Document 996XbOqby5BnDLYBbVXoeZLJD

7 j f I Chicago's Tribune Tower, now a famous landmark in that city, was featured* on the cover of the first issue of LEAD Magazine, published two years after ffie incorporation of Lead Industries Association in 1928. The lead used in the originat construction of the building is still in service today, some 48 years later. 2 Reflections at 50 i* The year 1928 doesn't impact strong on American historv. A young eri^ neer. Herbert Hoover, with a fine rf|, ord of famine relief in Europe afip, W W I. was calmly president. His con stituency was somewhat more restive The Volstead Act was driving a nation to drink. "Driving" in anv rase was the operational word as North Ameriran, took to the liberating road and your own car became a sine qua non in the pursuit of happiness. There is nothing on the record to show that Lead Industries Association, formed in 1928. was the product of these socio-economic pressures. The sprawling industry along the Detroit ' River was, in time, to consume, in bat teries, solder and TEL, nearly % of aa. nual lead production. But that was in j the future of the 50s and 60s. The lead i trade association formed in 1928 was ; concerned pretty much with the objec tives which constitute its charter todav: 1. To collect and publish information relating to the production, distribution, marketing, consumption and use of lead and lead products; 2. To disseminate accurate informa tion regarding lead products and how they best may be used; 3. To develop methods for the im provement of the welfare of those en gaged in the lead industries, or in the use of its product; and for such other purposes as, from time to time, may be of benefit to the lead industries, and in general to promote the serviceability of the lead industries to the community at large. An early list of membership appears in the May 1933 issue of Lead Maga zine. It is worth reproduction here on Page 3. Sic transit galena! A page in the his tory of the mining industry is revealed in this listing; the tides of merger, the finalities of death, depletion, and re organization. Those familiar with ILA membership today will recognize that, though many names have changed, the major pro- LIA26822 ,nicer? are -till very much on scene. However, membership in 1978 is diierse. Canadian. Mexican, Australian jrtd European producers are now mem bers. Secondary -melters are part of the association. So too are companies whose jcthity embrare lead application like .older producers, lead acid battery man ufacturers. cable and TEI. producers. ences on the growth of lead in the future as analyzed bv one industry spokesman: process improvements in the smelt ing of lead promise to overcome environ mental problems in lead reduction. major new uses for lead developing in the battery industry. Could reach 60 per cent of world consumption bv 1985. advances in battery technology, non-antimonial alloys, maintenance free batteries, continued reduction in SLI battery weight, wrought strip grid. growth of the electric vehicle mar ket, especially as a second or third fam ily vehicle. widening use of batteries bv the utility industry for peak power sha\ing. There is much ahead. At mid-centurv mark, our glass is not half empty but half full. The future: Change is a constant Change is no doubt a constant. But the rate of change accelerates. A ran dom sampling of headlines from Lead Magazines of yesteryear underscores this truism: "Highway Departments Overwhelm Jf, ingly Favor Lead Primers" l June 1933) "Lead-Acid Storage Batteries Serve as Reserve Power". National Broadcasting Headquarters. RCA Building, Rockefel ler Center. duly 1934) "New Jersey Master Plumbers Ask for More Lead in Codes" ( July 1933). Subsequent issues of Lead were to show other state craftmen endorsing this stand. "Lead-Sheathed, 115,000v Submarine Cable, Northwestern Electric Co., under Columbia River is first Oil-filled Sub marine Cable". I March 1933) "Brooklyn Moves to Replace Un sightly Overhead Power Lines with Un derground Lead-sheathed Cable". 11931) "Morro Castle Burns". Paint blistered, peeled and dropped off to reveal red lead beneath. (1934) "World's Fair New York 1939". Many fair buildings painted with white lead. "Tetraethyl Lead Boosts Octane for PT Boats and Carrier Aircraft." 1941 "Lead-Telluride Space Power Unit part of Atom Era." (1959) Trade-offs in materials are a fact of life in a technological society. We have seen them and are continuing to see them in the lead industry, It would be rash standing on the tiny hillock of fifty years to project another 50 years into he future. But here are positive influ- Lead Industries Association 1929 member companies The American Metal Co., Ltd. New York, N. Y. American Smelting & Refining Co. New York, N. Y. Anaconda Lead Products Co. East Chicago, Ind. The Andrews Lead Co., Inc. Long Island City, N. Y. Bond Manufacturing Corp. Wilmington, Del. Bunker Hill and Sullivan Mining and Concentrating Co. Kellogg, Idaho Cerro De Pasco Copper Co. New York, N. Y. Chief Consolidated Mining Co. Eureka, Utah Crown Metal Co. Milwaukee, WIs. The Eagle-PIcher Lead Co. Cincinnati, Ohio Euston Lead Co. (The Glidden Co.) Scranton, Pa. Evans Lead Co. Charleston, W. Va. Federal Mining & Smelting Co. New York, N. Y. Federated Metals Corp. New York, N. Y. W. P. Fuller & Co. San Francisco, Cal. General Lead Manufacturing Co. Denver, Colo. Globe Metal Co. Chicago, III. Hecla Mining Company Wallace, Idaho Hudson Smelting & Refining Co. Newark, N. J. International Smelting Co. United Metals Selling Co., Agents New York, N. Y. The Lewin Metals Corp. East St. Louis, III. Metals Refining Co. (The Glidden Co.) Hammond, Ind. National Lead Co. New York, N. Y. Northwest Lead Co. Seattle, Wash. Park Utah Consolidated Mines Co. Salt Lake City, Utah Rochester Lead Works Rochester, N. Y. St. Joseph Lead Co. New York, N. Y. The Sherwin-Williams Co. Cleveland, Ohio Silver King Coalition Mines Co. Salt Lake City, Utah Tintic Standard Mining Co. Salt Lake City, Utah Nathan Trotter & Co. Philadelphia, Pa. United American Metals Corp. Brooklyn, N. Y. United States Smelting Refining & Mining Co., Inc. New York, N. Y. USL Battery Corp. Niagara Falls, N. Y. Winchester Repeating Arms Co. New Haven, Conn. LIA26823 3 k CB talk hangs on thin lead alloy thread Circled area shows solder strip used to join contact points ot CB switch modules. 4 Millions of car owners and truckers use their Citizen Band (CB) ra rivet, weld or braze precious metals such as gold and silver to the tip of dios daily to converse with fellow CBevery switch arm to enhance electrical owners regarding traffic conditions, ac conductivity. Though logical, such pro cidents and other important informa duction sequences are expensive be tion. However, few of them are aware cause they require extensive labor. that the voice transmission that makes Another problem is the possibility of . CB radios so popular literally hangs on defects during each production step. , a thin ribbon of tin lead solder. TMI's way to mass produce switcher j The tin lead solder is playing a vital role in helping to reduce the cost and is to first apply the precious metal or ! other coating to the parent metal strip J improve the quality of all kinds of elec then to apply a ribbon of solder. Thi $ trical switches. This in turn has helped will later be used to join the switching v producers of electrical equipment such arm to a socket. Finally, the strip is cut - as CB radios to produce high quality into desired sizes at the manufacturing products at competitive prices. site. For example, Cherry Electrical Prod TMI begins a typical production se ucts, Waukegan, 111., is one company quence by using a phosphor bronie that takes advantage of tin lead solder strip that's 1,000 ft. long, 2,586-in. to achieve high quality electrical joints. wide, and 0.010-in. thick. .Next, inlay j The solder is incorporated in a highly strips of gold are placed wherever con- ^ sophisticated, multi-material clad strip tact points will fall. A strip of solder j developed by Technical Materials, Inc., is then placed where the finished arm | (TUI I, Lincoln, R.I. Significant dollar will eventually fasten to a switch or f costs for tooling, forming and assem socket. bly, as well as the added benefit of TMI has developed special tech- j reduced consumption of precious met als can be achieved by using this spe niques to apply the solder to the chd strip. In the first step, the tin le*<i ' cially engineered clad strip to produce solder alloy is carefully rolled to the switching arms. desired size. In the case of the cl- For decades, the common method of strip for CB arms, the initial size producing reliable switching arms was the solder strip is 0.007-in. thick to form them first and then either plate. 0.250-in. w ide. The strip is rolled, * j pressure bonded, directly onto the bare petal. Heat is then applied to achieve jemperatures that will make the solder flow enough to bond it to the base petal. After the metal has cooled, the jtrip is rinsed and processed through a giving device. The tool shaves the top 3nd sides of the solder strip to a very close tolerance, reducing the thickness from 0,007-in. to 0.0005-in., and the width to its original 0.250-in. The completed strip is then coiled and sent to a manufacturer. There pieces of the continuous strip are cut so the gold inlays fall exactly where desired, and the solder stripe on the other end where a contact (output) pin is to be located. According to TMI. any formable metal can be used for the clad strip. It can be provided in any length that can be conveniently shipped in rolls and in widths up to six inches and thick nesses from 0.003-in. to 0.040-in. The company reports that its tech nique of applying solder to the clad ding is superior because it is accom plished under ideal conditions. This method achieves much more uniform adhesion, compared to waiting to place the solder when the switches are as sembled. At that time, only delicate manual soldering at best, or more com plicated soldering systems can be used. The adhesion of both the gold and the solder is so reliable that failures are rare. Cherry Electric is able to form the contact arms without break ing the bond of either the gold or the solder. The company calls the final as sembly a Rotocode switch. Primarilydesigned for CB radios, it can have up to 50 switching positions. However, the same unit will work equally well in any application where complex elec tromechanical switching is needed. Solder theory and application emphasized at first U.S. solder forum Over 200 were in attendance at the First U.S. Solder Forum sponsored fundamentals on the opening day. Pa pers were presented on the basics of sol bv the Solder Manufacturers Committeedering, alloy selection, organic and of Lead Industries Association, Inc., inorganic fluxes and cleaning. The with cooperation from the Tin Research second day's program covered solder Institute, Inc. The proceedings were applications and techniques in the lamp, held at the Hyatt Regency O'Hare in automotive and electronic industries. A Chicago on .November 15 and 16, 1977. Westinghouse representative revealed The two-dav program produced a sig little-known lamp soldering practices, nificant interchange of ideas on solder while an engineer from Ford's Green ing technique1 and applications. Speak Island Plant described an improved ers included representatives from such method for soldering radiators. Other well-known companies as Bell Telephone speakers discussed wave soldering, the Laboratories, E.I. du Pont de Nemours hand soldering of micro-electronic de and Co., International Business Ma vices and preforms and pastes. chines, Westinghouse Electric Corp., and Ford Motor Co. Lively and infor Due to the high degree of in mative question and answer sessions terest shown, a second Forum will followed the talks. be held on November 13 and 14, The agenda for the Forum provided 1978 at the Mariott Twin Bridges for comprehensive coverage of solder in Washington, D.C. 1 One drawing of clad strip shows location ot pracious metal and solder. F. C. Disque, Technical Director, Alpha Metals, Inc., (at lectern) fields questions from the floor following his talk on special solder alloys at the First U.S. Solder Forum in Chicago, III. At Disque's left is J. F. Smith, Vice President and Secretary ot Lead Industries Association, Inc., who moderated the session. LIA26825 Bank and car leasing firms study electric vehicle potential A leading Chicago bank and [he big gest independent automotive leas annually and operating costs are high. In the first six months of 1977 alone the ing hrm in that city have teamed up to fleet completed some 54,000 miles of examine the potential for battery- travel. This was accomplished at an powered vehicles in congested urban average of 16 cents per mile, including area?. the cost of gas. oil and maintenance. The focus of [he study is on how elec This translates into an annual operating trics can be used in place of internal cost of S 17.000 per vehicle. combustion engine ilC) vehicles to de After bank officials had an opportun crease transportation costs, improve air ity to view a variety of new electrics at quality and reduce noise in downtown the 1977 International Electric Vehicle business areas. However, the more im Expo in Chicago, they decided to test a mediate goal is to determine if electrics battery-powered truck in actual opera can replace 10 gasoline-powered vans tion. In a cooperative effort with Lead now used bv the bank. Industries Association iLIAi. an elec The lleet. which consists of eight tric vehicle demonstration program was Ford Econolines and two Dodge mini implemented using GoLIAth, LlA's passenger personnel carriers, is main lightweight battery-powered delivery tained by the leasing company. They van. The vehicle, which is powered by are used to transport large volumes of an electric motor run off of a 112-volt mail and other correspondence between lead battery system, has a load capacity the bank's main Chicago office and its of about 1.000 lbs. 10 other locations in the Loop area. The GoLIAth was operated more than 70 volume of mail anually--more than 55 hours during the nine-day demonstra million units--surpasses the amount of tion period. It made more than 1,000 mail processed by the post office of a traffic and pickup/delivery stops while medium-sized city. Added to this are being driven about 240 miles. thousands of inter-office letters, memos, As a result of an earlier GoLIAth pro v ouchers, etc. gram and other studies, Commonwealth Operating on regularly scheduled closed-loop routes, the vehicles are in volved in extensive stop and go traffic Edison, the local utility, has been able to accumulate data on electric vehicle energy costs. and average only 10 miles an hour. The utility discovered that energy Since this is the most inefficient way to costs for electrics would be about half operate IC vehicles, they average only that of the presently-used vans. It esti about six miles to the gallon. The slow mated that GoLIAth used about 1 kilo speed and constant stopping and start watt hour (kwh) of electric energy for ing also influence the amount of main each mile traveled in downtown traffic. tenance and overhaul required to keep A commercial customer such as the the vehicles in service. bank or its leasing company now using Since the vehicles operate around-the- 24,000 kwh per month would pay about clock, they average about 108,000 miles 2.7 cents a mile for additional elec tricity used by the vehicle. To thi,, au 2.5 cents per mile must be periodic battery replacements. ad^de' f^or According to calculations, this b ' total electric vehicle energy cost to ab ^ 5 cents a mile. Conventional v, lr>Ut us,n? Meet gasoline getting only at 6 56 cents miles to a gallon 3an<j, a gallon downtown traffic have an energy coq 9.3 cents per mile. In addition, the tries are expected to have a much |0w^ maintenance cost than conventional |(^ especially in the type of service i o|y. ing slow speeds, limited distaii many stop-start cycles. and Based on the successful CoL[\||, demonstration, the bank is planning to make a more detailed investigation 0f electrics. The study would include .j* cific types of vehicles that could be in corporated in the bank's automotive licet. To determine what role electric* can play in the bank's operations, as well as other operations involving ^ automotive leasing company's Ihct 0[ over 25 lightweight trucks, additional operational and maintenance data is re. quired. For example, the leasing firm needs to know more about the lifetime operational use of electrics, compared with 1C vehicles. Electric vehicles used in England have an average serv ice life of 24 yean more than five times the life span of a typical IC truck. Because they require i fewer moving parts, electrics are easier j to maintain and repair and the need to stock hundreds of spare parts is elimi- ; nated. These and other factors offset the . high initial cost of electrics when c o b- pared with IC types. ; GoLIAth next to IC vehicle leased by bank. 6 Bank officials examine GoLIAth's battery storage area. LIAZ6826 gattery powered trucks handle paper work efficiently Rising energy costs are forcing indus try to take a harder look at how according to Don Norris, Plant Engi neer. the question of specific benefits their lift trucks are powered. Some remained to be answered. companies which traditionally favored Norris decided to make a detailed cost the use of internal combustion work comparison of electrics vs. gasoline- \ chicles for a diversity of reasons are powered trucks. He selected two high now finding that a switch to battery- free lift mast type trucks engaged in the powered trucks can be advantageous. same type of work. The raw findings are For example, in the paper making shown in the accompanying table. At an and concerting industries, where lift average per hour maintenance cost of trucks are the backbone of the material 3 1.60. the engine-powered lift truck cost handling operation, engine-powered the company 3936 during the year-long types used to be preferred. Lifting study period, compared with 8316 for heavy paper rolls is a drain on the bat the electric. And the intervening years teries of electrics in the 10.000 to have seen labor costs rise considerably. 12.000-lb sizes, and frequent replace Norris has converted the company's ment is required during the work shift. lift truck Meet to 14 battery-powered Since fossil fuel was less costly, histori models ranging in size from 2,000-lb to cally, than electricity for battery charg 12.00O-lb capacity. He has retained onlv ing. gasoline vehicles were favored. four gasoline powered lifts. The elec Now the cost picture has changed. As trics include three Allis-Chalmers trucks Lawrence Paper Co. determined, even w ith straight forks and two with roll with the expense for battery charging handling clamps. and handling, electrics can often pro Norris has learned from experience duce cost savings. The Lawrence, that the switch was not all gravy. He Kansas plant, which produces corru reported: "We've learned that to sus gated packaging materials, had relied tain our fuel savings we must adapt in almost entirely on internal combustion other ways, such as arranging for more lift trucks--eleven gasoline powered batteries to offset draindown under types. Only four electrics were used to heavy duty; training maintenance per handle stock and finished product in the sonnel to handle electrics; and having plant and on the loading docks. change-charge personnel available from The need for improved environmental the maintenance staff. On the other cleanliness, maintenance savings and hand, the electrics also perform well fuel cost reductions prompted plans for unloading box cars and other chores. In a Heel conversion to electrics. While the fact they have an edge of 35 percent in general benefits of electrics were visible, cost terms." Gasoline Truck Service Trips Shop to hours shop required General service 51 72 Clutch, transmission 14 102 Electrical 10 22 Carburetor 33 78 199 Electrical Truck Service Trips Shop to hours shop required General service 38 60 Electrical 59 43 69 LIA26827 7 1 Lead crowns spectacular South African exhibit center One of the most spectacular lead roof ing projects in modern times has concrete roof was originally to be pro tected by a plastic membrane. However, been completed at Cape Town, South the Cape Town City Architect's depart Africa. The Good Hope Center, one of ment became increasingly aware of the the many impressive public buildings in problems of maintaining the membrane. the city, has been crowned with 164 This factor, plus additional problems tons of lead. The roof was installed by expected, resulted in a switch to lead. Castle Leadworks of Cape Town and A quick cable to the Lead Development the company has guaranteed the lead Association of London, England, to in for 35 years. quire if the project could be accom Known locally as the Nervi exhibition plished brought back a prompt "yes" center, the building was designed by the and, after other details were arranged, famous Italian architect Pier Luigi 4-lb per sq ft copper-bearing lead was Nervi. The open-span, reinforced- specified for the project. Within five weeks of the telex l contract was signed and the lead ^ ing began. In the first step thick c'olt underlay was installed between the t' ber battens that form the skeleton of nj soaring structure. The lead was th* laid in the form of tiles with interlo^ ing joints and supported by copper clhJ rolled into the joints and nailed into th supporting battens. The lead tiles ^ approximately 2-ft. by 4-ft. A team of 64 men installed 38,Oo q copper clips and 600,000 copper nail* to create 39.372 feet of standing seam* In all, 9,500 sheets of lead were use^ Castle Lead's men worked in conjunction with Bastobell of Cape Town, who installed the cork insulation onto which the lead tiles were laid. The lead tiles were laid on the root of Nervi exhibition center under difficult working conditions. The spectacular lead root on the Nervi exhibition center was completed in less than 70 days. 8 LIA26828 Lead stands test of time at major hospital facility i\ |n addition to being one of the largest facilities of its kind. Kings County j-jospital in New York City boasts one 0f the largest and finest examples of ornamental architectural lead work in United States. And its excellent con ation nearly fifty years after installa tion attests to the durability of lead. Beautiful 4-lb hard antimonial lead spandrels, mullions and vertical friezes 0n several high-rise buildings in the hos pital complex combine to form an im pressive lead facade over the masonry. The Art Deco style ornamental patterns on the lead add to its attractiveness. The lead also was put to a multitude of other uses including roofing, flashing, jutters, downspouts, finials, crestings, cupolas, ventilating louvres and a cen tral spire. The durable quality of lead was evi dent recently in the course of an exten sive renovation of the lead work on two of the hospital's principal structures-- the Main Building and the Student Nurses Residence--both constructed in the early 1930s. Literally hundreds of spandrels and thousands of mullions, as well as friezes were taken down, refur bished and re-hung. Virtually all of the original lead was reused. The small per centage of replacement was due to irrepairable damage resutling from fires, vandalism and installation of air con ditioners. In some instances nails driven into the lead to hold it in place had destroyed the pattern. Some movement of the metal over the years and the physical damage men tioned above made repair work essen tial. In fact, some damage pieces had even fallen to the ground. If left un attended the entire svstem would have eventually failed. Simpson Metal Industries, College Point, N.Y., was contracted to remove and re-hang the lead facades. The com pany had to work with extreme care so as not to further damage the lead in the process. Joseph Squicciarini and Robert Berman, the architects involved in the project, designed an improved mounting system so the restored lead would be more securely anchored. The job of restoring the numerous spandrels, mullions and friezes to their original artistic integrity was sub-con tracted to Kenneth Lynch & Sons, re Kings County Hospital, located in New York City's Borough ot Brooklyn, is one of the largast tacilitios ot its kind. Workmen re'hang lead spandrel panels attar renovation. portedly the oldest architectural lead working firm in the country. Kenneth Lynch Sr., president of the firm, was responsible for the repousee work on the original lead at the time of its installa tion on the hospital. The thousands of architectural ele ments were trucked to the Lynch plant in H ilton, Conn., where the work was performed. On arrival the lead was sub jected to an acid bath, steam cleaned and wire brushed to remove dirt and debris which had accumulated over the years. The pieces were then individuallyplaced in a specially-designed lighted box to highlight the features of the relief. This made it easy to detect cracks and other damages. Ten lead burners were employed to mend any cracks or perforations that were discovered. Hydrogen torches were used for the burning so as not to mar the surface of the metal. The pieces were then returned to the light box for a second inspection. Following this, the lead was given another acid stripping bath, rinsed and air dried. After preparations were made for re mounting, a weak solution of acid was sponged onto the exterior face of the lead to darken it to a pre determined patination, prior to waxing. To replace the pieces of lead that were missing or beyond repair, the Lynch firm made a negative of the best duplicate panel. This negative was used to make the molds to stamp new panels. The Lynch firm also attached the mounting system devised by the archi tects. The spandrels were backed by ^'j-in. plywood, custom-cut to fit. Cop per straps, 2-in. wide, were soldered to the lead itself and secured to the ply wood. In the case of the mullions and friezes, the straps were soldered directly to the back, without the ply wood. Simpson Metal fastened the spandrels to a stainless steel support bracket that had been expansion-bolted to the con crete floor slab. The mullions and friezes were secured to the existing cedar wood blocking on the building with standard lock folds, and flashed. In all, the job took about two years to complete and all concerned are pleased with the results. Lead is once again demonstrating its ability to adapt to attractive architectural applications and hold up well in the process. LIA26829 9 Operating precision machinery re quires close worker concentration and attention to detail. Noise can seri ously interfere uith both these require ments to the point where work effort is effected. West Milton Precision Machine & Tool. Inc.. \ andalia. Ohio, faced such problems in their production plant. Re alizing that noise was the primary source of trouble, the company arranged for a noise survey. The survrv indicated that noise in the precision machine production area was being generated bv several sources. They included a lU-horsepower hydraulic pump, cooling fan. related valving, and pressures within the Huid lines. The acoustical analysis showed the noise levels were predominately in a high frequem y range. The range was so high that it was causing worker dis traction and loss of concentration. To reduce the noise, a lead/v invl-foam enclosure was installed around the ma chinery. The job as completed by two men in 15 minutes. Installation of the LIA expands noise control program The Lead Industries Association (LIA) has announced an expansion signed responsibilities for complying with OSHA regulations to learn more of its communications program directed about how lead can solve various noise to the noise control industry. control problems, particularly for ma Designed to further the increased use chinery noise abatement. of lead for a \aiietv of sound abatement applications in both industrial and com mercial i mstru' tion. the LIA noise con trol program is initially aimed at both architect- and acoustical control special ists who use lead to control noise in commercial and residential buildings. In recent years, increased emphasis has been placed on expanding the use of lead to control noise tor a wide variety of industries wh-' must comply with Occupational gaiety and Health Act lObHAi regulations with regard to the Most of the requests for information about the use of lead to comply with OSHA regulations resulted from a com bination of the publication of casehistory type publicity articles in trade magazines and a, series of advertise ments based on these case histories. Therefore, a part of the expanded pro gram will be to continue to emphasize the use of lead for noise control in both case histories and in advertisements dis cussing this subject. amount of noise to which workers can In order to more closely pinpoint the be exposed. Response to this program market. LIA is developing an illustrated indicated a desire among both acoustic slide presentation that discusses the use engineers md engineering personnel as of sheet lead, lead-loaded vinyls and lead compound materials to decrease noise levels in various applications. Ma chinery noise, one of the major prob lems encountered in complying with OSHA regulations, is discussed in detail in the presentation. It is being developed to present to audiences at noise con trol-related trade shows and for use in discussing the use of lead for noise con trol at meetings with various acoustical engineers and officials responsible lor complying with OSHA regulations at large and small companies. Another program in the LIA noise control project is to develop literature that discusses the wide variety noise control problems that can be solved with lead. This publication, primarily based on data developed for the illustrated slide presentation, will be used for di rect mail and leave-behind education4* material after the slide presentation. 10 LIA26830 w.ilkiaiKU,.. j production environments material was designed to insure road) Jt-eess to the pump for maintenance. Installation of the lead/vinvl-loam combination effecliieli induced the noise lev <1 in the adjacent precision machine ?h"[> work area. Sound level reading' before and aftei in the machine .hop "eie % dB and To dli respectively, j reduction ol II! dli The redui tion Brought about an inerease in employee morale and eonrinced the cnmpam to plan for additiunal nelo-iue- in other noisv areas. \s an added benelit. installation of tinlead limi-hum i m Insure- enabled the eompain. to - .mipli is it ft l .S. govern ment regulations for noise control. Lead suoresses billet saw sound Ta.-tali o -Mtiminum operates its ( rednick. Md. plant 2 1 hours a da\ to Idl tire need for high ipialiti aluminum ex trusion billets. A kei production opera tion involve- a huge high-speed sa nliieh i uts the east aluminum logs into the pn-cise billet lengths needed bi extruders. Tin- automatic billet cutter, built In Loma Machine Co.. New Rochelle, ,\.V., features a tungsten carbide saw blade. The blade, which runs at a rim speed uf 12.0110 to 15.000 surface feet per minute, was -elected tor it.- cutting ac tion. rather than its quiet operation. \n acceptable sound level was aihieied when l.oina lined the saw blade guard hou-ing with leaded foam. I bis keeps the saw's noise level below the 90 ill! limit during the eight-hour period of -awing, which greatlv contiihutrs to the comfort of the saw op erator and nearbv employees. Lead contains circular saw noise \t a large metal working plant, the noise lei el at the operator's station of a 2 1-in. diameter circular saw was be tween 120 and 150 dB. Worker effec tiveness was -ub.-tantially reduced and frequent shift changes were required. This resulted in decreased cost effieienev. The 21-in. saw was used to cut stain less steel pipe elbows and the greatest portion of the offending noise resulted from this metal to metal impact. There fore it could not be eliminated. Plant management worked with; Soundcoat to design and install a spe cially fabricated acoustical containment structure as follows: 1. The plant built an 8-in. high by 20-ft. long semicircular enclosure of sheet steel, to completely surround the cutting operation. The lower half was fixed to the Moor and the upper half mounted on steel rails so as to be move able. providing access to the saw. A viewing window was provided for the operator and a gear motor, limit >uitches and a control button installed for operating the upper section. 2. The inside of the enclosure was lined with 1| ..-in. Soundmat I two lead septums lloating in three lavers of foam), and 120 oz/sq. ft. Soundfab was used for seals at the lloor and the junc tion of the two enclosure halves. A leadvinyl curtain was installed beneath the machine in the scrap tunnel. The treatment reduced the sound level at the operator's station to 88 dB, a dramatic reduction of noise hazard. Lead's new cable partner boosts performance Improved technology developed to tect high voltage underground^^ has resulted in a lead cable sheath- * combined with a recently developed*" truded ethylene-propylene (EP) jn ?' tion. The improved system is provid' important cost savings for new c installations, as well as longer life j increased capacity. " The EP insulation replaces oi]., pregnated paper that was wrapn^ around the copper core of cable befo the protective lead sheathing was . plied. Elimination of the paper wra ping simplifies preparation for splicing and terminating of new cable installs" tions, an important cost-saving feature This is because solid extruded EP ^ much easier to work with and problems of oil migration are eliminated. Another advantage is the fact that EP-lead cable may be spliced or terminated using commercial premolded devices. Several other important advantages result from using the improved EP-lead combination. It provides a higher ca pacity than paper-lead in the same di ameter cable. Therefore, the cable can deliver more power in-the same size ducts. Temperature ranges of EP-lead do not change with the operating volt age. Also, the moisture-resistant con struction provides a greater safeguard in the unlikely event that the lead sheathing ever is damaged. The merits of EP-lead cable have not gone unrecognized among power cable specifiers. For example, Pulp Recycling Northeast Corp., is using EP-cable by Anaconda to serve its new pulp products plant near Glens Falls, N.Y. When plans were being drawn for the new facility, Jim Shorey, an electrical engineer with Rist-Frost Associates; the project con sultant, suggested the new power cable be used at the site. Shorey was aware that the pulp and paper business in the area is highly competitive and costs are carefully watched. He felt that the eco nomic `"edge" supplied by the EP-lead cable warranted its specification. The new EP-lead cable supplied the plant with power from nearby Niagara Mohawk power lines. Voltage over th* 35kV single conductor cable is stepped down to 4160 volts for three-phase, 480 and 270 volt service. Worker leads Anaconda EP-lead cable Into underground duct at site oI new pulp products plant near Stans Falls, N.Y. Cable construction (inset) Irom latt to right, is as lollows: (t) copper core (2) extruded strand shield oI EP: (3) EP Insulation; (4) Hypalon insulation shield; (5) lead sheath: and (6) polyethylene jacket. Lead liner secures cooling tower basin aterbed owners are always on the alert for a massive flood of water jjjgt can result when the waterproof membrane fails or ruptures. Extensive ivater damage results. With this in mind, imagine the dam age that would result if a rooftop basin folding 7.5 thousand gallons of water ruptures and sends a huge flood of water pouring through the floors below. This lt3s the possibility faced by the Univer sity of Missouri at Columbia. ML engi neers had to decide how to install a new waterproof membrane for the water collecting basin of a massive cooling rower atop the university's power plant. Water from the basin is recirculated through the cooling tower. The de vice cools heated water through contact with the air. As the hot water free falls inside the tower, it gives up heat to the cool air that enters through louvers along the sides of the cooling tower. The water falls into a large basin at the foot of the cooling tower where it cools before being recirculated. Built in 1964, the tower's redwood construction showed marked signs of wear by last year. Raymond Halbert, Director of Physical Plant and Construc tion for MU, decided that extensive re pair was in order. The architectural firm of Chinn and Associates of Colum bia was called in to prepare plans and specifications for the project. The deteriorating condition of the redwood floor of the tower's cold-water collecting basin was of special concern. The joints were opening up and consid erable makeup ate" ' as being lost through leakage. It was decided that re placement of the existing wood would not be feasible. The use of a plastic liner was also considered and ruled out. It was concluded that a lead liner over the existing floor would be the best way to go since the lead was an inert metal and showed little reaction to the chemi cals in the water. Installation of the liner was accom plished by three lead burners from Larrv Goad & Co., Ellisville, Mo. A total of 11 tons of 8-lb sheet lead was used to cover the area which measures about 44-ft. by 44-ft. About 25 rolls measuring 8-ft by 20-ft were used for the job, and 1,000 lbs of burning bar were consumed in joining the sheets. The job was com plicated by the fact that the sheet lead had to be installed around the cooling tower supports, bracing and pipe fit tings. Fashioning the lead into one con tinuous covering of the floor and sides of the basin as well as part way up the support structure, has provided an effec tive watertight liner. The extensive redwood repair work on the tower, which stands about 8 feet above the power plant roof, was per formed by B. D. Simon Construction Co. of Columbia. In all. about 40.000 board feet of wood was replaced. Much of the new wood went into the floored deck on top of the tower, an area approximating the bottom of the basin in size. All that remains to be done is some sheet metal flashing which will be accomplished in the spring. The university was especially pleased with the results achieved and plans to waterproof other cooling towers on the campus in the same manner w hen funds are available. Lead burner ioins one of the many lead sheets lining cooling tower basin. LIA26833 13 Insets at right: (top) Over 100,000 photovoltaic cells provide 25 peak watts to pump water for irrigation of corn crop at Mead, NePr. 8attery oank (bolow) stores elecu,, to provide back-up power during times when there is m sunlight. Ancient Egyptians, perspiring pro fusely in the intense African sun five feet to prevent shadows from falling on the arrays. The panels were arranged as their feet powered water wheels to so they could be tilted to a maximum irrigate adjacent farmlands with water 65 angle with respect to the horizontal from the .Nile River, would be astounded with a hydraulic piston system. to know that the sun could be used to The million-dollar irrigation project provide the power for this task. was funded by the Department of En Today, the largest photovoltaic proj ergy (DOE) and is being conducted by ect ever developed for converting sun the Lincoln Laboratory of the Massa light into electricity, pumps water to chusetts Institute of Technology and the irrigate 80 acres of corn on a farm near L niversity of Nebraska-Lincoln. Mead, Nebraska. In addition, the system According to Ronald W. Matlin of is used to power fans to dry the har MIT's Lincoln Laboratory, Nebraska vested corn. In both cases electrical en ranks second only to Texas in the use ergy is stored in lead acid batteries of energy for irrigation. The Mead loca which provide back-up power during tion was selected because it uses dif times when there is no sunlight. ferent equipment than other DOE solar The solar array consists of about irrigation experiments in the Southwest. 120,000 photovoltaic cells, arranged in Matlin noted that the energy require 28 panels each measuring 8 by 25 feet. ments for pumping water over large The panels are wired to furnish 6.2 acreage is heavy in the U.S. For ex amps at 150 volts and directly connected ample, a 160-acre quarter section re to two trailers. One houses a bank of quires 200 to 300 kW peak power. `This lead acid batteries supplied by C & D large-scale crop irrigation project repre Battery Div. of Eltra, which are capable sents one of the most promising areas of storing up to 85 kwh of electricity. for photovoltaic power systems to pene The other trailer contains three inverters trate a large market during the mid to to convert the stored DC voltage to 240 late 1980s," he explained. volts AC to power the AC irrigation The system at Mead, powers a 10 hp pump motor, crop drying fan motors pump which operates 12 hours a day to and other loads. irrigate the corn crop. Approximately Each solar array consists of two rows 1,000 gallons of water per minute is of panels, each 375 feet long, facing moved from a two-acre foot capacity south. One row was vertically offset by reservoir into an automatic gated pipe irrigation system. The photovoltaic system also tested the potential for grain drving. Two bins, each 27 feet in diameter and cap able of holding 6,000 bushels, were in stalled near the solar collectors to drv 12.000 bushels of corn. A 5 hp fan in each bin provided one cubic foot of air per minute per bushel of com through the 6,000 bushels when powered bv the photovoltaic array. Another important aspect of the Ne braska project is that data on incoming energy from the solar unit is being used to program an irrigation scheduling sequence. According to Paul Fischback of the L niversitv of Nebraska-Lincoln. "We have to rethink all of our normal practices which are geared to designing and running an irrigation system. The Mead system can pump at a con stant load for 12 hours from the irriga tion reservoir by using the batteries. Water is pumped into the reservoir out of an irrigation well during the night when off peak rates are in effect. Testing procedures at Mead report edly will be carried on for the next several vears. During the irrigation sea son this summer different pump methods will be tested, including variable speed DC motors directly connected to the array, as well as three-phase \C motors. 14 LIA2683A Wind-powered generator recharges electric carts operated by national park service } ,, -enetaior (at loft) is used to recharge lead batteries (right) tor electric carts driven by National Park Service personnel at Sandy Hook fh? I '.>. Department of the Interior | continues to he an innovator in de eping a wide variety of uses for -.-trie vehicles. |n an on-going program to conserve - rav and provide a more economical .ans of meeting its transportation relrements. the Department is looking h .olar energy as a power source for . If Vs. hast year National Capitol Re,n i NCR I installed a photovoltaic jr cell battery charging facility on - Washington Mall during the Festival American Folklife. The facility was -fd to recharge (lol.IAth I during the ctric vehicle's first demonstration w with NCR, and a variety of other G in the NCR fleet. Another interesting example of how r Interior Department is conserving r;v can be found at the Sandy Hook, I. unit of the Gateway National Recreational Area. This unit is one of four national parks in New Jersey and New York which span the New York Harbor. The four areas of Gateway are operated by the National Park Service branch of the Interior Department. The Sandy Hook portion of Gateway occupies 1.600 land acres of barrier peninsula reaching northward from the New Jersey coast into New York Har bor. Recause the area is located near the Atlantic Ocean, there is always a stiff breeze blowing. Sandv Hook engineers decided to develop a demonstration project to harness this source of solar energy and use it to power a generator to recharge batteries. The batteries are used as a power source for golf carts that are used to transport supervisory personnel throughout the park's exten sive acreage. The terrain is mostly flat, except for dunes along the coast of the narrow peninsula, and thus is ideal for the operation of this tvpe of vehicle. The wind generator ke*-ps 19 three cell. 6-volt lead batteries barged with 111 volt.- of electricity. This can be drawn off as needed when it's time to recharge the golf cart batteries. Officials of Gateway National Recrea tion Area are very plea-ed with the operation of the electric vehicles and the wind-powered electric generating sta tion. Thev also report that eleetr.es are quiet, economical to operate and do not pollute the air. The latter benefit is espe cially important in view of the Interior Department s plan to keep the Sandv Hook area as clean as possible If the demonstration program remains successful it is expected that additional electric vehicles and wind-powered gen erating stations will he installed in the other three units of Gateway. ARCHITECTURAL Lead Roofing and Flashing Detailed instructions on the simplest and most usual methods for forming or tommg lead for roofing and flashing apolications. Complete specifications. Dia grammatic drawings. Sixteen pages. A-5 Lead in Building A four-part data sheet containing informa tion on waterproofing, sound darners, roofing and flashing and anti-vibration ap plication. A-13 CERAMICS Facts about Lead Glazes for Art Potters and Hobbyists Detailed information on the proper formu lation, firing techniques, handling, etc. of lead fluxed glazes used by art potters and hobby ceramists. Illustrated. Sixteen pages. EMI Proceedings of First Internationa} Conference on Ceramic Foodware Safety Top international experts in ceramics, Food and Drug agency officials, and the international lead research community met m Geneva in November. 1974 to dis cuss heavy metal release from glazed ceramic foodware. Full proceedings-- speeches as well as question and answer dialog--were taped, translated and tran scribed. 272 pages. B*13 PAINTS Lead Pigments Bulletin Brochure. 12-pages, describes the advan tages and varieties of lead pigments in anti-corrosion paints. Covers red lead, dibasic lead phopshite. basic silicate white lead, basic lead phosphosihcate, basic lead chromosiiicate, basic lead silico chromate. Lists maior suppliers. F-7 CHEMICAL CONSTRUCTION & CORROSION PROTECTION Lead for Corrosion Resistant Applications Soft cover book, 156-pages, designed to familiarize engineers and engineering students with the corrosion resistance, design and fabrication data on lead and lead-based equipment. Defines plumbum senes and corrosion resistance of series. H*6 Lead Chemicals Soft cover book. 334-pages, is designed as a working manoai for the chemist or chemical engineer engaged in applied technology or pure research. Covers organolead compounds, oxides and hydrox ides. sulfides and tellurides, halides binary compounds, lead salts, lead chel ates. safety m handling compounds. Pur chasing price: $3.00. H-7 SOLDERING AND WELDING Solders and Soldering New 16-page booklet filled with basic in formation on soldering and the selection of the right solder alloy for the applica tion. Data is presented on a variety of tin lead as well as other solder alloys. Sev eral case history treatments of typical soldering applications are included. 1-6 Printed in U S.A. "Solder Puts it All Together for Manufacturer of Zippo Lighters" Two-page reprint from Production Maga zine details production soldenng of light ers at Zippo Mfg. Co. 1-7 Soldering of Electronic Products Booklet covers the use of tm lead solder as a highly reliable lOinmg method m the electronics industry. It includes informa tion on the control of electronic assembly components for solderability. fluxes and flux residue removal, solder alloys and soldering methods. 1-8 SOUND BARRIERS Directory of Acoustic Specialties Summary of available materials for sound insulation by barrier, damping and ab sorption methods. Sixteen page list of materials by brand name and manufac turer. Eighteen pages. J-4 Lead a Major Factor in New Machinery Noise Suppression Systems Description of techniques used to lower machinery noise levels with lead and taad composites. Lists machines that normally exceed noise level allowed by WalshHealey Public Contracts Act- Two pages. Lead Proves a Heavy Favorite as Sound Control Material A reprint of a feature from Product Engi neering illustrating lead's usefulness in sound attenuation to help meet OSHA noise requirements in factories and also on planes and trams. J-17 Specifying Lead for Noise Control Eight-page reprint contains guidelines to help architects and engineers fully utilize the advantages of lead as a noise control material. A number of case histories are included to show how some of these guidelines were used to solve a variety of commercial, industrial and residential noise problems. J-18 The Use of Absorber/Barrier Materials for Noise Control Enclosures Four-page reprint is concerned with noise abatement applications within the 10 to 15 dB range. It describes an installation using a quilted absorber/barrier enclo sure suitable for achieving these reduc tions, and presents the advantages of this material. Acoustical, economic, oper ational and maintenance aspects are con sidered. J-19 Takg a Fresh Look at Noise Control Two-page reprint from Modern Stores 6 Offices explains the usefulness of sheet lead plenum barriers for office space noise control. A case history illustrates the needs for an acoustical treatment and cost savings realized. J-20 A condensed story of the principles of the lead-acitf- battery and its chemistry, in cluding some of the fundamentals and definitions of direct-current electric en ergy, Two pages. L-4 Electrics Get Key Post Office Tests Reprint of a feature from Electrical World describing tests on the suitability and economy of electric battery-powered de livery trucks for the Postal Service. L-18 Electric Work Vehicles A 12-pag* folder describing batterypowered short-haul delivery vehicles and comparing their economics to internal combustion delivery trucks. L-19 Battery-Powered Industrial Trucks Spark Energy and Cost Savings This 16-page booklet offers an m-depth 100k at the many factors favoring the pur chase of electrics for industrial applica tions- A pull-out set of work sheets allows the reader to determine how electrics stack up against 1C types m his own oper ation. L-22 Saving Battery Dollars--What You Need to Know Three-part reprint from Modern Materials Handling deals with proper procedure m picking the right battery for the truck and job. it also discusses considerations >n battery charger selection. The third part offers guidelines for planning an efficient battery charging-room layout. L-23 Electric Vehicles: State-of-the-Art 1978 New 28-page booklet contains latest data on electric trucks, buses and passenger cars around the world. Case histones de scribe EVs in a variety of work applica tions- Other sections cover energy crisis and pollution problems and their effect on EVs; and the rote of lead batteries in V development. L-24 GENERAL "Lead Abstracts" and "Yearly Indices" Quarterly abstract of all current world literature on lead and its products and published research. A general index is published annually. Must be requested on company letterhead. M-2 d.ar. I.ad produce.: 5'Vc'u'ss7"iuopi5'"i pr.Cing trends for the metal ,,i sizes its signficance and value and m the future. M-31 r>* Leaded Grades: Answer to Free-Machining Neetfi Reprint reports on benefits derived using leaded steels for free mach.rw Case histones are employ** to a#^!' strate that these grades can enah?' partsmakers to raise production of a,,J? ity components with efficiency ana omy-;M32 *Con- Lead and Zinc Outlook 1976-1980 Booklet examines demand prospects >nn production for lead and zinc Over the four years. Current markets ana gr0wJ2 spoliations are also discussed 16-oao*. M-33 *" Occupational Lead Poisoning ... It Needn't Be ... A Manual for Managers Contains information of use to the indus trial manager on the safe handling of lead and lead products in industry. Typ*. and oermissibie levels of occupational lead exposure are discussed- Some prac tical controls and safeguards are $u*. gested. 16 pages, bibliography, M-34 r Brochure contains advice on occupational protection against over exposure to lead A checklist of good health practices is included. M-35 PLEASE SENO ME THE PUBLICATIONS MARKED BELOW