The Iron Age 1926-05-20: Vol 117 Iss 20

For Conte ns ond News Diget tern to Genie with the orang THE IRON AcE More industrial buildings of the ~ truly permanent type are covered with | FEDERAL CEMENT TILE ROOFS than with any other ate vee erie Sopa company THE IRON AGE May 20, 1926 In determining the type of by-product oven to be built, the iron and steel company must consider not only present requirements of coke and gas, but possible future require- ments, especially the amount of gas that will be required. THE BECKER TYPE COMBINATION COKE AND GAS OVEN which can be heated with coke oven gas, producer gas, blast furnace gas or blue water gas, is designed to take care of present and future demands for gas. That the iron and steel industry recognizes the advantages of this oven is demonstrated by the fact that virtually all of the by-prod- uct ovens contracted for in the past three years have been of this design. THE IRON ACE New York, May 20, 1926 ESTABLISHED 1855 VOL. 117, No. 20 Better Volume with Fewer Men Compensation by “Pay Unit” System Results in Higher Efficiency—Inventory Control a Feature ATERIAL reduction in man-power, increase in Mi the volume of output and decided improvement in the morale of employees have resulted at the plant of the Marmon Motor Car Co., Indianapolis, from a recent revision of production methods and from the inauguration of a “pay unit” system for compensating employees. The change in methods of production in- cludes the arrangement of manufacturing equipment in parallel lines at right angles to the line of assembly, which permits all material to enter one side of the plant by means of a single delivery aisle. In this way the circuitous routing of material is avoided. Stock piles at the head of the machine lines have GeUNNTN OU eMa Tee CU UEUUONSOReOONTADeaConnoaNeReOCeseTEaMnRRERS noRAE NNN OVADROOELLLOGAROOGRSLDONAOGOODOAEOD IONE UDGeUDOEEELONaneROCSOLOORHODALEDUGnenUORDLA‘entiUnDELEEODONOLEDOOODEN SOU RNOCHDOtHDECEEOELELOONROONRoNOECANN: SLPRAEUENNNOLANAOOUNDAONESHAONDOOCEOU ONCE Deas CHECRE CERO ONS DONDOROENLOUNaN EOE ON SHO Ote: been reduced to a minimum. They are visible and so grouped that they can be checked at any time. An abnormally large accumulation or a shrinkage below a safe level is noticeable almost immediately. Thus in- ventory taking has been simplified, so that a complete survey of materials can be made in half a day. Machines in each department are grouped as closely together as possible in sequential relation. No workers nor mechanical conveyors are employed to deliver ma- terial from one operator to the next. Instead, the man at the beginning of the line goes to the stock pile and gets what he needs, his time being figured in the cost of production. After his machining work is com- In This General View of the Machine Shop Will Be Noted the Proximity of Materials in Process to the Machines Working on Them. This is the starting end of several rows of machines through which the parts pass in straight lines, thus conserving handling labor and time and cutting down the number of employees MIM 1405 1406 pleted, he places the material within reach of the next operator. Naturally, with such an arrangement, pro- duction has been so scheduled that material progresses through the department at a rate which has been de- termined only after long study. In fact, sub-assem- blies, inspections and in some cases the finishing opera- tions are introduced into the manufacturing sequence. The proximity of machines in itseif has permitted the cutting down of the number of employees. For example, there are 37 machine tools in the main bear- ings department; they are operated by eight men. All machines are single-purpose tools, with the exception of the automatics. The company has found it profit- able to limit the function of a machine to one operation and to allow it to stand idle at times, rather than to widen the scope of its work in an effort to keep it in use constantly. Experiments in adapting a certain machine to a I aoe oe Ingersoll Miller at Work on a Gang Set-Up in the Marmon Plant. THE IRON AGE May 20, 1926 heat-treating operations are performed before material is delivered to the shop. The location of the heat- treating department at the entrance to the plant is advantageous. New Arrangement for Paying Men While the methods already cited have been im- portant factors in increasing the efficiency of the plant and in lowering production costs, the unique feature is the plan for paying employees. However, it is so interwoven with the entire system of plant manage- ment that an exposition of the plan involves a descrip- tion of the latter. The “pay unit” system is based upon the idea that the efforts of workmen should be directed toward the ultimate object of turning out a complete automobile, not toward merely milling a certain number of crank- case castings each day. Therefore, the worker is com- AOA ERDONERAOERUDONSEDNSADOOAROOONAEDOAAEOORAELOOERGOURAADONEED DARED OOEDOOEEEAUOAELDONELONORDOEAELOESEOUEAODDSABONAUDUNAGLEDESEAOEGGHONG OOOEDOOTONOHOOAEDAOERDOOEADLAEDOD GENT LOFOULOARODURAUDOGEDERNERDONOELOONAUDNONBOOEOEDONNGYNOARROOEOEOREA BOGIES The general design is like that of a planer, with tools operating from a bridge while the heavy bed passes underneath vena vennenntentaensenenecsennnneesenensnanensrseaneecenennecenasannns specific job have been made, to eliminate any unneces- sary employment of labor. The results have proved beneficial in reducing the cost of production. For in- stance, the lapping of crankcases is done on a drill, thereby effecting a saving equal to the pay of the eight men needed under the old method. Although there is a receiving and inspection depart- ment at the entrance to the plant, 90 per cent of the raw material is delivered direct to the stock pile at the head of each department. Extra handling and unneces- sary record keeping are therefore eliminated. All de- fective material in a department is placed each day on a salvage bench, where it is inspected by a salvage committee, consisting of representatives of the pur- chasing, inspection and engineering departments, the head of the salvage department and the foreman of the department visited. If the material fails to attain the proper standard, it is either returned to the maker or sent back to the shop to be repaired. To prevent any unnecessary hauling, practically all HUHENOUEREINERUEEEEOOEESUAERUOUEEDDECUEDOOEOEDURED EOURROGOERIDONEOTINSDOOAEDLOGELICETONAAREDREROLVERDOTROEODENRE OOO EDDENAUODEL DOODSLOCICOLAUTEOLONSCLLUDEGUDAERSHONEDOOOERDONELEDUOELDONROUOONODAONADOONEDDODEEHOGDODENEED DOSED UONAUONeReDoeeRDOOAEEOREROLONEEDOGENOLDONEDONELOOOORNONSGHORCERLOORAOONERDOSEROOEEONSE. pensated for his proportionate part in the cost of a completed pay unit which, for convenience, is a chassis or a motor instead of a finished automobile. To simplify the method of payment and to create a sense of group responsibility, the pay unit consists of an entire group. For example, the steering gear group constitutes a single pay unit. The individual employee is interested not only in his particular job, but also in the completion of the greatest possible number of steer- ing gears, because it is on the latter basis that he is compensated. All those involved in work in a single group or unit are paid in a group and are collectively responsible for the satisfactory character of their work. Foremen have become group leaders instead of bosses. Their purpose is to see that the proper num- ber of units is finished with a maximum amount of efficiency each day. Upon the completion of these units depends the group’s pay. Hence the foreman, in effect, is safeguarding the welfare of his men as well as acting as a supervisor for the company. oe May 20, 1926 THE IRON AGE 1407 eee SOUUUNUDUNEEOONEEHDOSDOOERLENODEAOEEOOUREOEUELONONOLONGUDAOOLOOGBDDOEROOODODOONNDEGOLONONLUDONRUDOELAGEEDLAEOOLENGEDSSNSUORELOOEOOOUNEOOGEDOONEDOOOELEDONOUOLADDORRDOOONDOEOOOUUSULODOULALEEDOOREOONEN GOES OOOSENDERODOSEOOUENEDORELEDEROOUELOGUBODONLOASUSLGONOOISED DONO OO OEAOOUELLONSLONEGLOLLODOOEEUDSOEGIOGDLANNLLGORDLOORDINCRDAGEOODERDOOAELOONDEDCODOEONOSOGRODONOOOUCNOCSRODERROONONOOD Dynamometer Test Room, Where Completed Engines Show Their Power sernenennenennsonne eessenenenny teenie OPEDOONEOONEDD OURO LANDOCUNOEUOOUDOONODANNORUDOCEUNEOAHOEREOOOROANOEOOOReEAOOOODONSaOENEDOUEOAECONONORHONOE Each pay unit is responsible for the perfection of the work which it produces. If upon inspection a part is found to be defective, it is returned to the unit from which it has come and is repaired, the men receiving no pay for the repair work. If it is necessary to send the part to another unit, the repair expense is charged to the unit which produced it originally. Furthermore, if the part is so defective that it is a total loss, the pay unit is penalized by failing to receive compensa- tion for its labor. Unless there is an even flow of material through the plant the possibility of a temporary suspension of susvecupveneennencienacnaneonensonsnsnenenennenveuncnsenneeneny ensue activities in certain pay units and in entire departments is great. The slowness of one unit in turning out the required number of parts, or carelessness which results in the rejection of parts when inspected, are factors which have been almost entirely eliminated, because each employee now takes pride in his work and also realizes that laxity upon his part will bring upon him the disfavor and even the condemnation of his fellow workmen. Keeps the Men on Their Toes The average efficiency of each worker has increased under the new plan. The employees in each group were euvennunensceesenenrsonensaney toveonenenennenes Lapping Crankcase on a Drill Press, Thereby Effecting a Saving Equal to the Pay of Eight Men Needed Under the Old Method Wren SOUHUULEDOGevenenennanenegennesoneneceneitccenenenusnsneoooesensosetenanecennsssovescevaseoeenecuveuenncsanesenenenensunsenscnenanscsvannenscocenessatsnecenersrereeuenensvnvenennenenernenonecsasusenssnueoustnssninanuvensunsnnvonevoursveneceerapersneneensneveragesnaueveusenveasepensveenssannsucsessvaveneaseonneesupecenensessusstcensnevesneseveenenesssseneoroeneeseeenese® Heat Treating Department, With Furnaces at Left materials and parts in eager to have companions capable of maintaining a high standard in their daily duties. They were intol- erant of the man who lagged on the job or who was not equal to the task assigned him. Sometimes the members of a group would suggest to the factory super- intendent that their job could be done by 14 instead of 15 men. They then would intimate that a certain man, not doing his share, should be dismissed. Of course, under such circumstances, rigid super- vision had to be exercised to see that that particular employee was not being “railroaded” out of the shop by those who had taken a dislike to him. However, it was discovered that in most cases the judgment of the men was correct and that they quickly had spotted the shirker or the inefficient. Thus, each man, perhaps unconsciously, became the personal representative of the management to that his fellow workers per- formed efficiently the tasks for which they were being paid. Installation of the new “pay unit” system and the rearrangement of the plant have resulted in many practical economies. Instead of 120 stock clerks there are now 30. Consolidation of the tool crib and tool room stores has dispensed with two men. Other minor employees have been eliminated. see Power Transmission by Belts Capacity as Affected by Angularity of Drive— Horizontal Position Better Than Vertical Experiments made in the laboratories of Cornell University, Ithaca, N. Y., by R. F. Jones, research en- gineer, on behalf of the Leather Belting Exchange, 119 South Fourth Street, Philadelphia, are reported in a pamphlet just issued. This report covers determina- tion of the relative power transmitting capacity of belts on vertical, angular and horizontal drive. It was found that the vertical belt transmitted about 12 per cent less power than the horizontal under average con- ditions. The percentage difference varies with the dis- tance between centers. A given increase in tension in- erases the capacity of a vertical belt more than of a horizontal belt. A vertical belt is thus more sensitive to tension, and ought to be tightened oftener to main- tain uniform capacity. At high tensions vertical, angular and horizontal THE IRON and Tools and Testing Instruments at Right. process are May 20, 1926 AGE Raw handled here PE Approximately 40 factory trucks, formerly in use, have become unnecessary because of the condensation of manufacturing operations into one plant. The work of the time office is but a fraction of what it formerly was, now that each pay unit is compensated in a lump sum. Moreover, the workers themselves, by keeping a close check on their fellow employees, have cut non- productive labor down to a minimum. They take pride in caring for their equipment and in keeping the shop clean, thereby removing the necessity for a large corps of sweepers and other laborers. The adaptation of certain machine tools to certain kinds of work has been another important factor in reducing the number of employees and in increasing output. Among the most beneficial effects has been the changed attitude of the workers. No longer are their interests centered in the narrow confines of their own jobs. They now have a proprietary feeling, kindled by the sense of responsibility which is theirs under the pay unit system. A premium has been placed upon initiative, ability and ‘the exertion of physical effort. They have a real conception of their part in producing a finished automobile and of the responsibility which the management has confided in them. drives perform more nearly alike; at low tensions they differ widely in transmitting capacity. The capacity for transmitting power decreases progressively as angles above the horizontal are increased above 45 deg. Between 45 deg. and horizontal there is practically no difference, except at low tensions, when the horizontal is better. Using the tight side of the belt as the underside gives about 12 per cent more power on a drive at 45 deg. angle, and about 6 per cent more power on a 67%- deg. angle, under average operating conditions. Domestic sales of oak leather belting in April are reported by the Leather Belting Exchange at 359,298 lb., valued at $609,369, or $1.70 per lb. This shows a sharp drop from March sales of 397,207 lb., valued at $678,828, or $1.71 per lb. It is considerably lower, also, than the total for April, 1925, at 380,443 lb., valued at $663,493, or $1.74 per lb. The reports represent about 60 per cent of the total product. Improving Low-Grade Iron Ores Beneficiation of Lake Superior and Minnesota Ores Important—Chromium Plating, Welding and Aluminum Bronze Also Discussed at Chemical Equipment Exhibition HAT the future of the iron ore supply of the Lake Superior district depends on the develop- ment of processes by which a tremendous tonnage of low-grade ore can be beneficiated economically to take the place of high-grade ore when the supply of the latter is exhausted, was discussed in two papers presented at an iron ore session, one of several tech- nical meetings held by the Associated Technical So- ceties of Cleveland, May 10 to 15, in connection with the second chemical equipment and process engineering exposition held by the Association of Chemical Equip- ment Manufacturers, Inc. The speakers pointed out that there have been important developments in meth- ods of ore beneficiation the past few years, but they indicated that the economical preparation of low-grade reserves sufficient, perhaps, to last for centuries, con- verting them into merchantable ore, is still an unsolved problem. Attention was called to the large amount of research work in the treatment of lean ore that is now being conducted, and some of the interesting results obtained in experiment stations were outlined. Technical sessions of interest to the iron and steel industry included, in addition to the one on ore, a session on corrosion and a part session on welding. Beneficiation of Lean Iron Ores ¢sfTVHE Economic Aspects of Lake Superior Iron Ore Beneficiation” was discussed in a paper by M. C. Lake, geologist M. A. Hanna Co., Cleveland. Mr. Lake was unable to be present and his paper was read by Prof. A. T. Sweet of the Michigan School of Mines. Mr. Lake’s paper gave data showing the depreciation of Lake Superior ore reserves and outlined what has been done in the way of beneficiation. He said that if the demand for Lake Superior ore continues to increase as it has since 1900, which is not expected by many, that district must produce 75,000,000 tons annually by 1944. If, however, the demand settles down to the average of the past 10 years, the future requirements will average 53,000,000 tons per year. The reserves of high-grade ore in the Lake Superior district are insufficient to maintain indefinitely a production equal to the rate of recent demand, unless new deposits are developed. On the subject of beneficiation, Mr. Lake said that the past 10 years have seen an important development in the methods of beneficiation. In Minnesota 9.1 per cent of the ore was beneficiated in 1919, 24.4 per cent in 1924 and 35 per cent in 1925. Of 7,706,000 tons beneficiated in 1924, 4,852,000 tons was washed and 2,375,000 was crushed and screened. This district has a large tonnage of loose sandy ores susceptible to low cost methods of beneficiation. At present the only beneficiation in Michigan is by crushing and by picking rock and lean ore from stock piles. Several attempts at beneficiation on a commercial scale have been made in Michigan and Wisconsin, but none are operating at present. There is a tremendous reserve of low-grade ore in the Lake Superior district averaging about 35 per cent iron, none of which can be marketed today at a profit, and the extent of its ultimate utilization will depend on how much the customers can afford to pay for this ore. It is still to be determined whether the highest grade of lean ore, which can be mined cheaply from open pits, can be beneficiated cheaply and in competi- tion with better ores. The estimate of the amount available for open pit mining is 12,206,000,000 tons. If 50 per cent of this is excluded because of adverse factors, there is still available 6,000,000,000 tons aver- aging over 35 per cent iron that could be mined by open pit methods and, if it could be concentrated in a ratio of two to one, it would provide 3,000,000,000 tons of iron or concentrates and greatly extend the life of the Lake Superior district. There is a large deposit of titaniferous magnetite in Minnesota which may some time be an important 1409 source of iron ore, the separation of which would have to be done by some chemical or metallurgical process. The plant at Babbit, Minn., for treating low-grade magnetic ore, of which large tonnages are available, is idle, because with the cost of beneficiation it cannot compete with high-grade ores at present prices. Mr. Lake discussed the work that has been undertaken at state expense to investigate the beneficiation of lean ores. The Michigan College of Mines will conduct a research on the beneficiation of non-magnetic ores as well as high-grade ores containing obnoxious metals such as sulphur. Treating Low-Grade Lake Superior Ores The future importance of the Lake Superior ore district, according to the speaker, will depend upon the development of processes which can treat low-grade ores profitably and sell them at a low cost per unit. If the Lake Superior district is to continue to market its ore at a profit, it must meet the rising costs and spend large sums for exploration and development of processes of beneficiation, said the speaker. The eco- nomic aspect of the situation requires an investigation to determine how much can be spent on Lake Superior ore beneficiation and bring a profit to the producer. The problem of the future supply of Lake Superior ore cannot be dismissed by the optimistic statement that, when the high-grade reserves are exhausted and the lower grade ores are needed, the latter will be beneficiated. W. G. Swart, mining and metallurgical engineer, Duluth, said that the probable ore reserve of the Lake Superior district is 2,500,000,000 tons, or a 50-year supply, and the assured supply is 1,500,000,000 tons, or sufficient for 30 years. He showed charts of the production curve of 11 exhausted mines in the Mesabi district. The peak production in that district in his opinion would probably be in 1940 to 1944, after which there would be a steady decline. Twenty-two washing and concentrating plants in the Mesabi district indi- cated the tendency toward beneficiation. He pointed out that some blast furnaces in making production records use high-grade Old Range ores and concentrates and another used sintered ore. Washing, in his opin- ion, is the most important of the beneficiation methods He predicted an increase in the use of the jigging process which at the start was more likely to be sup- (Continued on page 1474) The Tunnel Is Open on the Sides to 14 In. Above the Floor, the Tops of the Cars Forming the Bottom of the Kiln, and a Pit Is Provided the Full Length of the Track. Air cir- culates around the car wheels, which are thus kept cool, and repairs can be made beneath the cars while in the kiln and without any interruption in operations. Burner outlets show on each side. This view of the kiln was taken from the charging end. a new design for annealing malleable castings was placed in operation early in April by the Northwestern Malleable Iron Co., Milwaukee. This furnace is of the open fire or semi-muffled type, in this respect differing from other tunnel kiln annealing fur- naces, which are of the fully muffled type. The furnace was designed and built by Holcroft & Co., Detroit. An outstanding feature of this furnace is in the design of the tunnel, which, instead of being built solid from the floor, is open the full length on both sides from the bottom of the sand seal to the floor level. The car tops form the bottom of the kiln. The sand seal extends the full length of the kiln on each side. The side of the kiln rests on girder and plate mem- bers extending above the floor, leaving a 14-in. open space along both sides of the kiln extending down to the floor. This permits a free circulation of air under the cars, so that the wheels and bearings are exposed to the atmosphere and there is no need of water or air-cooling pipes. In addition to providing for the circulation of air under the kiln, a pit with openings at both ends extends the length of the kiln beneath the car track. This permits access to the bottom of the cars, so that bear- ings or wheels can be replaced or other repairs made to the cars without shutting down or interfering in any way with the operation of the kiln. An axle can be jacked up and repairs completed before the time comes for the car to be moved along the track by the charge of another car into the kiln. The cars are well in- sulated and, with the air circulation beneath the kiln, it is stated that the temperature of the car bearings never exceeds 120 deg. Fahr. Keeping the bearings ; TUNNEL-TYPE continuous annealing furnace of 1410 Unusual Tunnel Annealing Furnace Car-Type Continuous Kiln 210 Ft. Long Anneals 28 Tons per Day— Runs on 120-Hr. Cycle comparatively cool is expected to prevent much bearing trouble. This kiln was designed for annealing 25 tons of castings per day. Other tunnel-type continuous an- nealing furnaces have been built with considerably larger capacity, but the builder of this furnace was of the opinion that a kiln of 25 tons capacity would be more practical than a larger kiln that perhaps could not be operating at capacity except during periods of peak production. While designed for a daily capacity of 25 tons, its output since its operation started has averaged 28.8 net tons of good castings. Its fuel con- sumption has been 2600 cu. ft. of gas per gross ton of iron. Contrary to the rather common experience when equipment of a new design is placed in operation, it is stated that no troubles have developed in the operation of the kiln, and that it has turned out good iron from the start. The kiln is used largely for annealing mis- cellaneous railroad car castings and rear axle housings for automobiles. The over-all length of the kiln is 210 ft., the length of the kiln itself being 180 ft. At each end is a vesti- bule through which cars are charged and discharged. The height of the tunnel is 7 ft. 6 in. above the car top. The tunnel is divided into a 20-ft. preheating zone, a 75-ft. heating and soaking zone, and an 85-ft. cooling zone. The tunnel is built of fire brick and insulated brick and is entirely inclosed in a structural steel I-beam and plate frame. The pit beneath the tunnel is 6 ft. deep and 3 ft. 6 in wide and has concrete walls and floor. Above the pit are 6-in. channel cross ties, at a level with the top of the track rails. The outlet flues are May 20, 1926 THE IRON AGE Top of the Kiln, Showing Piping From the Main Supply Line.to Manifold and Automatically Controlling Valve for Each Manifold located near the charging end, all products of bustion passing up through a stack at that end. The cars have structural steel sub-structures with cast iron tops and a superstructure of fire clay blocks and insulating brick. They are approximately 7 ft. wide, 6 ft. long and 3 ft. high. The wheels have roller bearings. The track gage is 4 ft. 2% in. com- Operation of Furnace No packing is used, the castings being placed in the pots loose. The pots are of standard design, 20 in. high, and have trunnions at two diagonally opposite corners to permit lifting with a crane. The average weight of the castings placed in each pot is 400 lb. A car is loaded with 24 pots in six stacks, four pots high. Car Entering the Kiln at Charging End, Being Pushed In by a Ram. (Above) The vestibule door is left raised to show the operation. At right, the Oilgear ram equipment. The horizontal cylinder operates the car; the vertical cylinder, the door between vestibule and kiln The loaded car weighs about 22 tons, of which 5 tons is in castings. A loading and unloading track extends along one side of the kiln and pots are handled with a 3-ton e'ectric traveling crane built by the Harnischfeger Corporation, Milwaukee. There is a short transfer track at each end, by means of which a Fordson tractor moves cars outside the kiln. Used for both pulling and pushing cars, the tractor has a steel plate bumper at the front end, which permits its use for pushing. Before entering the kiln the cars pass through a height gage conforming to the clearance inside the tunnel, to avoid danger of cars being loaded higher than the top of the kiln. After a car is pushed into the vestibule the rolling curtain vestibule door is closed. The door in the kiln then is opened and the car is pushed into the kiln by a hydraulic-type ram supplied by the Oilgear Co., Mil- waukee. A car being pushed into the tunnel pushes the other cars along. A kicker cylinder under the track provided near the discharge end, pushes the end car out onto the transfer, thus doing away with the necessity of using pinch bars. The Oilgear system is used also for operating the charging and discharging doors. Temperature at the charging door, in the pre- heating zone, is 650 deg. Fahr. This comes up to a maximum of 1700 deg. in the soaking zone and at the discharge end of the cooling zone it is approximately 900 deg. The first manifold, starting at the charging end, is set for 1500 deg., the second for 1650 deg., and the last two each for 1700 deg. Temperature controls are all located in the heating and soaking THE IRON In the Pit, Showing Workman Standing Beneath Cars. This picture shows also the kick-off used in pushing cars from the kiln at the discharge end zones. Actual readings of the temperature of the iron inside the pots can be made with a portable pyrometer. While the kiln is being operated on a 120-hr. cycle, there is a possibility that the length of the cycle will be reduced. Although designed for charging five cars a day, six cars are being charged in the kiln daily— one every 4 hr. Forty-eight cars are used, of which 30 are in the kiln and 18 are on the loading and man . ~~ | AGE May 20, 1926 unloading line. Of those in the kiln, three are in the preheating zone, 13 in the holding zone and 14 in the cooling zone. The operating schedule makes it pos- sible to run the kiln over a three-day layoff of the loading crew. One operator then looks after the kiln and all auxiliary equipment. The furnace is fired with 535 B.t.u. gas, supplied by the “city gas plant, which is taken at the line pressure of 2% to 3 oz. The gas is compressed to 10 lb. per sq. in., two Ingersol]-Rand compressors being installed, each with a capacity of 8500 cu. ft. per hr. These are driven by two 15-hp. motors so connected that either motor can drive either com- pressor. Control of Gas and Temperature Air is inspirated by the pressure of the gas, making it unnecessary to supply air under pressure to aid ‘in combustion. Another advantage claimed for the use of high-pressure gas is the ease of control, there being only gas, instead of both gas and air, to control. High- pressure gas also permits the use of smaller pipes for gas lines and it is stated that there is less variation in the pressure throughout the system than with gas used at low pressure. From the compressor the gas passes into a receiv- ing tank in which a 15-lb. pressure is made and an Emco regulating valve is provided which automati- cally holds the pressure at 10 lb. on the feed line to the burners. The gas feed line, 3 in. in diameter, runs along the center line at the top of the kiln. The distance from the compressor room to the first mani- fold is 300 ft. Four manifolds are fitted, each feeding 18 burners, nine on each side of the furnace, making a total of 72 high-pressure burners. There is a 2-in. supply line for nine burners of each manifold, these extending down the side of the kiln. The burners used are No. 2 Hyperbo vertical burners, made by the National Ma- chine Co., Chicago. Gas control for each manifold with 18 burners is provided by a Dickson valve and two Globe manifold pressure regulating valves above the kiln. One Globe valve is set at a 7 to 8-lb. pressure, or to supply sufficient gas to maintain a temperature in the kiln in excess of the setting on the control instrument board, and the other is set at a 2 to 3-lb. pressure. When the Dickson valve is closed the gas, instead of passing through the high-pressure valve, is by-passed through the low-pressure valve. The Dickson valve is automatically operated from the instrument room and, by alternately passing the gas through high and a ate a ae } Loading and Unloading Track at the Side of the Kiln, Showing the Charging Cars and Method of Loading by Overhead Traveling Crane. One of the thermocouples in side wall of furnace appears at left, just above the empty car floor May 20, 1926 THE IRON AGE 1413 Instrument Room, Showing Two Six-Point Recorders at Top of Board and Four Controllers for the Dick- son Gas Valves at the Bottom. low-pressure Globe regulating valves, maintains in the furnace the temperature set on the dial of the control instrument in the instrument room. Each manifold has three gages. One is located above the kiln at the Dickson valve and one on each side at the manifold. Thus the kiln has fully automatic temperature con- trol. A pyrometer thermocouple, located at each Dick- son valve, is wired back to a Leeds & Northrup control instrument in the instrument room, which automati- cally maintains the temperatures pre-determined. There are twelve thermocouples in the crown of the kiln, six in the heating zone and six in the cooling zone, connected to two Leeds & Northrup recording instru- ments located on the panel board in the instrument room. These instruments record the temperature at various points in the heating-up, soaking and cooling zones. There are also eight thermocouples in the side wall of the kiln, to register the heat at the level of the bottom annealing pot. In the instrument room is a miniature model of the kiln, showing the location of each car. : An advantage claimed for the semi-muffled type kiln over a fully muffled kiln is lower cost, both of installation and of maintenance, due to elimination of the muffle. It is not claimed that the fuel economy will be more than slightly better in the semi-muffled kiln than in the fully muffled type. Compared with the periodic or box-type annealing furnace, the semi- muffled type is claimed to be superior, because of a better control of temperature in the kiln, resulting in uniformity in product, reducing scale and increas- ing the life of the pots. It is estimated that, with this furnace, it will be possible to get 50 heats from a pot. The semi-muffled kiln, owing to the method of firing, has shown little variation in temperature between the top and bottom of the kiln. Manganiferous Iron Ores in Experimental Blast Furnace The experimental blast furnace maintained by the United States Bureau of Mines, at its North Central experiment station at Minneapolis, has been developed to the point where it is now possible to undertake the solution of special problems. One of these is the effi- cient utilization of the manganiferous iron ores on the Cuyuna range and in other parts of the country. These ores are very important because of the limited supply of domestic manganese reserves. While it is the practice at a number of plants to add small amounts of manganiferous ores to blast furnace mixtures, there is some question as to the practicability of smelting a charge containing 100 per cent of these ores. It is desirable to know whether it is commercially feasible to use these ores, and if so, what grade of metal can be made from them and what type of slags will give the highest recovery of manganese. More alumina occur in these ores than in straight Lake iron ores. This fact raises a question regarding the smelt- ing of these ores. There has been considerable Miniature kiln board is at left speculation as to the effect of the rather large amounts of combined water present in Cuyuna Range ores. During a recent test, about 136 tons of metal was made by the Bureau of Mines in the course of 34 days’ operation of the experimental blast furnace. This test was designed to cover the important phase of the problem outlined above. The results obtained will be studied to determine whether they are com- plte enough to permit of drawing conclusions as re- gards recommending a commercially feasible process for the utilization of these ores. If this is not pos- sible, further experiments will be made. For the extension of its boiler house necessitated by its new blast furnace, Weirton Steel Co., Weirton, W. Va., has bought eight 900-hp. boilers to take blast- furnace gas and three 725-hp. waste-heat boilers for the open-hearth plant from the Heine Boiler Co. This company will furnish also three 800-hp. gas-fired boil- ers for the Indiana Harbor plant of the Youngstown Sheet & Tube Co. A Loaded Car at the Discharge End Being Hauled on the Transfer From the Vestibule to the Un- loading Track Sheet Metal Problems Discussed Elimination of Light Gages for Roofing—*Master Brand” Sheets Limited in Uses—Low Quality in European Mills facture and distribution of galvanized sheets lighter than No. 28 gage was reported by the sheet metal jobbers and manufacturers attending the fifteenth annual meeting of the Metal Branch of the National Hardware Association of the United States, at the Hotel Gibson, Cincinnati, on May 13 and 14. The three business sessions of the convention were characterized by an earnestness of purpose and a frankness of discussion which evoked much favorable comment from the members. One subject in the fore- ground of consideration was the disposal of second sheets. It was decided to send to each association member a questionnaire, so that the sentiment regard- ing this perplexing question might be crystallized and definite action might be taken. That the sheet metal industry is adhering strictly to the simplification program outlined by the Depart- ment of Commerce at Washington was indicated by re- ports of the various simplification boards functioning as an integral part of the association. For example, results of an inquiry among the members of the asso- ciation show that they favor the further elimination of certain grades of terne plate. Manufacturers already have discontinued the production of 12-lb. terne plate, and a letter is to be mailed to the members of the organization ascertaining their opinion about the elim- ination of 25-lb. and 30-lb. terne plate. SMesctan progress in the elimination of the manu- “Master Brand” Sheets Under Fire ROMOTION of the “Master Brand” galvanized sheet was dwelt upon by several speakers. Its merits were outlined by the manufacturers advertising and producing it, while its disadvantages were set forth by distributers who object to carrying it. In reporting as chairman of the Sheet Steel Board of Review on the elimination of light-gage galvanized sheets for roofing purposes, W. C. Carroll, Inland Steel Co., Chicago, cited the fact that in the six months from October, 1925, to March, 1926, inclusive, 52.5 per cent of the galvanized sheets manufactured by mills in the United States were No. 28 gage or heavier, while 45.5 per cent were No. 29 gage. Only 2 per cent were No. 30 gage or lighter. These figures were computed on the basis of mill reports giving a total of 60,000 tons for the period studied. Two-thirds of that tonnage was produced as formed roofing, the remaining one-third being flat sheets for roofing purposes. Percentage of Light Sheets Made for Roofing No. 28 Gage and Heavier No. 29 Gage No. 30 Gage ——$——$—$__——_— LN, erence Ve came * Flat Flat Flat Sheets Sheets Sheets Formed for Formed for Formed for 1925 Roofing Roofing Roofing Roofing Roofing Roofing Oct. 39.6 57.7 54.0 41.2 6.4 1.1 Nov. 40.4 75.3 52.3 24.5 7.3 0.2 Dec. 61.7 82.6 36.7 17.1 1.6 0.3 1926 Jan. 45.6 74.5 51.5 25.1 2.9 0.4 Feb. 46.9 62.7 51.5 32.5 1.6 4.8 March 45.1 41.2 54.9 57.7 . 1.1 The above report was based on mill production of 60,000 tons of galvanized sheets from October, 1925, to March, 1926, inclusive. Assuming that one-third of the production consisted of flat sheets for roofing purposes and two-thirds of formed roofing, the following facts were ascertained: 52.5 per cent of total production were No. 28 gage or heavier. 45.5 per cent of total production No. 29 gage. 2.0 per cent of total production lighter than No. 29 gage. 1414 The jobbers, in relating the conditions existing in their own territories, testified that in the Atlantic Coast district, from Maine to Maryland, no sheet metal lighter than No. 29 gage was made or distributed in the past year; that in Ohio and Indiana Nos. 29 and 30 gage sheets have constituted less than 20 per cent of the total consumption; that the condition in the North- west is favorable for the gradual elimination of grades lighter than No. 28 gage; and that No. 29 gage still is the prevailing standard in the South, although there has been marked progress in the discontinuance of the practice of marketing No. 30 gage sheets. To the buyer who professes an interest in quality, but who perhaps makes his purchases strictly on a price basis, the “master brand” galvanized sheet is a challenge, said Mr. Carroll, in an address on “The Master Brand.” The specifications which control its manufacture materially affect its cost of production and are so strict that no mill can live up to them with- out absorbing practically the entire extra of $5 a ton. Mr. Carroll emphasized that it is impossible to cover the entire range of purposes for which galvanized sheets can be used with one quality or one weight of coating for any particular gage. Thus the field of usefulness for the “master brand” sheet is limited, because the spelter coating is too heavy to withstand severe or rapid machine operations. Mr. Carroll classified galvanized sheets into four grades. In the first class are those sheets which are to be utilized for flat work or are to be corrugated only. In the second class are the sheets which are to be corrugated and subsequently formed in curving rolls. In this class would be sheets for culverts. Sheets for general forming work, such as cornices and ventilating systems, fall within the third class. In the fourth class are sheets which must be drawn in dies or formed by high-speed machine operations, such as garbage can covers, machine-made conductor pipe, window frames and sashes. The “master brand” sheet, according to Mr. Carroll, will qualify for all of the purposes in the first two classes and for the less severe requirements in the third class. It must not be recom- mended or sold, however, for any of the purposes con- templated under the fourth class. Roofing Business Not What It Used to Be N many localities jobbers and sheet metal contrac- tors have lost their interest in galvanized sheets, partly because of the lack of sufficient profit and partly because of the absence of quality. Whereas the roofing tonnage 20 years ago amounted to from 15 to 20 per cent of the entire sheet production, today it is only 5 per cent of the total. The sheet mills, by means of the master brand and the national advertising which assists in its marketing, are trying to interest the public in sheet steel and to regain for themselves and the jobbers and metal contractors the business which has slipped away in recent years. There is no reason, according to Mr. Carroll, why the same reasoning which applies to the master brand in galvanized sheets cannot be extended to other sheet mill product. He said that, at the fourth annual meet- ing of sheet steel executives at White Sulphur Springs, the recommendation will be made that licenses for the use of the master brand on other sheet products be granted to those who apply, when the analysis of the base metal can be approved and when there is as- surance that the finished product will be fully up to the best commercial standards for the grades in ques- tion. The general impression that the painting of gal- May 20, 1926 vanized sheets is unnecessary is an important miscon- ception, stated Joseph C. Eckel, American Sheet & Tin Plate Co., Pittsburgh, in a paper on “A Few Miscon- ceptions Concerning Galvanized Sheets.” He pointed out that the short life of the zinc coating, when sub- jected to atmospheric exposure, reveals clearly the necessity of painting to obtain the maximum service from the galvanized sheet installations. While the zine coating materially increases the life of the sheet, it is not a permanent protection. Especially in an in- dustrial atmosphere, the life of the coating is rela- tively short. In reply to the query, “When should galvanized sheets be painted?” Mr. Eckel stated that the protec- tive film which forms on the sheet under ordinary at- mospheric conditions mars the bright appearance of the sheet and roughens the surface sufficiently to retain a tightly adherent coating of paint. The change in the THE IRON QUNUUNLULLLONLUEUU ELSTON AGE 1415 distributers when the latter place an order for prime sheets. In this way the possibility of seriously dis- turbing the prime sheet market would be minimized, even though the plan would not remove seconds en- tirely from the channels of regular distribution and sale. It was agreed that this method would result in a wider distribution of seconds. The delegates finally voted to have the secretary canvass the members on this subject. Lack of interest in terne plate has been one of the main reasons why its sales have fallen off so heavily in recent years, said John Follansbee, Follansbee Brothers Co., Pittsburgh, in discussing “How Can We Increase Sales of Terne Plate?” He stated frankly that terne plate is being produced at or below cost and that, unless there is promotion of new uses for this product in the near future, there will be no market for it within 10 years. Since no manufacturer is producing ‘AKERS of sheets do not comprise the industry—they form only the production side of it. Distributers, jobbers and dealers, and fabricators who utilize sheets in their products, form also an inherent part of the industry. of it. They are the selling or distributing side Trade extension work for sheets is formulated for, and is as much in the interest of, distributers and fabricators as for sheet manufacturers. By developing public appreciation of the service value and economy of products and forms of use for which sheets are preeminently valuable, trade extension work will make it easier for fabricators and distributers to sell in growing volume. This quickening and broadening of public interest and demand, however, will manifest itself in larger volume of sale cnly to the extent to which fabricators and distributers render to the consumer the services of supply and all which that implies. From “Accelerating Business,” published by the Trade Extension Committee. 4 VLALEAVENEAUEANOOAEA SAPNA RELA ALAS ENATTTEA appearance of the coating indicates the proper time for the application of paint. Machine-Coated Sheets More Uniform Than Hand- Dipped NOTHER noteworthy misconception, said Mr. Eckel, is the impression that the old hand-dipped galvanized sheets were superior to the modern gal- vanized sheets of the same weight of coating. He pointed out that the life of the sheet as a whole de- pends upon the part carrying the least coating; that, even under the most modern methods, it is impossible to obtain a uniform coating; and that those who have spent their lives in galvanizing work do not hesitate to say that the modern machine-coated sheets carry a much more nearly uniform coating than the old hand- dipped sheets. Mr. Eckel directed attention to the widespread opinion that galvanized sheet manufacturers, to re- duce costs, are responsible for making sheets with a lighter coating than was formerly used. He said that this is a misconception. The change to lighter coat- ings has been brought about by the direct solicitation of the consumer, who has demanded forming properties with relatively little regard for resistance to corro- sion. In fact, the sheet manufacturers have been obliged to supply material for individual needs, and, where light coatings are required, the rate of produc- tion is retarded to such an extent that there is little if any monetary advantage. Another misconception is the opinion that because of galvanizing the base metal is unimportant. The zine does not provide a permanent protective coating and, should it become impaired, the necessity for select- ing the most rust-resisting steel base is of the utmost value, Getting Rid of Seconds ISCUSSION of “Disposal of Seconds” provoked con- siderable comment and led to the suggestion by L. D. Mercer, United Alloy Steel Corporation, Canton, Ohio, that the mills, instead of segregating second Sheets, should allot a certain percentage of them to rt ——— CUUUUUASAAANASAALT ESATA ! ! tt 1 more than 100,009 boxes annually, it is obviously im- possible for him to expend much money in promoting it. F. M. Fuller, American Sheet & Tin Plate Co., Pittsburgh, said that his company has been on the verge of discontinuing the manufacture of terne plate. Mr. Follansbee announced that within a short time his company probably will be making only two grades, an ordinary grade and a high-quality grade. European Quality Poor HAT American sheet manufacturers are producing material far superior to that in other countries was the contention of Charles R. Hook, vice-president and general manager American Rolling Mill Co., Middle- town, Ohio, in an address on “Present Conditions in the Steel Industry.” He told of his recent trip abroad and of the effort of French manufacturers to bring their plants up to the production standards of Ameri- can mills. The quality of the foreign product, how- ever, is poor. In one mill, according to Mr. Hook, 90 per cent of the material accepted as prime sheets would have been rejected in this country and stamped as sec- onds. He urged the members of the association to assist in bringing the sheet metal contractor to a realization of his responsibility to help in developing new markets and in regaining old business which has been lost in recent years. Mr. Hook pointed to the metal house as the out- standing development of the year in the steel industry and quoted the recent prediction of THE IRON AGE that the construction of metal houses will increase the consumption of steel heavily if the industry is awake to its opportunity and makes the best of an unusually favorable situation. Competition Is with Other Materials HERE is an opportunity for the sheet metal con- tractor to become a specialist in sheet metal and all of the products made from it, provided that he familiarizes himself sufficiently with the sales advan- tages of sheet metal over other materials and builds up a quality business, said J. J. Rockwell, president Crosby- 1416 Chicago, Inc., Chicago, in an address on “Recent De- velopments in Connection with the Work of the Sheet Steel Trade Extension Committee.” The distributer has the same obligation to his customer that the sheet mill has to the distributer, and the jobbers’ salesmen must become the teacher of the sheet metal contractor if the campaign of the Trade Extension Committee is to be successful. The danger to the sheet steel dis- tributer does not lie in the competition of his fellow jobber, but in the competition of those selling other material for the same purpose. A plan for compensating salesme