The Iron Age 1927-01-27: Vol 119 Iss 4

ESTABLISHED 1855 THE IRON AGE New York, January 27, 1927 VOL. 119, No. 4 Goodwill Is Steel Company Aim Comprehensive Plan of Employer-Employee Co- operation Has Been Effectively Worked Out in Commonwealth Plant at Granite City, II. BY BURNHAM FINNEY* capital and labor in the United States has been a subject of general comment. The industrial field in this country has been comparatively free of late from serious friction between employers and employees. Undoubtedly high wages and the high standards of living have been important factors contributing to such a favorable condition. Another explanation, how- ever, is to be found in the close personal contact be- tween industrial executives and their workmen, in the protective measures installed in plants to insure safety for the men employed there, in the expenditure of large sums of money to educate apprentices and to fit them for efficient service, and in provisions for the social and economic welfare of workmen in their life outside the walls of the industrial plant. In fact, com- panies have provided their men with as many worth- while things as possible so that they will be happy and ontented with their surroundings and their everyday Te, Those who will take the time to consider for a moment the activities of various industries will find that such programs as that just outlined no longer are incommon; and further investigation will reveal the fact that companies in the iron and steel business were ‘mong the first to recognize the value of setting up a omprehensive plan to enlist the continuous interest ind cooperation of their employees. Today these same mpanies are in the vanguard in extending their con- tact with their workmen into new channels or in widen- ng and deepening channels long since established. c recent years the era of good feeling between Commonwealth Steel Co. Has Comprehensive Plan Numbered among those which have expended large ms of money and inexhaustible energy in building an all-inclusive program designed to fit the par- war needs of its employees and to maintain a dent editor Tue Iron Aog, Cincinnati. mgm NHTSA UAH mmm semen spirit of fellowship and cooperation between them and the executives, is the Commonwealth Steel Co., Granite City, Ill. In its Commonwealth plan, to see that jus- tice and equal opportunity are insured to all, in its school for apprentices and other employees, in its home-building fund, in its Americanization work, in its safety program, and in a multitude of other activities are exemplified some of the fundamental reasons why American industry today is one of the wonders of the world. Team work, as well as the individual responsibility of each workman, is stressed constantly. The com- pany’s attitude is voiced in the following suggestion to new employees: “In our national life we recognize that our liberty and happiness as citizens of the United States depend upon the establishment of laws for the good of all, which we are proud and glad to obey faith- fully. Likewise, in a large industrial plant like ours it is necessary that we all recognize our mutual re- sponsibility, and that we all obey certain rules for the conduct of our work, if we are to have an efficient, well- managed business and are to get the practical results in production, which furnish our livelihood.” The Commonwealth Steel Co. prefaces its fellowship program (it prefers the word fellowship as a warmer word than welfare) by maintaining a just scale of wages, by providing safe and sanitary shop conditions, and by requiring from all superintendents and foremen that every workman shall receive the most considerate treatment. The management feels, and the men doubt- less also feel, that no fellowship program could be carried out without such a basis of sincerity and with- out such evidence of good faith. Plant Divided Into 14 Voting Divisions Preeminent among the activities of the Common- wealth Steel Co. is the successful functioning of the Commonwealth plan. The plant is divided into 14 DUM nT Commonwealth’s ‘Safety Message to Employees HE safety movement as carried out by the Commonwealth Steel Co. is epitomized in the following message addressed to its employees: As we go home this evening to our loved ones, let us be grateful that we have worked today in a safe shop among safe comrades, and let us carry the spirit of safety and fellowship with us into our homes and among our friends, and make of our neighborhood a brotherhood. Cfo lll MID MMT gg crc eens reece eg Rg eR 273 bait 74 THE IRON AGE January 27, 1927 27 on electing three Commonwealth Steel Co., which is to express «.fety. committee. The cfficiency and economy through its cast steel devicos | ttees forn general g in other words, rendering service and building char. ated meeting each month: acter.” entatives of the manage Safety Work An’ Outstanding Feature ’ ent and the senior ) of these commit Outstanding in the industrial relations program at ; nt regulations or .con- the Commonwealth plant is the organized safety work, 4 to each other is which has reduced the number of accidents by 80 to 90 rke it, no matter how per cent. There are 16 safety committees, each of Suggestions or requests first which represents a division within the shop. Each com- ee with his foreman, and the mittee has a delégate for approximately every 20 men, matter with the super- the number of members consequently varying with each , not made, the workman division. The chairmen of these committees constitute nittee. which v onfer with a safety chairmen’s committee, which holds a noon his method does not result in meeting preceded by a dinner once a month to discuss eement, the matter may be presented the safety problems confronting the company: At these th plan representative before the sessions the president, general manager or other éxecu- aie Sih discussion. nsideration and tives are in attendance to give advice and to help in working out plans. The general chairman of this com- he genet nittee a recom- mittee reports regularly on the safety work to the he general manager of the general committee of the Commonwealth plan. He can either put it inte execution or refer All of the delegates on the various safety commit- ent er further consid- tees must come from the ranks of the’ workers, not ( recommendation even the foremen being eligible. The workmen report ( estior referred to the presi- at once either to the foreman, superintendent, or safety ersonally or through his department any unsafe condition existing in their divi- the facts in the case sion. If nothing is done to correct the condition, the ( ry settlemei The Common chairman of the committee in that division reports the ery representative serving matter at the safety chairmen’s committee meeting and or the general commit- appropriate action is taken. be wl free in the performance of his duties Foremen are held strictly responsible for the pre- 1 shall not be discriminated against on ac- vention of unsafe practices. Constant vigilance on en by him in good faith in his their part is urged by the management, which keeps a . careful check of their safety activities. One of the At ecent meeting of the general committee most effective methods of reminding foremen of their ’ ( Howat Vice-President Pflager, General part in promoting safety has been the attaching to f Arthur T. Morey and other plant officials, in their correspondence of small printed messages from 14 committee chairmen, were present. the general manager. For instance, if an accident Reports on safety work and on the commissary were occurs in a certain department, the foreman receives a ide, and Mr. Howard, in reply to a question asked by report of it from the management. Accompanying the ne of the committeemen, outlined business prospects report is a message with the caption, “Accidents are the company. The fact was brought out that previ- caused—they don’t just happen.” The body of the recommendations of the committee had been taken ! I a satisiactory manner. ‘The Commonwealth plan,’ as set forth by the npany, “provides an excellent and practical basis for : putting all (from the office boy to the president) upon | ( me plane. Then as a unit we can work out the problems of the day in such a way that each one feels is a co-worker in the great purpose of the ' message reads: “The attached report is just another re- minder that it is necessary to constantly keep everyone awake to his duty of working safely. Accidents are caused, they don’t just happen.” The message is signed by Arthur T. Morey, general manager. These messages are changed so that seldom does a foreman receive the same one twice. Such reminders of safety and responsibility often MeL ee PL Typical Safety Rules in the Commonwealth Plant r D I Moiten n ( n we gT : : » surf: S ’ 1 n S bef } ; 6. N owed vedges binder € A} bh } j | d frequ A sa be mainta when 1} ; it ' ex th } llowir th } Rails und i ; : " whe row in tt \ : i = : The é ; s and chap ; I y \ d f th Dp ! l ts mus t vided for them. Nails must not be thrown on floor or laid on forms or , explode wher core trucks There are only two 1 or ld places for nails and chaplets—in the t all ba mold or in the box. et e di 11. Core trucks when placed in center gangway in the foundry must ther pet be so set that they provide opening molds to get between them of at least 2 ft. in intil the ‘ every 30-ft. so as to provide. means by the « f escape for men ahead of pouring adle 12. Foremen will see that work in the bays are careful to ust ‘ndles on slings and that the slings re always safely placed on flask s “1 3 a trunnions. In handling flasks a mar eben ‘oft tnd os hall be at each end of flask and on : Ian at air control valve so that the: od ‘ings may be placed on ‘trunnions ureiy ot » build Jib cranes are to be kept back " aga nist foundry columns when not !! to give clear passage to cram . 14. Files should not be carried it t ts, with sharp ends protrud- roc Ke inclosed with the routine correspondence passing m the general manager’s office into the hands of the foremen. Fear Not Emphasized in Safety Work onstructive suggestions are counted upon as the weapons with which to fight against carelessness and against unsafe methods. Therefore, there are no danger signs within the entire plant. The company believes in the positive as against the negative attitude toward all problems. An explanation of this policy was given recently by Mr. Howard, when he stated that “in this safety work we must not use fear, for fearfulness a twin to carelessness. Safety should mean under- standing and protection, and we should work more from the standpoint of avoiding accidents by becoming more carefully efficient. Fear is negative, carefulness s constructive. On this basis safety work should im- ve operating conditions, for carefulness and effi- y go hand in hand.” Safety Rules Published for Each Department Rules for every department have been tabulated long observation, and now are published in book- rm to be given to the employees and especially to listributed among new workmen unfamiliar with y practices at the Commonwealth plant. In the past few years the safety department has noted a contest among all of the 38 divisions of the ) see which unit could go longest without a lost- e accident. At the beginning of the contest a bright bulletin board, with red removable figures visible of the workmen, was posted in each department. appears in large print the number of consecutive that that unit has gone without a lost-time acci- ‘Should an accident occur, however, the depart- t loses its standing and must start all over again. \ugust of this year the pipefitters completed 1000 without a lost-time accident, and still are in the Ir de from the human element in the safety work, s by far the most important factor, the com- nas provided everything possible in the way of tor machinery and for other mechanical devices minate the danger of accidents. Educational Work for Employees upply the educational needs of its employees mpany maintains the Commonwealth school, ccupies the second floor of the Fellowship Club Established 20 years ago, it has been so de- that it now offers a complete high school tech- irse, at the completion of which the student is ‘a high school diploma by the Community High { Granite City. In fact, the work is closely ited with the public school system of Illinois. ‘ion to the high school course, eighth grade THE IRON Vaterial Is Piled in the Yard of the Commonwealth Steel Co. in Orderly Fashion to Prevent Accidents. In the foreground is material piled the wrong way, while the orderly pile in the background is the manner in which it is usually done in the Commonwealth storage yard AGE subjects are taught, and individual instruction is given in arithmetic, elementary and advanced shop mathe- matics, shop sketching and blue print reading, mechan- ics, foundry and machine shop practice, mechanical drawing and electricity. For entrance to the high school course completion of the eighth grade is re- quired but for admission to other classes the only qualification demanded is a desire to learn. The Commonwealth High School has the same re- quirements in recitations and examinations as the Com- munity High School in its regular courses. The four- year course is essentially a preparation for entrance into university engineering departments. The plan of having all of the work for a high school diploma offered in a plant school is a distinct forward movement in education. It places the opportunity for high school training within reach of boys who, for financial or other reasons, have left school thinking that they have lost their chance for an education. Now they learn while they earn. Can Complete High School Course While At Work Because of the fact that the Commonwealth High School is in operation throughout the year, except for a short summer vacation, it is possible for the students, by taking 12 hr. of high school study each week (in- cluding 4 hr. on company time for apprentices), and by receiving credits in manual training for their shop work, to complete the prescribed four-year high school course in approximately four calendar years, at the same time devoting their regular time to their daily jobs in the plant. So far as entrance requirements are concerned, the high school maintains the standards of an accredited high school. All teachers have State high school teach- ers’ “certificates from the Illinois State Board of Edu- cation. The equipment of classrooms and laboratories is modern. The entire cost of the school, including equipment and teachers’ salaries, is assumed by the company. No tuition or fees of any kind are collected from the students. The only expense borne by the high school students is that for their text books. Believing that its apprentices not only should have good character, but also should be men whose minds are trained to do their work intelligently, the company requires full high school credits for apprenticeship. Those who have not attained such qualifications are assisted by means of the high school course. Company officials look upon an apprenticeship in the plant as a scholarship, because it provides a livelihood while a man is learning a trade, and also gives him a chance to finish his education. When apprenticeship vacancies occur, applicants are notified to appear for an examination, consisting of a general questionnaire, in answering which penmanship and grammar are evaluated, and of a test in eighth grade arithmetic and spelling. In addition, they are gan Ute, «Pie RT ro AA LET Aig, Sara ae peg = 9 a nae and are ap- ncreased ac- months is the a . } rress rit! igi 51x ’ ; aol nterva atieitien hanges in the wage scale. oC performance both in | the the grade s made in the latter | vees’ service record. Under tice reaches journeymen’s attern makers’ trade, and in By application and earnest n that standard in a shorter Get-Together Dinners Held Frequently wship and school spirit among the give them the cultural advantage of men discuss subjects of current in- vether meetings and dinners are held . é They are presided over either by r by the student officers of the high ties at the Commonwealth Employees’ Benefit Asso- eligible for membership, er cé of his wages h member with an insur- ness and accidents ex- he course of employ- f state compensation law. We end seven days and 16 weeks, both the membe1 ‘ enefits being graduated ( ekly earnings of the em- e, the company at its own expense ! e and total disability insur- amounts of which range from ling to the length of service. If es the company’s employ, he has the erting the certificate into a life insur | physical examination, paying for it at t { lard rate for his age. The association’s rects board of governors consist ‘ et ilthough a representative of the fficio member Help Furnished in Financing Home Building For those employees who need assistance in finan g or purchase of homes the company has 4 me purchasing fund. Loans upon mort ea per cent interest, the borrowers re he mon col ent monthly in Be f ng an aj ation for such a loar ( | have enough cash to make an than 20 cel of the pur I é ! n ive as much ‘ a promoted Any employee wih ns that organi n has pa his wage educte rom his pay check 1 put ! nt ime in the Granite ( Na | ‘ I ellowship depart I vee’s messenge1 Social Features Not Neglected employees’ organizations wship Club, which occupies Any male « iractel eligible to its ranks Its rease ( rit of fellowship among tl mprove them mentally, moral] j [ Lue imount 20 i mont! i monthl The club’s affairs ar n governors made up of 28 mem : be1 rious departments ul ywwship Club has sent Christmas iy ba It holds an annual Christma entert excursions, picnics, minstrs show r social events have had st ‘ : it has a circulating and referencs libra ts AS¢ isketball and bowling t : have excited interest, while its club house. equipps with a reading room, and a pool room, affords pk Tee 76 THE IRON January 27. AGE 1927 surroundings for its members. The club’s audi rium, now outgrown by the 1000 members, has }. en. croached upon for the use of the school, and the com. pany has promised a new Fellowship building meet the club’s needs. The colored employees have their own fe!) wship club with headquarters in the Pine Street Young Men’s Christian Association in St. Louis. They possess an attractive club room, provided by the company, and i A s PRPS t ay Birr & Workmen Are Taught the Right Ways of. Handling Equipment to Avoid Accidents. The left-hand picture shows the wrong way of using a chain sling, and the right-hand illustration the safer way also enjoy all of the advantages offered by the Young Men’s Christian Association building. Community House for Foreign Employees In cooperation with the residents of Lincoln Place, near the plant, the company has built a community house which renders an important service to the for- eign-born people of that section of Granite City Classes in English and in American citizenship for the men, and classes in English and in sewing for the women, are conducted there. Besides, helpful groups for foreign children of all ages from the kindergarten ip have been established. Here they enjoy good times, and are taught to become intelligent and loyal citizens. The company maintains a commissary department, which includes a restaurant, store and meat shop. In the restaurant wholesome meals are served on the cafeteria plan, while employees can purchase groceries and shop clothing in the store. The commissary also 1 h« as a shoe department which handles workmen’s shoes. In connection with it is a shoe repairing section, needed for the safety requirement of having stout soles on snoes employees, where Commonwealthers may have heir own and their families’ shoes repaired at a con- derable saving. The commissary department is OP- erated witl profit to the company and is supervised : nt advisory committee of workmen from the ‘ nwealth plan and from the Commonwealth Fel- ws { ' Ir quipped dispensary with competent sur- geons in charge, any employee who is injured receives pI pt and careful attention. Modern sanitary locker re available to all of the employees. Monthly Publication Goes to Workers’ Homes ‘he Commonwealther” is the official publication of compat \ regular edition is distributed about every Six weeks, but a “home edition,” forming ® _. lum tor presenting and discussing Commonwea!t) ‘amily affairs” in an intimate way, goes into the home very Commonwealth employee about once a month. seq with each copy of the regular edition—which ye employees, to those from whom the com- January 27, 1927 pany purchases material, to the railroads to which the -ompany sells its products, and to the general public— is a personal letter from President Clarence Howard -alling the attention of the reader to certain features in that particular issue. Service the Fundamental of Business The more familiar one becomes with the activities * the Commonwealth Steel Co. in relation to its em- oloyees, the more one is impressed with the compre- hensiveness and thoroughness of its program. The fundamental reasons for establishing such mutual un- derstanding are best expressed in the company’s own language: “The basic purpose of a business or industry we conceive to be the rendering of service by means of the company’s product, this service combining the intel- ligence as well as the heart and hand of every in- dividual in the enterprise. The successful industry has due regard for the common interests of the parties con- cerned; namely, the public, the customer, the stock- holder, the employee and the management. “In the Commonwealth Steel Co. an opportunity is afforded to render highly constructive service, ex- pressed to the public in helping to make travel safe, and in efficiency and economy for our customers. The high goal of this service is character—expressed in company product, men and community service. “Realizing that cooperation is the true basis of suc- cessful industry, the employer and employee desire the most friendly and cooperative relation, the employer providing just and liberal wages, right working con- ditions, including safety, sanitation and all reasonable conveniences for the employee, and the employee cheer- PERSONNEL PROCEDURE Development of Personality Cited as Important in Preparing Men for Engineering Profession Conscious development of the personality as well as the technical proficiency of the engineering stu- dent was suggested as a duty of the university in pre- paring its graduates for business by Dean A. A. Potter, i the college of engineering of Purdue University, na talk before a conference of personnel managers and college placement officers at the Hotel Pennsyl- vania, New York, Jan. 21. In discussing the general subject of placing the college graduate in business ean Potter told of the work at Purdue of beginning the freshman year to bring out the individuality and personality of the student and of placing such informa- along with other customary material at the dis- | of future employees at the time of the young ns graduation. In stressing this phase of training dean was in accord with other speakers at the invention, representing both the business firm and iniversity, who recognized the danger of academic : ning if possessed to the exclusion of other qualifi- i ‘ons upon entrance into business. ,_ E Ek. Roberts, Westinghouse Electric & Mfg. Co., “ast Pittsburgh, told of the plan used by his company ‘nnually choosing 300 mechanical and electrical “ngineers from the country’s leading technical schools. “ve stated that one-third of the electrical and me- al engineering graduates in the entire country application each year to the Westinghouse com- ‘rom which a comparatively small number must sen for further study in the company’s training at East Pittsburgh. Here each man is given )portunity to work for a time in each of the di- of the organization and later allowed to develop ‘nts in the field for which his particular ability to be best suited. E. Dooley, Standard Oil Co. of New Jersey, particularly upon the policy of his company in ring too much pressure upon a _ prospective ‘ to secure his services. He recognized the at better results were obtained from college es who not only were fitted for the particular work in which they became engaged, but who THE IRON AGE Posters Are Used in the Plant to Remind Workmen of the Dangers of Careless Handling of Materials fully cooperating with the management in producing the highest quality and maximum quantity of output in a safe, willing and economical manner, thus render- ing full and honest service for just compensation. “The highest quality and quantity of production, commensurate with right working conditions and equip- ment, we regard as essential to the success and growth of our mutual interests and to enable us to meet com- petition and contribute to the supremacy of American industry.” felt they preferred this field to any other and con- sequently formed an association of lasting value. At the session on employment tests, O. W. Eshbach, American Telephone & Telegraph Co., New York, stated that his company based its reliance on this pro- cedure largely upon the results of tests given to present employees of the company, taking into consideration, of course, their relative proficiency based upon experi- ence. New employees may thus be placed in the type of work for which their ratings in the company’s test seem to suit them. M. S. Vitales, University of Pennsylvania, told of the considerable progress in the application of employ- ment tests in Europe, and stated that certain cities maintain municipal testing stations available for the use of smaller companies which are unable to afford personnel departments. W. V. Bingham, Personnel Research Federation, New York, discussed the applications for industry of the report on personnel procedure prepared by L. B. Hopkins, president of Wabash College, Crawfordsville, Ind., and before the war head of the personnel bureau of the Lynn, Mass., works, General Electric Co. Mr. Bingham cited the need of colleges and business or- ganizations to coordinate their work in filling the de- mand for university-trained men in business. “Educational Resources of Pittsburgh and the Car- negie Institute of Technology” is the subject of a booklet just issued by the Carnegie Institute of Tech- nology. Facilities of the school are outlined and a list of the plants to which students have access in the greater Pittsburgh area is included, with locations shown on a map of the district. There are many illus- trations. The booklet may be had upon application to the Registrar, Carnegie Institute of Technology, Pittsburgh. The rapidly increasing consumption of aluminum in Italy has caused the Government to undertake an exhaustive study of the aluminum industry with a view to its continued development in that country, accord- ing to a report from Vice-Consul Franklin C. Gowen, Rome, made public by the Department of Commerce, Washington. | New Stack Ranks Among Largest Weirton Blast Furnace Embodies Latest Standards i for Steel Works Service—New Dock Handles Coal Deliveries BY GEORGE F. TEGAN ry ( f the Weirton Steel Co., | h was lighted Nov. 20, 1926 tonnage I ron ear! on the ul present-day require- i { ; What the modern steel! Y what it Is ex- ned by A. E. Maccoun, Edgar Thomson lurnaces Braddock, Pa., a confer- under the auspices of the the Engineers Society of Pittsburgh Nov. 12, 1925. He 700 tons of pig yutput called for a furnace pproximately 21 ft. and a upable of taking 55,000 to 65,000 cu. ft. 1400 deg. Fahr., ves having 360,000 sq. ft. of iron was ex- meter T temperature of f Ther triking similarity between hose of the new Weirton No. 2 furnace It has a rated le ily ron daily. Its hearth diameter bosh diameter, 24 ft., while there ves that serve the furnace a com- irface of 365,600 sa. ft arison is offered with no thought of de- initiative of tne engineering those re- tor the new turnace, but rather to emphasize nstruc n of the stack, which is as large rgest in the country, present-day standards closely observed and that in its design as main and auxiliary equipment there has option of what experience has shown to I I way toward large production. ( ent with the building of the blast furnace ( added to its by-product coking plant, house and boiler plant. It also completed a dock and a harbor for the handling of now received by river from its ited near the Monongahela River above | , The capacity of the coke plant was doubled by the addition of 19 Koppers } ens to the original installation of 37 ovens of mie f The entire project was started and : é than a year, and while no claim of : +} performance commands atten the fact that the work was done with ant operations Furnace Can Produce 1000 Tons Daily the furnace is rated at 800 tons 1000 tons ed regularly over long stretches, just that a daily output of i i f 700 tons or more is being maintained ; in turt t rated daily capacity of 600 tons. : Whe put expected and the stack is so : ' designe t in be driven to exceed its rated 17 capacity without danger, an essential is a hearth at ' { leas 0 1 n diamete1 This furnace has a hearth 21 ft. 6 in. in diameter. The bosh diameter is 24 ft., ; the height of the stack, 92 ft., and the cubical con- } *} fs sieeiait tents about 43,000 cu. ft. The stock line is 17 ft, i The mantle is supported by 12 cast iron There are 12 tuyeres and 12 rows of copper cooling plates below the mantle and eight rows above. The large bell is 13 ft. in diameter, and the small one 5 ft. 6 in. The yard level is 20 ft. below the center line of the iron notch. The furnace is served by a double skip, electrically operated by a Lidgerwood liameter. columns. hoist, and is equipped with a McKee revolving dis- tributer and a Brosius mud gun and cinder notch stopper. The lining took 656,000 9-in. equivalent Olive Hill brick, furnished by the General Refractories Co The layout permits direct pouring into 65-ton ladles, which usually go to the mixer in the open-hearth plant. However, the ladles, which were furnished by the Wil- liam B. Pollock Co., are of the short-pouring type, so that iron may be delivered directly to the pig casting machine when the open-hearth department is not taking the hot metal. The cinder is granulated in a pit lying parallel to the cast house or is run into ladles for disposal on the slag dump; the disposal of slag, therefore, is possible in either crushed or granulated form. The stoves, four in number, are of the two-pass side-combustion type, 100 ft. high and 25 ft. in diam- eter, with 4%-in. square checker openings in brick 2% in. thick. Each stove has 91,400 sq. ft. of heating surface. No, 4 stove is provided with two hot blast valves and therefore can be operated on either the new furnace or the adjacent No. 1 furnace. The stoves are equipped with Mathesius hot blast valves, Weinel chimney valves and Steinbart gas burners, and use the chimney built for the stoves of No. 1 furnace. Water-Softening Plant Is Largest Ever Built The gas for the catcher and stoves through a dust a secondary whirler and then is cleaned Brassert-type gas washer, the surplus being burned without being washed in the boiler plant. For blowing the furnace an Ingersoll-Rand turbo-blower was installed in the present power house. It has 4 canacity of 70,000 cu. ft. of air per min. and is served by an Elliott barometric-type surface condenser. T° furnish the steam for the added blowing, pumping and turbine equipment, eight 900-hp. four-drum Heine been installed in an addition to the pres- furnace boiler house. These boilers are with Steinbart burners and with Foster bare- tube superheaters, arranged vertically in the wall opp0- site the burners. The extension of the boiler house necessitated the removal of the old water-softening System, and it has been replaced by a new Cochran is, hot-process, water-softening plant, com- plete with feed-water heaters, sedimentation tanks and This plant is the largest ever built of 160,000 gal. per hr. wer house, generating capacity was !"- b the addition of a 7500-kw. turbo-generator with a Wheeler surface passes in a boilers have ent blast equipped continu bolle r feed I and has capacity In the creased by) A \ condenser. storage yard has been built, which and is served by a 10-ton Heyl & Patter- A new ore 900 ft. long son ore bride ige, with a span of 281 ft. 6 in. from leg The bridge 's over-all length of 339 ft. January 27, 1927 ped with automatic rail clamps and anemometer yment to render it inoperative in high winds. A dumper, built by the Alliance Machine Co., is of traveling type and has a capacity to handle 20 n cars per hr. he bin system consists of 19 ore and stone bins, . capacity of 300 tons each, and a double central bin discharging directly into the furnace skips vrizzly coke screens. Fuel that sifts through the ies passes to automatic elevators, which dis- ve onto a separating screen of the shaker type, h segregates the nut coke from the braize. The r is used under boilers. The bins are of rugged | plate construction of suspended type and are ipped with Freyn lift gates, operated by air cylin- lers on the seale car. The latter, furnished by the \tlas Car & Mfg. Co., is of 50 tons capacity. The 49 new coke ovens, which went into operation n Nov. 1, are of 14% in. average width, 12 ft. high ind 40 ft. 8 in. from charging to discharging doors. Each oven will take 13% tons of coal per charge. Ad- litions to the by-product and benzol distilling plant were also built. Coal Is Delivered by River The new unloading dock, which is of reinforced merete construction, is 400 ft. long and 38 ft. above Ra AQ GSS Ae I Dob belie! AG THE IRON AGE full pool elevation. It has been equipped with a Mead- Morrison 4-ton unloading tower, capable of handling 400 tons of coal per hr. Buckets discharge the coal into a 125-ton hopper, from which it is fed to a 36-in. belt conveyor which carries the coal 650 ft. up a bank to a screening and transfer station. This station is so arranged that the coking coal may be delivered di- rectly to the breaker building as run-of-mine coal or may be screened, in which case the lump coal is di- verted to storage and the fines are sent to the coke plant. The system also can be used for handling steam and gas coal, as the screening station is equipped with grizzly screens which separate the coal into two grades, the fines for use under stoker-fired boilers and the lump coal for use in the gas producers and for other purposes. Harbor Protected by Ice Breakers The river for 110 ft. in front of the dock and for a distance léngthwise of 1500 ft. has been dredged to a depth of 14 feet below full stage. Three reinforced concrete ice breakers have been built at the head of the harbor to protect barges and equipment from float- ing ice, timber and debris. Concrete dock walls also have been laid for a loading dock to be built later for river shipments of finished steel products. HenADAGNRONESDUNGHUALNLAINNOUONESGLELELDINERCOONERNDOERTOOOENNAILLL IU 1¢sSRONSMUBENUREC VEAN | NseuN CURE \e4L08 HE Furnace Is 92 Ft. in Height and Has a Cubical Content of 43,000 Cu. Ft. The bosh diameter is 24 ft., and that of the hearth, 21 ft. 6 in. The skip incline is sup- ported by the stack instead of be- ing an independent structure COEPUNDNEEENDONNL EV ONHE HTH TERE ueE rae 279 A ea EP ARES ob SOE. ES es wrt l t | Jinter Meeting of Steel Treaters i ’ ‘r . > ' Centrifugal Casting of Steel and Steel Inclusions Prominent Topics—Normal and Abnormal Steel—Some Hardness Problems 9 .<<fy] sectional meeting of the American Society for Steel A 9 s held Washington. Jan. 19, 20 and 21. According to the well-laid plans of - rton-Balt re chapter, the annual winter sectional meeting at the Hotel Mayflower seve e contributions to technical questions. Though the attendance of < some of these other regional conventions, the enthusiasm and a new process for casting steel centrifugally was a feature g developed marked interest. A paper on the study of inclusions in ition to a vital steel-making problem. This is the first occasion when ( rmed part of the program of a sectional meeting. vexing and elusive problem of “normal” and “abnormal” steel was also a fea- ’s gathering. The contribution from members of the staff of the United States S rds clarified this question to a marked degree. Some problems connected with at I I I s hich the society as a whole is making is reflected in part in our report of rd of director In the following pages there are presented the chief features f the directors’ meeting. Steel Processes—Centrifugal Casting; Inclusi Steel Processes—Centritugal Casting; Inclusions oo nteresting papers were presented at commercial heats of 120 tons. It is stated that two on steel processes. One was devoted of the largest independents have already taken out “Centrifugal Casting of Steel,” con- licenses under the patents covering this process. ! Cammen, consulting engineer, New . z J Yor 1 the other was entitled “Fundamental Re- Investigates Inclusions in Steel Ss Non-Metallic Inclusions in Steel,” the author . . . conan. ; ° = In discussing the subject of fundamental research was Dr. C. H. Herty, Jr., physical chemist, ae d to steel ‘ bot Uni : , in steel manufacture, the second paper devoted to st¢ station, United States Bureau of Mines, r : lems en Pit ae processes, by Doctor Herty, classifies the problems en- countered in the making of steel and points out that ; . . i the fie or é in its manufacture Steel Tubes and Bars Cast Centrifugally che f Id for fund amental research = its : hes ~ is astounding in its magnitude and intricacy. He has With the statement that his paper was the first therefore limited his paper to the consideration of published announcement of the new art of fundamental research which deals primarily with slag- asting steel centrifugally, Mr. Cammen presented at metal reactions, giving particular attention to the cor ength details of the process, displaying formation and elimination of non-metallic inclusions. rts of the machines showing the methods of A brief abstract follows: g es centrifugally as well as the newer art Solid non-metallic inclusions in steel should fall ng bars by this method, which he claims is into the same class with phosphorus, sulphur, carbon destined to affect the entire steel business. A brief manganese and silicon in so far as specifications for t f Mr. Cammen’s paper follows: steel are concerned. There are no more grounds for S t centrifugally in the f f tut making all steel absolutely clean than there are for St ce rifugal n e for oO es ] 1 a demanding that all steel should contain under ¥%.") wo pI sses having nothing in common : a , ; a. } ntrifugal for ] i per cent sulphur Every kind of steel should have 4 oe ae - Se ertain specification on non-metallics, varying Ww! ; ~ ubes is of articular : , ed t ulloys which oe <a the kind of metallic present. One of the mos / A ) bre a aoa “5 important and most fundamental pieces of work '5 Ce ing comes ito co e - : teen: tic 7 ere it} a : therefore, to determine just how solid non-metallics iture is less certain, ¢ 10ugh , ; that it will be f ad 7 nea the properties of steel, with the two factors, >. d a , ; , , nt and type of inclusion, as the major variables ~ “ llets r large tubes, oe ; rl ar five possible sources of non-metallics I irth pr t s is apt to de velop longitudi- s i clay-lined molds suffers fron : N n-metallic matter in or on the scrap al crystallizatio e cost “oN 1] : io j I a] zat I th t N metallic matter in the pig iron. indling is a handicap in the use of _Non-metallics formed when the pig iron }s pa pe goes in details as to th duced into the open hearth, by the — tallurey of steel tube cas > aad ne . he metalloids silicon, manganese, Phos- e 17 . — sating, and » Ss and 1inum, and by the introduction : United States patents on this phur fr the iron. ’ ' 1. Forn on of non-metallic matter when f igal casting of bars Lich eat is worked with ore or pig iron. } W t ; a : : wm Formation of non-metallics when the final Ww I s make billets f sucl iddit , are made with blooming Figures are ; 9 eduction in costs, as compared wit! on-metallies in the finished stee! i f $3.60 to $8.50 per foal In owe five sources depends on the char- ; S rotist . ae tallic, the character of the slag Oe ee en ee the rate of elimination of l yhich is : i i ire that segregation will be tr i t) ae nae _ ’ ed or at least greatly reduced . a ee a as ) now the character of the metal as g 4 ten SCOsity = the steel and by d ed nd machinery capabl handling Ir rd re i re Se rae determine the rate of elimination 27, 1927 OO LEON CAMMEN EMIL GATHMANN metallics a number of fundamental studies are sary. These fall into two classes: (1) studies ¢ will enable us to understand more about the ation of non-metallic inclusions, and (2) the s which will enable us to know more about the ff elimination. Some of the studies under the heading are: (1) equilibrium between slag and |; (2) equilibrium in the metal phase; (3) relative s of deoxidation of various deoxidizers; (4) equi- librium conditions between deoxidation “products; (5) rate of diffusion of FeO from slag to metal; (6) sur- face tension and viscosity relations between the de- oxidation products. The fundamental studies under the second heading are: (1) agglomeration of inclu- sions; (2) surface tension and viscosity relations in slags; (3) viscosity of steel; (4) rate of upward set- tling of inclusions; (5) rate of absorption of inclu- sions by slags. These fundamental studies involve a tremendous amount of work, and. undoubtedly cannot be com- pleted in any short time. However, these studies are ecessary before non-metallic inclusions may be put n the same basis, in so far as our knowledge of them s concerned, as the other elements in steel. ta Discussion on Centrifugal Casting The remarks following Mr. Cammen’s paper empha- sized the interest there is in centrifugal casting of teel. Dr. H. W. Gillett, United States Bureau of Standards, who presided, said that the author pos- sessed both the mechanical experience and the metal- irgical background for solving such a problem. ‘undamentally centrifugal casting is a process in which centrifugal force is substituted for the force of eravity, said G. A. Dornen, Gathmann Engineering Co., Baltimore. As segregation is primarily due to gravity, it will be greater in centrifugal bar casting ‘han in ingot casting, because centrifugal force acts ike gravity and is greater. The same advantages Which are claimed by the author for centrifugal cast- ing could be secured by ordinary methods, provided the pouring of the metal was slow enough. Doctor Gillett ed that the structure and process of formation of trifugally-cast bars ought to be compared with of small ingots. It is well known, he said, that ‘ain prominent defects of large ingots are either ‘nt or less prominently displayed in small ingots. ._,v atious speakers, including Doctor Gillett, Emil mann, W. J. Merten and others, brought up ‘s questions, such as the possibility of segrega- and its control, the use of superheated steel, the ' of pouring, the temperature of the metal, how irs are built up, ete. Pours the Metal Cold as Possible to the matter of superheated steel, Mr. Cammen that steel at that temperature is not used in rocess, but an effort is actually made to cast steel as possible. In his own experimental work, THE IRON AGE AACOLSNEOUOEULTTVOUED CHANEL SSAA OOEELOOEEEO ODES OEREOOETERORIEDOUUEESOONEN ERE EePansENNEENEAIEH UH 18 Authors of Some of the Papers S000N)/TUUENEDOED NN aNLaaDNAOEDDOLAEanO TSUNEO EDERDERDERUEODEOEONDERDUMSDNEDEDN Hoeven teT onder otonEreerorevey VOUUNEUEND *CUDLLNU TASEMECEADS G0) O8URDDELPODEMEAUREONERONDREDOVENDEDELOEDS"URDEDEPEDEEDTD EEN DRE DONFEDNANSL SUNN DEURY CARNORE ONS LOTS ORO ens seneReRRpAREERD J.D. GAT W. J. MERTEN where the metal was melted in 50-ton furnaces, three- quarters of the ladle was poured off into ordinary ingot molds and the metal remaining in the ladle was used in the machine. In his concluding remarks Mr. Cammen laid em- phasis on the fact that segregation is due to the fact that the ability of steel to hold certain impurities in solution decreases with the temperature. This requires, however, sufficient time. In centrifugal bar casting, however, the metal freezes solid some 20 sec. after it leaves the nozzle and, as time is not available, segre- gation will not take place. At the Watertown Arsenal, however, where centrifugal casting conditions are such as to cause a slow cooling of the metal, segregation is not only present but is purposely aggravated. The author admitted that the advantages of centrifugally cast bars could be secured in ordinary casting by suffi- ciently ‘slow pouring, but pointed out that this would be impossible in an ordinary ingot mold, but was actu- ally profitable in a centrifugal machine. Thin Layers of Hot Metal Used Mr. Cammen called attention to the fact that, in centrifugal bar casting, only a very thin layer of metal, about %4 in., may be present at any time in a molten condition. The thickness of the cast bar is, therefore, immaterial so far as contraction cavities are concerned, since these can form only in liquid metal. While Mr. Gathmann claimed that good cast- ings cannot be made from gaseous steel, the author asserted that practically all of his work was done with effervescent sheet steel and yet, except for a thin layer on the innermost surface of the bar, the casting was solid and showed no blowholes. Sheets rolled from bars 1% in. thick proved to be, except as to surface in some cases, as good as those rolled from standard in- gots. It should be remembered, said the author, that centrifugally cast bars are not finished products, but are semi-finished material for rolling. The author stated that work has been begun on a bar casting machine to handle some 12 tons per cast in bars 4 x 12 in. and 13 ft. 9 in. long. Discussion on Inclusions in Steel The discussion of Doctor Herty’s paper brought out one important point—the need of a greater knowledge of colloidal chemistry and its relation to steel making. Doctor Gillett, by way of introduction, stated that the question of non-metallic inclusions is at the founda- tion of many of the serious difficulties at the present time and that a splendid study was being conducted by the author. Is Steel a Colloidal Solution? Is steel largely a colloidal solution and are we not dealing with colloidal phenomena in steel making? : ; } \ } } : 929 THE IRON AGE January 27, 1997 men, New Yor! be explained if be beneficial re- ts, such as sul- loidal. Some steels ments, which we are be bad. The n by shaking Mr. Cammen sald he welcomed Doctor Herty’s investigation as cation that the time has come for us to |; what kind of a solution steel is. ae Both Doctor Gillett and Doctor Herty expr. the conviction that a campaign of education is necessary and that steel makers and steel users must erate with physical and colloidal chemists in solving this problem, one of great importance to the stee| ” try and one little understood. Vormal Steel—Its Contrast With Abnormal rf mal and abnormal! steel absorbed 1. Two papers were urticular phase of heat treatment entitled, “Progress in the Study Abnormal Steel,” under .the joint ssociate physicist, and H. sici United States Bureau of Washington: the other was contributed by lurgical engineer research department, oteel Canton, Ohio, under the title Normal and Abnormal Steel Studied irst paper Messrs. Epstein and Rawdon ( lensed ac int f the t oncrete results ob in the study of normal and abnormal the Bureau of Standards, speculation and this much disputed subject being avoided le The characteristics of the normal d abnormal structure in carburizing and in tool steels trated. It is shown that with ordinary water ng abnormal steel is more prone to give soft ! 1. With more drastic quenching, sodium hydroxide solution, it ompletely prevent the formation of soft wwever, Il ring or in both normal and abnormal steel. In a side light, which should interest the general heat treater, it brought out that quenching in rdinary tap water, which often contains a good deal f air or other gases in solution, is very likely to give spot The e1 try of the hot steel into the water eleases the dissolved gas, bubbles of which cling to the steel and retard the cooling. By boiling the water, i ived gases may be driven off. Experiments in a steel mill indicated that normality and abnormality have their origin in the deoxidation procedure in steel making; in particular, additions of aluminum or ferrovanadium in the mold produce ab- normality The point s stressed that the terms “normal” and “abnormal” are unfortunate in thei onnotation, and should not be considered in the sense ot “good ind “tT Normal or ang ad abnormal simply mean steel of a certain structure, and one or the other may be preferred for different purposes. What Is Normality? Phe ibject of “Normality of Steel,” as discussed Mr. Gat, was treated in part as follows: y I b ff« ] fe i d l by n ype da ta reatn i \ = y a I I is I zed riace itrat scopical appearance of steels under different treat- ments can be directly connected with phenome: crystallization and grain growth. Discussion The discussion of these papers was animated and interesting. The authors of the first paper, Messrs. Epstein and Rawdon, find, said G. L. Kelly, metal- lurgist Edward G. Budd Mfg. Co., Philadelphia, that the oxygen content, as determined by the vacuum fusion method, bears no relation to the normality or ab- normality of steel, while Mr. Gat, in his paper, seems to reach an exactly opposite conclusion, a disagree- ment which will need to be resolved by further work. Much interest attac