Document QJVL57Ed72dLRDoaG6kxdJRE7

N: ) .. i 2 .. 3 .. 4 .. 5 6 .. 7 .. 8 .. 9 .. 10 .. 11 12 .. 13 .. 14 .. 13 .. 16 .. 17 .. 18 .. 19 .. 20 .... 21 22 .. 23 .. 24 .. 25 ..-26 .. 27 ) .. 30 .. 31 .. 32 ..33 .. 34 CRS more * 17 23 15 58 lies), a. ILL WHP iV&P IIP mm. m Current Safety Topics in the 111 Wm m As prtwiftd ii ffco Sessloas of fie Metals Sectiba at the 1951 National Safety' Congress r The American Package.................. ........................... 5 Use of Directional Explosives for Tapping Open Hearth Furnaces ................... ............................... ....... 5 The Jet Tapper Practice at the Open Hearth....................... 8 Safe Use of Cables arid Slings........... ............................. II Warehouse Safety ............... ............... ....................... . . 13 The Use of Wetting Agents to Control Dust in Industries.. 18 The Administration of Safety Programs.................. ...........21 Safety in Handling Magnesium............................................. 25 _ ** v The Part. Management Must Play in the Safety .Game.........30 Safety is a Way of Thinking..................... ........................... 33 Volume 18 Transactions 39th National Safety Congress NATIONAL SAFETY COUNCIL 425 No. Michigan Avenne Chicago If. Ill. If safety is to keep pace with today's rapidly advancing technology, we must continually have "new ideas." Each year, at die National Safety Congress, the ideas and experiences of many of the nation's top safety men are presented in the various sessions. Many of these ideas, devices and methods; first presented at a Congress session, later become generally accepted within their fields. In order to present this information conveniently and at small cost, the Congress Transactions are published in volumes, one for each Section or Division, along with a General Sessions and Detailed Index to all volumes. The 34 volumes of die 1951 Congress Trans actions are listed on the last page of this volume. Safety directors everywhere have found the Congress Transactions a useful aid in their accident prevention programs. In industry, for example, their judicious distribution to key personnel in management and supervision has proved to be of invaluable service. In preparing these Transactions, die proceedings of the Congress have been condensed and edited for reference purposes. Complete original manuscripts, with any charts or illustrations which were used, are available in National Safety Council files. Views expressed at the Congress or in tins record are those of the Congress participants and are not necessarily those of the National Safety CoundL TIE METALS SECTION The volume is a record of the sessions held at the 1951 National Safety Congress by die Metals Section. The conduct of these Con gress sessions each year is only one of the many cooperative activities which the Metals Section carries on in behalf of its members, and for the benefit of accident prevention work in the metals industry generally. The Section gives guidance in the preparation of a great variety of technical and educational material useful in the day-to-day safety programs of metals plants. The activities of the Section are under the direction of its Executive Committee, the members of which are listed at the dose of this-volume. 1 i *> > ft. ill] iJ 5 The American Package By ROB ROY MACLEOD r Chairman, National Affairs Committee, Buffalo dumber of Commerce, Buffalo, N. Y. (Summary of a Speech) Not long ago a refugee from the U.S.SJR. tended in New York. He looked about him at the wealth and hwhncss of American life and asked a question which we ought all ask ourselves: "Why should you have all this?" If we give an honest answer we must say that most of us merely inherited this Amer ican package. Bnt what is tins 'American package,' tins way of life which we have inherited. While we are only 7. per cent of the earth's popu lation^ we enjoy most of its automobiles, more titan half of its cars^ almost half of its telephones and electric power. Bat why is this? I do not think that we shall find the answer in things which we can see or touch, in our form of government or in our abundance of natural resources, bat in an intangible idea. The greatest danger of our times is in straying away from ffis idea. Any society may be divided into three general spheres; the religious or metaphysi cal. the socio-political, and the economic. The first of these generates ideas winch permeate and color the schemes of the other two. I fed that the baric concept upon which oar way of Bfe is built is that God is the master of men, and therefore the state never can be. The American ideology springs from the Judaic-Christian religion with its principles of one God, the brotherhood of man, and of all men equal before the law. The com munist ideology has its origins in the pagan religious where God became united with the state under, ooe head. Here we have the American package in its essentials, to contrast with the other package the people of the world are' asked to buy. But'what are we doing to maintain and preserve tins American, package? How may we help in tins time of crisis? First, we must strengthen our religious foundations. Second, we must realize that we must pay for our freedom. Third, we must realize that to have good government we must have good citizens in the government. Fourth, we most have courage and reso lution to face the dangers to come. And finally, since we are called upon to sacrifice, we must demand of our govern ment complete prudence and honesty in mak ing our sacrifices count. Use of Directional Explosives for Tapping Open Hearth Furnaces By R. H. FERGUSON Assistant Director of Industrial Relations. Republic Steel Corp., Cleveland, Ohio Probably no one job in the entire, cycle of open hearth operations has received more attention from a safety standpoint than that of the second helper and his task of opening up die furnace. All of us are familiar with the hazard and the possibilities of anacddent and that is one of the reasons the job has been surrounded with so many safety precautions. Accidents from this cause, while not entirely eliminated, have certainly been reduced, and any job change which would make it possible to spend less time at the tap hole should certainly receive serious study, Undoubtedly most of us never anticipated that the day would , cone when we would openly advocate the use of explosives as Metals Industry _ 5,35*8. g fi'g,g g-g, g-g g` 'g .5 *j --These are two features with which open hearth shop. Many present today re safety are particularly pleased: member the first use of oxygen to open a tap hole and some of the mistakes made down through the years. But that same production tool, the oxygen lance, the hose, the container and the regulator, if used as recommended, are-exceedingly valuable and yet must be surrounded with every pre caution. To overcome some of die difficulties ex perienced in tapping a furnace, with par ticular emphasis from a safety angle as well as resulting hazards to personnel from a poor tap, the idea of using directional ex plosives was suggested. The development program has been in progress for nearly four years. For the past eighteen months, the explosive, better termed the "Jet Tap per," has been in use by the furnace crews 1. The Jet Tapper accomplishes the open ing of the tap hole without any individual bang near the runner. The control station is behind a building column at one end of the furnace. The placing of the Jet Tapper in the tap hole requires but a few seconds' time, and this takes the second helper away from a normally hazardous location. 2. The Jet Tapper reduces the skulling in the stopper well, with the result that pouring is accomplished with fewer running stoppers. This reduces the hazards at the pouring platform where serious accidents may occur as the result of poor stopper control. It may be of interest to review briefly the surveillance testing that has been con ducted concurringly with development. at Republic's Warren Shop, and since the first of the year our Buffalo Open Hearth has adopted the jet tapping practice with considerable success. The explosive used is cydonite or RDX. I suppose it is only one of several bast burning explosives that might be used in a shaped charge. However, cydonite; com It was with considerable misgiving that pared to most commercial explosives, is rela I entered the discussions for developing the tively insensitive to impact, friction or heat. practice of using explosives. With a num It can be detonated consistently only by a ber of serious hazards already in existence, No. 6 electric cap or its equivalent In this it seemed that adding another was Just a little too much. If such a job was to be handled by special crews it meant one thing; particular charge, the cap must be located in the cap well provided, in order to cause proper functioning of the shaped charge. but to turn the job over to the regular op If -heated to a sufficiently high tempera erating men was a different story. ture cydonite will burn, but will not de To follow the first practice meant in tonate. For example, in testing, a case of creased man-hours, increased exposure, and 24 Jet Tappers was completely burned in a increased cost. To follow the latter meant bonfire of kerosene-soaked wood without that our training and explanations must be any sign of a violent reaction. In another thorough, and that each mdter, first and test six Tappers , were laid side by side second helper must be sold on the pro between steel plates, and a ISO--pound cedure. The latter practice was followed. steel weight was dropped nine feet onto the The procedures which have been estab lished are the results of considerable test ing, discussion, and evaluation. We did not upper plate. Although the charges were completely crushed, there was no evidence of detonation. seek the minimum level of precaution, but To illustrate the insensitivity to propaga rather have sought the maximum to make tion in terms of open hearth usage, a steel this practice as nearly foolproof as can be storage cabinet similar to the one used on devised- The procedures have been studied our charging floors, was built at -Du Pont's and evaluated and passed on by safety testing laboratory. This cabinet was loaded conscious personnel of three companies, with six Jet Tappers assembled and stored leaders in their respective fields. The Du as is done in the plant. One of the assemblies Pont explosives people, with years of know was wired to a blasting machine and de- how and field experience, have expressed the liberatdy fired. Although the one explosion opinion that this method of using explo scattered die contents of the cabinets, sprung sives is completely safe if handled in ac the door, and drilled a hole through the cordance with the safety recommendations roof of the cabinet, it .did not propagate to as set up. fire the neighboring charges. r be* the sev in i wa con uni tap wb s rifa jf l a %S 3 Use of Directional Explosives for Tapping Open Hearth Furnaces 7 i ye in fivLuJ station end of Tapper econds' x away Ding in pouring toppers. pooling v occur briefly a con* it. RDX. al fast used in e, comisrela3r beat, y by a Is this located o cause large. anperanot decas'^f another by side '--pound into the s were svidence ropagaa steel used on i Pont's i loaded 1 stored semblies and derplosion , sprung ugh the agate to We still wished io satisfy ourselves about burning. In (me to three minutes, the caps for some reason, a Jet Tapper after it is in once again that the insulation was sufficient place in the tap hole cannot be fired by the to protect the charge from heat under the operator, and (2), what happens If the severest conditions. heat breaks out and the gush of molten In setting up the use of the Jet Tapper, we metal washes the assembly down the runner were very careful to make sure that the into the ladle? work was thoroughly understood. We were Depending on the rate of heating or the in no hurry, and we were sure that there direction of heat in flux, the cap may be would be no mistakes. Some of the safety heated fast enough to shoot most of the and operating rules deemed necessary to do unconsmned charge, but as soon as any part this job are: of this charge; particularly the copper cover, 1. Jet Tapper head and caps are explo is destroyed by beat, the detonation will not result in proper functioning, and will seldom have the power to tap the furnace. In effect, the cap shoots some portion of two ounces of explosive without directional effect. ,, To determine"this behavior, several stand ard complete assemblies were placed in the tap holes of furnaces and deliberately left to bum. In a period ranging from three to eight minutes, each of the charges tested in this manner was heard to detonate. In the case of the three minute test; the report was quite audible; apparently the sives. Let us not forget that at any time. And they should be treated as explosives. 2. The storage of explosives must con form to the requirements <of the location-- either state or municipality. Remember tap per heads and caps are stored separately. 3. Details for such storage buildings are available. We suggest that you follow them. Note: Only responsible personnel shall have the keys to these storage magazines. 4. Only authorized persons shall be per mitted to transfer charges and detonators from storage to the furnace floor. cap fired all or at least most of the charge, 5. Be sure that the person malting up and this furnace was satisfactorily tapped. Jet Tappers is well trained and responsible In the case of the eight minute test, tire This job is done in the thermocouple room report was not much `stronger than the and in some instances the man handling report generally heard when firing a cap that equipment also bandies the tappers. alone, and we could only surmise that the Only a sufficient number of heads and rest of the assembly bad already been con caps needed for twenty-four - hours' use sumed by fire. The following conclusions should ever be removed from the magazine were then drawn: and prepared for use Develop the floor 1. In the event of misfire, wait for ex storage to hold only enough for this pur plosion. pose In this way excess materials on hand 2. The insulation of the charge will will be prevented, and it will be much easier protect it for at least three minutes in the to account for all Tappers. temperature of the tap hole. This gives the 6. When the furnace is ready to tap, the operator time to reach the firing station. hole is dug and raked ont as is standard (He usually does it in 10 to 20 seconds from practice The melter then secures the as the time he starts to push the assembly into sembly from the daily storage cabinet and the hole) gives it to the second helper. Prior to this, 3. Once placed, the Jet Tapper is never to tiie blasting machine should be placed in the be removed. Wait for the explosion and bracket on the furnace and connected with then go ahead as usual. the electrical circuit.- The handle of the To simulate the break-out condition, several assemblies were made up, standard in every respect'except that a dummy charge was used. (No cyclonite in the case, but containing the usual blasting cap.) These blasting machine must' he retained in pos session of the second helper, or the man who is to place the Tapper assembly in the hole. This is to make sure for .his safety and tiie safety of others that no other per units were tossed into thfc ladle during the son can fire the Tapper. The Tapper is tap, both' before and after the additions, then placed in fhehole. where thqy floated around on the steel. The second helper carries the Tapper to 8 Metals Industry the runner with the connector cord still loading pole. He places the Tapper in the month of tiie tap hole with the flat side of the insulating body down, and with his right hand on the end of the loading pole, pushes it in until it contacts the faring. He then drops the end 'of the loading pole into the runner, moves to plug in receptacle, removes the shunt from the connector cord, and plugs into the receptacle located on the back of tiie furnace. Retiring to the firing station, he inserts the key into the blasting machine. Only 10-20 seconds have elapsed. The operator is now in a. safe position. He should make sure all persons on tiie pit side have been warned. Particular attention should be given to persons on the pouring platform and crane operators. When he is sure that all persons are in tiie dear, he should fire. We recommend.a signal whistle warning. When the shot has been fired, the con nector cord can be recovered and returned to the daily supply cabinet for reuse. The rules prepared and followed in this work are available. 1. Make responsible personnel available for this work and explain it carefully, you will experience no difficulty. 2. Remember you are dealing until explo sives and molten metal. There should be no half way methods or jobs tolerated. This is a safe method of tapping an open hearth and will be found very useful to the industry. The Jet Tapper Practice at the Open Hearth . By HAROLD WALKER Gen. Supt., Steel Plant, Republic Steel Corp., Warren, Ohio and A. ROBERT ALMEIDA Arthur D. Little, Lie. Presented by Mr. Walker . It is rare indeed in open hearth experi ' years of apparent satisfaction with the con ence to depart radically or suddenly from ventional practice. the conventional way of doing things. At the beginning of the development pro Changes in practice are gradual and take gram it was hoped that we could reduce the place almost without notice. Over a period of years we have introduced new tools and have become mechanized, as required by the demands of increased .production. Great hazards connected with tapping a furnace. Since then we have,enjoyed not only a safer practice, but a practice that benefits the operation of the open hearth in many ways. strides have been taken to make our nulls and shops more productive and to make them better places in which to work. The im provements have been made slowly and con stantly and without excitement.' This is why we are excited. First; the jet tapper provides a good, dean, fast tap without heavy labor. The tap hole is opened from a remote position, and seldom do the slaggers have to use a tapping bar to How, however, we at the Republic Open knock out the hole. The task of the second Hearths are excited about a radical change helper has been made easier, and safer. . in our way of doing things. Thirty years .'Secondly, the uniform full stream flow of ago. we dropped the bar and sledge in favor, steel, right from, the start, has given the of the oxygen lance to open up the tap holes melter the opportunity to tap and make the of our furnaces; this year we are dropping additions under the best conditions. Skull the oxygen lance and substituting a direc production is cut in half, the manganese tional explosive charge; the jet .tapper. We drop is reduced and tap hole maintenance are making a significant change after thirty is improved. During ar.bc vbj s con tained it this ailable y, you exploild be ed. .1 open to the 1 it proice the amace. i safer ts the ways. .dean, V hole seldom bar to second r. . low of en the dee the Skull iganese tenance The Jet Tapper Practice at the Open Hearth 9 Thirdly, the pouring practice is cleaner hole, succeeding particles continue to pene- fer The running and leaking stoppers--trate until all material of the jet is ex- whichwere causedby plate skulls around die hausted. This action takes place in a matter stopper-- have been reduced to a minimum.~ of microseconds. As .we hear the explosion. With this improvement we are enjoying we happily observe a full stream of steel better surface; better quality, and better pouring into the ladle, working conditions. Description The jet tapper is a small, shaped explosive charge, designed specifically for the purpose of tapping the . open hearth furnace. Two ounces of a relatively insensitive explosive are enclosed in a bakelite case, which is fixed in proper position in a hollow insulat ing body with walls ooe-half inch thick. This insulation is sufficient to prevent the charge from bring destroyed by the heat of the tap hole; and sufficient to prevent die blasting cajp from bring detonated by the -beat for a minimum of three minutes when in the tap hole of the open hearth. The special high temperature electric blast ing cap fits snugly into the well provided in the rear of the charge. Development It may be of' interest to highlight the development of this new took During the period when the engineering teams of Arthur D. Little; Inc were observing closely the operation of the first two pressure blast furnaces, it was evident to them that some of our every-day operations involved one or more men under conditions which exposed them unnecessarily to serious potential danger. One such operation was the tapping of the furnace with the oxygen lance; which required the handling of cumbersome equip ment near the tap hole and .until such time as the iron or steel began to flow. The Arthur D. Little engineers concluded that a direc tional explosive of a type similar to the war time bazooka projectile; could be fired stati The bomb shaped insulating body, 3 inches cally from, a remote position to tap the hr diameter and 8 indies long, has a fiat furnaces. Two additional factors had to be bottom to prevent rolling, and is easily fixed considered and resolved in this connection: to a loading pole for proper positioning (1) the depth of penetration required to open against the facing of the tap hole of the die tap hole and (2) means of protecting the furnace. The loading pole is made of spiral explosive charge from die heat of the tap wound cardboard tubing. hole It was realized that a charge of suffi The hollowed shape, of the explosive and the copper liner are responsible for the ability of the jet tapper to punch a hole through the frozen crust of the tap hole, with little sideward and rearward blast ef cient strength could be designed .with due consideration given to' the structure of the tap hole On the other hand, various insu lating media were available but the assembly had to be held to reasonable size fect. This shaped charge will penetrate; At this stage, a patent application was filed under controlled test conditipns, about seven covering this invention, and the subject was inches of cold, mild steel. Yet in all our taken up with the duPont Explosives Divi experience there has never been any evidence sion in view of their extensive experience .of damage to the tap hole structure:,in fact, in the development of the'shaped or hollowed our tap jiole maintenance has been reduced, charge of war-time fame. The subject was and the tap holes are maintained straight as presented to them with the following spe originally designed. cifications: When the charge is detonated by the electric blasting cap, the high pressure de veloped by the explosion causes the copper liner to collapse progressively from its apex to die base, squeezing a jet of copper par ticles from the inner surface of the cone. These tiny particles, travelling at speeds up to 30,000 ft/sec. possess tremendous energy and will penetrate any type of target. As the energy , of individual particles .is dissi pated in penetrating-the facing of the tap . 1. A. directional charge was denied to perforate the crust of the tap hole--the crust bring an agglomerate of metallic and ceramic materials. . 2. Such perforation to be accomplished without causing damage to the structure of the furnace. 3. It required stability toward beat and shock expected by rough handling at the fhrnace .floor. * BB ? m >'* f i f t ` E ' hi i v " > :4k rJ-*To ;fg ; 'ii 10 Metals Industry 4. Above all, it must be safe to use, con sistent with ease in handling, placing and firing the charge. Temperature measurements were taken in the tap holes and various insulating mate rials tested to determine the rates of heating. Hock-ups of the tap hole structure were built in 55 gal. drums to simulate the fur nace conditions, and in these assemblies the first units were tested. At this stage, one ounce charges, capable of perforating 4 inches of cold, mild steel, were fired in the steel drums. With these tests satisfactorily completed, similar charges were tested at the furnaces themselves. Through a succession of furnace tests, a series of different models were fired, and evaluated under a variety of conditions. Surprisingly, it was found that the tap hole crust could be very tough indeed, and only when a two-ounce charge was finally used, did we successfully tap most of the heats. This brief history deserves emphasis in one respect, it should be noted that fire pri mary impetus to the development of this device came from the need for greater safety. As will be shown, the benefits to the operation have in addition been remarkable. Results The present design has been fixed for over a year, and nearly 2500 units have been fired to date. It is generally felt now that the occasional failures of the Jet Tapper to open the tap holes are attributed to irregularities in method of tap hole maintenance^ or unnsual conditions with respect to the particular heat, such as long charging delays which cause hard metal soaked holes. This paper will omit discussion of the methods of handling and firing which have become standard, these subjects bring cov ered by another paper by Hr. Ferguson of our Industrial Relations' Department As far as the operators are concerned, by flat we refer to the second helpers, the opening of the tap hole with the jet tapper is an easier task than the corresponding use of the oxygen lance: It is a one-man operation, with full responsibility given to him. He handles the charge and has possession at all times of the mechanism by which the charge can be fired. There is no doubt that the jet tapper has promoted safety. Our oper ators respect this device and follow to the letter the standard operating procedures. Their cooperation and compliance has been gained by the fact that the jet tapper does a good job for them. From the point of view of the mdters, it permits better control of the heat at tap time. Let us take a look at the operating results from the Warren shop. At Warren, our production consists by and large of low carbon rim grades, with a scattering of aluminum killed and low car bon silicon grades. With this schedule it is found necessary to plug the tap holes tightly, perhaps more so than at other shops. The following practice is followed to dose the hole; after tap, the hole is first chilled off until dean and dry, then filled with double burnt dolomite by the second helper from the rear of the furnace; and finally faced off by the first helper, again with double burnt dolomite. Raw dolomite is never used. With the jet tapper practice we generally gain a full stream flow of steel as soon as the hole is' opened. Thus, a tapping bar is not required to clear the hole. The resultant tap, about one to two minutes faster than the oxygen lanced tap, is steady and uniform. The tap hole itself is generally free of ridges, and is maintained in alignment, in contrast to our former oxygen lanced holes which tended to drift to one side. This uniform tapping of the heat permits our mdters to tap when ready; they do not have to wait for a little more temperature to protect themselves against a poor tap. Where we have to watch surface quality so critically, this is an important factor. It has also been observed that the man ganese drop from first to last ingot during pouring has been reduced. Generally our manganese losses are fairly high, since we work with highly oxidizing slags to promote good rimming. The frequency of a four point or less manganese drop has been in creased from 50 to 60 per cent. This again is of importance to quality and yield. The most tangible results of.the faster tap are given by our skull production. By eliminating the dribbling start of the tap, the jet tapper reduces both the number and weight of skulls. With reference to the heavy skulls on the low carbon rim grades, it may be noted that the frequency of heavy skulls has been reduced from 13.6 per cent to 7JS per cent Note also that 85 per cent of the success- 1 8 8 M ? s <8 ! i * & 9 ft J im 1*1 i l l s i n ~ Safe Use of Cables and Slings 11 fully jet tapped heats have not had any skull.Putting this on a weight basis by assuming 4000 lbs. as the weight of "bot tom" skull and 5000 lbs. as the weight of "1 ft or over" skulls, it is found that 203 jet tapped heats produced an average of 310 lbs. of skull per heat compared to 589 lbs. per heat for 323 oxygen lanced heats. This represents a reduction in skull of 47 per cent Actually, the number of scrap skulls has been correspondingly reduced so that on a weight basis the total skull has been cut by at least 50 per cent These re sults are certainly significant and represent important savings. At Buffalo, the jet tapper was introduced late in December and was quickly adopted by the shop. At the time of the preparation of. this paper, results were available on the firing of some 350 iet tappers. These results were considered premature^ although they paralleled closely the Warren experience. In fact, the skull savings were even greater, and the benefits of more important signifi cance in that shop whose production is made up of higher carbon killed grades. An important advanage to jet tapping, noticed immediately at Buffalo, came from the pouring platform. The operation of the ladle stoppers became much more uniform, and the frequency of leaking and running stoppers was substantially reduced This is attributed to the fact that skulls at the stop per well of the ladle have been minimized On he basis of actual ingot count, the use of the jet tapper in January cut the number of leaking and running stops by more than 50 per cent Safe Use of Cables and Slings By WILLIAM HOBBS JR. Asst. Mgr. of Sales, Wire Rope Division, John A. Roebling's Sons Co., Trenton, N. J. For many types of hosting duly, a wire rope sling is a very important part of the equipment The sling connects the crane book and die load and is the vital link. Be fore a crane can hoist a load provision most be made to connect the two together. Sometimes special pains are taken at the load for attaching, but, usually, the sling must be adapted to die natural contour of the load Stings which are Inadequate or insecure endanger human life, as well as valuable loads. While stings are a specialty, experi ence and data have been correlated into types and tables so that most slings'can be safely selected fay the user. Consideration of the angle of inclination, number of rope parts and factor of safely, may, at times, get things involved Dia grams can show what happens when you try to save by malting slings too short, which is to say a small angle of inclination. For instance, at 30s, die tension in die sling will double, malting it necessary to use a sting which li twice as strong as one that is used to handle the load verti cally. Try to make use of head-room. "How do yon determine the number of rope parts handling the load?" is a question often asked You simply count the ropes that are in the space between the load and the hook, irrespective of whether the slings attach to the load or pass around it A direct approach is used in the Roebling sling tables, wherein safety factors already have been included and in which safe loads are given. These are actual loads that can be lifted safely. Roebling slings are of three general types. The first, is round rope, which needs no ex planation. The second is the grommet type. It is a hand-made endless wire rope, fab ricated from a single piece of strand The third is the woven six-part Flatweave sling. In pasting around short-radius curves and sharp corners, wire rope suffers a reduction in strength. This fact has brought about three general load classifications--Classes "A", "B", and "C". Class "A" represents the best conditions of operation; UB", con ditions of medium severity and "C", the most rigorous types of duty. Class "A" slings suffer no loss in strength in their application to the load They are 12 Melds Industry used in large circular bodies. heavier than a spreader beam; because of Where the sling is protected' at the cor the bending stress which is introduced. ners of the load by suitable protective However, lifting beams are used to ad saddles, it is considered a Class "B" sling. vantage for loads with a shifting center of No- protection for the sling results in a gravity, because the hook attachment can Class "C* sling. be placed at any position along die beam. Slings -with loop splices often are sub-' jected to more abuse than special slings, so the safe loads for these are less than.the safe loads for Class "C slings. For unusual hoisting conditions or severe types of duty, special protective features can be incorporated in the design stage of the load. Saddle surfaces for the rope, threaded holes' for eye-bolts, or holes for hooks can be provided at little expense: Another .means of sling classification is descriptive of the manner of load attach ment--a cradle sling encircles the load. Round rope slings, up to. 1H .inch di ameter, are made of 6x19. classification "Blue Center"- Steel Wire Rope with inde pendent Wire Rope Core. Larger slings are made of similar rope; except the 6x37 clas sification is used. Grommets are fabricated of the 19-wire strand classification up to V/i indies and 37-wire strand classification for the larger sizes. It is no secret that wire rope slings will kink when improperly used, or handled. A severe kink can result in'as much as a fifty per cent loss of rope strength. After years of staidly, Roebling recently developed a A bridle sling hitches directly to die load, usually by means of fittings. Slings which have one end passed through the other compress the load. These are called choker slings, or amply chokers. To facili tate handling and to improve sling life, sliding choker hooks should be used. Sling fittings may be necessary at the crane hook or at the load. Among the many ^pes used at the crane hook are steelcasting equalizing thimbles. "Flatweave" or round rope slings often are attached or spliced to rings. Rings should he forged without welds, assuring maximum safety. Sometimes these rings are put through an additional operation--and formed into a pear-shaped link. Sockets or hooks are the most commonlyused fittings for load attachments. It is suggested that standard fittings be used wherever possible: Tins means low-cost slings and prompt deliveries. Sometimes the legs of a sling must be kept in a vertical position to prevent dam age to the load. This is accomplished by the use of a spreader beam. *. new-type sling, which is highly resistant to kink damage--the "Flatweave" sling. It is easy to handle and is recommended for use where the legs choke the load or where the sling comes in direct contact, in other ways, with the object bring lifted. The "Flatweave" sling body is fiat, flexible and free of scissors action between the six separate ropes that terminate in the seven-part, reinforced loops. The fiat body means minimum surface marking of the -.load in handling materials where this is important. Designed to fulfill a definite need, namely, those applications where kinking is a fac tor, it was recognized at the outset that "Flatweave" slings would be used for the most severe types of duty. Designed for all types of loads and conditions, only one set of safe load values has been established for "Flatweave" slings--Classes "A", "B" and "C* do not apply. Where it is necessary, standard or spe cial fittings can be supplied for' these slings. Usually, the loops are attached to the crane hook; although they can be attached through the use of other fittings. The loop is rein In such a beam the rope extends from forced substantially, with seven- rope parts, the ends of die beam to the crane hook, making it unnecessary to resort to outride patting only compression in die beaml servings for protection.' Lade of head-room may not permit the use of a spreader beam. Then it becomes necessary to attach the crane hook directly to the beam. This is known as a lifting Eye hooks, shackles or sockets are used as load connections. Thimbles can be fur nished in the loops, although they are rarely necessary. Ordinarily, "Flatweave" slings nuch : of sfc. -f r of can m. diition ndc; are dasated i> to ition will .A fifty ears da it to It is use the ays, - flat, seen the xtdy the s is -O facthat the for one died "B" spengs. rane ugh ein- irts, side ised farrely logs Warehouse Safety 13 are nsed with no fittings, other than the permanent swaged sleeves which form a part of the sling: "Flatweave" and round rope slings can work together for minimum sling cost The part which is dear of die load is not sub ject to wear or. kinking, and, consequently, lasts for an extended period of time; This part should be made of round rope. The parts in contact with the .load should be "Flatweave*' and renewals are confined al most entirely to these sections of the ding. Slings with lopps 'on each end are by far "the nSoistcommon.' For'years these were spliced, bdt mechanical means of splicing with pressed on fittings are today making better and safer slings available than ever before. 'The Number One and Number Two hole sleeves are.two new types where the end of rope is brought around the thimble and hdd permanently under- a pressed steel sleeve. The Tapered Sleeve Sling is another new and similar type but one which embodies a very unique safety feature. The end of the wire rope is divided and formed into a Flemish eye before attaching the stream lined tapered sleeve. Even the regular splice has been mod ernized info the Walles. Splice, in which all wire ends are inside the splice. No serv ing is required on these splices as there are no objectionable wire ends to injure a workman's hands. This gives it an addi tional safety feature as well as aiding appearance. Efficiency of the end attachments cm slings must be considered. They play a part in safely as well as economy. Obviously, a sling is* no stronger than its weakest part A rope may have a strength of one hun dred tons, hit a sling made from that rope has a strength of only eighty tons if a splice at one end has an efficiency of only eighty per cent The selection of end attachments on slings is important It's possible on large sizes, especially, to actually reduce the rope size, using sockets or tapered sleeves, winch de velop catalog rope strength, and obtain the same safety factor as spliced slings made of huger rope. It is also just as important to consider how tiie sling is attached to the load. When a wire rope is passed around unprotected corners on the load, its efficiency may be reduced to an appreciable extent Nothing has been gained by increasing the efficiency of the end attachments on the sling if the strength of the rope in the body of the sling has been reduced to a lower net strength than the attachments. Wire rope slings are correlated into many types and combinations, many of which are more or less common to certain industries. Very often what appears to be-a special sling requirement can be reduced to a stand ard type with the result that quicker de liveries can be obtained and at a lower price. In the past; some users have made a prac tice. of buying wire rope and having it spliced in their own plant However, today management and safety men are finding it more economical and more efficient to buy their slings from those people whose busi ness it is to recommend and manufacture slings. Wire rope has proven to be the safest material for sling purposes. The' greatest safety in the application and operation of wire rope slings is best realized when those responsible make an earnest effort to apply available knowledge to their specific prob lem and at the same time maintain a healthy respect for the law of gravity. ___ Warehouse Safety - By R. J. FOSTER J Secy* Republic Structural Iron Works, Cleveland, Ohio A typical steel warehouse^ could be de- approximately 175,000 square feet, and rep- scribed, as' an average industrial steel struc- resenting 'floor space interrupted only by tore with a monitor type roof, covering suporting columns and perhaps a small sec- .jF7 14 Metals Industry tion set off by low partition. The'support ing columns are arranged in such a manner as to define four or-five wide aisles some other steel products. - Approximately 700 warehouse distributors 'specialize in these industrial steel products and several hun 400 feet in length and serviced by electric dred others carry limited stocks in conjunc over-head cranes. tion with other goods and services. The average distance from the floor to Industrial steel distributors serve an esti- the monitors in the roof is around 50 feet; - mated half-million steel users in all parts ' some, but not all of the floor area is of the United States. For example, 334 paved, and various pieces of cutting equip member warehouses' reported handling in ment are located at appropriate spots in September 1950, -a total of 770,255 separate each aisle. These plate, sheet, bar and angle orders--an. average of 2^06 each. Repre shears, burning equipment, hacksaws, and sentative warehouses in the larger industrial high and slow speed saws are generally sit -areas fill 25,000 to 50,000 and even more uated adjacent to the driveway, which runs 'orders a month. Recent studies show that through one ride of the warehouse-struc the average size of a warehouse order ture. ranges from 800 to 1,500 pounds, depending On the opposite side there is located a railroad spur running inride the building where cars of incoming steel are spotted for unloading. The order flow is then from the incoming railroad cars to the stocking area, to the cutting machine, if necessary, to a zoning area, and therefore, onto outgoing motor trucks. To accomplish the entire operation, we need a superintendent, a foreman or two, and around 50 wage earners. Some steel warehouses may be larger or smaller, and in many instances, there is a fabricating operation closely allied to and considered a part of the business; however, this can be considered typical for the purpose with which we are concerned today. It is important to know that nearly onefifth of all the finished steel mill products in this country flows through warehouse distributors to a half-million steel users. In 1950, 13,282,000 tons, or almost 19 per cent of a total record output of 72,232,000 tons, readied consumers through- steel ware house channels. Now these warehouses fall into three general classifications: 1. Merchant products. In this group are nails, fencing, roofing, water and gas pipe and similar items. upon the territory. In the performance of tire warehouse buriness, there are relatively few so-called highly skilled jobs. Aside from a mainte nance man and a few machine operators possessing specialized training, the majority of* employees perform unskilled jobs con stituting for the most part the handling of fiinished steels inride the warehouse. Furthermore, our work pattern is far from constant; for example, there are days when we may have sufficient plate orders to keep a plate shear gang busy for several full turns; however, we may then experi ence a period when there are no plate or ders and the men who normally perform such work are assigned to other duties which may encompass other shearing activ ity, or perhaps hacksawing, stocking mateierial, helping another employee fill orders, or even performing janitorial duties in and about tiie warehouse. In normal times, practically all orders are received, filled-and shipped within 48 hours, so the volume and type of steel de sired by the customers govern the job as signments of our employees from day to day. Therefore, in order to assure an ef fective organization, we must maintain a high degree of flexibility in all job assign 2. Oil country goods. These indude the ments. pipe, tubing, drill rods and other products used to get oil and gas out of the ground and to pipe them in bulk for refining and redistribution. I have gone into this detailed data so that you may understand and readily appre ciate that although the safety hazards con cerned with machine operation do involve 3. Industrial steel products. These prod a few employees, our greatest hazard is ucts are made of carbon, alloy, high tensile associated with the very general responsi and stainless steels. They indude plates, bility of handling material. shapes, bars, sheets and strip in the hot A review of injury records as recapitu rolled and cold finished grades and many lated from accident reports by cause and i ! 4 i 1 < 1 1 I t c t s I S E L Q tT . H J J s t B P S S a o* O w tfl n _ a1 700___ he^ estixarts 334 f in irate pretrial note that irikr ding ouse ailed inteitors mty eong of far days rs to feral peri: orfonn odes tiers, and tiers a 48 . de asf to i efin a agn- i so iprecon'olve d is msi- pituand Warehouse Safety 15 responsibility indicates that more than 25 and injuries to arms and bands often result per cent of all our accidents each year are from these operations. attributed to material handling. In some years when experienced help was not read ily available, the percentage has risen as hi^i as 40 per cent The unloading of material from railroad cars and .stocking in racks or bins requires direct physical contact, since crane chains and blocking must be removed from the Industrial accident experience for iron lifts, material guided into the racks or lifted and steel work as recorded by the State of and placed by hand in the rack as required Ohio Industrial Commission--we find that and as feasible, depending upon weight and of the 1,143 accidents reported, 343 em size. ployees^ received eye injuries. 214 received finger injuries, and 113 received injuries in the lower extremities of the legs. During tins same period; nine developed hernias. There were 54 hand injuries and 62 foot injuries. Of the total number of 1,143 in juries, 646 were strode by dying, falling, sliding, or moving objects; while only 10 reported occupational disease. It, therefore, indicates that the greatest hazard comes from the Stock piling, switching; and han dling of materials. Of the total 1,143 acci dents reported, there were 14,199 days lost What we somehow fail to consider and which presents a serious problem is the cost of handling first-aid work in the average plant It las been impossible to determine what these costs are. In talking with many men in the warehouse industry, we find that Here are random statements from acci dent reports of some of the material han dling injuries experienced recently: 1. "In removing hoist chain from a lift of grader blades; the injured caught his left hand on the block under the lift As he pulled the hoist chain, the lift shifted, cut ting off his finger at the first joint** 2. "Injured employee and helper were pulling a bar out of the rack when one end slipped from Injured's hand and fell on his foot" 3. "Injured employee and fellow work man were turning angles preparatory to cutting. As one angle was turned, the employee's turning bar slipped out of his hand and dropped to the floor injuring his foot* there is a constant stoppage of work be 4. "Employee slipped when removing cold cause of minor injuries. This type of injury rolled rounds from a rack which resulted is not reported to the Industrial Commis in a hernia." sion, but nevertheless first-aid must be sup There is a multitude of examples like plied. Many companies employ doctors wbo these which could be cited; emphasizing the come to their plants to take care of such high percentage of- time each employee minor injuries. Others have full and part- spends in actual contact with the products time trained employees for this purpose. during his work turn. This is in contrast The loss of time presents a substantial to many operations in the iron and steel cost to industry. industry where, in spite of the proximity of Let us consider material handling as a huge machinery and similarly hazardous safely first problem in steel warehousing. operations, employees are relatively safe In performing a normal day's work most of due to remote controls and mechanical our employees are required to lift material guards. It is the exception in the steel by hand or with the assistance of some warehouse when the material can be un mechanical equipment which exposes them loaded, stocked, transported within the ware to crushing foot and band injuries during house, and loaded for shipment, without a majority of the work turn. an employee by' necessity having direct As we have already slated many of the physical .contact with it orders are small and it is not uncommon Essentially, this type of injury may not . that we receive a hernia claim when a be grossly different from those occurring worker has -attempted to lift or more what in other companies; but it is signficant that appeared to be a relatively small amount of experience has shown that accidents related material. At practically every piece of cut to the handling of material constitute our ting equipment, it is necessary in almost principal hazard. This is not strange due every instance that the employee personally to the nature of the steel warehousing op align the material on the shear or saw bed eration, which, after all, is virtually 90 per or table prior to cutting. Crushed fingers cent handling, of finished steel products. B8 16 Metals Industry A second problem with which we are much no friction for gripping. 'The rope slings concerned relates to that of protective devices. on the hoist and chains accumulate a sub It is difficult to conceive of any type of busi stantial amount of this grease and they, too, ness wherein the necessity for the wearing of soon become difficult to work with. The safely shoes should be more significant hi importance' of safety shoes and foot guards spite of aggressive safety committees, and under these conditions is certainly obvious. a Hood of promotional material, we have been unable to persuade a large percentage of our employees to take such personal precaution. Furthermore,' there exists an accident exposure to the foot which extends A third major problem which may not be peculiar to steel warehousing, but is one of major importance to us, is that of good housekeeping. The sloppy habits of workers and carelessness on the. part of supervision beyond the toe, since many crushing injuries, involve bones of the foot for which safety ; often floors, result in tripping hazards, greasy blocked "aisles, improperly., and un^ shoes in themselves provide no protection. evenly'piled material, arid'a host of other One of die chief complaints of our em everyday, simple but .serious, conditions ployees to safety shoes and to foot guards which tend to increase our accident potential. is brought about by the character of their work. Employees working around cutting equipment or within a rather closely defined area generally have little cause to object to tliis type of protection, but when their work'assignment requires considerable walk ing, such as is necessary in the warehouse, or climbing into and out of railroad cars, between racks and piles of steel, and some times on the steel itself, it has been our Our records are full of first-rid and lost-time cases caused by scratches and puncture wounds from loose wires for which proper disposal procedures were not. followed. Falls have resulted in deep cuts when employees were thrown against mate rial piled adjacent to an aisleway on which a piece of scrap or an unreturned tool had been thoughtlessly thrown. experience that they, for reasons of com Many injuries result from material not fort, and sometimes because of alleged properly and neatly stacked in the appropri cumbersomeness, object to the comment type ate pocket, rack or pile. Eye inflammations of safety shoe and guard. have resulted on many occasions from un The most obvious illustration is that of the crane operators in some of our smaller warehouses, who must come down out of necessary dirt in and about the machines or because some provided shield or screen had not been safely positioned. their crane cabs from time to time and - The character of a steel warehouse; its perform work on the floor. On such oc size and relatively small number of employ casions- they should, of course, be expected ees, may in many instances remove the per to wear safety shoes; yet, in the crane and sonal relationship often found in manu in climbing to and from the cab, such pro- facturing operations between a particular tectives are unnecessary. machine or area and an employee or group Other protective devices are, of. course; important and often present a problem, but not to the extent of the aforementioned and probably not any more so in the case of any other business. The wearing of goggles for of employees. In the absence of such a relationship, it is frequently hard to edu cate and expect employees to take a special interest in an area as large and as general as the one with which we are concerned. burning and grinding operations, the use It is a-problem to get the average worker of aprons by welders, and the Use of spe to place the scrap in the proper location, cial purpose gloves, where required, are a to remove and dispose of bundling wires, few examples. to replace-pinch bars and other tools in their In many warehouses, a substantial,amount proper- storage place, to wipe up excessive of cold finished steel generally has a pro grease that may spill on the floor .or other tective coating of oil to prevent the surface' wise become a hazard, and to give bis per-, from rusting or pitting. The handling of sonal attention to .the many, many other this greasy stock always creates a hazard everyday conditions which may. at some for which it is difficult to devise any specific moment become a real hazard to himself. protection. Gloves soon become saturated Safety programs constantly emphasize the' with the oils and rubber. gloves are inap need for "a place for everything and propriate since they would provide little or everything in its place," but the housekeep ing app hav indi Ii attil nifii wis met sha] and whs assi Act won higi shif tom imp and lead B to d safe dail ness vari ploj ent task edm dre viro chat pres S gem to b ers. safe the edgi mat tran ploy they ees raeei assi) diris toes a si indu the N. Warehouse Safety 17 nbr ooi Tic rds ms. not me x>d ers ion asj' mher ms ial. tnd tnd for not nts iteIch ad not ri ms unor ad its ay ^ CTv _ / SU- lar >up ia Juaal sal ed. leer on, es, eir ive erer-, her ' me. tlf. the ind ep- ing responsibility too often is thought to fresher talk might be the answer, but visu apply to our- personal lives only. It should alize -a situation wherein these moves are lave an equally important place in our made some times as many as four or five industrial life. times a day, depending on orders, material In every business enterprise the mental receipts, shipments, and amount of cutting attitude of its employees is of great sig required. Posters and safety signs, .assign nificance for a number of reasons. Safety- ments to .work with seasoned _ employees wise, it represents our fourth problem. Our when possible, regular safety meetings and men must be familiar with many sizes, safety huddles are now employed as edu shapes, types, grades and finishes of steel cational tools. But-there is need for some and must know their, way around the some fresh stimulants to help him bridge these what large 'area' ''within* which they are occupational and environmental gaps. Con assigned to work-during any given jwriod. cern for his personal safety as well as that Actually, the ideal steel warehouse crew' of 'his fellow workers should become as would consist of a very small group of automatic as the fife itself to which h is highly versatile workers who could be ' dedicated. shifted about from'job to job as the cus tomers' orders required; an objective almost impossible to .achieve under today's operat ing conditions. Nevertheless, this principal 'is exercised to the greatest degree posable and has been recognized by most labor leaders with whom we deal. This discussion was. to pertain to prob lems of steel warehouse accident prevention; consequently, I make no reference to the other more common categories of difficult situations encountered by indnsrty in general in the conduct of their safety mid accident prevention programs. We, by no means, are But this industry practice makes it difficult immune to these problems either and are to develop the proper mental attitude toward constantly striving to better ourselves through safety among our employees. The numerous appropriate and more intensified safety daily job changes demand a safely conscious ness always alert to existent danger. -The I have attempted to define for you four variety of tasks performed by cadi em problems which may be considered of pri ployee Aping his work turn, and the differ mary significance in the steel warehousing ent locations where he may perform these business, although they in themselves are tasks, complicate the problem of safety education. Familiarity with a fixed set of circumstances in a constant industrial en not strange to any other type of business activity. vironment is one thing, but.the varied, ever- Number one concerned the handling of changing character of our work pattern material. This strikes at the very roots of presents ah entiely Afferent problem. the steel warehousing business, which, by its Safety supervision at -its best must be general since it would be highly impractical to have a foreman with each team of work ers. They must be as self-reliant and acute safety-wise* as they are business-wise, hut the land of overall `experience and- knowl edge that develops these qualities is slow in ` very nature; requires an unusual amount of physical contact between employee and mate rial. It represents an activity which unlike most manufacturing and industrial opera tions today, depends for the most part on the actions of the worker himself who most of necessity be his own safety warden. maturing. New workers must be constantly Number two emphasized the problem of transferred into hew environments and em adequate personal protection and the need. ployment conditions for some time before for greater employee participation in safety they have been generally exposed. Employ shoe and other such programs. The signi ees working .with cold finished steel may ficance of this problem is heightened by the meet an entirely new. set of hazards when dose physical relationship between the em assigned to a job in the structural .or plate ployee and* die product as discussed earlier. dirision; shear operators, must be on their Number three involved the problems of toes when performing the responsibilities of good housekeeping and the obvious fact that a Stocker, and' a crangnan haters a hew ' only in a neat and dean environment can we industrial world when he steps down onto have a truly safe place to work. The prin- the warehouse floor. ,. aple of "A place for everything and every Normally, upon each move, a safety re thing in its place,"'becomes a keynote to 18 Metals Industry safety in steel warehousing where the va riety of sizes, types, grades and finishes of the steel carried in regular inventory is par ticularly great Problem number four was the employee's mental attitude in relation to the work pat tern of the industry. The high degree of flexibility in daily job assignments, bringing about a constant change in duties and indus trial environment, demands a general safety knowledge of the warehouse operation. This is difficult to establish except through expe rience gained during an extended employ ment period. The Use of Wetting Agents to Control Dust in Industries By G. A. MAU Vice Pre&, Johnson March Corp., Philadelphia, Pa. Within the past two decades chemists have developed materials with properties similar to soap but without the limitations, resulting in a large number of compounds with re markable physical properties. The behavior of these materials has suggested their use in a wide variety of industrial fields. These materials are known as Surface Active Agents since their primary effect is at the boundaries or surfaces between two phases. Reduction of interfacial tension, lowering of surface tension, increase of wetting power, deflocculation and emulsification are some of the results of this activity. The synthetic surface active agents first came into use in this country about 1930. In the few years since their introduction, they have become numerous and varied, and have found many uses in diverse fields. The surface active agents can be subdivided into five groups. Wetting agents, penetrating agents, dispersing agents, emulsifying agents and foaming agents. . Reference will be directed particularly, to the first and second groups. Namely, wet ting agents; producing increased wetting or spreading of an acqeous solution or suspen sion over a repellent surface and the sec ond group, penetrating agents, providing more rapid passage of a liquid into a porous solid. With the above brief discussion on sur face active agents, or as I will refer to them from now 'on as wetting agents or compound, I intend to discuss the use of wetting agents to control dust in industry and particularly, the foundry. I like the popular definition of a wetting agent, which merely states that a wetting agent added to water makes it wetter. Per haps, we should state for the purpose of keeping the chemical terminology straight, that a wetting agent is a material which, when added to water, or to any other liquid, will cause considerable reduction in surface tension. Safety and health have been benefitted by the use of wetting compounds in many industries. Safety--in providing bet ter visibility around plant and equipment, health by preventing die absorption or in halation of dust Dusts, whether toxic of not, are harmful and an attempt to group duks under the headings "active" and "inert" (with refer ence to effect on health) has proved unsat isfactory. Investigations have proven that practically all dusts may be harmful if breathed in large amounts over long periods. In this country, dust diseases usually des ignated as "silicons" is more or less common among workers in the mining; grinding; granite and foundry industries. According to Lanza and Vane; the estimated number of men exposed to Silica-Bearing Dust in various industries are as follows: Process Pcrcentageof Number All Employees Eiposcrf Metal mining .......................... ......100 Anthracite coil mining................... 20 Quarrying of granite, ganister, sandstone, etc.................................... 100 Smelting & refining............................. 100 Foundry workers................................100 Potteries, glass works, stone products 30 Grinders, buffets, sand blasters, vitreous enamelers Estimated total for mining, quarry ing and manufacturing mdnstries. 62,000 30,000 22,000 18,000 200,000 70,000 62.000 ... 430,000 The Use of Wetting Agents to Control Dust in Industries 19 wringing-- h expeemploy- l wetting wetring r. Perpose of straight, which, r liquid, surface a beneonds in ng betripment, . or in* harmful en that nful if periods. Ily dessonsmon rinding, cording number Dust in Number 2,000 30.000 22.000 18.000 200.000 70,000 2.000 ... 450,000 In addition to these there are "thousands of workers who have been exposed to silica dust in these various occupations and are now engaged in other forms of work." In order that we may better understand the purpose of this discussion on wetting agents for dust control it null be necessary to discuss the dangerous dust particle size and the wetting effect of saw water com pared to wet water with the proper surface tension and group combination. Not all of the particles of inhaled dust gain access or are retained by the human lungs. For these reasons, the size of the dust present in the industrial atmosphere should be determined. Investigations have proven that particles greater than 10 microns'in longest dimen sion. are very seldom found in the lungs, and that the particle size found most com monly in lungs were three to five microns.. Due to gravity which causes rapid settling of suspensions and due to the protective action of the mucous surfaces of the upper respiratory tract, rite larger particles do not penetrate to the terminal' portions of the lungs. Therefore, it is obvious that attention should be given -chiefly to those particles which are less than 10 microns in longest dimension and which can enter the lungs. This group particle size is very difficult to wet, and requires not only a low surface tension liquid but a fine atomizing spray nozzle. Dust control by wetting depends for its effectiveness upon the fact that, once the dust has been trapped in water or some other liquid, the particles are not easily dis persed again in the air, until proper disposal has been made. Dust control by wet methods is attractive from the standpoint of cost but has not been highly successful in certain industries, with raw water. Many articles have beat writ ten quoting not too good results in such applications as grinding wheels, rock drilling, mining, etc. Dust control with water is better than no wetring at all, but would not reduce the dust count sufficiently to be safe, and in the case of some dusts, could not be wetted at all, especially the sizes 10 microns or. less. To obtain better wetting, experimentation led to the use of wetting agents. The physics of wetting is not entirely tm derstood. The phenomenon is basically one of adsorption since a film of liquid must be adsorbed, upon the solid before wetting can occur. A liquid will spread on a solid if the surface tension of the latter is greater than the' sum of the interfacial tension be tween the solid and liquid and the surface tension of the liquid. Therefore, the wetting power of a liquid increases with a decrease in its surface ten sion. Many dusts are wetted only with great difficulty because of the presence of another film already absorbed on the surface. This film might be adsorped air, which occurs in a dust cloud. Then wetring will not take place unless the spreading force of the liquid is great enough to drive off the air layer. A wetting agent or compound of surface active agent groups will in most cases fur nish the spreading force of the liquid to drive off thejur layer and wet the dust _ Time will not permit a discussion of other than the high points of dust control in the foundry industry. ` About three years ago, I was handed some foundry dust that was collected around the muller, and asked whether it could be wetted with a wetting agent Much to my surprise, it was, a combination of foundry dusts that did not respond to water or any single type of group of wetting agents known at that time. We finally found a compound of surface active agents that would actively wet this dust Dusts difficult to wet can be wetted if the proper wetring compound is used and the application cor rect One without the other will not work. So far we have touched on a discussion of the types of wetting agents, that a liquid with low surface tension is best for wetting, providing the dust and liquid are compatible, that the size dust particle we should be most interested m is three, to five microns or generally particle size less than _ 10 microns. This size compares to fog particle sizes. The efficiency of wet dust control is de pendent upon the degree to which the parti cles are wetted. Important factors that de termine wettability or dusts are the proper wetting compound and the application of the proper particle size spray solution with noz zles designed for the application and spray pressures to create proper spray droplet size and pattern. 20 Metals Industry . Another big control is the selection of proper type noz wetting compounds are infinitely more ef zles. It is common practice to employ "a fective than spraying with water. nozzle" whether a solid or hollow cone or flat sheet spray. No matter how efficient the wetting compound may be, if the proper nozzle with proper spray pattern and angle are not at the right location, results can not be obtained. The methods usually employed to obtain fine atomization are high pump pressures, liquid with air misting nozzles and very low capacity nozzles. Plain'water wets the surfaces'o the floor sand, causing mud, .or. may . run to lower levels causing' puddles and. excess, surface moisture in spots. Because very little penetration takes .place air currents absorb the. moisture rapidly, allowing the sand to dry and become dusty shortly-after the water application. When applying wetting compounds to the floor a' flat cutting spray nozzle has been High pressures are not desirable for dust found most effective. wetting. The high pressure spray causes the Wetting compounds permit the wetting of dust to disperse beyond the spray area. floors in the melting and pouring areas .be Liquid air misting nozzles are very satis cause of quick deep penetration of the mois factory for spraying areas 10-20 ft from ture in the sand and. much less possibility tire nozzles. A very fine fog or mist spray- that sand near the surface will be wet can be obtained with these nozzles provided enough to cause spattering of metal. Pene sufficient nozzles are used for the spray tration with water is difficult and evaporates pattern. These nozzles are recommended for quickly. top spraying of shakeouts, sand conditioning, . Crane shake out . of castings, usually in crane shakeout; etc. volve large areas in the main hays of many Low capacity nozzles can be grouped and foundries. While the shakeout periods might used on medium pressures (40-70 psi) to obtain fine particle atomization, for dose be confined : to night or early .morning bows, when few employees are in the area, most proximity dust concentrations near equip ment or conveyor transfer points, etc These of the foundry becomes contaminated, with airborne dost that is easily vibrated loose nozzles are now available' in capacities of from the building structure and equipment 2 to 24 gallons per hour. - when tiie full force of workmen are at Most wetting agents are shipped in con centrated form and require dilution when. work. A fine atomized solid cone spray ap plied' from nozzles attached to the crane bridge over the shakeout area has been used used for spraying. Efficient, durable, auto matic proportioning equipment is required for successful wet dust control. Propor tioned meeting these conditions over a pe riod of years are now available. successfully at a foundry. At another foundry,, a special portable stand was built with the fog air misting nozzles; which, is placed in a position at oposite sides of the . working which might Wetting Compounds are of great benefit be 25 feet or more in diameter. This type to foundries, not only for dust control but nozzle is also used for spraying over the for such things as fire fighting; core knock shakeout table. out; deaning castings, core wadi, recondi tioning the moulding sand, cupola smoke control, sand tempering, etc. The fog air misting nozzle is used suc cessfully to supplement exhaust systems on shakeout machines. If the table is large and Dust control at' crane and machine shake the dust is not bring properly exhausted, outs, mailers, floors, sand conditioning, the air fog misting nozzle has successfully- grinding and cleaning departments are the controlled the hist in areas not exhausted. areas where foundries have proven wetting It might be over the ends of extra large compounds very successful. work extending over the table; or due to The application of wetting compounds on sand not leaving underneath the shakeout foundry floors or walks, prevents dust aris fast enough. ing when rolling equipment or men travel The amount of dust produced by sand over them. It keeps the floating dust.parti- conditioning equipment is influenced largely des from becoming airborne. For general by.whether the sand is handled dry or moist use, where tire sand is accumulating over ' The sand should' be-moistened, with wetting The Administration of Safety Programs 21 essmg.: . - - . v_ /- 'made, chipping on large or snail, irregularly 7 Wherever sand is thnftra from condition . shaped .castings disperses.enonnons amounts ing machines, direct pressure nozzles with .of dust Wetting compounds are effective in capacities considerably laty^-than the amir- softening.'cores, making them dustless and age' dost nozzles are recommended ' This .much easier to remove, from the castings. nozzle must have a fine atonrized:spray_:be- There are many other applications for catise; wetting oftfiesandis necessity-to wiring compounds to control, foundry dust, properly control die atmdspheric dust? De- and. there are certainly many more uses, pendeatnpon bin capacity, we also recom- such as tempering and penetrating agents. maid for large bins air fog. misting nozzles The?few., applications mentioned are merely over the. storage area to. control the .dnst to show the possibilities. and to revive the treatmentIn theeyent the I trust, I.baye explained: I. The purpose sand stanis loag'epoti^i to become dry "ami of_wettingagents, that practically any dust dusty. ' .can be coattpOed with the proper wetting , Writing compounds,arebeingsuccessfully cbmpobnd.' 2: That, dust particle sizes of used to control dost -arising daring, skip at three, to five microns or sizes less than 10 hand loading of nraller operations, which microns require low surface tension liquids are not extended Small capacity nozzles compatible with the' dnst 3. That a writing mounted over the. rnuQer bowl wiUwet.the compound must he atomized to fine micron floating dust particles with very little or size droplets for dost controL 4. That cor controlled. moisture. If tempering of sand rect nozzles for tempering'and general wet is required, the wetting agent is introduced ting; and fool-proof equipment are neces in the water line. sary, automatic proportioning and nozzle Core knockouts may produce even, greater. control to make wet dnst control a success. The Administration ofSafety Programs ByJL C. 3ECKSTEAD Din, Safety and Technical Employment, American Smdting-'aad Refining Co., S& I*te City, Utah In order to properly administer a safety spections should be conducted constantly to program, it is first necessary to establish the . follow, the progress of the safety program proper organ?ration.' Tins organization must and to' prevent bad practices from devdop- have the support of all individuals in tire mg and enlarging.. cqmpatQr from tire chairman of the board Fifth,, individual plant safety departments and president to the newest pay roll em- mnst be provided with trained personnel and ployee. . * provided with the authority and equipment ' Second, a definite safety polity must be :to.do the job expected, formulated by all levels of management in The following' outlines the organization conjunction with all members of the safety for the administration of a safety program organization* This policy should be flexible as it is presently set up in the American enough.to,meet changing conditions and Smelting and Refining Company. Here, enwgenaes without causing. confusion or safety .tecogmzed with the same impor- troTM^' . . . . _ tance as production by all levels of jnanage- Tfaud, it-is necessary that the importance ment " ' ^ P?,cr,cniI*asis to safety be recognized - The-committee on safety and technical by all levels of management and by every employment is composed of the ton execucmployee in the company including; em- tives of the companyinduding the rfctirnwu plqye^s just being birpL ; - of;the board, tiie presidait; the operating Fonrtfv.a definite follow-up and5 check . vice presidents, and represditatives.from the .S3Kftcni tiirbiih ..i4ptwts:3iid'.oii-'tiierSipot hi- ^financial mid legal departments. The direc- V*,;. ; `:-X'** ^!.* m i ?*' 1; -W i: ' `T- >'"> 22 Metals Industry tor of safety and technical employment re mining divisio ports to the president of the company and from the hygiene and medical departments, meets -with this committee "whenever condi is held once every two years in Salt- Lake tions permit or whenever problems of such a Gty. Recommendations, suggestions, and nature arise and are of such Importance to problems of each of the representatives are demand die attention of this company-wide. discussed by the group as a whole. safety committee. From these discussions, definite programs The department of safety' and technical of action and suggestions in connection with employment is composed of a director, three policy matters are prepared for presentation traveling safety inspectors, and secretaries. and recommendation to the committee on The inspectors report to the director of safety and technical employment in New safety mid technical employment through York. The committee considers these prob regular inspection reports of visits to die lems and suggestions, and, in tnrn, the di individual plants throughout die United rector of safety and technical employment States and Mexico. Thus, the over-all safety initiates the necessary procedures to put program is coordinated through one indi them into effect They concern such matters vidual to the president of the company and as safety, records of safety and employ to die heads of the various operating de ment, statistics, reports, training programs, partments. The most important factor in employee relations programs, employee wel making our safety program effective has fare; equipment standardization programs, been the whole-hearted suppoft and coopera and any other matters which may be neces tion of the executives in charge of our sary. In general, the delegates at this meet company. ing plan the course of action for safety, The functions of the department of safety and technical employment are first; to act training, and employment to be followed the next two years. in an advisory capacity to the various safety So far, the outline and functions-of the departments and to all plant managers of company's method of administering the the smelting company and federated metals safety program has been of a general na division. Its services are also available to ture and on a level above the individual the various mining divisions within the com plant Of course, all safety men. recognize pany if they see the need to call on us. Second, traveling inspectors visit each plant in the United States and Mexico at least once each year and make a detailed report in connection with safety, welfare, housekeeping, and sanitary conditions as they exist in each plant. Suggestions and recom mendations for correction or improvement of any problems or conditions are made to that regardless of how many policies and procedures and plans are formulated, they .are only as effective as the individual plants and individual foremen want them to be. Safety men know their success and the suc cess of the safety program depends upon the actual cooperation of the foremen in direct charge of the operating employees. At each of our plants located throughout the manager through the director of safety the United States and Mexico, full time and technical employment; who in turn safety directors and assistants are employed. works with the vice president in charge of These men are in charge, not only of safety, the department directly concerned to correct but of employment, of training of all types, the situation. If the problem is of a com and of employee relations. pany-wide nature, it is taken up directly with the president and the committee on safety and technical employment for clarifi cation. The management of the American Smelt ing and Refining Company has recognized that one of the best approaches to the prob lem of employee relations and employee In order that the individual plant safety good will is through the safety department. directors may have a part in the formula It has long been known-that men will re tion of policies and programs which are to spond to proper working conditions and safe be put into effect throughout the company, working conditions better than they will to a general company-wide safety meeting of a lot of talk and promises. The attitude of approximately 50 men representing each our company has been one of quiet action plant in the United States; Mexico, and the rather than promises and words. Tans with ation e on New probie diitnent put alters tployiams, *. wdTams, aecesmeetafety, lowed >f the g the al navidual ognize s and , they plants 50 ; upon xn in trees, ughont 1 time ployed. types, Smelt- ; probipioyee rtment rill re ad safe will to hide of : action The Admmstration of Safety Programs 23 The actual functioning of our plant safety not only safety problems hut the over-all departments is as follows. The head of the employee relations, problems which come up safety department has the rank of assistant in the day to day contacts of workmen and superintendent He reports directly to the foremen and department heads, as it is not superintendent of the plant involved. In possible to separate them. Throughout the some cases in small plants, he will report entire program, the importance of safety is directly to the manager. The - fety depart stressed in order .that foremen will train ment at the plant level is actually respon each new employee in safety as he is being sible for the administration of the safety trained in his new job. program through the operating heads and In training of any type, it has long been foremen. recognized that one good picture is worth a . From sound administrative and good labor thousand words. As a result; the major policies we do not have direct criticism or part of the training program is based on disdpHnejbythe safety department person films. Surveys of all the available films nel, of the workmen involved in the viola and picture materials are made in order to tion of safety rules or safe practices. The determine which apply in the best manner safety inspector calls these matters to the to the problems of our company. It was attention of the foreman, and he in turn agreed to purchase all of the necessary takes the necessary action to correct the equipment and tools to make this training . conditions at fault program effective and to continue it The If, through this channel, proper results program'is put on by the- xndmdual plant are not obtained, the plant safety director safety and employment departments. has the responsibility of presenting the prob Hus program had been In effect approxi- lem to the department head- involved. If, - mately a year before any important results after consideration at this level, the prob were noticed. After this time, however, lem is not corrected, he will report the several of the plants showed a very de problem directly to the superintendent and cided improvement not only in their safety manager of the plant for their action. At record but in the number of employee rela the same time, the department of safety tions problems which previously had been and technical employment is usually notified unsolved at the foreman level. of the problems concerned and is asked for any suggestions or help in solving the problem. This program has been expanded and continued. A circulating film library has been established in the safety and technical If the director of safety and technical em employment department's headquarters in ployment thinks it necessary for one of the Salt Lake; and films are distributed from traveling safety inspectors or himself - to there to each of the plants as they are re visit the plant, this is done immediately in quired. order to help In solving the problems con cerned. It is possible to see from this type of' organization that the safety department actually lias methods at hand to correct un safe practices and conditions or to correct attitudes of foremen and department heads in case it becomes necessary. These films are used not only to train foremen but also to train, individual work men. It has proved very helpful to the safety program in stimulating workmen to use safety equipment and to perform their work in the accepted safe manner to show them films followed by short explanation Everyone is aware that training the indi and discussion. vidual workmen, foremen and department heads is one of the most important problems in the -proper administration of a safety program. Our. company has been doing work along this line for several years. Throughout most of our plants we also make use of workmen's safety committees. These committees recognize that the re sponsibility for safety is solely the com pany's. These committees act in an ad Approximately four years ago, a very in visory capacity and make suggestions to tensified program was, started with super their foremen and to the safety director. vision in order to prepare than with the The suggestions as made receive prompt proper approach awl methods in dealing attention. Within a very reasonable time; with the workmen. This program covered explanation is given to the men malting 1**1 ii 24 Metals Industry ww- suggestions as to what action they can nection with our problems and their sug expect gestions are. sought and used. Also, they In.the administration of a safety program, in order , to evaluate the progress and to keep trade of what is actually occurring at. each plant, the local safety director sends to the department of safety and technical employment a complete report of each acci participate actively in our safety meetings which are held every two years.. They have a definite hand in the formulation of over all company safety policies, as in most cases the welfare and health of employees is definitely concerned with safety. dent as it occurs, assigning a breakdown of It is always a very difficult problem .to responsibility and stating in definite detail evaluate successfully the administration of what steps are bang taken to prevent a a safety program. For a long time this has recurrence of this accident." These reports been done by* the use of statistics which are followed up by actual on-the-spot inves are accumulated by the individual -plants. tigations by the traveling safety' inspectors However, everyone recognizes that statis and by the safety director when the plants tics have a very limited use as the methods are visited. of computing and reporting accidents vary Also, a monthly recap of what has taken place so far as absenteeism, labor turnover, accidents to all personnel of a first-aid, non disabling nature and of a disabling nature is made. These reports are prepared and combined for distribution to the entire com from company to company. As a result, it has been the polity in .our company for each plant to compare its record for-this month to the past month, and for this year to the past year, with itself and until other company' plants. pany each month. Thereby, each plant The figures in connection with frequency* knows exactly its standing so far as the which will be given are based on the Na safety record is concerned with all the rest tional Safety Council method of reporting of the plants.' lost time accidents. Our company reports A recap of every accident in the division an accident as disabling; lost time, if the is circulated to all plants. By accumulating man cannot return to his regular job on and studying all accidents of any nature his next scheduled shift. in the company, it is possible to spot trouble Starting in 1947 with the Smelting Com in many cases before it becomes serious. pany plants, the frequency rate for the year Also, a complete picture of what is hap 1947 was 15.9; 1948 showed a reduction to. pening at each plant in connection with acri- - 11.8; 1949 a further reduction to 8.8; 1950 dents gives a basis for. over-all planning a small reduction to 8.2; and the record for elimination of trouble spots on a com so far for 1951 is 6.0. You can see we have pany-wide basis. had a reduction from approximately 16 .to In order to make the administration of 6.0 in a period of four and a half years. our safety program effective, the coopera tion of everyone in the safety department with the medical department and with our hygiene department is required. The Federated Metals Division of the company in 1948 had a frequency rate of 40.1; in 1949 they had. 33.0; in 1950, 2214; and to date in 1951, 22JS. The reason for The American Smelting and Refining the difference in the frequency rates between Company has been one of the leaders in these two divisions is -that Federated has a the field of industrial hygiene. This depart different type of operation requiring a great ment has cooperated with and helped the deal of hand handling of. materials -in which safety department with the many problems bruised fingers and broken toes are the re which are common to both. Every safety sult These accidents are reported in our man recognizes the importance of the medi frequency tabulation even though the man cal department to the success of his pro misses only* one day from work. gram. He realizes that proper medical These figures have more significance when H treatment and proper medical education of the fact is recognized that many state indus employees is one of the keys to the success ' trial rommissions have become very liberal of the program. in malting awards to men for non-disabling As a result, the medical and hygiene de accidents in which no time is lost from his partments are consulted constantly' in con regular job. Our frequency figures include Ilg- agi ive erses Is -to of has Icb its. fo ods aiy ,a for Ills ear her ocy faing >rts foe on lin ear ave to foe of I4t for * sa eat uch reour nan ben hiseral his lode . Safety in Handling Magnesium 25 all of these awards, and they are figured in. our. frequency'rate in the same manner as if the man had lost time. When the award is made; on an accident which occurred in a prior, year, it is taken up'in our figures at the time the award is made. You have all been aware of the necessity in a good safety program of eliminating the no-lost-time and first aid cases as well as the disabling accidents. Our program has been geared to take care'of these problems also.: We are''endeavoring id'plot: Jobs and- departments'where sm'eral nOT-disabling ac- cidents occur`In' order that job" operations may be. studied along with working condi tions in order to eliminate this type of acci dent as we all know a. department reporting a large, number of non-disabling accidents is certainly due to have a serious lost time actident. ... In summary, I would like to point out the following requisites to foe proper ad ministration of a safety program: ' 1. Secure foe cooperation and participa tion of all members of management and supervirion in your, awnpany from the presi dent and chairman of foe board down to the newest employee. 2. ' In the formulation of policies and procedures which will affect foe over-all safety program of foe individual plants, set up machinery whereby the individual plant safety inspectors may have a definite part in the formulation of safety policies and procedures which will affect foe entire com pany and their jobs. Also, in. connection with this; make provision for the safety director .to make use of foe foremen and foe plant department heads in gathering their ideas and problems in connection with foe formation of foe over-all safety pro gram, as it is necessary for foe men closest to' operations to have a definite part in policy formation and program plans. '3. Make certain that foe safety personnel at..each-plant is properly selected, properly trained, and has the authority and enthusi asm to-do his job regardless of foe obstacles he. may encounter^;,; . . ".4. Sit tip the proper training procedures and media through 'whicfa -all members" of supervision including managers, superintend-, euts, department heads, foremen, mid work men can be trained. Also, make certain that in turn each individual workman is trained thoroughly and followed up in proper safety methods and practices. . 5. Provide help and suggestions to indi vidual safety directors as they need help. 6. Provide a.metbod whereby the prog ress of the safety program on a companywide basis and also, foe progress of foe safety program on an individual plant basis may be .evaluated and followed carefully. _ The success of foe administration of our safety program is definitely attributable to foe cooperation and participation in the pngram by all levels of-management from foe chairman of foe board, president of foe company, the' vice presidents, down through olant managers; plant superintendents, and safety, inspectors. Most of the credit, how ever,' is due to foe foremen who are foe ones who actually administer and put into practice foe functioning safety program. Safety in Handling Magnesium ' By WALTER BONSACK Vice Pres. and Dir. of Research, Magnesium Co. of America, East Chicago, hod. Magnesium, when molten or when finely divided, oxidizes rather fast under develop ment of . heat, ie, it will horn if , certain precautions are not taken. The fire danger which some people associate with magnetim probably is caused'by its early appli cation in flash powder in fireworks and more lately in incendiary bombs. Most people do not realize, however, that foe starting mixture in foe magnesium bomb is alum inum and iron oxide and foe amount of aluminum burned in this bomb is probably just as large as foe magnesium. The so-called "danger" associated with handling magnesium is no greater than handling coal, wood, aluminum, grain, or :r r ' :'i ,r *HS5 $ m iff-;,' "M r M Ui 26 Metals Industry any number of common materials. Coal pipe. Periodically the tubes are opened and dust, flour dust, wood dust and aluminum the accumulated magnesium crystals are re dust are easily ignited and are explosive-- moved. Since these crystals represent a large so is magnesium dust. Wood shavings, coal, ; surface, it is advantageous to melt them into aluminum shavings and similar material"will ingot form to prevent oxidation. Neverthe sustain a very good fire if allowed to ignite less, many carloads of crystals have been --so will magnesium shavings. Large boards stored fbr long times without danger. Dur and lumps of coal'are difficult to ignite. ing the melting of the crystals, alloying also Large aluminum or magnesium pieces are not easily ignited because they conduct heat away rather fast The fire danger of mag nesium depends cm the prevailing conditions as with all other materials. Underwriter's laboratories issued a report to the effect that magnesium alloys are safe materials to use in housings of portable electrical appliances under all ordinary conditions. If the alloy is at least .080 inch thick, danger from fire is very small. Magnesium in its production and use is handled in two very distinct phases which have their particular safe handling methods. These two are the liquid and the solid phase. The liquid phase predominates in the manu facture of the metal, its alloys and some of its semi-finished and finished production, as billets and castings production. Therefore, the handling of liquid metal will be discussed first is done as previously mentioned. t The third process, the Hansgirg process, reduces magnesium oxide with carbon at high temperatures under vacuum. This proc ess has had the least application because it is very difficult to handle. Again, the product has to be remelted to be poured into usable shapes. In the last two processes the magnesium formed in the reactions is in vapor form in a vacuum. The condensation and crystalliza tion of this vapor is very important If the magnesium would condense in the form of a very fine powder, it would become easily oxidizable and burn. By proper crystalliza tion this danger is eliminated completely. Metal vapors and metal dusts are dangerous just as coal dust, flour, or wood dust is. Since vacuum is employed, air is excluded and no burning or oxidation can occur. Get ting a good vacuum is, of course, a prune The raw metal magnesium is mostly pro requisite and holding it till the reaction units duced electrolytically from magnesium chlo are cold are safety requirements. ride. This magnesium chloride may be pro The raw magnesium is remelted for re duced from ores such as dolomite, from salt moval of non-metallic imparities or to alloy brines as found in Michigan or Ohio or other elements with it to make it into useful from sea water which is an unlimited source alloys. As with most other metals, mag of magnesium. The electrolytic process is nesium seldom is used as pure metal. Most carried out in a "cell furnace" and at regu of its applications are in the alloyed state. lar intervals magnesium metal is withdrawn The most common alloying elements are from the furnace. This metal, although aluminum, zinc; and manganese. liquid and quite hot; does not 'hunt" because it is protected from oxidation by sulfur- dioxide. In the last few years, new alloys have been developed which contain zirconium, cerium, and other rare metals. Although There are-two more processes which were, they are still in the development stage, these used during World War IL Since both new alloys already have found extensive produce the metal less - economically than application in aircraft construction. the electrolytic process, they were not used after the war. Some of these plants, how ever, are being reactivated at the present time to provide a greater supply of magnesium.' Preparation of alloys is a batch process; usually carried out in large steel pot fur naces. Since magnesium does not attack or react with carbon and silicon carbide, open Of these two processes, the Pidgeon proc hearth type furnaces constructed of these ess is the one used to the greatest extent. materials also can be used. .The metal is This process reduces magnesium oxide or melted and because it oxidizes very easily even dolomite, the ore, with the aid of fer- and since the oxide formed does not protect rosilicon in vacuum. The magnesium formed the metal underneath, as aluminum oxide is in vapor form and is condensed in crystal protects molten aluminum, it must be pro form in the water cooled end of the reaction tected by fluxes which consist of chlorides led and Z1 an into verthee been . Durng also irocess, bon at s procanse it product usable piesium 'orm in italluaIf the orm of i easily itallizaipletely. igerous fast is. cduded r. Geti prune in units for in to alloy ;U . -Host d state its are is have CCTlmyi, lthough e, these rtensive process, ot furtack or e, open f these netal is r easily protect t oxide be prohlorides Safely in Handling Magnesium 27 and fluorides, of alkali and alkaline earth heavily, an accumulation of stale in the metals. furnace bottom would provide a dangerous ' Magnesium melts at 1202 degrees F. and situation. If no scale or only very little is addition of qlloying elements lowers this present, ho danger exists. Loading the leak melting point somewhat At .temperatures ing pot heavily with flax will cause flux to just above the .melting point the metal can - leak rather than metal, or you may "freeze" be handled quite safely without oxidation. the metal in the pot by adding cold flux At higher temperatures fluxes or inert gases and metal, both good safety measures. protect magnesium from burning. Addition To prevent the .occurence of pot breakage, of beryllium or calcium in small amounts the pots are removed every week from die will reduce the burning tendency consider furnace and thoroughly cleaned. The scale ably, but since these two elements may is removed by hammering. The pot is then affect some properties adversly, they are inspected for defects and its wall thickness not always applicable. Since magnesium does is measured. If the thickness has decreased to not attack Iron, it can be melted safely in one-half of the original, the pot is discarded. iron or steel vessels, the furnace tools can be of iron and the metal and alloys can be transported by pumping through iron pumps and pipes. ,, Since all magnesium used has been han dled at least twice in the liquid state and since we are using thousands of tons of magnesium yearly, many people have learned .-Because magnesium is , a very reactive metal and since it will reduce most other metals from their oxides or compounds, it is necessary to see that all iron and steel f-*~nace tools and implements are free of to handle.the liquid phase quite properly. It is necessary only to recognize the char acteristics of tins metal, and to use com mon sense and the few special precautions shown as dictated by the metaL heavy oxide scales. The fluxes used in the The liquid metal or alloy is cast into melting of magnesium are very hygroscopic. ingots for the foundry, or into billets for Tools winch are covered with flux and have the rolling mill, the extrusion process of the not been dried properly may cause danger forge. For extruding and forging usually ous spattering of molten magnesium, as it round billets are poured, but for sheet and would with any other metaL plate rolling flat billets are poured. This The difference between magnesium and other metals is that the spatters of mag nesium will oxidize rapidly or burn while most other metals will just solidify and give off their heat This means that the same precaution to use only preheated dry fur nace tools is necessary for all molten metals, bat particularly is. necessary for magnesium pouring may be done with a hand ladle, with a tilting furnace or the metal may he pumped into the molds. In any case, the molds are filled first with ah inert gas, usually sulphurdioxide, and the metal then is poured replacing the gas in the mold. In this manner, oxidation las been stopped . during tiie pouring.process. because its fluxes attract water so easily. During solidification the billet or ingot The safe practice is to have a flux pot with casting is kept in sulphurdioxide atmosphere molten flux - handy In which furnace tools or sulphur and boric add is dusted lightly will be preheated to a safe temperature and over the surface exposed to the air. The in which they can be washed dean of ad burning sulphur will form sulphur dioxide hering oxides and floxesL and prevent oxidation. The sted pots in which magnesium is melted will become oxidized on the furnace side and a heavy scale of iron oxide forms. This scale breaks off the -pot and accumu lates in the furnace bottom. It is necessary to remove this- scale frequently through the-ports provided for tins operation. The reason for this precautionary measure is the fact stated before that ^magnesium reacts with most metal oxides and with iron oxide it could react explosively. In case a pot breaks or begins to leak Ingots obtained in this manner will go to the foundries to he tinned into castings. There are three common casting processes in use today. They are sandcasting, permanent mold casting, and die casting. Each of these processes has its particular application which usually is determined by the complexity of the casting design and the economy of the processes. _ Mass production of a fairly simple design and relatively small dimension will call for - die casting. Very complicated and/or large 28 Metals Industry needed certainly demand sand casting. Be tween these two extremes permanent mold castings find a very good application.. Per manent mold castings also are mass fabrica tion products. to react with the molding material. In sand casting, however, tins possibility, is1 quite real. - Usually the molds are green sand molds, it, they contain; three to five per cent moisture. The moisture will form steam with the hot metal,, the steam .will' be de Dies and permanent molds are made of composed by the metal, and.the hydrogen steel and iron respectively. In the first liberated can form explosive mixtures. Mag method, the die casting; magnesium is poured nesium can react with the sand.in the sand .into the die at high speed mid high pressure, mold and form silicon or magnesium silidde Le., pressures of 2000 lbs. per inch square or under the liberation of considerable heat .more and speeds of 200 ft per sec. or more. It is necessary to prevent these reactions The metal is cast at low temperatures, usu . and it is quite. posable to do so by the ally below 1200 degrees F. Sincemagnesium addition of inhibitors to-the molding and does not attack. steel, no reaction occurs core sand mixtures. These inhibitors usu between the die and die metal. The metal ally are ammonium fluoride, boric add and shot into the mold freezes instantly. sulphur and similar compounds. Diothylene With magnesium as with all metals in die casting, precaution must be taken that metal which may be forced out of the mold during the- initial shot does- not injure personnel. The wearing of face shields and gloves is necessary and Hash shields must be provided as usuaL Since pouring temperatures are very low, the metal shows very little ten dency to burn. The metal in the holding furnace is protected by sulphurdioxide gas. glycol is used to replace part of the water. With these inhibitors present in proper amounts, the green sand mold offers no more danger than any other metal poured in green sand. Again, to prevent rapid oxidation or burn ing of the surfaces of sprues and risers which are exposed to the air, these are sprinkled with sulphur flour to exclude the atmosphere. Pouring of permanent mold castings de pends on gravity. The filling of the mold cavity therefore is much slower than in sec tion thicknesses and much heavier in weight than die castings. The metal usually is poured at higher temperatures in order to fill the mold. All these factors require a neutral atmosphere for the metal, again sul phur dioxide is used.' There is one more process in which liquid magnesium is used and the process is weld ing. Arc, gas or electric resistance welding can be used. Magnesium is mostly arc welded in a protective atmosphere of helium or argon gas. The materials which are welded together generally are of considerable volume or area- or both and, consequently, carry the heat of the electric arc away fast Before each pouring the mold is filled with sulphur dioxide gas which is heavier than air. Since the alloys for permanent mold casting are cast at a temperature usually higher than 1250F. they are protected from oxidation in the furnace by fiux rather than by sulphur dioxide gas. To prevent flux .contamination of 'the castings, the metal is handled in a bottom pour or special ladle. enough so that metal outride the area of protection of the gas never readies a tem perature at which it could ignite. As in heliarc welding, the only protective devices necessary are those common in any welding, i.e., welders arc trained to handle magnesium and shields between welders protect them from light and flashes created by welding. The liquid metal is the metal in the bead and as stated before, it solidifies Contrary to the die casting practice; the cavity of the permanent mold is coated with an insulating paint or wash. Tins is used rapidly. Spot welding ate is done biff the temperatures are never 'ugh enough for ignition. . primarily to regulate the heat flow from the metal to the mold. Logically, it does not react with the metaL As soon as the metal has solidified, oxidation or burning possibili ties have stopped. It has been shown that in these two cast ing processes the metal has no opportunity Magnesium castings often are heat treated either to enhance their properties, or they are annealed to be processed into wrought materials. In both cases the metal is brought up to high temperatures .in furnaces. Be cause of segregation in composition it may be possible to cause slight indpient melting of not raaj use* trol Car peat cost II tion ings sibli are to 1 and It n heat danj in a % port' extii treai dical in a it is W is fl the distr take gas. injui hydr Fr of o of t! rial mud T< pres: and: temp 'mg : each thou Ga othei "g, other is re finer the i large Prop* expk Safety in Handling'Magnesium 29 Insand s'qujte n| ivi . Jr a steam 'be. dejrdrogen s. Magbe sand rilidde !e beat tactions by the ng and ts usudd and ithylene : water, proper 10 more n green r burn( risers ese are ude the b liquid is weldwelding tly arc helium kh are )idqr-^e rayet area of a tem- otecdve In any handle welders created octal in iolidifies bat the igh for . treated or they wrought brought ts. Be it may melting of eutectic.' If the furnace atmosphere is not protective the castings or materials may start to bora: Again sulphur dioxide is used for. protection. Sulphur dioxide cottrols constantly check the concentration: Carbon dioxide also can be used but it ap- This is true of any combustible dust It is therefore of importance to prevent any accumulation' of fine magnesium particles, An example is m grinding. Care W be taken that the grinding leavings are collected in water constantly. .The colors have to peam to be slightly less effective and more be cleaned <feily. If the proper wet collec- cosfly- ; * tion system is not available; the only safe If the-temperature control does not func- . way to grind magnesium is to grind.it in tion properly, it is possible to melt the cast- water or wet ings in the furnace and then fires are pos sible; This occurs rarely since double controls are used. If it should happen, it is necessary to kill the fire with G-one powder or flux and let tiie mixture cool, off in the furnace. It may mean a new furnace lining and new heating dements but beyond this there is no danger greater than molten aluminum alloys in a heat treating furnace. The Dow Chemical Company recently re ported that borontsichloride gas is a better extinguisher- of magnesium fires' in heat treating furnaces. Research experiments in dicated its effectiveness and the actual test in a 1000 lb. magnesium fire confirmed that it is better-than G-one powder. When magnesium bums, in a furnace; it is flooded with boronthrichloride gas. with the furnace lan on to insure good, even distribution, adequate precaution' has to he taken not to. get exposed to borontrichloride gas. Although it does not appear seriously injurious to health, it decomposes into hydrochloric add and boric add fumes. Finishing products may involve a number of operations not mentioned above. -In some of them heat again is applied to the mate rial but in general the temperatures are much lower and usually of shorter- duration. Chips as produced by saws, drills and other similar tools are not an explosion typehazard, but still a substantial fire hazard. In all-cases sharp tools and heavy cuts are the safest way of machining. No water or water solution cutting com pound can be used.- If any coolant is neces sary oils should be used. Turnings or bor ings may be ignited by a spark; a dgarette or the like. Therefore; smoking most he prohibited in these areas. Areas in which machines produce chips must be deaned frequently and thoroughly. The chips , are put in covered metal drums and stored outride buildings. Fine particles and grinding dust should be disposed of as soon .as a drum is filled, fine partides by burning and wet dnst by burying or by drying in a magnesium fire and burning. Large turnings and borings or scrap of this order also are handled in tightly dosed steel drums. As long as they are kept dry they are safe. These can be sold to com petent smelters to be remelted and salvaged as can all larger magnesium scrap pieces. In all these operations in which fine partides of magnesium are formed, it is best that the worker and personnel in the depart ment wear safe dothing. Proper dothing is To mention some examples, deep drawing, that to-which,the dust anil not stick, into press breaking-and forming; stress relieving which dust will not penetrate; and which and stabilizing which for magnesium require does not have folds like cuffs or pockets in temperatures of up to 600F. Paint bak winch dust-or chips may accumulate. Hard ing also applies heat to the. product but in surface dothing then is recommended. Caps each case the temperatures arc so lcrw that riiotdd be wom so that the hair does not be there is no dangerof ignition.' come filled with magnesium dust Frequent Castings,' extrusions, sheets, plates and thorough cleaning of all dothing is highly other shapes are subjected to -sawing, grind recommended. Also, the clothing worn should ing, rooting, sbearingj boring, trimming, and . be so- designed that it can.be taken off other similar operations in which material quiddy.'- . is remdved -in the foim ^of chips or even Water is not used; for magnesium fire finer particles such as dnst - The .smaller fighting'' The mam- reason for this is the the partide; the greater is ijs surfaced This fact tbat water poured on horning magne large surface can-oxidize'very rapidly and if sium usually infuriates such fires up to ex properly suspended in air may even cause ' plosions. . The reaction which occurs explains explosions. ' ~ : this- behavior. `Burning- magnesium phis Metals Industry Hydrogen in proper mixture with oxygen Since burning magnesium does not de- is very explosive. This same reaction occurs ' velop toxic fumes, it is perfectly safe to go when finely divided magnesium dust gets wet into the room in which magnesium burns and It corrodes rapidly under development of to remove either the burning magnesium hydrogen and heat At proper conditions the with a dry' shovel or to remove the mag mixture will ignite spontaneously' and a fire nesium around the burning part and let the has started. fire burn itself out or kill it with sand, If a large amount of water covers the G-one powder, etc. dust as in wet grinding, then there is no Magnesium properly bandied poses no danger. Also, if large amounts of water more of a fire danger than many other could be thrown instantly on burning mag metals or materials. Magnesium is safely nesium to quench the fire and cool the hot handled if its characteristics are known to magnesium below the melting point, no the people handling it The few bade safety danger would exist. It is very seldom that rules must be vigorously enforced. Fire so much water is available so it is much fighting must be taught to the supervisory safer not to use any. The best method is to staff and to the men in critical areas. The use powders, fluxes, or even dry sand and proper equipment always must be available dry, dean iron filings. The main object is and handy. Good housekeeping, though, is to smother the fire by separating the mag- always the best means of fire prevention. The Part Management Must Play In the Safety Game By L. F. REINARTZ Vice Pies, in Charge of Special Operating Developments, Armco Steel Corp., Middletown, Ohio If industry wants to continue to make real, lasting progress in the safety of its employees, top management must accept its personal responsibilities for the safety of its employees--"lip service" will not da Employees soon learn the difference between genuine interest and the "phoney" land. Top management must be willing to spend time, money and effort to help carry on a worthwhile safety program. I have always believed that plant safety programs are peculiarly American. They are part of our free enterprise system, be cause their success is based on cooperation between management and workers. These safety programs are not old. 'Seventy-five or more years ago, prior to the advent of the industrial age, large mechanized plants did not exist It is true that there were many accidents on the farm and in small shops. Little was done about eliminating them. In fact in a sort of fatalistic way, they were taken for granted. With the dawn of the industrial era, many operations were carried on under one roof. Heavy machinery came into bring. Very little attention was paid to design from a safety angle. Hazards; and serious acci dents, especially in steel plants, increased by leaps and bounds. Mr. Charles R. Hook; Chairman of the Board of Directors of Armco Steel Corpo ration, was a pioneer in the improvement of the safety of workers in the steel industry in the United States. Having always been interested in the employee first; as an indi vidual, it was only natural for him to take an active interest in safety when the Na tional Safety Council was organized in 1912. In those days it was an up-hill battle. Equip ment was inefficient; guarding of machinery was nil; safety apparel had not been in vented; housekeeping was terrible; coopera tion between management and workers was far from ideal, and training was non existent Mr. Hook's enthusiasm and interest, .once aroused, could not be dampened despite the stony stares of supervisors. Instead of los ing his temper, when his best efforts went for naught, he calmly and tactfully continued to triich and sell safety to his lay men. He qua felt den he vita wei ope / that nes: thm to ] I Iar aid kir suit met star sint, - der, wot E vise are ahes S in t and vise fina vise A mus obs< wit! eqm com stan by ; be ! the and N in s ager safe is, r Ti by 1 and is g poli< Wit] is ii Jl The Part Management Must Play in the Safety Game 31 s no other saely ira to safety Fire risory The tilable Bh, is aition. tme i from ; accu sed by :)>f J0*i~ ent of dustry i been i indio take e Na11912. Equip* hmexy en inopera 's was non- ;.once ite the >f los* t went (tinned a. He srid that there coaid not-be any consistent felt they were reasonably secure from acci dents. He meant Itl And die men knew he meant it when they saw him shot down vital machinery in production units which were not properly guarded or unsafe to operate. As time went on, supervisors saw proof that safety was amply good, sound busi ness. They caught the spark of his en thusiasm for safe operations, and began to preach the gospel of safety themselves. In the early days of safety; the spectacu lar revival type of approach was tried: first aid teams; banners, slogans, contests of all lands, prize awards. They helped, but re sults were not lasting. Gradually manage ment saw that this safety job could not be started with a big; dramatic push and then supply delegated, with a shrug of the shoul der, to the foreman and the individual worker. During the last ten or more years, supervisors at Armco, and many other steel plants, are held strictly responsible for safety, ahead of quality, production, and costs. Safety engineers have been important cogs in the safety program. They plan, chedc and exhort; as well as encourage the super visor and his men in safety. But in the final analysis, the job is done by the super visor. A down-to-earth practical plant safety job must be done by the foreman's contacts and observations; machinery must be designed with practical and effective safeguards; equipment must be kept in safe operating condition by proper preventive maintenance; standard safety practices must be understood by all who use them; the supervisor must be sold on good housekeeping, and, finally, the men must have interest and enthusiasm, and want to work safely. No company will make the- best progress in safety until its general and works man agement accepts its full responsibility for safe working conditions and practices, that is, really puts safety first. Top management is watched very closely by lower ranks of supervision, the foremen, and by the men. The price of cooperation is genuine interest in men, and a consistent polity to win their regard and good will. Without that a -successful safety program is imposrible. You can't force a man to be safe. You must teach him to want to own sake and for his fam ily's welfare. In industry, if there is cooperation and understanding between management and workers, you can solve almost any prob lem, including accident elimination. Management has some very definite re sponsibilities toward safety. It must pro ride a safe plant A safe plant means good housekeeping. It means fume and dost control, proper fighting, sanitation and ven tilation. One of the major causes in the early days for accidents was poor lighting. All of these things cost money, time and effort, but they pay off in safety, which, in turn, helps pay off in malting profits, the life-blood of business. Safe-guarding machinery: tins problem is not as serious as it was in former years, because most steel plant engineers have be come safety conscious, and usually incorpo rate ample guards in the original design. Nevertheless, it is essential that a safety engineer scrutinize and approve all new de signs and drawings for inclusion of ade quate safe-guards. Management should never put new machinery or equipment into oper ation until it has been checked and ap proved for safety by the construction engineer, the maintenance and operating su perintendents, and the safety engineer. Management must maintain an adequate system of preventive maintenance that in cludes a thorough search for hazards. This program is the direct responsibility of super intendents and foremen. Train, educate and enthuse safety-minded supervisors to plan and arrange all processes with careful attention to safety, and teach them how to spot accident hazards; be safety conscious. It is advisable that supervisors use note hooks and write down their obser vations. A check-list of possible accident hazards in his area to be investigated will help the foreman do a good job. Management, as represented by the fore men, must then train, educate; and enthuse employees to be safety conscious. We most play up the personal ride of safety, the fact that "You must not get hurt--so that you wifi not lose wages and security, and that you will not have pain or sorrow." A practical foreman once told me, when expbining his own long-time safety record, 32 Metals Industry "I look'out for No. 1--and keep-my eye------ Then, on the second Wednesday afternoon on No. 2." That's a splendid safety polity of the month, the division hcads-cany these for everyone. If we are to lave die best safety messages and directions to their re* success, we must bring the employees into spective superintendents, and secure their the safety program. - suggestions, advice and counsel. No better way has been found to entUt their aid than through a suggestion system which pays employees for ideas, safety, or otherwise. It is the foreman's job to interest his men in maldng safety suggestions. Incidentally, it is a good check for foremanship, also. Few employees will make suggestions in a group which is not on a good working basis with its foreman. On the third Wednesday each superintcndent meets with his own foremen and again carries die safety message down the line During the 4th week, the foreman, in turn, devotes the entire time of his weekly meeting with his employees to the subject of safety. Normally, these meetings last one half hour. The company pays for 13 Show employees, by of fullering pictures, films, through every sluing scheme why it pays him,, personally, to be * When an employee does ma1r j suggestion, it pays dividends in good will if the super- visor makes speed in rejecting or adopting the idea. It shows the employee that Ins foreman is vitally interested in the em- ployee's safely. " minutes, and the employee donates IS minutes. In all these discussions; which are entirely on a voluntary baas, the emphasis h hid on the fact that a safety program, to he successful, most be a two-way street, ideas must go from management to the workmen, and suggestions how to improve safety must be forthcoming from the workers up to general management Management must investigate all major ` ^*s one of the results^ of Anncos and minor accidents, even those in which no human loss has been sustained. There is only the difference of a split second, or a fraction of ah inch, between minor and major accidents. Get all the facts. Be fair in your investigation of an accident Profit by carefully studying the record of past accidents. ' safety program: In 1917, with 3,500 eraployees, Annco had 432 lost-time accidents in its East Works at Middletown. In recent >'cars' with 1,000 more employees on the Payroll, the number of accidents has been cu* down to an average of 26 per year, a reduction of over 93 per cent Several years ago, it was my privilege Plan major jobs carefully, ahead of time. *? ** ***" chf^e of Annco Coal Mine and brief every participant in what must . Operations in West Virginia. The public be done and how it will be done: That is a 'as been led to believe that not much ran sure way to help prevent accidents, men ** done to decease the distressing number that is conscientiously done, accidents sel- ami seventy of accidents m the coal mines, dom occur. The fact is that Armco, as one company Those, in my- opinion, are management's primary safely responsibilities. In order to help meet those responsibilities, alert managements are using every practicable means at their disposal to sell the value of safe practices. At Armco Steel Corporation, our general management holds the manager of each division strictly responsible for the accident prevention program in his division, In carrying ont this responsibility, he has ameeting on the first Wednesday in every month with his divirion heads, personnel assistant; chief engineer and safety engineer, The entire afternoon is sprat in analyzing die cause or cure for lost-time accidents of the previous month, unsafe practices, equipment, planning and selling policies for future accident prevention activities. 'n steel industry, by _ following sound PersonneJ and safety policies and practices *las ^e. to make great progress in Tfcmt y?15 reducing the number and the seventy of accidents in its mines, It is my firm belief that, with the cooperation we are receiving from the management of our coal mines and our miners, we ran and will bring these operations up to the high safety standards of Armco maimfacluring plants. In the final analysis, we most continue to talk; talk; and talk safety until it becomes an ingrained habit- with management and nrin. It has been my observation tint, when we begin to rest on our oars and .think we have arrived at a good safety performance, we had better look out Old Man Accident Safety is a Way of Thinking 33 ternoon y these el > iupcrinicn and rwn the nan, in weekly subject gs last for IS 15 nunich are nphasis rogram, ' street, to the improve : work- r Vnnco's 00 erocddents 1 recent on the is been year, a rivilege I Mine public H* \ mi__k . mines. Dmpany sound actices, less in ter and s. cooperigement we can to the amifac- xmtmue Kpcmes sit and t, when tink'wt nuance, Occident is* lurking around the corner to trip ns up.. We must keep everlastingly at -this safety job! Remember, as business leaders, we must produce profits for. the stockholders of oar businesses. Entirely outside its humanitarian aspects; die practice ;of safety is good.business. It lias been proved, over and .over again, that-it pays in cold caslu You can't afford to have accidents ! The greatest responsibility,;of course; for safety, rests with top management We must careftilly screen and select those who will lead our workers. They must be properly trained .to put the safety of the worker . first. They most know what to do and how to do it They must enlist the minds and. energy of those entrusted to their care to produce with safety a quality product at reasonable cost Thor goal must be no. accidents at'all. It is up to us, , as management, to strive constantly toward this goal! Safety is a Way ol Thinking (A demonstration lecture on the use of gadgets In thepromotion of . accident prevention) Chairman: Robert S. B. Holmes, Director of Training and Safety, National Tube Co. -Participants: Arthur-D. Murphy, Director ol Safety and Suggestion Plaii, Crudble Steel Co. of America. . Kenneth L. Ward, Ass't Supvr.. of Safety, Eastern District; Youngstown Sheet and Tube Co. WauAH H. Wilson, Supvr. of Safety, Ambridge' Plant, American Bridge Go. Editor's None: Because of the nature of the presentation, the .following, edited ver sion of this program is limited to orally presented material. The demonstrations pre sented by members of this committee bare been omitted due to printing and space Inn- . itafions. Robert S. B. Holmes: It is indeed a pleasure for the Visual Aids -Committee to have.this opportunity to talk with.you this afternoon, and to summarize the 1950-51 ac tivities of. the Committee: As Chairman of the Committee and speaking for the Com mittee, I. can . tell you tint considerable thought has gone into the selection of the fide for this meeting--Safety is a Way ~of Thinking: We.bdieve that safety is first and foremost a"way of thinking," there fore,1 we are interested in giving to each industrial worker that "way of thinking" winch will, carry lum safely through each working ' day. -. This: objective has . many facets. It has the. problem, of selecting the . right perron; -the problem . .of giving.-him . die needed .training :hnd ..experience;the problem of gmnghimadequatesupervision; and the problem of motivating him each day to bis greatest safety effort Yes! "safety is a way of thinking.** It is a "way of thinking" which causes a man, to dose auto matically the cover on a packet of matches before striking; it is a "way of thinking" which causes a man to reach for the bandrail when going up or down stairs; and it most certainly is a "way of thinking which forces each of us to stay within the confines of safe working procedure and to make a reality of the slogan, "Safety . First" You are now entitled to ask; "How do visual aids fit into the development of Vays of thinking*?" Your Committee believes vis ual aids fit in just as any other method of teaching,<or segment of experience fits in. Viroal aids contribute to our store of knowl edge; they aid retention of important points, and they tend to impress key points upon the mind, to the point where .the mind con siders them. : Ideas which the mind con siders, the mind acts upon. When the same idea is acted upon frequoitly, it becomes habit ` Our goal is the formulation of safe work habits. We need both the conscious and . file unebusdous. mind working at all times toward the prevention of. accidents. . The human eye i so designed that it sees anything that comes within its range of vision, but only when that virion is regis tered on the brain do we have perception. Perception then-is recognition; it is toward the perception of unsafe conditions and un safe,practices that safety objectives are diriected.: Virion, alone - is not enough. We, Metals Industry therefore; are faced with the problem of a paper in which could be printed just such using visual aids- in such a way that rec material. Since the advent of this paper, ognition of die hazard results from knowl known as the Foremenfs Safety News, ten edge of the cause. years ago, we have learned a lot that will Let us look to another aispect of safety be of' benefit to anyone attempting this as a "way of flunking." Accidents are no same program. respecter of persons, nor do they have any At the beginning, the paper was in the respect for the dement of time, they occur form of a newspaper, full of facts, sug in a split second with, the guard against gested procedures, etc, many'of the articles this split second happening being a "way of quite some length. The first issues were of thinking" which prevents all the factors mailed to the foremen via our company leading to an accident from coming together maiL We soon learned two things--long at the same time and in the same place. articles were not read, and the paper when In industry', we have what is known as "fed." We say that a machinist has the "fed" of his trade, a roll turner has the "fed" of his lathe, and a roller has the mailed to the supervisor's department was often lost, often put aside and forgotten and in general the paper was not used to advantage. "fed" of his null, but what is. "fed"? Later we began to mail it to the homes "Fed" is knowledge, experience, and many and found more success. Still later we be long hours of guided practice; all of these gan to use a front page of brilliant color, --knowledge, experience; and practice--add using a picture that would portray a good up to job "know-how." Job "know-how" is thought from which fluty could build an passed from one to another by communica interesting talk. We also strive to keep all tion. Perhaps the communication may be articles short and make sure they are writ of the type often cited where the old Roll ten in everyday language, and easily under Turner taught his son the "tricks of the stood by all of the foremen. Most of the trade" by lantern light, or it may be some material used in the Foremen's Safety News other type. is written in our own department from Visual aids can and should be one of the best tools that a safety engineer can use. The intelligent use of a visual aid in the right place at the right time can often reach the employee with a valuable lesson when other means have failed. We cannot pass over this subject of com munications without calling your attention to other means of communication that are equally effective On the platform, there are two exhibits which are here through the courtesy of the Youngstown Sheet and Tube Company, and the American Bridge Com pany'. I am going to ask Mr. _ Ward, of Youngstown Sheet and Tube to tell you ideas gathered from foremen's reports of injury, newspapers, unusual incidents. Seven Company Exchange information and ex change publications. We do not hesitate to publicize information on any idea, regard less of who presented it, just so it relates to safety. The paper is edited and made up in our own department, printed in the Company's print shop, then mailed out by members of our own department A special envelope is used to mail the News. We mail approxi mately 1,000 copies to the homes of our foremen and approximately 80 copies to people outside of our own company. about this means, of communication which The extent of the use of the Foremen's Youngstown Sheet and Tube employs. Mr. Safely News by supervirion at safety meet Ward, will you tell us about your releases? ings is reflected to us when we read the KL L Wars: Referring back to the open ing remarks made by the Chairman, relat ing to the necessity of putting safety across minutes of safety meetings and reference is made to the Foremen's Safety News. Mb.. Holmes : Thank you, Mr. Ward. On first to the foreman, and then to the worker, we assume that each of you have had the same problem confronting our department for a number of years. This is the con the other ride of the platform, there is dis played the materia] which the American Bridge Company uses. Mr. Wilson, will you tell us about this material? tinual cry by the foremen for material to W. H. Wilson-: The Safely Notes, which use in their safety meetings. With this is the American Bridge Company's monthly thought in mind, our department developed safety circular, is distributed to all plants ? i 2, $ 5* S ST'S SI'S ?l. S*'SUB 3 Q K B S T te s *. pvb 5* a. si vs Q . s'la. o k s* m si q. m p >o . o av o d c ti the ngcles rere any ong hen was tten ; to oaes belor, ood an all Tltlerthe etcx rom of ven ext to urdates ') ps of is ndonr to eft's setthe nee On dis can will liefa My tuts Safety is a Way of Thinking 35 department We originally started with 80 copies for Ambridge plant supervision. Our thought was to sell the safety message by means of pictures instead of so many words. The publication met with so much success that we increased the publication to 3000 copies per month, for plant-wide distribu tion. We later took in all plants of toe Com pany and made it company-wide distribution and various safety messages and instructions are featured eveiy month. These safety circulars are carrying our message to the worker. By toe rid of toe muItQith we are able to reproduce photographs which have added much to toe effectiveness of this little publication. No safety program is complete without housekeeping. The relation ship between toe title of this presentation, "Safety is a.Way of Thinking" and house keeping can best be illustrated by a very common situation familiar to most of us. You all recall, no doubt, the early years of your married life and toe change in thinking whieh took place when toe first child ar rived. For some tone thereafter, your housekeeping was entirely devoted to one principle--that principle bang "Keeping things out of Junior's reach." Tins is a "way of thinking" which has as its objective toe prevention of injury to toe child and the elimination of toe possi bility of breakage of priceless possessions. So, even in toe home, there is a relationship between safety and housekeeping. la fact, many of ns subscribe to toe belief that safety performance will rise and fall in a curve parallel to housekeeping performance; Housekeeping is not too difficult if one remembers, two very simple and very ele mentary rules. First; there should - be a place for everything and everything should be kept in its place; and secondly, those who make toe "mess^ should dean it up. Consider for the moment toe general as pects of housekeeping and the maimer in which general material currently available to you from toe National Safety Council can be used. We have here the Safety Graph on Housekeeping as prepared and published by toe Council; while we do not have time to run through and discuss all of toe sheets. of this Safety Graph, T am going to ask Mr. Ward to tell' yon how this general ma terial can be adapted to'specific situations plant You, no doubt, will want to make mental notes of how it can he - adapted to your own industry and your own company. Mr. Ward, will' yon trice over? K. L Ward: I have here a "Safety Graph," entitled Housekeeping, one of toe many produced and distributed by toe Na tional Safety Council. However, as important as the subject is, I do not intend to discuss toe contents of this chart with you, but rather, to discuss a new approach to the use of these graphs which we think will prove beneficial to your foremen in their discussion of the charts' contents with their men. As you.can-see, toe chart is' placed in a frame at the front of' which is a fight focused on toe page of the (hart only. The fight focused on toe page under dis cussion draws the attention of toe audience more to toe material and less to the dis cussion leader, allowing him to read the discussion material from toe back page of toe chart without toe feeling of stage fright so often experienced. Mr. Holmes: I should like to print out that Mr. Ward has not spoken about toe material contained in the Safety Graph, rather, he has talked about toe method of presentation--this is both fitting and proper when the controlling subject is visual aids because visual rid means exactly what toe name implies--a method of* assisting toe speaker, the instructor, or toe discussion leader to put across the points of his pres entation. A visual rid is literally something to lean upon and must definitely be sub ordinate to toe material and toe objective; so I consider it right that Mr. Ward's re marks be amfined to toe method and not toe material. Behind the use of visual rids in safety, there must be an overall plan. This plan must be worked out in advance and then toe plan must be made to work in practice. Simply- stated, it means, "plan your work; then work-your plan." Apparent in this relationship of planning toe work and work ing toe plan is toe problem of analysis. Because of the very significant position which analysis holds in' the safety move ment-, may lie toe reason why so many safety people are engineers. The Committee does not mean to infer' that analytical* thinking is a privilege re- Metals Industry y for engineers, rather, we do, accident- - Accident investigation has .no mean that people engaged in safety work value, whatsoever, if it does not succeed ;in must be able to analyze, to judge; and to developing a safer method of doing,the.;job. decide. Mr. Ward, will you discuss this . on which the accident: occurred. / matter of analysis? ^ 1, - Thus, we have completed three points.in Ms. Wash: Often, accidents seem to stem from uncontrollable factors, and the apparent cause is that the accident was due to'a hazard inherent to that peculiar job or occupation. .. Now, in safety work, such identification is not sufficient Since we are interested m the elimination of unsafe acts and unsafe conditions, we must go further. We must our accident analysis program. We have lookeihat the apparent causey we. have searched out the real cause; and we lave ** ? .our objective. But the full accident analysis, as we see it, is made un of four points. We must, establish responsibility; not necessarily responsibility forthe accident that has already hap- but rather, responsibility forthe Action of ffiToond^that caiised the seek out the real cause of the accident This ^dent We've all heard the old proverb, can best be done by the application of logic. -Something that is everybody's respoS- We must take what we have learned of ity is nobody's responsibility."' It never had the real cause and set up our objective--the a better application than it has in accident correction of the factors which caused the prevention. : A A TIO HA '. SAIF is f Y COUN CIL 1951 -52 lave n General CAoiman--HOWARD HOLLAND, Supervisor of' Safety; The. Youngstown ; Sheet*TubeComiohy. East Chicago, Ind. :' .':%.'= First Vice-Chairman--H. S. SIMPSON, Safety..Engineer, Caterpillar Tractor Company, . v;Peoria,;ili... \ ;v_v~:, >.:.;! -V-v':-" '. '. SecondFice-Chairnum--J.J. NOLAN, SaBrty;Engineer, Bethlehem Steel Company, Beth lehem, Pa. V. : ..'. Secretary--A. H. ZEILINGER, Safety -Engineer, The t Cblprado Fucl & Iron Corpora tion, Pueblo, Cola ` '; . " / News' Letler-Editor--W. H. -WILSON, Safety Director, Ambridge Plant, American --- Bridge Company,.Ambridge, Pa. . . .r '- News Letter.Co-Editor--V/. J.-lt. REDWOOD, Safety, Supervisor, Industrial Relations . Department, Aigoma Steel Corporation, Ltd, Sanlt .Ste.. Marie; Ontario,- Canada. Consulting Committee--*R. L. RIDINGER (Chairman), Director of Safety & Plant Pro tection, Inland Steel Company, East Chicago, Ind. ;. J. L. MacKENZIE, Supervisor of Safety,. South Works, United States Steel Company, Chicago, TIL; J. W. TYSSE, ; Safety Supervisor; ChkagO'Dfetrict, RQmblic Steel Company, Chicago, I1L Contest and StatistiesCommiltee---E. J, LANGLAND. (Chairman), [Safety Director, Great Lakes Steel Corporation, Ecorse, Detroit,. Mich.-;- J. P..LEONARD, Personnel and Safety Director, Btaw-Knox Company, Pittsburgh, Pa.; C. K. SUNDERLAND, Super- . visor of. Labor Analysis, United States. Sted. Company, Pittsburgh, Pa. Engineering and:Practices Comhiittee-^A.'"CL'.WHISMAN (.Chairman),. Supervisor of Safety,.Gary Steel Worif^.Uoifcd States Steel.Ox, Gary, had. . Fabricating Industry---GERARD O. GRIFFIN ;(Chairman), Director of Safety, Dravo Corporation, Neville Island,-Pittsburgh,' Pa-;?F-:;M.' BEAUDOIN, Manager Industrial "Relations, United. States'Steel Products^ Cripa^r,;.Petrolann.- Iron Works Division, Cftavnn -Pa > P . W FWflPRPR *. 'lifanitF>tiMwtfePpflfAcPntariw ' PtHclnmiti TOelrirt Company; Rockford Worics/Rockford, HL; WALTER E. WILLIAMS, Safety Engi- ' nw/ButiwMatefactomgCbmpaity.C^esbiu^^ L;WISE,Snpervitor "Per- sbnnel& Saf^t Bla#-KhoxvDmsimi, Blaw-Kiiib3C 'Gompanry; Blawnox, PaL C/:. rvV`-* Vi-.-. (: '--ir-'iS'.'-t V, 'X.'-X ;. Foundry Industry--]. D. HOLTZAPPLE (Chairman).'Personnel Supervisor, Continental Foundry 's ' Machine. Ccnni*aity;.Past Chicago, ; ?^D, r.FARRELL(Advisory Chairman),-Supervi^. 6f Saf^;/Umt^'States Stil Co^,Pitteburg^i, Pa.; *IRYIN * i A. 'BRINKMAN,..Director, of. Empl^rpmt, SifetyJand Welfare, MyJrintosh-Hemphill Company, Pittsburgh, : Pa.;GEORGE ^MD }< Safety. .Director, Minneapolis- > Moline-;-Cd; Mhtneapolis, MKnn.;; SHERMAN-RTCTIARpSQN;-. Aaastani- Pprcrmwl . J'Manager;*: American,Radiator a^jStandaidj'S^to Pa.; 1. A. G. STARRETT,. Persbnhid;;pinxtDr;,';l^ Co- .' lttmbu^ Ohio; G -J. 'VANr DAMN;; !^f(5y^piroS)r;f:iGinpbdI,--Wyaiit: &Cannon . r ^*'V.. mm S&. b * Sv,: inr- ,'Ji Metals Industry served solely for engineers, rather, we do mean that people engaged in safety work must be able to analyze, to judge, and to decide. Mr. Ward, will you discuss this matter of analysis? Me. Ward: Often, accidents seem to stem from uncontrollable factors, and the appar ent cause is that the accident was due to a hazard inherent to that peculiar job or oc cupation. Nowr, in safety work, such identification is not sufficient Since we are interested in the elimination of unsafe acts and unsafe conditions, we must go further. We must seek out die real cause of the accident This can best be done by the application of logic. We must take what we have learned of the real cause and set up our objective--the correction of the factors wdiich caused the accident Accident investigation has no value, whatsoever, if it does not succeed in developing a safer method of doing the job on which the accident'occurred. Thus, we have completed three points in our accident analysis program. We have looked at the apparent cause; we have searched out the real cause; and we have established, and set up our objective; But the full accident analysis, as we see it, is made up of four points. We must estab lish responsibility; not necessarily responsi bility for the accident that has alreadty hap pened, but rather, responsibility for the correction of the conditions that caused the accident. We've all heard the old proverb, "Something that is everybody's responsibil ity is nobody's responsibility." It never had a better application than it has in accident prevention. (7 F, St S, N N C, Ct B Ft B Ur,s Ft \ iasmiwn no dr 5 in have have have But t, is stabmsihap- the . the .xrb, abilhad dent o Officers of the NATIONAL SAFETY COUNCIL 1951-52 General Chairman--HOWARD HOLLAND, Supervisor of Safety, The Youngstown Sheet & Tube Company, East Chicago, Ind. First Vice-Chairman--H. S. SIMPSON, Safety Engineer, Caterpillar Tractor Company, . Peoria, 111. Second Vice-Chairman--J. J. NOLAN, Safety Engineer, Bethlehem Steel Company, Beth lehem, Pa. Secretary--A. H. ZEILINGER, Safety Engineer, The Colorado Fuel & Iron Corpora tion, Pueblo, Cola News' Letter -Editor--Vi. H. WILSON, Safety Director, Ambridge Plant, American -- Bridge Company, Ambridge, Pa. - News Letter Co-Editor--W. J. M. REDWOOD, Safety Supervisor, Industrial Relations Department, Algoma Steel Corporation. Ltd. Sault Ste. Marie, Ontario, Canada. Consulting Committee--*R. L. R1DINGER (Chairman), Director of Safety & Plant Pro tection, Inland Steel Company, East Chicago, Ind.; J. L. MacKENZIE, Supervisor of Safety, South Works. United States Steel Company, Chicago, TIL; J. W. TYSSE, Safety Supervisor, Chicago District, Republic Steel Company, Chicago, 111. Contest and Statistics Committee--E J. LANGLAND (Chairman), Safety Director, Great Lakes Steel Corporation, Ecorse, Detroit, Mich.; J. P. LEONARD, Personnel and Safety Director, Blaw-Knox Company; Pittsburgh, Pa.; C H. SUNDERLAND, Super visor of Labor Analysis, United States Steel Company, Pittsburgh, Pa. Engineering and Practices Committee--A. G. WHISMAN (.Chairman), Supervisor of Safety', Gary Steel Works, United States Steel Co, Gary, Ind. Fabricating Industry--GERARD O. GRIFFIN (Chairman), Director of Safety, Dravo Corporation, Neville Island,-Pittsburgh, Pa.; F. M. BEAUDOIN, .Manager Industrial Relations, United States Steel Products Company, Petroleum. Iron Works Division, Sharon, Pa.; E W. ENGERER, Management's Representative, Pittsburgh District, Bethlehem Steel Company, Pittsburgh, Pal; H. PALMINI, Safety Engineer, J. I. Case Company. Rockford Works, Rockford, 111.; WALTER E WILLIAMS, Safety Engi neer, Butler Manufacturing Company, Galesburg, 111.; P. L. WISE Supervisor Per sonnel & Safety, Blaw-Knox Division, Blaw-Knox Company, Blawnox, Pa. Foundry Industry--J. D. HOLTZAPPLE (Chairman), Personnel Supervisor, Continental Foundry . & Machine. Company, East Chiaigo,; Ind. ; 5D. A. FARRELL (Advisory Chairman), Supervisor of Safety, United States Steel Co, Pittsburgh, Pa.; *IRVIN A. BRINKMAN, Director of Employment, Safety, and Welfare; Mackintosh-Hemphill Company, Pittsburgh, . Pa.; GEORGE MILLIGAN,. Safety Director, Minneapolis- ' Moline Co, Minneapolis, Minn.; SHERMAN RICHARDSON, Assistant Personnel Manager, American,Radiator and Standard Sanitary Corporation, Pittsburgh, Pa.; A. G. STARRETT, Personnel Director, The Buckeye Steel Castings Company, Co lumbus, Ohio; C J.'VAN DAMN, Safety Director,-Campbell, Wyant .& Cannon .a Foundry Company, Muskegon, Midi.; E J. WALLMAN, District Supervisor of Safely, American Brake Shoe Co-, Chicago, III. Metallic Coating Industry--BONNIE TRENT (Chairman), Plant Safety Committee, American Hot Dip Galvamzers Association, Inc, Pittsburgh, Pa.; *C. M. ALLEN (Advisory Chairman), Staff Supervisor of Safety, Armco Steel Corporation, Middletown, Ohio; T. C CARRICO, Director, Welfare and Safety, Wheeling Sted Corpo ration, Wheeling, W. Va. Non-ferrous Metals Industries--M. L. ABEL (Chairman), Executive Vice-President, Mag nesium Company of America, East Chicago, Ind.; *H. G. HENSEL (Advisory Chair man), Safety Director. The Youngstown Sheet & Tube Company, Chicago, I1L; WILLIAM GILLIAND, Assistant Safety Director, Aluminum Company of America, Pittsburgh, Pa.; C L. McCOY. Director of Personnel, Chase Brass & Copper Company. Cleveland, Ohio; J. E NICHOLS, Director of Safety, Reynolds Metals Company, Reynolds Metals Building, Richmond, Va.; C L. RIENZO, Supervisor of Workmen's Compensation, Revere Copper and Brass Inc, Rome, N. Y.; WILLIAM S. VTSOKAY, Superintendent of Safety, Bridgeport Brass Company, Bridgeport, Conn. Steel Industry--W. E BARKER (Chairman), Safety Supervisor, East Works Plant, Armco Steel Gorp, Middletown. Ohio; G. J. EIGENBROD, Safety Supervisor, Republic Steel Corporation, Buffalo. N. Y.; STANLEY W. HALL. Supervisor, Em ployee Services Section, Sted Division, Ford Motor Company, Dearborn, Mich.; W. T. McLEAN, Supervisor of Safety', United States Sted Co.. Youngstown, Ohio; E D. MORGAN, Superintendent of Plant Protection & Safety, Bethlehem Plant, Bethlehem Sted Company. Bethlehem, Pa.; W. D. WILLIAMS, Assistant Supervisor of Safety, The Youngstown Sheet & Tube Company, East Chicago. Ind. Steel Warehousing Industry--JOHN G CUSHING (Chairman), Director of Industrial Relations, United States Sted Supply Company, Chicago, I1L; *F. W. KELSEY (Ad visory* Chairman), Supervisor of Safety & Welfare, Jones & Laugfalin Sted Corpora tion, Jones & Langhlin Building, Pittsburgh, Pa.; M. A. KING, Supervisor of Safety. J. T. Ryerson Company, Chicago. I1L; JOHN E .SPANN, Engineer, Chicago Ware house, Jones & Laughlin Sted Corporation, Chicago, III.; WALTER STONER, Super intendent Industrial Rdations, Truscon Division, Republic Sted Gorp, Youngstown, Ohio. Wire Manufacturing Industry--H. E FRAYER (Chairman), Safety Director, L. A. Young Spring & Wire Corp, Detroit, Midi.; *J.-F. COLLINS, Supervisor of Safety, The Youngstown Sheet & Tube Company, Youngstown, Ohio; PETER CONTARDO, Safety Director. John A. Roebling's Sons Company, Trenton, N. J. Health Committee--DR RICHARD J. BENNETT (Chairman), Chief Surgeon, United States Sted Company-, Chicago, I1L; DR E H. CARLETON, Medical Director, Inland Sted Company, Indiana Harbor Works, East Chicago, Ind.; DR A. M. EDWrARDS, Medical Director, American Sted & Wire Company, Cleveland, Ohio; DR S. A. NORRIS, Chief Surgeon, Jones & Laughlin Sted Corporation, Pittsburgh, Pa. Membership Committee--\V. M. NELSON (Chairman), Manager of Safety, Republic Sted Corp., Cleveland. Ohio; R H. BUMGARDNER Manager, Safety and Casualty Bureau, Tennessee Coal. Iron and Railroad Company, Birmingham, Ala.; R M. DAVIS, Genera] Supervisor of Safety', Homestead Wrorks, United States Sted Co, Mtmhall, Pa.; J. A. DOWNEY, JR, Director, Personnel & Safety, Sloss-Sheffield Sted & Iron Company, Birmingham, Ala.; A. L LOTT, Manager of Industrial Relations, The Sted Company of Canada, Ltd, General Offices. Hamilton, Canada. G J. VANDEVENTER Safety Director, Atlantic Sted Company, Atlanta, Ga. ifety, littcc. )rpo- Mant, risor, EtnXch.; >hio; 'tent. visor stria] (Adporaifety. /areoper- )D! .. A. ifety, IDO. nitcd iland IDS, i. A. ublic naltv VIS. shall. Iron Steel TER, Prognm Committee--E. H. HOUCK (Chairman). Superintendent of Safety and Welfare, Aliquippa Works, Jones & Laughlin Steel Corp., Aliqmppa, Pa.; C L. BRADSHAW, Assistant to General Sales Manager, Industrial Chain Division, Columbus McKinnon Chair Corp., Tonawanda, N. Y.; EARLE M. LAYMAN,. Director of Personnel, General SteelCastings Corp., Eddystone, Pa.; J. N. MAHAN, Supervisor of Safety and Insurance, Continental Steel Corp., Kokomo, Ind.; EDWARD MARTIN, Director of Safety, Oliver Iron and Steel Corp.; Pittsburgh, Pa.; ALLEN M. MORGAN, Manager, Industrial Relations Department, Haynes Stellite, Kokomo, Ind.; RUSSELL L PISLE, Superintendent, Industrial Relations, Chicago District; Republic Steel Corp., Chicago, 111.; T. R. SMITH, Safety Supervisor, Republic Steel Corp., Youngstown, Ohio. Trade Association liaison Committee--EDWARD C METZEL (Chairman), Assistant Supervisor of Safety, United States Steel Co, Pittsburgh, Pa.; P. J. BOWEN, Assist ant Safety Engineer, Great Lakes Corp, Ecorse, Detroit, Mich.; *PAUL E. GRUNDMAN, Safety Engineer, Rustless Iron and Steel Division, Armco Steel Corp, Balti more, Md.; J. F. JULL Safety Director, Consolidated Western Steel Corp, Los Angeles, Calif.; W. W. BRANT, Supervisor of Safety, Johnstown Plant, Bethlehem Steel Company, Johnstown, Pa.; G. A. RILEY, Supervisor of Safety, American Brake Shoe Company, New York, N. Y.; J. R. VAN SYCKLE, Safety Supervisor, Republic Steel Corp, Cleveland, Ohio; R. M. WALSH, Assistant Director, Safety and Plant Service, Intend Steel Company, Indiana Harbor Works, East Chicago, tod. Visual Education and Poster Committee--ROBERT S. B. HOLMES (Chairman), Director of Training and Safety, National Tube Company, Pittsburgh, Pa.; A. E. ASET, Safety Supervisor, Sheffield Steel Corp, Kansas City, Mo.; H. J. JONES, Manager, Industrial Relations, The Colorado Fuel & Iron Corp., Buffalo, N. Y.; PAUL LUNDQUIST, Safety Director, Acme Steel Company, Riverdale, I1L; D. D. MATEER, Supervisor, Safety and Welfare Department; Pittsburgh Works, Jones & Laughlin Steel Corp, Pittsburgh, Pa.; ARTHUR D. MURPHY, Director of Safety and.Suggestion Plan, Crucible Steel Company of America, Pittsburgh, Pa.; KENNETH L WARD, Assistant to Supervisor of Safety, The Youngstown Sheet & Tube Company, Youngstown, Ohio. Members-al-Large--*E_- F. BLANK, Asastant to Vice-President; Employee and Public Relations, Jones & Laughlin Steel Corp, Pittsburgh, Pa.; GROVER C. BROWN, Secretary, Industrial Relations Committee; American Iron and Steel Institute, New York, N. Y.; *R. A. CHAFFIN, Vice-President, Industrial Relations, Continental Steel Corp., Kokomo, tod.; *R- H. FERGUSON, Asastant Director of Industrial Rela tions, Republic Steel Corp, Cleveland, Ohio; *G. T. FONDA, Asastant to President, Weirton Steel Company, Weirton, W. Va.; *E H. FYLER, Superintendent, Industrial Relations, United States Sted Cd, Gary Steel Works; Gary, Ind.; *HL J. GRIFFITH, Assistant to Manager of Coal `Mines; Jones. & Laughlin Steel Corp, Vesta-Shannopin Coal Division, California, Pa.; *F. A. LAUERMAN, Director of Industrial Relations, Republic Steel Corp, Youngstown, Ohio;*J. A. OARTEL, Pittsburgh. Pa.; *R X. SCHMITT, Louisville; Ky.; *H. J. SPOERER, Director of Industrial Relations, The Youngstown Sheet & Tube Company, Youngstown, Ohio. Staff Representative--WM. N. DAVIS, Senior Engineer, National Safety Council, Chicago, HL Past General Chairman. 39 "J: ift * -4fit*,- tr..;} *\ ) Mi ft'- i . ' fi M Sr?- r! : i . X i-rl-y-i'. Other Volumes in this Seriesi volume 'will find much value in its companion volumes. Here is die list: TITLE VOLUME. No. General Sessions and Detailed Index'to all Volumes...................... :............ ................. . 1 Aeronautical Industries.................................................................... I.................................. 2 Air Transport Industry................................................................... 3 Automotive and Machine Shop Industries............................................................................... 4 Cement and Quarry Industries.................................................................. ...................... - 5 Chemical Industries .................................................................................................................. 6 Coal Mining Industry.............................................................................................................. 7 Construction Industry .............................................................................................................. 8 Electrical Equipment Industry.................................................................................................. 9 Farm Safety................................................................................................ 10 Food Industry (Including Proceedings of Refrigeration Safety Meetings.)..................... 11 Glass and Ceramics Industry................................... ........................................................... 12 Home Safety ........................................................................................... 13 Industrial Nursing ................................. *............................................................................... . 14 Industrial Subject Sessions (Sponsored by ASSE)............................................. 15 Maritime Industries (Marine Section)........;........... ............................ ............. 16 Meat Packing, Tanning and Leather Industries.......................................................................17 Metals Industry........................................................:............................................................... 18 Mining Industry .............................................................................. Motor Transportation Industry (Commercial Vehicle Section)..................................... Petroleum Industry .................................................................................................................... 21 Power Press and Forging Operations.................................. ............... -rrrTTs-...................... 22 Printing and Publishing Industry................................................................................... Public Employment (Public Employees Safety Committee)................................................ 24 Public Utilities Industries.............................................................................................................25 Pulp and Paper Industry........................................................................... Railroad Industry........................................................................................................................27 Rubber Industry .............................................. r......................... ........................................... ; 28 School and College Safety......................................................................................................... 29 Textile Industry ..........................................................................................................................30 Traffic Safety .....................'..................................................................................................... 31 Transit Industry' ...........................................;............ .............................................................. 32 Wood Products Industries.................................................................................V....................33 Human Understanding--A,Two-Way Communication (Early Morning Sessions)............34 20 23 PRICES OF EXTRA COPIES OF INDIVIDUAL VOLUMES TO MEMBERS VOLUME lto9 copies SIZE Each Less than 24 pages-- $029 24 to 48 pages-- 25 49 to 96 pages-- .46 Over 96 pages-- .69 10 to 99 copies Each $023 29 .40 .63 100 to 999 copies Each $0.17 23 25 28 1000or more Each $0.17 23 25 28 Complete set of Transactions (34 vols.)--$6.90 (I to 9 copies), 620 (10 to 99 comes), 5.70 (100 or more copies). NON-MEMBER prices are double member prices, except volumes 10, 13, 29 and 31. NATIONAL SAFETY COUNCIL 425 NORTH MICHIGAN AYE. CHICAGO 11. 1U. nuns h B.I.A. 40 2800--2}2--WHP 26