The Iron Age 1918-03-28: Vol 101 Iss 13

New York, March 28, 1918 MaAr 29 1918 Vile: yee) v HANGERS Save 15 to 33% power Cut lubrication 80% INVESTIGATE SKF SALL BEARING CO. Hartford Conn. 332 i“ “RR ae oa 4 Sc a. . ore os 7 eS + | as . : »t “ues a tea f cao : UUPUD Gee) REE Ta co bp a oy ¢ be aies 1 LL SF rie 7 serene + OT as AL i tevee @etrieg ray tetas Gat t. ames : uP CRY nh ites e Tia acta ae 3 os ie a a = _— Ld as - “TABLE OF CONTENTS - - - 823 oso INDEX - - - 385 2 Buvers’* Index Section 367 ontract Work Secti Caarine Ei Section 9 ‘ Hi ‘Ip and Situations Wi inted ; 349 Rar inant Mat a Wanted Section . . 042 Busines ss Opportuniti« 845 Professiona ices THE IRON AGE March 238, cae he Pe ah 3a Pn ee OX Ks KO XS) Ke) 1918 f CN YK KO XK ION KEENE KE) COXON 9.9,9,3.9. > - i a OE TR Gast, PLANT MIRON ANDISTEEL “pe a ae ey Pate)", FOURMARGE) STEEL'SERVICESSLANTS % Ya Ke ke We o 4 SOOO \7 OY \/ Ce) \/ AD hija [IRON XK KOK v YOCX KXOO) SOOCLOOOGOOU DOO DODO TODO OOO ODOC ODO OOO OOOO OOOOIOOO S . nee ee —_ -— A ee ae ee TE MI YY KK KIX) THE IRON AGE New York, March 28, 1918 ESTABLISHED 1855 The Design of VOL. 101: No. 13 Blooming Mills Faults of Existing Plants and the Needed Improvements — Details Discussed Range from Soaking Pit Building to the Bloom Shear oY H. Hi. S ONE surveys the efforts of the various de- A signers of blooming mills, he is strongly im- pressed by the tonnage that can be handled by a well-designed mill when operated by a good crew, and again by the woeful reduction in tonnage through faulty design, which no crew, no matter how efficient, can overcome. A blooming mill, while very heavy and costly, is a comparatively simple piece of machinery, and the points which must be watched to make it a fast mill are so few that we are taking the liberty of drawing a few compari- sons, in the hope that our personal observations may help to raise the output, and we might say reduce in some cases the first cost. For the purpose of this article, we will particu- larly discuss the two high reversing types. As a blooming mill performs but one step in an extended process, it will be necessary to touch briefly on the preceding and succeeding steps, so far as they may affect the operation of the blooming mill. If a blooming mill is to give maximum output, it is necessary that the material be supplied and taken away with a slightly greater speed than the maxi- mum which the unit can handle. In other words, the auxiliaries, the units of less value, must be ample to insure maximum production, or we cannot justify the large expenditure in the main unit. To limit the scope of the article, it will be supposed that power, be it steam, hydraulic or electric, is supplied in the proper quantities or pressures. We might add that this is a very common cause of limiting tonnage. Lengthwise Arrangement of Soaking Pit Building It has always appealed to the writer that the soaking pit building running lengthwise of the mill is superior to the crosswise arrangement. Trains of complete open-hearth heats can be spotted close to the furnace for charging, without cutting the trains. The approach table to the mill can be arranged so that it is covered by the soaking pit cranes, which serve as a spare for the ingot chariot, while the ingot chariot normally cuts the crane movement toa minimum. These points can scarcely be obtained in the crosswise arrangement, and not at times affect the supply of hot ingots to the mill. The most reliable ingot chariots are cable hauled. The motor-driven chariot seems to be in sad disre- pute, but we feel that with proper design it can be made superior to the cable-hauled chariot. The in- *For some years squad foreman on rolling mill work, fol- lowing a number of vears as chief draftsman for a builder of rolling mill equipment HUM MEL” terposing of a cable between the motor and the chariot, with the chance of its being cut by a dropped ingot, does not seem to be the best design. The chariot should deliver the ingot to the front table of the mill running along the side of the nar- row tail table to do so, thus cutting the delay be- tween the finishing of one ingot and the start of another. Pinions and Couplings Before the advent of motor-driven mills, there was a tendency, particularly on the part of one of our most eminent consulting engineers, to depart from the conventional pod end and coupling box, substituting in their stead couplings of such a design that play could be almost eliminated. His reason for this, no doubt, was that the continual pounding due to the reversal of a mill, with play in the coupling boxes, not only crystallized the ma- terial, which later on would fail, but had a very detrimental effect on the life of the bearing. In this connection, it has been the tendency to substitute machine-cut herringbone gears for the older style spur or staggered spur teeth. These gears as made by the better manufacturers are wonderful examples of accurate machine work. We have in mind a pair of cut pinions for a 40-in. blooming mill, which were set up, with their necks in two stands, with accurately machined semi-cir- cular grooves, and the pinions investigated with the search gage showed a clearance between the teeth of 0.006 in. It can readily be appreciated that the effect of the blow struck against a top pinion by) the reversed lower pinion after traveling 0.006 in. is decidedly different from the blow received where the clearance is probably 1, in., in the case of new and several times that in the case of old and worn cast pinions. It is absurd, of course, to put cut pinions of the extreme refinement shown into housings with the conventional old-style bearings. The aim has com- monly been to provide bearings that are held abso- lutely solid; these are made with steel cast shells filled with the best babbitt, well peened and accur- ately machined, with just sufficient running clear- ance to accommodate the oil film and arranged to be held tightly without adjustment in the pinion hous- ing. With an arrangement of this kind, it is im- possible for a millwright, who might be a mediocre mechanize, to make any adjustments whatever. The adjustments come directly under the machine-shop mechanic who machines the bearings. The old-style millman will probably raise the objection that this 795 794 refinement is a needless expense, but his objection will be tully answered when he discovers the life he gets from a bearing of this class. The bearing will wear as all bearings do, from the action of the re- volving pinion neck, but it has ceased to be an anvil, receiving blows from a pinion dancing about with the play usually allowed in the older practice. In other words, the use of engine-type bearings has been extended to include the pinion housing, which is now generally connected to the continuous feed pressure oiling system of the engine. Support of Floating Spindles We now find ourselves confronted with the ques- tion as to where we will get the necessary room lengthwise to remove a roll when a spindle or neck has broken off diagonally. The type of alignment coupling used between the pinion housing and the motor or engine is usually such that any extreme end thrust would do serious damage. Therefore it is necessary to block the pinion housing with a big square block let into the shoe plate, or, better still, by a separator bolted to the shoe plates and extend- ing from the pinion housing feet to a machine pad on the side of the engine bed plate. Now the only outlet we have for a diagonal break is to push the roll endwise through the roll housing window, which, of course, must break the set pins in the mill box. In order to make it possible to do this, there is only one arrangement of boxes and riders which we can use. That arrangement is to have the ears of the boxes on the outside, the set pin running through the housing for the lower box and through the top rider for the top box. To have strength in this top rider, so that the break will come in the set pins as desired, there should be lugs on the inside resting against offsets in the housing window. In this con- nection the design should center about the size of the set pin; castings and particularly bearing lugs should be made strong enough to break the set pins, even though the millwright should replace these pins with those made of high-grade steel, possibly heat treated. One point on a mill which requires careful de- signing and which in a number of cases has not received the consideration which it deserves has been the design of the spindle carriers. Some de- signers seem to think that a bearing carried on springs is the proper method of carrying the weight of the lower spindle and that bearings carried in a frame supported on springs at the pinion housing end and attached with springs to some portion of the top roll lifting arrangement is all that is neces- sary for the top spindle. The elevation of the bottom roll in the housing is determined by the relation of the bottom of the pass to the top of the table rollers, this distance being one-half the draft plus a clearance which good millwrights endeavor to keep between 1% in. as a minimum and 4 in. as a maximum. Now, for a given mill it may be necessary to have rolls of sev- eral different designs in order to make the sections desired. These rolls as they wear must be redressed, which reduces their diameter. As a mill is nearly always designed by taking the lowest position of the bottom roll as obtained from the above variables as the elevation of the lower pinion, therefore as deeper pusses are used and the rolls are redressed, the elevation of the center line of the bottom roll will rise above the elevation of the center line of the lower pinion. This will give the bottom spindle an inclined position, allowing the springs to extend, in which extended position they do not exert the pressure which they should to fully counterbalance the entire weight of the bottom spindle and carrier THE IRON AGE March 28, 1918 bearings. While these springs have adjustments and can be taken up, experience has shown that they are usually neglected. We therefore recommend a single center bearing arranged with a counterweight of sufficient size to counterbalance the entire weight of the spindle and carrier bearing, which, of course, exerts a constant pressure regardless of the position of the spindle and is freer from breakage than any design involv- ing a spring. When we come to the top or vibrat- ing spindle the problem is further complicated by the vertical movement of the spindle due to the high lifts which it has been necessary to use to get the wide slabs demanded by the modern universal plate and skelp mill practice. In order to get the articu- lating joints of the spring carried framework of the top roll carrier where they belong to avoid un- even spring pressures at various roll elevations, a design is required which brings the springs in a very unhandy location to support, besides having one-half the spindle and carrier weight thrown into one side of the top roll counterbalance rigging, which makes the entire counterbalance system un- symmetrical. A much better arrangement is to use one bear- ing in ‘he center of the spindle arranged with coun- terweights and combined on the same bed plate with the carrier of the bottom spindle. This design has all the advantages before mentioned and leaves the top roll counterbalance symmetrical about the cen- ter of the mill. Mill Engine Control One of the most essential factors in the rapid operation of a mill is a properly designed engine control. The best practice up to a few years ago, and one which was quite satisfactory from an op- erating standpoint, employed two levers. One was connected to the operating valve of the jack cylinder, which operates the main throttle arranged with a floating lever in such a manner that the main throt- tle would follow the hand in every respect. The other was connected to a similar floating gear on the steam cylinder of the reversing jack and sim- ilarly arranged so if the lever was moved a portion of its travel the cut-off in the high-pressure cylinder was changed in the same proportion. With this ar- rangement, good speed could be made with the mill, but it was open to the criticism that it was hard to make the engineers control their engines economic- ally by altering the cut-off with the reverse lever. To remedy this defect, two of the larger manu- facturers have brought out patented systems of one lever control. The one which combines the most features is arranged in such a manner that as the lever is moved to start the engine, the point of cut- off is sv far advanced there is no dead center on the common type two-crank engines with the cranks at 90 cey., thus enabling the engine regardless of crank position to be started in either direction. After the engine is started and as more power is required, the lever is moved further on from its mid- position, the cut-off is brought to an early point in the stroke, and the power is further increased by opening the throttle until we reach a linked-up condition with wide-open throttle. Then as still more power is required, it is obtained by dropping the links and advancing the cut-off until we reach the maximum power of the engine. It is understood, of course, the engineer operat- ing this engine may not know just what is happen- ing, but the fact remains that he is forced to operate his engine economically at lower powers and cannot achieve the full power of his engine without pro- gressing through the entire limit of economical March 28, 1918 operation before he reaches the high-power uneco- nomical operation of the unit. The writer does not know of anything which would relieve overloaded boiler plants of an unnecessary burden at such a low cost as a properly designed one-lever control on the necessarily uneconomical reversing engine. Another way to achieve economy of power in blooming-mill operation, though at a very large in- crease in first cost, is by the use of the reversing electric motor. This statement is particularly true, where access is had to hydroelectric or blast-furnace gas-engine-generated power. The performance of these units from either the operating or economical standpoint is admirable. Control of the Screw Downs Another feature which would easily justify the cost of complete rebuilding on a number of existing units is the screw-down arrangement, which is usually faulty in its power of speed. The best practice to-day is to use two compound wound 100- hp. mill-rating mill-type motors, of which there are several excellent lines on the market. The com- pound winding of these motors is necessary to pro- tect the motors from running away when the screw down is being run up, and the motors are partially unloaded or even accelerated by the counterbalance rigging on the mill. To cortrol these motors, we know of cases where a manual control is used, other cases where mag- netic speed control is employed, and again where magnetic control with a plain three-point master is used. With manual control, it is always possible, if it is necessary to use the screw dowm to close a split end, to develop the full power of the motors. With magnetic speed control in a similar situation, it is necessary to have the accelerating switches set, © so they will follow each other with great rapidity and even then it may be necessary to raise the top roll one inch, perhaps, before running down against the piece, in order to give all the switches a chance to close, so one will have available the full power of the screw-down motors to force the rolls together against the resistance of the hot bloom. The same is true with magnetic control and a three-point master with the addition that the operator must be a little more expert, to stop at a predetermined point. Personally we would recommend magnetic speed control, not because it is ideal, but because we con- sider it the best of the three bad bargains. Most of the later practice combines with each motor an extra size solenoid series brake, with the windings of the solenoid changed to suit the amount of cur- rent flowing through the motor. These brakes are used to assist the operator in catching size, and it is not considered good practice to increase the helix angle of the screw so that a tendency to back up under rolling conditions would have to be re- sisted by the motor brakes. The helix angle of the screw thread, which will resist the rolling pressure, is in the neighborhood of 3 deg. 10 min. figured on the outside diameter of the screw. Top Roll Counterbalance As intimately related to the screw down, we might next consider the top roll counterbalance. When of hydraulic type, the cylinders should be large enough to overbalance the heaviest top roll possible to be put into the mill through the housing window and at a pressure well below the lowest point to which it ever drops in the general hydraulic system, so the leakage can be made up at any time from the hydraulic line. In order to reduce the number of times it is necessary to introduce water, THE IRON AGE 195 so the accumulator will not bump, we would suggest that the volume of the accumulator be made as much as 100 per cent larger than the cylinder or cylinders counterbalancing the roll. Neglect of these fundamental principles or poor design in stuffing boxes or elsewhere has led opera- tors to discard their accumulators and allow the counterkalance cylinders to float on the line, which, of course, under certain conditions gives entirely too much counterbalance pressure, with attendant overloading of the screw down on the down travel. They have sometimes backed up the accumulator with an automatic motor-driven hydraulic pump, arranged to introduce sufficient water to keep the travel of the accumulator within certain predeter- mined limits, or in the case of new design, they have been led to use counterweights instead of hy- draulic counterbalance cylinders. All of these addi- tions and complications have arisen from faulty design uf what seems to be the most logical arrange- ment. Designs of Manipulators We wish to make a few observations in regard to the manipulators, of which there are several types on the market. As our experience has been mostly with one type, we will not draw any com- parisons, but there are a few points in regard to the Wellman-Kennedy type hydraulically and later electrically operated on which we would like briefly to touch. In the Wellman-Kennedy manipulater the lay shafts run past each side of the machine, one shaft urranged to operate the two right-hand side guards in unison and the other the two left-hand guards, thus making it impossible to get a side guard on the outgoing side of the mill in the path of the heavy bloom emerging from the pass. The travel of the side guards should be limited by bumping blocks so the side guards supports can- not hit the table girders, as it has been found im- possible to construct anything within reason which will withstand this treatment. The stops which are usually iron to iron are sometimes fitted with spring buffers but usually the extra side travel space re- quired for this is not available. The iron to iron should be fitted with a loose steel block on one of the bumping surfaces so it can be shimmed out in case of lack of alignment or in case wear has al- lowed the post to hit the table girders. The side guards themselves are usually made of a solid steel casting or of rolled steel slabs, usually one slab of sufficient thickness or sometimes two slabs built into a girder with separators, provision being made for independent expansion of the two slabs. To provide for the best possible control of the piece it is desirable to have the side guards run past the outside housing line to a point close to the rolls. The only space available for this without lengthening the roll body unnecessarily is the thick- ness of the outside collar, which is usually about half the thickness of the side guard proper. Thus we may have an end which can always be bent by the power of the manipulator. It is found, however, that the operating forces are willing to be careful and stand for the trouble of straightening the end if bent rather than take the operating penalization of doing without it. ; The side guards are usually arranged with two lugs which bear against the sides of the casting girder running from table girder to table girder between two rollers, and located about in the center of the side guard length. This is put in to take the pull or push of the bloom, if it is pinched between the two guards while being rolled, thus preventing the side guard posts from being pressed against the revolving table roller and also tilting the rack. 796 If these lugs, however, do not have ample clearance there will be scale troubles which will end in the operating force removing the girder and running without it. The side guards are carried on heavy steel cast- ings posts attached to the rack girders, which are built up of two slabs with separators, racks and stop luys, carried between them with through turned bolts. However, some designers have made the rack girder, rack and post in one large steel casting. While this is undoubtedly a cheaper de- sign, it certainly makes an expensive piece to re- place, for a small break or worn rack teeth. In the preliminary design the connection between the post and the rack girder must be very carefully worked out, to resist the shocks and operating strains which throw a heavy twisting moment into this connec- tion. The side guard pressures from the old hy- draulic manipulaters were usually about 25,000 or 30,000 lb., or roughly about 50 per cent of the total load of ingot and manipulater moved. In working out the electrically operated design, these figures were used in connection with the torque curves of the motors, to arrive at the motor sizes. In the earlier efforts too high a side guard speed was as- sumed, which on one particular design took but eleven revolutions of the motor for the entire side guard travel. To control properly the side guard travel of the electrically operated manipulater, it is necessary to use botn solenoid brakes and dynamic braking. The trouble that has developed is that in a side guard travel which might only necessitate a revolution or less of the motor, the angular travel of the armature is so small that it will not develop the dynamic braking force. In later designs for handling heavier ingots, where one necessarily uses a lower speed but a not greatly increased side guard pres- sure, it has been desirable to introduce the second gear reduction, between the motors and the lay shaft and cut down the size of the motors so the torque developed would not produce strains for which it would be impossible to design. This, strange as it may seem, produces a combination so superior in its control, that we consider it would be better de- sign in all cases regardless of the weight of the ingot handled. The side guard travel of the manip- ulater is powered with two motors running in series fitted with solenoid brakes of extra size with slip gears interposed between the motor and the lay shaft to protect the manipulater against the energy stored in the rapidly revolving motor armatures. We consider it superior practice on all mills, but particularly on mills that roll smaller sections, to arrange the manipulater with turning fingers on both sides of the mill. This will prevent dummy- ing a pass in order to get to the fingers for turning, and ‘as ene acts as a spare for the other, the ar- rangement may at times save delay on the mill. In a mill rolling small sizes, it is sometimes necessary to use beth pairs of fingers to turn a piece even with properly designed offsets in the side guard to facilitate this. Particular care should be given to the lift for which the fingers are designed, also the height of the side guards, as there is always a possibility that it will be necessary to increase the maximum size of the ingot over that originally contemplated, and as all wear on the end of the fingers and in the, pin joints of the finger mechanism tend to decrease the effective lift of the fingers, it is important that the two lay shafts be carried in bearings which are in one well-designed base plate, as the reactions which ccecur when an ingot is pinched between the two side guards tend to separate these shafts, and THE IRON AGE March 28, 1918 we know it would be impossible to hold these bear- ings separately on the foundation. It is usually best to provide windows in the table girders for the manipulater racks, to get the lay shaft location high enough so it will cross over the top of the shoe plates, thus shortening the projec- tion of the side guard posts. Mill Tables There has been a tendency in the later design of blooming-mill tables to provide means of adjusting the location of the table rollers endwise in order to keep the gears in proper mesh. This has been done by horseshoe washers between the bearing and the bevel gear hub or by means of an adjustable thrust bearing on the far end of the roller. Also it has been found necessary to back up the gears on the side shaft which are not against bearings by a split collar let into an annular recess in the side shaft. These seem to be moves in the right direction, as the tendency is toward cut gears of forged steel, to increase the life and decrease the power required. Front and rear tables are generally about 45 ft. long and are usually powered with two 100-hp. motors running in series. With direct-connected engines, which give a fast rolling speed, and with the increased size of ingots necessary to get the wider slabs and blooms of suffi- cient weight, so as not to finish the heavier sections in too short lengths, it has been necessary in some cases to increase the size of table rollers. This in- creased diameter of roller when run at a speed com- mensurate with the increased rolling speed is tend: ing surely toward the substitution of larger motors for the front and rear table drives, owing to the increased energy stored in the heavier rollers run- ning at the higher velocity. The Bloom Shear The type of shear or shears to be used beyond a blooming mill depends largly on the sections for which the mill is primarily designed. A shear for cropping sections from 6 x 6 in. to 8 x 8 in. in size for feeding continuous mills beyond the blooming mill should by all means be a horizontal shear, of which there are some very good electrically operated types on the market. With this type the spread from the action of the shear occurs on the top and bottom of the bloom and therefore the bloom will not have to be turned with collared rollers or other devices to make it enter the guides on the first stand of the continuous mill without sticking. In hindling small forging billets, which are often cut in very short lengths, it is sometimes necessary even with a fast shear to have three or even four pieces in the shear at one time in order to keep anead of the operation of the blooming mill. To give the'necessary speed for this service and also provide a unit with sufficient power for han- dling large forging billets or wide heavy slabs, the tendency in later design has been to use the vertical shear with a steam hydraulic intensifier, arranged with a floating valve gear after the style used on some of the high-speed hydraulic forging presses. In order to reduce the cost of the steam hydraulic intensifier it is usually designed to make two strokes to get the infrequent long stroke of the shear re- quired to handle big squares. If the blooming mill is feeding more than one continuous mill, it is neces- sary that the mill locations and table arrangements be such that a piece can be delivered to any mill at any time regardless of whether the previous plece is still on the entering table or not. The mill pulpit usually spans the mill tables on March 28, 1918 the entering side of the blooming mill and contains the roller, manipulater man and engineer. The en- gine should be on the same side as the pulpit to simplify the operating connections between the two. Of indicators there are a variety of types. Those fastened to the top of the housing screw seem to find the greater favor in the eyes of the operating force on account of their accuracy, but any indicator placed cn the mill proper is open to the objection that it is often obscured by the clouds of steam aris- ing from the mill. Druin or dial type indicators driven by cable and sheaves are often used and are placed either on the mill or ir. the pulpit. In an indicator of this type a heavy counterweight should be provided, to keep the cable taut, and the author is of the opinion that Aa NYS iad as . r ee ed THE IRON AGE THE FOUNDRY BUILDING* Modern Emphasis on Light and Ventilation— The Matter of General Construction The buildings to house a foundry plant should be decided upon after the layout of each and every depart ment and their inter-relationship is definitely settled upon. The design of building requires a discussion, first, from the standpoint of materials, and second, style or type. A structure as cheaply as one of wood. where cranes are to are desirable and may be made of gypsum or concrete tiles, upon which is placed a covering of “tar and gravel” other roofing. Adjacent to a cupola only steel be built today practically This is particularly true Non-combustible can be used. roofs or \7 re oe. Se se ) Oe Nd 1 a \ Roon tl Illinois Malleable Iron Co., Chicag Adva e Was Ta of tl it ‘ } to Carr "p Supports to the Roof Trusses, Thus Minimizing the Span ¢ he Worl Are \ g g Members of the Trusses Tl Otherwise (on the floor may b« e ft ! ‘ ina it the furnaces it should never have a multiplication of less than _ strictly fire-resisting roof should be used, and on al four to one, if for no other reason than to minimize ides of a building where other buildings are clos the error through sagging cables. Gear chain- >y wired glass in steel sash should be used, instead driven indicators will always have lost motion due °! ate apse? an a ee to wear, which means that they must always be read 206 Sircers au oe eee ae en after the screw has had a down travel to take up Sen ie aera ‘ld Se a = oe : the slack. If the roller by chance overtravels tne \ dla cieiis saaestcada ble |} cet 98 with. tite dives point, he must back up well above it and then come —;gof does not ordinarily require the carrying o down to it, with the delay incident to the extra’ ance other than for wood sheds. offices. etc.. and screw-down movements. One rather ingenious foundries built of this constru ! j ‘ scheme is to provide a tube running from the pulpit ince. It is a simple ques thematics t to an illuminated indicator on the mill, through hat the saving of it er a pe 1 which the roller looks so his vision is not obscured five years will pay for tl Le os by the steam. This should be a portable tube so it "00! Over one Sulit of timibs ts and © can be removed when making repairs. — eae ee ee eee ee The writer knows of one progressive plant where sti on x ( d es d yore ch vere d | experiments are being made with an indicator ar- [yoyyance dos ” — ranged to stop the screw-down motors automat lom is sufficis Yr ! ically at the proper point for the next pass. The State regulatior motors in this case are equipped with both solenoid y with regar he t and dynamic braking, to cut the overtravel to a vor} nd ther iry fu minimum. The automatic feature of the apparatus moke, cold in wint The Mo is arranged with a cut-out, so one can roll by hand, on, if for any reason it is found impossible to follow the set line of the reductions. 798 THE IRON AGE March 28, 1918 The foundry of the Moline Malleable Iron Co., St. Charles. Til Has Connecting One End of the Foundry Proper with the Corresponding End of the Parallel Building Given Up to Annealing and Shipping. In the foundry, which has a span of 140 ft., are three lines of columns: the valley of the roof is located over the central line and the two expanses of roof glass rise above the other lines of columns. The light character of roof construction and of the general illumination resulting are here indicated. In the annealing department the span is 90 ft. with- out columns, the roof here being of similar construction but supported by light trusses as indicated, with the window roof openings in a position calculated to allow the ready escape of the heat. The light character of the casting work does not require heavy construction as needed where heavy ice is required. The span of transverse cleaning room is 40 ft a Transverse Cleaning Building Shown in the Foreground crane ser March 28, 1918 Malleable Iron Co.’s plant at St. Charles, Ill., is an interesting example of a type of construction which has proved most successful in providing good light and ventilation. Light and ventilation are obtained not merely by a reasonable amount of window and ventilating areas, but by the proper distribution of them. It is not enough to provide plenty of window openings, but it is also necessary to arrange them in the proper way. The old-fashioned pitch roof, with a small monitor on the ridge, does not ventilate (labor commissions have ordered blowers). Experience has shown that a flat roof does ventilate, and comparative figures prove that the better light and ventilation cost no more than the old type. A modern foundry should be heated, and this can best be accomplished by means of a hot- air system, and through proper arrangement of fans and outlets it is possible to pump fresh outside air through the heating duct system in summer time. This is not often necessary if the building is properly de- signed. The hot-air system of heating is not necessarily the most economical to operate, but, owing to location of molders’ benches against the walls under the windows, it is difficult to place steam coils at this point, and steam coils are not effective if placed above windows on outside walls. A successful heating system is a valu- able adjunct in any foundry plant, particularly in the northern climate. Good lighting is best obtained by use of Mazda or nitrogen lamps of 50 to 500 watts’ capacity per unit, depending on ceiling heights. Few arc, gas and mercury lighting systems are economical or satisfactory. Plumbing must be complete to comply with increas- ingly widespread and stringent State laws. Drinking fountains, water for molders and other purposes should be provided and urinals at frequent intervals through- out the plant. These facilities when adequate prevent wasting time. In general, concrete is the ideal building material for foundations, and brick for side walls. Steel sash should be used in preference to wood sash as being little or no more costly and of much longer life and far cheaper to maintain. The proper kind and weight of sheet metal for flashing and gutters should be insist- ed upon, and a good roof is a good investment. Japanese Steel and Iron Output In August of last year the total producing capacity of the Japanese steel works was estimated at 890,000 tons a year, and was rapidly increasing, says the Lon- don Ironmonger. In the first half of 1917 Japan, exclu- sive of Korea, turned out 289,000 tons of steel shapes, the principal producers being the following: Japanese Government Steel Works.............. 200,000 tons ue TEN TO COS in kis ei a d si nswarase tie elen 22,000 tons Pe DOr. WOGG: catevciescrtds sed tedareneas SED TOE. COI 6s 6:0 wear eueu hb enteas bacon Kawasaki Dockyard Co 14,000 tons 10,000 tons 12,000 tons It is believed that the total output of these five plants in 1917 was 570,000 tons, and that in 1918 it will reach 850,000 tons. The production of pig iron in Manchuria began in the year 1915, when it figured for the first time in the export lists of the port of Darien. The iron is made from low-grade ore extracted from the mines in Penhsihu, or, as the Japanese call it, Honkeiko. In 1916 the production was 50,000 tons and in 1917 it was expected to reach 100,000 tons, although the manufac- ture was much impeded by the non-arrival of the new machinery that had been ordered abroad. Nickel alloy with an 8 to 10 per cent zirconium will take a fine cutting edge, according to the Chemical Trade Journal. Either cobalt or nickel with 8 to 15 per cent zirconium has its melting point reduced below that of any one of the three separate metals, with an increase of electrical resistance; and with 16 to 30 per cent zirconium the hardness is greatly increased, giving an alloy suitable for cutting tools. This application of zirconium has been patented. THE IRON AGE 799 Flag and Medal for Munition Workers In the windows of thousands of homes in New Haven, Conn., appears a new service flag which at- tracts much at- tention from visitors. New Haven is one of the cities in which many men who desire to enlist in the fighting - forces are turned away in order to re- tain their serv- ices in the huge munitions plants of that city. In order that these men might have some recognition of the patriotic work for which it was necessary to retain their services, the > Winchester Re- peating Arms MUNITION WORKER’S SERVICE FLAG t ‘ Co. conceived the scheme of rec- ognition which is illustrated herewith. In the * * * middle of the paper service flag is a repro- * * * duction of a bronze’ service at ou shew sone her eg medal which is furnished to 2mployees of the plant. The service flag is, of course, for use in the home window. The service flag is about 8 x 11 in. in size and has a red, white and blue border. The num- ber of persons in the household employed in munitions work at the Winchester plant is shown by the number of stars on the service poster, blue stars representing men and red stars women. A short walk about the city shows a large proportion of red stars, emphasizing the fact that thousands of women form an essential part in the direct war program of this country. The medals are intended to symbolize the war serv- ice rendered in the factories by the men and women upon whom the success or failure of the men at the front depends. They are particularly appreciated by the young men who have been exempted from war serv- ice on account of their skill and experience in the manu- facture of rifles and cartridges. The badges remain the property of the company until the wearer has been one year in war service with the company. Thus on April 6, 1918, workers who have been continuously in the employ of the company since the declaration of war will become the owners of their badges, but people who leave the employ of the company without giving at least one year to such service will be required to return the badges issued to them. Structural material for the construction of the new plate mills at the Baldt Works of the Penn-Seaboard Steel Corporation, New Castle, Del., is now being re- ceived at the site and it is planned to inaugurate imme- diate construction work to complete the mills for early operation. The Wharton Steel Co., Upper Hibernia, N. J., has commenced the construction of a clubhouse for the use of superintendents and foremen engaged at the Whar- ton iron mines. The building will be ready for occu- pancy about Aug. 1. Slight Reductions in Pig Iron and in Serap Recommendations Subject to Although the Price Fix- Industries boara WASHINGTON, March 26.- ing Committee ot! the Wai o attended the conference held on ana in March iron and St_é men wh 2() to consider the revision of the schedule of stee' prices have declined to make any statement as to the conclusions reached, in advance of the official pro mulgation of the new schedule by the President, it car be said that the modifications embrace but a cut of $i per ton in pig iron for steel making ($1 oni basic and $1.10 on Bessemer), but not in pig iron intended for foundry use, and a reduction of $1 in the price of scrap. In reaching this decision the Price Fixing Committee ignored cost sheets showing rapidly rising figures for January and February, also suggestions frem small pro ducers of substantial increases in certain finished prod- ucts, and the more urgent demands from manufacturers obliged to buy their pig iron, for a considerably greater increase than $1 per ton in the spread between pig and plates and shapes. The committee also rejected the plea that the iron industry and all industries dependent thereon would be benefited by a six months’ extension of the schedule and recommended to the President that it be again subjected to revision on June 30. A Large Representation The representation of iron and steel men at the con- ference was the largest and most comprehensive that has met with the War Industries Board since the matter of regulating prices was first taken up for considera- Those in attendance included E. H. Gary, chair- man, and J. A. Farrell, president United States Steel Corporation; E. G. Grace, president Bethlehem Steel Co.; A. C. Dinkey, president Midvale Steel & Ordnance Co.; E. A. S. Clarke, president Lackawanna Steel Co.; J. A. Campbell, president Youngstown Sheet & Tube Co.; John A. Topping, chairman Republic Iron & Steel Co.; Willis L. King, vice-president Jones & Laughlin Steel Co.; Francis J. Hall, vice-president Central Iron & Steel Co.; John B. Guernsey, president John B. Guernsey & Co., Roanoke, Va.; F. H. Gordon, general sales manager Lukens Steel Co.; A. H. Cordery and David Reeves, Phoenix Iron Co.; Edmund Blanchard and E. T. Burn- side, McCoy-Linn Iron Co., Milesburg, Pa.; Clarence H. Howard, Commonwealth Steel Co.; B. L. Sommer and H. O. Dimmick, Keystone Steel & Wire Co.; Joseph F. Savage, American Tube & Stamping Co.; H. Laird Curtin, Eagle Iron Co.; J. S. Hall, Interstate Steel Co.; James Bonner, representative of the American Iron and Steel Institute; J. V. W. Reynders, chairman, and Chas. N. LaPorte, secretary, of the Association of Steel Makers in Class III; and Roy A. Rainey and Scott Stewart, of W. J. Rainey. The Price Fixing Committee was represented by R. S. Brookings, chairman; F. W. Taussig; B. M. Baruch; Gen. Palmer E. Pierce, surveyor general of supplies for the War Department; Hugh Frayne, and Paymaster John Hancock, U.S.N. In the absence of Dr. Garfield, Fuel Administrator, his office was represented by W. A. Blauvelt and F. J. Herman. On behalf of the Federal Trade Commission, W. B. Colver, commissioner; W. W. Wooster, steel expert, and Francis Walker, statistician, were present. J. Leonard Replogle, director of steel supply; Alexander Legge, of the staff of the War Industries Board; Paymaster J. tion. of the Committee to the President Change Price Fixing New Schedule in Three Months S. Fuller, of the Navy, and Col. J. M. Army, also took part in the conference. Young, of the High Costs Held to Be Temperary Although the matter of revising the existing sched- ule of prices was considered by the conference from every angle, the outcome had been foreshadowed as the result of a general understanding reached as to conces sions that might be offered by the steel men, reflected in the which appeared in the market report of THE IRON AGE for March 21. Although the cost sheets before the conference showed large increases accurate forecast since the adjustment late in December, the representa- the Federal Trade Commission insisted that the conditions during January and February were ab- normal, that during March the rising tendency abated substantia!ly, and that for at least six months to come there is tives of every reason to look for a downward rather than an upward trend. The that small producers were handi- capped under the prevailing schedule for finished prod- ucts and that higher prices would bring out a larger production was aggressively met by the members of the Price Fixing Committee, who intimated that the rational way to assist the small manufacturers at the present time would be to reduce the price on pig iron and scrap rather than to force the Government to pay higher prices for material for the prosecution of the war. suggestion Suggested Concessions to Small Plate Mills The the small manufacturers that they should have better prices for their products was no doubt influential in bringing the Price Fixing Com- mittee to an agreement to extend existing rates on finished steel and probably deterred the committee from making a drive for lower figures. contention of There was a proposal! at one stage of the conference that the larger steel] companies might furnish ingots or slabs to the smaller plate makers at concessions in price. To the sugges- tion in reply that this would be practically pooling and in violation of the Sherman law, it is understood there was a quick retort that pooling was the thing aimed at and that the Sherman law would not stand in the way while the war lasted. The general conservatism displayed by the Price Fixing Committee is illustrated in the action taken with respect to the price of pig iron, the cut on which is limited to iron for steel making, leaving foundry iron, which in many cases is produced by smaller fur- naces, at the old price. Throughout the conference the best of feeling was maintained, and there was a notable absence of the rather sharp exchanges which marked the December meeting. Six Months’ Extension Refused The steel men present favored at the outset a six months’ extension of the schedule, on the ground that it would make for stability not only in the steel indus- try but among all consumers of its products. The steel committee, however, appeared to be convinced in advance that the extension should be limited to ninety days, and the intimation, not altogether devoid 800 March 28, 1918 that if to date are of humor, was made the cost sheets covering the calendar year reliable indications of what is to come the steel men might have reason to congratulate themselves on an limited to three months. extension The recommendation of the Price Fixing Committee forwarded to the White after the conference, and the promulgation of the revised sched- ule is momentarily awaited. It is believed that of other official business alone has prevented the Presi- was House soon press dent from acting more promptly and that there is no significance in the delay. At the time the schedule was December the President had held several conferences with the members of the Fed revised late in recently eral Trade Commission and the War Industries Board and without was, therefore, prepared to approve the extension further consideration. In view of the changes recommended at this time by the Price Fixing Commit tee, he may desire to review the minutes of the confer- ence before approving of the committee’s findings. New Prices Officially Announced WASHINGTON, March 27 (By Wire). The Council of National ing statement Tuesday: Defense issued the follow- “The President to-day approved the recommendation of the Price Fixing Committee of the War Industries Board that the maximum prices heretofore fixed by the President upon the recommendation of the Board upon coke, and steel products, published subject to revision on April 1, 1918, be continued in effect until July 1, 1918; that from April 1 to July 1, however, the maximum price of basic pig iron be re- ore, steel duced from $33 to $32 per gross ton, and that the maxi- mum price of scrap steel be reduced from $30 to $29 per gross ton. No new contracts calling for delivery of any said commodities on articles on or after July 1, 1918, are to specify a price unless coupled with a clause making the price subject to a revision by any authorized United States Government agency, so that all deliveries after that date shall not exceed the maximum price then in force, although ordered or contracted for in the meantime. It is expected that all manufacturers and producers will observe the maximum prices now fixed.” High War-Time Wages of British Workers Interesting examples of the large earnings of cer- tain kinds of labor in England in war time are given by a writer in the London Jronmonger. One of these refers to a puddler and is as follows: Some.of the stories going about of the high wages which are being earned by workers fabulous, but I know of a few munition may seem authentic instances that are sufficiently remarkable The highest remuneration that has come to my notice is that paid to four men who are puddlers at the Butterley Company's iron works in Derbyshire For three vears these men received for their joint labor an average of £120 a for failing to pay stated by week One of the fortunate quartet was summoned income tax amounting to £48, and it was the prosecution that his income during the vear for evied which the tax was was £998 The other instance relates to the earnings of a boy, and is given as follows by the same writer: that for boys’ This lad, shells, has earned on an average tlo5 per I should say Sheftield youth of 15 holds the copper bands for earnings a record who is employed on turning week for nine months at least His employer says he de serves all he gets, as he is the quickest and most reliable worker in the shop, and as a rule turns out three times a many bands as the men working beside him He seems to be a super-boy also in a physical sense for he stands 5 ft 91% in. in height and weighs 11 stone. Shell turning appears to be the best paying job in the munitions shops, and many shell turners and steel workers paid on piece rates earn from £9 to £14 a week, and I team who pays between £50 and £75 a year in income tax have heard of a cutler running a THE IRON 80] AGE Some working cutler ure 1id to be earning more t the employers The other side of the situation is following from the same source: Very large sun ire con vorkmet! hon week where the father and sey i ons and daughter engaged on munition worl \ I ! ther thousands of capable workmer nt countrys } ! fi cially losers rather than gainers 1 t} wal