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VOL. 38 NO. 3-4 1975 Lead is a four letter word... he politician generally gets wide pop Tular support when he takes a stand radiation ran be harmful: whether: the dentist's chair or the nuclear lal against lead. It is almost as popular as oratory. a stand jor motherhood. And about as Lead belongs in gasoline. It is not I meaningful. health hazard and it has been proved I Lead belongs in many more places contributor to engine efficiency and fin than it doesn't belong. Lead doesn't be conservation. In any case, lead does 1 long in paint for housing interiors . . . long in electric batteries that start y<x or other surfaces accessible to children. car and provide standby power in hosf Lead does belong in exterior industrial tais and communications systems. It I building paint that must withstand the longs in solder and cable as basics i ra\ ages of w eather. the electronics and communications i Lead does not belong in tovs which dustries. can he chewed or swallowed bv children. Control is the operative word in I Lead doe; belong where soundproofing mining, smelting and the application! is a requisite. In the plant and office this lead. Lead is a tour letter word. 5o{ use of lead eliminates sound pollution. "safe". And where lead belongs, Lead belongs where X-rav or gamma ran be made safe. 2 LI i ead alloy solder Diits the zip jn Zippo lighters H_ wafer-thin lead alloy solder SVeforms ha\e played a major role hflpinc George Blaisdell become suc'' -jul and. at the same time, has helped L' 'ierarette lighter achieve world-wide J r,ir lighting in wind, rain or snow: p.r guarantee ol lree repair. 1` ( Vor^e Blaisdell and his family own . yippo Manufacturing Co., in BradV r,| Pa. The eompanv is known for the jnl(,uj. windproof Zippo lighter, the ',.|.kn"n product of its kind in the (l-](g Presidents, kings, world statesn rnilitarv men and women, corporte |lrads. and millions of others all r the world, own Zippo lighters. The eompanv produces 33 models of p.htcrs. ranging from S4.75 in brushed (|irome to S560 in 14K gold. Its basic line consists of two standard sizes: a -hm model, that is about 114-in. wide jn(J 2]4-in. Iiigh: and a standard model that is approximately lAo-in. wide and oi4-in. high. According to Ray Lhler. Zippo's plant manager, tin lead solder plays one of the most critical roles in the efficient manufacture and operation of the fault ier lighters. He says this is why the ..offering operation includes verv string ent qualitv control procedures. Lhler explains that solder preforms hterallv help put the "zip" in Zippo lighters. The preform is used to solderjoin and seal a plate to the inner ease L the lighter. W hen this case is inserted min the outer shell of the lighter, the rr-uiiina en\elope forms a sealed enclo sure that contains the wick and the ab sorbent packing to hold the fluid used to fuel the lighter. Therefore, the sol dered plate must form an airtight and Irak-proof seal with the inner case. Otherwise rapid evaporation would waste tin- fuel and require too frequent re idling. All solder preforms used in the join ing process are 50/50 tin lead alloy. The preforms varv in length and width, depending on whether slim- or regular ize lighters are in production. Regular he preforms are ,015-in. thick, while the thin-size preform is .017-in. thick. The thickness variation is due to the difference in gauge of the stainless steel used for the two cases--.015-in. for the slim case and 0.018-in. for the regular rase. About -10 Of of Zippo's sales volume comes from more than 2 < ,000 commer cial accounts, comprising some of the biggest corporate names in industrv. Thev regularly order Zippos in huge lots to serve as premiums, promotional handouts, emplovee awards and sales in centives. Main times the company em blem is soldered on the face of the lighter. "If vou solder an emblem on. vou know it's going to stay. " says plant Manager Lhler. "If the emblems are epoxy-joined to the face of the lighter, vou know that sooner or later, they will come off. We've tried other joining tech niques. too. but we alwavs come back to solder because it's the best and most economical joining method we've found. He also points with pride to the fact that few of the thousands of lighters the Zippo repair section processes each day irnolve resoldering. Some bear the ravages of having been soaked in sea water, buried in snow or embedded in mud. Others have been mangled by washing machines, hydraulic presses and lawn mowers--and a few stopped bullets in World War II, Korea and Vietnam. Regardless of the reason for return, the lighters are enroute to their owners within 48 hours--included is a one-shot tube of Zippo lighter fluid and a couple of extra Zippo flints to boot. Overall view of circular work station used to assemble lead alloy preform tor Zippo lignter case. ^cNT^ o^_/2i_3' Lead Recycled ballast helps keep historic warship on even keel ecycled lead from an unusual source R is helping to keep one of the na The ships guns were removed as part of a long-range restoration program that tion's most historic warships on an even has been underwa\ since 1955 when keel. Scrap from lead used to line the the ship was brought to Baltimore from electrolytic refining tanks of an out Boston bv The Star Spangled Banner dated Baltimore copper plant has been Flag House Association. A non-profit donated as ballast fur the warship, the patriotic organization, the Association 158-vear-old l .S. Frigate CONSTELLA established the l.S.F. Constellation TION. Foundation. Inc., to undertake restora The oldest ship in the world still tion of the ship, which was being slowly afloat. CONSTELLATION is one of six 38-gun frigates authorized by a 1791 Act of Congress signed bv President George Washington. The lead ballast, which was cast in 64-lb. ingots, was used to replace weight lost due to the removal of the ship's cast iron cannons that weighed about 80.00U-lbs. The cast iron cannons are being replaced by plas tic replicas, which will be cheaper to maintain. Without the ballast, the ship would be improperly balanced and ride too high out of the water at its permanent berth, which is located at Pier 1, Con stellation Dock. Pratt Street. Baltimore. Md. The ship has been designated the' Bicentennial Flagship and it is docked near Fort McHenry where Francis Scott Kev was inspired to write'"The Star Spangled Banner" .during the shelling of Baltimore bv the British in the ar of 1812. .' *. d.estroy' ed bv- the . cumulatiu* r"awvaog.,es of-i time, coupled with a lack of federal^ funds to presen e the old ship ! re-turatiun is being carried out in gv - phases: interior restoration: armament and fittings: primary hull and secondary hull repair.-: replacement and repair of masts, spars and rigaing: and iD stallation of dock facilities that include ' a museum and reference library. ayL^eennietenntnial ro,e ^O/tf3^ Leaded bronze aids Revolutionary cannon reproduction uthentically duplicated Revolution A ary War cannon? will be displaced ^ tin-d at historic sites in the 13 "joinal state?- as part of next year's Bi.ntennial celebration of American Inje,.t ncie11' f Considerable time and effort heina debited to the production and ''reparation of these held pieces to as ' re that thee' are exact replicas of the original5' \t Harpers Ferry. ^ . \ a.. 61 of these fri-tnric weapons are being painstakingly jfiicned for reproduction by the l .S. National Park Service. One of the most important details of re-creation is the nietal content of the guns. The bronze aIlov. composed of copper, lead, zinc jn(l tin. approximates the percentage of each metal used in their 200-year-old counterparts. Small, fast-firing three-pounders: sixpoimders emblazoned with the crest of kina George III: stubby 21-lb. howit zers: and 2 1-lb. siege guns more than 12-ft. long are among the cannons be ing duplicated. Altogether. 15 different gpes of Revolutionary cannons will plav a part in the ceremonial events mark ing our Bicentennial. The cannons are being rough-cast by LaPan's Foundry of Hudson Falls. XA.. and the drown Xon-ferrous Foundry in Chester. Pa. The intricate, artistic dec orations found on the old guns are being copied exactly on the modern cannons hv hand. The rough castings are polished to a bright, golden color, distinguishing insignia are incised on the breech rings. and all the cannons are numbered or named. After proof firings with black powder, the guns will be mounted on carriages built out of solid oak in Glens Falls. NA.. by Adirondack Machine Corp. Some of the carriages are heavier than the guns thev carrv. Authentic even to the blue-grav paint that typified British Army weaponry of the period, the carriages were designed after exhaustive study of old paintings, draw ings and other records. W illiam E. Meuse, chief of historic ordnance of the National Park Service, is in charge of the project. The original cannons were designed and manufactured in Europe. A few guns were cast for the patriots bv foundries located primarily in the Phil adelphia area. The most notable of these was one operated bv J. Bvers. who turned out pieces equal in every respect to the finest that England's Woolwich arsenal could produce. Mostly, however, the Continental Armv relied on acquir ing cannons from French or other Euro pean foundries, or on capturing British artillery. Sound enclosure softens punch of press noise Industry face? heavy pressure today to comply with the noise control regu lations of the Occupational Safety & Health Act I OSH A i. When it comes to generating excessive industrial plant noise, automatic punch presses are among the leading offenders. So when a company like Associated Spring real izes a 17 db reduction in such machine ry noise, it can lie credited with quite an accomplishment. It can roughly be compared to paring down the painfully loud noise of a riveting gun to the sounds of city traffic heard from within an automobile. The company's Dayton. Ohio plant uses a number of huge presses to pro duce various type springs and custom metal parts. In an effort to meet OSHA's current 90 db industrial noise limit re quirement. locallv-hased acoustic engi neering consultants were brought in to \ o-ft. Since one of the prime rp ments was complete accessibility. press, a Singer overhead track-and system was fastened to the top ff ` 8-ft. high angle steel franiework" w . permit; easy- opening of the ' panel; for access to the machineCUrta'B Another consideration was to the enclosure available to the in out-How materials, while mainta^^ sound level control. This way'~'a,"n"ing yvith customized cutouts in the ei!'] sure s side panel curtain;. YjPU;n,t dows also were added. " m' A; a special safety feature, a h atari guard fence was included in thee ee,nr. sure design. Tile fence, a metal-latt'"* shield, was attached to the steel fra[fl independent of the roller-curtain action It remains stationary when the curtain is opened. W hen the guard is raised a microswitch is actiyated which de-ener View of cpen iead/vmyl sound enclosure surrounding noisy punch press a! Assoc/a'eo Soring. Qeyton, Ohio. Use of leaded vinyl decreases sound 17 do. or the eauivaient of reducing riveting gun noise rc that hearo from inside an automobile in heavy traffic. View from top of leaded vinyl sound enclosure for punch press shows how accordian-pleated loam-Jined material damps sound from sides of machine. Track and roller assembly that frames press facilitates movement of lead/vinyl curtain. study the noise problem. After investigating production flow, equipment maintenance, and machine accessibility, the consultants recom mended a sound enclosure system for one of the two -15-ton presses that proved to be the principal sources of excessive noise. The press produces metal yvashers from 26 gauge strip steel. 2Vo-in. wide. Made bv Singer Partitions of Chicago, the enclosure is constructed of lead/ vinyl curtain material combined yvith Tin. thick Mylar-covered acoustic foam panels applied to the inside curtain sur face. W ith the My lar covering, oil splash and metal trimmings cannot clog or de stroy the foam. The lead-loaded vinyl sheet specified was 0.75-lb./sq. ft. This dense, limp material provides the neces sary mass with flexibility and it is a highly efficient sound barrier. The enclosure measures 10-ft. x 10-ft. gizes the control circuit, rendering the press inoperative. Before the sound enclosure installa tion. the noise level reading was 101.5 db. despite the installation of vibration isolators to decouple the press from the floor. This compares with a post-enclo sure reading of 84.5 dh. The 17 db at tenuation achieved, without sacrifice in production capacity, convinced the com pany to install a similar enclosure for the second offending 15-ton press. Tom Campbell, division manager, noted that the noise reduction exceeds present OSHA requirements. And should a currently contemplated lower standard of 85 db he put into effect, the company would still he within compliance limits. "We were especially pleased to note im mediate workers' acceptance of this new system as an improvement to their en vironment and safety." Campbell said. ost people know that lead plays a M vital role in the design of yachts lead used as ballast in the keel keeps vaCht upright in the water. But few the ? know that lead is also playing anirnP ortant role in the desin Solf jroirs as w ell. ^ jlV lead in a golf iron ? Simply ted it provides the concentrated j,,ht that's needed in the newer, light weight irons to give them extra driving jiower. although the use of lead in golf irons n0[ new. the traditional wav to add -oncentrated weight for golf irons was to load the inside of the shaft with chunks of lead near the point w here the head is attached to the shaft. This tech nique adds deadweight that has been re ported to cause problems in achieving a smooth swing. Shamrock Golf Co.. Los Angeles, has taken an approach that it hopes will overcome the deadweight problem. Their solution is to move the lead weight from the base of the shaft to a special spot inside the clubhead. The concept is re ported to not onlv work, but to improve the performance of the iron as well. According to Shamrock, their method makes the overall weight of the iron less. Jack Nicklaus in a recent article in Golf Digest is quoted as saving: `'Dis tance is a problem for both seniors and women, and I think there are two rea sons. The first lies in equipment, i've increasinglv favored 'light-swinging' clubs as I've got older, and I think I'll jo more and more in that direction in the future. One reason is that clubhead velocity has twice the value of mass in terms of distance--the lighter the club, the easier it is to swing through the ball fast. Also, the lighter the club, the less it takes out of you physically to swing it. This can be a big factor as one tires towards the end of the round." Called a Power Pocket, the lead weight lowers the center of gravity and places the heaviest part of the clubhead below the center of the ball. Shamrock says its long irons using the lead weight give the high, arching flight of a five wood, while short irons using it give more bite. shamrock reports the improved tech nique is more time consuming and ex pensive. but it results in a higher quality product with improved precision. The first step in producing the head is to cast the basic head of the golf club. The faceplate is then stamped from the same type of metal and it is joined to the clubhead bv electron beam fusion, a process that fuses the two metals to gether to become one homogeneous piece of solid steel. In the next step, the desired lead weight is dropped into the bottom of the cavity directly in back of the face plate. The weight of the lead depends on the type of club being produced and the swing weight desired by the golfer. Swing weight is the relationship of the weight of the head to the length of the club. Shaped somewhat like a piece of chewing gum and ranging in weight from 2 grams to 23 grams, the lead weight is held in place with black epoxv. Lead puts clout in the clubhead Future sale? ,,f battery-powered in dustrial trucks and personnel car rier.- are likely to stem from three major factors: On-going: improvements in electric vehicle batteries and power system-. OSHA regulations that limit the amount of exhaust pollutants with Among the new developments are: High-voltage batteries-- up to 72v -- which make electrics more competi tive for heavy-duty applications. Stepless speed controls to reduce current usage, increase battery and component life. in plant.- and warehouses. Solid state chargers to maximize the Meadily rising fuel prices. Electric trucks offer performance im provements ranging from longer hatterv amount of energy input when charg ing a battery, thereby decreasing charge cycle time. life to sophisticated controls, added re Battery re-designs to produce more liability. greater economy and low main power from the cube and make it tenance cost.-. These advantages are re possible to put a more powerful bat flected in the increased purchases of tery into the same or smaller equip industrial electrics last vear. Sales of ment. rider-types went up more than 4.06H units in 1974. according to the Depart ment of Commerce. Sales of electric' hand trucks gained bv almost 1.500 units. This compare; with an increase of a little over 3.000 units in sales of IC trucks and tractors. And hatterv man ufacturers report an increase of over S13 million in sales to the material han dling market last vear. with the total reaching SMS.5 million. Advancing technology also is playing And to power electric vehicles there i- a full line of lead-acid batteries from 12 to 48 volts, and some to 72v. with capacities to 680 ampere-hours for 48v. and up to 1700 ampere-hours for a 72v. Also, element protection and improved scaling of container and cover have re duced leakage to prolong battery op erating life. Other devices which are extending battery life include: an important role in the upswing in hattery-povve-ed truck sales. Disc harge controls that prev ent hat terv abuse by warning the truck op erator when voltage i- < - da,,,.,, Cal. ,, OaTS'1* ignored, the control can ^ - shut down the truck. actually Safety cable connectors t0 el; the possibility of matchingTM'?1^ tery to the wrong truck or^ha **' Quick disconnect devices function as safety switches to ^ off power in case of an <-mer .Non-arcing connectors that v mize the problem of pittin,,n'ln'' burning of connector c,intact-^ cau.-e of operator errors, Some experts consider stepless controls--such a- SCRs' or power tran sistors--the most significant recent <j velopment in battery-powered trucks \ m,,ajo.r electrical . manufac, tu.rer is n,,u Ottering a new. improved K.R control that continuously monitors lift truck op orations like a computer. Reported ad vantages include improved ratin higher performance, greater fell ahilitv and ease of maintenance. The same prominent nianufau.uer made a detailed study of six types of operations involving a varietv 0f work, ing requirements. The study documents a broad range of savings in energy, op. crating and maintenance costs, sum marized in the following chart: *.',i/irone control rectifier Three reasons why electric trucks serve industry better TYPES OF OPERATION TYPICAL WORKING REQUIREMENTS RESULTS Material Handling Large variation m loads S136C yea'A saving! per eiectnc truck General Warehousing Palletized and mixed packages, drum handling 45' overall cos! reduction by using eiectnc trucks Automotive Manufacturing Heavy bulk, shock loading 70% savings in electric power vs fue; ana oi! costs Industrial Machinery Manufacturing All weather, fleet operation and individual specialized trucks 80% savings in maintenance costs Paint and Varnish Manufacturing Hazardous environment 75% savings m maintenance costs Heavy Industrial Wide temperature extremes, long runs, steep ramps, good to poor surfaces $2300 in main tenance savings per year per electric truck (fir$t 2 years of operation;' lit Holland Tunnel, which transport; Tan average of 57.(mO vehicles a dav ' etwi-en New Turk and New Jersey. also arries the liiahest capacity short-haul iraital tran-mission svstiin in the L nited states. (..ailed 1 1M. the system links Manhattan with Newark via a coaxial able snuglv encapsulated in a 1 ,,-in. uuck protective lead -heath. In all. the Ihniile cable i- enca-ed in approxi mately bdJ do-lbs. o| lead. The 1 i \l s v -tent proved its worth 'teller than expected. Originally sched uled to start operation in April. 1975. it was pres-ed into -ervice on lebruarv .'7 when a disastrous lire hit one of hew dork Telephone's central offices and switching centers in Manhattan. The blaze knocked out lob transmission lines, each carrying up to 21 voice cir cuits. between New dork and New Jer-' v. 1 he new svsteni was used to bypass ni">t of the aiieeted lines and restore telephone capacity between the two -late?. Developed bv Hell Laboratories. T4M "as manufactured bv Western Klectric. "ith overall coordination front AT\T. Western Electric has been making lead sheathed cable since lolll. Lead was originally selected as the protective ma terial primarily because of its adapt ability to extrusion and resistance to corrosion. These benctits hold true to day. The lead harrier provides the TIM cable with the maximum water tight intruritv and signiln untiv lengthens its life expectancy. Modern coaxial cable.- employ a num ber of coaxial conductors consisting of a -mall copper tube. ::N-in. in diameter, with a copper wire runninu lengthwise through the center. The- design is called "coaxial" because the tube and wire have the same center axis. The TIM line and its multiplexing equipment operate over coaxial cable to provide high capacity voice and data service for densely populated metropoli tan areas. It carries IU.32IJ voice chan nels over cable containing 22 coaxial tubes. Iniorrnation is encoded into short pulses c bits i transmitted -t i.._h rates, and decoded at the receiving end. Its large circuit carrying capacity leads to low cost, highly oflicient u-e of under ground ducts, and improved mainte nance.' Kegenerators along the New Turk/ New Jersey cable route are located in manholes at intervals up to 5. cOO-it. to reconstitute the digital signal- being transmitted. Multiplexers at each end of the line combine a number ot lower -peed digital inputs into the high -peed signal suitable for transmission on the 14M line. Idle new -vsten: will serve a- a lngli capacity artery On the extensive 11 net works now in ii'o in almost ail metro politan area-. Tl hims. which carry 1.5 million bit- per second, will -one as the i apillaries teedina these arteries. The T l.M ' aide w iii lit into the bin. ducts now used tor tin- '1 1 cables, in creasing the cupji liv ol these duet- bv almost a factor of four. Technicians from Bel: LaDc'Stcnes ana New jersey BeU Telephone Co. ccnnec: sections of T4M telephone transmission system under the ncHar.Q Tunnel The new system oe'.ween New yor* City ana Newer*. N.J., is the highest capacity. short-haC digital transmission System m the Unitea States. Reloading: A quick, simple and economical way to get more shots for the money Thousand? of people involved in sports such as skeet and trap shooting are finding that "packing their own'' can save a great deal of money ... in this case, money that would be spent for new ammunition. ^ ith special equip ment that's readilv available, it's a com paratively simple task to reload shells with complete safety and reliability pro viding that recognized reloading pre cautions are taken. It is particularly important to follow the instructions contained in arty one of the various reloading manuals available at any hunting or sporting goods store. Particular care should be taken to start with the lowest recommended charges listed for each load in such manuals. There are literally dozens of shotshell reloading tools on the market. They range in price from a S9.95 pocket-tvpe outfit that reloads a box of shells in an hour to semi-automatic equipment that can produce nearly 500 shells per hour. The a\erage shooter's needs can be ade quately met by tools in the S45 to $85 price range. All of them are self-con tained units that can load three or four boxes i 75 to 100 shell? I per hour. The first step in reloading of a shot gun shell is to select a clean, fired case in good condition. The cases must be stored by make--Remington. ^ inchester. Federal, etc.--and type--12. 16 and 20 gauge, because of reloading require ments. Both plastic and paper shells are abundant, but care must be taken to adjust tools to handle them. For ex ample. target loads contain light charges of shot and powder and are loaded in "high-base, permanent-wad" cases. Hunt ing loads, on the other hand, use heavy charges and are assembled in "lowbase. permanent-wad" cases of greater internal capacity. Before loading, check to make sure that all cases are carefully inspected. Cases that have been mashed flat, seri ously deformed, or torn, should be set aside. Basic components needed for reload ing begin with standard domestic "bat tery cup" shotshell primers that are available in several makes. All makes are good and all currently produced 12 gauge shells take No. 209 size. The best wads are the one-piece plastic wad column shot-cup type. Different cases have different height wads and all deal ers have charts telling which is correct for a particular case. The lead shot is the same no matter who makes it. Size No. 9 is usually chosen for target loads. Safety precautions are of critical im portance in reloading. Some of the pre cautions are ob\ ious--one should al ways wear safety glasses, never load in haste, and never smoke in the area. Primers should be carefully handled since they are the most hazardous of all components used for smokeless pow der loads. It is also vitally important to keep powder and primers away from heat, sparks and open flames. Powders should never be mixed and all shells must be carefully examined to insure they are in good condition before using. Though it must be accomplished with utmost care, reloading is simple. In the first step of a typical operation, the shotshell case is placed in a tube. At the bottom is a de-capping punch which pushes out the old primer. A downward movement of the tube seats the new primer. After it is seated, a carefullyselected amount of powder is passed into the case via a hollow tube. A wad is then inserted in the case atop the powder and lead shot is next passed into the case and seated in a similar manner. A pressure gauge at the base of the de vice shows the exact wad pressure. A cap-like die device with grooves inside is then placed over the case and, when SHOT the device is turned, the resulting folds creases in the shell. " In the finished shell, the crimps folds, should be tight and smooth no noticeable springback. and with most a very small hole at the c where the folds meet. Neither sho U? there be any overlap or crumplino 0{ the folds at the center. The latter indj cates too mm h case above the shut th former too little. Adjustment of eithe wad column heiuht or shotv rk-uiia..rog weight is the proper corrective action. The center of the crimp should recessed nearly 1/16-in. below the rim This is necessary to avoid having the crimp loosen under recoil forces. The walls of the shell case also should be checked to see if thev have buckled due to too much erimpinu fort Occasional minor crimp imperfection* cannot be avoided. Nich shells ihou]d' be fired first. Thousands of amateur skeet and tra? shooters who burn up several hundred shells each week, are using "pack vour? own" reloading techniques to add di-l mension to their sport and--most i: portantly--to make it as economical possible. Lead enhances organ sound at New York's Lincoln Center j allov plays a \ ital role in the rect mechanical linkage from the keys deacthates any number of stops with the M I ' ' .rfnnnanc r of one ol the nation'? to the pipes. The skill that went into push of a button. Since the Kuhn Com- ** concert hall oraans. Installed in de-iunin" the lead alloy pipes and the panv is not experienc'd in such elec : , 'full' Hall at Vn doik'- famed patience that went into construction of tronic technology, the system was built '"` ' l,, tenter for the Performing Arts. the organ have been rewarded in the bv Mr. Phelps' firm. It ean has Ll`12 pipes. Manv of the rich, brilliant tones that are produced. The tracker-type organ relies upon '* . ohich range trom to 16-lt. These were also aehie\ed by subtle ad '" are made front \arious corn justment of pipe scale and voicing, mechanical, rather than electrical link 'd (tllfi;? of lead alloy to provide the according to Lawrence Phelps, who age between kevs and pipes. This gives 1 ie earietv of musical notes required seined as Lincoln Center's consultant the performer direct and intimate con r ,, |iie in-tniment. \j|,,\ for the pipes ranges from 20 for the project. Phelps helped plan the tonal design trol of the phrasing, rhvthm and accent. It was designed and constructed both as "5 per cent lead conLent. 1 he ratio and \oicing. and the stop-control and a virtuoso instrument ami a- an instru pp.portioned according to the desired combination systems were created by his ment capable of hlendinu with chamber .Dal quality Lower tones emanate from Erie. Pa. company. "I feel that this is or full orchestra ensembles. j.ls'-A nFiAn1 es" co' ntainin-'; a -area. ter amount p,ac|. Pipes for the organ lacade have the finest instrument of its kind in New \ ork. and among the top dozen in the The organ arrived in New T ork in thousands of pieces, carefullv packed in e tehcr tin content and have been l nited States." he stated. "It's the re 10-ft. crates. A crew of six from the irnished to a magnificent silver luster. sult of 100 years of deep insistence on Swiss factor'- spent two months as The pipes of the organ, which was craft." sembling the instrument. Final tone fin fuilt by Theodore Kuhn Co., in Manne- Although the organ is a product of ishing was done bv Kurt Baumann of (1 jur[. Switzerland, are arranged in 85 traditional construction, modern tech the Kuhn Companv. Although the or ranks, distributed among 61 speaking niques were not ignored. A solid state gan's cost has not been revealed, ex 'P -leps. The console has four different electronic memory system, when preset perts estimate it at well o\er a quarter il mdependent manual keyboards with di by the performer, instantlv activates or of a million dollars. ir V/ view ot magnificent new organ in Alice Tully Hall at New York's Lincoln Center for the Performing Arts shows scores ol pipes made from lead alloy & console is Andre Marchal, lamed French organist, who gave the initial concert. High-rise hospital reflected in lead-lined pool Still water in a puol can exert a strong tranquilizing effect on the viewer. other facilities. The area beneath the large plaza is designed to house offices Architects therefore consider this benefit and medical lab facilities. The plaza along with aesthetic values when specify therefore had to be made waterproof ing the inclusion of a reflecting pool since it serves as the roof of the struc for apartment buildings, office towers, ture. museums and. most appropriately, hos Landscaping plans for the plaza called pitals. for installation of a large reflecting pool For example, a huge 50-ft. x 100-ft. that would be a peaceful setting for reflecting pool is now nearing comple hospital employees as well as patients tion at Nassau Countv Community .Medi and visitors. Lead was selected to line cal Center on Long Island. The Medical the reflecting pool because it will insure Center, which serves one of the most the watertight integrity of the roof. densely populated areas surrounding The lead liner for the reflecting pool metropolitan New T ork Citv. has con was installed by John F. Abernethy & stantly expanded in recent vears to keep Co.. Brooklyn. Company president Frank up with a continuing increase in pa Kiernan reports the reflecting lead lin tient load. Along with the expansion is ing created no unusual problems. "Being the need to take advantage of all avail pliable, lead is simple to work with and able space for both administrative and install,'' he says. "It can be easily fitted patient care. A combination of these two around and over through-roof joints, factors are the primary reason why the piping and other obstructions and, most new reflecting pool at the Community- importantly, lead can be easily joined. Medical Center was lined with lead. The fact that lead is compatible with The reflecting pool is incorporated in most construction materials and is the design for a raised plaza that con among the most corrosion-resistant nects the main building at the Center, waterproofing materials adds to its ad a!9-storv tower, and buildings housing vantage as a reflective pool liner." The reflecting pool at the Me(jj . ter will hold approximately 4 ;r? , ft. of water. About 16-in. deep was first lined with an asPhait A styrofoam composition withi/]181*' of tar board was then applied and^ top surface was tarred to provide a dation for the lead lining. U|>* I The lead contains 4 per cent antin, and 0.10 per cent arsenic to provide- B* creased corrosion-resistance and crease thermal expansion. The nr required a total of about IT tons of 1 j It was installed in 16 strips averam itun_ e_ ,,a,,chL. , .p.l1u..s. _aLbo.u. ta o__ne t. on of. ~ lead to burn the joints. Seventeen of the joints were 50-ft. long and there were thr 100-ft. long joints in addition to 12 u right joints. ^ The lead lining was homogeneously bonded to all through-roof penetratiom such as electrical, plumbina. drain and other surfaces. Eight skimmers will help maintain water level in the pool and keep it clean There are eight outlets around the pool edges to keep the water moving through the recirculating svstem. ' Close-up of leaa burner at work installing lead membrane tor reflecting pool of Nassau County Community Hospital courtyard shows how lead sections can be used to wrap around through-root obstruction. Lead burner pauses to examine one of 12 vertical joints used to form sides of reflecting pool. Vertical and horizontal joints required about one ton of lead. Lead burner at work on one of the three 100-foot long horizontal joints used to lorm waterproof lead membrane over hospital reflecting pool. AMERICAN WIND TURBINE GENERATOR HOT WATER STORAGE LEAD STORAGE BATTERV AREA ncreasing energy costs are a major I factor in the design of new buildmas. or the renovation and moderniza tion of existing structures. ^ ithout economical enersv to provide electricity and heatins. buildings become uneco nomical to own and operate unless the added expense for energy is absorbed in higher priees for manufactured products, and increased rentals for office space and housing. One solution for supplementary elec tric energy needs is solar power from on-site sources. Incorporated into the total design or redesign of buildings, it is being stored in lead batteries from two solar sources--sun and wind. Such energy sources, when combined with these batteries, can provide much of the electrical energy required for tomorrow's buildings. A look at developments under lay today shows how this might be ac complished. An excellent example of how such solar power sources can be combined ls a project now underway at the Research and Development Institute 'REDE i in Providence. R.l. REDE is the prime mover in establishing the Rhode Island Energy Conservation Sta tion ( RIECS i. which is to be housed in a recycled brass factory building originally built in the 1840 s. RF.DE is assembling a w ind and sun solar energy package that will provide for most of the building's heating, hot water and electrical needs. In addition, a miniature hydro-electric power plant to be installed in a small river that runs alongside the building will provide some electrical energy for the renovated structure. REDE's basic concept is to generate electricity from the wind and sun sources and store it in a large bank of lead acid batteries. The batteries are a key element to the REDE concept. REDE will utilize solar cell semi-con ductor devices which convert light di rectly into electricity. The best known of these devices is the silicon solar cell. Solar cells themselves have no storage capability. They generate only while ex posed to light. Since the power is usu ally required continuously, lead storage batteries will be used to store power that can he used during the time the solar array is in darkness. During the daylight, the array charges the batteries and handles the electrical load require ments, A multiple battery storage fa cility will be installed in the basement level of the RIECS building to store electrical energy. The lead batteries will be installed in such a manner that they can be vented through a basement level window on the river side of the build ing. Present plans call for installing ap proximately 50 batteries to collect en ergy from all three electric generation sources scheduled for installation. Ad ditional batteries can be installed as needed. It is significant to note that the combined solar cells and wind genera tors will help to insure that the batter ies are constantly being charged. Two wind generating devices will also be installed in the RIECS building. One is a Darrieus wind plant that looks much like a giant egg beater, while the other is an improved version of the ^ estern-type w indmill that is commonly found on farms Ll2t753 hen miners needed a serviceable Wmaterial for pants to near pros tions, premiums, design incentive awards and giv e-aw ays. pecting during the gold rush of 1819 Company president John M. Lewis in California, an enterprising man reports his company is currently pro named ].e\i N:ail" took a material ducing a large number of buckles con called dungaree and created what lias taining up to 90 per cent of lead. Ac hecome a u orld-famou- fashion. That cording to Lewis. "One of the major fashion look ha.- generated a neu in- factors in selling to companies is the dustrv to supply the material that looks 'feel' and weight of the buckles that is most like the original Levi fabric. Called achieved through the use of a high lead denim, it has spanned vet another in content. Lead provides the heftv. man dustry. the "western look " and with it sized fee-1 and appearance of the buckle. the need for large. ornate buckles of The Lewis Buckle line includes over the type that were popular in the mid 200 standard pieces that depict such di lid Hi's. verse personalities as Sitting Bull. Pop- For example. Lewis Buckle Co. has established a successful business that specializes in reproduction of belt buckles that look as though they could have been worn bv cold miners in lo-!9. In addition, the company has designed buckles based on well-known commer cial labels, firearms, trademarks, ears and comic -strip characters. A key to the success of the company's operations is the high lead content casting allox used to produce the buckles. Lead gives the ability to create the intricate designs in the belt buckles and permits the metal to lie antique finished or polished, whichever the design calls for. eve. and Santa Claus. Other subjects lor buckles include Women - Lib. the Model T Ford. Coca Cola. Schlitz and Bolls Bovce. Buckles are produced by a process called spincasting. It provides for fast, economical casting of most castable metals and plastics. Developed by Bomanoff International. Nevv ork City, the spincasting process involves the use of precision casting equipment, silicone rubber molds and entrib'ual force. I nlike other ca.-ting methods which may involve expensive dies and machinery, spincasting utilizes equipment suitable for prototype work or limited produc tion runs. The Palatine. 11!.. company currently After the model patterns for the produces 35J*t*0 buckles per week. It buckles are produced, they are placed supplies a nationwide chain of denim in the lower half of a two-part, 12-in. and jeans stores in addition to specialty diameter silicone rubber mold which store- like Marshall Fields in Chicago. has the consistency of modeling clay. In addition, the company has about 10U The upper silicone disc is then placed emporate accounts whose logos are re on top creating a sandwich effect. The produced on buckles for various promo mold is then vulcanized at 35(1- for about one and a half hour-, afti-r which the model buckle- are renew,-d. (;at and runner- aie tln-n cut into die j,a[. tern connecting the die cavity to a r-,-n. teal down-pnie and vent- and runners are then cut in. enmicctiiia die cavities to the perimeter. At thi- point thr actual ea-ting begins. Two halve- of v nb ani1 mold art iea-'i-mbled and placed in tie- -jiiii-casi. in it machine. Molten lead alloy pre heated to bit1) T. i- hand ladled tlironah the central down-pine and into the spinnine mold, t.entrifugal hirer -hunts the pewter-like metal tin ouch the i urved runners and into the mold cavitv. where it quickly solidities. The ca-t buckleare removed, allowed to cool and then arc sent to the next stage where they are polished, bulled and made n-adv fur shipment. Two-part silicone rubber mold is used in spmcastmg process to produce ornate lead alloy belt buckles LIA2675 A 14 Lead carries weight in furniture joining n incre-asing number of people today A are engaged ii. furniture making projects, "lhi~ interest stems from a de- ;jre for the crafted look in the home. ]us the high cost of purchasing such quality furnishing'. Whether constructed from ready-made jt. or one's own design, a trouble- ,ome part of assembling such furniture joining certain parts with an adhesive, plus step requires a reliable means of t.xerting pressure on the parts until the [,0nding process has been completed. The pressure can be applied with a variety ,f (lamps, but sometimes the furniture jejitin calls for adhesive-bonded com ponents that are too big to accommo date clamping. Possible damage to the airfare of the parts involved is another mnsideration. A resourceful upstate \ew Torker faced this problem when constructing a ,-offee table of his own design. He re- -orted to a product used for another jiobbv. skeet shooting, to apply the pres- -ure normally supplied bv furniture clamps. Simply stated, he "took the lead mit" of skeet shouting to hold the table components in position until the bond in'.' agent cured. The table was designed with an oak inlav top. over a plywood base, with tun sets of -1-in. thick oak legs. The Aft. x 2-ft. top was covered with 400 Underside ot cofiee table with oak legs secured by lead shot. These "clamps" were also used to hold trim around the edge of the table while it was being glued in position. oak tiles, approximately :!4-in. x :>-in.. all carefully organized and glued in an intricate pattern. As a result, there was no suitable clamping surface to bold the legs against the underside of the table during the gluing process. The use of wood or metal type clamps would mar the highly polished surface of the tiles and oak legs. It was at this point that the furniture maker derided to try lead 'hot. a pro duct of his skeet shooting liobhv. These pellets, packaged in cloth bags of 25-lbs. each, are used to reload shotshells. Here was an excellent source of concentrated weight in a soft flexible form that would not damage the wood surfaces. With two 25-lb. bags of lead shut positioned on each of the table legs, the duinu job was accomplished without rni-hap. The lead shot has since been used for fdling 12-gauge shells for the skeet shout ing and hunting season. However, addi tional bags are always on band to piovide lead shot "i-lampina" for future gluing jobs. Handmade furniture designers who are not hunting enthusia't- will find liags of lead shut readily available at most sporting good' stores. A one-time investment in lead shot can Milve many "sticky gluing problems similar to those encountered by the \ew York hunter furniture builder. CHANGE OF ADDRESS OR NEW READER Use this side of the coupon if you have recently changed your address or if you would like to be added to the mailing list for LEAD FOR CHANGE OF ADDRESS AND DELETION PLEASE ATTACH OLD LABEL. G ADD ME TO YOUR MAILING LIST (please check one) V ATTACH MAILING LABEL HERE ________ A__________ To ___________ Name, Title Company Street City, state, zip code L 11 2 f 7 E 5 PLEASE CHECK INTEREST Painting Health & Safety Architectural & Building Design & Radiation Engineers Ceramics Chemical Engrs. G Battery Power G Miscellaneous (please specify) 15 LIBRARY OF TECHNICAL INFORMATION The following publications and materials are available free of charge unless others noted. Send request to the rwise LEAD INDUSTRIES ASSOCIATION, 292 Madison Avenue, New York, N.Y. iq Q17 NEW LISTINGS CHEMICAL CONSTRUCTION & Controlling Sound with Lead Lead--a Modern Design Lead Pigments Bulletin Brochure, 12-pages, describes the ad vantages and varieties of lead pigments in anti-corrosion paints. Covers red lead, dibasic lead phosphite, basic silicate white lead, basic lead phosphosilicate. basic lead chromosilicate, basic lead sliico chromate. Lists major suppliers. F-7 Lead far Corrosion Resistant Applications Soft cover book, 156-pages, designed to familiarize engineers and engineering CORROSION PROTECTION Corrosion Resistance of Lead in Chemical Applications A chart presentation of the corrosion re sistance of lead and its alloys against 188 chemicals from 0s to 3000F . Six pages. H-3 BATTERIES A Primer on the Lead-Acid Battery Reprint cites three installations where lead is being used as a noise and vibra tion barrier: John Hancock Building: Baldwin-Wallace College: and New Eng land Medical Center, Boston. Four pages. J-12 Specifying Lead for Noise Control Eight-page repr.nt 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 Summary nf __ ' V,. ieau y0r r:,H g sound/vibration control sources, soldering ani 'le cages M-15 8 nd Use of Lead in the Automobii. Repnnt of article from cussmg in aetail the tions of lead m the vanoy. pages M-17 Lead--The "Clydesdale"Wnrw in Space * students with the corrosion resistance, design and fabrication data on lead and A condensed story of the principles of the lead-acid battery and its chemistry, in commercial, industrial and residential noise problems. J-18 Reprint from Space World applications of lead m i lead-based equipment. Defines plumbum series and corrosion resistance of cluding some of the fundamentals and definitions of direct-current electric en Practical Application of Sheet series. H-6 ergy, Two pages. L-6 Lead for Noise Barriers Illustrated. Four pages. M-19 Lead Industries Association' Sixteen.page brochure com.,, Lead Chemicals Soft cover book, 334-pages, is designed as a working manual for the chemist or chemical engineer engaged in applied technology or pure research. Covers organoJead compounds, oxides and hydrox 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 Discusses how the use of various thick nesses of lead bonded to or used m con junction with other construction mate rials determines the Sound Transmission Class (STC) rating of walls and partitions. J-15 scnption of Association it "* ture and managemer* and major activities ' is included, along domestic trade ass: cooperation is mam:? ides, sulfides and teilundes, halides binary compounds, lead salts, lead chel ates. safety m handling compounds. Pur chasing price: $3.00 H-7 Battery Powered Electric Work Vehicles A 12-page folder describing batterypowered short-haul delivery vehicles and comparing their economics to internal combustion delivery trucks. L-19 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 Lead, "The Cinderella Metal"* Booklet is reprint of talk Bl First National Conference * Availability - Utilization k r President, Noranda Sales'Coro dian lead producer, discusses -- Electric Work Vehicles A 16-page bulletin on electric vehicles for short-haul, multi-stop commercial ap plication. Lists major vehicle manufac CERAMICS Facts about Lead Glazes for Art noise requirements in factories and also on planes and trains. J-17 SOLDERING AND WELDING pricing trends for the metai sizes its significance anc vaiil and m the future. M-31 ^ Leaded Grades: Answer to turers as well as comparative costs electric vs. I.C. vehicles in closed-looped service. L-21 ARCHITECTURAL Lead Roofing and Flashing Detailed instructions on the simplest and Potters and Hobbyists Detailed information on the proper formu lation, firing techniques, handling, etc. of lead fluxed glazes used by art potters and hobby ceramists. Illustrated. Sixteen pages. B-ll Soldering Preforms Circuits Manufacturing reprint discusses how the use of lead solder preforms saves time and simplifies task of joining metals for automated production. 1-3 GENERAL Free-Machining Needs. Reprint reports on benefits <j- usmg leaded steels for free Case histones are employee strafe that these grades - partsmakers to raise product ity components with efficiency omy. M-32 ' most usual methods for forming or join ing lead for roofing and flashing appli SOUND BARRIERS "Lead Abstracts" and "Yearly Indices" Ecology in the New Lead Belt cations. Complete specifications. Dia grammatic drawings. Sixteen pages. A-5 Lead In Building A four-part data sheet containing informa tion on waterproofing, sound barriers, roofing and flashing and anti-vibration ap- Directory of Acoustic Specialties Summary of available materials for sound insulation by barrier, damping and absorption methods. Sixteen page list of materials by brand name and manufac turer. Eighteen pages. J-4 Bi-monthly abstract of all current worlo literature on lead and its products and published research. A general index is published annually. Must be requested on company letterhead. M-2 Publications and Films Reprint describes cooperate and environmentalists in southern Missouri lead pages. M-23 Childhood Lead Poisoning Highlights on Midwest and piications. A-13 PAINTS Follow the Safety Line with Chrome Yellow Lead a Major Factor in New Machinery Noise Suppression Systems Description of techniques used to lower machinery noise levels with lead and lead Twelve-page catalogue listing the publica tions and films available from The Lead Industries Association, Inc. M-13 The U.S. Lead Industry An annual review of activity within the in ferences where childhood ieafl were discussed Prepared . with the American Academy of M-27 FILMS Formulations and suggested applications for chrome yellow safety paints. Illus trated. Eight pages. F-5 Organolead Antifoulants An 8-page reprint describing how organo lead coatings have proven successful m preventing marine fouling. Tests were conducted in Connecticut and Maryland. F-6 composites. Lists machines that normally exceed noise level allowed by WalshHealey Public Contracts Act. Two pages. J-9 Sheet Lead Plenum Barriers Detailed description of acoustical plenum barriers and how to install them. Mate rials and installation procedures described and illustrated. Eight pages. J-10 dustry 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 Primary Lead Production Areas in the U.S. For schools, libraries. Il"xl4" map show ing locations in U.S. of most lead smelters and refineries, and lead mines. M-ll Lead In Motion A 21-min., 16mm color frim, properties and its potential for future applications are explo viewpoint that an atom of |elemental matter--is an arn energy--part of a universal order specify desired show alternate date. No charge viewer pays only return po' PRINTED IN U.S.A. NAME, TITLE COMPANY STREET CITY, STATE, ZIP CODE PLEASE SEND ME THE PUBLICATIONS MARKED BELOW WRITE IN CODE NO. <-TO REQUEST LITERA MAIL TO: LEAD INDUSTRIEASSN. INC. 292 MADISON AV NEW YORK, N.Y. If LIA 2675 6