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NUMBER ONE & X- * *W#
U. S. Army
/ii5(*a/fer*/aunc/img view of the IGY Nike-Cajun High Altitude Carrier Rocket of the type utilizing lead sulphide for the continuous measurement of water vapor in the earth's atmosphere. See story page 5.
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THE Calumet Skyway, the final link in the tollway stretching from New England and New York to Chicago,
The approaches, shown here under construction, to the three-span cantilever-type Calumet Skyway Toll Bridge will rise 125 ft. over
the Calumet River,
will, when completed, carry traffic from the connection with the Indiana Toll Road toward the heart of the city. When opened some time this spring, motorists will be able to travel from many of the major cities on the East Coast to Chicago, a distance that will average around 1,000 miles on safe and comfortable super highways.
The project, officially called the Calumet Skyway Toll Bridge, will be seven and three-quarter miles long. From the connection with the Indiana Toll Road, the Skyway will rise to ward the high-level, three-span canti lever bridge over the Calumet River, the main span of which will be 650 ft. and adjacent spans 325 ft. A vertical clearance of 125 ft. is provided over the river. The descent from the bridge will be made on steel structure, then onto embankments which will be con tinued except for structural steel over
passes and main ramp connections throughout the rest of the Skyway.
Almost 4 miles of the Skyway will be on structural steel that has all re ceived a prime coat of red lead paint to protect it from the ravages of weather and the industrial atmos pheres inherent in any large city. The red lead paint formulation used in the Skyway's steel was in accordance with Specification M-72, Type I of the American Association of State High way Officials, with the exception that
Vs to Vi boiled linseed oil, the bal
ance raw oil be substituted for the raw linseed oil in the vehicle.
This major engineering project was constructed under the supervision of the Bureau of Engineering, Depart ment of Public Works, city of Chi cago, Dick Van Gorp, Chief Engineer and George DeMent, Commissioner.
DeLeuw, Cather & Company, Chi cago, 111., are the consulting engineers responsible for the design and con struction of the entire Skyway. Ad ministration engineers for the city's Department of Public Works are John G. Duba and A. L. Tholin.
The completion of this final link of super highway from the East Coast to Chicago also completes the link of red lead primed steel throughout this entire toll highway system. No matter what the environment, sea coast, rural or urban, the structural steel for those roads in the states of New York, New Jersey, Pennsylvania. Ohio, Indiana and on into the city of Chicago received a prime coat of rustinhibitive red lead paints.
Standard Specification for
RED LEAD READY-MIXED PAINT
AASHO Designation M72-51, Type I
Per Cent by Weight
Pigment
Min. Max.
Red Lead (97% Pb304 ) Aluminum stearate
99.6 -- 0.3 0.4
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Lead's Use In Commercialized Atomic Power
AS a typical instance of the ex tent of one company's utilization of lead shielding in commercialized atomic power, two specific yet in most part technically unrelated appli
A huge, lead-shielded, chamber for loading and unloading urani um fuel for Southern California Edison's sodium reactor hovers over the "core" sunk deep be
neath the ground.
cations may be cited--Southern Cali fornia Edison Company's Sodium Reactor Experiment (SRE) and a low-priced miniaturized laboratory reactor -- both designed by Atomics International, a division of North American Aviation, Inc.
The SRE, located in the Santa Susana Mountains about 30 miles northwest of Los Angeles, was de signed and built for the Atomic En ergy Commission by Atomics Inter national as a part of the Commission's program to develop economically competitive civilian power from nu clear energy. It can be noted that lead shielding played no minor part in the experiment, which marks the first time a non-military atomic energy re
more usual use for lead in commer cialized or military atomic power, Atomic International engineers drifted to the unusual properties of lead as a reflector shield in a small 5-watt laboratory reactor. The reactor, de signed for schools, medical and indus trial laboratories, has as a unique feature a 6-in. thick lead neutron re flector-primary shield weighing ap proximately 3,800 lbs., which sur rounds the core vessel containing aqueous uranyl sulphate, homogene ous fuel suspension. It is purportedly the first reactor to employ lead as the only reflector material.
The advantages that result from the selection of lead for this purpose are:
actor has produced power for the
1. When the secondary shield water
generation of electricity by a private tank is drained, access to the interior
utility company. Now operating at full of the tank is permitted, since the
power, the reactor is designed to pro lead acts as an effective shield against
duce 20,000 kw. of heat from which residual gamma radiation from the
the Edison equipment will generate core. This feature allows ready modi
approximately 6,500 kw. of elec fication of the experimental facilities
tricity.
and the installation of new beam tubes
The significance of lead may be or special exposure experiments in the
laid to the need for safe mobile means water shield region. The number of
for loading uranium fuel into the beam tubes can be easily doubled at
tor and removal of any hot ele little expense if the number of lab
ment?. penetrating into the reactor oratory groups wishing to utilize the
lore ami transporting them to clean reactor simultaneously proves too
ing. Morage, or hot cell facilities large for the normal complement of
located in the reactor building. The facilities.
accompanying photograph shows this 2. The lead acts as an essentially
conveyor, a huge, lead-shielded cham- infinite reflector. This means that
l"-i hovering over the "core" of the experimental apparatus installed at or
teaetor preparatory to removing a hot near the reflector surface will not per
gamma-active component.
turb the neutron balance in the core
1 rom mobile gamma shielding, the itself and no hazard is presented by
movement of equipment during oper ation in the vicinity of the reflector surface.
3. Pressure resistance of the core vessel against sudden surges arising from any source is greatly increased. The lead is cast around the core vessel in one operation and is actually bonded to the core during the casting.
Information on other ramifications of the design may be had by refer ring to "Educational Uses of the Small 5-Watt Laboratory Reactor," by John W. Flora, Reactor Kinetics, Atomics International, Paper No. 57--NESC73, 2nd Nuclear Engineering and Science Conference, March 11-14, 1957, Philadelphia, Pa., published by the American Society of Mechanical Engineers.
All in all, where mobility is impor tant, lead for shielding purposes offers the best over-all combination of de sign properties as its use in core load ing-unloading and compact "shippable" research reactors testifies.
10.0
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6 36
Operation of this miniaturized atom ic energy research reactor, only 8 ft. high and 8 ft. in diam., is underway
at Atomics International.
At right, a cutaway of the miniatur ized reactor showing the 3,800 lb.
pear-shaped lead reflector shield.
! ,\ev Duke University Dormitory
The new dormitory, in the foreground, blends well with the older buildings on. the
beautiful Duke University's campus.
THE blending of the new with the Addoms Dormitory, will house 200 old, architecturally speaking, was coeds with dining facilities for 350. the problem found and successfully Cooling and ventilation of this 770,-
overcome by architects, Six Asso 000 cubic feet structure is accom
ciates, Inc., Asheville, N. C., in the plished by six large fans located
design of a new women's dormitory within lead-coated copper sheathed
on the campus of Duke University, dormers on the back slope of the roof.
Durham, N. C.
Among the newer materials used
In doing so, the architects have was 3-lb. hard sheet lead for lining
utilized every possible concept of the more than 600 linear feet of lime
modern construction design, materials stone gutters. Hard sheet lead, a de
and methods, within cost limits, of velopment of modern metallurgy, is
course, while maintaining, as the ac made from an alloy of lead with be
companying photographs illustrate, tween 6 and 7.5 per cent antimony
an outer facade that blends well with that is stronger than soft lead and as
the neighboring structures.
a result may be used in thinner,
This latest addition to the beautiful lighter sheets while retaining the well-
Duke University campus, the Gilbert- known resistance of lead to corrosion.
The 3 lb. hard sheet lead-lined-limestone gutters on the reverse roof slope of Duke Uni versity's new dormitory are shown below, along with detail showing method of installation.
The dormers shown are sheathed with lead-coated copper.
The non-staining properties of lead are also maintained.
The Pickard Roofing Co. Inc., Durham, N. C., installed the 3-lb. hard sheet lead gutter linings that varied St width from 3 to 7 ft. The lead sheets were formed on the ground and hoisted to position. - As shown in the accompanying detailed drawing, a copper cleat anchors the lead on the limestone fascia and a continuous hard lead strip embedded in the brick mortar loose-locks with the vertical section of the gutter lin ing. Loose-locked cross-seams, made in the direction of flow, are filled with nomhardening compound and are provided at not more than 8 ft. intervals^
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lead was required for the entire gut ter lining and, according to the roofer, the cost of installation was competitive with other high quality materials.
For more specific information on the details of installing the new hard sheet lead for roofing, flashing or gut ter linings, refer to the 1958 Sweet's Catalogs, Architectural File 8b/Le, the Light Construction File 2a/Le, or write directly to the Lead Industries Association.
The exceptionally wide gutters on the forward roof slope of Duke Uni versity's new dormitory are also lined with the new 3-lb. hard sheet
lead.
Lead Compound Semiconductors
lead :
Inc., 3-lb. that
The the . As ailed ^ the ud a dded with r Un made filled and 8 ft.
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hard
L ATEST developments in the uses Grounds, New Mexico, and will be an of lead compounds lend emphasis important addition to the total make to their unusual capabilities. Some up of the IGY investigative program.
multilingual films. The Army is al ready using this technique and CBSNews is switching from optical to
of these developments are completely
Other down-to-earth uses for PbS magnetic sound tracks in 16-mm.
unheralded and extremely provocative would include subminiature photosen news and documentary films.
and indicate that only the imagina sitive resistors, their over-all size be
However impressive, PbS does not
tion limits the extent to which they ing comparable to that of a crimped eclipse other lead compounds which
can be employed.
paper staple. Such components are are slated for use in electronic re
Fur example, the essential material available in complex and exact arrays frigeration and power generation. It
or component in a system developed and mosaics for a multitude of uses. may be that future household refrig
for the U. S. Army's Nike-Cajun Their signal to noise ratio is excel erators will depend on lead telluride's
Korket is lead sulphide, which is be- lent, particularly in infrared, and ability to cool under the influence of
imi u.-ed to obtain data on natural- vibration does not affect them.
voltage change. The Russians have
occurring water vapor in the earths
Also, lead sulphide photoconductive already developed a small radio based
c u mu u s envelope, an International cells, in combination with infrared on lead telluride, powered by a kero
(.< i ijihysical Year experiment (IGY). lighting, form an integral part of a sene lamp; this is converse to elec
Tin- Yike-Cajun nose cone contains process for superimposing an optical- tronic cooling or the production of
the components and electronic instru magnetic sound recording on motion electrical energy as a function of tem
mentation required for exact continu picture film without affecting the opti perature change.
um measurement of water vapor cal track, a process gaining in versa
All this indicates then that lead
pre-ent at various altitudes in the tility. To put it simply, magnetic strip compounds are remarkably able to
cour-c of the missile's flight -- up passes infrared rays which are modu keep pace with changing technology
wards of 100 km. at its summit. The lated by the optical track system util and are very much the subject of con
function of lead sulphide as a device izing PbS, a method which may foster tinued scientific attention.
for measuring water vapor content
depends on its ability to control elec-
11 n al energy under the influence of
radiation. By using the sun as a radi
LEAD COMPOUND SEMICONDUCTORS AND
ation source, water vapor acts to re duce it- intensity at varying altitudes In varying degrees, depending on its
Bond SvparatiM
THEIR APPLICATIONS
Mahllttr (T . 300" K) _______ cm^/yoh.*g
Application
content and accordingly induces
v. (T - 300s K) Itctfsns
holts
Moltiftf Point, ^
'arting proportionate outputs from I la- lead sulphide photoelectric cell. 1 lie resulting output, so to speak, i- monitored at a control station on d" mound for the information contauie.l. Actual tests or shoots are
PbTt
PbSs
PbS Bi2To3 ZiiSb CdSh
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0.3 0.26
0.4 0.16 0.5 -
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Lead Additions Improve Steel's Machinability
LEAD added to steel in minute quantities, 0.15 to 0.35 per cent,
Table I
Table II
has materially increased steel's ma chinability while at the same time providing longer tool life -- two sig nificant advantages that have resulted
MECHANICAL PROPERTIES*
(Hot rolled, cold drawn A.I.S.I. 8620, 2%" round)
CONSTANT PRESSURE MACHIN
ABILITY RATINGS FOR
j
LEADED AND NON-LEADED
in major economies wherever leaded Property Tested
Leaded .Sun-Leaded
STEEL CASTINGS*
steels have been used. These advan Yield strength PSI........ . 88.500 93,500 (Leaded castings contain 0.18 per cent lead)
tages are imparted to steel without L'lt. strength PSI.......... . 93,500 95,500
Average Ma-
materially affecting its mechanical % Reduction of area... . 54.7
56.0 Sample
Treatment
chinabiluy
flH.Y Rating
I see Table I) or heat treating proper % Elongation in 2 in. . . 14.0
14.5 1 PN Non-leaded, normalized 163 81
ties. An example of the economy that Brineli hardness ..........
197
207 1 LN Leaded, normalized
165 116
can be effected with leaded steel when Izod impact--Ft.-Lb. ..
12
9 1 PQ Non-leaded, Q & T
252 87
used for a pump rotor is indicated in Grain size......................
7-8
7-8 1 LQ Leaded, Q & T
252 116
the accompanying illustration. The capabilities of the steel in serv
`Source: Copperweld Steel Company
`Source: Crawford Steel Foundry Co.
ice are not materially affected, inas
much as the leaded steels can be forged, machined and brazed in ex actly the same manner as non-leaded steels and can be plated without any apparent effect on the bath composi tion. Leaded steels also have signifi cant advantages in deep hole drilling, making possible depths never before possible.
The lead is added to the steel in
distributed throughout the cross sec tion. It is this even distribution that actually permits the lead to serve as a built-in lubricant, reducing friction between the tool face and chip, thus providing freer machining with in creased tool life.
A more recent development is the addition of lead to steel castings, which have exhibited important in
and properly heat-treated to eliminate hard spots.
An excellent treatise "A Literature Survey on Leaded Steels, PB111917" has been published by the Office of Technical Services, U. S. Dept, of Commerce, Washington 25, D. C., and is available from them at $1.00 per copy.
the form of spherical shot, V30 in. in creases in machinability along with
diameter, and literally sprayed into increased tool life. A considerable im
the steel by a gun under air pressure provement in surface finish has also
when the ingot is teemed. The lead been realized.
does not alloy with the steel nor is it
The technique used in introducing
converted to a lead compound. It the lead into cast steels differs some
actually remains segregated in sub- what from the wrought steel and the
microscopic size and is uniformly special procedures that have been
developed provide the same even dis
tribution of lead in the steel casting.
The lead content is, however, lower
Castings requiring a lot of machin ing, such as these for large cranes, are where the machinability of the
leaded steels shows to advantage.
than in the wrought steels, averaging between 0.12 and 0.20 per cent.
Table II lists the average machin ability ratings of five tests made in
The Iron Age cast leaded and non-leaded steels. In this test, 1/g in. deep turning cuts were
Copperweld Steel Co.
made on 3.8 in. diameter sections, using peripheral speed of 40 fpm. and a tool thrust of 147 lbs.
The normalized samples were
In the manufacture of this pump rotor, the use of leaded steels in creased tool life by one-third while at the same time affecting production
savings. A comparison follows:
heated for 1 hour at 1,650 deg. F. and cooled in still air. Quenched and tempered samples were heated for 1 hour at 1,600 deg. F., water
A.I.S.I. 8620
Pieces produced before tooU must be ground ___ _--1,200
LEADED 8620
1,600
quenched, tempered at 1,000 deg. F. for 2 hours and air-cooled.
For maximum machining econo mies, it is important that the leaded steel casting be free of surface sand
Number of times tools caa be ground ...-----
Total pieces produced per tool _7,200
Total cost per piece$0.0075
6
6
0,600 $0.0056
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LIA 26137
CHIN-
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nt lead)
'j|e Ma-
.inability Rating
f The extruded lead strip is gently i hammered into the concrete joint
until dightlv above floor level.
The lead burner is adding additional lead in those areas where the lead strip did not completely fill the joint.
The completed lead-filled contraction joint. This type of joint filler is recommended for heavy-duty floors.
81 116
87 116 ry Co.
iminate
terature 11917" IfiBce of )ept. of D. C..
it $1.00
Lead As A Concrete Joint Filler Reduces Chipping
AT the newly - renovated Meter Information" bulletin on these type Division plant of the Westing- floors, the Portland Cement Associa house Electric Corp. in Newark, N. J.t,ion states that "The lead gives more
more than 1.200 ft. of extruded lead support to the edge of the concrete
strips were embedded in the contrac than does mastic and thus reduces
tion joints of the concrete floors of chipping."
the structure. These were placed in
In the Westinghouse job, the tooled
the joints in those areas where heavy joints in the concrete were made to
industrial traffic is anticipated.
accommodate *4 in. thick by 1 in. in
[.cad as a concrete joint filler, such deep extruded lead strips, the depth
as used on this job. materially reduces of the tooled joint being slightly less
the possibility of chipping in the joint than 1 in. to permit Vie to i/g in. of
area. It is particularly recommended the lead to extend above the level of
a- a joint filler for industrial or other the concrete. This is then hammered
hraw-dutv concrete floors where down carefully to roughly the floor
tnnkina is severe, especially of the level. At those points in the contrac
-loci wheel type. In its "Concrete tion joint where irregularities oc
curred and the lead strip did not completely fill the joint, additional lead, by means of the lead burning technique, was added. 0. G. Kelly Co. of Elizabeth, N. J., installed the ex truded lead strips.
The advantages incurred in the use of extruded lead strips over the more conventional method of pouring mol ten lead into the joint are many. No great amount of heat is generated within the joint and, as a result, the possibilities of the concrete spalling during installation are avoided. Also, no special care is required to see that the joint is completely free of mois ture before installing the lead strip.
pump eels in1 while duction lows:
LEADED 8620
1,600
6
9.600 $0.0056
ad-Add-Brifk Construction Solves Abrasion Problem
A\ unique corrosion - abrasion problem was encountered by the I ithium Corporation of America at its new Bessemer City, N. C. plant, which .i' solved by the use of lead-acidbric k construction. This corrosionabrasion problem occurred in a fog t v |>e scrubbing tower designed to "adi exhaust fumes from a rotary kiln in which an ore-sulphuric acid "fixture was to be roasted at tempera tures in the vicinity of 500 deg. F.
Although corrosion resistant mate rials other than lead had been used in the original design, small quanti ties of abrasive dust were present in the exhaust fumes and the combina tion of the abrasive action of the dust "ith the high heat of the exhaust
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hint iiiTiifia rft t tj r*-*w.., rirfirww>Ai>r il
fumes caused premature corrosion failure of the equipment.
In the redesign, the scrubbing tower and exhaust stack were lined with neoprene. It was necessary, however, to precool the exhaust fumes
The roaster gases enter the lead, acid-brick-lined chamber, at left in photograph, at 500 deg. F. where they are cooled prior to entering the
scrubbing tower at right.
before they entered the scrubbing tower to protect the neoprene lining. The precooling chamber, therefore, and the duct work from the kiln had to be constructed of materials that would stand up against the severe corrosion-abrasion attack and the 500 deg. F. temperature of the exhaust fumes. For this vital part of the in stallation, lead-acid-brick construc tion was chosen. The redesign in cluded a simple precooling tower measuring approximately 4 ft. in diameter and 18 ft. high of mild steel lined with Yg in. thick sheet lead for resistance against corrosion and one course of acidproof brick to protect the lead against abrasion and to act as insulation against extremes of tem perature. A square horizontal duct of steel, lead and brick lined in the
same manner as the precooler, con nected the kiln exhaust hood to the precooler. Since dust was expected to accumulate in the horizontal duct, brick was used only on the bottom and sides, leaving the topside easily removable and the duct accessible for cleaning. This removable duct cover was made of mild steel plate protected on the underside with sheet lead. The lead was held in place with steel bolts and w ashers which in themselves were protected with lead patches burned to the lead lining. Precooling was ob tained by a water spray occurring in the top half of the chamber.
This installation has proved very successful. The only maintenance to the duct and precooler in over two years of operation has been one re placement of the lead on the duct cover, which was done last July. The original installation required almost constant maintenance. What was once a continuous headache has now become an almost forgotten problem.
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;Van.o / Technical Information
The following article* and reprints contain information, drawings and specifications on the use of lead products helpful to architects, engineers and others interested. They are available free of charge exeept where otherwise indieated, upon request to the
LEAD INDUSTRIES ASSOCIATION, 60 EAST 42nd STREET, NEW YORK IT, N. Y.
MATERIALS OF CONSTRUCTION ANNUAL REVIEWS--LEAD AND LEAD ALLOYS
Lead and lead alloys in design and construction including research progress, engineering applies* tions, and technological advancements. With bib* liography, 195? and 1956 reviews (editions are not cumulative) available. Reprinted from "Industrial *nd Engineering Chemistry." September, 1957 and September, 1956.
INSPECTING LEAD LININGS
Latest methods of testing and inspecting sheet lead and bonded lead linings used in the chemical process industries are described. Reprinted from "Chemical Engineering." November, 1956.
BEST DESIGNS FOR LEAD INSTALLATIONS
A special report on the applications of lead and lead alloys in the chemical and metallurgical in* dustriei. Recommended practice for joining lead -hects. and the construction of wood stave tanks, launders, towers and flues where lead is involved are included. Reprinted from "Chemical Engineer* ing." March, April and May, 1956.
PORTABLE RADIATION SHIELDING MATERIALS
A special report on commercially available shield ing forms that can be used to build readily as sembled. hand stacked shielding walls. Prepared by the editors of "Nucleonics," May, 1955.
LEAD IN MODERN INDUSTRY $1.50 Postpaid
A fully illustrated, 230 page, cloth bound book describing all phases of the production and use of lead, lead alloys and lead compounds.
LEAD WORK FOR MODERN PLUMBING
$1.50 Postpaid, S1.00 per eopy in quanti ties of 10 or more Profusely illustrated with over 140 photographs and drawings, the textbook presents clearly to the plumbing student the necessary tools, procedures and the methods required for lead work.
LEAD BUILDING CONSTRUCTION BULLETINS
K series of specifications for the use of lead in building construction. 1 \vailable separately.)
BULLETIN NO. 1
Specification for Lead Waste Connections for Plumbing Fixtures with Integral Traps (Water Closets--Pedestal Urinals--Service Sinks).
BULLETIN NO. 2 Specifications for Lead Shower and Safe Pans.
BULLETIN NO. 3
Specification for Lead Drainage Systems.
Chemical
Laboratory
LEAD WELDING
\n informative as well as practical guide to lead welding. Reprinted from the "Welding Handbook, Third Edition" published by the American Welding Society.
LEAD FLASHINGS IN MODERN CONSTRUC* TION
Lead flashings as used in an ultramodern house in Randolph, Vt, Reprinted from "National Roofer," October, 1954.
SHEET LEAD WORK FOR THE SMALL HOME
A specification for the use of the new Zx/x lb. hard sheet lead on small homes.
THE STORY OF LEAD -- MATERIALS THE RAILROADS BUY (Parts l and 2)
Lead from mine to finished product with special reference to its uses by the railroads. Reprinted from "Railway Purchases and Stores," December. 1954 and February, 1955.
RADIATION PROTECTION
The place of lead in shielding against radiation in X-ray and atomic energy applications. Principles of lead shielding construction. Reprinted from "Lead In Modern Industry."
RED LEAD TECHNICAL LETTERS
A <eries of technical fetters containing red lead paint formulations. (Available separately.)
Technical Letter No. 11 -- Reeommended Surface Preparation of Steel for Red Lead Paint*.
Technical Letter No. 12--Painting Highway Structural Steel.
FEDERAL SPECIFICATION FOR PAINT: REDLEAD-BASE, READY-MIXED TT-P-86a
Covers four types of red-lead-base paints including two fast drying formulations. Many intended appli cations listed.
1
NEW MTERATLRE
LEAD SUPPLY AND DEMAND IN THE UNITED STATES
A short resume of lead supply and demand in the United States in 1957 and the outlook for 1958. Reprinted from "Engineering and Mining Journal". February, 1958.
UPON REQUEST, THE LEAD INDUSTRIES ASSOCIATION WILL BE GLAD TO MAIL "LEAD" REGULARLY, FREE OF CHARGE, TO THOSE INTERESTED, AND WILL COOPERATE WITHOUT OBLIGATION IN THE SOLUTION OF YOUR LEAD PROBLEMS.
PRINTED IN U. S. A.
20 BY ISAAC GOLDMANN COMPANY. INC.
NEW YORK CITY
Ll26139