal ap- safeguarding its men, and at all its coal min proved by the Department of Mines. This is of inside and out, has placed permanent danger aneeshatti eae eee How Act ENTS © N COA MINES l. Drive ut pt rm ng rs oO nside of ir'vé nd is crushed between them. 2. Driver crushed ir and side Driver ride n front of t I j Miner has not properlh blocked his car and when the dirt is clea! the wheels the ir runs awe down grade Careless testing of rocl TI top is bad between the crossbars but t S Ww ‘= ting tot Ss vi uch pick to ascertain whether or not it is safe enameled steel, and has an oval center, with the wherever the least danger of an accident exis word “Danger” in letters 4 in. high across the cen- When men are working in the shafts, a sign ter of the oval. The letters are white, the oval red placed reading, “Men in shaft,” to prevent acc and the remainder of the sign black. The company also uses a sign, “Do not pass under—2200 volts.” This has a red background and white letters. A dents caused by mistakes in moving cages. Whe! workmen are cleaning out or making repairs to inside of a boiler, a sign, reading “Man in boiler, sign, “Do not touch,” is painted in the same man is placed on the outside. In addition the stea™ 23, 1916 THE IRON AGE 717 this particular boiler is locked and the key d by one of the men engaged on the work repairs are finished. At all the coal mines a complete equipment of telephone systems places, such as stables, underground offices SAFETY PRECEPTS ire a place is safe fore you begin rk on it. the safety of the p and look for slips’ often as you nine the coal away eneath it. : t plenty of timber in vour working places. Set the timber IN TIME—delay is dan- gerous Where you are not sure the top is safe, set “temporary” timber for safety while put- ting up “permanent” timber. Set cross-bars in work- ing places that have been, or are likely soon to be, under great weight before you have mined it out. if the top coal is crushed or broken, do not leave it up— it is not safe. Do not put your hands on corners of cars to push, or place them. Keep YOUR track in good condition. Travel on roads made for that purpose. Do not pass DANGER signs. Use a clevis block in front of car wheel while loading, in all places going to the dip or to the rise, where cars would run away. To make it more safe use a_ tie-and-block in front of the car in all places going to the rise. Do not carry tools, like .ugurs or iron bars, on the shoulder on roads in which a trolley wire is hung. I to avoid accident to yourself. Help to prevent acci- dent to others. Always use the safety devices provided. It is better to cause a lelay than cause an iecident. Safety — it pays to think before you act ve the side of safety the benefit of a doubt. Make up your mind to prevent accidents as much as you can. » not be careless at vork, you matty be injured. sure everything is safe, then go to work. ell your Foreman or ther official of any bad condition or dan- gers as soon as you now of them. — eglects are apt ause serious acci- ou know how to revent an accident boss boss tells you to keep yourself do as you are the th, x er buildings where the men are likely to ‘te, are of fireproof construction, and kept 28—Look out for the man working near you— ‘you might hurt him. 29—-Do not take risks your fellow workman may be the one who will be hurt. 30—Every injury, no mat- ter how slight, should receive proper medi- cal attention. 31—Be careful not to injure your safety lamp. DRIVERS AND BRAKE- MEN 32—If you have learned bad or unsafe meth- ods of doing your work, cut them out at once. 33—Do not make switches.” 34—Do not ride in front of loaded trip unless your work cannot be done any other way. 35—Do not ride between cars unless your work cannot be done any other way. 36—Keep your trips under control. 37—Do not excite your horse or mule by rough or bad treat- ment. 38—Promptly notify the mine officials of— (a) Bad Track. (b) Slate, dirt, or posts piled along the side so that you cannot pass the trip in safety or keep it under control. (c) Bad roof, when known to you. 39—Take in posts or other timber when re- quired. 40—Put a “drag” on rear of car being hauled out of “dip” places. SHOT FIRERS 41—Do not fire shots with less than 100 ft. of “lead” wires. 42—-Do not fire shots with damaged “lead” wires or bad connections. Do not carry “electric caps,” except in a locked case. 44—Do not fire a shot where there is any coal-dust within 100 ft. of the shot-hole, or where the dust has not been thoroughly wetted for a distance of at least 100 ft. from the shot hole. 45—Do not put more than 1% Ibs. of explosive in any shot hole. 46—Do not fire shots where there is not enough shelter from the blast. 47—Do not go back to a miss-fire shot before the lead wires are disconnected and five minutes have passed 48S—If you have charged a shot and cannot fire it, fence off the place and put up a danger signal before leav- ing it. “flying 43 and neat as possible. ‘its are provided for workmen working at above the ground where a fall might cause At points where there is not clear- man between a moving car and wharf Iry. walls, buildings, supporting clearance” signs are displayed. The company has also had several hundred pic- tures taken showing how accidents occur in coal mines, and the best ways of avoiding them. These are used in lantern slide lectures, which are deliv- ered to the men in various halls in the towns of the company, and the lecturer describes how the acci- dent, as shown on the screen, has happened, and how it could have been avoided. Some of photographs are reproduced herewith. In the purchase of machinery for its coal mines and coke plants, the Frick Coke Company has drawn up safety regulations governing the purchase and construction of such machinery that do much to add to the safety of the employees. Much of the safety work of the Frick Coke Com- pany was perfected through the efforts of Thomas Lynch, a former president of the company, who died about a year ago. He was aided by superintendents and other employees of its various mines and coke works. A pamphlet, entitled “Safety Precepts,” printed in the English and in foreign languages, is given to each miner and he is required to read it. columns, ete., “No these Merchant & Evans Company The Merchant & Evans Company, Philadelphia, Pa., has celebrated the fiftieth anniversary of its founding by removing its offices and warehouse to a large modern building which it has erected adjoining its works on Washington Avenue, between Twentieth and Twenty- first streets, in that city. In 1866, Clark Merchant, who had retired from the United States Navy with the rank of lieutenant-com- mander, established the business in Philadelphia as Merchant & Co., dealing principally in brass, bronze and copper in all forms as then manufactured, and trading also in tin plate and other products that were imported from England and other countries. The continued growth of the business made it nec- essary to open branch offices and warehouses at several points in the United States, and to enlarge the line of products handled. The co-partnership of Merchant & Co. was changed to a corporation under the style of Merchant & Co., Inc., with Clark Merchant as its presi- dent. After Mr. Merchant’s death, Powell Evans as- sumed control of the business, which then became the Merchant & Evans Company. The company now has plants in Philadelphia, Wheeling and Chicago, and of- fices and warehouses in Philadelphia, New York, Bal- timore, Cleveland, Chicago, and Kansas City. To sat- isfy the demand for its tin and terne plates, the com- pany built a modern tin-plate mill at Warwood, W. Va., a suburb of Wheeling. President Evans early saw the possibilities open to manufacturers of gasoline-propelled vehicles and parts therefor, and to the company’s line he added automobile clutches, alignment joints, rear axles, jackshaft trans- missions, grease cups, metal tire cases, and, finally, completely erected gasoline motor trucks and tractor trucks. He is recognized as an authority on fire preven- tion and protection, and is chairman of the Fire Pre- vention Committee of the Chamber of Commerce of the United States, the National Hardware Association, and the Fire Prevention Commission of the city of Phila- delphia. During the existence of the old International Sprinkler Company, of which he was president, he de- signed various sprinkler heads, valves and other auto- matic sprinkler devices which came into wide use. Re- cently he secured official approval of a new type of fire door. The Marting Iron & Steel Company, operating blast furnaces at Ironton and Marting, Ohio, has bought 10 acres of land lying between those two points which will be used for future extensions, the nature of which has not yet been determined. Ce ar aaa a ne Pee ae re oe ws ga mae Organizing for Industrial Preparednes: The Inventory which Is To Be Taken by Five Directors in Each State Appoint- ed from Five National Some of the details of the industrial inventory which is to be made of the factories of the country in the movement to organize for industrial pre- paredness are given by Spencer Miller, Lidgerwood Mfg. Company, and a member of the Naval Consult- ing Board, in a paper to be presented at the spring meeting of the American Society of Mechanical En- gineers, New Orleans, April 12. It will be recalled that at the request of the President of the United States each of the following societies was invited to appoint a member in each state to serve as a director, each state thus to have a committee of five State Directors: the American Society of Mechanical Engineers; the American Society of Civil Engineers, the American Institute of Elec- trical Engineers, the American Institute of Min- ing Engineers and the American Chemical Society. The scheme has been brought about largely by the Naval Consulting Board’s Committtee on Produc- tion, Organization, Manufacture and Standardiza- tion, Howard E. Coffin, vice-president Hudson Mo- tor Car Company, Detroit, chairman. For taking the inventory, an elaborate printed form has been prepared. It will be “a strictly con- fidential, non-partisan, non-political and wholly pa- triotic inventory of our country’s manufacturing and producing resources. The information con- tained in these blanks is not to be used in any way to affect the business of the concern reporting, or for comparison with any other report of any kind previously filed by it. The value of this patriotic work can best be insured by making this report com- plete in every detail. We must deal with the prob- lems of an adequate national defense as we deal with the problems of our everyday business life. We must face facts—not theories. We must do now, in time of peace, quietly, efficiently and thoroughly, those things which all know must be done to achieve true industrial preparedness, and which, if post- poned until an outbreak of hostilities, must result in tremendous losses in lives and money.” The form properly filled out will give: 1. The names, post office address, age and nationality of the officers and directors. 2. Capitalization, commercial rating tion. and banking connec- 3. Description and location of expansion, its fire protection 4. The telephone and telegraph facilities of the plant Sources of raw material and its character plant, its possibilities for 6. Character of products, volume or tonnage and its value per annum a. 2 have ever been manufactured, the quantity produced and untimate possible capacity &. Character of proportion shipped abroad munitions of war labor—union, non-union or open shop number and nationality of employees. 9. If women are employed, and the possibility for further employment of women. 10. Transportation facilities- 11. Under the heading which is quoted in full. rail and water. “agreements” appears the following, AGREEMENTS Will bid upon WU. S. peace Will war Army and Navy contracts in time of accept U. S. Army and Navy Will accept minimum annual order (See Clause A)....... Clause A. Minimum order for annual production will be accepted with the understanding that such order will be restricted to that product for which the manufacturer’s equipment is best fitted. Also, that such order shall be for only such small quantity of product as will insure familiarity with the work upon the part of the manufacturer's organization. Organizations The manufacturer agrees that this minimun order shall be put through the factory in ' course and in such manner that foremen and thos holding positions of responsibility shall bec miliar with the peculiarities incident to th: facture of these goods. In time of war th« Ww facturer will be expected to concentrate u; th same product, and it is essential, therefore, that } entire organization, including purchasing, m turing, inspection, shipping, engineering, cos ing and administrative departments be m miliar with the work. Minimum orders will! of sufficient quantities to interfere with m turer’s regular production. Will accept payment in accordance Clause B... (Wording of Clause B not fully determined of going to press.) Will construct jigs and tools in accordance Clause ( Clause C. preserve The manufacturer will agree to mak« i one set of special jigs, tools, gaves ; fittings necessary for the production of thes: and corrected drawings shall be kept on fil engineering department of the plant covering such special jigs, tools, gages or fittings. In short, the engineering or designing department shall maintair at all times corrected drawings from which the shor , may, upon short notice, construct the necessary equipment for quantity production. Will enroll skilled labor in “Industrial Reserve (see Clause D). Clause D In war as now waged the industria! fore: has become quite as important as the fighting army Skilled mechanics in all lines of production work must be kept from enlistment in the regular army and must be retained in the factories, mills and mines for the production of munitions. It is es- sential, therefore, that the names of these skilled workmen be listed and that the men themselves be enrolled in the industrial reserve. Explanations and instructions as to the detail of such organization will be submitted at a later date. A _ button or other distinguishing mark will be supplied by the government in the event of war to skilled workmen enrolled in the industrial reserve, and such enroll- ment will be considered to carry with it honors equal to enrollment in the fighting army. A govern- ment card will be issued to each man enlisted Will agree to limit profits in time of war in accorda with governmental regulations (basis cost plus).. Will insert clause in all civil contracts making them tingent upon governmental needs in time of war... Will ot war. re List any and all agreements now in force 12. An inventory in detail of their capacity. agree to restore existing labor agreements at tools, furnaces, etc., THE FACTS COLLECTED We shall also know from this inventory: Whether America is independent of foreign countries for raw or manufactured war material, and if not, wherein we are lacking and to what de- gree, In what kind of munitions we have ample manu- facturing facilities and wherein we must provide means for making up the deficiency. Whether it be prudent for the government ' build new arsenals and other works in the centra! part of the United States. Possibly it will transpire that the most efficien! plan would be for a government factory to make standard gages, jigs and templates and loan or sé! them to certain shops for use in the manufacture ©! shells, rifles, etc. This work of industrial preparedness, Mr. Miller observes, should serve to inspire our machine 100 builders to perfect and improve their product and perhaps to standardize their machine tools to the end that those who must needs purchase them would find an adequate and immediate supply available case of emergency. The various engineering societies contain in their membership men who could prepare most valuable 718 23, 1916 on the subject of ammunition manufacture. present there may be many secret processes or the time being may not be forthcoming in of books and papers, which, however, might pared in advance and held until the hour of hen through patriotic motives they could nat- e published for the benefit of the nation at BETHLEHEM STEEL REPORT Net Earnings in 1915 Were $24,821,408.25, Against $9,649,667.71 in 1914 report of the Bethlehem Steel Corporation for - ended Dec 31, 1915, shows that the total net gs from operations of the corporation and its ry companies, after deducting expenditures for y and extraordinary repairs and maintenance ximately $4,391,000) amounted to $24,821,408.25, npared with $9,649,667.71 in 1914. From these earnings were deducted interest on bonds tes of subsidiary companies, amounting to 42,596.10, and appropriations for extinguishment of mining investments, amortization of patents, deprecia- of other properties and accruing renewals, $4,377,- 000, leaving as net income for the year $17,762,812.61, ompared with $5,590,020.18 for 1914. The orders on hand Dec. 31, 1915, amounted to $175,- 895.19, against $46,513,189.95 on the corresponding 1914. The average number of employees in the corpora- plants in the United States in 1915 was 22,064, against 15,586 in 1914. Wages paid in 1915 amounted to $21,800,664.19, against $14,312,948.78 in 1914. ‘ PLANTS NOW AT FULL CAPACITY EXCEPT ARMOR PLATE The joint statement of Charles M. Schwab, chairman of the board, and E. G. Grace, president, says that the corporation’s plants are working to full capacity except in the armor-plate department. From this statement the following extracts are taken: “At the beginning of 1915 the steel business of the United States was much depressed, due to some extent he European war. This condition was rapidly nged, however, by the very large orders for steel ‘ts placed in this country by the various Euro- governments and by an increased demand for consumption. This combined foreign and do- demand has created an unusual condition in the ndustry, and to-day there exists an actual shortage l-making capacity in this country. These condi- uupled with the difficulty of obtaining certain terials and an increase in the price of labor, have ed in a rapid increase in the price of steel well known, your corporation has had, for rs, well-developed organizations and plants for ifacture of ordnance and munitions of war. ting ability to meet and supply the extraordi- ind for such products accounts in large de- the increase in earnings over the previous the recent extraordinary market for all ee! products and for ships the various plants poration enter the year 1916 with all de- , With one exception, running at full capacity. ption is the armor-plate department. The Steel Company has practically completed de- the Government on all pending armor con- ( nts mtr ot acts for the current year have not been PROPOSED GOVERNMENT ARMOR PLANT (tention is called to the fact that a bill Congress and has, with the support of the the Navy, been recommended for passage ite Committee on Naval Affairs