Document dDnO7xY6EwKL0y97eVJ1oojre

7 Chicago's Tribune Tower, now a famous landmark in that city, was featured on the cover ot the first issue of LEAD Magazine, published two years after ftte incorporation ot Lead Industries Association in 1928. The lead used in the original construction ot the building is still in service today, some 48 years later. 2 Si Reflections at 50 i* The year 1928 doesn't impact strong on American history. A young eri^ neer. Herbert Hoover, with a fine ord of famine relief in Europe afip, W AA I. was calmly president. His C0|1 stituency was somewhat more restive The Volstead Act was driving a nation to drink. "Driving" in anv rase was th( operational word as North Ameriran, took to the liberating road and vour own car became a sine qua non in the pursuit of happiness. There is nothing on the record to show that Lead Industries Association, formed in 1928. was the product of these socio-economic pressures. The sprawling industry along the Detroit ' River was. in time, to consume, in bat teries, solder and TEL, nearly % of an- nual lead production. But that was in j the future of the 50s and 60s. The lead i trade association formed in 1928 was ; concerned pretty much with the objec tives which constitute its charter todav: 1. To collect and publish information relating to the production, distribution, marketing, consumption and use of lead and lead products; 2. To disseminate accurate informa tion regarding lead products and ho* they best may be used; 3. To develop methods for the im provement of the welfare of those en gaged in the lead industries, or in the use of its product; and for such other purposes as, from time to time, may be I of benefit to the lead industries, and in general to promote the serviceability of the lead industries to the community at large. An early list of membership appears in the May 1933 issue of Lead Maga zine. It is worth reproduction here on Page 3. Sic transit galena! A page in the his tory of the mining industry is revealed in this listing; the tides of merger, the finalities of death, depletion, and re organization. Those familiar with ILA membership today will recognize that, though many names have changed, the major pro- LIA26822 ,|ucers are -till very much on scene. However, membership in 1978 is di^rse. Canadian, Mexican, Australian jrtd European producers are now mem bers. Secondary -melters are part of the 3;sociation. So too are companies whose jctitity embrare lead application like .older producers, lead acid battery man ufacturers. cable and TEI. producers. cnees on the growth of lead in the future as analyzed bv one industry spokesman: process improvements in the smelt ing of lead promise to overcome environ mental problems in lead reduction. major new uses for lead developing in the battery industry. Could reach 60 per cent of world consumption bv 1985. advances in battery technology: non-antimonial alloys, maintenance free batteries, continued reduction in SLI battery weight, wrought strip grid. growth of the electric vehicle mar ket, especially as a second or third fam ily vehicle. widening use of batteries bv the utility industry for peak power sharing. There is much ahead. At mid-century mark, our glass is not half empty but half full. The future: Change is a constant Change is no doubt a constant. But the rate of change accelerates. A ran dom sampling of headlines from Lead Magazines of yesteryear underscores this truism: "Highway Departments Overwhelm Jf, ingly Favor Lead Primers" l June 1933) "Lead-Acid Storage Batteries Serve as Reserve Power". National Broadcasting Headquarters. RCA Building, Rockefel ler Center. duly 1934) "New Jersey Master Plumbers Ask for More Lead in Codes" ( July 1933). Subsequent issues of Lead were to show other state craftmen endorsing this stand. "Lead-Sheathed, 115,000v Submarine Cable, Northwestern Electric Co., under Columbia River is first Oil-filled Sub marine Cable". I March 1933) "Brooklyn Moves to Replace Un sightly Overhead Power Lines with Un derground Lead-sheathed Cable". (1931) "Mono Castle Burns". Paint blistered, peeled and dropped off to reveal red lead beneath. (1934) "World's Fair New York 1939". Many fair buildings painted with white lead. "Tetraethyl Lead Boosts Octane for PT Boats and Carrier Aircraft." 1941 "Lead-Telluride Space Power Unit part of Atom Era." (1959) Trade-offs in materials are a fact of life in a technological society. We have seen them and are continuing to see them in the lead industry, It would be fash standing on the tiny hillock of fifty years to project another 50 years into he future. But here are positive influ- Lead Industries Association 1929 member companies The American Metal Co., Ltd. New York, N. Y. American Smelting & Refining Co. New York, N. Y. Anaconda Lead Products Co. East Chicago, Ind. The Andrews Lead Co., Inc. Long Island City, N. Y. Bond Manufacturing Corp. Wilmington, Del. Bunker Hill and Sullivan Mining and Concentrating Co. Kellogg, Idaho Cerro De Pasco Copper Co. New York, N. Y. Chief Consolidated Mining Co. Eureka, Utah Crown Metal Co. Milwaukee, WIs. The Eagle-PIcher Lead Co. Cincinnati, Ohio Euston Lead Co. (The Glidden Co.) Scranton, Pa. Evans Lead Co. Charleston, W. Va. Federal Mining & Smelting Co. New York, N. Y. Federated Metals Corp. New York, N. Y. W. P. Fuller & Co. San Francisco, Cal. General Lead Manufacturing Co. Denver, Colo. Globe Metal Co. Chicago, III. Hecla Mining Company Wallace, Idaho Hudson Smelting & Refining Co. Newark, N. J. International Smelting Co. United Metals Selling Co., Agents New York, N. Y. The Lewin Metals Corp. East St. Louis, III. Metals Refining Co. (The Glidden Co.) Hammond, Ind. National Lead Co. New York, N. Y. Northwest Lead Co. Seattle, Wash. Park Utah Consolidated Mines Co. Salt Lake City. Utah Rochester Lead Works Rochester, N. Y. St. Joseph Lead Co. New York, N. Y. The Sherwin-Williams Co. Cleveland, Ohio Silver King Coalition Mines Co. Salt Lake City, Utah Tintic Standard Mining Co. Salt Lake City, Utah Nathan Trotter & Co. Philadelphia, Pa. United American Metals Corp. Brooklyn, N. Y. United States Smelting Refining & Mining Co., Inc. New York, N. Y. USL Battery Corp. Niagara Falls, N. Y. Winchester Repeating Arms Co. New Haven, Conn. LIA26823 CB talk hangs on thin lead alloy thread Circled area shows solder strip used to join contact points of CB switch modules. Millions of car owners and truckers use their Citizen Band (CB) ra rivet, weld or braze precious metak such as gold and silver to the tip of dios daily to converse with fellow CBevery switch arm to enhance electrical owners regarding traffic conditions, ac conductivity. Though logical, such pro- cidents and other important informa duction sequences are expensive be tion. However, few of them are aware cause they require extensive labor. that the voice transmission that makes Another problem is the possibility of CB radios so popular literally hangs on defects during each production step. a thin ribbon of tin lead solder. TMI's way to mass produce switches The tin lead solder is playing a vital is to first apply the precious metal or role in helping to reduce the cost and other coating to the parent metal strip improve the quality of all kinds of elec then to apply a ribbon of solder. Thh trical switches. This in turn has helped will later be used to join the switching producers of electrical equipment such arm to a socket. Finally, the strip is cut as CB radios to produce high quality into desired sizes at the manufacturing products at competitive prices. site. For example, Cherry Electrical Prod TMI begins a typical production se ucts, Waukegan, 111., is one company quence by using a phosphor bronie that takes advantage of tin lead solder strip that's 1,000 ft. long, 2,586-in. to achieve high quality electrical joints. wide, and 0.010-in. thick. Next, inlay The solder is incorporated in a highly sophisticated, multi-material clad strip strips of gold are placed wherever con 1 tact points will fall. A strip of solder developed by Technical Materials, Inc., is then placed where the finished arm lT.MIi, Lincoln, R.I. Significant dollar will eventually fasten to a switch or costs for tooling, forming and assem socket. bly, as well as the added benefit of TMI has developed special tech reduced consumption of precious met als can be achieved by using this spe iniques to apply the solder to the clad strip. In the first step, the tin lead cially engineered clad strip to produce solder alloy is carefully rolled to the switching arms. desired size. In the case of the clad For decades, the common method of strip for CB arms, the initial size producing reliable switching arms was the solder strip is 0.007-in. thick to form them first and then either plate. 0.250-in. wide. The strip is rolled, * LIA26824 pressure bonded, directly onto the bare petal. Heat is then applied to achieve temperatures that will make the solder j]ow enough to bond it to the base petal. After the metal has cooled, the strip is rinsed and processed through a giving device. The tool shaves the top pid sides of the solder strip to a very close tolerance, reducing the thickness from 0,007-in. to 0.0005-in., and the width to its original 0.250-in. The completed strip is then coiled and sent to a manufacturer. There pieces of the continuous strip are cut so the gold inlays fall exactly where desired, and the solder stripe on the other end where a contact (output) pin is to be located. According to TMI. any formable petal can be used for the clad strip. It can be provided in any length that can be conveniently shipped in rolls and in widths up to six inches and thick nesses from 0.003-in. to 0.040-in. The company reports that its tech nique of applying solder to the clad ding is superior because it is accom plished under ideal conditions. This method achieves much more uniform adhesion, compared to waiting to place the solder when the switches are as sembled. At that time, only delicate manual soldering at best, or more com plicated soldering systems can be used. The adhesion of both the gold and the solder is so reliable that failures are rare. Cherry Electric is able to form the contact arms without break ing the bond of either the gold or the solder. The company calls the final as sembly a Rotocode switch. Primarilydesigned for CB radios, it can have up to 50 switching positions. However, the same unit will work equally well in any application where complex elec tromechanical switching is needed. Solder theory and application emphasized at first U.S. solder forum Over 200 were in attendance at the First U.S. Solder Forum sponsored fundamentals on the opening day. Pa pers were presented on the basics of sol by the Solder Manufacturers Committeedering, alloy selection, organic and of Lead Industries Association, Inc., inorganic fluxes and cleaning. The with cooperation from the Tin Research second day's program covered solder Institute, Inc. The proceedings were applications and techniques in the lamp, held at the Hyatt Regency O'Hare in automotive and electronic industries. A Chicago on .November 15 and 16, 1977. Westinghouse representative revealed The two-dav program produced a sig little-known lamp soldering practices, nificant interchange of ideas on solder while an engineer from Ford's Green ing technique1 and applications. Speak Island Plant described an improved ers included representatives from such method for soldering radiators. Other well-known companies as Bell Telephone speakers discussed wave soldering, the Laboratories, E.l. du Pont de Nemours hand soldering of micro-electronic de and Co., International Business Ma vices and preforms and pastes. chines, Westinghouse Electric Corp., and Ford Motor Co. Lively and infor Due to the high degree of in mative question and answer sessions terest shown, a second Forum will followed the talks. be held on November 13 and 14, The agenda for the Forum provided 1978 at the Mariott Twin Bridges for comprehensive coverage of solder in Washington, D.C. Line drawing of clad strip shows location oi precious metal and solder. F. C. Dispue, Technical Director, Alpha Metals, Inc., (at lectern) fields Questions from the floor following his talk on special solder alloys at the First U.S. Solder Forum in Chicago, III. At Disque's left is J. F. Smith, Vice President and Secretary ol Lead Industries Association, Inc., who moderated the session. LIA26825 5 Bank and car leasing firms study electric vehicle potential A leading Chicago bank and [he big gest independent automotive leas annually and operating costs are high. In the first six months of 1977 alone the ing lirm in that city have teamed up to lleet completed some 54,000 miles of examine the potential for battery- travel. This was accomplished at an powered vehicles in congested urban average of 16 cents per mile, including area;. the cost of gas. oil and maintenance. The locus of [he study is on how elec This translates into an annual operating trics can be used in place of internal cost of S 17.000 per vehicle. combustion engine l 1C) vehicles to de After bank officials had an opportun crease transportation costs, improve air ity to view a variety of new electrics at qualitv and reduce noise in downtown the 1977 International Electric Vehicle business areas. However, the more im Expo in Chicago, they decided to test a mediate goal is to determine if electrics battery-powered truck in actual opera can replace 10 gasoline-powered vans tion. in a cooperative effort with Lead now used bv the bank. Industries Association iLIAl. an elec The lleet. which consists of eight tric vehicle demonstration program was Ford Econolines and two Dodge mini- implemented using GoLlAth, LlA's passenger personnel carriers, is main lightweight battery-powered delivery tained by the leasing company. They van. The vehicle, which is powered by are used to transport large volumes uf an electric motor run off of a 112-volt mail and other correspondence between lead battery system, has a load capacity the bank's main Chicago office and its of about 1.000 lbs. 10 other locations in the Loop area. The GoLlAth was operated more than 70 volume of mail auually--more than 55 hours during the nine-day demonstra million units--surpasses the amount of tion period. It made more than 1,000 mail processed by the post office of a traffic and pickup/delivery stops while medium-sized city. Added to this are being driven about 240 miles. thousands of inter-office letters, memos, As a result of an earlier GoLlAth pro v ouchers, etc. gram and other studies, Commonwealth Operating on regularly scheduled closed-loop routes, the vehicles are in volved in extensive stop and go traffic Edison, the local utility, has been able to accumulate data on electric vehicle energy costs. and average only 10 miles an hour. The utility discovered that energy Since this is the most inefficient way to costs for electrics would be about half operate IC vehicles, they average only that of the presently-used vans. It esti about six miles to the gallon. The slow mated that GoLlAth used about 1 kilo speed and constant stopping and start watt hour (kwh) of electric energy for ing also influence the amount of main each mile traveled in downtown traffic. tenance and overhaul required to keep A commercial customer such as the the vehicles in service. bank or its leasing company now using Since the vehicles operate around-the- 24,000 kwh per month would pay about clock, they average about 108,000 miles 2.7 cents a mile for additional elec tricity used bv the vehicle. To thi- ,u. 2.5 cents per milie must Ibe addedJDofut periodic battery replacements. f According to calculations, this firing total electric vehicle energy cost to abo^ 5 cents a mile. Conventional vans fleet gasoline at 56 cents a gallon 4 getting only 6 miles to a gallon downtown traffic have ail energy cost 0| 9.3 cents per mile, In addition, the tries are expected to have a much lower maintenance cost than conventional especially in the type of service invo|v. ing slow speeds, limited distance many stop-start cycles. and Based on the successful GoL[.\(|, demonstration, the bank is planning to make a more detailed investigation 0j electrics. The study would include cific types of vehicles that could be in. corporated in the bank s automotive lleet. To determine what role electrics can play in the bank s operations, j j well as other operations involving tf* automotive leasing company's lleet 0[ over 25 lightweight trucks, additional operational and maintenance data is rf. quired. For example, the leasing firm needs to know more about the lifetime operational use of electrics, compared with 1C vehicles. Electric vehicles used in England have an average serv ice life of 24 vearv more than five times the life span of a typical 1C truck. Because they require i fewer moving parts, electrics are easier j to maintain and repair and the need to stock hundreds of spare parts is elimi- ; nated. These and other factors offset the . high initial cost of electrics when c o b- i pared with IC types. | GoLlAth next to IC vehicle leased by bank. 6 Bank officials examine GoLIAth's battery storage area. LlA2662fc gattery powered trucks handle paper work efficiently Rising energy costs are forcing indus try to take a harder look at how according to Dun Norris, Plant Engi neer. the question of specific benefits their lift trucks are powered. Some remained to be answered. companies which traditionally favored Norris decided to make a detailed cost the use of internal combustion work comparison of electrics vs. gasoline- v chicles for a diversity of reasons are powered trucks. He selected two high now finding that a switch to battery- free lift mast type trucks engaged in the powered trucks can be advantageous. same type of work. The raw findings are For example, in the paper making shown in the accompanying table. At an and converting industries, where lift average per hour maintenance cost of trucks are the backbone of the material 3 1.60. the engine-powered lift truck cost handling operation, engine-powered the company 3936 during the year-long types used to be preferred. Lifting study period, compared with 8316 for heavy paper rolls is a drain oil the bat the electric. And the intervening years teries of electrics in the 10.000 to have seen labor costs rise considerably. 12,000-lb sizes, and frequent replace Norris has converted the company's ment is required during the work shift. lift truck Heet to 14 battery-powered Since fossil fuel was less costly, histori models ranging in size from 2,000-ib to cally, than electricity for battery charg I2.00O-lb capacity. He has retained onlv ing. gasoline vehicles were favored. four gasoline powered lifts. The elec Now the cost picture has changed. As trics include three Allis-Chalmers trucks Lawrence Paper Co. determined, even w ith straight forks and two with roll with the expense for battery charging handling clamps. and handling, electrics can often pro Norris has learned from experience duce cost savings. The Lawrence, that the switch was not all gravv. He Kansas plant, which produces corru reported: "We've learned that to sus gated packaging materials, had relied tain our fuel savings we must adapt in almost entirely on internal eombustion other ways, such as arranging for more lift trucks--eleven gasoline powered batteries to offset draindown under types. Only four electrics were used to heavy duty; training maintenance per handle stock and finished product in the sonnel to handle electrics; and having plant and on the loading docks. change-charge personnel available from The need for improved environmental the maintenance staff. On the other cleanliness, maintenance savings and hand, the electrics also perform well fuel cost reductions prompted plans for unloading box cars and other chores. In a Heet conversion to electrics. While the fact they have an edge of 35 percent in general benefits of electrics were visible, cost terms." Gasoline Truck Service Trips Shop to hours shop required General service 51 72 Clutch, transmission 14 102 Electrical 10 22 Carburetor 33 78 199 Electrical Truck Service Trips Shop to hours shop required General service Electrical 38 60 59 43 69 LIA26827 7 1 Lead crowns spectacular South African exhibit center One of the most spectacular lead roof ing projects in modern times has concrete roof was originally to be pro tected by a plastic membrane. However, been completed at Cape Town, South the Cape Town City Architect's depart Africa. The Good Hope Center, one of ment became increasingly aware of the the many impressive public buildings in problems of maintaining the membrane. the city, has been crowned with 164 This factor, plus additional problems tons of lead. The roof was installed by expected, resulted in a switch to lead. Castle Leadworks of Cape Town and A quick cable to the Lead Development the company has guaranteed the lead Association of London, England, to in for 35 years. quire if the project could be accom Known locally as the Nervi exhibition plished brought back a prompt "yes" center, the building was designed by the and, after other details were arranged, famous Italian architect Pier Luigi 4-lb per sq ft copper-bearing lead was Nervi. The open-span, reinforced- specified for the project. Within five weeks of the telex, ^ contract was signed and the lead roof ing began. In the first step thick cork underlay was installed between the tin,, ber battens that form the skeleton of the soaring structure. The lead was then laid in the form of tiles with interlock, ing joints and supported by copper clip, rolled into the joints and nailed into the supporting battens. The lead tiles approximately 2-ft. by 4-ft. A team of 64 men installed 38,000 copper clips and 600,000 copper nail, to create 39.372 feet of standing seam,. In all, 9,500 sheets of lead were used. Castie Lead's men worked in conjunction with Bastobeli ot Cape 7own, who installed the cork insulation onto which the lead tiles were laid. The lead tiles were laid on the root ot Nervi exhibition center under difficult working conditions. The spectacular lead root on the Nervi exhibition center was completed in less than 70 days. 8 LIA26828 Lead stands test of time at major hospital facility i\ |n addition to being one of the largest facilities of its kind. Kings County hospital in New York City boasts one 0f the largest and finest examples of ornamental architectural lead work in [he United States. And its excellent con dition nearly fifty years after installs[ion attests to the durability of lead. Beautiful 4-lb hard antimonial lead spandrels, mullions and vertical friezes on several high-rise buildings in the hos pital complex combine to form an im pressive lead facade over the masonry. The Art Deco style ornamental patterns on the lead add to its attractiveness. The lead also was put to a multitude of other uses including roofing, flashing, matters, downspouts, finials, crestings, cupolas, ventilating louvres and a cen tral spire. The durable quality of lead was evi dent recently in the course of an exten sive renovation of the lead work on two of the hospital s principal structures-- the Main Building and the Student Nurses Residence--both constructed in the early 1930s. Literally hundreds of spandrels and thousands of mullions, as well as friezes were taken down, refur bished and re-hung. Virtually all of the original lead was reused. The small per centage of replacement was due to irrepairable damage resutling from fires, vandalism and installation of air con ditioners. In some instances nails driven into the lead to hold it in place had destroyed the pattern. Some movement of the metal over the years and the physical damage men tioned above made repair work essen tial. In fact, some damage pieces had even fallen to the ground. If left un attended the entire svstem would have eventually failed. Simpson Metal Industries, College Point, X.Y., was contracted to remove and re-hang the lead facades. The com pany had to work with extreme care so as not to further damage the lead in the process. Joseph Squicciarini and Robert Berman, the architects involved in the project, designed an improved mounting system so the restored lead would be more securely anchored. The job of restoring the numerous spandrels, mullions and friezes to their original artistic integrity was sub-con tracted to Kenneth Lynch & Sons, re Kings County Hospital, located in New York City's Borough ot Brooklyn, is one of the largest tacilities ot its kind. Workmen re-hang lead spandrel panels alter renovation. portedly the oldest architectural lead working firm in the country. Kenneth Lynch Sr., president of the firm, was responsible for the repousee work on the original lead at the time of its installa tion on the hospital. The thousands of architectural ele ments were trucked to the Lynch plant in H ilton, Conn., where the work was performed. On arrival the lead was sub jected to an acid bath, steam cleaned and wire brushed to remove dirt and debris which had accumulated over the years. The pieces were then individuallyplaced in a specially-designed lighted box to highlight the features of the relief. This made it easy to detect cracks and other damages. Ten lead burners were employed to mend any cracks or perforations that were discovered. Hydrogen torches were used for the burning so as not to mar the surface of the metal. The pieces were then returned to the light box for a second inspection. Following this, the lead was given another acid stripping bath, rinsed and air dried. After preparations were made for re mounting, a weak solution of acid was sponged onto the exterior face of the lead to darken it to a pre determined patination, prior to waxing. To replace the pieces of lead that were missing or beyond repair, the Lynch firm made a negative of the best duplicate panel. This negative was used to make the molds to stamp new panels. The Lynch firm also attached the mounting system devised by the archi tects. The spandrels were backed by t*4-in. plywood, custom-cut to fit. Cop per straps, 2-in. wide, were soldered to the lead itself and secured to the ply wood. In the case of the mullions and friezes, the straps were soldered directly to the back, without the plywood. Simpson Metal fastened the spandrels to a stainless steel support bracket that had been expansion-bolted to the con crete floor slab. The mullions and friezes were secured to the existing cedar wood blocking on the building with standard lock folds, and flashed. In all, the job took about two years to complete and all concerned are pleased with the results. Lead is once again demonstrating its ability to adapt to attractive architectural applications and hold up well in the process. LIA26829 9 Operating precision machinery re quires close worker concentration and attention to detail. Noise can seri ously interfere uith both these require ments to the point where work effort is effected. West Milton Precision Machine & Tool. Inc.. \ andalia. Ohio, faced such problems in their production plant. Re alizing that noise was the primary source of trouble, the company arranged for a noise surrey. The surrev indicated that noise in the precision machine production area was being generated bv several sources. They included a 10-horsepower hydraulic pump, cooling fan. related valving, and pressures within the Huid lines. The acoustical analysis showed the noise levels were predominately in a high frequem y range. The range was so high that it was causing worker dis traction and loss of concentration. To reduce the noise, a lead/\ invl-foam enclosure was iristnlbd around the ma chinery. The job . as completed by two men in 15 minutes. Installation of the LIA expands noise control program The Lead Industries Association (LIA) has announced an expansion signed responsibilities for complying with OSHA regulations to learn more of its communications program directed about how lead can solve various noise to the noise control industry. control problems, particularly for ma Designed to further the increased use chinery noise abatement. of lead for a \aiiety of sound abatement applications in both industrial and com mercial i mstru' tion. the LIA noise con trol program is initially aimed at both architect- and acoustical control special ists who use lead to control noise in commercial and residential buildings. In recent years, increased emphasis has been placed on expanding the use of lead to control noise for a wide variety of industries wh-' must comply with Occupational gaiety and Health Act lObHAi regulations with regard to the Most of the requests for information about the use of lead to comply with OSHA regulations resulted from a com bination of the publication of casehistory type publicity articles in trade magazines and a, series of advertise ments based on these case histories. Therefore, a part of the expanded pro gram will be to continue to emphasize the use of lead for noise control in both case histories and in advertisements dis cussing this subject. amount of noise to which workers can In order to more closely pinpoint the be exposed. Response to this program market. LIA is developing an illustrated indicated a desire among both acoustic slide presentation that discusses the use engineers and engineering personnel as of sheet lead, lead-loaded vinyls and lead compound materials to decrease noise levels in various applications. Ma chinery noise, one of the major prob lems encountered in complying with OSHA regulations, is discussed in detail in the presentation. It is being developed to present to audiences at noise con trol-related trade shows and for use in discussing the use of lead for noise con trol at meetings with various acoustical engineers and officials responsible lor complying with OSHA regulations at large and small companies. Another program in the LIA noise control project is to develop literature that discusses the wide variety noise control problems that can be solved with lead. This publication, primarily based on data developed for the illustrated slide presentation, will be used for di rect mail and leave-behind educati011" material after the slide presentation. 10 LIA26830 production environments material "as designed to injure readv access to the pump for maintenance. Installation of the lead/vinvl-loani ,-umbinution effectively i educed the ,,oise level in the adjacent precision machine shop work area. Sound level ivading- before and aftei in the machine .hop "eie 9f> dB and 18 dli respectively, a [eduction ol II! dB The reduction brought about an in crease in emploj.ee morale and con vinced the cnmpaiu to plan for addi tional cmlo-iiie- in other noisv areas. \s an added benelit. installation of the lead viinl-lo.im i m Insure- enabled the compam. to , oinplv with l S. govern ment regulations for noise control. Lead suoresses billet saw sound i'.a.-talc o Mtiininum operates its Fred erick. Md. plant 2 1 hours a da\ to lill the need for high quality aluminum ex trusion billets. A krv production opera tion involve- a huge high-speed saw which i uts the cast aluminum logs into the piccise billet lengths needed bv extruders. 1 he automatic billet cutter, built bv Loma Machine Co.. New Rochelle, X.Y.. features a tungsten carbide saw blade. The blade, which runs at a rim speed uf 12.01)0 t'i 15.000 surface feet per minute, was -elected lor it.- cutting ac tion. rather than its quiet operation. 5n acceptable sound level was aihieved when l.uina lined the saw blade guard hou-ing with leaded foam. Ibis keeps the saw's noise level below the 90 cl 15 limit during the eight-hour period of -awing, which greatly contiihutvs to the comfort of the saw op erator and nearby emplovees. Lead contains circular saw noise \t a large metal working plant, the noise level at the operator's station of a 2 1-in. diameter circular saw was be tween 120 and 180 dB. Worker effec tiveness wa- -uh.-tantially reduced and frequent shift changes were required. This resulted in decreased cost effi- eienev. The 21-in. saw was used to cut stain less steel pipe elbows and the greatest portion of the offending noise resulted from this metal to metal impact. There fore it could not be eliminated. Plant management worked with; Soundcoat to design and install a spe*cially fabricated acoustical containment structure as follows: 1. The plant built an 8-in. high by 20-ft. long semicircular enclosure of sheet steel, to completely surround the cutting operation. The lower half was fixed to the Moor and the upper half mounted on steel rails so as to be moveable. providing access to the saw. A viewing window was provided for the operator and a gear motor, limit switches and a control button installed for operating the upper section. 2. The inside of the enclosure was lined with Fw-in. Soundmat I two lead septums floating in three lavers of foam), and 120 oz/sq. ft. Soundfab was used for seals at the lloor and the junc tion of the two enclosure halves. A leadvinyl curtain was installed beneath the machine in the scrap tunnel. The treatment reduced the sound level at the operator's station to 88 dB, a dramatic reduction of noise hazard. Lead's new cable partner boosts performance uxi mgu vtuuige underground k has resulted in a lead cable sheath-** combined with a recently developttj truded ethylene-propylene (EP) ?` tion. The improved system is prov^. important cost savings for new c installations, as well as longer life " increased capacity. The EP insulation replaces oil.; pregnated paper that was wrapp*[ around the copper core of cable befo the protective lead sheathing was plied. Elimination of the paper wrl ping simplifies preparation for splicj^ and terminating of new cable install*! tions, an important cost-saving feature This is because solid extruded EP ^ much easier to work with and problem* of oil migration are eliminated. Another advantage is the fact that EP-lead cable may be spliced or terminated using commercial premolded devices. Several other important advantage* result from using the improved EP-lead combination. It provides a higher ca pacity than paper-lead in the same diameter cable. Therefore, the cable can deliver more power in-the same size ducts. Temperature ranges of EP-lead do not change with the operating volt age. Also, the moisture-resistant con struction provides a greater safeguard in the unlikely event that the lead sheathing ever is damaged. The merits of EP-lead cable have not gone unrecognized among power cable specifiers. For example, Pulp Recycling Northeast Corp., is using EP-cable by Anaconda to serve its new pulp product* plant near Glens Falls, N.Y. When plan* were being drawn for the new facility, Jim Shorey, an electrical engineer with Rist-Frost Associates; the project con 1 sultant, suggested the new power cable be used at the site. Shorey was aware that the pulp and paper business in the area is highly competitive and costs are carefully watched. He felt that the eco nomic `"edge" supplied by the EP-lead cable warranted its specification. The new EP-lead cable supplied the plant with power from nearby Niagara Mohawk power lines. Voltage over the 35kV single conductor cable is stepped down to 4160 volts for three-phase, 480 and 270 volt service. Worker feeds Anaconda EP-lead cable into underground duct at site of new pulp products plant near Glens Pells, N.Y. Cable construction (inset) from left to right, is as follows: (1) copper core (2) extruded strand shield of EP; (3) EP Insulation; (4) Hypalon insulation shield; (5) lead sheath: and (6) polyethylene jacket. Lead liner secures cooling tower basin aterbed owners are always on the alert for a massive flood of water t^at can result when the waterproof ^embrane fails or ruptures. Extensive nater damage results. With this in mind, imagine the dam age that would result if a rooftop basin folding 7.5 thousand gallons of water ruptures and sends a huge flood of water pouring through the floors below. This ivas the possibility faced by the Univer sity of Missouri at Columbia. ML engi neers had to decide how to install a new waterproof membrane for the water collecting basin of a massive cooling rower atop the university's power plant. Water from the basin is recirculated through the cooling tower. The de vice cools heated water through contact with the air. As the hot water free falls inside the tower, it gives up heat to the cool air that enters through louvers along the sides of the cooling tower. The water falls into a large basin at the loot of the cooling tower where it cools before being recirculated. Built in 1964, the tower's redwood construction showed marked signs of wear by last year. Raymond Halbert, Director of Physical Plant and Construc tion for MU, decided that extensive re pair was in order. The architectural firm of Chinn and Associates of Colum bia was called in to prepare plans and specifications for the project. The deteriorating condition of the redwood floor of the tower's cold-water collecting basin was of special concern. The joints were opening up and consid erable makeup ate' ' as being lost through leakage. It was decided that re placement of the existing wood would not be feasible. The use of a plastic liner was also considered and ruled out. It was concluded that a lead liner over the existing floor would be the best way to go since the lead was an inert metal and showed little reaction to the chemi cals in the water. Installation of the liner was accom plished by three lead burners from Larrv Goad & Co., Ellisville, Mo. A total of 11 tons of 8-lb sheet lead was used to cover the area which measures about 44-ft. by 44-ft. About 25 rolls measuring 8-ft by 20-ft were used for the job, and 1,000 lbs of burning bar were consumed in joining the sheets. The job was com plicated by the fact that the sheet lead had to be installed around the cooling tower supports, bracing and pipe fit tings. Fashioning the lead into one con tinuous covering of the floor and sides of the basin as well as part way up the support structure, has provided an effec tive watertight liner. The extensive redwood repair work on the tower, which stands about 8 feet above the power plant roof, was per formed by B. D. Simon Construction Co. of Columbia. In all. about 40.000 board feet of wood was replaced. Much of the new wood went into the floored deck on top of the tower, an area approximating the bottom of the basin in size. All that remains to be done is some sheet metal flashing which will be accomplished in the spring. The university was especially pleased with the results achieved and plans to waterproof other cooling towers on the campus in the same manner w hen funds are available. Lead burner ioins one of the many lead sheets lining cooling tower basin. LIA26833 13 Insets at right: (top) Over 100,000 photovoltaic cells provide 25 peak watts to pump water lor irrigation oI corn crop at Mead, Nebr. Battery bank (bolow) stares electricity to provide back-up power during times when there is no sunlight. Ancient Egyptians, perspiring pro fusely in the intense African sun five feet to prevent shadows from falling on the arrays. The panels were arranged as their feet powered water wheels to so they could be tilted to a maximum irrigate adjacent farmlands with water 65 angle with respect to the horizontal from the .Nile River, would be astounded with a hydraulic piston system. to know that the sun could be used to The million-dollar irrigation project provide the power for this task. was funded by the Department of En Today, the largest photovoltaic proj ergy (DOE) and is being conducted by ect ever developed for converting sun the Lincoln Laboratory of the Massa light into electricity, pumps water to chusetts Institute of Technology and the irrigate 80 acres of corn on a farm near Lniversity of Nebraska-Lincoln. Mead, Nebraska. In addition, the system According to Ronald W. Matlin of is used to power fans to dry the har MIT's Lincoln Laboratory, Nebraska vested corn. In both cases electrical en ranks second only to Texas in the use ergy is stored in lead acid batteries of energy for irrigation. The Mead loca which provide back-up power during tion was selected because it uses dif times when there is no sunlight. ferent equipment than other DOE solar The solar array consists of about irrigation experiments in the Southwest. 120,000 photovoltaic cells, arranged in Matlin noted that the energy require 28 panels each measuring 8 by 25 feet. ments for pumping water over large The panels are wired to furnish 6.2 acreage is heavy in the U.S. For ex amps at 150 volts and directly connected ample, a 160-acre quarter section re to two trailers. One houses a bank of quires 200 to 300 kW peak power. `This lead acid batteries supplied by C & D large-scale crop irrigation project repre Battery Div. of Eltra, which are capable sents one of the most promising areas of storing up to 85 kwh of electricity. for photovoltaic power systems to pene The other trailer contains three inverters trate a large market during the mid to to convert the stored DC voltage to 240 late 1980s," he explained. volts AC to power the AC irrigation The system at Mead, powers a 10 hp pump motor, crop drying fan motors pump which operates 12 hours a day to and other loads. irrigate the corn crop. Approximately Each solar array consists of two rows 1,000 gallons of water per minute is of panels, each 375 feet long, facing moved from a two-acre foot capacity south. One row was vertically offset by reservoir into an automatic gated pipe irrigation system. The photovoltaic system also tested the potential for grain drving. Two bins, each 27 feet in diameter and cap able of holding 6,000 bushels, were in stalled near the solar collectors to drv 12.000 bushels of corn. A 5 hp fan in each bin provided one cubic foot of air per minute per bushel of com through the 6,000 bushels when powered bv the photovoltaic array. Another important aspect of the Ne braska project is that data on incoming energy from the solar unit is being used to program an irrigation scheduling sequence. According to Paul Fischback of the L niversity of Nebraska-Lincoln. "We have to rethink all of our normal practices which are geared to designing and running an irrigation system. The Mead system can pump at a con stant load for 12 hours from the irriga tion reservoir by using the batteries. Water is pumped into the reservoir out of an irrigation well during the night when off peak rates are in effect. Testing procedures at Mead report edly will be carried on for the next several vears. During the irrigation sea son this summer different pump methods will be tested, including variable speed DC motors directly connected to the array, as well as three-phase \C motors. 14 LIA2683A Wind-powered generator recharges electric carts operated by national park service ll The I'.S. Department of the Interior continues to he an innovator in de eping a wide variety of uses for --trie vehicles. In an on-going program to conserve - rav and provide a more economical ,jns of meeting its transportation relrements. the Department is looking h solar energv as a power source for . KVs. hast vear National Capitol Re,n i NCR I installed a photovoltaic ar cell battery charging facility on - Washington Mall during the Festival Imerican Folklife. The facility was -fd to recharge Col.IAth I during the ctric vehicle's first demonstration las- with NCR, and a variety of other C in the NCR fleet. Another interesting example of how f Interior Department is conserving r?v can be found at the Sandy Hook, I. unit of the Gateway National Recreational Area. This unit is one of four national parks in New Jersey and New York which span the New York Harhor. The four areas of Gateway are operated by the National Park Service branch of the Interior Department. The Sandy Hook portion of Gateway occupies 1.600 land acres of barrier peninsula reaching northward from the New Jersey coast into New York Har hor. Recause the area is located near the Atlantic Ocean, there is always a stiff breeze blowing. Sandy Hook engineers decided to develop a demonstration project to harness this source of solar energy and use it to power a generator to recharge batteries. The batteries are used as a power source for golf carts that are used to transport supervisory personnel throughout the park's exten sive acreage. The terrain is mostly flat, except for dunes along the coast of the narrow peninsula, and thus is ideal for the operation of this tv pc <>f v elude. The wind generator ke- ps 19 threecell. 6-volt lead batteries - burned vvilh 111 volt.- of electricity. This ran be drawn off as needed when it's time to recharge the golf cart batteries. Officials of Gateway National Recrea tion Area arc very plea-ed with the operation of the electric vehicles and the wind-powered electric generating sta tion. Thev also report that eleetr.es are quiet, economical to operate and do not pollute the air. The latter benefit is espe cially important in view of the Interior Department's plan to keep the Sandv Hook area as clean as possible If the demonstration program remains successful it is expected that additional electric vehicles and wind-powered gen erating stations will he installed in the other three units of Gateway. FOR CHANGE OF ADDRESS PLEASE ATTACH OLD MAILING LABEL. (pilau chick one) U ADD ME TO YOUR MAILING LIST Stmt City, ttati, zip cadi ARCHITECTURAL Lead Roofing and. Flashing Detailed instructions on the simplest and most usual methods for forming or toinmg lead for roofing and flashing apolications. Complete specifications. Dia grammatic drawings. Sixteen pages. A-5 Lead in Building A four-part data sheet containing informa tion on waterproofing, sound darners, roofing and flashing and anti-vibration ap plication. A-13 CERAMICS Facts about Lead Glazes for Art Potters and Hobbyists Detailed information on the proper formu lation. firing techniques, handling, etc. of lead fluxed glazes used by art potters and hobby ceramists. Illustrated. Sixteen pages. EMI Proceedings of First Internationa} Conference on Ceramic Foodware Safety Top international experts in ceramics. Food and Drug agency officials, and the international lead research community met in Geneva in November. 1974 to dis cuss heavy metal release from glazed ceramic foodware. Full proceedings-- speeches as well as question and answer dialog--were taped, translated and tran scribed. 272 pages. B*13 PAINTS Lead Pigments Bulletin Brochure. 12-pages, describes the advan tages and varieties of lead pigments in anti-corrosion paints. Covers red lead, dibasic lead phopshite. basic silicate white lead, basic lead phosphosihcate, basic lead chromosiiicate, basic lead silico chromate. Lists maior suppliers. F-7 CHEMICAL CONSTRUCTION & CORROSION PROTECTION Lead for Corrosion Resistant Applications Soft cover book, 156-pages, designed to familiarize engineers and engineering students with the corrosion resistance, design and fabrication data on lead and lead-based equipment. Defines plumbum senes and corrosion resistance of seriesH*6 Lead Chemicals Soft cover book, 334-pages, is designed as a working manoai for the chemist or chemical engineer engaged in applied technology or pure research. Covers organolead compounds, oxides and hydrox ides. sulfides and tellurides, haiides binary compounds, lead salts, lead chel ates, safety m handling compounds. Pur chasing price: $3.00. H-7 SOLDERING AND WELDING Soiders and Soldering New 16-page booklet filled with basic in formation on soldering and the selection of the right solder alloy for the applica tion. Data is presented on a variety of tin lead as well as other solder alloys. Sev eral case history treatments of typical soldering applications are included. 1-6 Printed in U S.A. "Solder Puts it All Together for Manufacturer of Zippo Lighters" Two-page reprint from Production Maga zine details production soldering of light ers at Zippo Mfg. Co. 1-7 Soldering of Electronic Products Booklet covers the use of tin lead solder as a highly reliable |Ommg method m the electronics industry. It includes informa tion on the control of electronic assembly components for solderabiiity. fluxes and flux residue removal, solder alloys and soldering methods. 1-8 SOUND BARRIERS Directory of Acoustic Specialties Summary of available materials for sound insulation by barrier, damping and ab sorption methods. Sixteen page list of materials by brand name and manufac turer. Eighteen pages. J-4 Lead a Major Factor in New Machinery Noise Suppression Systems Description of techniques used to lower machinery noise levels with lead and lead composites. Lists machines that normally exceed noise level allowed by WalshHealey Public Contracts Act. Two pages. J-9 Lead Proves a Heavy Favorite as Sound Control Material A reprint of a feature from Product Engi neering illustrating lead's usefulness in sound attenuation to help meet OSHA noise requirements in factories and also on planes and trams. J-17 Specifying Lead for Noise Control Eight-page reprint contains guidelines to help architects and engineers fully utilize the advantages of lead as a noise control material. A number of case histories are included to show how some of these guidelines were used to solve a variety of commercial, industrial and residential noise problems. J-18 The Use of Absorber/Barrier Materials for Noise Control Enclosures Four-page reprint is concerned with noise abatement applications within the 10 to 15 dB range. It describes an installation using a quilted absorber/barrier enclo sure suitable for achieving these reduc tions. and presents the advantages of this material. Acoustical, economic, oper ational and maintenance aspects are con sidered. J-19 Take a Fresh Look at Noise Control Two-page reprint from Modern Stores A Offices explains the usefulness of sheet lead plenum barriers for office space noise control. A case history illustrates the needs for an acoustical treatment and cost savings realized. J-20 Modem Uses of Lead in the Construction Industry This 20 page booklet covers significant uses of lead in construction applications, it deals chieffy with lead for plumbing, waterproofing, roofing and flashing, anti* vibration and sound barriers, J-21 BATTERIES A Primer on the Lead-Acid Battery A condensed story of the principles of the lead-aetd- battery and its chemistry, in cluding some of the fundamentals and definitions of direct-current electric en ergy, Two pages. L-6 Electrics Get Key Post Office Tests Reprint of a feature from Electrical World describing tests on the suitability and economy of electric battery-powered de livery trucks for the Postal Service. L-18 Electric Work Vehicles A 12-pag* folder describing batterypowered short-haul delivery vehicles and comparing there economics to internal combustion delivery trucks. L-19 Battery-Powered Industrial Trucks Spark Energy and Cost Savings This 16-page booklet offers an m-depth 100k at the many factors favoring the pur chase of electrics for industrial applica tions. A pull-out set of work sheets allows the reader to determine how eiectncs stack up against 1C types m his own oper ation. L-22 Saving Battery Dollars--What You Need to Know Three-part reprint from Modern Materials Handling deals with proper procedure m picking the right battery for tne truck and job. it also discusses considerations <n battery charger selection. The third part offers guidelines for planning an efficient battery charging-room layout. L-23 Electric Vehicles: State-of-the-Art 1978 New 28-page booklet contains latest data on electric trucks, buses and passenger cars around the world. Case histones de scribe EV s in a variety of work applica tions. Other sections cover energy crisis and pollution problems and their effect on EVs; and the role of lead batteries m V development. L-24 GENERAL "Lead Abstracts" and "Yearly Indices" Quarterly abstract of all current world literature on lead and its products and published research. A general mdex is published annually- Must be requested on company letterhead. M-2 Primary Lead Production Areas in the U.S. For schools, libraries. H"14- map show ing locations in U.S. of most lead smelters and refineries, and lead mines. M-ll The U.S. Lead Industry An annual review of activity within the industry that contains a general summary for the year and a series of charts and tables giving current statistics on lead production and consumption. M-14 Lead--a Modem Design Material Summary of properties and available forms of lead tor radiation control, sound/vibration control, electrical energy sources, soldering and ceramics- Eight pages. M-15 ---------ability/Utihzation. K. C President. Noranda Sales Corp dian lead producer, discusses Buontv * pricing trends for the metal ana *1 ** ,t. signficance jna valu. LIT"* and m the future. M-31 th l>* Leaded Grades: Answer to Free-Machining Needs Reprint reports on benefits derive* using leaded steels for free machi^"* Case histones are employed to^dem"*- strate that these grades can Vn^?' partsmakers to raise production of ,, , >ty components with efficiency ana -V*' omy-,MJ2 y *Con- Lead and Zinc Outlook 1976-1980 Booklet examines demand prospects production for lead and zinc over the n,J* four years. Current markets ana aroJh apphcations are also discussed. 16-pages Occupational Lead Poisoning ... It Needn't Be ... A Manual for Managers Contains information of use to the manstrial manager on the safe handling * lead and lead products in industry. Tyn*. and oermissi&ie levels of occupational lead exposure are discussed. Some prac ticai controls and safeguards are $u*. gested. 16 pages, bibliograpny. M-34 r Lead and Your Health Brochure contains advice on accuot>oni protection against over exposure to lead A checklist of good health practices ii included. M-35 * Old Paints and Rural Lead Poisoninf Booklet discusses the incidence of lead poisoning among children m small towns and rural areas, a problem usually asso ciated with big cities. The need for lead screening programs to detect and correct the problem is emphasized. M36 Directory of Lead Casters Booklet lists 58 companies throughout the U S. that produce lead products for industry. Data on each firm includes type of casting method, products produced and auxiliary services offered. A contact name at each company is provided. M-37 FILMS Lead in Motion A 21-mm., 16mm color film. Lead's prop erties and its potential for unlimited fu ture applications are explored from the viewpoint that an atom of lead--like all elemental matter--is an arrangement of energy--part of a universal system. Tg order specify desired show date and one alternate date. No charge to borrow: viewer pays only return postage. N-2 Occupational Lead Poisoning ... It Needn't Be I PLEASE SEND ME THE PUBLICATIONS MARKED BELOW WRITE IN CODE NO.