Document K63kQ5ZLXw5gQ7zY7q2ge8GNw

VOL. 36 NO. 1-2 1973 si f A E new dimension has been added to the Association's Acommunications program this year. For the first time we have embarked upon an advertising effort di rected to college engineering students. We want them to P know the positive role lead plays in our technological society: lead's contributions in ultrasonics, piezo-electrics, THE VOICE OF emergency stand-by power, uninterruptible power sys tems, sound attenuation, x-ray shielding, sound explora AN INDUSTRYS tion, communications. The current ILZRO project at the Rhode Island School of Design on the concept of a lead/ zinc house is the theme of one such ad. It is appropri A ately headlined: "A House for the Future in a LumberL short World". We believe that many changes for to morrow are incubating in the colleges of today. Not to address ourselves to these engineers of the future would be a serious oversight. P Fi James C. Buck Chairman. Industry Development Committee, Lead Industries Association, Inc. Ri 'tW-.lrVrw. `gJ.JjtAtdB. LIA0508A 2 uuic i iuonuc. itLiuno AT QUEBEC JUSTICE BUILDING If a judge presiding over court pro ceedings in Montreal's new Palais de Justice building issues an order for "sil ence in the court'', he can do so know ing that noise he is hearing is coming from inside his courtroom rather than from outside sources. In fact, all work ing areas of the gleaming 17-story steel, glass and marble building's working areas--courtrooms, judges' offices, jury rooms, general offices, conference rooms, etc.--are designed so that noise from one area will not pass through adjoin ing walls or partitions. The result: the Palais de Justice, which houses the De partment of Justice for the Province of Quebec, is probably the quietest court building yet built. Erwin Cleve, of the Montreal archi tect firm of David & Boulva, who de signed the building, says the Palais de Justice represents a classic example of the wide variety of noise control tech niques that can be designed into a building to insure that its working areas are as quiet as possible. He added that this could only be accomplished by carefully selecting materials that will solve each noise control problem that might be encountered when the build ing is completed and in use. John Hillenbrand, project coordina tor for Franz Patella, Inc., Montreal, partitions contractor for the Palais dc Justice, reports that sheet lead solved the most critical sound control problems encountered in constructing the build-' ing. He says sheet lead was used to soundproof the tops of partitions and walls, as one of the materials used to construct soundproof multi - material partitions, and to build sound barriers in sections of the building's heating and cooling system. The use of sheet lead to construct a sound barrier for the build ing's heating and cooling system is one of the most unusual applications. The system extends around the per imeter of the building and is enclosed in an open sheet metal housing that runs along its entire length. The sheet metal housing and the pipes, vents and con vectors it encloses provided a sound channel for noise to travel up and down the length of the building and into each room. The architects therefore decided to install a series of acoustical baffles at the partition line of each office to stop noise in one room from traveling into an adjoining room. Hillenbrand reports that 2 psf sheet lead was used for the several hundred heating and cooling sys tem acoustical baffles required for the project. Each baffle measured about 2y.> ft. high and 15 in. to 18 in. deep. The sheet lead acoustical baffles were in stalled in conjunction with the parti tions that form the walls of the various offices. A combination of the sheet lead acoustical baffles and the material used to construct the partitions provided an installed Sound Transmission Class (STC) rating of 45. There also are nearly 90 courtrooms in the Palais de Justice. Sheet lead plenum barriers for the partitions of these rooms are about 2 ft. high and total about 80 ft. long when installed over the top of each wall. One of the most unusual applications for sheet lead was its use in building a sound barrier above the walls of the Palais de Justice Grande Court. It is a large, dramatic room that features stepped spectator seating; a court that is arranged around landscaped curved and rectangular tables rather than in a traditional judge/jury box arrangement; and sweeping, curved walls. The sheet lead plenum barrier installed above the curved walls is nearly 3 ft. high and about 175 ft. long. Approximately 100,000 square feet Line drawing shows how sheet lead sound-barrier was installed in building's heating and cooling system. i i INDUSTRIAL NOISE APPLICATIC LEAD HELPS UTILITY SOLVE TOUGH COMMUNITY RELATIONS PROBLEM: NOISE While only a trained acoustical engi opgrating temperatures of the equip neer ear. fully understand the highly ment; and it had to be capable of pro complex noise control situations en viding an adequate degree of sound countered at LILCO's Northport plant, attenuation for both high and very high it can be simply stated that they evolved noise levels since they were not con around the following causes: sistent throughout all sections of tht equipment to be enclosed. Induced draft fan equipment that To help solve the multiple problem; was being installed to improve the ef encountered in meeting the noise con ficiency of the first two power genera trol requirements for the new equip tion units. The equipment and its ac ment being installed at its Northport cessory ductwork was so big that it plant, LILCO turned to Transco, a lead Thermal/ecoustlcal panel contains 1 psf sheet lead in LILCO plant. When the Long Island Lighting Com pany decided to build a new power could not be installed inside the power plant of either unit and for that reason the exceedingly noisy sounds emanating from the equipment were traveling ing manufacturer of thermal insulation panels. Transco, which has installed thermal insulation panels at more than 50 electrical power plants throughout generation plant at Northport, N. Y., it throughout the community. the country, worked with LILCO engi took particular care to insure that the installation was one of the quietest in POWER PLANT NOISE CONTROL SYSTEM the utility industry. The reason: The utility's Northport power plant is sur rounded by a residential community I 6UUU0H OMlt 1 rXMAL aoUUUOi COMVXS mlti Of men of t u tv w h ad that is country-like quiet ... so quiet that sound levels that would be accepted without question in most residential areas adjacent to industrial sites would seem excessively loud. To solve the problem, Long Island Lighting Company developed strict noise control specifications for the first two power generation units that were in stalled at the plant. Not only were the walls, ceilings and floors inside the two power generation units covered with sound-deadening materials, but the buildings housing the equipment also Power unit #3 at LILCO plant uses three types ot composite material lor noise control. were enclosed in similar materials. Induced draft fan equipment that neers to develop the combination ther It was for these reasons that the utility was being installed as original equip mal/acoustical panel system. It was encountered no community relations ment for the third power generation unit used for the first time at LILCO's North- problems involving noise resulting from that was being built. Because the power port plant and the manufacturer reports operation of the plant. The company, plant design for the third unit was it has since been specified to solve known locally by its initials, LILCO, basically the same as the first two units, noise control problems for other utilities. wanted to continue its good neighbor its induced draft fan equipment and its The ductwork and induced draft fan policy when it decided to add new equip accessory ductwork also had to be in housing for the first two power genera ment to improve the two existing power stalled outside the unit's main power tion units required about 20,000 sq. ft. generation units. At the same time, plant. Exceedingly noisy sounds were of panels. They were delivered in pre LILCO was building a new, third power emanating from the equipment in much cut sizes ready for installation. This generation unit and the utility wanted the same manner as in the first two considerably reduced installation costs it to be as quiet as the first two units. units, but the noise was intensified and and decreased equipment downtime In doing so, the utility spent many amplified because the third unit included while the two units were being modified. hours monitoring noise levels, locating the addition of a massive electrostatic Use of the pre-cut panels also per noise sources and investigating solutions precipitator adjacent to the induced mitted the third unit to be readied for to the overall noise problem. It was draft fan installation. operational testing quicker than would eventually solved by using single and Several additional problems had to be have been possible had the panels been double layers of sheet lead for the pri overcome before the noise barrier to cut-to-size in the field. Approximately mary sound barrier of a newly de enclose the noisy equipment could be 55,000 sq. ft. of panels were required veloped combination acoustical/thermal installed: the panel system used to en to enclose the third unit. The accom panel system that enclosed the various noise sources. close the equipment had to be able to withstand the approximately 450F panying line 1was' accomp,l ,T , LIAOt0Pf1 XPAND THE USE OF LEAD P FOAM/LEAD MACHINERY ENCLOSURES HELP MEET OSHA NOISE STANDARDS Industrial management is directly re sponsible for seeing that plant noise levels meet standards set by the 1970 Occupational Safety and Health Act. Presses, automatic riveters, screw ma chines, lathes and many other machines commonly used in metalworking run at noise levels above the 90db standard set by OSHA. Now machinery enclosure ex perts are offering a range of products to help solve the problems. The machinery enclosures can achieve reductions of up to 50db, depending on how carefully the enclosure is installed and the original noise levels encountered. The enclosures can be custom-built to enclose any type of machinery regard less of size and configuration. Ports can be designed into the panel enclosures to permit stock input and output and, if needed, a specially designed door can be installed to permit operators to enter the enclosure. Standard-size panels are also available to facilitate do-it-yourself noise control machinery enclosures. The panels, available in standard 2 ft. x 4 ft., 2 ft. x 8 ft. and 4 ft. x 4 ft. sizes, are supplied with the aluminum extrusion framing to permit construction of the sides and roofs of machinery enclo sures. > In many cases it is not possible to enclose the complete machine because it must be accessible to the operator. Here, it may be possible to shroud the gears and other noise producing elements and still have the work station accessible. If this is not possible, the entire unit can be isolated in a "room" or "tent" made from leaded vinyl plastic cur tains. One typical sound enclosure system consists of 114 in. thick lead/foam ma terial; an extruded aluminum framing system; and flat aluminum sheets, in gages ranging from 0.049 in. to 0.062 in., for the exterior face of the panel. The lead acoustical/foam material consists of two sheet lead septa, each weighing l/> psf (.0078 in. thick), that are sandwiched in acoustical foam. Se lected because it meets UL-94 regula tions for fire retardancy, the acoustical foam will not "dust out" or delaminate from the sheet lead like some other material. In addition, the lead/acousti cal foam tends to be self-healing should workmen have to drill holes in the panel, e.g., for electrical conduit. The material encircles the cable and tends to seal potential openings through which sound could travel. L I 4 050P7 5 tLECl KIU^) KUKLMUk. vr VEHICLES IN DEEPEST U.S. SALT MINE (in ack to the salt mines" is not just k# an expression, but a way of life for the 225 employees of the Morton Salt Company at Painesville, Ohio. They work in the deepest salt mine in the United States and they produce about 1.5 million tons of rook salt a year. The 2,000 foot-deep mine, located on the shore of Lake Erie about 30 miles east of Cleveland, taps a vast bed of rock salt--an estimated 100,000 square miles of it--that is believed to be the largest deposit of its kind in the world. At Morton's Painesville mine, rock salt is mined by the "room and pillar" method. In this mining technique, about half the rock salt is removed from the working face of the mine while the remainder is left in the form of pillars to support the mine roof. To accomplish this, a 10 ft. deep undercut is made at the base of the work face and a series of multiple holes for explosives are me chanically drilled the same distance into the face of the wall. The work face is blasted at the end of a work shift, pro viding about 500 tons of rock salt to be processed by the next work shift. Supervisory personnel play an im portant role in the safe, efficient opera tion of the mine. One of their most important jobs is to constantly check the work face to see that it has been properly undercut at the base, and to in sure that the holes for the explosives have been properly drilled and placed. Just as important, the supervisors also check to see that the explosives have been properly set before the work f&ce is blasted. Since the work face being blasted can cover as much as 4,000 ft., it is essential that supervisors be quickly transported from one point to another along the work face. Until recently, supervisors at the Morton Company's Painesville salt mine were carried to and from the work face areas by diesel-powered personnel car riers. A maintenance crew, operating from an underground shop on the mine's working level, also utilizes the carriers. In addition, the carriers were used to deliver small parts to and from the mine's store room and the bottom of the shaft, located about half a mile from the maintenance shop. The diesel units have now been re placed by battery-powered cars. Assis tant mine manager John J. Harkins re ports that one of the main reasons for making the replacement with batterypowered units was to improve air qual ity at the working level of the mine. "The new vehicles are quiet and pro vide a somewhat more comfortable ride than the diesel tractors we still use for our work force," Harkins said. "And we especially like the fume-free aspects of the electric cars since they reduce the amount of diesel fumes our mine ven tilation system has to contend with." he added. A total of five battery-powered units are now in use at the mine. All five can transport four supervisors. One of the carriers, the largest of the five, features a rear-mounted compartment that can be used to haul parts and supplies. The vehicles are standard industrial models that have been fitted with wideturf tires in order to insure good trac tion on the floor of the mine, which is covered with a thin layer of coarse rock salt creating the same resistance to trac tion and sand. "There will continue to be a need fo, diesel tractors to perform a number o! heavy hauling and pulling jobs involvec in the everyday operation of the mine,' explained Harkins. "However, it is ex pected that the electric vehicles wil provide us with an economical and bem ficial means of replacing a number c our other diesel tractors." The batteries used to power the smai est of the new vehicles are 6-volt. Tb batteries range in amps from 190 to 22 and, unlike automobile batteries, tal repeated deep cycling, or charging ai discharging. The largest of the five v hides is powered by a 36-volt, D.1 traction-type motor which transmi power to a worm gear different) through a matched set of three dri belts. THIS MOTORBOAT IS NO STINKPOT Wew pleasure boat can travel at 5 knots on Its lead-acid batteries. Batteries of the Electra are rated at 272 amp. hrs., 24 volts. The designer of a new, battery-pow ered craft, called the "Electra-18", The Electra is powered by two heavyduty marine batteries. The two 200 lb. thinks his boat offers a practical and batteries, each delivering 272 amp-hours pleasurable solution to the pollution at 24 volt's, are contained in a box keel, problem. It promises to put more plea which also contains the boat's electric sure for more people back into pleasure motor and an automatic bilge pump boating. This is a timely development, that prevents the motor from flooding because the growing popularity of boat from excessive rainwater. The total ing has brought with it increasing com weight of the boat, including the keel plaints about noise and water pollution. box and its equipment, is 1,100 lb. Be "A lot of waterfront communities are cause the weight is at the craft's center- outlawing standard power boats. Con line, the boat is unusually stable. servationists and naturalists are pressing The inboard power system for the hard for tougher laws prohibiting noise craft, a permanent magnet electric mo tor that delivers ^-horsepower, can run the boat for about 30 miles at 5 miles per hour cruising speed. At 3 miles per hour, the boat can be operated for 12 hours. A solid-state controller permits variable speeds down to below 1 mph. To recharge, dual automatic marine battery chargers plug into any 115 volt 60 cycle outlet. The cost to recharge the batteries is but a few cents. A tran sistorized circuit prevents overcharge and, with good care, the batteries will last several years according to the com pany. In addition to being designed to pro vide optimum stability, the hull and keel also provide protection for the boat's heavy-duty propeller and rud der. The craft has a 5% ft. beam and a draft of only one foot, making it especially useful for shoreline exploring. Company president Branson reports that work is in progress for a mold to produce a 30 ft. fiberglass electric boat. He says the boat_will be known as the "Electra-30" and it will have an 8 ft. and pollution of the waterways by inter beam and a draft of 18 in. The boat nal combustion engine craft. Our boat also will have 2,000 lb. of lead acid is designed to eliminate these prob batteries in the box keel and it will have lems", comments Norman Branson, pres a total displacement of between 5 to 6 ident of the boat company which pro thousand pounds depending on the num duces the Electra. ber of people aboard. Designed for trolling, the fiberglass The battery capacity of the newly de boat is also gaining acceptance for veloped Electra-30 will be over 30 kilo leisurely sightseeing, picnicking and watt hours and the boat's maximum cruising in light traffic waters. The com speed will be about 6 knots. At a speed pany reports that the boat is easy to of 5 knots, the boat is expected to run maintain and is so safe and simple to for more than 12 hours for a total dis operate that a novice sailor can handle tance of about 60 nautical miles before it. recharging. L I A050PO AIRPORT X-RAY MACHINES TO FOIL SKYJACKERS Ai irlines are now required by the FAA passengers preparing to board a jumbo radiation from medical X-ray appai to inspect all carry-on luggage. As jet. Tests conducted by Western Airlines tus. a result, an intense competition has de and Pacific Air West Airlines at Los According to the manufacturer, t veloped among manufacturers of lead Angeles International Airport have de equipment is "ultra safe" in terms shielded X-ray devices designed to speed termined that with the new X-ray sys radiation hazards. The unit's entire the inspection process by eliminating tem, the average bag inspection takes ray generator system is enclosed the need for hand searches. about 10 seconds, indicating that rela 5/32-in. thick, 10 psf lead except i The new inspection systems make it tively little delay is encountered by the X-ray tube slit which directs ! possible to view the contents of carry- boarding passengers. beam. * on airline luggage or packages without opening them, thus providing a quick, Using a proven medical diagnostic tool, the device produces visible images Lead also plays a critical role in efficient means of inspection and deny of the contents of luggage or a package. unit's fluoroscopic viewing system, ing a potential skyjacker a favorite means of carrying concealed weapons or explosives aboard an aircraft. One typical X-ray surveillance system has been successfully tested by Western The images, which are viewed on a screen seen through a specially designed porthole, are similar to those seen in a three-dimensional photograph negative. The images consist of shadows of vary direct viewing of the screen is accc plished by use of a mirror so t primary radiation from the X-ray ti will not strike the viewing port. To sure complete shielding from any ; ondary radiation, the viewing port c Airlines and Pacific Air West Airlines at Los Angeles International Airport ing density and a specially trained op erator of the new device can detect sists of 14-in. thick leaded glass. and by Delta Airlines at New York's weapons and explosives by their shape. One major airline announced er Kennedy International Airport. Despite its advantages, the new air in the year that it will spend over The Delta tests conducted at Kennedy line passenger security device has one million to buy and install up to 25 X- International Airport over a three-week potential hazard. Excessive radiation machines at the airports of its syst< period were highly successful in demon from the system's X-ray unit could re The first installation was scheduled strating X-ray capability in rapidly and sult in genetic and physical damage to New York in March and most machi efficiently providing a visual inspection the human body. Therefore, an effective are due to be in operation by e: of all hand luggage. Airline officials esti radiation shield had to be built into the summer. This particular machine mate that widespread use of an X-ray new system. This was accomplished by permit inspection of an average pas: fluoroscopic unit throughout its system using sheet lead, one of the most effi ger's carry-on items in five seconds, would reduce from minutes to seconds cient radiation barriers known. The airline estimates. The X-ray mach the time required to process an indivi metal lead plays a critical role in the are sensitive enough to show the 1 dual's carry-on baggage. For example, it successful and safe use of the new bag of shaving cream in an aerosol can could take as long as five man-hours to gage inspection system, just as it has are harmless to contents, including manually inspect carry-on luggage of for years in guarding against harmful exposed camera film. 8 L I t 0c 000 *><*&*] CANCER TREATMENT The detection and treatment of cancer through nuclear medicine is highly complex, but it can be simply stated that it involves the injection of minute amounts of radioisotopes into the hu man body. Their combined or individ ual effect on cancer areas is then re corded and studied by a variety of spe cialized techniques. The science of nuclear medicine has one major disadvantage. Radiation from the radioisotopes that are inherent in nu clear medicine can endanger the human body. Improperly used, radiation can result in genetic and physical damage and even death. Therefore, every effort is made to avoid exposing the human body to excessive radiation when radio isotopic medical techniques are used. Cancer patients being diagnosed or treated with nuclear medicine techniques are not likely to be exposed to. undue radiation. Doctors, technicians and other specialists in nuclear medicine however, must work daily with radio isotopes, and since the effects are cumu lative, they must be constantly shielded against radiation. Various techniques have been de veloped. One of the most effective is to surround the radioisotopes and all ac cessory equipment such as X-ray instal lations with a protective lead shield. While such shields are designed to pro tect personnel from the three sources of radiation--alpha, beta, and gamma rays--they are primarily used to shield gamma rays which are the most dan| gerous because they are the most pene trating. Protective lead shields are provided for radiopharmaceuticals from the time they are shipped from the manufacturer until they are injected into the body. Lead is the foremost material to be con sidered in designing for efficient shield ing against X-rays or gamma rays, the two most common types of radiation encountered. According to the Atomic Energy Commission, when other shield materials are considered, "comparisons are usually expressed in terms ol lead because it represents the best practical gamma shield for most applications". Although lead's primary shielding property is mass, its use invariably saves weight and space. Lead's low cost and the ease with which it can be cast, extruded, rolled, machined or otherwise formed, combine to make it one of the most efficient and economical shielding materials. Lead radiopharmaceutical shields and shipping devices are typical products supplied to this market. To produce the devices, pig lead is melted and poured into round, cylinder-shaped molds with a solid core. When the lead has cooled and the desired shape of the shield or shipping device has been formed, it is removed from the molds. If required, the sides of the devices are machined and then painted. A typical radioactive shield or ship ping device that would be used to ship a radiopharmaceutical is about 3 in. high, has lead walls about IY2 in. thick, a ]/> in- diameter hollow core, and weighs about 2 lbs. Because each type of cancer requires a different type of radiopharmaceutical, literally thousands of shielding devices are required by the radiopharmaceutical industry. They are used by the more than 3,000 hospitals throughout the country that have radio isotope facilities and by various can cer research and detection facilities. Pharmaceutical companies also use the devices to ship radioactive materials to the various hospitals and cancer re search and detection facilities. Safes and glove boxes are custom de signed according to specification. A typical safe might have 6 in. thick lead walls and weigh several tons while a single-station glove box might have inch-thick walls and weigh as much as five tons. Glove boxes are equipped with lead glass ports so that technicians will have a clear view of the interior. In addition to its advantages of being the densest of any commonly available material and being available in a wide variety of forms, lead has another, more meaningful advantage with regard to its use as a radioactive shield material. Be cause lead does not become contam inated by neutrons or gamma rays, it may be used continuously without fear of its becoming a radioactive source it self by emitting harmful rays. L 7 0 f- 0 c i COMPUTER DEMAND FOR MASS-PRODUCED SOLDERED JOINTS RESULTS IN INCREASED USE OF LEAD ALLOY PREFORMS It wasn't too long ago that many solder joining operations used only the timetested, hand-held, preheated soldering iron and a solder wire or bar. While still in wide use today for such applications as roofing and gutter systems, water proofing, etc., the continuous effort by many industries to either partially or completely automate production lines has wrought (or brought about) many changes in soldering procedures and techniques. One soldering innovation that is find ing increased use is the solder preform. Preforms have been made economical and practical as the result of a number of developments: the availability of high quality solder alloys, faster-acting fluxes and techniques for the proper heating of parts. Just what are lead alloy solder pre forms? Simply stated, they are manu factured solder configurations contain ing a fixed quantity of metal alloys-- with or without a flux core. Preforms are designed to produce perfect solder fillets for specific joints in an assembly. They can be manually placed on the area to be soldered or they can be dispensed automatically by a variety of mechanical devices that are usually custom-designed to perform a specific solder preform in stallation. Once in place, solder pre forms can be joined by any conventional heating method compatible with the as sembly. This includes infra-red lamps, induction resistance, natural or propane gas torch, oven or hot plate. Depending on the specific requirement, one or a combination of these heating techniques can be used to make joints with lead alloy solder preforms. There are thousands of preform shapes available. Each shape is a deriva tive of one or more of the following four most common shapes: Wire: Round, square, oblong and oval shapes can be made from either solid wire of flux-filled wire. As a general rule, wire shapes can be cut and formed into straight or curved segments, made into rings and coils, or stamped into continuous loops and other odd shapes. Punched parts: Solid wire of flux- filled ribbon can be used for punched parts in the form of discs, washers, sleeves and odd shapes. Flux-filled discs must have a solid portion to hold the top and bottom of the disc together. Spheres: Spherical shapes are avail able only as solids. Solder-coated metal forms: These are precoated metal punchings that contain a specific thickness of solder alloy. Because of their ease of installation, the speed with which they can be as sembled and the highly effective joints they provide, lead alloy preforms are being used by the thousands to join computer components. To keep up with the demand, a number of companies that specialize in producing solder products, have established separate divisions whose sole product line is geared toward ser vicing the computer industry. Some of these companies have lead solder pre form specialists who work directly with computer manufacturers and their sub contractors when the components that use the preforms are at the design stage. A typical example of the thousands of mass-produced lead alloy solder pre forms used in the electronic data proc essing industry are tiny chains of wash ers that are used as grounding elements for the hundreds of wires installed in a computer terminal block. The terminal block's job is to sort out signals that direct data to and from various parts of the computer and there are as many as 200 to 2,000 such terminal blocks in an average computer. There are literally hundreds of ap plications for lead solder alloy pre forms. They range from air filters to wire mesh components and in all cases, their use results in time and money saved in assembly, elimination of solder waste, and an improved soldered joint. Perhaps just as important, their use also permits the joining of a wide vari ety of micro and subminiature assem blies that could not otherwise be effec tively jointed. Installing solder preforms before wiring a computer component. Typical electronic circuit board showing preform: after they have been melted Into place. Many kinds of solder preforms are used to speed assembly of electronic circuitry. LARGEST U.S. UTILITY RELIES OIM LEAD-SHEATHED CABLE; CONDUCTS MAJOR TRAINING SCHOOL Key steps in joining feed sheathed cable include: shaping the sheath with a wooden "dresser", top left; tapping the cable to assure a good tit. bottom left; cleaning the joint area, center; pouring solder on the joint, top right; and hand "wiping" it lor a smooth surlace, lower right. Consolidated Edison Company is the nation's largest electric utility. It lines, or cables, are constantly being re routed, expanded or otherwise modified provides electricity to the five boroughs to provide additional service required of New York City and part of West by the thousands of new homes, apart chester County ... an area of approxi ments, office building and commercial mately 660 square miles and a popula and manufacturing facilities that are be tion of nearly 10 million people. The ing added to the city's roster each year. utility services more than three million In addition, existing underground lead- customers ... all the way from the sheathed electrical cables must also be world's tallest buildings to multi-story constantly serviced, maintained and re apartment buildings that house thou paired. sands of people, to single family dwell ings and the thousands of New York City metropolitan area industrial plants that account for an impressive 10 per cent of all the nation's manufactured products. As part of the enormous effort re quired to insure that its underground power distribution system operates as efficiently as possible, Consolidated Edi son has developed what may be the util ity industry's most comprehensive train The key 'element in providing electri cal power to the utility's vast number of customers is Consolidated Edison's enor mous underground electrical power dis tribution system. It consists of 5,000 volt to 27,000 volt electrical cable; most of it lead-sheathed, and it contains nearly 70,000 miles of electrical lines . . . ing department. The department has de veloped a number of highly specialized training schools designed to train Con solidated Edison employees in the art of installing, repairing and maintaining the wide variety of components that make up the utility's electrical distribu tion system. enough to extend from New York to San One of the training schools is the Francisco 12 times. The lead-sheathed Consolidated Edison Cable Splicing School which, because of the extensive use of lead-sheathed cable in the utility's underground electrical distribution sys tem, specializes in splicing and joining this type of cable. The school is the most extensive of its type in the country and is, so far as is known, the only one of its kind operated by a utility on such a large scale for trainees of other utilities. The school instructs trainees of other electrical utilities--some as far away as Hawaii--and, in addition, has at one time or another instructed military engi neers from all the Armed Forces. The school is divided into a three-part course. The first course, during which the students leam to make 26 different kinds of lead-sheathed cable joints, runs from 8 to 10 weeks and it is designed to teach the basics of underground power distribution cable splicing. The second course is a six-month field training pro gram where cable splicing techniques learned during the first course are prac ticed during supervised on-the-job as signments. The third course is a threeweek advanced program and it is given at the Cable Splicing School. L 140506! AMERICAN REVOLUTIONARIES RE-CYCLE KING GEORGE I A20-lb. fragment of one of the most famous pieces of sculpture in read to the citizens and soldiers of New York for the first time at the site of American pre-revolutionary history haswhat is today the City Hall for the City been unearthed in Wilton, Conn., where of New York. That evening, a group_of it has been buried for nearly 200 years. enthusiastic patriots angrily attacked The fragment is from a 4,000-lb. eques the statue. trian statue of King George III, the last Not content with attacking the statue, king of the American colonies, that stood the patriots placed a rope around His for only six years after it was erected Majesty's neck and toppled him and his atop a high marble pedestal in 1770 at horse from the marble pedestal. The Bowling Green Park on the Island of angry men then attacked the lead statue Manhattan. with axes, cutting the head from the The statue was made in London-- oddly enough in the light of later events by a man named Joseph Wilton--and shipped to New York where it was un veiled in the summer of 1770. The lifesize statue, like other classical Roman statues of the day, was complete with toga, sandals, and a wreath of laurel. The king and his horse appeared to be made from gold, but both were cast from lead and coated with gold leaf. The statue was never popular among the majority of the Colonists. In fact, it had been up only a year when the British erected an iron fence around it (the fence still stands today) and threat ened to levy a 500 pound fine on any one caught defacing the statue. body, disfiguring the nose, and prying the laurel wreath from the King's head. Within a matter of days, as the Amer ican Revolution got underway, the stat ue was hacked into pieces of approxi mately 20 pounds each. With British forces encircling Manhattan and the American Revolution only five days old, the decision was made to make good use of the lead by turning it into bullets to fight the British. The valu able lead was loaded into wagons and carted off to a military depot in Litch field, Conn., where at least half of it was melted down and cast into bullets for the Continental Army. According to detailed records still preserved in Litch field, women of the town made 42,088 cartridges from the scrap lead. On July 9, 1776, a courier arrived Bullets cast in Litchfield account for from Philadelphia bearing a copy of the only about half of the two tons of lead Declaration of Independence which was in the statue and the fate of the missing pieces has been a matter of specul; for many years. While it isn't known exactly hov pieces of the King George III s wound up in and around Wilton, assumed that men driving the wagi Litchfield stopped off at a tavern i area and left it unguarded while rested and ate. Some local Torie; believed to have discovered the pie< the statue and stole several piec keep them from being turned intc lets. The 20 lb. fragment of the that was recently unearthed at Wil the only piece to have been disct in more than 100 years. Louis Mi native of Wilton, found the piect small swamp that is only aboi: miles from his home. He locat fragment with an electronic mei tector and as soon as the water th covers the swampy area evaj sometime this summer, he expt return to the area and contin search for additional fragments t) believed to be in the vicinity. Mr. loaned the lead fragment to the IV of the City of New York where displayed early this year along rare engraving depicting the s! King George III being toppled f pedestal by patriots on July 9, L I A0f'0r*4 BATTERY-POWERED VEHICLES APPROVED FOR HAZARDOUS AREAS An important section of the new Oc cupational Safety and Health Act Powered Industrial Truck publication B56.1-1969, Part II. ANSI is one of is concerned with the use of industrial several nationally-known organizations vehicles in hazardous areas. Basically a whose materials handling equipment hazardous industrial area exists where fire protection recommendations become various ignitible or explosive gases, va law when adopted for powered indus pors, dusts or fiber particles are present trial trucks. in the atmosphere in sufficient quanti The regulations also state that all ma ties to cause fires or explosions. terials handling equipment to be oper These conditions are commonly found ated in hazardous locations must be in chemical and petroleum plants, flour clearly marked with a label or some oth and grain mills, underground mines and er identifying mark indicating their ap plants engaged in the production of proval for use in one or more of the ammunition, paint and varnish products. three hazardous locations. Three classes of hazardous locations OSHA regulations specify battery- are defined by OSHA: powered explosion-proof vehicles as the Class I locations--those in which only types permitted to operate in all flammable gases or vapors are, or may three classes of hazardous industrial be, present in the air in quantities suf areas. ficient to produce explosive or ignitible A key factor in the ability of materials mixtures. handling equipment to qualify for the Class II locations--those which are EX (explosion-proof) Label is the re hazardous because of the presence of quirement for an explosion-proof bat combustible dusts. tery. Lead acid battery manufacturers Class III locations--those where eas have played a leading role in helping the ily ignitible fibers or flyings are present producers of lift trucks and other types Dut not likely to be in suspension in of materials handling equipment to quantities sufficient to produce ignitible qualify their vehicles for the EX-Label mixtures. by working with them to develop speci ally designed explosion-proof lead acid The first section of the OSHA powered batteries. industrial truck specifications states that From a fire protection standpoint, the all new vehicles must meet design speci most critical component of EX Label ve fications established in the American hicles is the electric power system. The National Standard Institute (ANSI) batteries of such vehicles are enclosed in special trays that have yi6-in. thick hinged steel covers. Ventilation for the trays is provided by a design that pre cludes the accidental insertion of foreign objects through the vents in such a way that a short could occur across the cell terminals. The housing for the battery tray con sists of a /'jg-in. thick malleable iron compartment. A fuse block for control and power circuits is built into the hous ing. A tumbler type lock is fitted to the fuse block to prevent unauthorized per sonnel from engaging or withdrawing the connector plug. EX Label vehicles also are provided with explosion-proof enclosures for the lift pump and traction motors and all electrical components. As added safety precautions, electrical conduit from the battery to the drive and pump motors is covered in flexible woven wire. Rules and regulations listed in the new OSHA requirements also establish 12 specific safety steps to be followed when changing or charging the lead acid batteries of electric-j>owered vehicles op erating in hazardous areas. They include a requirement that battery charging in stallations be located in specific nonhazardous areas designated for that pur pose and a ruling that battery compart ments and/or covers shall be kept open to dissipate heat while charging bat teries. LEAD QUIETS NEW JET-POWERED SAN FRANCISCO BAY FERRIES S 14 Rosr of new jet-powered San Francisco Bay commuter terry will be silenced by lead acoustical barriers. The population of Marin County, which is across San Francisco Bay from the City of San Francisco, has ex panded to the point where there is a daily morning and evening commuter rush-hour traffic bottleneck on the bridge which connects the two points--the fa mous Golden Gate Bridge. To solve the problem, the Golden Gate Bridge and Highway Department have developed an integrated transportation plan that in cludes the use of special buses and a San Francisco Bay ferry system that, un til the Golden Gate Bridge was built, provided the only direct route between Marin County and San Francisco. The first phase of the ferry plan was ~ completed a little over a year ago when ferry service was initiated between San Francisco and Sausalito, a small Marin County community just north of the bridge. The second, and far more dramatic phase of the program is scheduled to begin late this summer when residents of Central Marin County will be literally "jetting" to work on board one of three new gas turbine driven, water jet-pro pelled ferries that are now being built. Each designed to transport 750 passen gers at maximum speeds of 28 knots, the 165-foot ferries will cost about $7.71 million. It is estimated the ferries will be able to transport more than 11,000 passen gers during commuter hours, thus po tentially eliminating at least half as many cars on the Golden Gate Bridge and its approaches during rush hours. The ferries will be powered by three aircraft type gas turbines which will in turn provide power for the three water jets that will propel the vessels. Each turbine will develop a maximum speed of 2,500 ship horse power (SHP) while the water jets will each be capable of a maximum 16,000 lbs. thrust. Just as passengers have to be isolated from the high-pitched roar of jet air craft engines, passengers aboard the ferries will have to be isolated from the high frequency sounds of the gas tur bine engines that will drive the water jets. The turbines produce sounds that are close to the threshold of pain for the human ear and, in order to protect pas sengers against such discomfort, the en gine rooms of the three ferries will be enclosed by an acoustical barrier. To be installed over the top of fire zone insulation to meet U.S. Coast Guard A-60 requirements, the barrier will con- , sist of 2 psf (%2-in. thick) sheet lead laminated to a 1/2-in. thick insulating board. The sheet lead/insulating board laminate will be installed over all engine room wall areas of each of the three vessels. Designed to provide the utmost in commuter comforts, the ferries will have a passenger and cocktail lounge on the main deck and a forward observation lounge and another cocktail lounge on the upper deck. The engine room of each of the three vessels is located aft and abuts the main deck and upper deck cocktail lounges. Therefore it would not be possible to carry on a norma conversation if these areas were no being covered in the combination leat insulating board noise barrier. Speaking of lead's use as a noise bar rier aboard ships, John Weiks of Phili) F. Spaulding and Associates reports tha lead's acoustical properties have beei used to advantage in marine vessels fo the past 20 years. For example, lead ha been used for noise barriers aboar minesweepers as well as a variety c high-speed, water-jet propelled U.f Navy experimental ships. In addition manufacturers of pleasure boats also u lead to silence engine noise. L IA 0 5 0 Q 6 CONCEPT OF LEAD/ZINC HOUSE EVALUATED Innovative lead/zinc house. There is always something new under the sun if you are innovative enough. How about a lead/zinc house? Working on a project assignment from 1LZR0 (International Lead and Zinc Research Organization), the Rhode Island School of Design has come up with just that. The design work is completed. Next step is the building of a prototype. In addition to demonstrating tradi tional and hybrid applications for lead and zinc in housing, the prototype will include such new developments as a variety of lead composite materials, wrought zinc roofing systems, new finishes and improvements for zinccoated steel building panels, and zinc die castings produced with recently im proved die casting techniques. Such rela tively new housing applications as sheet lead for sound attenuation also will be included. Although the metal house has been designed for factory-built mass produc tion anywhere in the world, the basic prefabricated design is so flexible that it can be finished in many ways to satisfy individual tastes and require ments, using classical as well as con temporary materials, finishes and tech niques. A basic aim of the design is to convince the architect and specifier that lead and zinc products should be con sidered for a variety of new applications. The metal prototype house also will emphasize several specific advantages of critical importance in today's ecology. The availability of lumber, for instance, has become a major problem due to in sufficiency of land reserves, particular! in Asian countries. This has resulted i erratic supply and rising prices. The ILZRO design incorporates a nov( core and service module that centralize service facilities. Such units as kitchen and bathrooms are positioned in a cor area to minimize costs and to increas efficiency. Rooms requiring fewer ser vices, such as bedrooms, are attached like annexes, to the core area. Comparative cost data are not too rc liable at this point of development, bu; one estimate puts the cost of producing 10,000 lead/zinc houses at $14 to $1( per square foot. This compares to $11 to $20 per square foot for conventional wood-constructed housing. Progress on the lead/zinc house will appear in fu ture issues of Lead Magazine. FOR CHANGE OF ADDRESS PLEASE WRITE IN NUMBER FROM TOP OF ADDRESS OR ATTACH OLD LABEL. ADD ME TO YOUR MAILING LIST (pleas* check one) V ATTACH MAILING LABEL HERE ________A_________ Name, Title Company Street City, state, zip code PLEASE CHECK INTEREST Painting Health & Safety Architectural & Building Design & Radiation Engineers Ceramics Chemical Engrs. Battery Power O Miscellaneous (please specify) ( i NEW LISTINGS Lead Keeps Classrooms Quiet Reprint illustrate* how sheet lead was installed as plenum barriers between rooms in a Greenlawn. N.Y. school. Lead-shielded audiometric room will provide accurate bearing tests. J-13 A Crackling Market for Electric Forklifts Business Week reprint details the upsurge in use of electric forklift trucks in com pliance with stricter Federal and other antipollution regulations. L*l6 Electric Truck Stops Corrosion Problem Replacement of a propane powered lift truck with a battery driven one solved industrial plant corrosion generated by propane fumes. Electrical World reprint. L-I7 Publications and Films Twelve-page catalogue listing the publica tions and films available from The Lead Industries Association. Inc. M-13 Stained Glass Artist Illustrated description of the work in lead stained glass of artist Mrs. Roberta Katz of Arkansas. M-25 ARCHITECTURAL Lead roofing and flashing Detailed instructions on the simplest and most usual methods for forming or joining lead for roofing and flashing appli cations. Complete specifications. Dia grammatic drawings. Sixteen pages. A-5 PAINTS Follow the safety line with chrome yellow Formulations and suggested applications for chrome yellow safety paints. Illus trated. Eight pages. F-5 Red lead based paint systems Provides details on general properties and suggested uses of recommended paints. Instructions on surface preparation for a variety of applications. Listing of LIA recommended formulations. Thirty-two pages. F-l PLUMBING Lead plumbing catalog and specifications Specifications and details for the use of lead in plumbing. Waste connections, shower and safe pans and chemical lab oratory drains are covered. Four pages. 0-2 CHEMICAL CONSTRUCTION & CORROSION PROTECTION Corrosion resistance of lead in chemical applications A chart presentation of the corrosion re sistance of lead and its alloys against 188 chemicals from 0* to 3000*F. Six pages. H-3 BATTERIES A primer on the lead-acid battery A condensed story of the principles of the lead-acid battery and its chemistry, in cluding some of the fundamentals and definitions of direct-current electric en ergy. Two pages. L- Electric trucks are the choice Reprint from Electrified Industry. Opera tional and maintenance experience of a major company with battery powered inpiant vehicles. Four pages. L-10 Lift profits electrically Provides performance data on electric battery powered vehicles for industrial use. Cost calculators are designed to help buyer estimate depreciation, operating and maintenance costs. Sixteen pages. L-14 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. B-ll SOUND BARRIERS Directory of acoustic specialties Summary of available materials for sound insulation by barrier, damping and absorption methods. Sixteen page list of materials by brand name and manufac turer. Eighteen pages. J4 Lead a major factor in new machinery noise suppression systems Description of techniques used to lower machinery noise levels with lead and lead composites. Lists machines that normally exceed noise level allowed by WatshHealey Public Contracts Act. Two pages. J-9 Controlling sound with lead Reprint cites three installations where lead is being used as a noise and vibra tion barrier: John Hancock Building: Baldwin-Waliacc College; and New Eng land Medical Center. Boston. Four pages. J-12 Sheet lead plenum barriers Detailed description of acoustical plenum barriers and how to install them. Mate rials and installation procedures described and illustrated. Eight pages. J-10 ANTI-VIBRATION PADS Ways to reduce press vibration Two installations of lead asbestos pads to reduce heavy machinery vibrations. Sec tional drawings and loadings are given. Two pages, illustrated. G-l Lead asbestos anti-vibration pads Specifics on lead anti-vibration pads in cluding design and sizing, specifications for the sub-contractor, and list of pad manufacturers. Three pages. G-3 CABLE SHEATHING Lead-covered underground cable use increasing Reprint outlining a major utility's recent experience with lead sheathed under ground cable. Details on where this type cable is desirable. Graphs. Four pages. C-2 GENERAL Lead Welding Reprint from American Welding Society Handbook. covers methods of welding lead, joint design, torch manipulation and welding speeds. Other sections cover safety promotions and common applica tions. Bibliography. Fourteen pages. 1-1 The U.S. Lead Industry--1972 An annual review of activity within the In dustry that contains a general sumTnary for the year and a series of- charts and tables giving current statistics on lead production and consumption. M-14 Primary lead production areas in the U.S. For schools, libraries. Il"xl4" map show ing locations in U.S. of most lead smelters and refineries, and lead mines. M-ll Lead--A Modern design materia) Summary of properties and available forms of lead for radiation control, sound/vibration control, electrical energy sources, soldering and ceramics. Eight pagss. M-15 The new lead belt Reprint of article details operations at the new lead belt in Missouri. Booklet de scribes activities at four mines, four con centrators and three smelters. Twelve pages. M-16. Use of lead in the automobile Reprint of article from Metals Week dis cussing in detail the various applica tions of lead in the automobile. Four pages. M-17 Lead--The "Clydesdale" workhorse in space Reprint from Space World detailing the applications of lead in space exploration. Illustrated. Four pages. M-19. Ecology in the new lead belt Reprint describes cooperation of industry and environmentalists in developing southern Missouri lead mines. Four pages. M-23 FILMS Lead Matrix A 26-min., 16mm color film. Demon strates that lead is one of the basic ele ments In the matrix that binds our civili zation together. To order, specify desired show date and one alternate date. No charge to borrow; viewer pays only re turn postage. N-l