Document wgjkqzJybZ6MqeRDNr97Zqzn4

PLAINTIFFS EXHIBIT AL-547 P 0 I N T C 0 M F 0 R T W O R. K S V 0 L U M E 57-a 1948-1955 "'N * * Mi ` . . * r.*v. "si* -j*'**.. ** APC 000001 ALCOA PLANT HISTORY APC 000002 POINT COMFORT TORES VOLUME 57 OOPT NO. 3 APC 000003 HISTORY OF POINT COMFORT WORKS VOLUME 57-A 1948-1955 Note: For information from 1956 on, please see the following volumes: Volume 57-B - Point Comfort Operations Volume 57-C - Point Comfort Smelting Volume 57-D - Point Comfort Refining TABLE OF CONTENTS Page No. Name of Operating Company Construction fc General History, Section 1 Highlights in the Building Story History of Construction General History 1 2-21 22 - 30 Production History, Section 2 1-43 Power Department, Section 3 1-38 Mechanical Department, Section 4 1-58 Electrical Department, Section 5 1-18 Laboratory fc Metallurgical Depts., Section 6 1-10 Personnel Dept., Section 7 1-67 Purchasing Dept., Section 8 1-5 Accounting t Traffic Depts., Section 9 1-22 Public Relations, Section 10 1-15 Chronology, Section 11 1-24 Charts fc Tables, Section 12 Building Additions Management Personnel Floor Areas APC 000004 A Table of Contents, Continued Charts b Tables, Section 12 - Continued Production Efficiencies Employment Data Table showing Wind Movement b Rainfall Data 1949 to 1955, Inc . Power Department Data 1950 to 1955, inc. Natural Gas Data 1950 to 1955,Inc. Maps, Plans. Photographs, Section 13 Aerial View of Plant Plant Map B-27275 LSK-243-T - Dark Storage Room for Photostat Room Bldg. 1 C-111-PC - Condensate Disposal System and Layout A-118-PC - Bldg. 37 - Alkaline Ore Reclamation Layout of Equipment B-223-PC - Midway Well - Equipment Layout Well House A-26115 - Bldg. 9D - Alumina Reactivator General Plan b Details of Steelwork. A-26118 - Bldg. 9D - Alumina Reactivator Sections and Elevations A-29785 Bldg. 37 - Alkaline Ore Reclamation Elevations. A-29793 - Bldg. 37 - Alkaline Ore Reclamation Details of Steelwork - Dust Collector. Dwg. No. C-SK-50-PCP - Typical Section through Engine Houses 11 b 65 Dwg. No. C-360-PC - Maintenance Shop for Bldg. 9 - East End Photograph of Maintenance Shop, Building No. 9 (1952) Type 53 Potlining, Lines 4 b 5, Dwg. A-771-PC Type 53 Potlining, Lines 1, 2 b 3, Dwg. A-780-PC Plan of Bay Front Addition - April 1954 Miscellaneous Photographs Historical References, Section 14 News Release regarding increase in aluminum smelting capacity at Point Comfort Works. Point Comfort Wind Movement and Rainfall for 1950 to 1955 inc. Housing Department, Section 15 APC 000005 HISTORY OF POINT COMFORT WORKS HAKES OF OPERATING COMPANIES AEUMIHIM COMPANY OF AMERICA April 16, 19ij8 to data APC 000006 A POINT COMPORT WORKS - CONSTRUCTION HIGHLIGHTS IN THE BUILDING STORY April 16, 1948 April 22, 1948 April 26, 1948 August 11, 1948 October 16, 1948 Ootober 16, 1948 December 29, 1948 January 7, 1949 February 16, 1949 March 25, 1949 AOy 30, 1949 August 5, 1949 August 12, 1949 Jauusry 23, 1950 February 10, 1950 March 8, 1950 Mej 1, 1950 June 24,25, 1950 August 31, 1950 Decision to Locate tha Plant In Texas. Authorisation Issued - Two Potlines. First Contract far Clearing Site -- Continental Construction Company. <>.' First Contract for Grading Plant Rita -- R. B. Zachry Company. First Gas Through Matagorda Transmission Line. First Power 'Produced by LeRol Gas Engines Used for Temporary Lighting. First Building Foundation Started -- Bldg. #5 Authorisation Rarlaed -- Three Potlines. First Steel Erected - Building 5* Dock and Dredging Completed. First Building Completed. Authorisation Revised to Include Cafeteria. First Engine, #40, Building #5 Started. Baking First Potline Started. First Pot Tapped. Baking Seoond Potline Started. Baking Third Potline Started. Plant Open House. Authorisation Closed. % 11 APC 000007 FLAOT HISTORY Due to tba loss of production caused by the scheduled closing of the Hlagara Reduction Plant In February, 1949, and the expiration and canofiliation of power contrasts at the Vancouver Works, the construction of nore reduction facilities beoane neoessary. On April 21, 1948, Authorisation Number P-16956 vaa lasuad to construct a two potline Reduction Plant capable of producing 76,000,000 lbs* of alunintia each year. The authorisation was later revised on January 7, 1949, to construct a three potline plant with a oapacity of 114,000,000 lbs. per year. A further revision was made to the authorization on August 5, 1949, to Include a cafeteria. Low cost power required for the production of nltmlmHn vas very scarce, so for a number of years the problem of low cost power using gas engines as prise movers vas studied. The data secured in the operation of the gas engine plant at Jones Mills during World War II indicated that production of reasonable oost power by the gas engine method was feasible. A decision was finally reached In Pittsburgh to build this plant in Texas on a tract of land at Point Comfort on the east side of Lavaca Bay approxi mately five miles from the City of Port Lavaca. This tract of land consists of 3,041.64 acres for which the necessary options wore secured. This lend vas purchased from, and deeded to the Alminun Company of America on the 20th day of May, 1948, by the following persons* W. E. Bauer Marjorie Bauer H. C. Smith Frankie Smith Port Lavaca, Texas Port Lavaca, Texas Port Lavaca, Texas Port Lavaca, Tans The land purchase vas made with mineral rights reservations as follows* m L APC 000008 5/384 loo Participating Royalty Interest to Bauer ft Snith 4/384 Frank Liddell 11/384 national Bank of Connerce aa executor for John H, Tucker Estate The above ehova a total of 3Q4L*64 acres purchased, hat only a sail portion of thlB acquired land lias vithln the plant fence* The fence encloses a total of 132*50 acres* The supply of natural gas required far power generation was eoverad by a gas purchase contract dated April 23f 1948 hetuesn A*C0*JL* as buyer and Stsnolind Oil aid Gas Company and others as sellers* This supply* along with others secured later, vas sufficient to operate a three unit plant with acme excess available for sale if desired* This gas supply vas to be made arailahle by building two natural gas lines, . one approximately 13 miles long from the gas fields in Matagorda Bey and one 16*62 miles long from the Franoitas Field, Jackson County, Texas* Both lines to he owned and operated by a subsidiary pipeline company - Basely, The Lavaca Pipe Line Ccmpeny* It vas also evident that a greater portion of the housing far prospective employees would here to be provided* The Calhoun Development Company, a subsidiary company, vas forned on February 15, 1949, to build the necessary employee homes* The site chosen for this new plant had been given the nine of Mitchell Point by the early settlers, and was veil seasoned vith tradition and history* The none given to this site at the start of construction vas Point Comfort, and this designation was officially approved on October 7, 1950 by the United States Board on geographic names* It vas highly fitting that Alcoa, plmoer of Aoarica'a alwinun industry, should follow In the footsteps of these early settlers and build the pioneer aluolnun reduction plant in the State of Texas* Most of this site vas covered with meequlte and hrriL--ohe mod before the grading could be started this had to be removed* On April 26, 1948, a oostract A3 was 1st to the Continental Construction Company, Contract Number 11669, to clear the site of all andargrowth. The core borings conducted for foundation Investigation revealed the fact that the top of the Beamont clay varied from en elevation or 17*5 to elevat ion 13, except for a few Isolated cases where sand pockets vers found. No rook formations were encountered. Gtnbo vas found from the top of the clay to surface throughout plant site. On May 9, 1948, a topographic survey for the plant vaa collated by Phillip G. Young and submitted for bids to James Stewart & Co., Inc., Dallas, Texas, and H. E. Zachry, Sen Antonio, Texas, Drown & Root Co., Houston, Texas, and Continental Construction Company, Port Lavaca, Texas. On August 11, 1948, the grading contract vas awarded to H. B. Zachry Co., and numbered 11820, and on August 17, 1948, Zachry began moving the equipment in and on August 19, 1948, began moving dirt on Road "A", entrance road, to bring the yard level to 17.5' elevation. A total of 568,337.97 cu. yds. was moved and the plant grading was completed December 31, 1948. The H. B. Zachry Company Contract bIto included tha Installation of storm sewers, sanitary severs, industrial waste sewers and the building of all 2C ft. asphalt surfaced shell roads. Tho sever linos were subcontracted ;y Zachry to Sfapiro Builders of Fort Lavaca. Terns of Contracts In addition to the original terns of the various contracts, a consider able amount of extra work vas perforned under Article 3. This vas due to the fact that in sono cassa final drawings and specifications were not ccnplote at the tiro the contract was let. The load bearing capacity of tho soil at this plant was such that it was not necessary to drive piles for support of building foundations. The only locations whero it was necessary to uso piling was at Building #23, Lift Station, Building #33, Reservoir, and Building #60, Dock. At these locations sheet steal i4 APC 000010 a4 piling was used and installed by CQ.e Peterson, lac., Contract lhanber 11930. The piling was necessary at these locations only because of the deep excavations and to hold the fill* pongteftM flgm The superintendence for the construction of this plant was being carried on under Mr, E, B. GUlenwater, Acting Construction SigMSintandent, 1*0 arrived hare fron the Davenport Works on April 15, 1948, and vbo left our employ on April 1, 1949* On Bovember 18, 1948, Mr, H, F. Robey, Jr, arrived la Port Lavaca and assisted the duties of Construction Superintendent with Hr, E. E, GUlenwater acting as assistant, Mr, L, E, Henbert arrived on August 1, 1948, froa the Pittsburg Office to assune the duties of Purchasing Agent, Temporary- Facilities The temporary office quarters for the plant were established In Port Lavaca early in August, 1948, Continental Construction Company was authorised to build a frame office building 24*x36*, one story high, and covered with alumna sheet* Oils was completed around the middle of August, 1948, and Alcoa employees vho had been using office space in the Lavaoa Hotel, Port Lavaca, established headquarters in the building. At this time Alcoa's employees con sisted of only two or three people, but the ensuing nonths ware to eee the arrival of accounting, employment and purchasing personnel. During the Month of October, 1948, a snail tanporary building was con structed at the plant site, at Point Comfort, as headquarters for the engineer ing staff setup. As the work progressed, need for eocmnnications between these two groups became increasingly important. This problem was solved by the instal lation of a radio telephone by tho Southwestern Associated Telephone Company, This was a temporary expedient at best, so negotiations for extension of telephone serrloe were entered into lnaedlately. During November, 1948 erection of s aaall quonset 20*x36* to serve as a 15 APC 000011 temporary office during construction vas started on the plant sits* Early in December, 1948, the foundation vas poured and erection started on the min Construction office building. Ibis building vas e quonsat 132' long by 32' vide and divided into offices for various departments* Daring this period construction vas started on two 40'atlOO' quonsats to provide storare facilities. Alterations and a concrete floor vas added later to the south quonsat to provide a permanent building for use as a carpenter shop and assigned building Nunber 13A, A concrete floor vas also added to the north auonsst later to provide additional storage and assigned building number 15A, A batch plant vas also erected by Brown & Lane and located in the vest area where \ rav materials were centered and concrete mixed and transported to the fomdatlcn area in mixer trades. The temporary offices vara only a small part of the oversell activity, however, as other temporary facilities were also being erected during the period from August, 1948, through January, 1949, These consisted mainly of temporary power, water* telephone, light, gas, air and oil lines together with roads, fsmees, etc. During the week of October 17, 1948, the plant site vas rialtad by H, F, Robey, Jr., E, C, Collins, J, Junget, V, Boyd end L. L, Neubort, at which time interviews relative to the letting of the general contract were held with seven (7) General Contractors and two (2) Electrical Contractors bidding for same. The general contract vas officially awarded to Consolidated hestern Constructors, Ino, on November 3* 1948, and given Contract Number 11895* The period between August and December 31, 1948, sew the construction proceeding at a very good rate, and during December the gracing, scrubber qysteo, sanitary and storm severs were essentially completed* The stars sever system i3 almost three miles in length and is up of reinforced concrete pipe as large as 54 inches in disaster, pipe is A6 buried at various depths from four feet to twelve feet to insure proper drain age. This ayatera. la designed to carry off surface water mainly in the potroom areas, and has inlets located at points necessary to insure rapid collection and run-off. In general, the carbon plant, service building, engine roan and yard areas drain to gunlted drainage ditches. The scrubber system is a network of underground gravity piping iddch is used to carry off water used in the prooess as part of the air cleaning sysrtam. The water is carried off to a reservoir and after treating and settling is pump ed by pressure to the scrubber towers. Sanitary sewers are six to twelve inches in diameter and installed at depths varying from four to eighteen feet. 'Sewer connections are mode at all washrooms, which in turn tie into the main sanitary savor system. All waste matter, which I3 discharged into this system, will be treated at a disposal plant before being finally disposed of in Lavaca Bay, thus insuring one hundred percent sanitation. The sweet water system begins with a 150 GPrT wall located on the "Bon Vard" property approximately l^PO ft. south of Highway 35 and approximately 2,900 ft. East of Highway fl72 and runs approximately a distance of 9 miles in a south westerly direction and ties into the plant loop. This line is constructed of 8 inch welded wrought iron pipe installed at a minimum depth of 2 fe *t. Construction of the plant railroad, consisting approximately of 3*53 miles of track, started during the month of October, 1948, at which time the grading and ditching into the plant proper wa3 completed. The plant railroad connects with the Point Comfort and Northern Railroad and various spurs servo the power, aluminum, paste and general divisions of the plant. The plant railroad was purchased from the Point Comfort and Northern Railroad and was constructed for them by the VAn. A. Smith Construction Co. The 4160 volt power distribution system originates at the H.G. sets and 1t APC 000013 switch gear assemblies, two located In Building 5 and two locatod in Building 7, and runs to the 6 substations located at various points on the plant site* Construction of this system started during the week of July 11, 1949 nnd was essentially completed during the week of November 14, 1949 The system was energised during the week of January 16, 1950. This work was performed under Consolidated's contract Humber 11895# who in turn sub-oontracted this work to Fischbach & Moore, Electrical Contractors. The yard lighting for the plant site consists of lighting standards, bracket ams on buildings, aluminum light polos with concrete bases, transmission towers with flood lights and vapor proof fixtures for lighting roadways, parking end working areas and substations. Construction of this system started during the week of Vay 6, 1950 by the Fisk Electric Company under Contract Ninber 12223, and was completed during the week of June 26, 1950. The dock is of interlocking steel sheet pile construction with concrete cap and deck. It has a timber fender system and rip-rap shore protection. Creosoted pile clusters are provided along the shore line. Vtork on the dock was started In January 1949 and completed in March, 1949. It was necessary that this dock work be carefully scheduled in order that it would not interfere with dredging the turning baain and channel. The turning basin 300 feet wide by 800 feet long was dredged in front of the dock to a depth of 9 feet. It was deeided at thi3 tine that a channel 100 fe9t wide by 9 feet deep would be dredged to the P8::j Cavollo Port Lavaca Channel, which would insure 9 feot of water up to the dock. The carbon plant equipment and the first shipments of structural steel began to arrive in December, 1948 and Consolidated Western started to excavato for foundations. The plans for the main office building were also completed by Wyatt C. Hedrick, architects, during the month of December, 1948. L8 APC 000014 A8 Buildings Tha construction of tha angina houses started on Deesmbor 4, 1948, when excavation for building end equipment foundation began. The three engine bouses are constructed of structural steel with reinforced concrete footings, piers and curtain vails, aluminum corrugated siding and roofing and vith mod end alvminum rolling doors. In order to facilitate pouring the foundations for the gas anginas, which ere circular, five seta of steal foraa vere fabricated. The fores consisted of an inner ring and an outer ring vhlch vere assembled in plaoe. Tha concrete vas then poured between the rings. The use of the forms made it possible to pour five engine foundations at tha sane tine. Construction of the forms vas such that they vdre easily ramoved after the concrete hardened, and set up on the next foundation site. 411 engine foundations vere poured using the sane five original sets of forms. Early in December, 1948 structural steal for the engine rooms was shipped by the fabricator. In an effort to avoid handling th3 steel any more than vas necessary, building foundations vere pushed ar-. much as possible. However, rainy weather delayed completion of tha foundations until early in February, vhen erection of the first structural steel on February 16, 1949 vas finally started. As soon as erection of structural steel was sufficiently advancod, agplicatior: of alminun roofing and elding began. A forty ton overhead travel ringcrane vas installed in the building to facilitate the handling and installation of equipment. During this p3rlod, work vas also progrossing on construction of the control house from which all equipment within the engine h .useo will be controlled. Work vas also progressing on an oil storage building which will contain tha pumps and other equipment necessary to pump the lubricating oil to the equipment. The oil itself will be stored in four large 20,000 gal. tanks which a' A < i APC 000015 are set on conorete foundations outside the building. The first engine arrived at the plant site in April. Those engines are 11 cylinder internal combustion radial engines using natural gas for fuel. Each engine is used to drive a generator producing SC current for production and AC current for driving engine auxiliaries. By means of a closely coordinated shipping schedule of the generators and anginas, it was possible to make the Initial assembly without a great deal of difficulty. Thin was accomplished through th9 use of an assembly stand which embodied a pit irf.th e concrete foundation and a structural steel framework. The generator was placed in the pit and the engine mounted on the ata-si framework while the flange coupling was made. After this was dono the entire unit was raised with a AO ten crane and placed on its permanent foundation. As far as th9 completed installation was concerned, this was only preliminary, as all auxiliaries had to be placed and connected, and the piping for gas, lubricating oil and water installed, and the control equipment connected. Each engine has a control panel which shows exactly how the engine and generator is operating, wfaeth-r or not it is oprrating efficiently, if any of the cylinders are hot, or any condition has developed which might cause difficulty as well as whother or not all the auxiliary equipment is working properly. This panel also provides protection against hearing failure of the engine, and removes the engine from the line in the event of a bearing failure. An electrically-operated fen is maintained in each engine base for the re moval of heat created by the generators. Lubrication of the engine is accomplish ed by the use of a sump tank for storage from which lubricating oil is pumped into the engine under presTtrro. The air is the engine houses is constantly kept claan by means of an evaporative cool'ng system which washes and cools the air. 10 APC 000016 * 10 re power produced in tho engine house is collected by a ring of aluminun bus which encircule3 the engine house except on the north end. / Inis bar trysten further transports the power to the potroons, at which point it is usoc in the production of altxnlnm. Early in March, 1949, excavation war- started for the potroon buildings* At Foint Confcrt four such buildings, each 984 feet long, make up vhat is commonly called a "potlina". There are three such lines at this plant or a total of twelve potroon buildings* The buildings are constructed of structural stool with olueimn roofing and siding. A feature of th9 construction is the use of aluninur. ventilating doors along the sides. These doors are raised outward allowing ventilation along the entire length of tho building* Additional ventilation is provided by an open type ventilator on th9 roof running tho length of the building, Each building is equipped with two overhead traveling crar.es for handling equip ment and row materials. Tho operators' cabs rounted on the cranes ava totally enclosed and airconditioned. The pots are the vortical spike suspension "Soderberp" mm Inal 51,000 ampere type, thirty-four pots to a build'ng. Curtain walls for the potroon buildings were oast on a slab ru:d lifted into place with n crone* The U3e of this methen redwood the amount of form work necessary, and also reduced tho length cf time for completion of the build .`ng ''rundetions* The passageways between potroou.e are insta'le et convenient intervals and, vit'. o feu minor exceptions, are o'* be sor-e construction as the potroor.s* These nassareuoys provide, among other things, toilet facilities, art1 will permit passage from one building to anothev with material a, tods or repair parts. Const uction of the Ore Unloading building. Timber 4C, was started during the week of l'ay 23 under Consolidated's contract No. 11895. This ; *1 APC 000017 A 21 building is constructed of structural Bteel with reinforced concrete piers and curtain walls, aluminum siding, and steel roof deck* At this tine corstruction was also underway for the alumina end cryolite storage tanks and bucket elevator* The ore and electrolyte storage facilities for this plant were designed to unload ar.d provide adequate storage of ore and electrolyte materials for a plant with fora* petlines maximum, However, the second CO* diameter reserve storage tank was not initially installod. If a fourth line is built this tank will have to bo installed to provide an adequate reserve supply of ore. Those facilities were designed to handle 100 tons per hturr of alumina end tho proportional tonnages of electrolyte materials* To provide the necessary equipment at tk' least expense, the33 facilities were contra!ly located between lines two and throe. For this same reason the bucket elevator installation, rather tiion bolt conveyor with storepo tank? between each pair of potroons, was selected* Lxeavation for the Petal Service building, 1'unber 19, began during; tho week of March 14, 1949* under Consolidated's Contract No, 11895. This building is constructed of structural steel with reinforced ccr.crete piers and curtain walls, alwainur. siding and steel roof deok. This buildin/- is designed to handle the casting, weighing and shipping of all pip production and is equi;pod with a a5,000 lb. ladle pouring car end e traveling Jib crane for strip;ing 14' 0 lb. pin. burin-- ' ay, 1949, construction of the paste plant buildings va~ started. Puildings 52, Fitch are: Coke Storage, 54-' Mixer Building, 53 rotlining Storage FuUding, 54 Grinding, 541 Passageway, and 54^ hunout, c~e constructed of structojal ste 1, with corrugated aluminum siding and steal roof deck* Building 55, Ta'* Storage, is constructed of concra'a with concrete roof deck* Building 54, Paste Control, is instructed of concrete and masonry with exterior and interior walls o'* unrlazed tile end concrete roof slab* Building 54D, Control '> * fow APC000018 12 House, Is constructed of reinforced concrete vith tile vails and steal roof deck. The design of the Point Comfort pasta plant combines tho good features of the carbcn plants built during boric b'ar II for the Defense Plant Corporation and those of the Alcoa paste plant vhlch vas completed in 1941. To meat the construction scliedulo cot up for the Point Comfort Plant, it vas necessary to procure the pasta plant equipment as promptly as possible. For this reason and because of the modern design of the DPC carbon plants, the purchase of the carbon plant equipment fror. the Burlington ETC plant vas negotiated through bar Assots Administration. Thin purcliaso M2 approved in the fall of 194S. Dismantling of equipment from Burlington began in November, 1948. This vork vas contracted to Eichleav Corp. nrc was performed undor the super vision of our Messrs. Sharhlin and PJhoados. The vjorl: of dismantling and shi-ping the Burlington carbon plant ocruipnant vas completed is the middle of January, 1949. Host of it vas on tho plant site at Point Comfort forks by the middle of February, 1949, that is, tho equipment u!iich vas going to 1-e used at this plant. Equipmont which was not scheduled for installation or use at Point Comfort fork'? was shipped to Cresaona 1 'erke for storage ;r.d disposal. T-hj Point Comfort VorJis paste plant consists o~ a materials unloading end crushing facility, and coke end hard pitch storage, building number 52} a grinding building, nmber 54, a nixing building, number 54-'- and s tur storage and punping facility, building number 55. Building number 52 hero ir. identical vith that of the PFC plants except tint no dust collecting equipment van. installed, and differs from the J.-PC building of the snr.o number in that coho is reclaimed from, storage to proca n by naar.n of an ovorbond crane vith t clun aboil bucket rather thr.r. a monorail crano. Also a feature x.hich has proven very satisfactory is a screw at tho discharge end of one of the baits vhlch spout ooke directly from cars to tho conveyors feeding tho bunkers in building number 54. ^pC 000019 a 13 Euildinr msober 54 is practically identical with the IPO grind-'ng building in design oreopt tho packing materini facilities and that jortion of the building was eliminated in tho Point Comfort design and slight changes in elevation of ecuipment made for tho Teocaa layout. Building number 54A, the nixing building, was patterned aonauhat after Alcoa's pasto plant vith, of course, improvements as recommended by their operators. Tho ventilation of the mixing and grinding buildings was given serious consideration and ft. adequate fume system installed in tho mixing building to handle tho paste funes from the mixers and fron the paste hucket3 at the loading station. An electrostatic dust collector collects dust at ail transfer points in tlio convoying system in buildings 54 and 54' thus keeping the building etaosphero clean. The tar storage arc handling system for Point Comfort forks differs from that of other plants in that steam jackntod linos are usod for handl'Rg the molten tar rather than tracor linos previously usod ct other locations. This was necssssry since wo handle a highor molting point pitch for tiie paste binder and do not use any hard pitch. This system oo far has boon entirely satisfactory. To handls tho pasto from the Paste Plant to tho potrooms, a narrow gi-.uga trad; system was installed, vith micarta rails through the potroenn tc elirdnato any hazard from grounds in the potroorn area. Tills oyster with r. remote controlled electric nulo for handling tho e rr, In builc.ing3 54 and 54-' resulted in an economical swotor. for handling the paste from t:i3 paste plert to tho potroons. Potlining for tills plant is all received -"amixeb in Mock" which only require crushing and "anixing prior to ir.st.-.'latior. in tho pots. Building numb-.r 53, the potlining storage building, has an elevated iloor 1o facilitnto unloading of the blocks of prsnixod lining from box cars, the floor being approximately loval with the car floor. These Mocks are proco sod thru a grizzly to a spiko roll crualior which breaks than up to 1--l/2n minus pieces. The crushed pranix is convoyed by belt and redlor elevator to hoppers in AU <i APC 000020 building number 54A from which it is withdrawn end weighed before charging into a mixer. This is done os o weigh cor. Tor is added in the mixer and the finished potlining material handled to the potrooms over the narrow track syston in the center passageway. Auxiliary or Genera? Facilities Construction of a modern rcaching shop to incorporate a great rauy of the up-to-date machirg tools van started leta in March, 1949, under Contract Number 11895 by Consolidated Western Stool Corporation. The completion of this machine shop will make possible moat on-th-spot repairs without delay. This building is constructed of structural steel and concrete vith reinforced piers ard curtain walls, aluminum siding and steel roof deck. On March 7, 1949, Contract thmbor 12048 was awarded to the 0' Hourba Construction Company of Houston to build the administration building. This building is entirely modern and completely air-conditioned. Tho foundation is of reinforced concrete vith side vails of hollo;/ tile end brick facing. Tha construction of t /o wash and locker room buildings,'Building 17 and Build- ng 21, for the convenience and comfort of employees was started during tha April-Hay, 1949 period. Construction of building 21 startod durir.r tho weak of April Uth, 1949 and the construction of building 17 was startod during tha week of May 1C, 1949. Each of tiiese buildings ara constructed of structural stool and masonry vith reinforced concrete frundrtims, exterior and interior tile vails r.nd with steal roof deck. Euilding 17 servos tha ulininur division of tha plant and building 21 serves tho genor-l plant. The buildings are oquipped vith modern sanitary facilities, including sl/owors :rd lockors. The construction of tho Stores building, Number 15, was started on Mey 6, 1949 under Consolidated'3 Contract No. 11895. The foundation for this building is reinforced concrete vith corrugated aluminum siding end steal roof deck. An oH storage building was later added to the storage facilities. This ; * r APC 000021 building la a onestory structure with concrete foundation, exterior til 3 walla and 4n reinforced concrete roof* A concrete loading platforo connects the stor^. roon and oil house. Construction of the oil house was started the veel: of August 8, 1949 tinder Consolidated' a Contract Number 11895* Construction of building 51* Boiler House, was started during the week of liny 16 under Consolidated *3 Contract Humber 11895* This building has concrete foundation, aluminum aiding anti corrugated aluminum roofing. Two 300 K.F. and two 125 H.P. unit stean generators furnish steam necessary for production and heating. Three Ingorsoil--Rand size type air compressors furnish the necessary compressed air for production. * A natural but imposing feature of the entire plant is that it is completely enclosed vith an. all aluminum fence. Posts, wiro, staplo~, everything that goes into the fence, is made of aluminum. ?<ost people will agree thr-t this all alun-'mr-. fence ia a fitting and symbolic climax to the completion of one of the Southwest*s greatest industrial plants. APC 000022 A 16 TIAT!?"" CC-TrniTir-TTS Tha follovinf notes on the weather conditions portray sore reasons for dairy in construction* Sept. 9-10-11-12 23M. No work for 4 days duo to rain. Too vet for rradinr. "/eek of Nov. 7 to 13 V'eek of Nov. 14 to 20 Two days lost due to rain. Two day lost due to rain. Friday, Jan. >2. Thursday, Jan. 24 Monday, Jan. 31 Friday, Fob. 4 book of Fob.13-19 T ndcy. Fob. 21 Tuesday, f!erch 1 Thursday, April 1 Vtondry, April 5 2nd.' ole of April 16-30 ooJ' of Anril 30--"'ey 7 ` 1 osJ- of lay 14-21 '.fed., June 9 Tliuro.,Juno 1C July 2-9 mi Ono day lost due to rain. Ono day lost duo to rain. i'c.ndcy lost due to snow on Sunday and cold Tenporaturo (14) Part of day lost. Plant va3 saturated i;ith rain - only three days worked. Construction delayed part of day duo to rain. Construction v>ry 3lov due to rain. b'orkod stovpocl at 11: CO ' due to rain* No work due to rain. Fork possible onlv on J'cndry of first week and little progress second wool: duo to heavy ra-'n of 7.01". Construction very slow due to rain of previous two weeks. ri-"h winds slowed sheetin'- of roof on rid". Hunbar 7. Rain stopped construction in the afternoon. Ha`n halted most construction for the dcy. Fourth of July weekend was rainy and slowed construction considerably for most of remain ing week. 4 APC 000023 * 17 July 16-23 July 23-30 Aur. 6-16 Sept. 10-17 Oapt. 17-24 Oct. 1-g Oct. 22-29 Dec. >17 Fob. 21 'pr. 15-22 -`.pril 22-29 June 1 Juno 19-20 July 8-15 July 15-nopt. 9 Heavy rains ovsr weekend delayed f-undati^n construelien and picket lino of Corpus Christ! Foilor Makers daleyed work one day. Rain on Sunday slowed construction fo'.mdcticns. Rain hsrapered foundation construction end slowed other work. Heavy rain sto pod work conplotoly Friday, 10th., and vary little progress was cade tho repair'dor of week. Total rainfall for week - 7.03 inchas. Additional rninfa] 1 and hurricane scaro caused considerable delay. Much effort was expended In preparing for hurricane which apparently wuld strike Point Comfort, but fir.nliy v-*ereO. off toward tho Louisiana Coast. Heather entronaly bad with hurricane driving toward Port Lavaca. The locrl l",.c.. Fn^i' oer3 office advised thr.t all personnel' bo evacuated from plant site on Monday Morninp. Trie 3tom apain veered off at. 1030 'ondrr ovenin;- and struck iho coast at rreeport, Texas. The hirhest wind velocity recorded at plant site was 35 'FH Rainfall from lata dundr.y afternoon until Monday afternoon van 9*03''. Plant site was conpl otely flooded. Very alow progress was r.no ir. con struction for remainder o" uaak. Rainfall for week '.ss 5.32,! which delayed con struct!'':! considers' ly. Internittor rr.im saturated plor.t site - Constr'ctier. van slow. 125 'tain halted construction for nos: of dny. Hcinfrll for wee'' vo3 l.!?*1 - slowed constriction. I^avy rain over week end. Cntistrecti' r. hampered uli'litly. Most c r.3true tie- was sto- ped Thursday by "rin. Fain delayed preparation for Open House. I? infnil of 3.63" stopped yard crews for no si. of week. Occasion:! rain, but construction was largely inside work of odds and ends uhich were not affoctod try the weather. 4 3 APC 000024 * 18 Tho following Is a list of direct contractors who performed verio.s typos of construction at this plnnt* CONTRACT NUVBEF. American Bridge Company 12196 Tutorials Unloading Bauer-Snith Dredging Company 11928 Dredging Eerryhill-Titus Company C E Engineering C-. Supply Co. Then. Bate Sons 12329 12174 12253 Painting Insulating Lagoon, Parking Lot No. 1 end Roads. Chlca-'o Fridge Conmny Continental Construction Compaq Consolidated Vestern Steel Corp. Sub-Controctore American fridge Co. Fischbach & Koore Inc. Janar-Olrsen Const. Co. Frown Lane Company Wallace Plumbing Co. T. G. Audish Pittsburgh Plate Glass Co. Courtney Welch & Co. 11840 11669 11895 'ater Toni:, Oro Tank t Lino Talk ''iscellaneous ,;ork and Grubbing General Contract Corpus Chrieti Sash & Door Co. 12244 Insulation Fotroor* Colvnn3 Cyclone ''enca Division of American Steel and ' ire 11896 Fence Eichleay Corporation 12177 Pot ?'oc:inr.iccl Section Fisk Hoctric Cortpcny 12223 Garber. Plant Moctrierl and Street Lighting Flanders Construction Co. 12141 Storri Sower Cunito and Sodding J. I. Gerrett riumVng Companr 12190 ,:iscollano- u.-; MunMry- T. L. Grantiand 124?3 Heuling and .Spread ir." Topsoil Grinnoll Co., Inc. 12191 Sprinkler The E. V. Houseman Cc . Hills Nursery 12144 12283 Steel Office Partitions Seed of Storm Ditches (Erosion) V i.. ARC 000025 A 19 Janar-Olnen Construction Layno-Teras Co., Ltd. Ole Peterson, Inc. E. C. Pritchett Co. Santa Fe Tank & Tower Co. Wb. A. Snith Constxnxstion Company Ferry D. Sr-eed Southern Petals Mfg. Co., Inc. Trinity Fainting Co. il. F. Zachry Company V"s3tern tut '''proofing Co., Inc. S C i .1l0o3.036 COFTRACT KIT fit: 12293 11776 11930 12254 12150 121C6 1227.8 12437 12145 11820 12A48 12476 VdseeUaneous Sheet Votnl V"ork Water wells Dock, Steel arxi F^chnnical Erect ion in Carl>:n Plant. T'echanicnl Erection in Fachine Shop Savage Disposal Scrubber Tovers Railroad Repairs Miscallana -as Viork Installation and Recorditioning Cafeteria liruipront Painting Savors and Grading Waterproof of Reservoir Seeding and Sodding APC 000026 A 20 INTERESTING FACTS REGARDING TOT-'L ilJ/JTTITFJS OF VARIHNG Cf)?:STTuCTTO!? VAT-y.I/j, : USED Concrete Struetin:cl Sta-el Erected Consolidated Western Steel Ole Paterson Buildinr A1mad nun - All BuildJ.re3 Siding Roofing Aluninun Fus Engine House Area ' Potroon Aroa Miscellaneous Stacks Breeching 1,600# each 840.-' each TCT/1 ALUMINUM Aluminum Sash Installed Glazing - Factory Type Other Type Totrl Floor Area All luildings, including throe Cuonaets 13A, 15A end Construction Office 2,460 linployed at Peak of Construction 62,650.29 cu. yds. 13,927.5 tons 1.903.5 Tons 15,830-0 Tons 649,810 J&&71. 998,847 Lbs* Lbs* Lbs* 802,215 5,450,922 Lbs. Lbs. Lbs. 216,000 33.6,800 6,766,569 112,706 43,464 3,086 Lbs. Lbs. Lbs. Lbs. 3q. Ft Lights Sq; Ft 949,669.61 4jG* Ft, t J*t APC 000027 ------- a Original Construction Organization Name Responsibility C. H. Keefer Construction Superintendent R. A. Seyle Assistant Construction Superintendent J. F. Thompson Construction Purchasing Agent J. V . Mason Construction Office Manager E. S. Boswell Construction Storekeeper W. P. Watson Construction Property Accountant L. C. Drapela Engineer - Electrical and Engine House T. V". Weaver Engineer - Engine House Mechanical and Piping L. J. Larkin Engineer - Superstructure Construction R. A. Rosenquest Engineer - Painting and Built-up Roofing J. C. Caraway Engineer - Bus Fabrication and Erection J. G. Covington Engineer - Substructure, Field Party and Misc. J. M. Gerbig Engineer - Potroom Mechanical and Piping T. J. Sherman Engineer - Plant Electrical H. C. Barber Engineer - Engine House Electrical Miscellaneous Data 83,924 Cu. Yds. dirt removed from 6th Line area, (includes 3,926 yds. gumbo from potroom area). 19,530 Cu. Yds. concrete placed. 4,490.72 Tone structural steel erected. 972. 56 Tons aluminum bus 9.43 Acres added to plant fenced area. 1 - 21. 1 APC 000028 POINT COMFORT WORKS 1951 Smelting Extention General In 1950 the Government urged the aluminum industry to proceed with a large expansion program, and late in the year Management approved a two potline addition to the Point Comfort Works to provide a portion of Alcoa's part in the requested expansion. Request for Authorisation P-1773 for two potlines and associated facilities necessary to increase Point Comfort primary aluminum production by approximately 39, 000 tons annually was issued December 4, 1950 and approved by Authorization TR-21983 on December 8, 1950. To encourage this expansion the Government authorized the depreciation, for tax purposes, of 80 per cent of the cost of the facilities over a five year period. Engine houses, potrooms and complementary buildings, and extensions to existing buildings were constructed similar to comparable structures of the original plant. Twelve cylinder radial gas engines were used for power generation, thus requiring six less engines and shorter engine house buildings. Gumbo removal and grading of the site was begun early in January of 1951 and was completed during April, 1951. At 8:54 a.m. on February 26, 1952 the pots in Line 4S were ready for baking-in and Engine House 11 was cut Li. Engine House 63 was cut in at 8:22 a.m. on May 6, 1952 for Line 5S. Except for the ingot casting facilities, all major construction was essentially complete at the end of August 1952 and the Authorization was closed September, 1952. Authorization TR-24984 was issued September 17, 1952 for the completion 1-21.2 . APC 000029 A 1951 Continued of the work originally approved. The principal facilities authorized for this extension were: 2 Engine Houses, size 55 feet by 481 feet, complete with 74 engines, generators and auxiliaries. 8 Potrooms, size 38 feet by 984 feet, complete with 282 Soderberg pots and auxiliaries. 180 6ot extensions to Building 19 and 2 D.C. Ingot casting units complete with related facilities. 100 foot extension to coke storage building. 3 - 23 feet 6 inch I.D. tar storage tanks. 1 - 75 foot dia, ore storage tank and auxiliaries. 125 foot extension to material handling building. 1 Electric maintenance building, size 40 feet by 80 feet. 54 foot extension to wash and locker building. Additional lagoon for scrubber water system. Necessary additions to general service facilities. Temporary Facilities The Quonset building used as an office for the original plant construction was not being used by Operations and was assigned to construction for similar use. Two 40 by 180 foot Quonset buildings were constructed north of the Engine House 63 site for stores use. One 32 by 64 foot Quonset was constructed on the west side of Engine House 6 3 for bus fabrication use by the electrical contractor. small frame building was constructed inside the northwest corner of the plant fence for first aid and plant protection use. 1-21.3 APC 000030 1951 Continued' A temporary shelled parking lot was provided for contractor's employees. General facilities such as water, compressed air, 440 volt power, sanitary sewer, roads, railroads, etc., were provided for temporary use. Completion Date for Major Facilities as reported to the Government FacUlty Completion Pate Potrooms 28-34 (Line 4) 2/52 Potrooms 66-72 (Line 5) 4/52 Engine House 11 3/52 Engine House 63 4/52 Soderberg Pots - Line 4 3/52 Soderberg Pots - Line 5 5/52 Nordberg Engines (Final Engine) 6/52 1 - 21.4 APC 000031 IS B u ilt-u p Roofing. Seline Sheet Metal W orks <uo0 oa U 8a2e. i 8 8sA o u E u JB Uu a B fva O, aV 0, V P^ oo o+p* o O O 4fm8a* f3a 3 4M+ u 5 U ts .4 o (EA u fa o B* oE <J O 6 *o> A 4> 6* o O o 5 o 4*4 Q u Va to o >fa4 to o A fa (fa rBt u A o to o fVa Ivt >4 6 3 HO St < W Q U<o 468222 vo z Aa uN U i) a7 P (M *no rvf> pp ctu <o t- --4 sO n> o in m O' O' --*4 *Q o vO O' m O' O' 00 n A 0 -o ^ e* e e* * rN --m4 O' ~> e* O' rm o>o m rvj o 40 p *n 4 *n o m 4 "O 03 r m m <<o 4 'T 40 r* m 4 >msoo 0 O' m vO e m O' $ fua Jfai 11 uz o<OMo' o*On' >oo fOM n0l >O0' rN- M4 0(M0 40 o 0O0m0' >fo M *00 1 - 21.5 2907 P*4 40m N mm O' N oin I0U0 O' 3 <M APC 000032 A Wood insulation in potrooms u9 uthu*4t I H > Q <8 1 i 5 &s *o h> JO .03+ 3 s9 a f 4* i 8 w S *3 l u 2 V4 iI s Corpus C h ris t! Sash It Door Co. *ohui 6 g u wo aa U n 4OuM- a oo *2 J3 u UM, tTaVJS 3H ao in oo r4 oo-C0O o O Jil Uh4i JhfeO** 8O D uz om N 4MO** a u1 .5 E o u g 8 8 o u a 6 5a X o hi *8 8 * U S <C co oWH o 4f-* vv4OOO*' (* 4* ** NO co 4t"* oi o 4* cm nmj f" 1CO4 4 4* 00n00a * n*ini >sooo wr~- o aO' CS 4 <0 ta- 4* 4* 4* 4* 0m*04 CO viinnO 4CO* 4> vocO4co 4 4MOO*'' *4 ofinn 0o1r~04 MOrs4j' omo14 omo*4> 1 - 21.6 * 4*444 3220 486597 APC 000033 8 M*l P rin cip a l C ontractor - Continued u Vo z lu 2-8 OiCnO' x0O0 no jo oniinnj 00 O' oNin m tn O Z NM vnO 1 - 21.7 APC 000034 ' * v : **r April 10, 1952 UILDlTTr NUMBERS - POUT? COMFORT WORKS .7 o. 1 - Office - Cafeteria --Gate" House: - Gate House 4 - Pot Roont 4a,B,C- Passageways 4D,E - Toilet Room 4g - Gas Scrubber 5 Engine House 5A . - Control House 5B - - Walkway 5C . - Main Circuit Breaker House 5D . . - GiL House 6' i - Pet Room 6A,B,C- Passageways 6D,E - Toilet Room 7' 7k,B 7C 7D . - Engine House - Tie Circuit Breaker Houses - Main Circuit Breaker House -. Walkway 8 . - Pot.. Rootr. 8A*BfCr-^Passageways - - 8G. --Gas-Scrubber :.. . ' . 9 -Engine House 9A . - Control House; 9B' . - Walkway 9C v - Main: Circuit Breaker House 9D : ' v -^Alunina- Reactivator-. . 9E;-/.- 94 'Power' Maintenance Shop; : . 5**;}sif*' * VS -sz. ' 'v ft *-&&& Walkway *** v ** fs# . :?r: V ' . / *. *--- ;x APC 000035 BUILDING DUMPERS - POINT COMFORT V/ORRC (No--t 1 : . ' . 1 it -- ' . . v.-' ^ r'"- _ . . ........ i.c' _ . ,, .. _ .'! 1 '.i . 14D,K - :iorv- _ :j. ------ . ----- -- - Toilet Moons 15 15A 1 cj2 - Stores - Storos-North Quloonssoett NNuutt -- CCoOoO tr) Moo Pl'- - S torcs-viionsc t Hliuutt- - ii II II Itorage -Quonset Nut -orts- Quonset Nut-N.E. pi Ports- Quonset Hut-;:.;:. PI - Pet peer., J o. -- .p T- 3 c n r c, V S l':. G - (\ -t ^ L! c i'*jj o (j r> T' 1/ - Nash cr Locke- 18 1J.'`t * p i Pw loD,M in? 10H in -* </ m 20 ' 20A,B,C 203,0 20G Pot" Room - ?3SU3revi\V3 - Toilet ?.oor:o -- ' *o r.ori .ol ri* - oi - caret:.- _ I'etsl C torn;-! - >l'i'a. ^r* *r*j rr.-v; G b.a..^>r -- - Pot Room - Passageways . - Toilet Rooms -- Gas Ccrub'bor 21 22 22A,B,C 220,E ,. - V/a sh Rc Lee Me _ Pot Room - Passageways - Toilet Rooms ; '-- Lit Station :';.n;-2!tt^r;:;;:Vy>^G'as4apEubber/`' - '-Av.l -^ . s " it .2 ;-^.Ty. ,* - v ; *'v.' ?J .' * . ' .*.' civ !M GvlM .. > .tySi:. ',p r lli^3S^i-i^v.5ewagei:lilsp'DsaI;MElant-:... A;-'-.- :. -.T.^ 'T'i'--'2Sfc^-?.l^^Ch3j6rinator-;House'''-~ Sewag^Dispoffai'"* Planter?** ...: - j.'- V .. . _ ,;\ .. i* iiT -m'"Vrir--*-'i O:-*"V*''-'-- > * Vt: ' .>*u`,.v*-- *%M V.--. ' . ' W ' ` M-'-T' In-1'--*v<,~';-i|,',,< APC 000036 '0 63 . 63A,: 63c Engine-.House. , . Tie .Circuit Breaker House - Circuit Breaker House % POINT CCMFCRT WORKS OaiERAL HISTCRT 1952 The developments of the plant's third year of operations were centered around four major events. 1. The completion and starting of the fourth and fifth reduction lines* 2* The changeover of unions iron the C.I.O. Steelworkers to the A.F.L. Aluminum Council. 3* The beginning of construction of the holding furnaces and B.C. easting equijaunt. U* The formation of a. basic experimental program designed to develop the Vertical Spike Suspension type potrooas into e more adaptable production unit. These events were the primary coneam of the plant's supervisory personnel during 1952. The completion of construction of Potlines 1*S and 5S brought to an end the large scale construction program which had been in progress for 18 months. Further it added to the facilities both a new design of engine and a further development of the V.S.S. typo pot. Both have required the consideration and attention normally required of aew types of production facilities. Attendant to these units was the usual problem of training a large group of new people to operate the equipment. The changing of unions from the C.I.O. to the A.F.L. # accomplished by on election late in 1951# brought on the contract negotiations neoesssry with each change in union type. Because of wage stabilization, it was necessary to prolong these discussions over a six months period during which time much was accomplished to change the attitude of the employeea from anti-company to pro-eoapany. The labor relations greatly improved with these negotiations and the stabilisation of the work force and lower labor turnover. 1-22 APC 000039 1955 Continued on all parts. A record was kept on the wear of all bearings, pistons, gears, thrust shoes, etc. A good picture was gathered from these two units as to show us the way all the 11-eylinder engines are wearing. No trouble was found on either unit. The exhaust leakage on 12-cylinder engines is still a problem. The tests which have been run on spring loading the flanges are encouraging. Further tests have been delayed until we obtain operating data on expansion joints in the engines in Building 65. Lubrication Sun Oil Company's Test Oil No. 7 was evaluated on the full scale engine oil evaluating program, testing oils in the 70-80 viscosity index range. The Medium V. 1. Sim Test Oil No. 7 was evaluated over a six-month period with a minimum of wear and carbon deposits. Due to this good showing of the Sun Oil, the Sinclair Medium V. I. Range Oil No. 9157 six monthr. evaluation test was started in November to confirm the Sun Oil test results. To correct an unsatisfactory method of filling engine cylinder force feed lubricators, an automatic fill system was designed during 1954 and im proved on during 1955. The new power house, Building 65, has the auto matic fill system on all the twenty-six new units. During 1955 we had twentyone old units operating with the automatic fill system. After a number of inspections and discussions it was decided to set up a new anti-friction bearing lubrication program. The lubrication 3-35 APC 000125 1955 Continued practise to be followed in the future is ae follows: No bearing will be lubricated until the motor ie set up on a re conditioning program with the exception of the heat exchanger I motor bearings which will continue to be lubricated during the routine periods. In order to find another source of supply, tests were started in 1954 and continued during 1955 to find different brands of filter cartridges which would give the same performance as our present Hilliard cartridges. Hilliard Corporation introduced a new type full flow oil cartridge which gives die same performance as our present cartridge and is considerably cheaper. By using an adapter this new type cartridge was installed in our nsw power house, Building 65. An authorisation was approved during 1955 to purchase the adapter to convert our present filter' cartridges to the new type in Power Housee 11 and 63. This program will be started in 1956. There was one change made during 1955 in power house cils. Texas Company's URSA-P40 Oil (our ML 689) was discontinued in Building 7, being replaced with Sun Dynavis 600 Oil. The twe engine cils now being used and their location as to the power house using that oil are: Our ML 692 - Gulf Parvis H Power Houses 11, 63 and 65 Our ML 692 - Sun Dynavis 600 Power Houses 5, 7, and 9 1955 Expansion The year was one c.' expansion at the Point Comfort Works. Power 3-36 APC 000126 a 1955 Continued Department expansion included the construction of an additional power house. Building 65, with equipment and extension of existing services. Twenty-six new power generating units were installed in Building 65. Their major components were Nordberg, 12-cylinder radial engines and Elliott 1400 KV.' D. C. generators. Sin additional generating units which had formerly been installed in Buildings 11 and 63 were also installed in Building 65. Three generating units were moved from Building 11 and three generating units were moved from Building 65. Of these six units, ail auxiliary components were moved except foundations, stack bases, ex haust silencere and air washer pumps. The new power house is similar to those built in the 1951 expansion with seme minor changes. Generators and some auxiliary equipment were slightly up-rated. An automatic unit load balancing and unit load current logging cubicle was installed to do automatically the major portion c: the duties performed for other power house buildings by a control room operator. The water circulating through the air washers is pumped by lour ci:cuLating pumps instead of the individual unit circulating pumps used in our other power house buildings. Several additional substitutions of aluminum for steel ing were made. Welding was substituted for clamping cn the main D. C. bus system. Two additional bays were provided In the new powerhouse for the installation of a General Motors generating unit. This unit was not installed by the construction contractors but will be installed 3-37 APC 000127 1955 Continued by our maintenance personnel during the first half of 1956. The new power house building wae essentially complete an December 27, 1955, at which time it was placed in operation. The new power house. Building 65, was staffed with operators from our other power house buildings and no operating difficulties were exper ienced when the power house was placed in operation. Miscellaneous Data Average No. of employees 138 Average No. of generating units in operation 169 Average D. C. power load 18f, 324 KV.' Total power generated 1, 605, 695,843 KWH 3-38 APC 000128 POINT CCHFCRT WCEKS HECHAHICAL DEPARTMENT 1950 I. OPERATIONS Building #1 Main Office During the aparing end fell months, the air conditioning system being only soul-automatic, it was necessary quite often to change txca winter operation to suimer operation end vice versa. The temperature at plantsite depends quite a bit onthe direction from which the wind blows. When the wind blows from the north, the temperature can drop as much as 20 in a natter of 2 or 3 hours. Conversely, when the wind blows from the south, the temperature can goup as many degrees in about the same length of tine. Therefore, we found itdifficult to keep the occupants of Building 1 satis fied as to heating and cooling during these months, especially during April and November. plan to install controls which will automatically change the system over from euaaor to winter operation and vice versa. Potrooas lt-26 One of our big B 4t M costs throughout the year was that of maintaining crust busters. For sake of comparisonj during March 1950 a cost of (2,266.08 (one line in operation) was charged against P. 2c H on crust blisters, and (10,633.90 was charged for December (three lines in operation). Efforts will be extended to cut these costs to a minimum, which for 3 line operation should be about $6,000 per month. Building r29 it 29A - Lime Storage - Lagoon The first car of quick lime was unloaded to tank storage. Building 29, on the afternoon of January 2iu On January 25, we began filling the lagoon at 2130 P.K. and had it completely filled by 9i00 A.H. January 27* During the Initial filling, lime and calcium chloride were added to the water. The quick lime was added at a rate of 32li lbs. per hour, and the li - 1 APC 000129 19S0 Continued calcium chloride vu added at a rate of 220 lbs. per hour, the water flow at 1200 gpn. On January 27, this equipment was ready for continuous operation with the starting of potline one. The ph of the lagoon water was 8.6 Initially. On February 3rd, the scrubber system was started and the scrubbers serving potline fl were placed in operation. The system was run inter mittently under manual operation during tho period from February 3 to February 20, and on continuous operation from February 21 to March 9. On ^*arch 9$ the line slaker was placed on automatic control and tied in with the return pump, the timer set for 6 minutes maximum time after tlie scrubber return pump in building ,"33 had cut out* -e found it necessary to shut down the sinker approximately every two (2) weeks for cleaning in order to assure Good operation of the equipment. This could be done without shutting down the scrubbers. Potroas .'crubberB It was found that the best time to change the spray heads in the scrubbers was at night since men working in the bright sunlight were subject to burning from creosote and pitch fumes in tho washers. - e also found that the calcium carbonate tended to build up in the small l/hn die. monel piping as well as in the spray nozzles* When tho nozzles were changed in Line 25, wo found that those of stainless steel were holding up well with practically no vear| those of hardened steel, fairly well) while those of cast Iron were badly worn and corroded* The timer for tho automatic intermittent operation of the chlorinator was installed in October* Previous to this time, the Chlorinator was operated manually. h-2 APC 000130 1950 Continued Building #51 Boiler & Compressor Roan When using brackish water in the boiler feed, the Nalco treatment with frequent blow downs perfomed as we had anticipated, permitting very little scale build-up on boiler tubes* During February, the boiler feed to the 300 R*P* boilers was changed to distilled water and the Nalco treatment diecontinued* Howwrer, the 125 H*P* boilers continued to use the Nalco treatment as brackish water was used far feed water to them* During the first pert of the year, gas meters and the steam flow meters were frequently out of adjustment* Thus ve were unable to obtain reliable readings from either and as a result cannot depend too much on the efficiency readings for this period* In April, ve calculated the prooess steam boilers efficiency with an orsat apparatus and flue gas temperatures. This efficiency was approximately 80 When the Pittsburgh Equitable Motor Company's engineer came in May and corrected the meter, the calculated boiler efficiency was 70% using steam flow and gas meter readings as the basis far calculation* During the strike, ihich began on August 2U, the boilers and compressors were operated with engineers as operators* This was done from August 2h to August 28 when at In 00 P.N. the regular operators returned to the job* This was a temporary measure) however, as on August 31 at lDtlS P*K., the boilrrs end compressors were shut down for the duration of the strike* Buildings 52, 53, 5U & 5Ua - Paste Plant Experience during the early months In 1950 Indicated that each corner of the hammers in the 3650 Dixie Kills would last for approximately 1-1/2 months, and thus that replacement would be necessary two times per year* U- 3 APC 000131 1950 Continned On the rhole, the majority of the paste plant equipment ran fairly veil daring the year vith only routine repairs and maintenance* This vae better than ve expected as most of the equipment was used equipment, haring been purchased from the Burlington, N. J. DFC plant (War Assets Administration). Building 55 - Tar Storage On August 31# the steam vas cut off in the tar storage tanka and Jacketed lines due to the strike and vas not turned an again until September 25* .t the time steam vas turned off ve vere concerned about the time required to get the pitch molten again and vere agreeably surprised at the ease with which the pitch vas roaelted'in the storage tanks and jacketed tar lines. The system vas tested out on September 26, and the valves vere found to be Tee and all indications vere that the pitch vas fluid. The ease of reheating the pitch might hare been die to the fact that hot weather prevailed and that the veil Insulated tanks and Jacketed lines had not permitted the tar to completely cool down to its freezing point. On the whole, this equipment operated satisfactorily throughout the year with minor maintenance required on steam leaks and sticking plug type tar valves. Sweat Water System and Gas Lines The initial chlorination of the sweet water system during January vas not satisfactory. This system vas rechlorinated during the first two (2) veeks in February and on February 27 vas declared safe for drinking purposes. During February, the water meter at the Midway Well vaa installed and the following sweet water consumption vas recorded for March i Midway Veil Point Comfort Village 1,286,900 gallons 1,1450 Point Comfort Works 1,285,U50 Ward Tap li - U 0" APC 000132 19$0 Continued The sweet water consumption for December was as follows! .Midway V eil U,192,0fl2 gallons Point Ccafort Village 696*000 " Point Comfort Works 3*1(96*062 " Ward Tap 0 During March, the first month in which all zosters were installed* the foliowing gas was delivered to the Services Lines (excluding Power Department use) and used as follows! Total 1*U53*09U cu. ft. Boiler House (Steam) 1,062,615 " " Boiler House (Distilled Water) 303,03U " " Heating & Mfg. Purposes 7,145 " During December the following gas was delivered to Service Lines and used as follows! Total 1*666*316 cu. ft. Boiler House (Steam) 1,152,000 * " Boiler House (Distilled V.'ater) U39,318 n Heating & Mfg. 295,000 " Oeneral During July, operation, repair, and maintenance of the Point Comfort Village Sewage Disposal Plant was assigned to the Mechanical Department. This was under the supervision of V. J. Hultquist, Jr., who took the necessary tests and qualified as a water plant operator, receiving a state issued class C certificate. The strike on August 2h added some unexpected headaches. Our main tenance crews vsre getting organised and used to working together and familiar with their work. The strike disrupted this and because of it we U-5 APC 000133 A 1950 Continued lost quite a few good sen* However, it had its good side too as we lost sooe Ben that had been agitators and who we were glad to see go* Safety-vise, August was a bad aonth far the Mechanical Department as ve had two (2) lost time accidents, one serious* The serious one occurred an August 21 when M. K. Little, a 1st Class Millwright, fell from a ladder while repairing a rolling door in the potrooos* He landed an his head, resulting in a serious head injury* On August 21, around-the-clock millwright service was instituted 7 days a week, for servicing the potroca equipment. This was instituted mainly to take care of cruet buster maintenance but these men are available for other work* During August Request for Authorisations were written far an alkaline ore reclamation Building r"37, and a paste aggregate sampling equipment installation, and the design drawings for the additional tar storage capacity at Building #5$ were completed* Ve also were able to practically complete our paint scheduling set-up, and estimate of painting requirements for the next five (5) years* This work was done primarily to determine the minimum number of painters to be employed in the fall and to get an idea of the painting requirements for 1951 so that this could be included in our 1951 Authorisation Budget* After the strike, men were recalled to work on September 22 but no men were worked until September 23 at which date a total of only 16 men reported, ten (ID) shop men, four (U) millwrights, and four (U) men in the Yard Maintenance crew* Throughout the Inst week of the month and during tho first week in October work was hampered and slowed down due to absentee ism, better than 2$% absentees each day* As of October 1** because of the strike, we had lost 8 men. In addition to 8 others whoa ve were unable to contact since the resumption of operation* a- 6 APC 000134 1950 Continued The Wildcat strike started on October U and hampered all operations from October 11 to October 2$ at which date the maintenance men who had not returned to work during the strike were called back. II. ETPEPJKHfTAL AMD DEVELOBSKT Building 0U-26 - Potrocms During August fifty-four (5U) experimental bi-metal spikes were completed in the shop for installation in tto (2) pots in Building #26. The installation however was delayed due to the strike an August 2lu In addition to the above* quite a bit of design work was completed in an effort to improve the workability of the vacuum crucibles as well as to improve end possibly eliminate the excessive maintenance on the crust break ing machines. Building r713 - Machine Shop During June* it was decided that in addition to performing regular maintenance that the shop would machine steel pieces for experimental bi-^netal spikes to be used in Building 026; and during July* two (2) pots of bi-metal spikes were turned ever to the potroom people. >JLbo during this month* the shop jigged up to make approximately 900 more bi-metal spikes to completely equip the building 026 pots with bi-ootal spikes. During August, the shop completed the set-up far machining and threading collector bars for replacement of those burned out in potroaa use. With the strike on August 23* all work was halted in the shop* and activities were not resumed until September 23. As a result of the strike and the decision to reline most of the pots in Potline 1* one of the shop's first Jobs after the strike was to thread and face the collector bars for this rellning program. U- 7 APC 000135 1?50 Continued Building *29 & 29A - Lime Starare - Lagoon During April, wo Increased the alkalinity of the lagoon water to a ph of 10.5 to 11.5 in an attempt to raise the ph of the scrubber return waters which had been running between 3.0 and 3.5. V.e found that even when the lagocn water was maintained at a ph of 11 we wore unable to increase the ph of the washer return waters above U, and that it was Impossible to add enough llae to the lagoon water and keep it in suspension through the system in order to have the washer waste water ph anywhere near neutral. Following thi3 test the ph of the lagoon was brought back to 8 which resulted in a ph of approximately 3.5 for the return water from the scrubbers. During the period when the ph of the lagoon was held at 10 or above, the forebay pumps had to te removed and cleaned of calcium carbonate deposit an the average of once every ten (10) days. This did not necessitate closing down the systemsj however, as usually only one (1) out of the four (U) pumps was cleaned at a time. During November, trouble was encountered in attaapting to adjust the slaker and lime feeder to maintain the lagoon ph within the limits desired. Apparently as had been thought before, ve wore getting short circuiting in the lagoon. Flans were made to place baffles in the lagoon to eliminate this. Potrocm Scrubbers During October the drain pits of the washers for the second and third lines were cleaned out and dried and coated with Kopcuc to prevent corrosive attack an the concrete walls exposed to the acid washer waters) and during November the drain pits of the first line washers were coated with Line Oil Company's E-120 Asphalt compound. U*8 APC 000136 19S>0 Continued Buildings #521 S3* 5h & SU-A - Paste Plant On February 1st it vae found necessary to Install a vibrator on both the internediAte and fine d ust hoppers of the Richardson Scales, as during some parts of the season, quite a bit of moisture condensed an the coke and caused it to stick in the hopper during the doping operation* Vibrators were found necessary to clear the coke from the scale hoppers during the tine they are open* III EQPUMEHT Building *1 * Main Office During January, construction crews continued to work on the installa tion and adjustment of the air conditioning equipment. This work was completed during February on the nain air conditioning units; and, with the Installation of the Quantcmeter Room Air conditioning equipment during September, all of the construction work on heating and ventilating equipment in Eldg. No* 1 was completed* The Photostat Machine and accessories were set up and in operation January 31st* The Oaalld Machine was moved from the Construction Quonset Hut during January to its permanent location in the basement of Building *1 and was in operation on January 30th. ith our reproduction equipment ve are able to handle practically all types of work Including reproduced tracings from either original tracings or blueprints. During January, the office equipment for the Engineering Department was also set up complete and in use with the exception of some filing cabinets and minor accessories* During May all of the office furniture in the plant, ineluding Building 11 and the Construction Quonset was cheeked for corrosion and damage; and where found necessary was repaired and reflaished* This work was done in our shop and by our men under the supervision of Oensral Fireproofing h-9 APC 000137 1950 Continued Company^ Mr. Ray Haught. In most eases, furniture needed repainting In spots where scoffing and scratching bad exposed the metal surface and it, in turn, had rusted. There was soae evidence that corrosion was due to perspiration froa individuals using the equipment. An evident conclusion fran the inspection was that this climate is very hard cm steel farniture. Curing August, a dark room was constructed in the basement off the west end of, and connected to the blueprint room for storage of sensitised papers and cloths. This as shown an Drawing No. LSK-2U3-T. (See Maps, Plans and Photographs). Buildings #lr-26 - Potroaas During October, a Pangbom Blast Cleaning Machine vas installed In Building ,'26 for sand blasting collector bare far the relining program. Building #13 - Machine Shop By February 13, practically all of the major tools were installed and In operation, the last one being the Buffalo Iron V.arker which grrived on this date. Same smaller tools were yet to be received, and one larger tool, the Barnes 2-Spindle Drill was installed but had not been wired. In October the 2-Spindle John Barnes drill was transferred to St. Lawrence Works for drilling bus bars. Building *33 " Reservoir & Pumping station The West reservoir was drained and construction let a contract for ironiteinr the reservoirs. This work was done during the latter part of April and the East reservoir vas drained and iranited during the first part of May. The fire pump vas Installed complete as of June 1st except for the gasoline tank. This vas not installed correctly until September 8. U - 10 APC 000138 * 1950 Continued Building #51 ~ Boiler and Compressor Room All of the equipment in this building, except the two (2) 125 H.P. boilers end accessories had been placed in operation prior to January 1st. On January 9# the two (2) 125 H.P. boilers were fired up and checked. On January 3$ the steam flow meter for thb No. 2 (East) 300 H.P. boiler was i placed in Berries. The gas meter in the lines feeding the 125 H.P. boilers Ii was installed and placed in operation on February 16. During November, the distilled water tanks in the Power Houses and the pressure tail; In the Boiler House were inspected and found contaminated with rust. The taides in the Power House were cleaned out and painted to prevent rust and the pressure tank in the boiler House was replaced with an aluminum tank of approximately the same capacity. Buildings #52, 53j 5U and 5UA - Paste P^ant On Karch 28th, baker-Perkins Mixer 07 arrived from the Burlington, N.J., DPC Plant and installation began with Ole Peterson Company doing the work. This mixer was installed complete and ran at no load June 2. It was placed on regular paste mixing service on June 5. On June 9, a paste box soap spray unit was designed and placed in operation to coat the Soderberg paste boxes with farm soap to permit ease of removal of paste by potroom crews. This system consisted of an alanite versatile type puap and two (2) 60 fan type spray nozzles. It worked very well in coating the boxes and resulted in considerable saving of material over the previous method used, mopping the soap on the box sides. During October, the brick type hoist was permanently located west of Building fi5UA with access doors opening from the mixer and batch blander floors. The drive was changed from gasoline to electric motor drive* U - 11 APC 000139 1950 Continued Building '55 ~ Tar Storage In August, a Stuard vater separator vaa Installed in the air line from the Boiler House to the ground storage pitch tank. This was done to remove vater trora the air used to agitate the pitch Inside these tanks. During December, changes were made in the steam lines for hasting tar tank cars prior to unloading, making it possible to simultaneously steaa five (5) cars. Building #$6 - Control House During August, two (2) paste aample baking furnaces were installed and placed in use. Also, the email Bekan paste mixer vas received from Alcoa Reduction Works and vas placed in service September 22. Sweet Water System On February 15, Hr. Horst, l"ales Development Division, New Kensington, advised us that it had been decided to place the Midway vater line and the Francitaa gas line under cathodic protection. Electrically Insulated joints, vere installed at the Veil, at the Point Comfort Village take-off, and at the plant entrance for the sweet water line. The design was approved by Hr. Horst and the insulated Joints installed during April. Gas Lines During November 1950 installation vas completed on a 250 barrel tank to contain distillate separated from gas passing through Lavaca Pipe Line Company'8 pressure reducing station. This proved to be a profitable addition as since that date ve have sold approximately $1,200.00 worth of distillate each month. See Drawing No. C-lll-PC muter Maps, Flans and Photographs. U- 12 APC 000140 1950 Continued IV. PERSONNEL Following is a breakdown of the average number of employees (Pittsburgh Payroll Employees Excluded) for each mcnth of 1950: January February March April May June 37 U0 Itli U9 53 6l July 63 August 76 September 53 October 61 November 70 December 77 As of January JL there were thirty-five (35) hourly paid and eleven (11) administrative and office employees in the Mechanical Department. As of December 3lot there were seventy-seven (77) hourly paid and twelve (12) administrative and office employees on the Mechanical Department roster. These were distributed as followsi Ho. of Employees No. of Empliyees January 31 1950 December 31# 1950 Auto Mechanic - 1st class Auto Hechanic - 2nd class Blacksaith 2nd Class Boiler & Compressor Attendant Laborers Layout Kan 1st class Machinist 1st class Machinist 2nd class Mech. Helper - Shop Mech. Helper - Millwrights Kech. Helper - Yard Sc Halnt. Millwrights 1st class Millwrights 2nd class Painter 2nd Class Pipefitter 1st class Tool Room Attendant Carpenter 2nd Class Truck Drivers Water Treatment Plant Operator 'Welder 1st class Welder 2nd Class Total Hourly Paid Employees Clerks Foremen Stenographer Plant Engineering & Drafting Total Administrative & Office Force 0 1 1a 2 1 2 1 7 5 0 1 h 0 0 0 0 2 1 1 2 35 2 2 1 6 11 1 0 1 U 13 o U 0 11 Hi u 3 9 3 1 1 1 2 0 1 u 77 2 3 APC 000141 1 6 " 12 Total Department U - 13 lt6 89 1950 Continued r.t the beginning of the year, the Engineering Staff was ooapoaed of one (1) Plant Engineer* Hr. R. 0. Norvillej one (1) Senior Vtaff Engineer* G. T. iTe echj one (1) Staff Engineer Aluminum Plant* b. C. Hanning; one (1) Staff Engineer - Paste Plant* R. B. Walker; one (1) Junior Staff Engineer, C. L. Pattereon| and one (1) Draftsman* A. T. McCarty. At end of year the above staff was on hand vith the exception of Mr. A. T. McCarty* draftsman* who resigned late in .ugust to return to school at Texas University, the addition of Hr. V. J. Hultquist* Jr.* vho transferred fi*on Construction to this Department on Hay 1st as staff Engineer in charge of Civil Engineering work* and hr. R. Hart vho vas promoted from Millwright 2nd Class to lard L Paint Foreman. We had a total of 39 separations frost the department during 1950* 38 hourly and one draftsman* or about 5Q turnover in hourly paid employees based on total number hourly employees as of December 31* Ibis high percentage was mostly due to the two strikes mentioned above. u - u* APC 000142 MECHANICAL DEPARTMENT - 1951 I. OPERATIONS Potrocms - Bulldinga #U-26 Daring the year, spike puller maintenance vas considerably reduced by repiping the hydraulic system. The new piping consisted of the use of hydraulic hoee in all places where it was possible to eliminate threaded pipe joints. We used Eastman Kfg. Company's hydraulic hose ends in this application, and they have proved satisfactory* Far the month of January, Pi & M on crust busters amounted to $13,138.82, three (3) potlines in operation. R L l' cost accumulated against the crust buster account for December vas $7,755*18. Cause of this decrease in R & K cost, ve believe can be attributed to the equipping of the crust breakers for aami-automatic operation and thereby reducing considerably the time the demolition tool is actually in operation. Bulldinga *29. 29A k 29D During December the control of the ph In the lagoon required considerable attention due to tleing in the new washers in Lines l*f. & 5S* Also Lagoon 291. vas becoming more and more silted up as the year progressed which meant ve were actually obtaining less retention time of the treated waters in the lagoon which has added to the difficulty in maintaining the proper ph control for the lagoon waters. Lagoon 29A will have to be cut out of service, drained and cleaned just as soon ac lagoon 291; is ready and can be placed in operation. Other than the difficulties mentioned above our water treatment facilities operated during the year with a minimum of maintenance* Scrubbers The potrocn scrubbers ran fairly veil during the year with little main tenance other than cleaning out of the pits and spray pipes and nosslas* U - 15 APC 000143 IP51 Continued \ e found It necessary to clean cut the pits on on average of one (1) set each 10 days and the spray noszles one (1) set each 2 months. Sweet Veter, Brackish Water and Service Gas Systoma Sweet Water Consumption March December Midway Kell U,177,800 gals. 6,532*200 gals. Point Comfort Villsgo 600,200 373,900 Point Comfort Works 3,S77,600 6,158,300 * Wsrd Tap 00 Brackish Water Consumption _ March December well Ho. 1 Veil Ho. 2 21,hl5,U00 gals. 13,297,300 3,389,100 gals. 3.355,900 " Total 3U,712,700 " 6,7U5,000 Service Lines Oas Consumption March December Boiler House (Steam) 973*061 cu. ft. 1,165,955 cu. ft, Boiler House (List. Water) U75,396 " " 52U,210 " - Heating and Mfg. 112,375 " " 93,555 " " Total 1,560,835 " 1,783,720 " II. HTFLP.EENTAL u DEVELOR-IUIT Potroom Buildings fir-26 During January and February, Mechanical crews revised demolition tool mountings and back heads on crust blisters to provide for semiautomatic operation of the demolition tool. This step was taken in an effort to find a solution to the breakage of demolition tool front heads and cylinders. This breakage was thought to hove been caused by the tool continuing to opcrato aftor going through the pot crust. This experiment proved satis factory a program was begun to change over all the aruat busters to semi-automatic operation. This program was completed late in the fall of 1* - 16 APC 000144 1951 continued 1951 and now all of our crust breakers are equipped with this feature* During March, ve received and installed for test one (1) Cisco RC80 paving breaker made by Cisco Division of the Reed Roller Cit Company. This tool proved to be satisfactory and since the cylinder is a machined part whereas the CP-117 cylinder is a forging of un-unifora vail thickness ! and because ve found other features of the R*C* 80 tool of a better design, we began a program to change over to the R.C* 80 tool as fast as replacements were required on CP-117 equipped crust breakers. By the end of the year approximately $0% of our erupt breakers were equipped with R.C. 80 demolition tools. Then installed, the Cleco tool was altered as follows! fronthead to take 1-1/2" round steel shank, latch for retaining bit moved from tool mounting bracket, and cylinder provided with exhaust ports used upward to keep from blowing ore into the face of the operator. During November, tests were made on spike puller controls in Building l?li. Investigating the poesible uae of solenoids for operating the spike pullers. These solenoids would eliminate the Elllnwood slave units and hoses which connected the slave units on the spike pullers to the master units in the crone cabs. These hoses required expensive counterweights and were a cause of considerable maintenance even with our best efforts to counter weight then and keep them out of the way. The first test of solenoids did not prove satisfactory as they did not have sufficient pull to operate the valves. The first solenoids used had 60 lb. pull and in order to get a successful installation with solenoids, we found it necessary to go to larger ones with 10$ lb. pull. The larger solenoids proved quite satisfactory and os a result of this development all of the spike pullers in the new lines were ordered to be equipped with solenoid operated controls* These were to be installed early in 2952m U - 17 APC 000145 1951 Continued During August, Mechanical crews completed fabricated bi-snetal spikes far Building 026 and coopleted changing from all steel spikes to bi-aetal spikes in thirty-two (32) pots of this building* During the year, the ore bin gates were reversed in an effort to eliminate ore from piling up on the bottom flange of the electrode casings* This did not vork as expected due to the magnetic field about the pot i&ich tended to hold the gates open once they were opened to place ore on the pots* Various experiments were aade using counterweights and springs* with the springs doing the better job of relieving the situation* The proper tension spring vaa not found until late in the year at which tine a program was begun to so equip the ore bins on all pots* This program should be completed early in 1952* Buildings 029* 29A & 29E On December Ujtfa wooden baffles were installed in lagoon 0295* These were installed in an effort to eliminate short-circuiting of the scrubber return waters in the lagoon* It will not bo known whether they are satisfactory until same time in 1952 as the lagoon will not be used until early 1952* III* ECUIFKD'T Main Office. Building 01 During June* Mechanical crews began alterations and additions to provide offices and a geology lab for Alcoa Mining Company. These offices are located in the basement* SDUth end* Also provided was a new man door in the south end of the building to provide acoess to tbs office parking lot* and the card rack and time clock removed from the main floor to the basement. These additions are as indicated on Drawing #0179~FC* See Maps* Plans* and Photographs* li - 18 APC 000146 A 1951 Continued Also during Juno* our crews began work Installing partitions and other things necessary in the northeast corner of the building to provide additional office space for the Employment Section of the Personnel Department* See Dvg. #D-178-PC. Both jobs were to be completed in January 1952* Buildings U-26 Potroomg On January 11, Mechanical crews completed fabrication of a spare jumper bus for one (1) pot to be used temporarily when one of the cathode bus sections must be removed for repair* On September 1st, a new building, #37, was erected by the Mechanical Department to be used to crush and store alkaline ore for re-une In the potrooms. The bulk of the work (of installing and building proper) was contracted; however, the equipment vaa set in place and installed by mechanical crews* See Drawings #A-29785 and A-118-PC, Maps, Plans and Photographs. Equipment installed consisted of a 21*" pan conveyor #30, #3030 Dixie Hammer Mill and 11*" screw conveyor #28* A dust collecting system was installed to keep working conditions in this building tolerable. This system is show on the prints in the appendix hereto. See Dvg. #A-29793 Maps, Plans and Photographs. Late in March an authorization request was written to change over all of the steel spikes in Lines 1S-3S excepting Building #26 to bi-metal spikes. This work was authorized on April 27 and designs completed and arrangements made to handle the machining and other components of the job by July 15. During July this program was actively underway with our crevB handling the revisions complete to the spike clamps while the work of machining both the steel and aluminum sections of the spikes was contracted to outelde vendors. The aluminum sections were both rolled and machined at Maasena Works and the U - 19 APC 000147 19$1 Continued bottom steel sections machined by Hunt Tool Company, Houston, and 50% by Coastal Iron Works, Corpus Christi* Since this vas such a large program and for insurance purposes and to get the job completed on schedule, it vas deemed best to split the vork of machining the steel sections between two (2) concerns rather than give all of the work to the lowest bidder* The difference in price between the lowest bidder was not sufficient to warrant our taking a chance on placing all of the job in one shop* V.e equipped our 20 ton -Lufkin trailer and set up a program whereby we hauled the all-rteel spikes to Houston and Carpus Christ! to be cut and remachlned and returned the finished sections trom these locations to the plant. Tho first machined spike sections were received here during the week of August 18 and by September 1 this program vas in full swing. To change the claopo to fit the new bi-metal spikes it was necessary to remove them from the pots and completely rework them in our shop. ThiB job vas begun during the week of July 28 and vas completed on December 31, a total of 10,U72 being removed, revised, and replaced in the pots during this tine. Also, it vas necessary to reraelt and recast all of the V-blocks. V.e desipjied a new V-block and molds but had the actual remelting and casting of the new V-blocks done by a small foundry in Carpus Christi. This Job vas begun in August and progressed at a rate which was paced by the machining of the bi-uBtal spikes. In all cases, ve wore able to have V-blocks avail able when bi-metal spikes were ready for installation in the pots* A total of 10,000 V-blocks were recast on this program* The weight of the revised V-blockB being less than that of the old V-blocks, we ended up with a fgn*~n mount of aluminum which ve could return to the pots* U - 20 APC 000148 1951 Continged The shop assembled the top and bottom sections of the bi-metal spikes, using the wheel press for this job. Not only did ve convert the 10,550 steel spikes to bi-metal spikes in Lines lS-35, (except building /J26 which had previously been converted to bi-netal spikes of a different design), but ve also utilised the scrap steel from the operation to sake the bottom or steel spike sections for the two (2) new potlines liS-5S and assembled these vith the aluminum top sections in our shop. The work for the nev lines was done under shop orders issued by the Construction Division and the machining of the steel spike sections vas done by the same shops that machined our spike sections for the old lines. The top secticn of the all steel spikes vas salvaged for use in the nev lines, this vay ve were able to use the old heads and save considerable machining expense* The steel sections of the bi-metal spikes in the old lines were 5" in dia. whereas those in the new lines were machined to U-l/2" dia. During November completed fabrication of five (5) individual pot baking shunts, these to be used in baking in individual pots under the relining program. Buildings 5, 7 & 9 During August a new Building, 09D was erected by the Mechanical Deportment and various items of equipment vere installed by Mechanical crews to provide reactivation of activated alumina used in engine rocm oil filters. '*o Drawings jfA-26U5 and A-26118. <?ee Maps, Flans and Photographs* Buildings m it 13-A On July 30 an Oxweld shape cutting machine vas Installed in Building iH.3. This vas purchased primarily far the bi-metal spike conversion program to burn out clamps and vas promptly put to work eight hours a day on this job* U - 21 APC 000149 1951 Continued On September 7, the millwright shop vas moved from Building #52 to the vest half of Building #13-A. This to give the Paste Plant more t storage room in Building #52 to handle materials for our expanded I facilities. Building #13-A space vas formerly used as a garage. It vas altered, and various equipment vas added to equip It far use ms a Millwright Shop. Also, installed vas a 10* x ID* office for the Millwright Foreman. See Drawing #Ol58PC, Maps, Plans and Photographs. Cn December 26 a new Delta site 6 inch Jointer vas Installed in the Carpenter Shop, east half of Building #1>-A. During the year, the equipment and the machine tools were rearranged in Building #13 to provide more streamlined flow of work and more efficient use of the facilities. Also a concrete pad vas installed south of the building to Increase the layout area of finished and partly finished jobs. Building #19 In November, Mechanical crfcvs began construction of women's toilet facilities in Building #19 for use of the female employees in the Shipping Department. This work to be completed early in 1952. Buildings #29. 2P-A & 29-B During August, Construction crews began installation of a new flume and settling lagoon and forebay #29-E to supplement lagoon #29-A. In addition, three (3) new pumps were purchased to bring the total number of pumps to seven (7). Vork on this project vas expected to be completed early in 1952 at ihich time the #29~A lagoon would be drained end cleaned out, end the 29-E lagoon placed in use to handle scrubber return waters. Building #51 Boiler & Compressor Room During May, the It" cast iron drain line returning eooling water from the compressor to Building #33 was removed and replaced with a 6" steel It - 22 APC 000150 A 1951 Continued voided line* This vaa necessary because of continual leaks in the U" Bell St Spigot line* In June a aodel #502 iola Catalyst unit vaa installed in the aftercooling system. This was done to eliminate scale build up an the pipes by keeping various minerals in suspension* The Building #50 Air Conditioning system vas also tied into this unit during June* On October 1st, ve completed revising the distilled water system in the Boiler House end Engine Rooms* This consisted of adding an aluminum pressure tank to the Boilo' House, cleaning and painting the 500 gallon tank in the Boiler House) and cleaning and painting the three (3) distilled water tanks in the Engine Rooms* On November 2, Mechanical crews completed installation of a Strothers WoHe heat exchanger and an Ingersoll Rand aftercooler in the compressed air system. This additional aftercooler vas (necessary because with the ] 'J evaporative typo Niagara aftercooler Initially installed here, the air vas not being sufficiently cooled and ve were getting considerable condensation of moisture in the air lines feeding the potrocm. This resulted in faulty operation cf the air tools and the vacuum tapping equipment. > itb the additional . demand for air required for the tvo (2) nev potlines, it vas imperative that the problem of moisture in the air be eliminated as it would increase with the added load. Thus, the nev condenser type aftercooler vas purchased as part of the new construction program and installed. This additional aftercooler vas so installed that it could be used separately or in series with the Niagara aftercooler. Normally the two (2) aftercoolers are used in series. The results of this Installation have been most gratifying as ve have practically eliminated this problem, .lines the compressor cooling water in our original installation vas in a dosed system, cooled by circu lation through the Niagara afterooolar, ve found it necessary to install a U - 23 APC 000151 1951 Continued Struthers Wells heat exchanger vhen ve installed the Ingereoll Rand aftereooler to give us complete flexibility of operation, that is, so that ve could continue to operate our compressors whenever the Niagara aftereooler vas down for cleaning and servicing* Buildings #52, 53, 5U, 5U-A, 55 & 56 On January 26, a motor operated exhaust ventilator vas installed in the roof of the primary crushing and unloading facilities south end of Building #52, and the building vas designated as Building >2-A, to distinguis h it and its facilities from Building #52* On January 26, the 3030 Dixie Kill # vhich had been installed in the plugging material system, Buildipg #5U, vas removed and installed In the nev alkaline ore crushing building, #37* Also removed vers pan conveyor #35 and screw conveyor #28, these to be installed with the Dixie Kill* Alterations were completed on this equipment and it vas ready to be reinstalled in Building #37, March 31* On February 20, the foundation vas completed for a new 60,000 gallon capacity tar storage tank No* 6* This tank differod from our present tanks both in that It had three (3) times the capacity of any ve had heretofore used and also it vas to be a vertical tank, all of our other tanks being of the horisontal type* The vertical tank vas selected for economy* In this installation ve were able to save approximately $5,000.00 over a horizontal tank of the same capacity. Cta March 10, this tank vas completely set by Chicago Bridge and Iron and on July 27 vas placed in service. On February 28 a Black, Bivalla 2c Bryson tank car unloading platform vas installed at Building #55 to give the operator safe access to the domes of tar tank cars* During April much work vas done by Stephena-Adamsm Company in an attempt to make their car pullers work at Buildings #52 and Ob April 12 their earviee representative had exhausted every effort and stated that he U - 2U APC 000152 1951 Continged could see no way of asking the csr pullers work ss designed by Stephens- Adamson. Flsns were nade to alter the electric hook-up which should relieve the difficulty. This work won't be completed until early in 1952 because of slow delivery of the electrical equipment required. Curing his visit* however, Stephens-Adamson's hr. Dobscha was able to pit the Building #U> car puller in good operating condition and it has worked satisfactorily since that time. Under the 1952 expansion authorisation TR-21983* a new paste mixer if8, discharge hopper, screw conveyor* and dumping station complete with fuae control equipment woe designed end ordered for Building #5b~A by the Mechanical Department. Also* included under this authorization five (5) rotary vane feeders* an 11" measuring redler conveyor #23-B* a 12" x 7" bucket elevator #31* and a 16" dia. screw conveyor #32 were designed and ordered for installation in Building ?5U. This system was installed at the request of the operating people so that they would have an alternate means of handling both intermediate and course coke fractions from tank storage to the Richardson Scales. This installation was to give then insurance of continued operation which is required because of the increase in capacity of the plant from three (3) to five (5) lines. The redler conveyor* elevator* and screw conveyor were used from surplus equipment originally purchased fTon the Burlington, !<'. J. DPC plant. This work should be completed in April 1952. On June 11 a sample aggregate preparation unit wee installed in Building This unit consisted of an /Ills Chalmers flour type sifter for producing six (6) different sized samples tran ooke added to it. It will be used by the Paste Testing Laboratory la preparing experimental paste nixes. U - 25 APC 000153 19$1 Continued On June 29 we installed a Tineas Olsen type L compression testing machine in tbs Paata Testing Laboratory* Building On December 10* mechanical crews completed fabrication of one (1) portable plug mill (8-3A" dia. screw) to be used to extrade plugs far the potroams. This isn't the final answer as far as a plugging machine goes but is only a atop-gap measure to take care of this problem until ve hove the time to complete designs for a machine which can be operated from and on potroom cranes* to extsude the pings as needed* eliminating the use of the plug reheating fumaceB. If our Expansion Program is completed on schedule* we hope to get back to this* problem by the fall of 1952* and should be able to have something designed which will satisfy the operating people by that time. Oaa Lines On November 7* a 2" gas supply line was installed from the 3" main parallel to and north of Austin Road to Building ^13-A. This for hasting the Millwright and Carpenter Shops* weet Water System On December 27* the installation of an auxiliary drive unit for the ffl sweet water well at Midway was completed* This consisted of a gasoline driven Waukesha engine and a right angle drive with Amarillo gear head* This Installation was made to insure our water supply in case of electrical power failure such as occurred in the winter* JanuaryFebruary of this year* Also installed was a building to completely enclose the present ptsep* the right angle drive unit and the new gasoline engine. See Drawing 0B-223-FC* Maps* Plans and Photographs. Oenaral Cta December lU campleted grading and shelling the road Aram the south end of Fannin Road to the Plant Dump. U - 26 APC 000154 A 1951 Continued On December 27# the shavers in Building #21 were revised ccoplete to ecconsaodate additional employees hired Tor the work added under the 1951 Expansion. IV. PERSOKTEL Following 1s a breakdown of the average number of employees (Pittsburgh Payroll Employees excluded) for each month of 195ll January February March April May June 60 89 91 92 9U 96 July August September October November December 98 108 111 125 125 127 Ac of January 1# there were seventy-seven (77) hourly paid and twelve (12) administrative and office employees in the Mechanical Department. As of December 31# there were one hundred and twenty-five (125) hourly paid and nineteen (19) administrative and office employees on the Mechanical Department's roster. At the beginning of the year# the engineering staff was composed of Plant Engineer# R. 0. Norville# who was in Alcoa# Tennessee and Pittsburgh offices working on new design for Potlines Us and 5S# Senior Staff Engineer 0. T. Breisch, Staff Engineer Paste Plant R. B. Walker# Staff Engineer Aluminum Plant D. C. Manning# Staff Engineer Civil Engineering Work V. J. Hultquist# Jr.# and Junior Staff Engineer C. L. Patterson, ft the end of the year# the staff was as above with the following changes! January 29# 1951 J M. Thomason# and February 5# 1951# A. G. Rust were transferred from Point Comfort Power Department to this Department as Junior Staff Engineers! September 30# 1951# D. C. Manning left the Company to work for Government Civil Service at Redwood Arsenal# Huntsville# Alabama# Guided Missile Development Workj October 8# 1951# S. B. Ward was hired as Master MeohasLcj and# December 1# 1951* R. L. Schaeffer was transferred from the Power Department U - 27 APC 000155 4. 1951 Continued to this Department as a Junior Staff Engineer. On October 1, 1951* J. K. Thomason vas loaned to the Construction Division to supervise installation of Potrocn and Paste Plant equipnent, 1951 llspsnsian Program. Re is scheduled to return to our Department in April or May 1952. In 1951 we had a total of sixty-fire (65) separations from the Department or approximately forty-nine pr cent (ljf) turnover in hourly paid employees, using number employed as of December 31* Five (5) of these terminations were temporary employees, "College Boys", who were employed as laborers to work during the summer months. The large majority of the hourly turnover were helpers vho complained that our helper rates were too low, living expanses in this area too high, housing difficult and in some cases impossible to obtain. In fact, other than laborers and helpers we had only eight (6) terminations of journeymen. It - 26 APC 000156 MECHANICAL DEPARPEWT - 1952 I. OPSRATICBS Potline Expansion the sajor parte of the two-potline expansion program were completed by the Pittsburgh Construction Departaent Fbrees in the first quarter of 1952* Line 5-S having bean started on 5-8-JJ2* Ingot Casting Facilities By April 1# the foundation and floor slab for the 6-bay extension to Building No* 19 had also been completed. However* due to a steel strike* no definite construction program could be set up for the completion of this building extension* Tentative eohedules were set up on July 15* 1952contemplating a starting date of March 1* 1953* for the ingot casting department* Very little design work on the furnaces and ingot easting machine had been accomplished at this time* Ob Baptsmber 22 and 23# Messrs. Patterson and Bragrton were in Pittsburgh to discuss this project with John Horne end others* As e result of these discussions and further talks with Mr. Robey* who subse quently came to Point Comfort* the following: was plannedt 1. Attmapt to maintain the March 1st starting schedule. 2* Promises ware obtained for delivery of building steal about November 1* 1952* 3* The Mechanical Department at Point Comfort would complete Buildings No. 19 - .Scale House end No. 19 - Office sod remove the old seals house. 1*. Pittsburgh people would cnplete the design of the holding furnaces and ingot nesting machines and foundations end related equipment. Bugr would also 1st all contracts and place requisitions as fast as the design progressed. At e later date* Mr. Robey decided to send Mr* U* S* Stroud to point Comfort ee Construction Superintendent for this project* Re assumed these U - 29 APC 000157 1952 Continued duties on November 17* 1952. At the end of the year, foundations for the D. C. Pits vere veil undarvey but requisitioning of equipment was being held up because design work was not complete. Saaks Washer hater Supply Sprays and Drainage System The underground drainage system to the line 18 - 2S - 33 was found to be badly restricted due to build-up of a calcified deposit in the vitreous pipes* The lines vere freed by mechanical cleaning by the Underground Flexible Pipe Cleaning Company. This process resulted in earn damage to the vitreous pipes and it is thought that several such cleanings would destroy the usefulness of the 6" courtyard laterals* The larger trunk severs to the Building No* 33 cusp was not thought to be ouch damaged by the cleaning process* An open trench was ocnpleted for washer unit No* 2 it-G in Septeaber to replace this underground lateral* About a four-inch layer of soft material was deposited in this trench by January 1* 1953* The trench is easy to clean and premises a good solution to further underground pipe trouble* All the smoko washer towers in Lines IS - 3S wars equipped with >outoide spray risers* access platforms and spray bayonets which can be serviced fTcn the platfbrma. This work was completed in January 1953 and should make it possible to maintain the sprays in continuous good working order without exposing personnel to conditions inside the washer towers* The control of alkalinity in the recirculated spray water from the lagoon remains unsatisfactory. Largo deviations in Ph value and alkalinity occur which cannot be controlled eatisfaetarily by the present methods of lime additives* li - 30 APC 000158 1952 Continued Boiler Plant Steam dmaands bare required operating both gas fired boilers in Building No* 51 eren through the suamer months* Potable Water System A new 200 gpa (No* U) veil was completed in April 1952* 200 feet from Midway Mo. 3 veil to be used for standby Berrios* The demand for additional pure water to replace the brackish vater now being used in the evaporative pooling system in the engine houses led to planning for additional facilities* Authorisation was granted tot (1) Purchase a tract of land at Midway* (2) Brill a 500 gpm well and purchase pumping equipment, (3) Provide a power and control line from the plant to the Midway wells* As of February 1st, 1953, deed to the land had been secured and a purchase requisition placed for the well drilling and pump* Engineering work was proceeding on auxiliary equipment and power facilities* Brackish Water Supply No* 1 and No* 2 brackish well pumps on the plsntsite were pulled and overhauled in September. Considerable difficulty was encountered in pulling Mo* 2 pump due to concrete which had inadvertently been dropped in the easing at the time the pump was installed* Additional coata due to this condition were assumed by the original contractor far the pump installation* Railroad Trackage A mininrun of maintenance work was performed on plant railroad tracks* This work was done under contract by the P*C* it N.R.R. Company* Budget provision was made for rehabilitation and improved drainage of road bed in 1953* This work was begun in late December* U - 31 APC 000159 1952 Continued Plant Drainage Ounnited drainage ditches vers cleaned in September and October. Up to two feet of ailt was removed. It vae apparent that the earth shoulders of the neveat Ditch "D* were not holding op dne to failure of grace to eetabliah itself. Considerable damage to the granite was visible in August. An authorisation was obtained to regunnite damaged sections and to extend the granite two feet higher. When this Job was undertaken* much additional granite failure became apparent and further damage was caused bp heavy rains. An authorisation of 150*000.00 was requested for further repairs to Ditch "D" and for improvement and extension of shallow earth ditches daring the year 1953. navigation Channel The channel from the Pass Cavallo Port Lavaca government channel to Aluminum Coapany of America dock was redredged to e minimum depth of 9 feet during the period June 26* 1952 through July 11* 1952. All channel markers were repainted. Indications are that it will be necessary to redredge this 22*000 foot channel every two years. II. EXPERIMENTAL & DEVELOPKEKT Exposure Racks* Corrosion Samples & Rust Freventatlvee This department continued to maintain three outside exposure racks under the direction of D. 0. .rprowl* of the Aluminum Research Laboratory. Samples are mounted or taken down and sent to Aluminum Research Laboratories as directed. Cm Inside exposure rack is maintained in building No. 15 ibr testing rust preventive compound*. U - 32 APC 000160 19$2 Continued Pissing Compounds Samples of 3 types of sash glazing ccsapounda were installed in Potroca h on March 13, 1902. These materials were in good condition at the end of the year* The materials tested were as follows! Aluminum Sash Putty Aluminum Dual Glaze 0lazco Putty J-735 W* S* MoOuffle, Inc* w S. MoOuffle, Ine. Kuhn Paint Company A fourth type installed in mid 19h9 has failed* This is Tringlaze, Pittsburgh Plate Glass Company* Plastic Pipe Two-inch diameter Kraloy "D" rigid plastic pipe and fittings were used for approximately 600 feet of underground distilled water piping to the power house storage tank. It was found that the coomited Joints will not withstand temperatures carer 160 F* The high coefficient of thermal expansion of this material makes it difficult to use where vide temperature changes are involved* Hot Surface Paints Two types of silicone paint were used on smoke washer ducts to the fans* The maxi aura operating temperature is approximately 120C. Kansas Paint & Color Company's Rot Surface Aluminum straight Paint has stood up veil since September 2b, 19$2, It may be applied while the surface is hot. Hot nirface aluminum "Modified" point failed iaaediataly by alligatorlng* Mixer Hardsurfacing In April a new Paste Mixer was installed having protective veld beads welded to a steel saddle section* It is too soon to form conclusions as to vaaring ability of this type protective measure* U - 33 APC 000161 1952 Continued Crust Breakers A CP-608G5 Demolition Tool vas installed In December cn one crust breaker machine for IS - 3S. These tools hare store striking power than the CM17 or the deco RC-80 tools now in use* It would be desirable however to count these tools on a heavlar type crustbrsaker carriage* in. LOG OF MAJOR EVENTS (See Chronology)* IV. ECtTIRCTT & BOHDIKCS Compressed Air To give added air supply capacity* a new lOitO CFM (at 100 poi) Ingaraoll- Eand Air Compressor was installed during December* This boosts our full load capacity to ljl60 CFM. Drilling Bjuipaent During the year* several places of new equipment were installed in the Machine Shop. In February a It' arm z 11** diameter column Carlton Radial Drill vas Installed* This vas purchased to supplement our existing 6* x 16* diameter caiman Carlton Drill during times the 6* drill was sat up on special Jobe* and also to supplmuant the 6' drill for the normal shop load* To handle Basil drilling jobs a Uj" Delta Bench Drill was installed in March. Qaa Burning Equipment To eliminate a need far heavier transportation in "out of Shop" burning Jobs a Cushman motor soootsr stake car was purchased In April and equipped to carry a burning rig* Cleaning Equifant m June a portable acidising unit was assembled in Building 13 for uae in cleaning steam chests* condsnssrs* pumps* etc* U - 3U APC 000162 192 Continued Welding Equipment During August the welding section of the shop was provided with handling equipment* Oam 1|Q*000 lb. end one 30*000 lb. capacity car was Installed to facilitate handling of heavy steel pieces Into the welding bays from the center shop crsno area. Tracks were laid for the railroad type cars. Alsu installed were welding curtains to completely enclose the welding area* Turret Lathe In November a No. 3A Earner Swasey Turret Imthe was installed two piece crust breaker bits and other repetitive work* Relocation Facilities fc Maintenance Operations During February* the Electrical naintenanee shop was moved from the northeast five boys of Building 13 to their new electrical shop Building L9. At the sane tine the Millwright crews vers moved from the western half of Building 13A to Building 13* Changes were made to provide offices for a Master Mechanic* an additional shop clerk and the millwright foremen* The motor naintenanee and repair shop was moved into Building 13A* and the pipe fitters moved into the area vacated by the motor shop. During November and December* a wash rack end e hydraulic truck lift was installed* A con crete pad was poured on the eouth side of 13A for handling ears and trucks* Pneuaaulc Tool Repair Shop During Hay* a new repair shop was outfitted in Building 18?* for main taining all potrocn air tools and crust breakers* Material Handling Unit In August* a Iwupster Dmpstar Unit was installed on a new cab over engine truck* Tanks and trash hoppers were received for handling pleat trash to the Armp and far other material handling* h - 3$ APC 000163 A 19$2 Cantinged Hew bttlldinpg All mv building construction coapleted In 1952 ia shown co tha photostat of plant sap, drawing B-27275-PC. (Sea Maps, Plans and Photographs) Cross hatched sections show the new construction. Building 15-c, a 2,000 square foot steel Quonset building forderly used by construction forces, vss sored from tha north side of ths plant site to a location adjacent to Building 13A. The building was equipped with a sprinkler syaten and is used by tte stores departsKit for lusher storage. Completed in Septeaber 1902. Other Buildings All other buildings completed during 1952 and described as to size and use by the departmental history of the departxunt affected are as follows t Bldg. 9-8 Power department maintenance shop. Bldg. 19 3 Bay extension of ingot casting departaant. Bldg. 1?-B Metal scale bouse. Bldg. 19-C Ingot casting deparhoant offlea. Bldg. 19-D Ingot casting cooling tower. Bldg. 19-B Chlorine storage far ingot casting departaant. Lldg. 52-A Leanto for unloading crew. The old seals offS.ee in Bldg. 19 (no nunbar) was moved. V. rateCHHEl The following is a breakdown of the average nuaber of hourly and salaried employees excluding the Pittsburgh payroll, engineering office and drafting roamt U - 36 APC 000164 1952 Continued Month Hourly Salary January February March April Hey June July August September October Korqnber Deomabar 12U 128 133 128 132 lkk lkB Uj9 11*6 Ui6 152 155 5 6 6 5 5 5 8 6 7 7 7 7 Changes In Personnel Separations & Transfers from ths Department R. 0. Norrilla transferred to Alcoa September 1, 1952 V J. Rultquist left the employ of Aluminum Co. of America June 15, 1952 J. K. Thomason transferred to Vernon narks October 15, 1952 A. G* Rust transferred to Vancouver Works August 31, 1952 0. T. Brelsch transferred to Hassons Works February 15, 1952 S. W. Word left the employ of llumimaa Co. of America October 1, 1952 Hary Jo Jones left the employ of the company August 17, 1952 New Employees and Transfers to the Department A. R. Paulsen vent on Point Comfort payroll August 1, 1952 Assum'd position of Chief Mach. Engineer Sept. 1, 1952 A. E Ereyton transferred from Construction Division and became a Staff (Civil) Engineer June 1, 1952 G. E. Brubaker transferred from the Power Dept, and beenno n staff Engineer October 1, 1952 n. rnith transferred free the Power Dept, and became a Staff Engineer November 1, 1952 0. AHereon was promoted from Maintenance Foreman to Hester Mechanic on October 1, 1952 Carl Jacobs was promoted from Assistant Maintenance Foramen to Maintenance Foremen October 1, 1952 k- 37 APC 000165 A 1952 Continued M* M. Little ns promoted fraa Millwright 1st Class to Assistant Maintenance Forenan May 26, 1952 0. Kaosay was promoted froa Painter to Assistant Yard Forsnan January 7# 1952 Charles P* Jackson was eaployed as a Senior Draftsmen Septsober 1, 1952 Clark Arnold was aaployed as a Senior Draftsman Hoveaber 3, 1952 Alfred 0* Fields was aaployed as an Expediter for the Construction Dept, to assist in the Construction of Itagot casting Facilities 10-7-52. V. s. Stroud was re-assigned iron the Wanatehee Construction Project to duty as Construction 3opt. for the P* C. Ingot Casting Project on Now* 17, 1952* 1.-38 APC 000166 MECHANICAL DSPAETHENT 21 ACTIVITIES In January, the work load in the nachino end fabricatin'* shops was increased to provide miscellaneous items not available from outside sources for the then under construction ingot casting plant* By mid-year the emphasis had changed to maintenance, including a project for shortening and remachining all the anode spikes from Potlines 1, 2, and 3. This work was set up on a 20 shift per voek basis and was completed by the end of the year. The continuous use of one engine lathe and the turret lathe was involved* However, the work of machining 2-piece crustbreaker bits had ceased due to a switch to forged tits which arc purchasod fully fabricated. At year's end, there was a backlog of fabri cating work for a new flotation plant that will absorb all the time that can be spared from maintenance work for four months. The two 12,000 lb. per hour steam runerating units operated throughout the year at from l/2 to 3/U of full capacity. There were no months when it was not necessary to operate two boilers jrart time. In 195h, an additional load of 2,000 lbs. per hour will Le required whenever the proposed flotation plant dryers are in operation. It is judged that the present boilers can absorb this load. The fact that most of the time there will be no standby unit is unchanged from the present condition, and is not thought to warrant provision of an additional boiler under present ctean requirements. The two distilled water boilers have been provided with six additional cleanout openings to facilitate tube and shell cleaning. The demand for compressed air is unchanged and requires the continuous operation of three IOI4O CFM machines with occasional need for starting the fourth IChO CFM unit which was installed in 1952* h - 39 APC 000167 1953 Continued The in^ot casting furnaces and D.C. units were largely completed by the Pittsburgh Construction Department by July. The Mechanical Department work load for alterations to spray boxes* molds, troughs* trough heaters* furnace door hydraulic system* fluxing system* ingot charger* and auxiliary equipment did not diminish until December. Vhile the open trench* which vas installed to replace the underground 6" drain from 2lr-G smoke washer has been very satisfactory from an operating standpoint* it was found to be a safety hazard. The expense of providing covers for the entire trench makes the- further construction of such flums doubtful. To facilitate cleaning the 8W drain laterals in the courtyard* rectangular cleanout pita were constructed at approximately 115 ft. inter vals in the Line b and Line 5 laterals. This has proved helpful and the construction of similar pits on the Line 1* 2* and 3 laterals has been authorized. The removal of approximately 200,000 cu. ft. of sediment frees 29-L lagoon was accomplished by a contractor in June and July. All cleaning of underground drains in 1953 was done by our own forces. A gas engine driven flexible cable sever auger vas put in service in December to clean the 8" laterals. Indications are that lagoon 29-A will be filled with sediment to the practical working limit about torch 1* 195U after 12 months of use. Keeping 8" underground saoke vashor drains open continues to be a problem, but it is believed that with the additional cleanout pits in the courtyard laterals* satisfactory drainage can be maintained in 195b* Attention is now*being given to the increase in friction losses in the smoke washer recirculating supply lines. Fobin Hood of the Technical Control Department* has been assigned responsibility for making further investigation 1-1*0 ARC 000168 1953 Continuod end experiments aimed toward improvement of o reration and maintenance of the entire enioke washer system* No dredging of the Alcoa navigation channel was required in 1953 and at present there are no plans for dredging in 195U* The replacing of channel markers was done as necessary by Lavaca Pipeline Company and no outside contractors furnished any services in connection with channel maintenance in 1953> An inspection in December shoved that all markers were in place and navigation lights functioning* A new (No. 5 ) 550 gpo well was drilled about 1,000 feot from Nos. 3 and Li in the Kidvay > ater v-ell Held. This well, under 2h hour test, pumped 620 gpn co-tinuously. A 20,000 gallon storage tank was also installed at Midway along with three booster pumps operated through an all electric control system governed by water level in tjhe gravity tanks at the plant and at the City of Point Comfort. The severe water hammer which had caused many pipe joint failures in the past was eliminated* The continuous pumping capacity of the system has been increased from 220 gpn to 500 fepn The increased pump capacity was in operation in October, Lut remote control from the plant tank was not in operation until December. Maximum summer continuous demand for water from this system ic expected to bo about 360 0*i- '.,'ith the incorporation of Point Comfort as a city, it has become necessary to submit a monthly report on the operation of its water supply system, which is the same as that for Point Comfort Plant. Frequent sampling is also required* l.hen additional water became available from the potable system, the use of brackish water in tho power houso evaporative cooling systems was U - U1 ARC 000169 19$3 Continued discontinued* The use of brackish water has also been discontinued in all of the air conditioning systems, krackish water is now used mainly as condenser water far the buildinr Mo* $1 distilled water plant; for L. C. casting sprays; Building 19; and for the potroom 6zaoke washer sprays* All of these systems recirculate water. The capacity of brackish wells now far exceeds requirements* Extensive regradin' and ballasting of plant railroad tracks was under taken this year and conoleted in November. This consisted of reworking l;000 ft. of track by providing rock fiilod cross drains on 6 ft. centers; placing new ballast; and leveling the track. An additional 2,000 ft. of track vas releveled with existing ballast. All work was done under contract by the P.G. & K. Railway* Only normal track maintenance will be required in 195L. Fegunniting of drainage ditch t. continued into the first part of 1953 putting this ditch in first class condition. The problem of preventing undercutting of the guimito and washouts during heavy rains depends upon the establishment of grass cover on the shoulders. liucn improvement in this respect resulted from seeding and sodding; which vas done upon completion of gunniting repairs. Shallow earthen run-off ditches wore cut parallel to powerhousec 5; 7; and 9 to provide adoquatc drainage of the area; to prevent flooding of powerhouse easements, and to provide proper inlets to the Fannin Foad gunnitod ditch. Extensive new ditch work and regradin - wan undertaken; particularly in the vicinity of Buildings 52; 5ii and 33* 11 of the above work was carried out under an authorization. Luc to lack of rainfall and insufficient well pumping capacity; a grass cover had never become veil established adjacent to powerhouses h - 12 APC 000170 19?3 Continued 9t 11 and 63. This condition is harmful because of damage to ~as engines from dust taken in by tho fans* Two attempts to seed these areas had failed* During the late summer extensive codding was undertaken. Native salt Bermuda grass was transplanted. Enough water is now available from the new pumping facilities at Midway to allow irrigation to supplement natural rainfall* Resurfacing of the main plant road system, (1Q,6?0 feet) was carried out under authorization during the last ouartor. Tventy-two hundred (2,200) feet of shell road to tho plant dump was built up and regraded* E^?~I;-r...TTAl A!!D DBVT.LOPHENT WORK Tho use of two-piece shrink fit crustbreaker bits was abandoned the last half of the year in favor of one-piece forged bits. This step reduced the number of new bits used by 1/3 and greatly reducod machine shop load since the forged bits arc purchased complete* This department continues to maintain expoauro racks under the direction of 1. C. 5prowls of the Aluminum Research Laboratory for the testing of aluminum and other samples. Camples arc mounted or removed and rent to Aluminum Research Laboratories as directed* A number of painted steel panels were installed inside the potrooras for exposure test purposos. This project is under the direction of F.* I. V.ray. Kansas Paint and Color Co. HR-2? Tilicone Pleat Resisting paint applied on hC smoke washer duct 9-2h-?2 has been satisfactory on this approximately 300F. potroom smoke duct* 1 - U3 APC 000171 1953 Continued MAJOR EVERTf At the be."iimlnrr of the year the biggest single Job of the Mechanical Department was minor design work and construction work on the Inrot Casting Plant* V. Stroud vqa assigned by the Pittsburgh Construction Department to supervise construction which was undertaken by contract* In April, planning was under way far the design and construction of a Flotation Plant to reclaim pot skimmings and for a spike cleaning machine* Both of thocc projects involved new buildings. As tho work on the Ingot Casting Plant tapered off, tne time of the draftsmen and staff engineers was devoted more and mare to the latter two projects. At year`r end, foundations and build ing design for the Flotation Plant and Spike Cleaning Plant neared completion and connitmont had been made for buildings. Equipment layout and dosign was 752 complete and much of the equipment for these projects was on order. For economic reasons tho spike cleanin' plant was given priority. ECUIPHCiT, UIHIKC-S AND LAKD Equipment employing potroam D.C. bus current for welding was assembled by the Electrical Department. This welder consists of a reactor and a resistor, for varying the voltage, all mounted on a hand truck. The poten tial across 7 or 6 pots is used to obtain ijO to 50 volts welding current which nay be regulated downward by cutting in additional resistance. Tills weldor is safer to operate and produces a more stable arc. It is not finding great favor with the operators, apparently because it involves unfamiliar proceduro in setting up tho circuit. A 10 x 10 hydraulically controlled hack saw was purchased and installed in tho machine shop, Building 13. a - Ui APC 000172 1953 Continued A 110 cu. ft* gas enrlne driver. portable sir compressor was purchased* A 32' x 132' Quonset B building, formerly used as a construction office, was moved approximately 1,000 ft* to a location vest of Building ho. 37* This building was designated as Building 13-B. It was placed on a reinforced floor slab and provided with two interior partitions to provide (1) a paint shop, (2) tool storage for yard service, and (3) storage for Mechanical Department. A ll'Ii" x ll'U" x 9'6h high concrete blocl: control house was erected at Midway for pur?) controls. The Building 1 main office entrance lobby was improved by the installation of an aluminum and plastic partition, aluminum planter boxes, md infornation counter.' In Building 15, .'toreroom, a new receiving office and a lavatory wore constructed and provided vith air conditionin'' equipment. Powerhouses Nos. 5, 7 and 9 were equipped with aluminum doors through out to replace the original wood doorc which had rotted out as a result of the high relative humidity maintained in these buildings. The 36O acre V.'ard Bench near Mdway, Texas was purchased as a site for jrn additional water well and to protect the existing water wells supplying tho plant and the City of Point Co:ifort. li- US APC 000173 MECHANICAL LLPAT-TIx^T 195b iinchine Shop In January, as vas the case all during the year, potroom functions drew most machine and millwright shop tiao. Changing out spikes in building 26, cutting* romachining, and re-tipping anode spikes as well as continued potlining requirements kept the shop well loaded during early 195U in all sections. In July, anode spikes again began acting up by cooing apart at the Joints* thus causing quite a load on the xalllwrirht crews. In the last quarter, addition of a spike cleaning building No. 26-H anc flotation building gave added load to the shops as did the start of fabrication of pot shell, cradle and dock plate straightening facilities for buildings 13 and 37. ioiler ~lant The two 12,CQO lb. per hour steam generating units operated throughout the year at about 3/b full capacity with the result that there were no months in which it was necessary to operate the boilers part time. The load frou the new flotation plant was absorbed as vas anticipated without over loading our capacity. Air Compressors The demand fer compressed air remains practically unchanged and requiros continuous operation of three 10b0 C. F. K. machines with occasional need for starting the fourth 10b0 C. F. ft. unit. Smoke Kasher Water Fupply-nprays & Drainage System The 8" underground return laterals for the scrubbers were cleaned on schedule with little difficulty. The cleanout pits constructed in 1953 proved thoir worth in this operation. All cleaning vas done by our forces. b - 1*6 APC 000174 A Continued Lagoon No. 29-A was cleaned in July by a contractor using vacuum trucks. Approximately 9,755 cubic yards of sludge vas removed and transported to the disposal area three fourths of a wile away. The job vas accomplished by j three trucks working around the clock in two weeks time. Both Lagoon 29-A j and 29-B will need to bo cleaned in 1955. j ! Robin Hood of the Technical Control Deportment studied the friction iI loss in the smoke washer recirculating supply lines and found excessive build up was causing too much friction loss. L program vas veil under vay by year's end whereby the four inch and three inch supply lines from "C" passageway to washers were removed, cleaned uEing air operated boiler tube cleaners, and replaced in a more favorable location on the outside of the potroom buildings, 'e expect to complete lines on<j, two and three by /pril, 1955* .`hr. Hood also found that tests in lines one, two and throe scrubbers indicated hard copper water tube and fittings were most suitable for piping inside the washer towers, and lines one, two end three were equipped with this type material. Navi ration Channel & Plant Dock * No dredging of the Alcoa navigation channel was required in 195U Plans are to dredge this channel in the fall of 1955. The replacing of channel markers was done as necessary by Lavaca Pipe Line Company. An outside contractor installed one pile Dolphin across the turning basin from tho plant dock to facilitate better securing of barges in event of hurricane. In Juno, a 5 ton, 60 foot boom stiff-leg derrick and hoist unit vas installed on the south end of the plant dock to facilitate lo/Mng and un loading of barges. h - U7 APC 000175 A 1951* Continued fbtable Water System The 20,000 gallon storage tank and booster punps, installed at liidvay in 1553* proved its utility in 1951* with a noticeable change in water hanrasr and resulting decrease in maintenance. In Septeatoer* 1?5U* tests were mde on wells numt*rs three* four and five. It vns concluded that well pump number five should have one stage removed to cut down capacity and pugging frequency. If number three and four pump bowls were altered and lowered to approximately l)iO feet* it would insure that those bowls would be below the well pumping level under all forseeable conditions. Tests are continuing on the water 83 requested by Texas bureau of Health. Railroad Trackage As expected only normal maintenance was required on plant railroad tracks in 1951* with P. C. L N. Railway following tills work. Plant bralnare .System The shallow run-off ditchos between powerhouse buildings five* seven and nine, prevented undercutting of the gunlted ditch along Fannin Road. Mo work was necessary on any of the gunited ditches durinr the year. Storm severs were installed to drain the area on the north side of Austin l oad from Archer Road to building 51*-A. e felt that with added potable water capacity at liidway we could sod the areas between the powerhouses nine, eleven and sixty-throe with nativo salt Bermuda grass and keep it watered. However, we found that during the drouth months tho grass died even though ve kept it wet by irrigating. Plant Roads One thousand foot of shell road from Lagoon to Fannin Road south of 1* - 1*8 APC 000176 195k Continued Ditch X, including a timber crossing, vas built for use vhen hauling lagoon sludge to dump. Two hundred anc! seventy feet of shell road was constructed from plant road at Building 19-D to the bayfront. This also included a timber crossing. Only normal maintenance was required on other plant roads* Gas Lines During July emergency authorisation was approved and the underground gas supply main from Building 51 to building 19 was replacod with an over* head line* In the fall, a`two inch underground supply line was extended Tom Building 13-A to Building 37 to provide service to the deck plate heating furnace which vi11 be installed there* Construction aid Major Building Changes Other :najor construction and building changes than those mentioned above are as follows * constructed 10,500 square feet concrete metal storage pad south of building 19; removed and replaced 3,600 square feet of metal storage floor space building 19J removed existing pi? casting platform and replaced it with new type casting platform and heat resisting brick floorj revised truck unloading dock at south end of building 15 and installed a bite-Hite adjustable platform; paved area between Buildings 15 and 15-A; constructed steal yard office. Building 15-F (106 square feet); and constructed three new offices in the went end of Building 56, Alterations were begun on building 37 to equip it for straightening pot cradles and deck plates* This work will be completed in March, 1955* Exposure Racks This department continues to maintain exposure racks under the direction of D. 0* f.prowls of the Aluminum Research Laboratory for the testing of h - u? APC 000177 aliiTrriniEi and other samples* Samples are mounted, removed and sent to Aluminum Research Laboratories as directed* Faint and Glazing Tests The project of testing fourteen different types of paint finishes for smelting plants continues under the direction of R. I. Wray* In addition, in April, 195U an industrial cnanol finish foroalated vith tho now Epon Rosin, Kuhn Paint Conirany, Houston, Texas, Ku-Pon (trade name). Red Lead Primer !!o. 5001, and Ku-Pon Enamel - Gray Ho. 5000 was applied to one of the ventilators in Building 19 to test its use in an atmosphere adjacent to chlorine fluxing operation. To date it has proved satisfactory. Kansas Paint and Color Co. IR-25 Silicon Heat Resisting Paint applied on b-G smoke washer September 1952 has remained satisfactory on this approx imately 200F potroom smoke duct. ^ Also bein~ tested are four different glazing materials for use in smelting plants. They were installed April 1952 in Building 1. Work Load Additional work load was assumed by Mechanical Department work forces in 195h due to tho following operations* Progran for welding tips on anode spikea in all linos. Maintenance of new spike cleaning plant. Maintenance of new flotation plant. Increaso in number of collector bars, collector strap revisions, and other items required by increased potlining schedule. Program for drilling and pinning anode spikes. Increase in anode spike repairs due to extensive joint failures. Requirements far two-shift operation of Dempster Dumpster. Notwith standing this new work, the total Mechanical Department work force had a U - 50 APC 000178 A IPgtt Continued net reduction from 166 hourly non la December 1953 to 160 men In December 195U. Buildings Thu follouin-r buildings were constructed during iPSii* Building 15-F Steel yard office* Building 26-H Spike denning building* Buildln - L6 Grinding building - flotation plant. BuiIdin- U6-J\ Building U7 Building 1(7---A Two hundred fifty ton storage tank flotation plant* Flotation and drying - flotation plant. Cryolite thickener tanks - flotation plant* Building l7-D Carbon thickener tanks - flotation plant* h - 51 APC 000179 MECHANICAL DEPARTMENT 1955 Machine Shop In January, aa was the case all during the year, potroom functions drew most machine shop time. Preparing collector bars, collector straps, in sulation shields and other materials for lining up to ten pots per week ac counted for much machine shop time. In addition several major items were completed. In the first quarter the machine shop fabricated equipment for straight ening deck plates and cradles. For the first six months they pinned the joints of anode spikes at a rate of up to 100 a day, before the job was stopped in May pending a new type of joint (bronae plug). They also performed quite a bit of renovating work on equipment for changing back to 2-1/4 x 5 inch collector bars. During the fourth quarter, in addition to the above, much was done on new construction work for anthracite unloading and storage facilities in the Paste Plant. Alec a lot of work was performed in the final stages of preparing Line 6 for baking. Millwrights As was the case of the machine shop, millwrights spent most of their time during the year installing and maintaining potroom equipment. During the first quarter, facilities were set up in Bldgs. 13 and 37 for straightening pot shells, cradles and deck plates. This work continued at one pot per day through September. Millwrights were busy doing numerous new con struction jobs such as the installation of the 1-1 /2F Simpson Mix Muller 4-52 APC 000180 1955 Continued* in Bldg. 54-A, installation of dust collectors at Flotation Plant, installation of recycling system. Flotation Plant; and during the last quarter, installing various items in the anthracite unloading and storage system - Paste Plant. Millwrights continued to follow preventative maintenance schedules through out the year. In September a Silent Hoist KRANE-KAR was purchased for the millwrighta. Yard Maintenance Yard maintenance crews were busy completing several items of foun dations, concrete walkways, small concrete floor slabs, as well as repair ing brick flooring in various potroom buildings, and repairing furnace hearths and arches Bldg. 19. They received two major items of equipment During the year - a 30 ton L,CRAIN Moto-Crane and a Caterpillar bulldozer. To aid in trash hauling and to supplement a five year old truck, a new* Demp ster truck was purchased. Machine Records A program of maintenance records started in August of 1954, was checked again in January and expanded to encompass most of the functions of the Mechanical Department. Cards were set up in the master mechanic's office and active records were begun at that time. In September an active preventative maintenance program was established in the motor vehicle repair shop with all plant departments participating. Boiler Plant The two 10, 000 pound per hour steam generating units operated 4-53 APC 000181 A 1955 Continued throughout the year at about three-fourths full capacity with results that there were no months in which it was possible to operate any boiler part time. To reduce maintenance a straight through type tube condenser was installed in the distilled water system. Air Compressors In September a new type XLE Xngersoll-Rand compressor was installed in Bldg. 51 bringing the rated air compressor capacity to approartmataly 5,290 c.f.m. Present load permits us to have one air compressor idle st all times. Smoke Washer Water Supply-Sprays and Drainage System The eight inch underground return laterals for the scrubbers were cleaned on schedule during the year with little difficulty. The clean out pits constructed in 1953 again proved their worth in this operation. All cleaning waa done by our forces. Lagoons 29-A and 29-B were cleaned In August by a contractor using vacuum trucks. Approximately 18, 000 cubic yards of sludge were removed and transported to the disposal arsa 3/4 milss away. No attempt was made this time to completely empty these lagoons only to a specified depth. This saved both time and money. The program to eliminate some of die friction in the smoke washer recirculating supply lines by removing same of the scale using air operated boiler tube cleaners was completed sarly in 1955. During the year extensive tests wars made on our existing fores mains and it was decided to install a naw fourteen inch force main overhead from the forebay of the lagoons at 29A and 29B 4-54 APC 000182 1955 Continued to aupply scrubbers for Potroom 6. This work was essentially complete at the end of the year. Navigation Channel and Dock During May, a survey was completed on the plant channel indicating that the channel should be dredged in the fall. This was completed in September. Replacement of channel markers was done as necessary by Lavaca Pipe Line Company. A breakwater was started in May just south of the plant turning basin using broken concrete, bricks, and other heavy materials that prior to this time had been taken to the plant dump. The facilities at the plant dock were very useful in unloading varicus items of structural steel and equipment for the installation of Line 6. Engines for Bldg. 65 were received by barge and unloaded at the dock. During February a flasher beacon platform was knocked over by an outgoing barge. This was replaced by contract. Potable Water Periodic checks we. e made during the year of the 20, 000 gallon storage tank at Midway to insure that water coming into the plant was clean. Tests were made monthly as requested by the Texas bureau of Health. On May 25 the potable water main was fractured about 10 feet west of the plan fence where the main enters the plant area. This happened accidentally as a bulldoser was digging a new drainage ditch west of Fannin road. It was necessary to lower the main at this point in July. 4-55 APC 000183 1953 Continued Railroad Trackage As expected, only normal maintenance wai required on plant railroad tracks in 1955 -with P. C. fe N. Railway following this work. Plant Drainage System The drainage ditch north of the plantsite was partially filled and covered i to permit the conatructicn of Line 6 and a new open type ditch was opened northward along Fannin road to a point which would include Line 7 thence west to the bay. Various storm sewer and sanitary sewer laterals were constructed during the year to accommodate construction of new offices, toilet rooms, etc. 520 feet of 12 inch concrete pipe was laid tc drain Bldg. 19-T} cooling tower. Plant Roads ^ Work was begun in & major repair program to replace bad sections of paved plant roads. This continued throughout the year. A decision was made to replace "high use" pavement with reinforced concrete type paving. Gas Lines Early in the year all major gas line valves were painted red and wrenches and signs were attached to ind:cate the building or facility ser viced by each valve. In July a tie-in was made to provide gas service to Bldgs. 54-E, 13-E, 101 and 102. This work was done under contract to Sanders Welding Service, supervised by Lavaca Pipe Line Company. Gas lines were laid to service new power building No. 65. Construction It Major Building Changes Other major construction and building changes 4-56 those mentioned APC 000184 1955 Continued above are as follows: Replaced 260 sq. ft. of concrete floor in front of furnace No. 4, 31dS. 19. Installed concrete pad and retaining wall north of Bldg. 46. Installed 40 x 60 ft. concrete pad north of Bldg. 19. Replaced 1,550 sq. ft. of damaged floor area, Bldg. 19. Extended hot metal track passageway 870 Ft. Installed 16,000 sq. ft. of concrete road adjacent to Bldg. 13-E. Installed concrete paved r.oad between Bldgs. 15 and 15. Installed concrete access road to Bldg. 52. Installed concrete floor slab for quonset Bldg. 54-F. Installed access road and slab for trailer storage for nitrogen chlorine fluxing. Bldg. 19. Installed concrete roadway into Bldg. 37. A management conference room and a ladles lounge room were constructed in tho basement cf Bldg. 1. A ICO ft. dia. bus turning and parking area was completed on Fannin road opposite Bldg. 1. Placed metal vents around the vent stacks and completely re surfaced the roof of Bldg. 54-A. Exposure Racks Responsibility for maintaining exposure racks and reporting to D. C. Sprcwis of A.R. L. was transferred to the Metallurgical Department early this year. Paint and Glazing Tests All paint end glaaing tests listed in 1954 continued through 1955. During 4-57 APC 000185 1955 Continued the year It was decided that the aluminum aiding on a portion of the west ends of potroom buildings 4 through 18 should be blasted and painted as pro tection against corrosive fumes resulting from fluxing of aluminum in the Bldg. 19 casting furnaces. The siding was coke blasted and two coats of Alcoa Grey fume resistant enamel were applied over a sine chromate primer. The coke blasting proved to be very expensive and the dust was a serious impediment to plant operations. New Procedure In August the Mechanical Department was revised to include a con struction maintenance group tinder A. E. Brayton. The functions of this department were formerly carried out under the supervision of the master mechanic. Carpenters, painters, masons, truck drivers and the general labor crew are included in this department which is under the direct super vision of Foreman R. Hart. In September an apprentice training program was begun in which the Mechanical Department participated - enrolling eight second class and thirteen mechanical helpers in the layout, machinist, pipefitter and mill wright trades. Also in September a Co-op arrangement was begun with Southern Methodist University. John Spencer, mechanical engineering major, was assigned to the Mechanical Department. He and James Blumer, civil engineering major, alternated during the remainder of the year. 4-58 APC 000186 POINT COMFORT WORKS ELECTRICAL DEPARIKEST 1950 During January, February, March and April the major items of vark vore in connection with starting three potlinea. Cbe an January 23, the second on March 8, and the third on May 1* The vater rheostat vas connected in each line before starting* Considerable additional work vas necessary during this period due to failure of potline circuit breakers, and Insufficient vater supply to the vater rheostat* The staff noved from the construction office to the main office building In March. Preparations were nede for visitors1 day in Juno* Installation of No. 7 Baker Perkins mixer vas completed in June* Fabrication and Installation of two paste furnaces and automatic controllers vas completed In July* The plant vas shut down August 2ti by a strike. In September a Request for Authorization vas approved to Install tho vater rheostat in potline 1LVS far restarting* A Request fear Authorization vas approved in November to repair the potline circuit breaker in potline 3LVS after failures cm October 3^ and November 2* A Request for Authorization vas approved in Decanter to fabricate a motor test panel to be uaed in the electrical maintenance shop. The average number of employees for the year vas 20. Willian Boyd Virgil R. Walker Jaraos C* Caraway B* P. Wllkerson T. E. Oliver Merrill V . Heft E* / Hove Electrical superintendent Assistant Electrical Superintendent Electrical Engineer Electrical Engineer Electrical Engineer Electrical Engineer Electrical Maintenance Foreman 5-1 APC 000187 A 1950 Continued Merrill W. Heft was laid off July 21, 1950* T B. Oliver was transferred to the Pittsburgh Office effective September lfl, 1950. ELECTRICAL CEPAKTKHIT 1951 There was a great deal of activity at the beginning of the year in oaklng plans for the 1951 expansion. A cold, rainy period of weather started on January 29, and lasted through the first two weeks .of February. Power and telephone lines were broken, isolating most communities in this area. Cur sweet water supply from Midway was cut off because the REA power line was broken by the ice end wind. A Request for Authorization vac approved in March to purchase and install remote control gate openers at the plant entrances. A Request far Authorization was approved In March to revise tho Jacknotor controls. The spring return was abandoned and a weight used in its place. The project was completed in September. Lighting and power wore installed in the millwright shop building 13A in April. Experimental bus was fabricated and installed in May in an idle pot bo measurements of magnetic fields could be taken. Fifty cycle induction heating tests were ran in June on aluminum, copper and brass billets. Requests for Authorization were approved in June to fabricate one spare set of cathode bus and purchase and install mancooler fane on potrocm functional cranes. power and lighting were completed in new buildings 9D and 37 in July. 5-2 APC 000188 1951 Continued A Request for Authorisation was approved in July to purchase materials and install additions to the public address system in the potrooms and engine houses* The engine house system vas completed in October. Approval vas given in July to revise the potline circuit breakers. One breaker in building 7C was completed in December. Additional bus changes vere made on the experimental pot in October and November. Lighting and power vere completed in October for tlie new offices in the basement of building 1. Pot voltmeter bases, power supplies, and voltmeter fuse mounts were fabricated for the metering system in the 1951 expansion. The average number of employees for the year vas 23* '..'illiam Boyd Virgil R. Walker James C. Caraway 1'. P. 1 ilkcroon ?. A. Hove F.lectricol Superintendent Assistant Electrical Superintendent Electrical Engineer Electrical Engineer Electrical Maintenance Foreman James C. Caraway left February 23, to work in the Pittsburgh Office. He returned to Point Comfort April 30. E. P. 1 ilkerson left April 30, for a 21 month tour of duty with the Army Air Force. r. A. Howe died June 13. A. L. Barton vas made Electrical Maintenance Foreaan June 18. i.illiara Eoyd transferred to the Pittsburgh Office July 1. Virgil Tim Walker assumed William Boyd's duties. Vincent J. Fitsgerald transferred from the Power Department to the Electrical Deportment August 6. 5-3 APC 000189 A POINT CCMFORT WORK!* KI2CTRICAL DEPARTMENT 1952 The 1951 expansion m nearing completion in the early part of 1952. The electrical maintenance crew moved into the new electric shop* Bldg* U9* the last week in January* i Additions to the plant public address system* aa authorised on TR-23UH** were completed In January* Completed in March were the following items which were fabricated and assembled for the potline metering in the 1951 expansion 1 Pot voltmeter bases Anode Alarms ' Voltmeter lead fuse mountings Power supplies Ampere-hour meters Volthour meters Voltage regulator asaeofcliaa The water rheostat was installed for use In baking the fourth potline in March and moved to the fifth potline for )j(ay baking. The installation of two axial flow fans on each 8-ton potroom crane was completed in May* Major revisions ware made in all potlina breakers in accordance with the revisions which ware made for the second potline in December 1951* The electrical power and control installation was coaplated in March for No* 2 sweet water well at Midway. An industrial league softball lighting installation at Point Ccnfort Village was completed In July. A fourth air conpreaaor was completed in the boiler house in December* Reqisats for authorisation were approved in Decsaber to close the 2* RV loop and to purchase and install an MO eat for use on experimental pots* An experimental air-cooled* 2500 ampere pot shunt was built in December attempting to find a way to reduce maintenance eosts end eliminate the use of water in the potrooma. 5 - li APC 000190 1952 Continned A large Indicating aaneter was installed in potrooa 72 but plans for installations in all rooms vers abandoned pending further engineering. The average number of hourly employees for the year vas 28. Salaried personnel at the beginning of the year* Virgil E. Walker Janes C. Caraway Vincent J. Fltsgerald A* L. Barton Korcne Freeman Lucille Buchanan Electrical Supsrintendazrb Staff Engineer Staff Engineer Electrical Maintenance Foreman Stenographer Shop Clerk Lucille Buchanan quit February 1, 1952. Mattie Mae Erraey was hired as shop clerk January 28, 1952* John R. Petrich transferred from the Power Bepartmant to the Electrical Department as a staff engineer April 1# 1952 and quit October 31# 1952* Archie V. Benner vas promoted from electrician to assistant electrical foreman May 26, 1952. Walter E. Weber transferred from the Paste Plant to the Electric&1 Department as a Jr. Engineer October 30, 1952. James C. Caraway vnt to Pittsburgh October 22 to help with the electrical work for the D.C. Casting system and returned November 12. S-5 APC 000191 EKX'TRICAL DEPARTMENT 1953 Tho L. C. Casting facilities in Luilding 19 ware veil underway in January* and the electrical wiring and air conditioning installations for the ceale House and Kill Office were completed during the month. A 10-Ton crane was installed in tho east bay of Building 19* in larch, 1953- An 8-Day extension to Luildinr 19 for increased shipping facilities was erected and the 25t and DljO volt power lines were conpleted in March. Other projects conpleted during this nonth weret a pneumatic tube system from the Casting Boom in Duilding 19 to tho ,, uantometor Labor atory' in 1alldin- 1, and air conditioning installations in buildings 13* U9 and 5-A. An illuminated plant entrance sign was erected in April# The A iz H electric Company* Electrical Contractors for L. C. Casting* conpleted their wori: in May and the first casting unit went into oporation Kay 15. A 15-Ton crane was erected in tho wost bay of Building 19# Two pots with experimental cathode and anode bur arrangements were also completed. One 10,000 ampere D. C. output Motor-Generator set vac installed for experimentally increasing the load current through one or two pots* The main entrance lobby of Building 1 was renovated in June including li-htin- revisions. The fabrication of thirty air-coolod shunts for production use,started earlier in the year, was conpleted in June. Mew lirhtin- fixtures were installed in the corridors of Luildinr 1 and two crucible temperature measurin' stations were added for D. C. Castinr in Building 19* in July. V-'ith tho hurricane season approaci.ing, the month of August was partially devoted to preparing for emergencies. An emergency plant telephone system 5-6 APC 000192 1953 Continued vac installed, and an emergency antenna for the plant radio transmitter vas tested. Other projects completed during this month vcres electrical equipment for a new paint building; an inrot charging machine; susp pumps for three electrical manholes; and a L,l60 volt power line to Midway pumping station. An expcrimmtal ACSF. test span built for Aluadnun Research Laboratories vas completed in September. The installation of rootor controls, operator controls, and reelite on the shipping crane to operate ingot grabs and ton-c, and c Jj,l60 volt emergency pover line vere completed in September. / series of fifteen meetings designed for electrician training wore completed in this month. During October, a potroon vcldlnr- machine, using pot voltage as a source of power, vas fabricated; a direct telephone line to Houston from the plant vas put into service; the L,l6>0 volt power linos were extended to close the h KV Loop; the public address system vas expanded in buildings 19 and 16F; and the installation of air conditicninr far the Storeroom, Building 15, and revisions to building lighting in Buildings 15 19 vere completed. Beceirber brought about the completion of a number of items as veil as the beginning of new projects. Installations collated vcrei outside lighting for Lavaca Pipe Line pipe racks, Llectric Gate Operators for Gate ho. 3, and the aluminum telephone control cable for Midway. Automatic control of the Midway pumping stations from the plant site was initiated on December C. The equipment and control tiring in the Paste Plant vere revised during this month. Ten special itoms of maintenance, which were outlined for the latter part of 1953, wore completed in December. 5-7 APC 000193 1953 Continued Engineering on the Flotation riant and Spike Cleaning Luilding was well underway by the end of the year. Virgil R. v.'&lker continued as Electrical Superintendent. 5-8 APC 000194 KIZCTT.IDAL lZPAET^T 195U Following the completion of installation of an all aluminum telephone control cable from building 51 to Itldvay in December, 1953# a hronch extension of the control line was installed in January# 1951*# from the intersection of P. C. L Railway and 1 Idvay line to Point Comfort*c water tower. 5?inton Electric Company erected the line but splicing was done ty the plant maintenance people. Considerable pioneering work was done in per fecting a satisfactory splicing technique for the all aluminum telephone cable. In fact# considerable maintenance was necessary throughout the entire year on the Mdvay Control Line, remaking splices which had failed because of the lack of knowledge of the proper technique by the original contractor. Also completed in January was the installation of a remote reading liquid level gage for the 150,000 gallon water storage tank. The gage is located in building 51. An electrical fire occurred January 6# in the Unitrol Control Panels# building 5i-D# due to a short circuit in the control wiring. Damage was not extensive, being confined mainly to one section of burned wiring. Operation of the Pasto Plant was interrupted only four hours. The electrical controls and power for the spike retipping program in building 13 were essentially completed in January. In February# the pendant control station on the 25 ton casting crane in building 19 was revised to permit pig pouring as well as pouring hot metal into the D-C casting furnaces. In March# a long-term program was initiated to install wood strips on FP. 30 ton crane blocks to protect the insulation. 5-9 APC 000195 A 195lx Continued In Building 19, the pig-stripper power feed was revised to facilitate removal of 30 feet of pig casting reck to make room for $0 pound pig noIds. Completed also was the electrical phase of installation of a 2050 g.p.a. lift pump in Building 33* Curing 1-arch, a program of daily checksI on the laterline-Angus recording potline ammeters was initiated to determine the ultimate limits of accuracy and to promote increased reliance on these instruments* Daily readings were continued for two months and then changed to twice weekly. After six months of twice weekly readings, the frequency was dropped to weekly. It was proven that the instruments were basically stable and when once adjusted and left undisturbed they could be depended upon for accurate indication. Sinton Electric Company reported April 13 to con.jence work on the spike cleaning and flotation plants. Kost iof the UUO volt power for the spike cleaning and the flotation plants was installed this month. Experiments on spocial bus configurations for two experimental pots were concluded and the original bus was reinstalled. Also in \pril there was installed on each PP. 30 ton crane, a mart rail at its ladder opening. fix Lino 1 water coolers were moved inside locked potroon restrooms to dotermino whether maintenance costs could be reduced. Finally in April, tests were made to determine the suitability of bolted stecl-to-alumLnura joints, with and without copper shins. In iny, wort: continued on spike cleaning and flotation plants, with most electrical work in spike cleaning being completed. Essentially completed in Kay, was a fourth furnace and one new pyrotltration table for potroam control. Building $6. 5-10 APC 000196 195U Continued Power for a 5 ton stiff-leg derrick and hoist on plant dock was installed this month. During June, work progressed faster on flotation and crushing plants with miscellaneous loose ends being picked up for spike cleaning. Engineering was started on pig mold revisions and on Building 37 equipment changes. Also during Juno, one set of end pot spare bus for Lines 1, 2, and 3 was fabricated. In July, work started revising power and lirhting for Building 37. Also, all remaining work on spike cleaning was finished and nearly all work except lirhting was finished for flotation and crushing. Spike cleaning operations started July 16, 195U* In August, the balance of work required to revise power and lighting in Building 37 was completed. Also completed was improved storeroon lighting facilities. A 25 watt universal public address amplifier was purchased for emergency, public servico, and other useB. Also in August, work was corapletod for flotation plant, crushing operation being started September 1, and the balance of operations starting September 15. In September, engineering for general revisions and overhaul of the ore unloading facilities started. Power and lirhting for portable r'uard house at northwost gate on Lock Foad was completed. In October, paste yoke *!o. 1 was experimentally equipped with a new grade of insulation. Noma gradeG-5 or Formica grade FF-55, for purposes of evaluating this insulation versus presently used grade, UN-25* 5-11 APC 000197 A 195 h Continued In October* three new offices were constructed in the west end of the paste laboratory room of building 56 complete with two one-ton window air conditioning units. In Novenber, the job of moving the remaining potroom water coolers inside locked rooms was completed. Vork started on pig-mold revisions and revision of crane pendant* building 19. In December, pig-mold revisions were completed ahead of schedule. The removal of the Engine House PA system, which had been declared surplus, was finished. Pole !Io. 33 on Midway lino was relocated to remove it from a new highway rirht-of-way. Installation of new equipment in luilding 37 was started. Electrical work for an audiometric tost room* building 1* was completed. Electrical work was completed for Open ffouse cere:3oniee at Point Comfort's Chopping Center and also for Alcoa's Christmas Party. Improvements wore made to the planned maintenance program, including an improved system of keeping records. 5-12 APC 000198 ELECTRICAL DEPARTMENT 1955 During January, work was continuing in Bldg. 37 Spike Pinning Shop. The electrical installation of the 200 ton Chambersburgh wheel press and the Ohio 30" shaper were completed along with the wiring of two roof fans. Also completed was the radio voice control line from Bldg. 1 to the test span location at the bay for the purpose of controlling the Mining Div ision's plant transmitter. This also included revisions to provide 440 volt continuous power at the transmitter location. Solenoid operated brakes were placed on each of the two Alumina ele vators in Bldg. 41A to prevent elevators from coasting backwards during a power failure and clogging the elevator shafts with ore. One crucible furnace for laboratory use was assembled during January. In February, electrical work in Bldg. 37 Spike Pinning Shop was com pleted with the installations of the swing type monorail hoist, the one-ton monorail hoist, the twe-ton hoist, and the Avery drill press. Also completed was the fabrication cf twelve aluminum pipe columns for the Fire Station at Point Comfort, Texas. The installation of an independent public address system for meetings in the plant cafeteria was completed during March. Ale < completed v/as the lighting in t^e new lounge room of Bldg. 1. Considerable work was performed on a power feed to the construction area of the new potline. Electrical work was completed for the removal of quonset Bldg. 15D 5-13 APC 000199 1955 Continued from the construction area. F.ngineertag was started an ths quonset's con version to sn Aoto Repair Shop Bldg. 13E. Also completed during March was the installation of the Simpson Muller Mixer in Bldg. 54A. In April* a program of replacing the floodlights on 35 potroom crane cabs with 300 watt, R-40 lamps and Joy Vibra-proof sockets was started. Engineering was started on a 60 volt A.C. power system to feed the 12*1/2 ton gantry to be used to carrying crucibles of hot metal from toe potroom* to Metal Service Bldg. 19. The power feed to the construction area was completed during April, as was the air conditioning installation in the lounge of Bldg. 1 and in the offices of Bldg. 10F and Bldg. 18F. A test set up of Fedders Room Air Conditioners on the west side of Bldg. 19 near 19D Cooling Tower was finished. The Flotation Plant revisions, which consisted of M<wg an aerator and inclined screw conveyor to toe cryolite drying system, were also com pleted. The electrical work on the installation of a belt conveyor from the coke hopper to elevator No. 112 in Bldg. 52 was completed, as was lighting for Bldg. 13C and 13D rest rooms. Several tests were run on the pig stripper rail in Bldg. 19 during April and May, to determine the amount of current leakage from each rail to ground and between rails. Current leakage to ground was reduced 5 * 14 APC 000200 1955 Continued greatly by removing eeveral reinforcing steel rods in the concrete adjacent to the rail. | A general program of replacing defective safety switches on anode Jack Motors was started in April with fixe ordering of 100 new safety switches. This replacement program is to be a gradual one with delivery of the first 100 switches scheduled through July, 1956. 2a May, work was completed on the Auto Repair Bldg. 13E. Engineering work was started on the Installation of a fifth air compress* or in Bldg. 51 and dust collectors on the carbon and cryolite dryers of the Flotation Plant. This installation required the addition of one section to the load center in Bldg. 47. A balance hood for Bldg. 54A control room was completed in May. Test terminals were Installed in the midway control cable to facilitate testing of the cable. During June the electrical service to the gasoline pumps including light ing, and the floodlight replacement an potroom cranes was completed. The air conditioner installation in Bldg. 13A was completed along with lighting in the guardhouse on Iamar Road west of Bldg. 25, and the elec trical Installation of a combustion catalytic test unit including control cab inets and temperature recorders. The electrical Installation on the cryolite dust collector in the Flotation Plant, and the installation of a lighting standard with four floodlights south of Bldg. 13 were completed in July. 5-15 APC 000201 A as t Engineering was ccjifciaued vn tht inetiAUtir-n rf & fifth air ccmprasarr in Bldg. 51 and work was started on the 440 volt power feed into the build ing. V.'Oirh nu the air compressor installation in Bldg. 51 continued through August and wark was started on fabrication of 140 voltmeter panels to be used in Line 6, an the 440 volt power feed from Sub-station 3 to Bldg. 101 and 102. Considerable work was done during August cm the 60 volt power feed installation for the gantry and ore locomotive and on the carbon dryer dust c-'ilector and the load canter addition. V.'ork was completed on the air compressor installation during Sep tember including the 440 volt feeders from SuL-station 4 into the building, as was the fabrication of 140 voltmeter panels and 41 fuse mountings for installation in Line 6. Electrical work was completed in September on the collector blast i cabinet, the block oven, the collector bar even and n crane barrier in Pot Repair Bldg. 54E, and on the carbon dryer dust collector in the Flotation Plant. Engineering work was dene in September on revising the floodlighting o: the pipe line storage racks. In October work was completed on two dust proof boxes for the DB-16 ammeters for Line 6, and the pipe line storage rack lighting revisions. Work was started, during October, on rebuilding the water rheostat 5 " 16 APC 000202 1 1955 Continued for use la beking in Potline 6. Work was continued on the anode effect alarms in Lino 6, and on mod ifying the D. C. ore locomotive for 60 volts A. C. During November work was completed on fabricating the sixteen anode alarms for Line 6, on the water rheostat rebuilding, and on the electrical installation for moving the wheel press and cradle press from Bldg, IS to Bldg. ME. The all electric drive pig stripper arrived during November and was put into operation. Lighting was added in D. C. Casting on each furnace for illuminating the two casting pits. Considerable engineering was done during November on forthcoming Paste Plant revisions. The 12-1/2 ton gentry arrived at the plant and the 60 volt A. C. power feed to the rails was completed. Considerable work was performed on the gantry during November and several revisions were made on the control and power circuits. During December the motors and starters for the pumps which supply bay water to the water rheostat were installed. Work on the gantry was also completed during December and work was started on installing a conductor along side the gantry rails to reduce the reactance lose in the steel rails. Engineering work was started in December on a tar heating kettle in 5-17 APC 000203 1955 Continued Bldg. 54E and for aa sntomatic low nitrogen pressure alarm at Bldg. 19. Considerable work waa dona on repairing a surplus gas furnace control and other equipment which was donated to Calhoun County Independent School District. 5 - It APC 000204 A POINT CCKFCRT WCRKS LABORATORT 1950 I. OPERATIONS The Point Comfort laboratory started operations In January 1950 vith three people on the payroll. Analyses were made on carbon materials and lubricating oils until February vhen the first metal vas produced. The vork load of the laboratory gradually increased as the plant got Into capacity production and at the end of 1950 routine control vork vas being done on bath, boiler waters, and wash water froa the scrubber oyster., as veil as many miscellaneous materials. The metal produced vas analyzed by means of a quantoneter, a direct reading spectrograph which enables the laboratory to analyze the metal much faster and more accurately than with the conventional spectrograph. This instrument vas the first of itc kind to be installed in our Company's laboratories and also the first direct reader to be placed in any of our reduction plant laboratories. II. E-PFKD'FNTAL AND DEVfLOH\U:T A method was developed to determine KgF2 in bath by means of the quantoneter, and 8one experimental vork vas done on analyses of petroleum coke by spectro- graphic methods. III. LOO C7 lAJCF FVFFTC January - Laboratory started analyses of carbon materials and oils. February First metal analyzed. April New source unit purchased and installed. AUCTI8t Vork load greatly reduced because of strike. October Resumed normal operations. Air conditioning of spectrographic laboratory completed. IV ECUIRfllT APC 000205 The only major piece of equipment purchased during the year vas new 6-1 1950 Continued source unit for quantometer. V. PERSONNEL Tlie laboratory personnel consisted of Chief Chemist* laboratory supervisor (Hr. Matocha), a stenographer* and Increased from one analyst in January to five in Hay and continued at that level during the remainder of the year. VI. PRODUCTION The number of determinations performed by the laboratory during the year vaa 66*570J the average number of employees 6. LABORATORY 1951 I. OPERATIONS The Point Comfort laboratory continued through the year 1951 Kith the same key personnel as in 1950* The number of determinations performed in the laboratory climbed gradually during the year due to the reporting of more of the minor impurities in the metal produced. The spectrograph was used to determine some minor impurities that could not be determined on the quantometer. Vegetation samples from the area surrounding the plant were taken twice during the year. II. EZPERBS1ITAL Additional work was done on spectrographic analysis of petroleum coke. Experimental work on oil well sands was done for Alcoa Mining Company. III. LOG No events of particular importance occurred in 1951. iv. ec'jibieut No major pieces of equipment were purchased during 1951* 6-2 APC 000206 4 1951 Continued V. PSRSC3HEL The key personnel of the laboratory regained as in 1950 with F. R. Killer as Chief Chemist and C. K. Matocha as Laboratory 'uperviBor. VI. PRODdCTIOfl The number of determinations performed by the laboratory during the year vas 136,196) the average number of employees 8. 6-3 APC 000207 A. POINT COMFORT WORKS LABORATORY 1952 OPERATIONS The Point Comfort Works Laboratory continued through 1952 with the same Buperriaory personnel as in 1951* Additional analysts were added daring the year to take care of the increased work load caused by lines ItS and 5S starting production. A new spectrometer and recording Consols were purchased during 1952 for the Quantonster to enable us to analyms alloy samples fko ths ingot casting fscilitiss being constructed. Additional channels for some minor iapuritles were also added so that the spectrograph was no longer needed to analyse for certain ainor Iapuritles. Vegetation samples were taken from the surrounding area once during the year* in the fluoride study. EUERIMF3TTAL v;ork wee continued on spectrograph!c analysis of fluorides and coke during the year 1952. The new "Reflected beam" on the new spectrometer was tried. The work is still in progress. Experimental work cn analysis of alloys# 2LOO and 2L02# was started with very promising results. A "Blotter Test" for used lubricating oils was started in cooperation with the Power Department. It la still in progress. LOG February - R.F.A. for ths new Spectrometer written. March - First sample from Lins LS. May - First staple fraa line 5S. j * i 6-L APC 000208 A 1952 Continued June * Closer control of Spar (CaFg) started in Potrooos vith great lnerease in work load in Laboratory. September - Hew Spectroaeter and Console installed* Noreaber - Instruction on sampling far Head Casters and Foreasn started* ECniRCTT A new Spectroaeter and recording Console were purchased during 1952* A new eanpls storage cabinet was purchased for sasq&es from lines 1*3 and Ss* PERSONNEL The supervisory personnel reaained unchanged rtnrlng 1952 with F. R* Killer as Chief Chemist and C* X. Matocha as Laboratory supervisor. The number of analysts increased from four in Decsober 1951# to seven in Decsober 1952. Ten new employees were hired and seven quit# giving a net gain of three* No employees were transferred in or out of the Laboratory in 1952* PRODUCTION The following shows the number of snployees and the work performed by the Laboratory during the year! Average Number of Employees Number Metal Saaplas Number Other samples Chemical Determinations Quantooeter Determinations 9 27#755 10# 1*01* 22#923 131*253 6-5 APC 000209 LABORATORY 1953 The Point Comfort Corks Laboratory changed supervisory personnel several times during 1953* Three more quantometer operators were added to provide round-the-clock service needed because of starting of inrot casting operations. The practice of reporting more of the minor impurities vas started in September. Vegetation samples were taken every quarter and the ashed samples sent to the Aluminum Research Laboratories for analysis. The grinding of bath and the pyrotitration equipment was moved into the plant under tho Control Department. Practically all experimental work was stopped during 1953 because of the rapid turnover of personnel. A new method of determining Cl in pitch using Quinoline was adopted in Noventoer. The bath grindinr and pyrotitration equipment was removed from the laboratory and placed out in the plant under the supervision of tlie Control Dopartracnt. The followin'* shows the number of employees and the work performed by the laboratory during the yoarr Average Number of Employees Number of Ketal Samples Humber of Other Samples Chemical Determinations Quantometor Determinations 13 35,610 12,06C 21,012 201,151 6-6 APC 000210 POINT COMFORT WORKS LABORATORY 1951* The Laboratory continued three shift operations during 195U. The work load increased slightly at the end of the year due to increased activity in the ingot department. The personnel of the chemical laboratory did not change during the year, but the work load increased due to more saaples fron the control department. Vegetation sampling vas changed from quarterly to bimonthly and the method of reporting the results was changed, be now use an isofluor nap as veil as a chart to show the fluorine in vegetation collected in the vicinity of tho plant. An attempt was made to find a suitable indicator for determining ratio in low ratio bath. None vas found that gave satisfactory results. All other experimental work vas dropped because of lack of experienced personnel. A spare rotary interrupter unit of the new type vas purchased for the quantomo ter. A mall crucible furnace assembly was purchased and installed for deter mining ratio and Si(>2 in flotation plant sables. The following shows the number of employees and the work load of the laboratory during the year: i-tel Samples Other Chemical Determinations Quantooeter Determinations Aver. No. Employees U.*983 11,195 20,693 307*500 13 6-7 APC 000211 A LABORATORY 1955 Th Point Comfort Laboratory cootinaad three*shift operation during th year with th work load increasing slightly dus to incraasad actirity of tha ingot casting department. No increase in personnel was made to take care of this additional work. Oaring the summer mention period* two of the summer scholarship students worked in the laboratory* Harvey Janota for the second summer and Tom Flores for his first.* At the end of the summer* Mr. Janota return* ed to school* but Mr. Flores decided he could not continue his schooling and was given a permanent Job as quantornate r operator. Vegetation sampling was continued on a bimonthly schedule. The pro* cessing of the samples was returned to the basement of Bldg. No. 1, shore it was done on weekends. A new laboratory building was designed and construction started to take .care of the increased work load expected due to Line 6 After construction was well under way* it was decided to convert the building into Accounting offices, because if an ore refining plant is constructed at Point Comfort, the laboratories would be integrated and Bldg. 101 would not have been large enough for the combined operations. The following shows fixe number of employees and the work load of the Laboratory during the year: 6*8 APC 000212 1935 Contlanod Arm|a nmbar of uoplofH* Motel Somploo Othor Chomicol Dotorminati noi Oualomatar Dote mnlnati ana 12 47,519 13,310 22,724 426,954 A. 6-9 APC 000213 a METALLURGICAL DEPARTMENT 1935 The Metallurgical Department operated tlie year 1955 with the services of fear engineers, two technical assistants and one secretary. Daring the year, twenty-three projects were undertaken and either completed or con tinued into 1956. Points of major interest were as follows t 1. Experimental work that led to the ass of Mended 65 and 110 pitch hinder in the manufacture of anode pasta. 2. The testing of a Catalytic Combustion Unit to incinerate the onburned tars in the waste gas stream from the Soderberg pots. This teat was not successful. 3. Development work in regard to improvements and design changes in the anodes in Lines 1. 2 It 3 to improve operation and redoes R k M. | 4. Establishment of an air conditioner test station to evaluate the use of aluminum coils and fins in the unit type hams air con ditioner. 5. Continued maintenance of atmospheric test racks for oxposuro of aluminum and other metals to Gulf Coast atmospheric conditions. 6. Development work an the combination nitrogen-chlorine fluxing in die Casting Department to reduce corrosion and attack of buildings duo to the use of neat chlorine. 7. The lining and evaluation of some thirty pots with graphite inserts. These linings show promise of lowering the cathode voltage loos. 8. Assistance with the investigation of the feasibility of the establish ment of equipment to remove the propane* butanes and heavier components from the incoming wot gas stream. 9. Establishment of a technical report file at Point Comfort to make readily available die information contained in those reports. 6-10 APC 000214 * PERSONNEL DEPARTMENT - EMPLOYMENT SECTICW 1950 OPERATIONS The principal functions of the Employment Section includet Receiving and screening job applicants* Interviewing and placing applicants and inter-departmental transfers. Indoctrination of new employees* Recruitment of technical personnel* Compilation and maintenance of employment and seniority records* Clerical detail on military leave* General employee assistance in getting living quarters* LOG OF KAJOR EVENTS January 1, 1950 through April 1950* 300 IQ tests were given to hourly employees. August 3t 1950, first employee left on military leave. August 2h, 1950, first strike occurred* eptother 25, 1950, production workers started returning to work from strike* October 3# 1950, first employee returned from military leave. October 12, 1950, second strike occurred. October 23, 1950, second strike strikers began to return to work. Decanter 1, 1950, first seniority list was mailed to the union. Won the softball championship for the year 1950. PERSONNEL As of January 1, 1950, there were three fpeople in the Employment Office including the employment manager* As of December 31* 1950, the force had increased to five. 7-1 APC 000215 A 1950 continued PRODUCTION Total applicants, all kinds, for the year Total applicants, pre-screened and interviewed 3,000 (Estimated) 2,000 (Estimated) Total number ofpeople employed (Hourly) Total number ofpeople employed (Salary) 617 26 Total number of employees placed on military leave Total number of employees returned from militaryleave 32 3 Total number of employees givenindoctrination 6it3 Total number of schools visited for technicalrecruitment 3 The following shows employment data for the year 1950: Hourly Paid Engagements! Newly Hired Rehired Returned from Layoff Returned ft*00 Military Leave Total 576 12 26 3 517 Separations! C,uit with Notice Quit no notice Laid Off Dismissal - Discharged Leave - Military Leave - Other Total U3 185 3 Hi 32 29 yz Engagement Kate Separation Rate 155 77 Average Employees Hourly Paid Iveekly Paid Monthly Paid Total 399 1D6 36 512 7-2 ARC 000216 A PERSONNEL DEPARTMENT - INSURANCE SECTICN 1950 The administration of the insurance program vms carried on in the enployraent office and functioned under the iraaediate supervision of the employment manager. As of January 1, 1950, ve had designated one full time non-erempt clerk (Mary Joe Starnes) to handle the detail and she vas assisted frca time to time by another employment clerk (Allen Menke), depending on the load of the moment. The duties of the clerk assigned to insurance included daily appearances on the insurance portion of the indoctrination for new employees and all the "selling" of the voluntary program. The following history is significant! Voluntary Life Program January 1, 1950 - No. of employees covered December 31, 1950-No. of employees covered No. of claims filed in 1950 Claims Money Paid in 1950 Percent of Eligible Employee participation as of 12-31-50 133 U01 None None 60 Employees Group Program January 2ht 1950- No. of Employees covered December2bf1950- Ko. of employees covered No. of claims filed in 1950 Claims money paid in 1950 Percent of eligible employee participation as of 12-31-50 2U2 563 303 17*693.7li 9% The claims and amounts paid under the Employeee Qroup Program are broken down into the following classifications! Title No. of Claims Amount Life Personal Hospitalization Personal Surgical Sickness and Accident Dependant Hospitalisation Dependent Surgical 0 53 hi 27 96 60 305 0 $U,375.55 2*79lu25 3*201*714 U,96l.70 2*360.50 31775937711 7-3 APC 000217 19$0 Continued PERSONNEL DEPARTMENT - MEDICAL DISPFHSARX SECTION - 1950 OPERATIONS The Medical Section provides first aid Bervice for plant injuries and limited personal cases. On plant injuries it provides continuing surveillance and care until the case has been closed. Pro-caploynent physical examinations and annual re-examinations of employees are standard services far operational employees. Par construction forces and subsidiaries, this service is con tinuously offered but the decision to do or not is left with the department. The staff personnel under the doctor's direction complete in the dispensary such laboratory tests as urinalysis and blood study. When blood tests indicate positive sypkLllls, samples are sent to the ctate Laboratory for confirmation of results. EXPERIMENTAL ACT DEVELOPMENTAL Heat cramps and upset stomach cases vere a problem in the summer of 1950. Accordingly, we submitted for Dr. Irwin's consideration a summary study logging such cases for the months of June, July and the first fifteen days of /ueust 1950. LOO OF K/.JGK EVENTP. January 1, 1950, the dispensary was operating eight hours per day, six days per week on the day shift. January 23, 1950, service was increased to sixteen hours per day, six days per week covering day and afternoon shifts. January 23, 1950, ceased X-ray taking at Lester-Helcher Clinic in Port Lavaca and began X-ray at the plant dispensary. January 2 3, 2950, doctors began daily visits to the dispensary and ordinary cases were no longer sent to the Lester-Helcher Clinic in Port Lavaca* 7-b APC 000218 1950 Continued January 30, 1950, the service was Increased to cover all shifts, six days pear veek. February 10, 1950, tho dispensary vent on a 2l*-hour, seven-day veek basis* June lb, 1950, ve began blood testing vhich included blood typing, Kahn test and hemoglobin. Complete blood count vas done when requested by the doctor* ECUIFHEKT In June of 1950, ve added the following equipment for the blood program* 1 Aloe-Fedar Universal Shaker 1 - International Clinical Centrifuge 1 - Aloe "Lifetime" Senlogical Water Bath FKRSO'-'VEL As of January 1, 1950, the Lester-Melcher Clinic of Fort Lavaca supplied the doctor service at the clinic and a plant nurse vbb in attendance at the plant site* The dispensary built up to a five nan crev with the addition of first aid men as follows* Employed 1-16-50 - Eugene Gutierrez Employed 1-23-50 - Bobby Ihepard Plnployod 1-30-50 - ri Tuttle lihiployed 2-10-50 - Kenneth Roemer There were no changes in personnel throughout 1950. PRODUCTION Cases Treated by Dispensary Company Original Company Redressing Personal Original Personal Redressing Total 1,255 2,003 1*86 7-5 APC 000219 1950 Continued Physical Examinations Pre-Employment Physical Examinations Employee Physical Examinations Total X-Rays Taken Routine Stero Chest Ui" x 17" Chest Injuries for Diagnosis Injuries, Repeat for Prognosis i | Total Blood Tests Taken Nuner of specimens sent toState Laboratory 7U9 615 l,i61i 86U 113 18U 31 886 h 7-6 APC 000220 PERSONNEL DEPARTMENT -SAFETY AND CCKFEHSATICN SECTION 1950 OPERATIONS The principal functions of the Safety end Compensation Section include t Coordination of all safety and related activity connected with the safety progras for operations and subsidiaries at Point Comfort Harks. Inspection and analysis of the plant and its equipneat to detect unsafe and/or hazardous conditions. Investigation of accidents which may occur within the plant* The conducting of safety training meetings* Coordination of safety committee activity and the administration in part of the Varkman's Compensation Insurance. LOO OT MAJOR EVENTS February 28, 1950, installed first safety bulletin boards. March 21, 1950, first quarterly safety meeting held. October 1, 1950, first safety indoctrination held. December, 1950, Point Comfort wen the Reduction Division lowest accident severity record for the year 1950. EQUIPMENT May 19, 1950, stretcher boxes were provided throughout the plant, PERSONNEL Through the year from January 1, 1950, through December 31, 1950, 0* L. Royer was Safety Director* The insurance carrier through the year was Associated Indemnity Carperation* PRCDlTTIOtl Safety Indoctrination Quarterly Safety Meetings 26 Meetings, 111* Employees 3 Meetings, 671 Employees 7-7 APC 000221 19$0 Continued Year's Total of "First Report of Injury" (Fora filed vith `r'tate Accident Eoard) Actual Compensation Claims Settled Compensation Clalns Total Compensation Paid During the Year Total number of Formal Accident Investigations Mads Plant Accident Frequency Rate for the Year Plant Occident Severity Rate for the Year 220 15 8 $l#5370O UU 25*63 0.28 7-8 APC 000222 PERSCemEL DEPARTi-fENT - PLANT PROTECTION /J!D FIRE PROTECTION SECTION 1950 /a of January 1, 1950, there vere four shifts of guards each operating under a sergeant who in turn was responsible to the guard captain. The guard force operates on a continuous shift, seven day a week schedule. In carrying out the general plant protection detail, the prime respon sibilities includet guarding entrances and exits, fence and area patrol, investigation of misdemeanors, control of plant automotive vehicular traffic, checking of employee identification, operation of fire truck and ambulance as needed, operation of fire clock patrol, pickup and delivery of overtime meals, delivery of the U. f>. mail, chauffaring overtime and sick workers home, and operation of storeroom as required after day hours. The plant operates two main pedestrian gates for inside plant entry. .oot'i ware manned on a 2l*-hour basis. The new construction required additional gate tending chiefly during daylight hours. In normal operation Gate #3 (near Building #1) is used for vehicular traffic entrance tut In 1950 Gate 3A ran a heavy construction traffic total up through June. Fire protection at Point Comfort Village required regular servicing and inspection of the hose house and equipment there as veil as the maintenance of a skeleton force for firo fighting. As of January 1, 1950, there vac a total of 3I1 guards including the captain and four sergeants. The force had reduced to a total of 26 by December 31, 1950. Turnover included one transferred out. Plant Protection Data for 1950 Vehicular traffic handled through plant Gate #3 h5,800 Vehicular traffic handled through plant Gate #3A 38,600 Visitor Passes Used 960 7-9 APC 000223 1950 Continued llunber of construction companies or services handled for which special passing* identification* etc** to operating area was required OvertinB Heals Delivered Special Service Trips (ChaufferingVehicle) Highest number of watch clock stations on route at any one period during the year Ambulance cases* assists Fire calls answered Complaints and Investigations Handled I46 1*710 U73 19 19 33 30 7-10 APC 000224 PERSOJfJJEL DEPARTMENT - JANITORIAL SECTION 1950 January 1, 1950 December 31* 1950 6 employees 17 employees The Janitorial staff is responsible for the cleanliness of all plant offices, restrooms, and shower rooms* At the beginning of the year, three (3) men were working in the powerhouses and three (3) other men in the main offices* In January, six (6) new men were added, `three (3) to Building A* and one to the Paste Plant, and two (2) to the maintenance department areas* February, 1950, a continuous shift for washroom r'17 started and two janitors were added for general office and restroom housekeeping in the potroaos* September 22, 1950, the in-plant janitors were included in the C*I.O* bargaining unit, while main office janitors remained outside the group* Qrval Royer acted as foreman of the janitor department during the year. 41 7 - 11 APC 000225 A PKSSO!WEL DEPARTMENT - LABOR RELATIONS SECTION 1950 Labor rolatlons in 1950 divides itself into three natural phasest the pre-union phase* the union organizing phase* the strike and settlement phase* Prior to eptember 22, 1950* at which tins the Master Agreement* CIO ! Steelworkers became effective for Point Comfort, ve operated under tho guidance of general company personnel practices as spelled out in the Personnel Manual as veil as certain working rules and overtime provisions which were founded in both current CIO and AFL Contracts governing relatione 9 elsewhere in the company* In the beginning of the year* the departments had been fairly defined for seniority purposes and progression in jobs was following an established pattern. Differences of opinion between management and labor regarding i each others rights and privileges* duties and responsibilities* were at a minimum. At least the expression of any such differences was at a minimum* Although the first union organizing propaganda literature was distributed to employees beginning March 7* 1950* we had* as early as December 9* 19U9* positive indication that labor organisers were working in the operating group. As early as February 1G, 1950* the CIO who had leased a property on Highway fjS adjacent to our property erected a large sign on the roof of the building advertising the steelworker organization. During tho union organizing period* all parties concerned conducted themselves judicially with respect to organizing on plant property and plant time* There were only two significant incidents which were out-in-theopen violations. The company conferred with the unions involved and they ceased* At one time it was the AFL and the other the CIO group* 7-12 APC 000226 A 1950 Continued There were the customary changes and counterchargest offensive and defensive tactics chiefly at the Highway ,->35, tut no rough stuff of any significance was observed during the organizing period. The interested parties petitioning far bargaining rights were the International Aluminum Workers Council, AFL| the DSA-CIOf and the Oalveston Metal Trades Council and International Association of Machinists, jointly. In the consent election held May 8 and May 9 at the plant site, there was a grand total of 356 votes cast, but a majority of the valid votes had not been cast for any position on the ballot. This necessitated a run-off election held Kay 22 and 23. 351 votes were cast this time thich represented 92% of the eligible voters. The Steelworkers received a total of 206 votes defeating the Metal Trades Council aid the International Association of Machinists, Jointly, who garnered lii5 votes. Accordingly, the N.L.H.E. certified the USA-CIO as the bargaining agent effective Hay 31, 1950, and contract negotiations began June 26, 1950, at which time the company was presented with a contract proposal containing twenty-four articles. When the contract negotiations broke down and a strike was called, the United States Conciliation Service entered negotiations, a series of talks between September 7 and 20, during which time the strike was being carried on, finally resulted in the strike settlement. During negotiations, prior to and during the strike, the working rules had never been a problem. It was natural, therefore, that the strike settlement for this plant brought it under the jurisdiction of the CIO Master Contract. The union misunderstanding and misrepresentation to their people of what the 10 settlement meant to the local works resulted in a strike coansndng October 12, 1950, which the union claimed it did not sanction. 7-13 APC 000227 A. 1950 Continued At a nesting of October 20, 1950, at which tiae 62% of our vork force was at vork, the strike notwithstanding, the union agreed to return. As of December 20, 1950, and as a result of negotiations at the master level. Point Comfort Yidrks was given an additional?.03 per hour tinder effective date of December 11, 1950. Violence flared at the plant entrance on Highway #35 during the second strike. As a result, five leaders of the union were arrested for their participation. Few formal grievances were handled beyond the first step in the grievance procedure during the year 1950. The personnel director and the works manager represented the company in the handling of labor relations. Various staff personnel were included from time to time in union discussions vhero their presence was necessary. LOG OF HAJ0F. FVFKTS March 7, 1950, first union organizing literature passed "out in the open" at Highway #35 gate. March 23, 1950, K.L.R.B. notification that a petition for certification of representation had been filed. Kay 8 and 9, 1950, N.L.F..B. consent election held) four places on the ballot: International Aluminum orkers Council, AFL) USA-CIO) Galveston Metal Trades Council and International Association of Machinists, Jointly. May 22 and 23, 1950,n.L.RB* "Run-Off Consent Election." Two places on the ballot: USA-CIO, Galveston Metal Trades Council and International Association of Machinists, Jointly. June 27, 1950, first contract negotiation meeting. August 22, 1950, breakdown in contract negotiatiaxsj J* 0. Hubbard, United tates Conciliator, enters the negotiations. 7 - 11: APC 000228 1950 Continued August 23, 1950, union and company signed strike memorandum for orderly shut down of plant beginning at 12t01 a.m., August 2iu August 23, 1950, crew shortage began before agreed upon hour. September 7, 1950, canpony and union with U.S. conciliator cormance strike eettlsnent talks. September 20, 1950, company proposes to the union the 10% settlement. September 21, 1950, Strike Settlement Agreement effective for September 22, 1950, brings Point Comfort under the Master Contract, DSA-CIO. October 12, 1950, wild cat strike began. October 20, 1950, strike settlement held. October 23, 1950, strikers began to return to work. December 20, 1950, Master Agreement on economic items gives Point Comfort 0.03 per hour additional under effective date of December 11,1950. Grievance Summary Number of second step grievances handled 3 Number of third step grievances handled 0 Number of fourth step grievances handled None Number of arbitration cases handled None 7-15 APC 000229 PERSONNEL DKPARWE-2JT - ffiFLOZHIlIT SECTICN 1951 OPERATIONS The principal functions of the Employment Section during 1951 continued as in the year 1950. There mi a gradual de-enrphasia in the job of assisting employees in getting living quarters in the various surrounding towns because the housing facilities at Point Comfort Village expanded to meet operational needs* LOO OF :iAJOH EVENTS January 3# 1951* the first employee was hired for the construction division for the expansion of lines b and 5S* January 0, 1951* new identification cards were issued to all employees* February 28, 1951, visited Palacios High School to talk to commercial and chemistry students* March 1, 1951 the Port Lavaca High School was visited* March lb, 1951* revised hourly and salary retirement booklets were nailed to employees* May 13, 1951, Etayton Rank spent a woek at Tapoco, North Carolina, at the -arks Publication Editors Conference* June 6, 1951, recruited production applicants at Edna, Texas* July 6, 1951# A. L. Dymond and H. C* otory visited the University of Texas to interview engineering graduates* Aunist 7, 1951, applicants were recruited at Beeville, Texas* Von the 8 oftball championship for the year 1951* PERSONNEL As of January 1, 1951# there were five people in the Employment Office including the Employment Manager* 'tayton Runk, employment clerk* 7-16 ARC 000230 1951 Continued continued to devote about one-half of his time to public relations detail and the publication of the local plant pqper, Tezalcoa Round-Up. As of December 31# 1951# there were four people in employment. During the year the turnover vas effected by four employed, three quits, one military leave, and one transfer* PRODUCTION Total applicants, all kinds, tar the year Total applicants pre-screened and interviewed 2,300 (Estimated) 1,600 (Estimated) Total number of people employed (Hourly) Total number of people employed (salary) 576 U9 Total number of employees placed on military leave Total number of employees returned from military leave 32 10 Total number of employees given indoctrination 625 Total number of cchoolc visited for technical recruitment 0 The following shows employment data for the year 1951 Hourly Paid Engagements Newly Hired Rshired Returned from Layoff Returned from Military Service Reparations Total U67 33 66 10 375 C.uit with Notice xuit no Notice Laid Off Dismissal - Discharged Loave - Military Leave - Other Engagement Rate Separation Rate Total 73 212 0 6 32 75 35B 97 67 Average Employees Hourly Paid Weekly Paid Monthly Paid Total 596 127 50 773 APC 000231 A PERSONNEL DEPARTMENT - EJCUP.ANCE SECTION 1951 As of January 1, 1951* one non-exoopt clurk was handling the detail with little assistance. Indoctrination meeting appearance on practically a daily basis vas continued throughout 1951* Effective October 31* 1951* Mary Joe rtames quit vith notice to accept a civil service appointment in Alaska* At that time* Jesnie Rosenbaum* in addition to her secretarial duties* took over the entire task of insurance detail* The following summarizes the business far 1951* Voluntary Life Progran January 1, 1951 December 31, 1951 No. of Employees covered No. of Employees covered No. of Claims Filed in 1951 Claims Money Paid in 1951 Percent of Eligible Employee participation as of 12-31-51 U01 601 2 312,000 80$ Employees Group Program January 24, 1951 December 24, 1951 No. of Employees covered No. of Employees covered No. of Claims Filed in 1951 Claims Money Paid in 1951 Percent of Eligible Fiqplbyee participation as of 12-31-51 563 844 721* r-46,915.36 95% The claims and amounts paid under the Employees Group program are broken down into the following classificationst Title of Claims Amount Life Personal Hospitalization Personal Surgical Sickness and Accident Dependent Hospitalization Dependent Surgical 2 135 76 51 273 187 72E S1*,000.00 10,730.50 4,815*84 6,020.93 12,910.29 8,437.80 C53&.36 7- 18 APC 000232 PERSONNEL DEPARTMENT - KEL'ICAL DISPENSARY SECTION LOO OF MAJOR EVENTS 1951 June, 1951, annual physical re-examinaticns ware put on a regular schedule plant wide* July, 1951# the blood study was expanded to include the Rh factor* Fnbruary 18, 1951# Dr. Kelcher sustained serious injury in an outside autcraobile accident* May 7# 1951# Dr. Melcher returned to active practice* July 2ht 1951, Dr* Kelcher collapsed while an duty at the plant. August 2, 1951# through August 15# 1951# Dr. E* L. Smith was used for re-annu.il physical examinations* September 9# 1951# Dr. Kelcher returned to active practice* November 26, 1951# Dr* Melcher collapsed while at the Lester-Melcher Clinic. July, 1951, we began to sterilise our own bandages at the plant dispen sary. BSPIFKENT In July of 1951# we added the following equipment: 1 Auto Clave Steriliser. PERSON? ?EL As of January 1, 1951# the Lestar-Kelcher Clinic was supplying service by plant visitation five days per week. The dispensary was being operated by Effie Easllng, Registered Nurse# and Eugene Gutierrez, bobby Shepard, Sam Tuttle# and Kenneth Roaaar# First Aid Attendants* Effective January 3, 1951# Bobby Shepard was placed on military leave of absence* He enlisted in the U* S* Navy* 7-19 APC 000233 A 1951 Continued January 22, 1951, Joe Herrera vas employed to fill the vacancy- created by Shepard*s military leave of absence* pnODLTTICTT Cases Treated by Dispensary Ccnpany Original Company Redruscinc Personal Original Personal Redressing Total 5U 2381 657 Physical Examinations Pro-employment Physical Examinations Pre-eoployaent Partial Physical Examinations employee Annual Physical Examinations Total 535 38 213 E35 X-Rays Taken Routine Chest Stereo 11" x 17" Chest Injuries for Diagnosis Injuries, Repeat far Prognosis Total 1,112 125 206 20 1,165 Blood Tests Taken 1,125 Humber of npecimonts sent toState Laboratory 28 7-20 APC 000234 PEFSCKNEL DEPARTMENT - SAFETY JfflD CaiPTTTSATIO?! SECTICW 1951 LOG KAJCF. EVERTS July 2G, 1951, first fatal accident in plant. October li, 1951, first Safety Coordinators meeting. Kovember 1, 1951, changed compensation insurance carrier ft:an Associated Indeunity Corporation to Texas Employer's Insurance Association. Noveuber 1, 1951, first Foreman's Scoreboard compiled. December 27, 1951, first Safety remittee meeting which included hourly rated committeemen. PiuiSuIf.-IEL Throu-.h the year from January 1, 1951, tiirough December 31, 1951, 0. L. r.oyer was Safety Directca*. FT.CIXCTI'r Safety Indoctrination Quarterly Safety Keatings 153 meetings, U50 employees 3 meetings, 1,098 employees Year'8 Total of "First Poport of Injury" (Fora riled with State Accident Board) 135 Actual Compensation Clairos 19 Settled Compensation Claims 18 Total Compensation Paid during the Year f5,036.00 Total number of Fomal Accident Investigations Hade 36 Plant Accident Frequency Rate for the Year 16.36 Plant Accident Severity Rate fur the Year 1*.69 7-21 ARC 000235 A PERSONNEL DEPARTMENT - PLANT PROTECTION AND FIRE PROTECTION - 1951 Plant protection responsibilities for security and fire remained essentially the same in 1951 as they had in 1950. The preparation of meals by the cafeteria for the overtime employees on the U - 12 shift saved the force additional travel time required to make town trips for this purpose. The electrification and remote control of the gate at Fannin F.oad and Austin Road provided better security for Building #1 and the adjacent parking area. Such moves, combined vith other efficiences allowed us to redistribute and cut back our forces throughout the year without affecting security. The expansion program far lines bs and 5S brought extra gate work at Gate 3. The vest side of the plant (dock side area) handled considerable vehicular traffic, which required the presence of operations guards during daylight hours. As of January 1, l?5l, there was a total of 26 men including the captain and sergeants. By December 31, 1951, the force had been reduced to 22. Turnover included two transfers out. Plant Protection Lata for 1951 Vehicular traffic handled through plant Gate f3> 53,^72 Vehicular traffic handled through plant Gate r3A 780 Vieitor Passes Used 1,239 Number of construction companies or services handled for tfiich special passing, identification, etc., to operating area was required. 31 Overtime Meals Delivered 1,915 Special ervice Tripe (Chaoffering Vehicle) 8U7 highest number of watch clock stations on route at any one period during the year 13 7-22 APC 000236 1951 Continued Ambulance caseB, assists Fire Calls Answered Complaints and Investigations Handled 18 19 12 7-23 APC 000237 * I PERSONNEL DEPARTMENT - JANITORIAL SECTION 1951 January 1, 1951 - 17 employees December 31, 1951- 18 employees During 1951, the operations of the Janitor section continued to provide services far offices, restroaas, and shower roots. General work assignments vere as follows I Building #1 Buildings #13, 15, 50, 21 BuildingB #19, 5U, 56 Power Potroco Building 17 U men on evening, 1 day aan 2 evening nan 1 day aan 3 day oen 2 day men U oen (shift) May 1951 began use of Gnox disinfectant in washrooms for protection against athletes foot. June 1951 initiated locker assignment and clean-up system in Buildings #17 and /21. August 1951 special assignments vere m^de for emergency service in preparation for huricane season. October 1951 construction began on enlargement of locker rooms in Buildings #17 and #21. Old Eradley showers and wash basins vere replaced with standard equipment. October 1951 Janitorial section reached 1002 participation on the Bond Drive program. December 1951 Janitor service was extended to storeroom. A day man was permanently assigned to that area. Since the first janitor was employed in Point Comfort V.orks in January, 19U9, through December 31, 1951, the total departmental personnel turnover consisted of a loss of seven men, four of which were transferred out. Orval ioyer had charge of the Janitorial program until June of 1951 when he was replaced by Allen Menke, employment interviewer. 7-21* APC 000238 A PERSONNEL DEPARTMENT - LAECE RELATIONS SECTICJI 1951 Labor relations in 1951 were narked by the firm establlahnent of the CIO contract proceedings in our plait relationships and then the breakdown in the CIO leadership which finally resulted in the AFL gaining the bargain ing rights late in the year* Beginning on January 2, 1951, the CIO opened up the question of the potroon work load. A series of intermittent meetings on this problem eventually brought forth the increase in potman crews firon twelve (12) to fourteen (Hi) per line* ' The understanding reached, beginning May 1, was that the additional potmen were summer potmen. Sumer was to extend from Kay 1 through November 30 at which time we reservod the right to remove the extra people as ve began the so-called winter schedule* Parly in the year, job descriptions had been completed for all hourly rated classifications and copies of these job descriptions vere placed in the hands of the union* Job progression lines in the operating departments were agreed upon between the company and the union and vere in established operation by Parch 1951* The appearance of AFL organisers in Port Lavaca early in July sot the stage for the "raiding." Consequently, AFL literature began to be passed out at Highway -435 gate on July 25. The N.L.R.B. consent election involving the Pteelvorkers and the Aluminum Council of Port Lavaca, A.F.L., resulted in an AFL victory with the Council receiving 3Wj to 219 votes for the Steelworkers* There were 6l6 people eligible to vote in this election and 93^ of then voted* The Aluminum Council of Port Lavaca, AFL, waa certified as the bargaining agent November 30, 1951, and contract negotiations began an December 18, 1951, with the new organisation* 7-25 APC 000239 19gl Continued LOG OF MAJOR rVFNTS January 2, 1951. union opened up the question of potrooa work load. February 27, 1951. Job descriptions were completed far all hourly rated employees. March 5. 1951. Job progression lines in the operating department were agreed upon between the conpony and the union. May 1. 1951. company increased potman crew from twelve (12) to fourteen (lit) per line. July 11. 1951. AFL organisers show up in Port Lavaca. July 25. 1951. AFL union "raiding" literature passed out at Highway 05. September 26. 1951. N.L.R.B. notified the company that a petition for certification had been filed. October 2k and 25. 1951. N.L.R.E. Consent Election heldj USA-CIO vs. Aluminum Council of Port Lavaca. AFL. November 2. 1951. K.L.R.E. certification of Council to bo effective November 30. 1951. December 16. 1951. new contract negotiations began. Grievance Sunmary Number of second step grievances handled 33 Humber of third step grievances handled 13 Humber of fourth step grievances handled Hone Number of arbitration cases handled None 7-26 APC 000240 1951 Continued FEtSOHNEL DEPARTMENT - CAFETERIA AMD IN-PLANT FEEDING SECTION - 1951 Although construction had been completed on the cafeteria building as of August 1* 1950* did not make a contract for catering service until January 6* 1951* Progressive Cafeterias* Inc*, a Chicago concern* became the caterer and the local resident manager was a Mrs* Alice Lindburg* Food service in the cafeteria began on January 31* 1951* and noon day lunch* Mondays through Fridays* vas provided* Three separate one-half hour periods for service were established beginning at 11130 a.m. and ending at liOO p*n* Breakfast service vas soon provided from 7:15 to 8|00 a.m. end in March carry-out lunch service vas provided for employees an the day turn whose continuous operations did not allow them access to the cafeteria building* nix stations in the plant were designated as food delivery points and the employee who desired a carry-out meal* ordered such at the plant gate on the wey to work. The cafeteria personnel delivered the lunches at an appointed time to the neoessary station* The overtine meals* especially for the midnight turn and the week end days* presented a problem. Guards picked up such orders and procured them in Port Lavaca* 'a of August Hi * the cafeteria arranged their work schedule so as to be able to prepare overtime lunches for the li - 12 shift* This resulted In (1) slight increase in revenue* (2) great increase in quality* (3) time saving for guard force* The vending of candy* gum* ooke* etc** through machines vas extended promptly to ten locations in the plant* Cuero Coca Cola Bottling Works serviced the drink machines and Victoria Vending Enterprises serviced the candy* gum* and tobacco machines. Both venders are controlled by eontracte with the caterer* 7-27 APC 000241 A 1951 Continued Poor housekeeping has not Increased because of the machine vending but coke bottle losses were a constant problem* No solution has been found yet even tho .gh the Janitor force maintains constant bottle pick-up. tUnor vandalism, chiefly In the Production Department areas, occurred through the year to vending machines, but investigation never turned up the culprits* Several special lunches and plant dinners were provided to special groups during the year* The service and quality of food was maintained at an excellent level throughout the year* Tho average daily customer count climbed steadily upward from 130 customers a day in February to a peak of 220 a day toward the end of November* The average customer check varied between 53# mid 6U# throughout tho year* Carryout meals climbed steadily and peaked at about 110 per week in late December. Overtime meals varied from 0 to 60 per week. These are those provided by the cafeteria and reflect only a part of the overtime meal total because of those which must be purchased elsewhere on holidays, weak ends, end midnight shifts* The Safety Director assisted the Personnel Director in liaison work between the company and the caterer for approximately half the year* In August, the Employment Interviewer (Henke) relieved the safety man of these duties and continued to the end of the year. `ro. Ruth Fletcher Leca-ie manager of the cafeteria on Kay 31, 1951* 7-28 APC 000242 POINT CCMFQRT WORKS PERSONNEL DEPARTHEMT 1952 The seope of the Personnel Department activity for 1952 ineludedi Enployment Insurance Medical and First lid Dispensary Service Safety and Compensation Training Plant Security - Plant Fire Protection Plant Janitorial Service Labor Relations Cafeteria A brief historical resume of aach subdivision of personnel fallows* EHFLOflffiHT SECTION OperatiooB The principal functions of the Employment Section during 1952 continued as in previous ysars During 1952, we employed aora people than in previous years due to ths starting of potlinas 1*-S and 5-S and poirarhousaa Noe* 11 and 63* During the summer vacation period, sixtyfive high school and oollage students vara provided employment. At the end of 1952, ve had a total of 83 employees on Military leave* Log of Major Events January 25, 1952, started filing form B-81, Notice of Termination, with Taxes Employment Commission on every employee terminated. February 1, 1952, started hiring employees for Linas U-S end 5-S. February 28, 1952, recruited potmen applicants in Cuero, Texas. March U, 1952, Dymond, Story, Idler, and Oaugler attended Career Day, University of Houetwj, and Interviewed three engineare. Daring April, potroon applicants vara reoruited in Oonaalaa, Wharton, and Victoria* June 1, 1952, started hiring tenporaxy summer employees. June 26, 1952, C. E. Blakeway, Rersonnel Director for Brow k Root, Inc*, visited Point Comfort for area wage surrey* 7-29 APC 000243 a 1952 Continued June 30, 1952, to July U, 1952, Story visited Rockdale Works to aid then in setting up their Employment DepertoMit* July 30, 1952, H. Q* Boone, Federal Buzvtau of Investigation of Houston, interviewed a cross section of twenty (20) Point Comfort Works enployeae. August 4, 1952, V>* 7* Cook, Pittsburgh Personnel Departmaxt, and an auditor of Metropolitan life Insurance of Mew York spent two days auditing the Employees oroup Flan* Septasber 5 1952, installed photos of employees on Military leave in tha cafeteria* October 28, 1952, A* J. Dingleaan, auditor far Equitable Life Aawance Society, audited the Voluntary life Plan* Equipment January 1$, 1952, Employment Section taoved to new offices provided in basement of Building Ho* 1* Additional desks, filing eablnsts, and thrsatrs- type seats for lobby were purchased and a Talk-A-Fhone systea was installed* Personnel As of January 1, 1952, there were four people in the l^ployasnt Office Including the Employment Manager* As of Septeefcer 1, 1952, Allen Henke, interrlewer, began apending more time doing photographic and related work for V. 0. Ssylis in Public Relations Department* As of Deosaber 31, 1952, there were five people in Employment* IXrring the year the turnover was affected by five employed, three quits, and one transfer* Production Total applicants, all kinds, for tha year Total applicants pre*ecreied and interviewed 1;,000 (Estimated) 2,600 (Estimated) Total number of people employed (Hourly) Total ntaber of people employed (Salary) 736 90 Total number of employeee placed on military leave 30 Total nnaber of employees returned from military leave 8 Total number of eetployees given indoctrination 8)0 Total number of echoola visited for technical recruit* sent 7-30 1 APC 000244 A. Personnel Depart-amst 1952 - Continued INSURANCE SECTIW The aeainl stratiop of the insurance pro^raa continued in the Bnplqyaent Office, functionally under the general supervision of the Boployaent Manager. As of January 1, 1952, one nen-eocenpt clerk was handling the detail with little assistance. Indoctrination meeting appearance on practically a daily basis was continued throughout 1952. Effective Ajaril 1, 1952, Jeanie Rosenbaum transferred to the Personnel Director's office and Mrs. Dumas took over the insurance details. Both Metropolitan and Equitable plans were audited during the year. Two major changes in the plans went into affect. 1. Voluntary Life - all employees insured as of March 31 were covered for an additional 151 life for a period of one year at no additional cost to the employee. 2. Metropolitan Employees droop - August 1, employee benefits were increased to the followingt $10.00 per day for room, special services increased to $100.00, and siekneae and accident to $30.00 per veek. The following summarizes the business for 1952. Voluntary Life Program January 1, 1952 - No. of employees covered Deeeober 31, 1952 - No. of employees covered No. of Claims Piled in 1952 Claims Money Paid in 1952 Percent of Eligible Employees Participation as of 12-31-52 Employees Group Program 601 61h 1 $8,010.99 79.2% January 2U, 1952 - No. of employees covered December 2b, 1952 - No. of employees covered No. of Claims Filed in 1952 881 1,107 9lB 7-31 APC 000245 Personnel Department 1952 - Continued Claims Honey Feld in 1952 Percent of Eligible Employees Pertidpetion of 12-31*52 $62,3142.07 97.8* Claim end Amounts Paid under the Employees Oroup Program Title Ho. of Claims Amount Life Personal Hospitalisation Personal surgical Sickness and Accident Dependent Hospitalisation Dependant Surgical 1 136 73 58 W5 275 W $2,000.00 10,71*2.58 U,029.20 5*720.514 20,81*1.50 19,008.25 MEDICAL DISPEH5ART SECTION Operations The Medical Section in 1952 continued to provide first aid service for plant injuries and attention on a United first aid basis for personal cases. With the above, the pre-employment physical and annual re-examination, including complete laboratory data, constitute the chief service of this section. Experimental end Developmental Several new anti-biotic ointments were introduced to combat infections and promote healing of surface bums and abrasions. Log of Major Events June 21, 1952, Luther Bailey, Employment Manager, Rockdale, and Dr. Richards, Rockdale, visited Point comfort to observe our medical facilities end policies. July 1, 1952, Dr. John P. P.obinson replaced Dr. T. C. Melcher ae plant physician with Dr. 5. Vi. Lester. July 17# 1952, Janice E. Laurence, R.I., replaced Mrs. Kfflt S. Sealing, R.N., as plant nurse. February 1952, a new diathenqr was added to our Mediosi Section. August 1952, vs got extension cylinder for X-Ray machine to take spot X-Rays. Also viewer for dark room. 7-32 APC 000246 Personnel Department 19$2 - Continued Personnel Plant visitation by Dr* S* V* Lester* br* T. 0. Halcher* and Dr* J* P Robinson five days per vnk* Cn maergeney call 2b hours m day for company injuriee. Mrs. Effie S* Zasllng* R*N* v&s in charge of the plant dispensary until August when Janios Laurence, R.N.* replaced hsr* Tbs department is operatod by Eugene Outiarres* X-Ray Teeinieian* Kenneth Roemer, Laboratory Technician* San Tuttla and Joa Herrera* First Aid Attendants* Production Cases Treated by Dispensary Company Originals Company Redressings Personal Originals Personal Redressings Physical grata! nations Total 1*615 S*b55 2*123 637 Pre-Employment Physioals Pre-Employment Partial Physicals Employee Annual Fhyaieals Total 817 43 I-Rays Taken Routine Stereo Chest lb x 17 Chest Injuries for Diagnosis Injuries for Prognosis Total 1*398 91 301 25 T3B5 Blood Tests Taken - l*b38 Number of specimens sent to Jtate Laboratory - 32 7-33 APC 000247 Paroan>1 Department 19$ 2 - Continued 8AFETT AND CUMPENSATICH SBCTICR Operations The principal functions of the Safety and Compensation Section continue to Includes Coordination of all aafety and related activity connected with the safety program for operations and subsidiaries at Point Confort Korks* Inspection and analysis of the plant and its equipment to detect unsafe and/or haaardoua conditions. Investigation of accidents which nay occur within the plant* The conducting of safety training meetings* Coordination of safety conlttee activity and the administration in part of the Vorkaan's Coapenaation Insurance* Major EVanta The year was uneventful ae far aa any serious injuries were concerned* This was bast reflected by the very low severity rate of 0*2ii which won for Point Comfort the Smelting Division's Annual Severity Award* In May* 0* L* Royer attended the eaapanywlde meeting at Tapoeo Lodge* In October* T* E* Adams attended the National Safety Congress at Chicago* Personnel T* E. Adams Joined the department in February and after a brief indoctrination in general personnel work was assigned to the .Safety Section* By the end of 1952, he had assumed a great deal of the responsibility for safety* Mrs. Dorothy Kolodsey Joined the department in August aa stenographer* 7 - 3k APC 000248 4 Personnel Depertrcent 1952 - Continued Production Number of Safety Training Mootings Conducted Total Attendance 3k l,3k7 Number of Safety Committee Meetings 59 Nunber of New Employees given 3&fety Indoctrination 658 Number of Safety Indoctrination Meetings 122 Nunber of Safety Glasses purchased for employsee 26 Number of Potroan Goggles Reconditioned l$h99 Number of Foreman*s Scoreboards compiled 12 Number of Employer's First Reports of Injury" filed 162 Nunber of "Employer'a Supplemental Reports of Injury" filed 20 Plant Accident Frequency Rate for the year 11*05 Plant Accident Severity Rate for the year 0*2k Number of "Guides to Accident Preventionn distributed to employees 1,32k Number of "Accident investigations" processed 82 Number of Lost-time Injuries 26 Operations TRAINING SECTION The Training Section was instituted at the start of the year* 0. L* Royer assumed the duties of Training Director* The functions of the department Include all phases of training, s*g*, Conference Plan for Management, Red Cross First Aid Training, Cn-The-Jbb Training, coordination of apprentice prograns, etc* Log of Major Events 17 technical employees went to Houston in September to attend tba Economic Mobilisation Course* 7-35 APC 000249 A Parconnal Department 1P5D - Continued 0. L. Royer vent to Tapoco Lodge in June and to Webster Hall* Pittsburgh, in December. Equipment September 1952 an opaque projector vaa purchased for use in the Training Department* Personnel 0. L. Royer handled primary responsibilities for training* i Production January Management in Action 3 Meetings February Management in Action U Meetings April Annual Report 2 Dinner Meetings April April Human Relations Union Contract (AFL) | U Meetings 6 Meetings May Rumen Relations 9 Meetings Key July Annual Report (Hourly) Confernos Leader Training 7 Meetings 10 Meetings July Power of Your Vote 2 Dinner Meetings August Safety lit Meetings September Technical Training 32 Meetings October "HQBS0* 2 Dinner Meetings October First Aid Training 5 Classes November Accountant Trainee Program 3 Men (100 Weeks) December First Aid Training 2 Classes In addition to the above, indoctrination training vas continued far all new employees* Ibis vas administered by the Training Dapartment and by the individual operating departments. Tbs Potrocos begin s formal program of 7-36 APC 000250 Personnel Departa<nt 1952 - Continued this type in September undsr the guidance of V. E* Qou A training program for Potrocm foremen vas also started by hr. Oosa daring September* PLANT PHOTECTICK AND FIRE FROTBCTICR Plant Protection responsibilities for security and fire rsnainsd essentially the sane in 1952 as in 1951* The fores included one captain, five sergeants, and sixteen guards. T. B Hargrove vas promoted to ssrgsant on August 25, 1952* Plant Protection Data Vehicular Traffic 12,U75 Visitor Passes Proeesssd Number of Service and ConstructionOonpanlas Handled 1,666 39 Overtime Meals Delivered 3*959 Special Service Tripe (Chauffer Service) watch-clock stations Visited Daily l,23li 16 Ambulance Cases Handled 23 Tire Calls Answered lit Complaints Investigated lit JANITORIAL SECTION During 1952, the Janitor force vas increased from 17 awn to 22 men* Tvo man were added to the Power Janitor force, and three were employed for the Production areas. This increase vas necessitated by the overall growth of the areas serviced by the Janitor force* On November 1, a reassignment of Janitors vas mads for purposes of supervision. In this reassignment, the Janitors working In the plant were made responsible to the foremen in whose are^s they vorksd, thereby creating 7-37 APC 000251 rersonnel Department 19>2 - Continued a closer relationship betveoi the foreman and the worker. Previously, Allen Henke, Bsploymant Interviewer, was responsible far all janitors throughout the plant, regardless of Wiich shift they were on* This reassign ment placed seven sen under Production, two under ths Paste Plant, five under Power, two under the Mechanical Department, and one under the Stores Department. This left five sen in Building Bo* 1 still aider the super vision of Allen Menks* There was a turnover of only one man in the Janitor Section during 1952, and this was due to a dismissal for excessive absenteeism LABOR RELATIONS SECTION Negotiation meetings were held almost continuously from January 1 to July 1. The first series of Meetings resulted in the signing of the a*F*L* Contract March 3* Later seatings related to the five-year contract signed July 1 which is similar in most respects to the A.F.L. Master Contract. Production Number of Negotiating Meetings held 29 Number of Second Step Grievances Handled Number of Third Step Grievances Handled 10 5 Number of Fourth Step Grievances Handled 1 Number of Arbitration Cases H(sidled Nans Number of Stabilisation Petitions Personnel 7 A* L* Dyaond resigned as Parsannsl Manager effective August 1, 1952* H. T. Condon, Pittsburgh Office, reported to Point Comfort aa Personnel Manager September 29, 1952. 7 - 3fl APC 000252 Fereonnel Department 1!>$2 - Continued CAFETERIA The eafeteria ha regained under the earns managnant for the entire year. Types of services have remained the same, with the changes only in volume. In November# OPA pries restriction were removed# but customer food prices have remained constant throughout the year# even though retail prices of such items as meat and staples have risen considerably. An estimate of 1,172 meals are served weekly in the cafeteria, with a weekly sales figure of $691*30. (December 19, 1952) A mwraary of the Cafeteria's 1952 Profit and Loss Statement along with their sales and monthly cost of food index is a follows * Honth Pood Cost (By Per Cent) cTsaas January February March April May Jme July August September October November December 7U.ll! 7U.99 62.86 6U.33 6U.U3 63.07 6U.19 66.21 59.30 50.20 5U.33 53.68 Average 62.66 Total Net Profit, 1952 Sales *5,9U0.06 5,782.U9 5,922.19 6,130.6U 6,775.98 5,861.85 6,681.53 6,2U0.10 6,297.38 7,270.88 6,096.21 6,351*81 $6,260.9U Profit or Loss $-32?.U9 -277.52 32.15 -U0.22 118.69 56.87 88.79 -U6.19 321.2U 738.15 U6U.01 U50.88 $131.US $1,577.36 The downward trrnid of food ooat is attributable basically to the cafeteria< maturity. Experience helped to build up efficiency and cut waste. Menu could be more closely planned end portion prepared in line with anticipated sales. The stabilised work force helped in tbs program of building efficiency and cutting costs. Sale Increased in line with the manpower growth and stimulation of the carry-out food Berrios. The latter, originated dozing 1951, grew to the 7-39 APC 000253 Personnel Department 1952 * Continued impressive figura of A?0.00 vorth of weekly *! by the end of Deember 1952* Bctra activities throughout the year also added to this ealss figure. Tho cafeteria's year ended Kith a total of $1,577*36 in hot profit, and an average aonthly profit of $131*65. Tending continued under the service* of Victoria Tending Enterprises for candy and cigarettes, and Coca-Cola Bottling Company far soft drinks. A sanasry of income from these activities follows i Total Income from Vending Cooa^ola Candy and Cigarettes Total Cli, 190.00 1,867.29 $6,057*29 CcnEaiosicn Aron these itous is based an the following rates: Coca-Cola Lass 25# per esse sold 50# per ease for bottles lost Cigarettes 2# per peck Candy 1O'* of gross sales 7-60 APC 000254 KRSONKEL LEPARTKZNT 1953 EULomiirr section The principal functions of the Employment Section during 1953 continuod as in previous years. During 1953 our prime function in the em ployment field van to hlro routine replacements and to staff the new department D. C. Casting. During the suraaer vacation period 76 high school and college students and teachers were provided employment. Of this number, fifteen were working scholarship employees in a newly inaugurated program. At the end of 1953, ve had a total of 60 employees on military leave. As of January 1, there were five people in the Employment Office including the Employment Manager. Allen fcenke transferred to Rockdale Works March 1, 1953 as Employment Manager. Oscar Hunter was employed April 27# 1953 as a training assistant. INP'IP-ANCS SECTION The administration of the insurance program continued under the imnediate supervision of the Employment Manager. Curing the year* one non-exempt handled the detail with some assis tance. Oscar Hunter handled the Indoctrination phase. The entire program was streamlined to insure fewer errors and prompter service. Examples* (1) Tome unnecessary forma anc letters were eliminated] (2) A cross file index of deductions was installed to check with Payroll] (3) Tho Personnel Manager discontinued signing routine claims, neither plan was audited during the year by the carrier's auditor, however, the private firm of lyfarand, Ross and Montgomery, of Houston, made a spot check of deductions. 7 - la APC 000255 19$3 Continued Only ono major change remained in effect. Voluntary Life - the 15 ' reversionary life clause war. extended for another year at no additional cost to the employee. The follo-ulnr summarises the business ;fcr 19$3* Voluntary life Prorram j January 1, 1953 - No. of employees covered December 31, 19$3 - No. of employees covered No. of Claims filed in 19$3 Claims Money Paid in 19$3 Percent of eligible employees participation as of 12-31-53 SU* 91*9 3 26,10$.16 81.01# Employees Group Program January 2ht 19$3 - No. of employees covered December 2L, 19$3 ~ No. of employees covered No. of claims filed in 19$3 Claims Money paid.in 19$3 Percent of eligible employees participation as of 12-31-53 Claims and Amounts Paid Under the Employees Group Prorran 1,131 1,21*0 9S7 68,306*05 90.08^ Title Mo. of Claims Amount Life Personal Hospitalisation Personal -Curgical Sickness and Accident Dependent Hospitalisation Dependent Surgical METICAL MfPEMSAFY EECTIOi: 3 136 80, 88 380 270 Wf Grand Total t 6,000.00 12,6$8.72 $,632.90 8,035.73 21,699.15 ,26 105.16 9U,U11.21 During 1953, service of the Medical iepartment consisted of treatment of all plant injuries and care for personal cases on a limited basis. A continuous annual physical program was carried out. Influensa injections were made available to all employees on a voluntary basis. 7-U2 APC 000256 1953 Continued Lumbar spine X-rays are now being made on all applicants routinely to help in the classification of each new employee, Quantitative Kahns are being done instead of sendiar spocinens to State Lab* A total of 675 shots of polyvalent influenza vaccine were administered to employees. In foptenfcer Dr. J. Vi. Torsne replaced Dr. J. P. Robinson as Plant Physician, and Mrs. Willie A. Zanders, R.N. became Staff Nurse to replace Mrs. Janice Laurence, R. N. In December, Kenneth Roomer transferred to the Chemistry Laboratory. Plant visitations were made by Dr. S. Lester, It. J. ?. Robinson or Lr. J. Tonne five days per week. They were on emergency call 2U hours a day for company injuries. Krs. Janice Laurence, P. U. war in charge of the plant dispensary until September when Lrs. Willie A. Sanders, F.. !i. replaced hor. The department "was operated on n twenty-four hour basis by Eugene Gutierrez, X-ray Technician, Kenneth Foemer, Laboratory Technician, fan Tuttle and Joe Herrera, First Aid Attendants. Caras Treated by Dispensary Ccr-.rppny originals Company rodres sings Personal originals Personal redressings Physical Examinations Total 1,826 2,218 2,290 7a 77*77 Pre-employment Physicals Employee Annual Physicals Total 166 966 T^2H X-Rays Taken P.outino Stereo Chest lfc x 17 Chest Lateral Spine on Applicants Injuries for Diagnosis Injuries for Prognosis Total 7 - U3 i#a? 81 6 330 APC 000257 1953 Continned blood Tests Taken Quantitative Kahns t 1>Ij38 9 SAFETY A'D COMPENSATION SECTION The principal functions of the section continued to include the investigation of accidentst coordination of Bafety connittee work, safety training, inspection of plant safety conditions and anra.1n1 stration of Workman's Compensation Insurance. A new combined Monthly Safety Report was designed to rive a clearer picture of accident rate ahd severity. Injury analysis reports were instigated to focus i,mediate attention cr. all accidents in an attempt to remedy unsafe conditions and acts. The Third Quarter Management dinnor had as its theme Safety. Ralph Hicks presided at the mooting. T. E. Adams attended the Co.upany-vido Safety lirectars Meeting in Pittsburgh. T. E. Adams became safety Director on July 1. ftroduction dumber of Employee Safety Indoctrination Meetings Number of Employees given safety indoctrination Humber of Poe fafety -lasses purchased Number of potroom goggles reconditionod Number of "Employer's First Report of Injury" filed Number of ''Employer's Supplemental Report of Injury" filed Plant accident frequency rate for the year Plant accident severity for the year Number of accident investigation reports processed Number of Rafcty committee meetings held Nu-iPer of Safety - Training mootings held Number of lost-time injuries 60 3h3 3o 2ii5 136 26 79h 0.9U 223 6U 38 20 TRAINING SECTION The functions of the Training Department during 1953 were similar to those of tho previous year with the addition of an Snployees Information Rack Service* 7 - Ui APC 000258 A. 1953 Contlnoed An extended visit to Point Comfort was made by Lr. J. A. Dickinson iron Pittsburgh. A Ii-year .Gunner orking Scholarship Program started in June with 15 High School graduates. 1. L. Valker and 0. L. Royer attended the Sumacr Training Conference at Tapoco in June. Major Choiles bstes was guest speaker at the Uth wuartor .'Linagenont Dinner in December. James H. Greene and 0. L. Koyer attended the Winter Training Conference at lobster Hall, Pittsburgh, in December. In Karch a new lomra Bell U Howell projector was obtained in exchange for the DeVry unit. An UK electric typewriter was obtained in September. A VuGraph projector was obtained in December. The following training m.etin-s or programs were accomplished or started i January Training Program ``or Females 16 meetings January Handling Grievances 2 dinner meetings January First Aid Training 2 classes February Lcononics (In Cur Hands) 22 meetings February llectrical Dept. Conferences 60 meetings March Gaiety Director Training 18 weeks April Annual Deport Annual Report U dinner meetings 9 hourly meetings Kay Technical Report riting U meetings June Gtudent Sirnor Training Program 12 meetings June Plant Training far 0. H. Hunter 7 weeks July Safety 7 - US 2 dinner meetings APC 000259 1953 Continued August September Safety (Foremen) Safety (Foremen) 12 meetings 16 meetings October Safety (Foremen) it meetings Movenfcer Induction Program for Koch. Dept. It meetings Movonfcer Job Training 15 meetings November Shorthand Training 18 meetings becenfcer Hunan Eolations (Major Estes) 1 dinner meeting Iccomber Chart of Accounts 12 noetings Lcenter Conference Leading (Females) 18 meetings The following programs were continued durin.'* the year* Accountrnt Trainee 3 participants .jaployee Indoctrination U00 Information Rack Service 35*000 booklots - 1.Ii5/employee Potroora Training for Technical Personnel Potrooa 5-day Induction Frogran The followin'- pro-Tans were carried over from 1952 and conpletod durin- the year t Technical "taff Trainee Program 25 meetings. pla-:t ft.ctectio;: a?ie fikl protection The principal functions of Plant Protection remained the same during 1953 as they had been in former years. The degree of activity was stepped down appreciably, however, and several casual services were discontinued* Sgt. P. L. HaskLn, rr. attondod the annual firemen's Training School July 19-25* at Texas A & K* A reduction of the plant protection force from 22 man to 18 men was effective September 28* Oate 3A was closed except at shift change time, 7 - U6 APC 000260 A 1953 Continued the ore storage gate is open only at scheduled hours and a number of incidental minor services discontinued. Fire inspections of the plant vere made by Factory Mutual inspectors on the following datest J. Elucher J. L. lianlove J. Elucher S. D. Hiller February 5. 6 May 5. 6 August h5 December 7. 8 All fire extinguishers and hose vere inspected and defective equipment replaced. Plant Protection Data Visitors Passes processed Materials Passes processed .1 elding end burning permits Fire alarms ansvered Ambulance runs made Trips made for Medical Section Reports of oil barge loadings LAEOE RELATIONS SECTION 1.038 U96 101 10 32 133 105 January $ - Agreoosnt on rights of employees bumped from a job classification to claim first vacancy in that classification* W. C. Jackson resigned as President of the Council and J. L*. Klinichok vas elected to that position. Juno 2U " J* L. Klimichek resigned as President of the Council and V.. C. Jackson vas reinstated on a temporary basiB* July 9 ~ Ratification of vage agreement. April 23 - Conversion from Old Series to New Revised Series Consiners Price Index in computing Cost of Living escalation. August 10 - Houston o. Hickman elected President of the Council. December 30 - Negotiation of Vacation Agreement for 195U* Number of 3rd Step Grievances ------- ....... 17 Number of Negotiation Meetings-- -------- - 7 APC 000261 7 - h7 * 19$3 Continued CAFITCP.IA The cafeteria continued to be operated by the Progressive Cafetorias Incorporated. lire. F.uth Fletcher continued to be the local manager. Durinr the week of June 8* a Mobile Unit was put in operation to i provide on-the-job meals for employees on all shifts. Until the week of June G* Mrs. Fletcher employed five people in the cafeteria. 1th the addition of the Fiobilo Feeding Unit* it became necessary to fcrinr this number up to seven plus four full-tine operators for the Mobile Unit* end o part-tiro I-bbile Unit worker for each work day. The total* therefore* is now eleven full-tins employees* one part-tine employee and the manager. Following the initiation of Mobile Food service, cafeteria gross sales have consistently shown an increase and cafeteria operating losses have been consistently reduced. In fact* in most months the cafeteria has shown a small operating profit since the Mobile Unit was jut into use. 7 - US APC 000262 A HSRSOKTSL EEPAPTI-CNT 1951* !IFL0E?IT fecticci During 1951* our prime function was to hire routine replacements as needed. During tho Burner vacation period, forty-nine high school and college students were employed. Of this number, twenty-seven were working scholarship students* At the end of 1951;, we had a total of fifty-nine employees on military leave. During the year, four major changes were made in the general employment policy* (1) age.limitations were set (25-39 years); (2) Production department began interviewing potroom applicants; (3) iiodical devised a more thorough pre-employment physical examination; (1*) a consent to employment of a minor vas signed by all employees hired under 21 years of age* In liay a new plan was announced regarding the placement of returning veterans* Total applicants, all kinds, for tho year Total applicants pre-screened and interviewed 2,6u (Actual) 1,1*00 (Estimated) Total number of people employed (hourly) Total number of pooplo employed (salary) 112 32 Total number of employees placed on military leave Total number of employees returned from military leavo Total number of employees given indoctrination I' SIJFi/rCE fECTIO!: 10 25 167 The administration of th.c insurance program continued under the immediate supervision of the Employment Ennagor. Voluntary life Insurance The reversionary life clause vas extended for another year at no additional cost to the employee and the amount vas increased from IS per cent to 25 per cent. The records wero audited during Novenber. He significant errors were found. 7-U9 APC 000263 a 1951 Continued Employees Group Insurance Under the nev agree.ient several changes beca:c effective September 1, 1951 in the plan and coverages. Listed below are the changesi Administration 1. 'lew enrollment cards for personal coverages* 2. New enrollment cards for dependent coverages* 3* i.'eu certificates to cover all coverages. 1* Hew announcement booklets* 5* ' aiver cards to be signed by people declining* Coots - Veekly 1. life or wife and children increased from *60 to 1*70 2* Children only increased fTom .10 to 1.25 Coverages Personal 1. Life insurance increased from 2*000 to S3500. 2. Hospitalisation ineroaned from 10 to 13 per day. 3. Special services increased from "100 to 130. 1. Sickness and Accident from 30 to 10 weekly* (a) Inclusion of the difference between Workmen's Compen sation and flO weekly for industrial cases* 5* Maternity coverares to include fenale employees* 6. Maternity severance pay in the amount of C210 to be raid at ti:e of termination. Dependent 1. Hospitalization increased from ; 5 t-o C13 per day. 2. Special services increasod from 50 to 130. 3. Maternity coverages increased from 100 to 205 Lurin'- August Mr. Horan of 1 etropolitar. Life Insurance of Houston* audited the records. Ho significant errors vero found. The fcllowing summarizes the business for 1951 Voluntary Life Program January 1* 1951 - ho. of employees covered December 31# 1951 * Mo. of employees covered Mo. of Claims filed in 19SU Claims Money Paid in 1951 Per cent of eligible employees participation as of 12-31-51 919 976 3 25*111*77 62.7$ APC 000264 7-50 1951* Continued Employees Group Program January 2lj, 1951* - Ho. of employees covered December 21*, 1951* - Ho. of employees covered Mo. of coverages filed in 1951* No. of claims filed in 1951* Claims money paid in 1951* Per cent of eligible employees participation as of 12-31*51* 1,21*2 1,21*8 1,731* 1,072 $109,937*61 98.1*2 Claims and amounts paid under the Employees Croup Program* Title No. of Claims Amount Life Personal Hospitalization . Personal Surgical Sickness and Accident Dependent Hospitalization Dependent Surgical 1* 226 11*8 91* 71*6 5H* I773H Grand Total f 9,500.00 16,601.92 8,727.50 8,782.59 1*0,861**60 25*261.20 rmzh& 25*1*1*1.77 135,179.58 ?aiic.AL lipr::;.caf.y rixtiCK From January 1 until October 25* medical personnel were on duty two Eiifts each day. Hours were 8*00 A. K. to 1**30 P. K. r.nd 8*00 P. M. to 1**00 A. Km Plant. Protection personnel, all cf whom have Red Cross first aid training, treated first aid cases in the off hours. Twenty-four hour coverage war resumed on October 25, 1951*. Treatment of ail plant injuries and care for personal cases was on a limited basic with physicians on call 21* hours per day. Programs of pre- omployracnt examinations and annual physicals were carried out. Influenza injections were again made available on a voluntary basis. Luring the first full year in which lateral lumbar spine X-rays were taken, 6.7 per cent of applicants were rejected on the information so obtained. V. 1. R. L. tests were substituted for the Kahn test and are run by departmental personnel. Umpire analyses are made by a local laboratory. 7-51 APC 000265 A 195k Continued A total o' 63k Injections of polyvalent influenza vaccine were ad ministered to employees on a voluntary basis* An audiometer and a testing room have been installed* The testing program will begin in February, 1955 after personnel have been trained* A stereo shifter was added to the 7-ray unit* Plant visitations were made by hr. J. V. Tomne five days per week. He and Lr. S. 1.'. Lester are on emergency call twenty-four hours per day. !rs. Janice Laurence, R* N, was re-employed to repl&co V. A. Sanders. Cases treated by Dispensary Company Originals Company Reeres Bings Personal Originals Personal Redressings Total 1.517 1,877 l,kl8 3180 OT2 Physical Examinations Pro-employment Physicals Employee Annual Physicals Total 2li0 1.0U3 -rm X-Rays Taken Routine Stereo Chest lii x 17 Chest Lateral Spine on Applicants Injuries for Diagnosis Injuries for Prognosis Spine on Injury Total 1,217 102 217 255 96 ____ 5U "OTE Elood Tests Taken 908 SAFETY /.TTj CGi:FEMr-ATI0?? SECTION Tho Safety Section continued the coordination of the safety program which included accidont investigations, safety committee work, safety train ing, and plant safety inspections. The section continued administering Workmen*6 Compensation Insurance* 7-52 APC 000266 A 193U Cootinned Beginning in November* the Industrial Engineers began investigating all lost tine avl other serious accidents. The purpose of this change is to have safety reco-nendationr backed by technical knowledge. The Safety director attended the area safety meeting at the Davenport Vorks in April. The five-year safety award program was initiated during the third quarter. There were twenty-four "Gambling V.ith Safety" conferences held during Aurust and r-eptember which vrero attended by 380 employees. V.'. R. Gilliland visited Point Comfort for two days in March. The Safety Sostion assumed the administration of the flood Analysis program. Production Number of Employee Safety Indoctrination lieotin'-s Number riven indoctrination Number RX glasses purchased Number of Potrooa goggles reconditioned Number of Employers1 Reports of Injury prepared Number of Supplemental Reports of Injury Plant Accident Frequency rate for the year Plant Accident severity rate for t) year Number of accident investigations processed Nunbor of Safety Comittee meetings Number of '"afety Training meetings Number of lost time injuries for the year Number of first aid classes completed or inprogress 52 167 U5 19U I63 1? 53U 2.97 163 57 2ii lh 6 TRAINING rbCTIOiI The Training bepartnent administered Purdue Supervisory Reading Test to 77 management, personnel. ThiB was to assist the University in developing this psychological t6st. The following training meetings or programs were accomplished or started during the year* January Training of Job Trainers 10 two hour meetings January Vehicle Driver Training 15 one hour meetings January Artificial Respiration Training for Electrical Department lj one hour meetings 7-53 APC 000267 * 19?.It Continued February February February Kerch Horen .arch April Kay June June June July July July July Auruat August . optanber September optember October Public Relations 2 one hour dinner meetings Indoctrination Program for Female Employees b one hour meetings Shorthand Refresher Training 6 one hour meetings Cost Progran 1 one hour dinner meeting 9 one and a half hour departmental meetings Personnel Development Program 72 one hour meetings Plant Training for J. C. Alley 6 months Annual Report 3 one hour dinner meetings 10 one hour plant meetings Management Study-Power Department Auxiliary Plant Protection Training Management rtudy-Production Department 1 6 one hour meetings j ) Student Summer Training Program Report i!riting 22 two hour meetings 3 one hour meetings < Economics (Let*s Face It) 2 two hour meetings : Management Study - electrical Department i. First Aid Tralninc 18 two hour ; actings ;1 Management Study - Mechanical Department Safety 2It on6 hour meetings Industrial P.elatio s (R. K. Heineman) 2 one hour dinner meetings Purdue Supervisory Reading Test Shorthand Refresher Training Ii3 one hour meetings Indoctrination Program for New Female Employees 8 one hour meetings 1 - Six APC 000268 ; I Continued October Office Supervisory Training 15 two and one half hour meetings hovca/Ci* Industrial Relatione 2 one hour dinner meetings becembor Lccenber Industrial Relations Civil i-efanse - First Mid 2 one hour dinner meetings li two hour meetings Lecenbor First Aic Training 12 two hour meetings The following proprais were continued curing the yean Accountant Trainee - 3 participants to Juno; $ thereafter. Lnployaer.t. I:icoctrination - 167 Information I.aci: Service - 33*273 Looklets* 11.69 per employee fbtroora 'gaining for Technical Personnel On-the-job 'ecretarial Training The following programs were carried over from 1953 and were completed daring the years January Conference Leading (Females) U meetings Tlie ioUovdnr miscellaneous activity vas performed during the years Attended five American Society Training iiroctors1 Meetings in Houston. Attended Texas Personnel and hnnEpeacnt Conference in Austin. howed Miscellaneous films r> follows: "It1 r everybody's i.usiness" "Reservoir Ln~ineering" PLAHT FbQTbCTIO'! A'T) TIKE rTOTOCTIOM Tho degree of Plant Protection activity was stepped up a little cue to several construction projects going on in tho plant. The organisation and basic training of tho Plant Auxiliary Fire brigade was completed February 27. 7-55 APC 000269 195Ii Continued An Auxiliary Plant Protection Force of nineteen men was organised. Training was completed Juno 11* 195li All fire extinguishers and hose were inspected and defective equipoent replaced. A new Villis Kodel I.lits Burry Fire Firhter was delivered to riant Protection larch 9* 195U* A new Jeep "tation ' agon was doliverod to Plant Protection Gctobor 5* Two new ruard houses we: re built anc put in service. Plrnt Protection lata Visitors Passes processed Material Paasos processed ' ire Alar.is Answered Ambulance runs made lumber of / irst Aid Treatnents riven ;.y Plant Protection I.'uauer of Accidents investigated lumber of Trips made for Firct .Aid ; lumber of Tripe made far Personnel lumber of 'elding and Burning pormits issued Reports of Oil large Loadings 9B2 900 15 21 90 26 61 57 67 92 mi: r;:i/Tr;.T? pictih; 1 he position of Labor Relations .Tac~cr was established October 1* 195U ty the appointment of iliir L. Goza to improve tiiu labor relation facilities of the existing management team. ir pri ary duties aro labor relations* contractural relations with the union* and other related ratters. A union election rrm by CIO ay 17 anc'. 1G* disturbed vh.ut had been vory rood labor relations. The campaign* as usual* was based on rash promises and much abuse of individuals aud of the opposing union, both sides avidly sourht to find and prosecute grievances both before and after the election. After tho new agreement was si,mod* activity gradually diminished and 7-56 APC 000270 195U Continued no serious troullc has resulted. ftowever, many grievances are now carried to arbitration. In October, t! plant was visited by K. Hoineman, Lirector of Industrial Relations, along with George S. Linated and K. A. Zonarich of tho USA - CIO International Union. Luring a resting attended by local plant and union officials, lir. Einsted cited sore ninety odd items which tho union alleged were causing friction and sdsunderatandinr. At the time, plant officials were of the opinion tho list was fceinr- presented as propaganda for the benefit of the. local union. Lator events have borne out thin opinion. In tho course of management dinner meetings, iir. Hcinoman presented an enlightening and well prepared version of the general aspects of the contract. As a follow-up, a series of dinner rBetings were provided for the foremen group with contract interpretation and areas of responsibility being discussed b/ tho plant Labor Relations Manager. flthou~h no one would deny a rise in union activity subsequent to tho change from AFL to CIO aB bargaining agents, there lias been no evidence of real unrest or dissatisfaction among the hourly employees and no serious threat to efficient plant operation. Lai.or has been plentiful and absenteeism and turnover have boon Lolow normal. CAFL'Ti'F.I/ Tho Cafeteria wan operated by tho Progressive Cafeterias Incorporated, 'rr. Futh Fletcher, local manager. Thore ai-c four employees in tho Cafotorla kitchen. Four employees operated tho mobile feeding unit an shifts and a part-time employee assisted on days. 7-57 APC 000271 19$U Continued Breakfast end lunch wore served in the dining rooa lionday through Friday each week. Tlie ciobila unit operated three shifts per day every day. Special dinners were served to -roups ranring from sixty to one hundred twenty people on tvolvo separate occasions. 7 - jg APC 000272 A PERSONNEL DEPARTMENT 1955 Daring 1955, the fauction for the Employment Section wee to secure routine replecemente end hire extra help for the summer months, personnel for the Construction Division end the additional people required for our ex panded facilities. A program of psychological testing of all new employees was inaugur ated. As a result of the company-wide survey of employment procedures, we made some changes in the order of our procedure and intensified the use of the patterned interview and the telephone check. Total applicants, all kinds for the year............................... 3,728 (Actual) Total applicants pre-screened and interviewed................ 1,700 (Estimated) Total number of people employed (hourly)................... Total number of people employed (salary)........................... 212 88 Total number of employees placed on military leave . . Total number returned from military leave...................... 3 33 Total number of employees given indoctrination............... 390 Insurance The administration of the insurance program continued under the im mediate supervision of the Employment Manager. Voluntary Life Insurance - The reversionary life insurance was extend ed for another year at no additional cost to the employee and the amount was increased from 25 per cent to 30 per cent. The records were audited during the month of October by Mr. McOuirk, of the Equitable Life Assur ance Society. He commented the program was in "excellent condition". 7-59 APC 000273 * 1955 Cannoned Employee Croup tnenrance * The same coverages remained in force without any changes. The Plan was not audited. Voluntary Life F- ogram January 1, 1955 - No. of Employees Covered .... 976 j December 31. 1955 - No. of Employees Covered . . 1.111 No. of Claims Filed in 1955 ... 0 Claims Money Paid in 1955. . . . $0.00 Per cent of Eligible Employees Participation as of 12.31.55 . . . 83.47# Employees Group Program January 24. 1955 - No. of Employees Covered . . . 1.259 December 24, 1955 * No. of Employees Covered. . 1,362 No. of Coverages Filed in 1955. 2,206 No. of Claims Filed in 1955 . . 1, 553 Claims Money Paid in 1955 . . $182,552.04 Per cent of Eligible Employees Participation as of 12.31>55. . 98.0% 7 - 60 APC 000274 * 1955 Continued Claim* and Amount* Paid Under the Employ*** Croup Program Title Life Personal Hospitalisation No. of Coverages 0 339 Amount $- - - 28,159.86 Personal Surgical 185 10,533.25 Sickness and Accident 119 24,955.70 Dependent Hospitalisation 1,005 83, 399. 90 Dependent Surgical 558 35, 503.33 TOTAL 2,206 $182,552. 04 Medical Di*p*nary During 1955, service* of the Medical Section consisted of treatment of plant injuries, pre-employment physical examinations and annual em ployee physical examination*. Influ*ns* injections were available to all employees on a voluntary basis. A program of audiometric testing on all pre-employment and annual physical examination* was started in March. In July, hematocrit deter minations were added to our physical examinations. In August the program of lateral lumbar spine X-ray* was extended to the annual physical exam inations. Dr. J. W. Tomzne continued as medical advisor. Ca*es treated by Diapen*ary Company Originals...............................1, 556 Company Redressings..............................1,558 Personal Originals..................................1,273 Personal Redressings........................... 328 Total 4,715 7-61 APC 000275 1955 Continued Physical Fysminationa Pre - empl oymeni..................................... Employe* Annuals ..................................... Total 366 1.158 1,524 X-Rays Taken Routine Stereo..................................... 1*479 14 x 17 Chest................................................................. 94 Injuries for Diagnosis .................................................. 280 Injuries for Prognosis......................................... 45 Applicant Lumbar Spines........................................... 326 Annual lambsr Spines. . . 278 Spines on Injuries. . . ..................................... 38 Total 2,540 Blood Tests Taken: 1*367 Safety and Compensation Monthly awards were made to production workers with outstanding safety performance. A Labor-Management Safety Committee met once a month. Point Comfort Works completed 1* 000, 000 man hours without a dis abling injury on August 10. A barbecue was held fer all employees. Fore men Barton and Summers attended a Safety School and Safety Director Adams attended a Disaster Rescue School at Texaa A It M. Safety Indoctrination Meetings - All new employees Prescription Safety Glasses Purchased....................33 First Reports of Injury.................................... 84 Supplemental Re ports of Injury...............................* 27 Accident Investigations.....................................................83 7-62 APC 000276 1955 Continued The following program* were continued during th* year: Accountant Train** - varied from two to four daring 1955 Employ** and Safety Xndoctrlnatiaa - Z74 amploy*** Plant Fir* Fighting Training - At*. 52/month participated Information Rack Sarvice - 36,950 booklet* - $1.67/ employee On-the-job Secretarial Training Th* following program* war* carried over from 1954 and were completed daring the year: February - Qffie* Supervisor Program February - Standard Coarse of First Aid The following miscellaneous activity was performed during th* year; Plant Visitations - three during year Served on TMA panels at Victoria College, Southwest Texas Junior College and Texas A It I. Prepared several papers for presentation at Tapoco. Visited Rockdale twice during the year in eonaeetion with the Trade Program and th* foreman Selection Survey. Visited SMU to discuss Co-op Engineering Program. Provided Victoria Optimist Club Program. Miscellaneous Film Showings as follows: IBM's "The Right Touch" XH's "Man With a Thousand Hands" Plant and Fire Protection The principal functions of Plant Protection remained the same daring 7-63 APC 000277 1955 Continued 1955. The degree of activity was stepped up dua to construction of Pat* lina No. 6. Number of Visitors Paaaaa......................................1, 550 Number of Material Paaaaa........................... 1*721 Number of Ambulance Calls.................................. . 22 Number of Fire Alarma........................................... 4 Number of Vehicle Accident* on Company Property...................... 3 Number of Trips for Firat Aid.................................. 58 Number of Trips for Personnel............................... 97 Community Relations During 1955, the Community Relations program was forwarded through such mediums as the Texaleoa Round-Up, placement of Alcoa advertise ments in community newspapers, news releases, plant tours, contributions to local community projects and participation in local civic affairs. March Dinner meetings held for Kiwanis, Rotary and Club members and wives. April United States Savings Bond Drive increased parti cipation to 50.4% of employees. October Held the first Alcoa Employees' United Fund Drive. December The Children's Christmas Party was attended by 800 children. A. Published six issues of the Round-Up. B. Published the booklet Calhoun County Progress. C. Conducted plant tours for eight groups. 7-64 APC 000278 1955 Continued D. Loaned films to civic groins an a number of pccaaions. E. Provided cheat X-rays for 66 Calhoun High School seniors. F. Cave a prise for the Calhoun County Youth Rodeo. G. Assisted Point Comfort pre-eehool clinic and Palacios polio vaccine programs. H. Distributed "Aluminum by Alcoa" to all employees. Z. Designed and addressed 2,030 Christmas cards. J. News releases - thirteen Cafeteria The Cafeteria continued to be operated by the Progressive Cafeterias Incorporated. Mrs. Ruth Fletcher continued to be the local manager. Breakfast and lunch were eerred in the di aing room Monday through Friday each week. The mobile unit operated three shifts per day every day. Special dinners were served to groups ranging from 60 to 120 people on seventeen occasions. Labor Relations A Labor Relations Committee was organised on February 6, 1955. Its purpose was to consider and advise on major plant problems with e view toward maintaining efficient operations in conjunction with good labor re lations. The Committee is composed of representatives from different departments in the plant. A Fortmsn Training Program was initiated to better acquaint foremen with the rules and regulations of the Master Contract. During these meetings 7-65 APC 000279 * i 1955 Continued Contract Interpretation* and the daclelone of the Arbitrator on other plant grievances were discussed and analysed in ord.tr that the foremen would have a better knowledge of what they could sad could, not do toward maintaining better labor relations less grievances. These meetings were held per iodically during the year. A plant-wide Safety Committee was organised and was composed of five Union representatives and five Company representatives. Dinner meetings are held once a month with planned programs designed to keep the Commit tee informed on the Company's safety program. These meetings as a whole have proved very successful. In May, plans were formulated for an Apprentice Program. After spending considerable time in drawing up Apprentice Standards, obtaining in structors and selecting apprentices, outlining related courses for the various crafts, obtaining final certification end Union agreement, the program was officially started an September 12 with fifty-two apprentices attending. Claeses are scheduled on Monday and Thursday. This program is still active with no serious labor relations problems to date. The dual duties of Civil Defease and Disaster coordination were turned over to Labor Relatione in July, 1955. Xn connection with Disaster coor dination, extensive plans and precautions were made in case of a hurricane. Letters were sent to all employees to obtain volunteers to assure adequate coverage. Key personnel were assigned to specific responsibilities. Arrange ments were also made for taking care of minor emergencies in the plant. 7-66 APC 000280 1955 Ccatoud This Department attended the following activities daring 1955: 1. Southwest Area Conference on Industrial Relations held in Houston in May. 2. Wage Negotiations in Pittsburgh in July. 3. Training in Company-wide Employment Program* and Labor Relations as they pertain to the Refining Division held in Bauxite* Arkansas during November. A total of sixty-six grievances were heard at the Third Step level of the Grievance Procedure during 1955. Of these* thirty were appealed to the Fourth Step level. Five cases were carried to Arbitration with decisions rendered on two of the cases. Problems relating to Yeterans Reemployment Rights arose during the latter part of 1955. Meet of these have stemmed from die difference in our Plant Policy before April 1* 1954. These problems are still active. 7-47 APC 000281 PURCHASING BEPAMEEIT HISTCRT 1950 Hr* ... R. :telzar, Jr* was appointed District Purchasing Agent in February having been transferred front Construction Division Purchasing Department. I!r. J. R* McGhee was appointed Assistant District Purchasing Agent in July having been transferred fTcm Construction Division Purchasing Department* The department also has two stenographers assigned* In August and September the purchasing for three subsidiary companies was transferred fren the Construction Division* The Alcoa Mining Company is drilling oil and gas veils to develop reserves for gas engine operation* The Lavaca Pipe Line Company is transporting the gas to the plant site* The Calhoun Development Canpany is building and maintaining various housing projects* The following is a record of Local Purchaseai Alcoa Alcoa Mining Lavaca Pipe Line Calhoun Development Co* 1,979 111 68 12 PDFCHASING DEPARTMENT HISTORY 1951 /An additional stenographer was added in February. Mr* J* R. McGhee was transferred to Rockdale v/orks as District Purchasing Agent for the Construction Division in August* Mr* George H. Centebar was transferred from Pittsburgh Purchasing Department to Point Comfort -orks as Assistant District Purchasing Agent in August. Hr. Joe ? Mohair was hired in November as an expediter* The following is the record of Local Purchases i Alcoa Alcoa Mining Company Lavaca Pipe Line Co* Calhoun Development Co* l*, 835 6hS 27L 66 8-1 APC 000282 PORCHASIHO DEPARTMENT 1952 This department was responsible again this /ear to filialnun Oompeny of America (.%elting Operations)* Aleoa Mining Compaq (Oil and Oas Division)* Lavaca Pipeline Company (Oas Transelssian Lines)* Calhoun Development Company (Employes Housing)* and Construction Division (D.C. Casting Unit). The departaent had a District Purchasing agent* Assistsnt District Purchasing Agent* and three stenographers until Hovember* when L. G* abb was transferred from ALaddun Ore Company at East St. Louis as an Engineering Buyer* The following is the record of looal purchases! Aluminum Co. of America Alcoa Mining Company Lavaca Pipeline Company Calhoun Development Company Total 5*985 925 292 88 Hotel All D.C. Casting orders were placed under the name of Aluminas Company of America* 6-2 APC 000283 fjrchap dig depatt:e:t 1953 burinr the year* charges in corporate structure set up the Aluminum Company cf Anerica (Smelting Division)* Aluninua Company of America (Klning Liririon - Oil and Gas Department) Aluminum Company of America (Housing Department), Lavaca Pipe Line and Construction Division as the divisions rervod by the Purchasing Department* Tide dcpcrtnont hnd c District Purchasing Agent* Assistant District Purchasing Agent* Engineer luyer, and one secretary and three stenographers at tho start of the year* ' On December 1* P. K* Marquette vas tranBferrod to this plant from Kassena, Mew York Operations* to replace V. R. Ptclzer, Jr. who is to be transferred to the Houston Office of tho Mining Division as Purchaslnr Agent* effective January 1* 195In All purchasing for the Aluminum Company of America (Mining Division * Oil and Gas Department) will be carried on from this location. The foliowin- is the record of the plant purchases on local order numbers only and does not include purchases made for the plant by Pittsburgh Purchasing Department. Total !'o. of Orders Total Value ACOA .''melting 5,2/6 51*157,592.69 ACQA Mining llv. ACOA Housing tiv. 730 867,5Hi.35 33 12,533*95 Lavaca Pipoline 219 31*73li*01 Total 6,258 52,069,375.20 8-3 APC 000284 A. PURCHASING DEPARTMENT 195U During the year* this department vas responsible for the purchasing activities of Aluminum Company of America (Smelting Division and Housing Department) as veil as the Lavaca Pipe Line Company* No differentiation has been made between orderG issued for the Smelting Division and the Housing Departrent. The department personnel consisted of a District Purchasing Agent, Assistant District Purchasing Agent, Engineering Buyer, and three stenographers until June 30, when G. H. Centebar was transferred to the Pittsburgh Purchas ing Office. On October 11, L. E. Laird transferred from the Power Department to become a buyer trainee and filled the vacancy created by George Centebar*s transfer. The following is a record of plant purchases on local orders only and does not Include purchases of Alumina and Cryolite from the Refining Plants! Total Ho. of Orders Total Value Aluminum Company of America (Smelting and Housing) l*,l*0l* 880,732.85 Lavaca Pipe Line Co. _JL6 11,970.65 U,569 $892,703.50 8-1* APC 000285 * PURCHASING DEPARTMENT 1955 This department was responsible lor all purchasing activities of tha Aluminum Company of America, Smolting Division, and tha Lavaca Pipa Lina Company during tha past yaar. Excapt for tha laying of a short pipa line by Lavaca Pipa Lina aarly in tha year, thara was vary Uttla activity for that company. la contrast, thara was considarabla activity for tha Smalting Division as ws wars involvad with purchasing work for tha addition of tha sixth potlina. Tha department was involved in a number of personnel changes during tha year, bat generally consisted of the Purchasing Agent, Assistant Pur chasing Agn. engineering buyer and three itanographers. During March, ,1 L. E. Laird was assigned to work on construction activities and C. M. Clayton was transferred from Industrial Engineering to tha Purchasing De partment as a buyer trainee. On June 30, L. E. Laird was transferred to tha Pittsburgh Purchasing Department. The following is a summary of tha local orders placed by tha Purchasing Department during the year 1955. It will be noted that tha summary does not include purchases of alumina, fluoride, and cryolite from the Refining Plants. Aluminum Company of Amorica Total No. of Orders 4, 759 Total Value $1,293, 012. Lavaca Pipa Line Company Total............................ 127 4, 86 27,193. $1,320,205. l S-5 APC 000286 1 ACCOUNTING DEPAREJT 1950 Although the first pig was produced at Point Comfort in February 1950, it vos necessary for the company's permanent accounting organisation to commence work along with the first construction at Point Comfort, to handle those phases of accounting that do not end when plant construction ia completed* The following department heads were at work on January 1, 1950, iiandliug a gradual involvement of accounting work froa construction to operations: Nai'je From Occupation Bogan Work at 1*0int Comfort F. E. Rogers Caldervood Forks Chief Clerk September 191$ ?. VJeinheimar Niagara Works Ass't. Chf. Clk. November 19h9 Jim Phillips Davenport Forks Cashier July 19U0 C. F.. Goodwin Pittsburgh Office Asset Custodian January 19hP Chapman. Hensell Local Timekeeper October 19U9 Joe Dugat Local Fayiaaster January 19h9 Joe Allen Washington, E. C. Invoice Clerk April 19li9 E. S. Snyder Niagara Works Storekeeper January 19U9 by August 1950 the construction accounting was completed and the accounting effort vela fully centered on production activities* During 1950, an average of U7 employees was engaged in the Accounting, Payroll, Timekeeping, f.tores and General Office effort at Point Comfort* 9-1 APC 000287 ACCOitflTEIG DEPARTMENT 1951 The following Department Heads were at work all year of 1951 in the Point Comfort Works Accounting Department: F. E. Rogers P. Veinheimor Jim Plilllips C. F.. Goodwin Chapman Hensell joe Dugat Joe /.lien E. S. Snyder Chief Cleric Ass't. Chief Clerk Cashier Asset Custodian Timekeeper Paymaster Invoice and Freight Bills Storekeeper and District Traffic Manager hr* H* C. Whitesell, District Traffic Manager for tne Construction Department, was transferred to V.enatchee Works in October 1951, and the local traffic work was incorporated into the local stores work under the direction of Mr. E. 5. Snyder. During 1951, an average of U9 employees was engaged in the Accounting, Payroll, Timekeeping, Stores, Traffic and General Office effort at Point Comfort. In January 1951, a new Model 1250 Automatic t'.ultigraph printing machine wan purchased under Authorization TR-217U1, replacing a hand-fed nultigraph machine carried over from Construction. In January 1951 a new Model 22115 (lii5) National Cash Register payroll machine was purchased under ^uth. TR-212S3, replacing a Burroughs Payroll Machine transferred in from Davenport .orks during Point Comfort construction. 9-2 APC 000288 4 POINT CCKPGRT V.ORKS ACCOUNTING EEPARTKENT 1952 F. E. Rogera Chief Clerk P. Weinheiaar Assistant Chief Clerk Hr* Weinheiaar was transferred to our Pittsburgh Office Novanber 1# 1952* The selection of a replacscant at Point CoafDrt was deferred until 1953* During April 1952# Point Comfort Uorka was connected in with our Company* s private'line teletypewriter network* This cane at an opportune tine# as Western Onion vas out on strike most of April. Cashier Jin Phi 111pa - Cashier 1 Assistant Clerk 1952 Work Load Imprest Fund Cash Books Aluminas Company of America Calhoun Developnent Company Lavaea Pipe Line Company 91* pages 51 pages 20 pages Number of Rant Accounts 12-31 Number of Vater Accounts 12-31 Number of House & Lot Sales Accounts Nunber of Defense Bond Accounts Employee's Sales Oders - 1952 29U 267 U9 11*7 7#150 Asset pspartaant C. E. Goodwin - Aaaet Custodian Assisted by li Clarks# 1 typist 1952 Work Load Number of Individual Assets as of 12-31-52 9-3 APC 000289 A 1952 Continued Aludnua Company of America Normal Depredation Amortisation 1L*707 U721 Calhoun Developnait Company Normal Depredation Amortisation U70 396 Lavaca Pipe Line Oaapany Ronaal Depredation Aaortisation 161 lil Payroll & Tinekeeping Joe Dogat - Paymaster Assisted by 5 Clerics Chapman Hemsell - Timekeeper Assisted by 1* Clarks On April h our Plant payday was changed from Thursday to Friday in order to give these departments sufficient time to prepare the paychecks each week. On December 1* 1952, the local Alcoa Mining Company payroll was placed in this office* 1952 Work Load Number of employees on local payroll: 1-1-52 12-31-52 Aluminum Company of America Calhoun Development Company Lavaca Pipe Line Company Alcoa Mining Company 912 2 5 0 1,109 2 5 U Cost Office C* L. Ashmore -- Chief cost Accountant Assisted by $ Clerks, 2 Typdste 9-U APC 000290 * 1952 Continued Cue Clark was transferred out of this department November 1# 1952# to the Production Departaant for training as an Ingot Casting Foreman. 1952 Vork Load Ntsnber of Factory Invoices issued* Aluminum Company of Aasrioa Calhoun Eevelopaant Company Lavaca Pipe Line Company Alcoa Miming Company 1,880 288 327 6 Humber of Journal Touchers issued* Aluminum Company of America Calhoun Development Company Lavaca Pipe Line Company 823 208 11*1 Humber of Metal Invoices issued Humber of Cafeteria entries Niaaber of Freight hills paid* ALuiinua Comparer of America Calhoun Development Company Lavaca Pipe Line Company 1#282 58,091 7,1*75 28 61 Number of Invoices Approved & Listed* Aluminum Company of America Calhoun Development Company Lavaca Pipe Line Company 10,993 278 1*1*5 Stores E. 5. Snyder - storekeeper H. I<. Flanery - Assistant Storekeeper During 1952# such was done in connection with the reduction of Reclmation Stores. The following tabulation explains how this was accomplished* Number of Purchase Orders involving transfers to other Company Plants 71* Number of items included in above orders 21*9 Total value of all materials shipped in accordance with these orders 9-5 01,727.59 APC 000291 * 1952 Continued A worthwhile luabar storage has been prorlded for this facility* It v&s a temporary quonset hat used by the electrical contractor on the 1951 Extension* was waved to the Tielnity of our rtoreroaa. The building is equipped vith racks which make for a Tory efficient and neat storage arrange- sent for this eosaodity. Prior to the availability of this building* the handling and storage of luabar used valuable floor area of quonset huts* i badly needed for proper storage sad segregation of other Materials. Lumber stored in this manner (not properly racked or binned)* does not make for efficient storage and {roper segregation* The availability of two additional quonset huta* else 1*0 feet X 160 feet turned over to us upon completion of the 1951 Extension* aided greatly in providing ranch needed storage facilities* Storage bins left in one of these buildings proved valuable for storing <p-l spare parts carried for use in the power department. They were coved frcn Building 15# the sain stores building* The plan created raany additional storage bins for which we have found ready use. The second quonset hut gave us the ranch needed spaoe for 8torage of fire brick* hl-terap insulation and iteas of a bulky nature. Plane were laid the latter pert of the year to r eloeate steel supplies such as plate* pipe and bar stock* Work on this is progressing and when completed, a fenced area will be provided which should give us the control required for proper handling of our steel stores* Racks for the effielmt storage of shovels* autoBohile and truck tires and "Y" belts were designed and built at this location. Ve are prepared to furnish drawings to any of our plants which are interested In these facilities. The added tnrdan of receiving a large percentage of naterials required for the new D-C casting installation was experienced. This work was 9-6 APC 000292 1952 Continued accomplished with our normal operating fares. The number of people engaged In the various stores functions follovsi Receiving 6 This includes typist on Receiving Reports, and a filing clerk. Dispensing 6 Two of these people assigned to outside storage areas. Che assigned to the Ul30 P.M. to 12130 A.M. Shift. Accounting 5 Includes posting, card clerics, H.R.B. accruals, order clerk, catalogue weak, etc. typists 2 Typing Purchaaing Department Requisitions, Osneral stores typing and stationery supervision. Foreman 1 Oeneral Floor Supervision Janitor 1 R. Plenary arrived December 15 from ftoeielare works, to begin his duties at Point Comfort feorlcs as Assistant Storekeeper. In Vt&BBdLD up the following tabulation will further shov the activities of this department during the year 19U2. Number of Forms Processed Miscellaneous Receiving Reports Aluminum Company of America Lavaca Pipe Line Company Calhoun Development Company 12,1(01 ll*l* 293 "'.tores Requisitions - By Items Aluminum Company of America Lavaea Pipe Line Company Calhoun Development Company 11*8,720 125 90 Returned Material Reports Aluminum Company of America Lavaca Pipe Line Company Calhoun Develop&ent Company Employees Sales Orders Miscellaneous Shipping Cbrders iltwlnua Company of America Lavaea Pipe line Company Calhoun Development Coapany *-7 232 0 0 7,150 1,197 35 11 APC 000293 4 1952 Continued Purchasing Depurtaant Requisitions Alnaixun Coapany of Aaerica Larsos Pipe Line Company Calhoun Derslopoant Corapany 6Ui2 2li6 6U Accounting Trainees Plant training of Aecounting Trainees for our Pittsburgh Office was couuenced at Point Comfort Works in Hovoofciar 1952 with the employment of three traineesi Edward W. Tidwell Faynond S Vaughan Woodrow K. Burgess 9-8 APC 000294 * POINT CONTORT V.CKKS ACCOUNTD; DLPANThLNT 1953 C. If. Gear vas transferred to Point Comfort from Vancouver ir.orks in April as Assistant Office Manager* The local records of the Calhoun Development Company vere closed on April 30 due to dissolution of this Alcoa subsidiary. Their activities were absorbed by Aluminum Cong)any of America. A heavy emphasis was placed on training of new and old personnel durinr this year. The throe Accountinr Trainees placed at the plant by the Pittsfcurrh Accounting Department passed the half-way nark of their two-year schedule. James C. Alley was employed in December to receive a twelve month's traininr program for 'tores leadership. A program of train ing by job rotation for promising clerks in related accounting work was begun in `September. A program for the introduction of the new Smeltin- Plant Accounting Frocodure was carried out ir. December. Deetinrs were held with all plant departments for a coamon interpretation of proper accounting with respect to Laoic plant records such as tine reports one ;)aterial requisitions. "heir participation in this change was assured ty whole hearted acceptance of their ideas for cub-accounts to better control their costs. Tim follouin- detail will rive an idea of the Accountin'* Department's production* Cashier - James A. Phillips 9-9 APC 000295 *. 1953 Continued 1953 Activities Dec. 31 Number of Pent Accounts Number of House and Lot Sales Accounts Number of Defense bond Accounts Number of Employees Pales Orders Water Accounts Transferred to City of Point Comfort October 1> 1953 277 1)1 210 5,605 Cost Office - Clarence L. Ashmore - Chief Cost Accountant 1953 Work Load Mumi or of Factory Invoices Issued Number of Journal Vouchers Issued Number of Sales Invoices Issued Pie . 1,1)21) Ingot 1)22 Number of Freight bills PaJd Number of Invoices Approved L Listed l,92l) 1,038 1,81)6 8,025 9,1)15 The D. C. Casting Department began production during May vhich added a new set of metal records necessary to take care of fabricating accounting. Asset Department - Carl L. Goodwin - Asnet Custodian 1953 Activities Number of Individual Assets Processed Luring 1953 Aluminum Company of America New Shoots Add Sheets retirements Normal Depreciation Amortization Donations to City of Point Comfort 61)6 223 - 278 61) 338 66 Calhoun Development Co. (U months) Normal Depreciation Amortization 53 - 7 Lavaca Pipe Line Company Normal Depreciation Amortization 29 9 3 5 Total Number of Individual Assets as of 12-31-53 Total Number of Authorizations Closed During 1953 Total Number of Shop Orders Closed Luring 1953 15,668 88 1)55 9-10 APC 000296 19$3 Continued Payroll & Timekeeping - Joseph C. lrugat - Paymaster Chapman A. Hemsell - Timekeeper 19$3 Activities No. of Employees Aluminum Company of America Lavaca Pipe Lin:- Company Jan. 1, 19$3 1,109 $ Dee. 31, 19$3 1,190 $ Calhoun Development Company 2 Alcoa Mining Company h General increases were put into effect for th-e hourly employees January 1st, July 1st and July 13th. Escalator adjustments were made February 2nd, liay lith, /umet 3rd and November 2nd. storeroom - Luther F. Rogers - storekeeper Hay 1, Fj. Snydor started devotinr full tine to the Traffic Department duties and F.. K. Flanery assumed the Storekeeper responsibilities. December 1st, la*. Flanery was transferred to Pittsburgh Office and L. J. Rogers succeeded in. Flanery. The number of people enraged in various stores functions are as follows! Deceiving 6j bir.bursinr 7j Accounting Si and Typist 2. ' rovised edition of local stores catalog war issued the latter part of Iecember. Additional facilities in the Ftoreroon have added to the efficiency of this section, they consist of a new air conditioned Receiving Office, Ladies Lounge improvements, Talk-a-Phone speaker system, new 1,000 pound fork lift truck to replace the heavy li,000 pound lift truck and a new half ton pick-up truck. 9-11 APC 000297 1?5? Continued Humber of Feme Processed Fdscellaneous Receiving Reports Stores Requisitions - Ey Item Return Katerial Reports Employees Sales Orders Miscellaneous Shipping Orders Purchase Department Requisitions 12*856 66*115 U7o 5*605 980 U*303 SHIPPING- L TRAFFIC I-eginninr April l,far the first tine Point Comfort had an independent Traffic Department. Prior to this time the Traffic Department has been conbinod with the "tores Department and the traffic manager has been hand ling both the torekeepor and Traffic assignments, beginning in April* the Traffic Lopartnent was separately set up independent of tho stores procedure. The Shipping Department, which had prior to that time teon under special supervision* was changed to the overall supervision of tlie Ingot Department and the foreman which, had been in charge was transferred to the Potrooms. The shipping facilities were completely changed during the year due to the expansion program v.hich necessitated removin- the old Ehippinr offices and scales and re-establishing thorn in a different location, addin,- nine sections to the shippinr buildin- and changing shipping facilities to include the ihipraent of sheet ingot. Durin:- tJ-e year, considerable metal was shippsed via b arge from our docks to the Government "tockpile and experimental shipments were .made to the. Davenport, Iowa, ..orks via Largo. Except for the amount of timo required for barge shipnents in transit and tho lack oi' adequate crane loadin' facilities on our dock, tho shipments wore satisfactory. These shipments vrere iuade at a cost considerably lower than tf>e normal rail shipments to these locations. As early as there is an adequate supply of metal to allow 9-12 APC 000298 19;3 Continued & larger volume to bo in transit betweon here and 1`avenport, the bar.ro shipment offers considerable cost redaction for transportation of both inrot ana pi;; between this location and Davenport or between this location rnd the '.overnnent ' tockpile. 9-13 APC 000299 accounting departi-djit 195U K. S. Vaughan and Woodrow H. Burgess, accounting trainees, graduated from their training program the latter part of 195U. R. r# Vaughan was transferred to the accounting staff at Lafayette orks December 1, and W. II. Burgess was as simod to the Cost Office here at Point Comfort* Two additional trainees, V. L* Hicks and W. L. Harries, were started in the Accounting Trainee Program. James C. Alley completed his tour of training in all plant departments and assumed his duties as Storeroom Foreman* Our new Smelting Plant Accounting Procedure enabled us to present a monthly departmental blue sheet for each operation in the plant to all supervisory personnel by departments. The accounting group covored tho cost records for January and February with a detailed explanation. Thereafter, the department heads carried on their own meetings. The use of teletype facilities in fales Invoicing Procedure started the middle of 19SIi It eliminates delay in rendering invoices and expedites the use of the analysis sheets by vendee. Job rotation for promising accounting people continued through 195U. The following detail covers tho 'ccountinr Department's production* Cashier - James K. Phillips was cashier. He had one clerk. 195h Activities Dec. 31 Number of Rent Accounts Number of House and Lot Sales Accounts Number of Defense bond Accounts Number of Employee Sales Orders 266 6 219 2,312 host of our itouso and Lot accounts were sold to Equitable Insurance Co. 9 - 1U APC 000300 1951* Continued Payroll L Timekeeping Paymaster -- Joseph C* Lugat* assisted by It clerks* Chief Timekeeper - Chapman A. Hensell* assisted by 3 clerks* 1951* Activities Number of Employees 1-1-5It 12-31-51* Aluminum Company of America 1*190 1*197 Lavaca Pipe Lino Company 55 One general increase vent into effect for hourly employees on August 1 and for salary employees on August 2. Asset Department Chief Property Accountant - Carl E. Goodvin, assisted by 3 clerks* 1 typist. 195I> Activities Humber of Individual Assets Processed during 19?It* ALUKTHfll COMPANY OF AN!.RICA Non-Aicrtizable Amortizable LAVACA FIFE LINS CO.'IPAHY NEl i SHEETS 329 82 ALL SHUTS 119 21 R-TIKLISKTS 152 53 Hon-A. jortizatle Amortizable 2 13 Total Humber Individual Asset hheots All Companies Total Humber Individual Assets All Companies 6*660 lit*531 Number of Authorizations Closed Luring 1951* - All Companies Humber of Shop Orders Closed During 195lt - AH Companies 1*5 It92 The Company adopted the "Sum of tho Years Digits" depreciation procedure for all assets acquired during 195Ii* Storeroom Chief Storekeeper - Luther F. Rogers* assisted by 17 clerks* 3 typists. 1951* Activities Number of Miscellaneous Receiving Reports Number of Stores Requisitions Processed Number of Purchasing Department Requisitions 9*902 69*01*1 U*238 9-15 APC 000301 1951i Continned The Traveling Requinition system, inaugurated November 15* 195b* materially reduced the paper work volume the last 2 months of 195b* A local material control procedure was started in January which required the combined effort of Purchasing, ftores and the Engineering Department. Cost Office Chief Cost Accountant - Clarence Ashmore, assisted by 5 clerks, 2 typists. 195b Activities Number of Factory Invoices Issues Number of Journal Vouchers Issued Number of Sales Invoices Issued Number of Freight iillc Paid Number of Invoices Approved 658 397 1,795 1,002 1*055 7,125 7,630 A two-day reduction was made in the dates for all reports due in Pittsburgh wldch necessitated tho improvement of Accounting procedures. The Cost Office lent every support possible to the Cost Aware Program by preparing many new detail sunaaries never before requested. THATHX DEPART. HIT ith the opening of navigation in the upper Mississippi River, our first barge shipment of metal was shipped February 23* Lading in tho firGt barge consisted entirely of sheet ingot destined for our Davenport Works. Approx imately 53*000 net tons of pig and ingot were loaded into 50 barges and shipped to Riverdale, Iowa, before the close of navigation on November 5* 195b. A meeting of all plant traffic representatives was held in Pittsburgh November 8 through 11. The agenda of the meetings covered practically an functions of the department. An interesting up-to-iate report was given by 0. F. Reynolds and others of the Administration Procedure Connittee. Representatives from Commodity Managers' offices were also in attendance. 9-16 APC 000302 I?5Li Continued Experiments were conducted Kovenber U and 5 relative to handling alumina in rubber containers (Seald-Eullr rysten). Feasibility of roving alumina in euch containers in barge lots was considered. The experiment at Point Comfort consisted of filling and emptying the container. 9-17 APCOOO303 ACCOUNTING DEPARTMENT 1955 During 1955 an earnest effort was made to simplify parts of our ac counting procedure both on the part of ths Pittsburgh Office sad at the local level. Gains were made through: penny elimination* changes in method of invoice approval and freight bill listing* use of teletype facilities to permit earlier dosinge which makes for more effective statements, and elimination of unnecessary details connected with the payroll plan for the purchase of U. S. Savings Bonds by employees. A new Local Exempt Salary Plan was adopted at the Works as of March 1 covering personnel on both the local payroll and the Pittsburgh payroll. This new confidential payroll was set up as a separate unit of the regular Payroll Department. ^ The Construction Department established their office for the sixth pot line expansion early in the year and several trained people were provided for that effort. Woodrow H. Burgess was transferred to the Houston Office of the Mining Division July 1, 1955, and William B. Hicks followed on December 1, 1955. John C. Thomas was employed for the Accounting Trainee program September 5, 1955. Job rotation continued for the more promising people during the year. Cost Office Clarence Ashmore - Chief Cost Accountant Assisted by six clerks* two typists 9-18 APC 000304 A 1955 Continued 1955 Activities Number of Factory Invoices Issued Number of Journal Vouchers Issued Number of Sales Invoices Issued Scrap Hi Ingot Number of Freight Bills Paid Number of Invoices Approved ACOA 1,637 965 m 8 456 1,134 6,664 10,764 LPL CO, 315 159 m m 20 214 Fixed Capital Carl . Goodwin - Chief Property Accountant Aelilted by three clerks aad ona typist 1955 Activities Number of Individual Assets Processed daring 1955. Aluminum Company of America New Sheets Add Sheets Retirements Non-Amortisable Amortisable 721 216 238 9 ft 111 Lavaca Pipe Line Company Nan-amortisable Amortizable 5 36 -- Total Number Individual Asset Sheets All Companies Total Number Individual Assets All Companies 9 040 15. 420 Number of Authorisations Closed During 1955 - All Companies Number of Shop Orders Closed During 1955 - All Companies 54 552 Storeroom Lather F. Rogers - Chief Storekeeper Assisted by eighteen clerks and three typists 9-19 APC 000305 1955 Continued 1955 Activities Number of Miscellaneous Receiving Reports Number of Stores Requisitions Processed Number of Purchasing Department Requisitions 10,985 75, 356 8, 833 Robert Been was added to the Storeroom personnel and placed on a plant* wide training program. Due to the sixth pot line construction 15D and 15E were discontinued as auxiliary storerooms and the equipment was moved to other locations. The plant garage was relocated and forty feet of this building was assigned as a parts department under storeroom supervision where the facilities of a modern service station are available. Many new items of Alcoa products have been added to the Employees Sales section with very satisfactory results in the eale of Alcoa Wrap and Alcoa Aluminum Fastners. Payroll lc timekeeping Joseph C. Dugat * Paymaster Assisted by five clerks Chapman A. Hexnsell Chief Timekeeper Assisted by four clerks 1955 Activities Number of employees 1*1*55 12*31*55 Aluminum Company of America 1197 1394 Lavaca Pipe Line Company 55 A general increase became effective August 1, 1955, for both hourly and salary Including an hourly increase of . 03 per hour retroactive to August 1, 1954. 9-20 APC 000306 1955 Continued Cashier James M. Phillips - Cashier Assistant Clerk - one Part-time Bond Clerk - one 1955 Activities December 31 Number of Rent Accounts 231 Number of Defense Bond Accounts 653 Number of Employees Sales .Orders 3202 A plant-wide Savings Bond Drive was held the last part of April where a gain was made of 145% over the number of participants in 1954. A payroll check cashing service was installed at the Paint Comfort Shopping Centex* March 4 between the hours 9x00 A. M. sad 3:00 P. M. Payroll checks are given out and may be cashed. Traffic Department Barge movements of sheet ingot to Davenport Works were held to one barge per week end for s total of 21, 717 net tons. After the close of the nor mal navigation season. Federal Barge Lines inaugurated s movement to Riverdale, whereby barge was used to St. Louie and truck beyond. After release of five barges, scheduled to move in this manner, further loadings were cancelled as of January 11, 1956. It was explained that the demand at Davenport Works was too grsat to continue the barge-truck service. Starting September 15, shipments of reclaimed cryolite to Rockdale Works for tills psriod amounted to sixteen cars containing 365.5875 ast tons. 9-21 APC 000307 A. 1955 Continued EittBtiTt ut u made of our dock where ell structural steel, required for the 1955 expansion, was unloaded by American Bridge Company. 9 * 22 APC 000308 PUBLIC RELATION F. DEPARTMENT POINT COflFOP.T YCRIS 1950 There waa no organized Public Relations Department at the Point Comfort Works during 1950. The plant personnel - with the assistance of the Pittsburgh Public Relations Depart.Tent - staged an open house program that was one of the year's hirh points. The program attracted some 10,000 persons on June 2l* and 25. The visitors wore shown through each section of the plant and accorded full hospitality*" The open house resulted in rather extensive publicity, as did the pouring of the first netal produced at Point Comfort or, for that matter, in Texas on February 11. Considerable newB space also was devoted to the visit of Alcoa Pre8ident Roy Hunt to Houston and Port Lavaca on February 21. On hay 16, 1950, five members of the Point Coofort Forks staff - George R. Stout, R. Stelzer, George Rhoades, F. F. Ropers and A. L. Dymond were selected as directors of the Port Lavaca Chamber of Commerce* Tho Toxalcoa Roundup, the Point Comfort Lorhe publication, was established in December. It was set up as a one-pase mimeographed product by the Dmployment Office. 10-1 APC 000309 PUBLIC RT-LATiaiS DEPARTMENT POINT CO TOP.T WORKS 1951 On January 11, the company made the announcement that two new production units costing 115,000,000.00 would be added to the Point Comfort Works* Three months later, the works figured in the news again when 0* L* Buchanan, Superintendent of the Lavaca Pipe Line Company, was elected to the Port Lavaca City Council. The Public Relations Department of the Point Comfort Works was created and began functioning July 19, 1951* It is headed by Vemon G. Miylie, who is directly responsible to the 'Works Manager* The first task at hand, of course, was the double-sided one of setting up an office and making appropriate contacts both among company people and others in the communities in our immediate airea. Tliis was promptly under taken, and -- as rapidly as possible -- carried out* The Job of setting up an office included establishing a file system for both photographs and informational stories for public release, and obtaining a stock of booklets and the like to bo jassod out or nailed on appropriate occasions. Three company films - "Unfinished Rainbows", "Curiosity Chop", and "This Is Aluminum" - were borrowed on a permanent loan basis from the Pittsburgh Office. A movie projector for the Bhuvlnr of those and other films was placed on order by the . orks. Press relations perhaps occupied the largest anount of the Department's tlno during the latter part of 1951 primarily because of announcement of plans to construct the Rockdale Works. The announcement tarns handled through the Point Comfort Public Relations Department, which has since continued to serve as the news outlet for the Rockdale Area* 10-2 APC 000310 1951 Continued Tho first news releases regarding the Rockdale V.orks were made late in July. Early in September, Hr. imylie joined a group of Pittsburgh officials in Leilas and from there made the news announcement that Alcoa was to undertake construction of a plant at Rockdale. This received extensive use in newspapers in the Rockdale area and throughout the state. From Dallas. Mr. foylie proceeded to Rockdale for a week-long contact visit in the area. Other key news stories which were handled through the Point Comfort Public Relations Department- included an announcement that Alcoa was planning to build approximately 100 additional houses and a recreation hall in Point Comfort Village, as well as a week-by-week report to Rockdale area papers on progress at the Rockdale l orks site. In addition, the Public Relations Department assisted representatives of Tho kail Street Journal, The Mew York Times and The San Antonio Express in preparing stories about the growth of the aluminum industry in the South west. The Public Relations Department took over full production of the Texalcoa Round-Up, tho plant publication, in October. At that time, it was a sin.-lo-page, mimeographed sheet. In December, it was enlarged to a slickpaper, printed booklet six inches wide and nine inches deep, 'ihe December issue contained 12 pages. The Department, throughout the last six months of 1951, stood ready to assist in the distribution of news releases prepared in Pittsburgh and in the preparation of stories there for the Alcoa News or for outside groups and individuals. Ruch assistance frequently was requested. The Public Relations Department was active in moves to have both Calhoun 10-3 APC 000311 1951 Continued and "Ham Counties declared as critical defense areas* Vhile such desig nations vere not finally obtained until the early part of 1952, the work started well back in 1951* On a carasunity service basis, the Public Relations Department spent considerable time collecting data on Calhoun County's growth, which was turned over to the Port Lavaca Chamber of Ccsanerce* Some 500 copies of this statistical report have been distributed to interested parties* The Red Cross blood collection program for Calhoun County was administered by the Point Comfort Public Relations Department, as was the county-wide program for the American Cancer society. A campaign inside the Point Comfort Works Loosted the number of employees participating in the Defense nond Program from three to twenty percent. The Public Relations Department also made one of its prime objectives the promotion of certain activities in Point Comfort Village* Films were shown rather extensively in both the Point Comfort and Rockdale areas, and the demand for speaking appearances was pressing. The plant was visited by the Houston Purchasing Agents Association, the American Institute of lining and Metallurgical Engineers, a group of eastern investment bankers brought to the Gulf Coast by the Central Power and Li-ht Company, and tho student affiliate chapter of the American Chemical Society at St* Kory's University in San Antonio. An over-increasing number of requests for information and booklets about the Aluminum Industry were received and processed. io - u APC 000312 POINT CCHFCRT WORKS PUBLIC RELATIONS DEPARTMENT 1952 Administration The staff of the Public Relations Deportment vu increased to three persona* Kiss Margaret Kessler was added as secretary in February* Hre* Lois Norton came to work in August* The department took orer responsibility for all plant photography in June. In December* the Job of setting up a master file of all negatives pertaining to the Point Comfort works -- some 5*000 of than -- was begun* Press Relations A total of 216 news releases were mailed to newspapers in the immediate plant area* These papers included the Port Lavaca ave* Edna Herald* Qanado Tribune* Victoria Advocate* Palacios Beacon* Refugio Timely Remarks* Shiner Oasatto* Karnes City Citation* Kenedy Advance* Toakum Herald-Times * Cuero Record* Qoliad Advance Ouard* Consoles Inquirer* Yorktown News* De Vltt County View* Hallettevilla New Era-Herald* Hallettsville Tribune* Karnes County Neve* and others* These releases contained general information* names of new employees* prenotions* service annivarseries * and the like* Releasee containing general information were sent to larger newspapers around ths state and to the wire services which circulate information on a statewide and national bads. Newspapers in this category include the Houston* San Antonio, Corpus Christi* Austin* Dallas* Fart forth Press* the United Press* and the International News Service. Information for a general story about the aluminum industry in Texas was provided to J* L. Baughman of the Houston Chronicle* similar information was furnished to Clarence La Roche of the San Antonio Evening News* and material for a story about the central Texas Gulf Coast was furnished to Don Kings of The Houston Chronicle* 10-5 APC 000313 1952 Continued Mr* Baughraan as directed to Rockdale for stories about the Rockdale, Sandow, and Southern Railway, and about the history of lignite* In addition, the members of the Public Relations staff wrote stories that appeared in Texas Preview magazine, The South Texas nagaslne. The Review magazine, and the Part Lavaca aagasine* Information was furnished for an article in business Week magazine, a story in Diesel Progress magazine, and a story In Engineering Keve-Record. Visits to newspaper offices were intensified, and numerous editors toured the plant as public relations guests* A press tour was conducted in connection with the start of the fourth and fifth potlines which was attended by about one dozen newsmen and magazine writers. A new file of press photos was started, as was the preparation of a special information kit about the plant* Advertising One advertisement was placed in the Port Lavaca Wave regarding the expansion program. Work also was started on a aeries of eight ads to appear in area newspapers angled along a ccnmunlty relations 11ns* A connunity relations advertisement was placed in two general circu lation magazines in Texas, an industry magazine, and two chamber of conaerce magazines. Publications The Texalcoa Round Up became a slick-paper, magazine-type publication and was published eight times. It contained such general features as listings of service snoiversarieB, births, promotions, and new employees* Educational articles were Included about the of bauxite and about 10-6 APC 000314 1952 Continued the Alaskan project. One Issue featured a comunity relations story about Calhoun County* another contained a story about our tax contributions* and another dealt with our recreation program. A eries of articles about various departments in the plant was started. Departments about which stories mure written included Power* Accounting* Mechanical* and the natural gas branch of Alcoa {lining. The F.ound Up started the year with a circulation of 1200. As the number of plant employees was increased due to expansion* the number of copies cir culated was increased. We' also started mailing the Round Up to eane 500 persens in the Port Lavaca area as a canmamity relations enterprise. At the end of the year* the circulation figure hAd risen to 2000* which* for the foreseeable future at least* should be ample. In September* the Public Relations staff began printing a mimeographed announcement sheet which was called The Point Comfort Bulletin. It was published bi-weekly and designed to fill the gaps between issues of The Round Up. Employee Relations Weekly motion picture programs were initiated at the Point Comfort recreation Hall during 1952 for the entertainment of the people of Point Comfort Village. The hall was completed in February. The movie program was started in April. In all* the program was carried on for 12 weeks and attracted a total of 1*855 persona -- an srerage of 151; per weekly showing. The largest crowd was 227* the smallest waa 112. The hall, was equipped to seat 150 persons. The movie program waa discontinued during mid-summer. It was not resumed In the fall because the hall was put to uss at that time as a temporary classroom fbr first and fifth grade students of the Calhoun County Independent School District. 10-7 APC 000315 1952 Continued A recreation program was organized for the first time* An eight- teen plant softball league played on our lighted field, so, too, did a four-team Little League circuit for boys between the ages of eight and twelve, 'a fall moved in, an eleven-team vmen's volleyball league was organized* The email beys played a football game called "The Aluminum bowl." A hamburger dinner waa provided 67 the Point Comfort borke for all of the boys who participated in the Little League baseball program. A total of 2$00 ChriBtoas cards were mailed to employees of the Point Comfort Vorke and to other people. Each employee received a card signed by hie imediate superior. The cards were hand addressed, hand signed, individually stamped, and sealed. The 25-Year Club was revitalized. and a dinner was given in their honor in Port Lavaca. The Public Relations staff arranged several other parties and dinners. Conminity Relations The first organized group of plant visits was held. In the first visit ing group were tlie toachars of the Calhoun County Independent School District. Than came students from Port Lavaca, Victoria, Ganado, Vanderbilt, Edna, Austwall, and Vhartcn Junior College. Schools and libraries were provided with technical books about aluminum and charts explaining the diwinm process. A blood collection held st the plant in August under the auspices of the Red Cross brought 1U3 pints* The Public Relations staff worked an the program to bave Calhoun County declared a critical defense area. The public relations manager 10-8 APC 000316 1952 Continged spoke before the South Texas Geological Society In San Antonio, and participated in the Fourth of July celebration at Palacios. He also assisted vith the Alcoa exhibit at the Texas Stats Fair, attended the annual convention of the Texas Manufacturers Association, attended a TMA ccsnnnity relations seminar, and handled Alcoa's activities in connsction vith the Governors Conference in Houston* Plans vers mads to help vith the fencing of the Indianola Ceaetary, a landmark in the Pert Lavaca area, and to initiate a student vork program during the Burners. Congressman Clark Thompson visited the Point Comfort V.orka, as did State Representative Jimmy Patti son, Mayor Charles Luther of Palacios, and the managers of nearby Carbide and Du Pont plants* Erection of a sign at the plant entrance vas started. A display unit was obtained for overhaul and use at county fairs and in other exhibits* An intensive program of civic club participation vas undertaken. Pro grams vers provided clubs et Victoria, Palacios, Blessing, and Port Lavaca* In all, there were 18 programs. P.ockdale This office handled all public relations matters for the P.ockdale 'works until the arrival of a public relations director at that location in May. Initial vork was undertaken with George Sessions Perry for a story that eventually appeared in the Saturday Evening Post. A series of stories vare provided to newspapers in Central Texas introducing Rockdale Works management people. A comprehensive story about the Rockdale Works was written for a special issue of the Rockdale newspaper* 10-9 APC 000317 A POINT COMFCF.T WORKS FJBLIC EULATIOKC DEIAHTXINT 1953 Leainnin or. April 1, the Personnel Department assumed so.:ie of the activities of the Public Relations Lepart::ent due to the resignation of t:-.c Point Comfort Public Relations Director and tlie change of policy for public relations in Texas from a plant public relations director to an area public relations director. The Public relations Director far the area is located at Rockdale* and the Personnel Department at Point Comfort handles community relations and enployec relations only* with the other functions of public relations for the area tein.- handled from the Rockdale location. Community Relations Durinr 1953* tie Public Relations propram was forwarded through such mediums as the Texalcoa Kound-Up, placement of Alcoa advertise-.xnts in community newspapers* news releases* Open Pourc for the American Society of liechamical An-inoers* and plant tours for students. Community Relations covered such ovents rs the Red Cross Mood Collections, the incorporation of Point Comfort, and the penoral recreation prorran. On September 1, 1953* Alcoa loaned Mi,000 to lynnhaven Playground Association. Lois Norton became editor of the Texalcoa Round-Up. Si;: iss.ies of tro Texalcoa Round-Up were published* with the following features t January-Febru ryi > Peview of 1552} f story on Inpot Department Iiarch-Ai-Tj.lt Story on Palacios Kay-Junei Point Comfort's Annual Report Meetings. 10-10 APC 000318 1953 Continued July-August -"Incorporation of Point Comfort and history of locality. Septr.mLer-Octoben <m-?chool iond Program, as presented ty Citizen's Advisory Committee November-BecemLeri Four Years of Progressj the electrical Department. "The fort Lavaca Vave requested and vas given permission to reprint entire rtory on Point Confort and this locality for benefit of readers vho are not on our mailing list. **Thc issue on the Bchool bond vas distributed at the Port Lavaca Chamber of Commerce and throughout the county. This depart ment received letters from the School board of Trustees and tho National Citizens' Coajaission for Public chools citing Alcoa for interest shown in public schools through its publication. The found-up received an award for editorial merit in the field of feature writing at the Editor's Conference in June, which was attended by the Round-Up editor. The story receivin'- the award was one on Alcoa :ininr published durinr 1952. News releases, both local and Pittsburgh, were rent out to the Victoria Advocate, Port Lavaca Vave, Palacios Beacon, Lena Herald and Ganado Tribune. Pittsburgh news roleasec covered Alcoa's answer to the Department of Justice rcrardin" purchase of Canadian aluminum, the College -cholarship Program, hr. hoy < . Hunt's 50-yoar Vorvice Club award, Annual Report for 1952, and rtory entitled "Aluminum Industry ;nds Record Year." Local news releases covered such subjects as the Student Suai.ier Vorking Scholarship, Point Confort Annual Report, incorporation of Point Comfort Villa-o, announcement of Sponsoring Committoe end .election Board members for Alcoa 5'cholarship, naming of 6 student candidates for scholarship, etc. The followinr Alcoa advertisements were placed in community newspapers Alcoa's Progress is Your Progrees Announcement of Alcoa fcholarship Program Alcoa's 65th Anniversary 10-11 APC 000319 1953 Continued A weekly movie program war conducted at the Village Recreation Hall for six week?. The program was mace up of Alcoa's "See It Now" films, educational short:;, travelogues, animated cartoons, and Varner bro6. short features. Oren !lou:e was held for 126 members of the South Texas Division of the American Society of Mechanical Lnrinecro and their wives. Houston and Dallas Sales Offices were hosts to the Open House and tho barbecue that followed the plant tour. This department arranged appropriate displays. Plant engineers served as ruides on the tour. numerous photographs were taken and distributed to the .Sales Offices and A.S.M.O. officials. The following groups were taken on plant tours, followed by refresh ments in the Plant Cafetoriai 12 students of tho Pirate Engineering Club, Victoria College 38 members of the Victoria Hirh School cience Club li5 members of tho Industrial Arts Club, Port Lavaca High School Softball and Little Learue were played at Point Comfort Recreation field during the summer. Herb Story was first Little League president. Oscar Hunter was Little League secretary, as veil as softball con'dssioner. Forty percent of Little League players were sons of Alcoans. /icon presented trophies to uinnin- toais ir. softball end Little League and jerseys to Little -eague All . tars, Pen H. .loans, in behalf of Alcoa, presented the Calhoun County Little League Organisation 2,150 for buildinr of a Little League Park in Port Lavaca. Eight Alcoans were members o'- the VFW team which won the Calhoun County softball championship. Shirts inscribed with "Alcoa" were purchased for members of a bowling team made up of Point Comfort employees which competed once a week In a bowling league at Victoria* 10-12 APC 000320 A 1953 Continued I:. H. Sloane, In behalf of Alcoa, loaned "[(,000 to a playground association in Iynnhaven for purchase of fencing and playground equipment. The association leased the playground area from Alcoa on a 10-year no-charge basis. V.ithin the 3fl-ycar period, members agreed to pay back the <L,000 from membership fees. The area was fenced in and Includes the followin'- equip ment* basketball court, tennis court, softball diamond, swings, seesaws, merry-go-round, slides, and picnic tables. The bloodmobile of the Southeast Texas lefense Blood Center at Leaumont made two visits durln 1953* Cn January 5> 162 pints of blood were collected] and on July 22, 115 pints were collected* Land was made available ty the Calhoun County Development Company for a Methodist Church and a Lutheran Church at Point Comfort. Congregations moved in buildings and renovated them. This office secured automobile license plates upon request of employees. This department, in cooperation with the U. 3. ravings Livision of the Treasury Department, conducted a one-week drive in Point Comfort and Lynnhaven to recruit moncers for the payroll savings plan. A ijoeting was held on Juno 2h to answer numerous queries made by residents of Point Comfort Village in re"crd to incorporation. On July 11, by special election, the city was incorporated. A survey was made of retail drug and rrocery prices to determine price levels that would be feasible and acceptable in the establishment of like businesses in Point Comfort. A survey was made of several city c-ovemmnnt plans from information gathered iron the League of Texas Kunicii^alitieo in Austin. The object of the survey van to offer, as a courtesy to the officials of newly-incorporated Point Comfort, a number of solutions for their appraisal* 10-13 APC 000321 A 19$3 Continued A survey vas made of recreational facilities at other industrial plants in this area in connection vith a proposed plan to develop recreational facilities on the Layside of Point Comfort* E. H. Sloane presented the City of Point Comfort vith deeds to the water and sever rystems, recreation Hall vit: furnishings, softball field, boat dock, and all streets within the city{limits* Mayor Earl Lrmey accepted the gifts and exprossed the City's appreciation* The Point Comfort Works entered a float, on which an ingot vas mounted, in the Port Lavaca Annual* Youth Rodeo curing September. A streamer, vith Alcoa's emblem at' the top, bore the inscription! "Alcoa's Sheet Ingot* The Largest Inpot in the Largest State." At the Palacios County Fair, the Paint Comfort .orks exhibited a ! display made up of photographs depicting Community relations and plant facilities. Our 1953 safety award vas displayed also* This same display vas exhibited at Port Lavaca's Youth Rodeo. 10 - lh APC 000322 PUBLIC RELATIONS EEP/LETSI-IIT 195k The Public P.elations program used such madia as the Tcxalcoa Round-Up, place/lent of Alcoa advertisements in community newspapers, news releases, plant tours, contributions to local community projects and participation in local civic affairs. Six issues of the Round-Up and the Calhoun County Statistical Booklet vere published. Plant tours vere conducted for eight groups. TiLns fron our library were loaned to civic groups on a number of occasions Chest X-rays were taken on 56 seniors fron Port Lavaca High School. Twenty-seven men were enrolled in the Sumner 1 orkinp Scholarship program. A float was entered in the Calhoun County Youth Rodeo Parade. Sponsored Port Lavaca Pony League. The Point Comfort Shopping Center was completed and a 1*3 lot Lay Front addition was developed in Point Comfort. A post office far Point Comfort was sponsored. Erection of a fire station in Point Comfort was started. The Alcoa Foundation Scholarship was awarded to Harold L. Lrmey. A Children's Christmas Party was given for about 700 Alcoa children. Two Pittsburgh news releases were 3C-nt out to local papers. Light local news releases were sent to local papers. Advertisements were placed in the Port Lavaca Magazine and the South Texan. A display board featuring Alcoa products and news items of local interest as set up in the Housing Department Office. 10-15 APC 000323 CHRONOLOGY MKCHAMIGAL DEPARTMENT - 1950 January 1-31 Mechanical crews busy making necessary revisions and final adjustments to production equipment preparatory to beginning production of aluminum in Texas. All initial potroom equipment for use in the first potline was turned over to Production Department. January 1 All equipment in operation in Building No. 51 prior to this date except for two (2) 125 H.P. boilers and accessories and same minor auxiliaries. January 3 'team flow meter for the #2 (East) 300 H.P. boiler installed. Building 51. Mo. 1 (Vest) boiler* Bldg. 51* shut down for inspection and cleaning. Boiler inspected by the field inspector for Maryland Casualty Company and found satisfactory. January 6 300 H.P. Boiler No. 1 (Vest) placed back in operation. Bldg. 51. January 9 January 16 Soap spray unit for paste buckets installed in Bldg. 5b. Gas meters installed in four (b) inch gas service lines feeding Buildings 1, 13* 15* 50* 51* 56 and 19. January 19 Cottrell electro-static precipitator Bldg. 5b turned on. Fan had discharged to atmosphere parlor to this time. January 2 it--31 Bldg. 33 pumps first operated* used in filling lagoon. February 1-31 All initial potroom equipment for use in second potline turned over to Production Deportment. February 1-10 Found leaks in the West Reservoir of Bldg. 33. February 1 Installed vibrators on fine and intermediate hoppers of Richards cn Coke Scales Building 5U. February 10 Completed installation of 5 gang 50 It. mold benches* Bldg. 19. began operation of bG and 6g washers. No. 3 Compressor Bldg. 51 shut down for repairs. February 10-15 Washers 12Q through 2bG turned on to check drain lines and foundations for leaks. February 13 Washers bG and 8g shut down due to broken drain. Restarted February 15. February 15 Boiler feed to 300 H.P. boilers in Bldg. 51 changed to distilled water. Nalco treatment continued In the 125 H.P. Boilers. 11-1 APC 000324 A 19$0 Chronology Continued February 16 February 16 February 23 February 27 February 26 March 1-31 March 1-15 March 1 March 7 March 13 March 28 April 1-30 April 1-15 April 5 April 15-30 May 1-31 May 1-15 Gas service line mater for the 125 H.P* boiler, bldg. 51, installed. Potroom washer system shut dam for inspection. Restarted February 20. West ere discharge valve handling ore from day tank to 0ore bucket broke loose fron the 16" C.I. pipe flange connecting it to the bottom of the tank. .weet vater system tested safe for drinking purposes. Potrocm control facilities installed complete Eldg. $6, Color dynamic painting complete Eldg. 13 Repaired and replaced the are discharge valve (see February 23) and altered* and replaced a similar valve using voided steel flanges in place of the C.I. flanges. Yale & Towne Scales giving trouble vhich continued throughout the year. Most of the troubles were in the scale printweights. Steam whistle was installed in Eldg. 51 for Indicating shift changes. Three of four pumps for supplying vater to the water cooled baking shunt for the second line failed and were ropaired by our shop. Jib cranes for 25,000 lbs. ladle covers installed In Eldg. 19. baker Perkins Mixer Ho. 7 arrived for installation in Building 5Ua. All initial potroom equipment for use in the third potline turned over to Production Dept. Chlorinator installed in Eldg. 33. Cre and cryolite tanks painted with prime coat red lead, one coat aluminum paint containing Prussian Llue, and one final coat aluminum paint pi. Electrically insulated Joints installed in the sweet water line. Ladle tilting car for 25,000 lbs. ladles installed Lldg. 19. Ironited Vest Reservoir Eldg. 33* Steel rack added to Bldg. 13. Ironited East Reservoir Eldg. 33 11-2 APC 000325 a 1950 Chronology Continued May 8 Baker Perkins Mixer No. U Bldg. 5UA drive gears failed. The teeth were repaired by doweling, brazing and recutting In our shop. Kay 30 Baker Perkins Mixer No. it. Bldg. 5UA placed back in service. June 1 Fire pump installed in Bldg. 33. June 5 Baker Perkins Mixer No. 7 placed in Paste Service Bldg. 5UA. June 7 Plugging material system placed In operation, crushing and transferring reclalaed bath. Bldg. 52 rad Bldg. 51l* June 15-30 July 22 Shelled area around Bldg. 55 with oyster shells. Both main service line gas meters were rtnoved for repair of ruptured`diaphragms. August 1-31 Two Paste Sample Baking Furnaces installed in Bldg. 56. August 1-15 Stuard water separator installed in air supply line to Bldg. 55. Au-mst 7 Replaced spray tree piping in UG and 8g scrubber washers. August 15 One C.I. Sheave an the continuous car puller far Bldg. 1*0 broke and both C.I. drums were replaced with steel drums by Stephens-Adanson at no cost, our craws doing the week. August 21 Around the clock Millwright service instituted 7 days a week for servicing potroora equipment. August 2h Strike called. Aurusrt 27 Rhut. down Lime rLaker and Feeder Fldg. 29 due to strike. August 31 boilers and compressors 1 ldg. 51 shut down due to strike. Steam cut off in bldg. 55 find bldg. 51iA equipment due to strike. September 1-15 Vet veil cleaned out Bldg. 33 found about 18M of carbon and ore dust in it. Septeraber22 Taken mixer installed in Bldg. 56. September 23-30 Replaced spray tree piping in 12G and l6G washers. September 25 Boilers and compressors Bldg. 51 started up after strike. Steam turned on in Building 55 and Building 5UA equipment after the strike. n-3 APC 000326 4. 1P50 Chronology Continued September 30 Veter motor installed in sweet water line Midway i.ell* October 9 Restartod Line Dlaker and Feeder Bldg. 2? after strike. October 11 Wildcat strike. October 15 Brick type hoist peroanontly installed at Bldg. 5UA veBt side. Timer installed In Bldg. 33* November 1-30 Painted inside of distilled water tanks Bldgs. 5* 7 and ? with M Catha-coat" and replaced steel pressure tank Bldg. 51 with an aluminum tank. Leeember 15-31 The 300 H.P. Boiler No. 1, Bldg. 51* shut down and inspected by field inspector for Maryland Casualty Caapony and found to be in good shape. Installed tonic car steaming line Bldg. 55* December 30 First carload of are was unloaded at Bldg. No. U0. 1951 January 1-31 'Widened walkways N & S Bldgs. 5* 7 & 9# Raised walkway between Buildings 5 & 7. January 8 Coupleted handrail about roof Bldg. 5U-A. January 11 Completed Jumper Dus for 1 Pot Blags. L-26. January 26 Motor driven ventilator installed roof Bldg. 52A. January 28 February llx February 20 #3030 Dixie Manner Kill, '-35 pan conveyor and ;23 3crcw conveyor removed from Bldg. 5U. Installed ball mill operators shelter Bldg. 5U. Foundation complete for tank 6, Bldg. 55* February 28 Black, Sivalls and Bryson tank car unloading platform installed Bldg. 55* Pump house tfl* March 1-31 March 10 Installed accoustical ceiling and storm windows in Bldg. 5A. Tank 6, Bldg. 55 set by Chicago Bridge and Iron Company. April 1-31 Kay 1-30 Ftephens-Adamson Company representative worked on car pullers Bldgs. 19 and 52. Replaced U" 0 C.I. line Bldg. 51 to Bldg. 33 with 6" 0 welded steel line. June 1-30 No. 2 (east) 30 H.P. boiler Bldg. 51 inspected by Maryland Casualty Caapany. APC 000327 11 - u * 1951 Chronology Continued June 11 June 29 June 30 July 27 July 30 August 2 August 6 August 30 August 31 September 1 September 7 September 13 September lij October 1 October 7 November 1 November 2 November 7 November 27 December 1-31 Staple aggregate preparation unit installed in Bldg. 5U Installed Type "L" compression testing machine Eldg. 56* Eagan installing offices in south basement Eldg. 1 for Alcoa Mining Company and offices in the northeast wing basement for the Personnel Department. Tark 6, Bldg. 55* complete and placed in service* Qxweld shape cutting machine installed Eldg* 13* Installed ladders and valrvays to day storage tanks Eldg* 5UA. Installed ladder roof Eldg* 5UA to roof Eldg* 5ii* Completed >erection Eldg* 9D* Completed changing 32 pots from all metal to bi-netal spikes Eldg. 26. Altered spike puller. Installed fire hose stations Bldgs. 5, 7 & 9. Bldg. 37 and equipment installed complete. Millwright Shop moved from Bldg. 52 to Eldg. 13* Installed exhaust fan from Dry * ell Eldg. 33. Started brush painting Nordberg Engines Bldgs. 5 7 6 9. Completed revising distilled water system Eldg. 51. Completed cleaning and repainting the surplus paste plait equipment. Began construction women's toilet Bldg. 19. Completed 5 individual pot baking shunts Lldgs. U-26. Installed Struthers-.-.ellc heat exchanger and Ingersoll Rand after cooler Eldg. 51. Installed 2" 0 gas line to Bldg. 13A. Completed Installation of Drill Press, Blue Streak -aw, and Di-Met Saw* Bldg* 56* Rearranged equipment in Lldg. 13A. installed a pad at south end Eldg. 13A. Cut in scrubber lines to IjS and 5r> scrubbers* U-5 APC 000328 1951 Chronology - Continued Decanter 10 December lU Decanter 26 December 27 Decamber 26 1952 February 11 Februrry 19 February 26 February 28 March 3 Kerch 5 Kerch 7 Kerch 11 Kerch 21 April 7 Completed (8-3/ii" die. ecrew) Portable Plug Mill Bldg. 5U. Dafflae installed Lagoon Eldg. 2913* Graded and shelled road to plant drop* Jointer Installed In Bldg. 13A. Revised shower and locker facilities Bldg* 21* Completed partition and can door Bldg* 52 to Bldg* 5U* Installed an additional iiO lockers plus washing and shower facHitlen in Bldg. 9* Installed* solenoid operated controls on spike puller Bldg* It* Completed robending all copper collector straps for Bldg* 28 and 30, and bending and punching collector straps for Bldgs. 32, 3U 66, 68, 70 and 72. Installed 90 new lockers, new shower heeds and piping, wash basins, etc., in Bldg* 17* Shop fabricated liOO switch pistes for US-5S. Drilled and tapped 272 copper dead heads for lines U>5S* metalled lit" Delta Drill Preen and Delta Carbide tool grinder Bldg. 13* Fabricated 13 2500-anp capacity and 13 L5QO-anp capacity water ehunts Bldgs* U-26. Shop Orders were closod or. Rev Potrocn Bldgs* 28-3U* Ccnpleted baking and starting. Completed fabricating miscellaneous hand tools and equipment for lines hS-5s. Poured 30' x 70' concrete pad south of Bldg. 13* Completed installing offices in south basement of Bldg. 1 for Alcoa Mining Co., and in the northeast wing for the Personnel Lpt* Installed maxifolds and piping for acetylene and cocygen used in Bldg* 13* Installed soap spray for paste buckets under Mixer Ho. 7, Bldg. 5UA* Installed potable water veil Ho* 2 at Midway. 11 - 6 APC 000329 1952 Chronology - Continued April 8 April 10 April Hi April 16 April 1-30 Kay 2 May 15 May 16 May 20 June 3 June 11 June 26 AUtTU8t 1 August 8 Purchased six vacuum crucibles* four crucible lids and two tapping bails for hot netal handling lines LC-3S. Purchased two Cushman stake cars* one for Mechanical Dept* burning rig bldg* li3* and one for Electrical Dept* tool carrying and burning rig bldg* U9* Installed air operated shifting controls for paste track switches in Eldgs* 51i and 5UB* Installed eight ere discharge Taira lift assenblies for four ore buckets lines 1S-55* Completed mechanical work in changing to bimetal spikes in lines 1S-3S* Completed* installation of Baker Perkins Mirer No. 8* one mixer discharge hopper* one 16" link belt screw conveyor and one paste dumping station under mixer No. 7* Bldg* 51*A* Coaplrtod installation of ground storage tanks Nos. 7* 8 & 9* Installed steam jacketed tar line complete from No. 3 Pitch Control Tank to No* 10 Mixer Bldg* 5UA* Installed repair shop In Bldg* lflF for maintaining crust breakers and air tools* Installed 3 CP-60-NCB Demolition tools on crust breakers lines l-3S* Completed installation of Unit 2ii rotary vana feeder* Unit 23-B* 11" horizontal redler* Unit 31* bucket elevator and Unit 32* Hi screw conveyor* Bldg. 5U* Assembled a portable acidising unit Bldg. 13* .Shop orders were closed on new potroera Bldgs* 66-72* hairing and starting completed* Purchased li tapping crucibles and 2 11da* for metal handling linea,ltS-5s. Purchased one 3 ou* yd* dump bed for 2 ton Chev. truck for Mechanical Dept* Purchased and assembled 3 auxiliary frames for lines ltS-5S* Installed capstan type car puller at Bldg* $$ pomp house No. 2. Purchased "Dempster Dumpster" unit and one 2-tan trash truck for Mechanical Dept* 11 - 7 APC 000330 19!)2 Chronology - Continued August 13 August U; August 21 August 25 August 26 August 27 September 12 '^eptflober 17 October 1 October 6 October 9 October 10 October 13 October 15 October 30 October 31 November 7 November lli Coapleted redredging the Alcoa channel and turning basin* Installed soup poop In redler pit at Bldg. 29* Installed necessary intermediate colunns In the JOQ lb* pig nold bench Bldg* 19 to prevent sagging* Installed jib crone and hoods for furnaces in Blacksmith area Bldg* 13* Installed one 1*0,000 lb* end two 30*000 lb. oapacity runout welding cars* Bldg* 13 Installed welding curtains in welding section of Bldg* 13* Coapleted extension to bldgs* 5C* 7C and 9C* Moved 321 x 6U' construction Quonaet Hut and installed it adjacent to Bldg. 13A calling It 15C* Coapleted removing settled deposits from 29A lagoon to Plant Bumps* Authorisation was received to proceed with D*C* Casting facilities in Bldg. 19* Pulled* inspected and replaced brackish water well No. 2* Installed facilities in Bldg. 16? to produce one pot per day of potlining blocks and collector bars for iiS-5S pots. Installed Bldg* 52A leanto. Installed open flume froa washer 2liQ to nanhole in courtyard* Installed 2" underground air line fran bldg. 51 to Cldg* 13A* Installed partition for enclosing safety shoes in bldg* 15* Installed lumber storage rock in Bldg* 15-C. Completed shelling area south of bldg. 15 for a steel storage area* Installed enclosed system for steaming pitch tank cars at Bldg* 55 pump house No* 1. Completed installation of Bldg. 9E maintenance facilities* Completed installing two pots In lines 19-33 with shoveled monolithic type potline Project 52-1* Reworked west drainage ditch along track No* 6 to drain properly south from Bldg* 5U to Ditch "X". 11-8 APC 000331 19',2 Otronolocy - Continued November 2U November 26 November 28 December 8 December 15 December 29 December 31 Installed No. 3A Varner Svasey Turret Lathe in Bldg. 13. Completed repairs of potroom floor damage resulting during the removal of potlining from lines 1S-3S. Installed two gallon kerosene tanks south of Bldg. 15 on concrete foundations. Installed 12* x 12* steel sliding door into carpenter shop south side Eldg. 13A. Fabricated vood tool bins* Power Dept.* Bldg. 9E. Installed air compressor No. U* Bldg. 51* Completed overhauling brackish water well pump No. 1. Installed outdoor shed for o^gen and acetylene storage and manifold connection south of Bldg. 13. Used aluminum "Utilituba" piping into Bldg. 13. Completed cleaning the underground smoke washer drainage system lines 1S-3S and 280' of the main from lines 1S-3S to lines LS-5S. Installed $00 lineal feet of 20'0* vide shell road into "Boneyard" south of Building 52. Installed vehicle wash and grease rack Bldg. 13A. Installed two pot shells lines lS-35 with experimental Project 52-2* "Y" Bar Monolithic type potlining. Painted LO engines in Bldg. 9 and 28 in Bldg. 7 plus aux iliary equipment. Conpleted plant maintenance painting far 1952. including Potroams h, 6. 8. 10, 12* 11* steel. Installed Dings Magnetic separator in ball mill discharge Bldg. 51. 11-9 APC 000332 * CHRONOLOGY 1953 January 5 Bloodmobile visit* January' 7 Completed storage rack for collector tar stock, east of building 13* January 12 Started fluid paste. Line 5* January 23 Connleted repairs to gunnited drainage ditch, (Part of ra-25009). January 2; Completed installation of Do-All contour saw for building 13 Machine Shop. January 31 Completed work of installing platforms and exterior spray manifolds in Linos 1, 2 and 3 smoke washers, (TR-2L61C). January Received and put in service 10-1/2 cu. ft. Hough Payloadcr for Potrooms (TR-25133) January Initiated training program for female employees. February 1 New school occupied in Point Comfort Village. February 6 Got title to 366 acre tract at Midway for water well and pumping installation (P-252Oh). February 20 Completed installation of baffles around brackish water spray pond. February A. 5. Koehler, property holder in Lyrmhaven, declared bankrupt. Property later sold J. A. Peeler A Associates. Fet. il March Four Technical men and four foremen trained at Davenport for Point Comfort Ingot Castin- Department. larch 1 Soundin_6 in lagoon 29-P showed that this lagoon war filled with sludge to the limit of its working capacity. 'arch 2 Attended conference with area school superintendents at plant cafeteria. Pei 'cholarahip program. March 5 Started rocirculating smoke washer spray water through lagoon 29-A. March 9 Completed installation of an additional condenser for distilled water plant, building 51* March 16 Completed 2" compressed air line extension to Eldg. 13-L. March 18 First experiments with 1.27 ratio bath. 11 - ID APC 000333 C hronology 1953 ~ Continued March 23 March 29 Inarch 30 .'larch April 1 April 3 April 3 April 13 April 20 April 23 April 23 April 23 April 23 April 23 -.pril 30 April April April April April Received and put in service Insecticidal Fog Applicator for .nosquito control (TR-25358). Completed installation of air conditioning in building 19, Electric Maintenance Shop. backlog of machine shop and fabricating shop work was very nearly caught up. j Many leaks in the brackish water lines were developin'-. Repaired line to 15-2 and started excavating Joints in 6" line from veil r2 for recaulking. Traffic Department organized independent of Stores. Completed installation of automatic temperature control on heat treating furnace in blacksmith shop, Building 13. Completed a 130'J It. shell road extension to ;.o. 5 ..ell at Midway. Mtartod fluid paste. Line 1. Little League play started.| Installed replacement elevator bolt on one ore elevator. Building hO, (TR-25229). Completed revisions to suppartin;-- stoel under erenaast fan tgliding 5U, dust collector system (S.O. 6103). Conversion from Old ferier to Me',: Revised Meries Consu-oers Prico Indas in computing Cost of Living escalation. Started interviewing scholarship candidates. Completed erection of illuminated plant entrance sign. Calhoun Development Company dissolved. Housing function incorporated undor Aluminum Company of America. Contractor started removin'- sludge from lagoon 29-1 to disposal area. Assistant Office iianarer transferred from Vancouver. Personnel Department assailed commmity relationship work. Contract concluded for gas from Kellers Bay Area. Contract concluded far gas from Colama Creek Area. 11-11 APC 000334 ChroncIxjfQ' 1953 ~ Continued rxy 11 iiay 11 I-ieti'' Kay Kay June 1 June 1 June 2 June C June 12 June 12 Open House for A.C.M.L. Started Casting D.C. Ingot. Started U6 hour tapping tycle. Hr. wa. Stroud, who had been aseigned by Hr. Kuhns to supervise construction of In-ot Casting facilities, loft Point Comfort with the major part of the construction work complete inc the first furnace ready for operation, because of delayed deliveries and late design work in Pittsburgh, there were several months of work ahead to complete all details authorized* Policy made for sellinr Point Comfort Village dwellings* reasonal hurricane preparation. Started hiring seventy-six ten;orary summer employees. started helpin- the cafeteria hire four rotating shift female employees vhr had husbands as employees. Had received and put in operation ii ton gas driven road roller for Mechanical Department. A labile Unit was put in operation to provide on-the-job raools for employees on all shifts. Had received used coke dryer from Vancouver Works. Completed fabrication of 3^ air cooled shunts for potroo.is, June 2h June 2h Jane 27 Juno June July 1 July 3 Looting called ir: regard to incorporation of Point Comfort Village. J. L. Kliraichek resigned as President of the .Aluminum Council and J. Jackson was reinstated or. a temporary basis. ct up and attend r. display of aluminum oducts at the Palacios Fair. Negotiations completed for gas from forth hrancitas Hold. Softball League far men and women organized* tarted staffing Casting Department* Alcoa presented Calhoun County Little League organization with i:2,150.00 for building of little League Park. 11-12 APC 000335 A Chronology 1953 * Continued July 9 July 11 July 13 July 22 July 22 July 22 July 22 July 29 July August 7 August 10 August 15 August 18 August 21 August 21 August 21 August 26 August September 1 September 1 Fratification of wage agreement. Residentc of Point Comfort Village voted to Incorporate. Installed nev exhaust fans on laboratory roof, Luildln- 1. The condition of these fans shows that it will be necessary to dismantle and repaint interior surfaces yearly. Lloodmofcile visit. Completed installation of ladders on all smoke washers for access to smoke ducts by technical control men. Completed alterations to Building 1 main office lolly (IK-29291). Started fluid paste. Line 1. Started lov ratio bath, line 5* Contractor completed removal of sediment from lagoon 29-L. Completed 250,000 improvement program to plant drainage system (TR-2S009-R). Houston 1* Hickman elected President of the Aluminum Council Vote taken at Point Comfort for City Officials. New City officials sworn in at special ceremonies. Plant Cafeteria. Co:Tpleted overhauling of Prenix i edler, Luildinr 53 (new chain end wear plate). Completed installation of steam cleaning rack for crustbreaker shop, building 18? (TR-2553h). started fluid paste, Line 3* Property deeded to Lutheran Church in Point Comfort Village. Construction completed on six (6) dwellings on one aero plats adjoining plant. Arrangements node to sell Iytmhaven house L lot notes to the Prudential Insurance Company of America. Iynnhaven area leased to Oak Park Recreation Association for playground. 11-13 APC 000336 A Chronology 19$ 3 - Continued September 1) Completed relocation of tuonset building 13-P for Mechanical Department (TR-256U5). September ID Started fluid paste. Line 2. apteraber 11 Completed concrete block electric control house at Ilidway, (5.0. 6350.17). 'eptenber 11; Completed replacement for distilled water line} replacement from boiler house, building 51, to powerhouse storage tank. September 25 Completed concrete block sandblast enclosure adjacent Buildin- 13-C (S.O. 61)85). September 28 Plant Protection farce reduced to 18 men. September ?C Scpteraser 30 started low ratio bath. Lino U. The First Baptist Church had ground breaking ceremonies in Lynnhaven Subdivision. Septeix er Received 100 CFK portable air compressor for Mechanical Department. -eptemter hater main in Point Comfort Village broke and caused a serious water draw dwn in the plant (gravity tank. October 1 Completed installation of two-way water metering system in pit to meter water to and from Point Comfort City System. October 1 Mechanical Department undertook the regular inspection and maintenance of t: e Point Comfort City sewage cisposal system under contract betveon the City and Aluminum Counany of 'merica. October 1 Point Comfort streets, water, sever and recreational facilities deeded to City of Point Comfort. Octobor 1 Leased 270 acre Coates Tract adjacent to Point Comfort Village. October 1 Started low ratio bath. Line 1. October 1 Started Industrial L.n~inoorirv Department. October 2 Octobor L Completed reballasting of railroad track system. Reduced number of shift foramen from 8 to li. October 28 One of the oro elevator belts. Building 1)0, parted. Ten:;orBry repairs made - new belt ordered. 11 - Hi APC 000337 * Chronology 1953 - Continued October 2G October 30 October October October Novorfcer 2b Novenfcer Novoriser December b December b Decemoer 15 December 28 December 30 Decomber 31 December 31 December Decenbor December Started low ratio bath, line 2. lixer No. b vac out of service due to stem leaks in saddle and blade. Received 8,000 lb. capacity lift truck to replace truck damaged by fixe (TR-25955)* Completed new receiving office for stores, EuiIcing 15 (TR-256b3). Completed experimental cyclone installation for jnoke washer 16-G. Conpleted installation of facilities far Cal; Park Recreation Association in lynnhaven (TF-25976.) L.S.P. pitch tanks ,f3 and b developoc steam leaks in tank heater colls. These were repaired by welding. Authorized to construct staff housing in City of Point Comfort. Completed clean out pits for moke washer drain laterals. Lines b and 5 (TR-29blG). Completed replacement of concrete cover slab3 around bus risers. Lines 1, 2 and 3. (TR-25569). Roceived 1000 lb. capacity lift truck for stores department (TR-2o323). Started log ratio bath. Line 3. Negotiation of Vacation Agreement for 195b* bldway revised purrp system and nev well (US) was in operation and sweet water was being delivered to powerhouse heat exchangers. Completed S2C,OOj plant road resurfacing program, (TF.-26b20). Aluminum tubin' hydraulic linos in DC pits failed after six months service, replaced with extra heavy steel. Completed revision of paste plant facilities for experimental operation. Completed remachlninr of all anode spikes in Lines 1, 2 and 3 (part of TR-26122)! 11 - 15 APC 000338 Chronolo-y 1953 - Continued Decenixjr Lecenber Lecanber Decenber Hou Saalting Accounting procedure introduced to rianarenent. Gas Pipe Storage Packs erected near plant. School District to expand Point Confort school facilities, -idwell well power and ccfntrol lines completed. 11-16 APC 000339 CHRONOLOGY 1951t January 1 General wage increase of tvo cents per hour* January 7 Began cutting off and remachining spikes* Lines U and 5* January 8 February 5 Completed cutting off and remaohining 10*000 anode spikes* lines 1* 2 and 3* i Completed facilities for welding on tips and remachining spikes* all lines* Purchased jeep station wagon for use by Engineering ftaff. February 22 Factory Mutual fire inspection. February 23 Started barge shipments to Davenport* February 25 February 26 Startod recirculating smoke washer spray water through Lagoon 29L. Completed construction of the 15 cleanout pits* Lines 1* 2* 3* courtyards. March 31 Purchased 300 G. P. K. fire pumper. Installed jib crane at 200 ton wheel press* Building 13* Installed third smoke washer lift pump. Building 33\ April 2 Installed monorail beam for hoisting mixers in Building 5iiA. April 20 Interviewed summer scholarship candidates* Arrangements made for homB mortgages with the Equitable Life Insurance Company of Iowa. April 22 Plant visited by Congressman Thompson. April 23 Iyimhaven land (1-1/2 acres) sold to First Christian Church. Hay 7 Completed reconditioning of nnode spikes* Lines It and 5* began last January 7* Rebuilt Niagara aftercooler* Building 51* toy 11 Factory Mutual-fire inspection. toy 1^ X-rays for Fort Lavaca High School seniors. toy 18 Union election won by C. I. 0. fiay 2h Alcoa Foundation Scholarship awarded to Harold . Ermey. June 1 C. H. Gear and 0. L. Royer attended the summer Training Conference at Tapoco Lodge. June 7 Fifty-nine aumnsr students to report for work. 11-17 APC 000340 A 199b Continged June 21 Lend development completed for bay Front Addition, Point Comfort* June 23 Completed installation of 5 ton stiff leg derrick crone at plant dock* July 9 Installed oxygen and acetylene manifold for spike retipping shop, building 13* July 16 Constructed shell road from Fannin Road to lagoon* July 19 Changed Machine Shop evening shift ft:on Tuesday through Saturday to Monday through Friday. Auguct 1 Ganeral wage increase of eight cents per hour* August 2 Completed erection of buildings 1*6 end ii7 August 6 Completed storm sever. Flotation plant area. Completed cleanout of Lagoon 29A. Aurust 11 Commenced nev system of Machine Maintenance Control records* August 16 Staff houses completed in bay Front Addition, Point Comfort. August 17 Sponsored pony basoball league* August 20 Completed installation of overhead gas line6 from building 91 to building 19* August 29 Purchased Luda truck with voiding and luraing equipment, building 13* Spike cleaning equipment completed* Soptcnber 1 K. L. Morton and C. C. Voltz visited plant to take pictures for the "Highlights" film, baptist Church completed in Lynnhaven. Fork begun on Point Comfort fire station. September 3 Installed foundation for dock plate stroightoner, building 37* Constructod steel yard office, L'o. 15-F. September 0 Factory Mutual fire inspection. September 10 Installed hurricane mooring dolphin at charnel turning basin. Sept6obor 17 Replaced water supply line to building 2irG smoke vasher. Constructed roads at Iruildin-s 1*6 and U7* Completed painting flotation buildings and equipment. September 29 Flotation Plant commenced operations* 11 - 18 APC 000341 l?Sh Continued September 30 Completed Installation of Pdte-Hite dock unloading facilities, building 15. Installed 16" unloading screw, building 52-A. Local Evaluation Committee started their work. Octoter 1 Established Lalor Relations office. October Completed installation 3^00 square feet brick paving, building 19. October 22 Constructed three offices at building $6, Installed roof ventilation over spike rotipping, Building 13. Installed gas, air and water supply to building 37. October 30 Participated in Calhoun County Youth Rodeo. November 8 began pinning Joints of anode spikes, all pot lines. Additional punpinr capacity installed Point Comfort sewage disposal plant. November 12 Replaced water supply to building 20-G, smoke washer. Repaired hearth of ingot casting furnace Mo. 1. November 15 Comenced use of "traveling" requisition. November 22 Point Comfort land sold for telephone exchange. lioventer 29 Installed storm sewer along Austin Rood from Archer Road to building 51i-A. November 30 Factory Mutual fire inspection. December 1 Point Comfort Shopping Center formally opened. P. A. system removed from gas engine houses. Accounting Trainees completed two-year schedule. December 10 Installed paved area between building 15, 15-A and 15-L. December 12 Installed 300 ton press, building 13. December 17 Installed 270 foot shell road from building 19-D to bay front. Replaced spray tree piping Lino 1, 2, and 3 smoke washers with copper tuba and fittings. December 22 Lowered lidway water main and provided sleeve to cross under new ptved road from Highway 35 to Port Alto. December 23 Installed cradle straightening press, building 37. Handled Christmas party for employees1 children. December 2h Replaced water supply to 16-0 smoke washer. December 27 Changed over operation of s.ke washer system from Lagoon 29-D to 29-A. 11-19 APC000342 19C'U Continued December 31 Installed 2 1/2 inch water line to penthouse building 5Ii--A roof complete with hose rack. Machine Shop completed, the following during 195U on li 1/2 inch and 5 inch diaiaeter spikes t Weld ends and lathe turn 2360 Salvage and recondition 77GU Drilled and pinned .joints 1813 New fabrication 1200 11-20 APC 000343 January 13 January 14 January 24 February 2 February February 11 February 17 February 19 February 23 February 25 February 24 March 1 March 3 March 4 March 10 March 15 March 17 March 22 CHRONOLOGY 1455 School purchased additional 5.4 acrea - Town of Faint Comfort* Completed assembly of dock plate heating furnace com plete wife gaa burning equipment* Bldg* 37* Completed installation of 30" Ohio Shaper* Bldg* 37. Installed 200 ton Cbambersburgh wheel press* Bldg* 37. Replaced asphalt roadway into Bldg. 37 with 1* 250 sq* ft. 4" concrete paving. Money requested for sixth potline. Organised a Plant Labor Relations committee. Replaced flasher beacon in boat channel. Plant ewpanelon of one potline announced. Fire Station completed Feint Comfort. Area telephone system changed to dial automatic. hiatelied deck plate and cradle pressing equipment* Bldg. 37. Completed Installation hoisting equipment. Bldg. 37. Opened Semi-Monthly Confidential payroll. Construction Division office opened. Construction Dept, occupies temporary quarters in Bldg. 1. Began barge shipments of motel to Davenport. Installed pay station and check cashing service at Point Comfort Shopping Center. Host to Smelting Division Safety Conference. Host to Port Lavaca Lions Club Ladies' Night. Host to Port Lavaca Rotary Club Ladles' Night. Heat to Port Lavaca Kiwants Club Ladies' Night. Factory Mutual representative inspected plant. 11 - 21 ARC 000344 March 11 'April 1 April 8 April 9 April 11 April 29 April 10 May 6 May 6 May 9 May 10 May 13 May 16 May 26 May 27 June 5 June 9 Major portion of lota in Nortb Lynhevux sold. U. 8. Saving Bond driro iacroaaod employee participation to 10.4%. Inetalled 10,000 gal. gasoline etorago tank at Bldg. 11E. Quonsat building located on now Engine Honao aite waa re moved and a temporary fence aeparating plant area from Construction waa completed. Clearing and grading contractor commenced excavating and grading operations, and began building the temporary coaatractian office and parking lot. Conatmctioa Beyl, occupied their office. Math potllno foundation contractor arrived. Moved Bldg. 19D quooeet to Bldg. HE location. Copatmeted 150* aaad aholl road. Bldg. 19 cooling tower to bay ahoro. Dirt moving operatlona on the plant aito proper wore com plete except for dresaing up operatlona. Tine grading for pot alab in Bldg. 74, and excavation for footers for Bldgs. 54E and 65 waa begun. Largest daily rainfall of year - 1.49 inches. Labor difficulties between operating engineers and contract ors stopped all work Friday, May 13, and Monday, May 16. First car of fly ash received from Rockdale Works for mao la concrete formula. Completed repairs broken 8" Midway water main. The first concrete was poured for the pot slab in Bldg* 74 and footer for Bldg. 54E. Storm with 70 Mph. wind at plantaito minor damage. Steel contractor arrived for sixth potliaa <" 11- 22 APC 000345 JU 13 JM 17 Jta* 30 July 5 July? July 11 July 18 August 1 August 3 August 5 August 10 August 17 August 28 September 1 September 9 September 12 September 15 September 18 September 18 reus one-bedroom houses denoted to spools. Cleerlug sad grading contractor completed his contract sad extra work. Plant perimeter fence was completed during the week. Contractors' forces exceeded 300. Auth. Tt2l452 issued for experimental General Motors engine-generator to ho installed in tka oast end of Bldg. 85. First stool erected for Potliaiag Bldg. S4E. Factory Mutual representative imported plant. First potroem steel erected for Passageway 72C. First steel e rected for Engine House 85. Construction Dept, had labor difficulties. General Wage Increase. Factory insurance Association representative inspected plant. Contractors' forces exceeded 400. Completed 1,MO, 000 man hours without a disabling Injury. Math Petline Bus Shop sot up. Contractors' forces euceeded 500. Laboratory Bldg. 101 sad Wash sad Locker Bldg. 102 laid out sad the excavation footers begun. Trade Apprentice Training Program established. Petlining Bldg. 54E was complete except for roof ventila tors and operations people began moving in. Chart of Apprentice Program with fifty-two earaloes. Began shipment of reclaimed cryolite to Rockdale. First arc struck in the Bus Shop. jj . ZJ APC 000346 flentembes 19 September 1? September 21 September 29 September 90 October 1 October 7 October 12 October 19 October 17 October 18 October 91 November 24 November 19 December 7 December 19 December 22 December 27 BsgttOM Of M RepalrBUg* S4B4 Sipitbn* welded. y . . i . ' * ; . ' Steel erection ccntraeter completed moving cf equipment Sind mica from job eite. Money requested to porehase 261 acres adjacent lead from lAfi 9ati Coates. Completed fastallaHonNe* 5 air compressor*. Bldg* Sl Held tto flrit Alcoa Smployo**' Uhited Fuad Drive. Development of Bay Tread IddMcn * Taint Com/ert Money requested to purchase fifty-five acres land adjacent Point Contort Village from Simple.' Factory Mntaal representative inspected plant. First Nordberg engine set for sixth potline. Drawings for laboratory Bldg* 101 were revised to con vert Ota facility primarily to an office betiding with n small section reserved for laboratory use. First shipment of Nordberg engines (11) arrived by barge. < Completed 1955 Plant Paint Program. Potroem 76 was first petroom tnmod ever to operations for pot baking. First pot pasted in sixth potline. First engine started in Bldg. 65 for testing (one of six old oass relocated from Bldgs. 11 and 65). Potroom 74 was the last of the petroe ns turned over to operations. Alcoa Childreas1 Christmas party attended by 800 children. Began baking Line 6. 11 - 24 APC 000347 Tmt 1949 1950 1951 1952 A. BUILDING k PERSONNEL HISTORY POINT COMPORT WORKS Building Additions 9, 91. 9. 99 94A CftUtmlM by CoaielidatM Western Steel Company Petereon Conet. Othere A. C. O. A. Conet. Engr. H.P. Rohey 1. 90. 56. 2 O. Roorke Const. Co. 52 Ole Petersen Inc. 6 Others 19B General Supply Co. 15.21,29.19,11A.15A, Consolidated Western 99,27.5.2A, 91.7,9. Steel Co. 9A, 5A, 9D, 9C.7C.9C, 7A.7B, 94,94C* 52A, 94D, 4.6. S 10,4A.6A.SA.4B, 6B, SB, 4C, 6C, SC. 19A. 19 12,14.16, IS, 10A. 10B, IOC. 12A, 14A. 16A, 12C. 14C.16C.20.22.24.26. ISr, 12B.14B.16B.1SB, ISC. 20B, 22B, 24B, ISA. 26P.20A. 22A.24A.26A, 20C, 22 C. 24C, 26B. 94B, 17.10P,29.40,22,26D, 26E, 20D, 20E, 4D. 4E, 6D. IOD, 101, 14D, 14E, 1SD, 22D 37 Ole Petersen Inc. V.J. Hultquist fti Jamer Otmen 15B Ole Petersen Inc. It J.L. Sorrell E.B. Mayer Co. 21 Ext. Ole Petersen Inc. 19 Ext. Ole Petersen Inc. 49.1BH, 39.9D Ole Petersen Inc. 15C, 15D, 15E General Supply Co. 11.63 Am. Bridge k Others 11A, 11C, 63A. 63C. 55 Ext Cook Const. Co. k Others 9E ACOA 19C R.L. Andersen 19B Black Brollier Co. W. Stroud V.J. Hultquist J.L. Sorrell A.E. Brayton J.L. Sorrell APC 000348 Tor Building Additions COMtmUd by 1952 (Cant'd) ItF But., 44A, 4SA, 7QA, T2A, MB, MB, 2t, >0,22, 24,24C, 2SA, 20A.22A, 24A, 28B, 20B, 22B, 24B, 2!C,20C,22C,24C,M. M* 70,72,70B, 72B, 44C, MC, 40 C, 20D, 20E, 240, 24X, MO, MX, 720,72X. 72P A.L. Johnson Co. aid Others 1953 1954 19E isr 24H.44.47 W. Horraca Williams ACOA Metallic Bldg. 1955 12C.12D 45A 45.45C. 74,74,78.50, 74A, 74A, 7SA, tOA, 74B, 74B, TIB, 40B. 72 C, 74C, 74C, 78C, 54E, 740,500. 76I.I0E Mercer Const. h Others Fleischer Seagea Coast. Ii Others Am. Bridgs h Others A. C. O. A. Const. Engr. W. Stroud A.X. Brayton A.B. Paulsen A.X. Brayton C.H. Keefer J.r. Clark APC 000349 W orks Power Production Asst. Production Potroom Paste Plant 111 hec XXX erf orf erf erf erf * CQ fl A 0) IQ cQ jo* ccc e **4 232 o 111 a 5 s c h ti h Ci< < ki 5; hO Q Q Q W o taEo r *i X X X ? erf ecoo g gg g w WH -rWt ^ * U n n *n 3 33 3 X IQ tO 03 03 X h V Ui bi U* U< X 9* VI Di Si 0) (n a 3 VVi IQ '0034 0. ewu oa Jh* Jh* JVl XV Xh r-4 m*-> g 4 < tf 3 ooouu WVCa3i ui U| Ui Lw Ui ^ ^& V. M V V V v mooO <mVoc VOl VO VCi Cbl lu4) 3V 4) u#> XX* UU Q Q Q Q Q Q 04 to X X M H4 **4 *-4 H>1 t-H *** o HI J g is g ico4d> cioad> ccood foucti 75 CO *cn1 *v"oS ^io4 rt"o* 2rt erf erf m mM h4 Mmh 2 d d o' n IQ IQ 21 c m k> v m 91 in in in in in ^ P*ll O' O' ^O' pO. ' ^O' ^O' * APC 000350 3333s*OHh bhhhh 4> V V aassa uft Ao of d d d d U< l* U< k< U< c V *3 g1l 2w tc JS w g4 CO o m b b h tL X, 5* o " M " B B m * *3 B fl ^ ^ 3^ ^3 of of eg r* r* >. >. >. C i 0 "e 2* J3.S U bl VV 2 034 CO S* JMS CV BII S g u Sim o o * * < rt 2ZP.P.D. & d d of of d d d d < < <' < * ,g 00 .S s* g2 X| CA A A A A j C>ttt CC tC 6X> 60 <* ft *hi *N * V t> it 4 *fa #fa * it t> t> ft 4* it i> <<cohO3ottji QQQQQ Q a. a. & 0i (K a. s h h --* uC1 2 0> >*3e5n "Cco*c. w ei> cv VV VV bl b. ao XX o C1 to X e <o O*-' id id to ftto 3 c :i uo 22 JJ XX hi ft 1 411 I O fsi fA -+ m m m lA m in in O' O' O' O' O' O' -* A, APC 000351 O ffice P u b lic A, H, H, * 14 TV>3. V>O* ceo ceo 4U co* co* H hi w *H eO o ,o rt u 1u Of eO'Oc e'Ob--c ooooo ESEcc && o o oc Tco) o JJJHH H << K h4) *V+ ' co CEO CfOi 4<44 4) of 1 oe0VM ccou4> >> 4M) 9 mu40O>0 Of oGu4o)O o of 0U4Go)O of o*4Q4)fi of mOh4G>O of m <u OGO of 2 uwuWWW ol U* u< u u< & u uu ^^^ 4> QC0( u4) 4) 0) NN 4> 4> 4> 4> - +4 44 4- +4 5 wwwwj uM 3 p c*5 ci z 04 rt 0 hrwt iO^n p-1 i^a mM^ i^n** m^mH^I > A- J i APC 000352 1 POINT COMFORT OPERATIONS FLOOR AREA IN SQUARE FEET Y ear Bldg. No. 1949 5 51 53 54A 55 1950 1 2 3 3A 4 4A 4B 4C 4D 4E 5A 5C 5D b oA bB bC 6D bE 7 7A 7B 7C 8 8A 8B 8C 9 9A 9C 10 10A 10B 10C Use Power Houae Boiler House Potlining Storage Mixer Bldg. Tar Storage Main Office Cafeteria Gate House Gate House Potroom Passageway Passageway Passageway Toilet' Toilet Control House Breaker House Oil House Potroom Passageway Passageway Passageway T oilet Toilet Engine House Breaker House Breaker House Breaker HouBe Potroom Passageway Passageway Passageway Engine House Control House Breaker House Potroom Passageway Passageway Passageway Sq. Ft. Yearly Floor Area Total 55,005 4, 800 6, 576 18,891 454 85,726 28,800 5, 346 239 239 39,946 2, 112 1, 056 1. 056 397 774 1. 613 320 410 39,946 2, 112 1, 056 1, 056 774 774 55, 005 80 80 320 39.946 2, 112 1, 056 1,056 oO, 705 1, 613 320 39,946 3, 840 1, 920 1. 920 Yearly Cumulative Totals 85,726 (Continued on Page 2) APC 000353 Bldg. Year No. Use 2- - * Sq. Ft. Yearly Floor Area Total Yearly Cumulative Totals 1950 Cont'd 10D 10E 10F 12 12A 12B 12C 13 13A 13B 14 14A 14B 14C 140 14E 15 15A lb 16A 16B IOC 17 18 18A 18B 18C 18D 18E 18F 19 19A 20 20A 20B 20C 20D 20E 21 22 22A 22B Toilet Toilet Foreman's Office Pot room Passageway Passageway Passageway Machine Shop Carpenter Shop Storage Potroom Passageway Passageway Passageway Toilet Toilet Stores Storage Potroom Passageway Passageway Passageway Wash & Locker Room Potroom Passageway Passageway Passageway Toilet Toilet Material Handling Metal Service Metal Service Passageway Potroom PassagewayPassageway Passageway Toilet Toilet Wash h Locker Room Potroom Passageway Passageway 1, 077 1. 077 514 39.946 2. 112 1, 05c 1,056 25.890 4, 000 4. 224 39.946 2. 112 1, 056 1. 05u 774 774 8. 431 4, 000 39.94o 2.112 1.05b 1, 05b 10. 1 DO 39.94o 3. 135 4, 992 4, 992 397 774 5, 745 2b.537 2,112 39.94. 3. 2c4 1. Obb 1. 056 39 7 774 2, 41 3 39.94b 2. i 12 1,0-jb (Continued on Page 3) APC 000354 Y ear Bldg. No. 1950 Cont'd 22C 22D 22E 23 24 24A 24B 24C 25 25A 26 26A 26B 260 26E 26F 27 29 31 33 40 50 52 52A 54 54B 54C 54D 56 Use -3- Sq. Ft. Yearly- Floor Area Total Passageway 1.05o Toilet T oilet Lift Station Potroom 774 774 59 39.946 Pas sageway 2. 112 Passageway 1, 056 Passageway 1, 056 Sewage Treatment 189 Sewage Chlorinator House 53 Potroom 39,946 Passageway 2, 112 Passageway 1. 920 Toilet 1, 077 Toilet 1. 077 Foreman's Office 514 Garage (Fire Station) 720 Lime Storage 2. 279 Oil House 597 Pump House 899 Ore Unloading 4. 825 Plant Office 2. 814 Coke Storage 53, 997 Coke 3, 422 Coke Grinding 21, 853 Passageway 3, 367 Runout Bldg. 704 Control House 9b0 Paste Control 3,818 90o, 008 Yearly Cumulative T otais 991, 734 1951 15B Storage 37 Ore Reclamation 4. 000 3,260 7,260 998,994 1952 9D Alumina Reactivator 9E Maintenance Shop 11 Engine House 11A Breaker House 11C Breaker House 15C Warehouse Stores 18F Ext. Material Handling 18H Safety 19 Metal Service 19B Mill Office 19C Scale House 21 Wash and Locker Ext. 26C Passageway (Continued on Page 4) . 659 3, 102 53, 865 80 300 2, 048 12, b 3b 2, 338 14,400 663 468 2, 160 1. 920 APC 000355 -4- Year Bldg. No. Use 1952 Cont'd 28 28A 28B 28C 30 30A 30B 30C 30D 30 E 32 32A 32B 32C 34 34A 34B 34C 34D 34E 39 49 55 63 63A 63C 66 66A 66B 66C 68 68A 68B 68C 68D 68E 70 70A 70B 70C 72 72A 72B 7 2D 72E 72F Potroom Passageway Passageway Passageway Potroom Passageway Passageway Passageway Toilet Toilet Potroom Passageway Passageway Passageway Potroom Passageway Passageway Passageway Toilet Toilet Garage Electric Shop Tar Storage Ext. Engine House Breaker House Breaker House Potroom Passageway Passageway Passageway Potroom Passageway Passageway Passageway Toilet Toilet Potroom Passageway Passageway Passageway Potroom Passageway Passageway Toilet Toilet Foreman Bldg. (Continued on Page 5) * Sq. Ft. Yearly Floor Area Total Y early Cumulative Totals 39.946 3, 840 1, 056 1, 056 39.946 2, 112 1, 056 1, 05c 774 774 39.946 2, 112 1, 056 1, 056 39.946 2, 112 2. 448 2, 448 1, 161 ,1, 161 2 000 3, 200 24o 53. 8o5 80 300 39,94o 4, 896 1,050 1, 056 39. 946 2.112 1, 056 1.056 774 774 ,39.946 2 112 1.056 1, 056 39.946 2, 112 2. 448 755 755 574 522,824 1,521,818 APC 000356 -5- Year Bldg. No. 1953 19E 1954 15F 26H 46 47 1955 13C 1 3D 54E 65 65A 65C 72C 74 74A 74B 74C 7u 76A 76B 7oC 76D 7oE 78 78A 78B 78C 80 80A 80B SOD 80E 1956 13E 54F 101 102 Use Chlorine Storage Steel Yard Office Spike Cleaning Bldg. Crusher Bldg. Flotation Bldg. Toilet Toilet Potlining Engine House Breaker House Breaker House Passageway Potroom. Passageway Passageway Pas sageway Potroom Passageway Passageway Passageway Toilet Toilet Potroom Passageway Passageway Passageway Potroom Passageway Passageway Toilet Toilet Automotive Repair (Formerly 1 5D) Potlining Storage (Formerly 15E) Accounting Office Washroom * Sq. Ft. Y early Floor Area Total Y early Cumulative Totals 760 760 1,522,578 80 1. 192 1, 085 2, 572 4, 929 1. 527, 507 112 112 13, 000 45. 885 120 384 2. 370 39,946 4, 740 1,05o 1, 056 39,94o 2, 112 1,056 1,056 775 775 39, 94o 2, 112 1. 056 1, 056 39,946 2, 112 1, 545 894 894 244,062 1, 771, 569 6, 400 6, 400 6, 006 4, 840 23,646 1, 795, 215 APC 000357 P O IN T COMFORT WORKS METAL PRODUCTI ON DEPARTMENT PRODUCTION EFICIENCIES CD-J ^K GROSS PRODUCTION LBS, 43, 154,413 96,815,932 130,946,109 167,725,718 191,342,678 187,622,498 10.53 9.02 9.14 8.51 R. 25 8.46 LB. C ./LB . NET A L 1 3 S 3 ffi S mm m oo . oc*n --*--rc-x> icno cvo n-- .................................................... LBS B A TH /LB , NET A L M H/LB NET AL. .00937 .00749 .00827 .00753 .00582 .00589 AL CONTENT A LL PURE METAL 99.312 99.514 99.524 99.668 . 99.673 99.579 RQ 5 m S K ro m in Ifi U> HOURLY MEN EMPLOYED TONS PASTE PRODUCED 22,084 31,228 50,961 52,752 56,517 55,877 LB S . INGOT CAST 33,300,724 91,470.913 163,804.379 Ssnaa 9* ff> 01 o* * j APC 000358 1 | | i POI NT COMFORT WORKS EMPLOYMENT DATA OSM. OSH. TO TAL 541 ro CO ro m CO oo r-. r* CC o CNI Cm cm is X On UJ >is O J Q. * < 2 *a UJ UJ O >o < cc j-- C4 UJ X Q. > < fci 0.H w* CO <n a o*> uo r-. OS CO CD r*h %n CO o CO ro r-. o CSJ o Cm in CM o O'* CO os oo uo 5S fs r-- 1 ro ws cc o> <n o r^N r-h os co ro co n CM CO ec in c ro <X> cc CM n i -1 < - CO co o cn r-*. cr ro cO cc cr> m 0 m ro CO - -J > UJ -J 2 l/> zo p < a < a i/) Oh. 5S os CM wo r>-- to c rs. go CM CD r-. fM. CM ro CM ro R ro oo ro CO CM ro in in r-> o CD - CM o o z 5 UD CC CM r-j r*. R CO ro m CM cm cm < Cl >- _J Ct O cr>O oz z * ro ro m CO -r r*-. CO CD co -J < r- co CO CD " r-. ro ro o CO m r-. CO CM !* u.. z r~ UJ 2 UJ kJcJ O < o oUJ Ss X o W UK ro O cO co cm to CM ro ro 0 r--. c- co uo co CM Cm os ro CM CM CO r-- os r-~ CO uo ID ro ro CO ro co Cm R <T> > CD r**. co 2 CO Cm R o n m E? a o MS o> o> o> <*> On * 1 i l APC 000359 0*N QUIT w| TH NOrice ONN QUIT NO NOTICE ; si ; a aj s POI NT COMFORT WORKS Wl ND MOVEMENT AND R A IN F A L L DATA Jw *> z *c X J kl *> mc X in 2 ro r-k r 0 r- ^ m oo o uj . Z c X J kl > z i K X 93 796 1203 1289 1088.5 587.5 959.5 | V C L. m a X > i/r rv ea 254 797 312 511 654. 448.5 553 <*7 cm * Q rg (A vo lo 159 1433 719 1017 1054.5 818.5 614 UJ JL. go cm kl p, f\i z O* J m rv m co Cm ^ -3 DTRECTI ON COMPASS POINT J ki */ > c X J kJ > > v t X J kl Ul * m CC X Ul yj 65 5.9 92 2106 13.6 986 2716 14.5 2108 1355 13.9 1493 2579.5 11.9 1778.5 2393 13.5 1968.5 2229 13.5 2143.5 n V ^ C| ^ Cw rC ^ U5 v 146 5.4 0 326 8.8 120 865 15.3 238 699 'll. 6 214.5 585.5 10.2 349 382.5 12.6 155.5 811 12.4 313 O C> CO r-! oo <NJ <T> C> Cm qq 0 117 143 255 374 90 323.5 O r-- vO Q to -- _! kM* 05 07 --* /--> c--c SO GPO HCD? 2V !V S 0^ noo eDo vgo v6ee o) o6u. c Mc X w*> kn u"> tt HRS. o r CALM 458 504 108 100 193 147.5 113 i* a. MO K k. Io 197 1575 348 1850.5 103.5 1768.5 700.5 1464 8760 8760 8784 8760 8760 8760 J < 0- k. z -- c< --oXX *u> J-<1 j 0 19.17 26.97 29.81 26.86 13.82 19.47 A APC 000360 1 P O IN T COMFORT WORKS POWER DEPARTMENT PRODUCTION TABLE .< _i "oi fsf Rmrsi ~^ e"o oOC*sj iCon* Q <x- .**<* ^ 5M Ir> iC S> a cJ sJ _ -- _? o 5" 5?S 00cc0) 5o" ms s ^ (A s ^ n o u" %Mn 5 ecOco (C<sn. n E2 cc R s'-5 %r* rC>'T S8 ceoo 3 O m m 1^**/>) o0ro4- C> no> *n co s? 0-0. Mu" So* r. cO K% R SCr>O In S ss9 S In APC 000361 P O IH T COMFORT WORKS MATURAL CAS DATA INCLUDES MOOOT, MAGNOLIA, STEAMBOAT PASS, COLOMA CREEK INCLUDES COX POINT APC 000363 r C.O t_ L> k" *T* ^.,n-S-n APC 000365 -E>/^ W5-<N-f T)oil Lc-4TI<N / >. ;T5T2i,.?-C6-^^ '' *R.7"''5 -df3?,<dk c^.-^ ALUMINUM COMPANY OF AMERICA - KNQINUOUfra^DSPARTWKMT * > . ... -. . ' . i -^TV> TE A:q^lon,cry,,-T>I^Vv f \ i I I I i i i APC 000369 ft * >* Fa. A*. > C-fc **%- IS Ct A * 4w * V*t*aH,14.v* m t* M**-NW*M**'*{4'M****MwMAfvei *.-! **44* ***u ^jL,*%4mv * 9m Ife', 4'AW|. w - I 4.4 Tt* *rf (Vm(^'u N L *** ** * > 4 * M M< tU, |J c N -'.r, *- Wt A ** * ' l*i ft- . ri * HI 1 PV It . i -1 *' *l ; .r* AI 'A . 14 . ' .4 - 0 rl U i; Li *t ", V i. 4 ' GlWfAV. Notti A ^ ** & l 'l*fc t r w> J>t *> p* j i*t> *;-v>v4 #...* ;. 1. * * *jt*- *i *i >*. **> A1 - J* . V# . ' . . . - - - - # v . , 4I * tt | 1^1 I M. 1V* MMfc * , * . lM *'," - *1 rt*tT>aw.n\i A it <; '*.. m. L |* * * I'* ' V i ^l 1 . , ! `i J?BlHX-AB.?:.PffT W0Ae S:ji^ JtaXlfiSaj.fcJLL|VATIW| ..AE'fcwnt.. MJi ate4jMnMu>Aztiie APC 000370 S' I...V- APC 000371 **Jf|1 !V* f ) *#>? * 4akfci-`{, i 'J &1 ; . ) ; H'| * l/LiM' 1>I -*. *** * 7F'*s&srtf. `1 fc sr~ _ ** <* * II IX fa>a figgy </ ( --<w ll-o* %% t*u. 9ssss*Litm li* Alt ^ *V** AWA4. &ZX?3lz __ 000372 -i53:i . .. i | mmm ] i _ ---------------------------:------1 jI r:_-- I Mil * APC 000377 A ii I iv t *- * ) l l> j i t:U UJ I t:J ' *3 I E> .] .*> i n: <~r raj ij * -Si * T-** W! . i-W j^r . ii:l *T i if- i f\ r x * . M-i-5;, . .,4 V. & . APC 000378 ii APC 000379 LlI (/) 2a < Ul QL 4-3 o K UJ -J1- *. *4f<-- < O H U > > tn >* Ui Zo a: o UzJ < cn% le a>< 4 o o2 O a *- vt z z ui o 2 z oo"* n > 3 ^ L2 ! .-. fi ! p^l Kmh|hmw^K--^ ^Wa> ALCOA FIRST IN ALUMINUM ALUMINUM COMPANY OF AMERICA 801 Gulf Building Pittsburgh 19, Pa. For Release In Publications of June, 1952 Or anytime thereafter A seventy percent increase in aluminum smelting capacity has been made possible at Aluminum Company of America's Point Comfort (Texas) Works by an addition to its gas-fueled power generating facilities. Foint Comfort, the world's largest internal combustion engine generating station now has a total engine rating of approxi mately 350,000 horsepower. The increase in available power will give Point Comfort an aluminum producing capacity of 85,000 ton3 annually. The first aluminum was poured at the Point Comfort Works on February 11, 1950. Point Comfort was the first new aluminum smelting plant built after World War II and the first in the grow ing Texas aluminum industry. The original power plant included 120 engine-generator units, U.0 of them housed in each of three buildings. To increase the power output, 7l|- new units have been installed in two additional buildings. APC 000392 All 19l+ engines, built by Nordberg Manufacturing Company, are of the two-cycle, radial type, incorporating an advanced de sign of dual spark ignition. The engines have a ll^-inch bore and a 16-inch stroke. Although the 7lj. new engines are similafr in general design and appearance to the 120 original ones* there are important dif ferences between the two* The new engines have 12 cylinders in stead of 11 and> since the cylinders are the same size, the new model develops about 9 percent more power. In addition) A distinctly new type of stabilizing mechanism is employed in the new engine to permit the master crankpin bear ing assembly to gyrate and yet to prevent it from rotating in response to the torque from the connecting rods. This was accom plished in the original 11-cylinder engine by means of a planetary gearing system. In the new engines, however, a simple crank mechanism operat ing between two connecting rods and their knuckle pins is substi tuted for the gearing. The relatively small torque tending to rotate the master crankpin bearing assembly is aosorbed by small reactions on two of the pistons. Although the same impulse generator is used for ignition on both model engines, it is combined with the distributor as a single unit in the new model, instead of being driven separately. Except for these changes, the two engines are essentially the same. In both models,' intake and exhaust are timed by the pistons as they uncover ports in the cylinder walls. This eliminates in take and exhaust valves. APC A ~3 - Natural gas is admitted by cage mounted gas valves. The valves are operated by a cam on the crankshaft and are so located that the gas is admitted into the path of the incoming scavenging air. This assures thorough mixing and efficient, economical burn ing of fuel. A valve Inserted in the gas line and controlled by a hydraulic governor varies the amount of gas delivered to the cylinders according to the load on the engine. Alcoa has found that the compact cylinder arrangement of the engine simplifies maintenance. All bearings are renewable bush ings, and the heads, pistons, cylinders, and bearings are inter changeable. This reduces to a minimum the number of spares required. Seventy-four Elliott electric generators are located in the lower level of the new power houses and are joined to the engines by direct coupling. Each engine-generator unit, with its auxil iaries, operates independently. Each of the 7ii- generators produces 1100 kw (DC) at 667 volts, and 135 kva (AC) at l\.2$ volts and 214. cycles. The AC power is used for driving auxiliaries such as the scavenging air blower, oil and water pumps, and radiator cooling and generator ventilating fans. This eliminates the need for a common auxiliary power system and the possibility of a total station interruption. As in the original plant, each engine-generator unit has its own control panel. In general, the oasic engine shutdown and protective features, v/hich proved so successful in the original installation, have been employed in the two new stations with such minor changes as experience indicated. APC OOO394 * -4 - The auxiliary equipment for the new units is essentially the same as that in the original plant. The only important change is a slightly different arrangement of the engine cooling radiators and their fans, developed in the interest of simplicity and effic iency. j All of the new engine-generator units have aluminum stacks 1 with an overall height of 50 ft. Electrical conductors in the plant addition are aluminum as they were in the original plant. This includes about 9 milliqn pounds of aluminum ous conductor alone for the entire plant. Addition of the 74 new engines will raise the daily consump tion of gas at Point Comfort from 30 million to 50 million cubic feet. Point Comfort gets its gas from bo^h on-shore and off-shore wells. Alcoa buys gas from nearby sources and has also developed some gas wells of its own. Construction of the new smelting facilities followed the pattern set in the original plant. Construction was aided by the fact that Alcoa made provision for expanding the plant in the original planning. # # #. APC 000395 POINT OCKFORT WIND MOVEMENT AND RAINFALL PGR 0950 A weather station m established at Point Comfort Works daring the early construction period) however* the graphic records were not analysed until November 19h9. A table showing wind movement by direction and velocity and total rainfall by months for the year 1950 will be found under the Charts & Tables Section* The wind instrument and rainfall gauge was relocated In April of 1950 eo that all the instruments making up the Point Comfort Weather station could be consolidated in Building 5A* one of the engine control houses* Below is listed the weather Information that is available from this sourest A* Temperature B* Barometric Pressure Cm Rainfall D. Wind Velocity E* Wind Direction F* Emergency Storm Warning (Radio Reports)* Probably the high light of the weather at Point Comfort Works during the year 1950 was the extremely dry year. The actual rainfall was only slightly greater than oDe-half the expected rainfall* There were no hurricane scares of any consequence* The nearest one of the 1950 season vent into the Coast one hundred or more miles below Brownsville* Texas* APC 000396 POINT CC1IF0RT WIND KOTOMEJfT AND RAINFALL for 1951 A chart of the wind novament by direction and Telocity and rainfall by months for the year 1951 will le found under the Charts L Tables Section* Total rainfall for the year 1951 waf about eight inches greater than 1950j hwerer, in general it was ccnsidered a rather dry year* Half of the total twenty-seven inches rainfall fell in two racethe, Kay and September* There were no hurricane alerts on the immediate Qulf Coast* Probably the outstanding weather condition of 1951 was the extreme cold weather with the accompanying rain and ice during the latter part of January and early February. Potable water supply to the plant was disrupted for several days due to power line failures to the Midway wells* Telephone service was out and the highways practically lapaseable* Labor supply was kept 14) by doubles and planned call-ins* Oas supply pipe lines to the plant froa the bay fields failed due to fTeeting in the reducing valves. This did not cause serious complications In the power supply to the potroons because the FTanoitas Field was able to carry the total lead until the other lines were put back in service* APC 000397 POINT COMFORT V.THD MOVEMENT AND RAINFALL 1952 Total rainfall of 29*81 Inches vaa about one Inch greater than far 1951* Precipitation varied greatly from month to month vith months alter nately dry and vet* The largest monthly rainfall for year fell during :'eptonber* and accounted for 35 percent of the year'* total. The largest dally rainfall fell on September tenth and eleventh* accounting for 30 percent of the year's total* There vere no hurricane alerts during the year for this area. 1953 The year is considered to be fairly dry* vith about three inches less than 1952* and vith 52 percent of the year's rainfall occurring in Kay and August. Tho largest dally rainfall for the year foil the veek-end of August 31* On May 13* some hall vas noted vith 1.03 Inches rainfall. There vere no hurricane alerts for this area during the year. APC 000398 FOIST COMFORT WORKS WEATHER DATA 195h The year 195U was unique In that its rainfall vaa only half the average yearly rainfall in this area as established from the beginning of measurement at this location. Only 13*82 inches fell, compared to 26.85 inches per annum averaged over the 38 preceding months. The tenths of February, March, Hay, June, July, septentoer and Decenfcer were dry coopered to corres ponding months of previous yeare, while October was wetter than previous Octobers. January, April, August and November vere in line with previous observations. Wind recording instruments vere out of operation 20.2 per cent of 195U* but shoved about normal wind movements with prevailing wind from south or southeast. 63 per cent of the recorded tine, but with a slightly higher average velocity than in 1933* Minimum recorded outside air temperature was 29 degrees recorded in January and maximum temperature was 107 degrees recorded in June. Average temperature for the year was 75 degrees. APC 000399 POINT COMFORT WORKS WEATHER DATA 29S5 t The pattern of wet months end dry months for the year 1955 very i closely resembled that of 1953, except for the months of August and September, which were wet and relatively dry respectively for 1953 and the exact reverse for 1955. Total rainfall of 19.47 inches was below the long term yearly average for this area. The September total rainfall of 4.68 Inches was the largest monthly total lot the year. On May 10 the largest daily rainfall of 1.49 inches was recorded. Wind recording instruments were out of operation only eight per cent of the total time and showed normal wind movements with wind being from South and Southeast 50 per cent of the time. Average wind velocities were about normal except for southerly winds which blew with an average 14. 3 MPH, which is higher than previous recorded average velocities for south wind. Minimum recorded outside air temperature was 29 degrees recorded in December. Maximum temperature was 101 degrees recorded in July. Average temperature for the year was 74 degrees. APC 000400 po.C't cquxp.t lipi's : HOUGH!" LEPAPPILIT Lynnhaven 1953 Due to the dissolution of Calhoun Development Company on April 30# 19b3 the Aluminum Co-.pany of America .Housin' Department war ret up to : ancle all vorb Cornerlp taken cere of by the Calhoun Ivelopix-nt Co yony ar.-mization, as well es all construction work in prepress at that tine. Construction vork covered by Authorisation TH-25L26 under Calhoun Levolopncnt Co.npE.ry, for the building of three houses in Lyr.nhavcn and eIterations and additions to tie forks iianaper's House, van started on larch 23 and completed on July 6. The (. alhoun Development Company 1953 ;'istory node mention of tho bankruptcy of ;r. . 3. Koehler of Houston^ Texas, who had purchased :.i>rty-two (62) lots in Lynnhaven. Offers to purchase this property fror Lym'mvc.n Inc., uric!. -..-as the Co.-;:any formed by Jar# Koehler to develop this property, were redo by ,lu.-d.nur. Co'-pan,: of America and othrr intrrc-'tcd par-tics. John Peeler and Associates of Pert Lavaca, Texas, were successful :n purchasinr this property and ar-e : lannl-r to start devclopx-r.t shortly after the 1st of January 195k. 'Jr.cior date of f e,vtc.n..cr 1, 1?,. 3 > ai-ranre. ents were .race by -.luninum Co runny of America i;ith the Iincential Insurance Co many of America whereby they voile take over all existin' nortrancs on property purc'.ased by Alcoa employees in Lynnhaven, and continue t'lr iTactice until the f-unds con tracted for this purpose became exhausted. 15-1 APC 000401 153 Continued Ground-breaking ccrcnoniec for the First baptist C .arch to bo constructed in Lynnhavcn ucre held or. September 30, however, no construction work has as yet teen started. A proup. of local Port Lavaca citizens iave formed the First Christian Church and have expressed interest in securing lend in Iynnhaven for their Church edifice. There has boen no land deeded for this project to date. Anrther local -roup of Port Lavacane are interested in securin'- acrearc in Lynnhavcn, at the intersection of Calhoun street and Texas Gtate Hiphway bo. for'the construction of a Modern Lowlinr ,-lley. 'pprovr.l of the sale of this land for the purpose mention, c? is still under advisement. A fTou- of Lynnhaven residents forrxd t!ic Gal: Park hecrcation Assoc iation to establish u playground for the Children in t.is arou. On Tcpteraber 1, Aluminum Company of America rranted this organisation a lease on approximately 3*3 acres in block 10, Lynnhavcn for this play-round. The organization has had the- area completely fenced and playground equipment installed. A pu1 0" basement, containing epproximniely 0.253L acres ;:as cold to !Tr. Pearl .ilson on July 31, 1933* This i asenont is in block 10 adjoin- in~ the Oak Park i-ecrer.tion Association lease. There vas one new home built in Lynnhuven curin'- the year by other thar. Alurdnun Company employees, brinpin;- t!:e- total of homes constructed ty oth.:r th.- n Company employees to twelve (12). Three (3) homes crifinally owned ty Company employees were sold to non-or.iployeo3 durir.p the year. A total of fifty-three (53) hones have boon sold to Company employees to date, with twenty-one (21) hones occupied under the Rental Lease Agreement. 15-2 APC 000402 * IV,.3 Continued Point Comfort Villasc Utility' verb under Authorization T!!-2u755, taken over l.y the T. brown Construction Company due to the bankruptcy of A. '. iCoelilcr* \nr completed on I-iay U. T. H. Lrovn Construction Company of Victoria, Texas, was the success ful bidder on the work covered ty Authorization TH-25530. This work con sisted of constructin'- c 'torn trainere litch to connect with tie existin ' drainage ditch on Pease Ptre-et. ` ori: on this project was started on iiay 22 and completed on Juno 2;. Or. ..ay 5, a contract was awarded to the T. A. Irovr. C onrtr:ctio:a Company to install all utilities, except sanitary sewage facilities, covered under Authorization TH-25?'"c which vac issued to construct six (6) two bedroom houses on lusdnua Company of /nerica property south of Texas ft:.Ac Hi-'awry Ho. 35. >.orte vrns started on June 3 and Lroupht to completion in Pu'uct. The contract for the sanitary sever lin-. s, includin' septic tanks, pumpin' station unu evaporation beds, lv;- awardod to t'.tj . tandare Contract in'- Company of bay City, Texas, in July. Cork van started iux3uistcly and ca-ipletcd in Au'-ust. On June 2!., a Public iectinp was held in the Point ^o-d'ort Village Pecreation buildin- to discuss t'-e possibility of sclf-yovernncnt for the villa,-o. At this racetin ~ petition van prepared and si "no:' by thirty-four voters arc- then presented to trie Judpc of Calhoun County. On June 2u, a notice of an election to be Isld on July 11 was si.-ned by County Judre .'lovarti Hertzo- and ported in the Village. The election was duly held on July 11, with the results bcinp unanimous 15-3 APC 000403 1?;3 Continued Tor incorporation, am:; the- nine of Point Cc::xfort Village to be changed to the tit/ of Point C-.ifort. On July 2hf County Judec caused a notice to be posted callin' for an rovera the new city. The election van duly held on Au-ust 15 with the following persons elected to office* Payor City harehall Alrierrsin Rarl L. draey J. K. Thanas Fred Lerfjoron Toy Alexander Archie tenner ten Thonas Flow'd Forrest All facilities a~c. utilities formerly owned and operated by Aluadnun Co.ipany of 'rerice, includin'- Recreation Fuildin-, Playcround, boat Pier, later Lines, Sewnr Linos, Streets, Savar.c Plant and Vator Tower were dedicated to the r.ev City of i^oint Confort on Octobor 1. and office space for use of the Alcoa Ronsin 1 e;art:.icnt vac leased iron he City. Construction of a half Servico station vac started on July 1 on the station vts completed -r;c in operation in fq.teas.er* In January, a rroup of Point Co.ifort rcsidontr orra- irod a Lutheran Church, anr. arra.n-cd to hold sorviccs in the Recreation buildiny. They also requested t' c Company to donate land -"or both a Church Luildinn and a Parsonage. On August 2d, tro lots were deeded to this rroup for their Church 15 - U APC 000404 A r. fTTlfriri luildin- and on September 23, an additional lot van deeded lor a Parnonare. In uptonber a former Amy Earraclcs building was moved to the Church site for croction an a C-lurch edifice. ork of rcnodelin- tide structure is still underway. Ir. October, /uthorication TH-2ult5l wan received covering the construction of seven Staff ' ouscs on tic Icy Front, including utility work, gradin'* and slopin'* o: Fluff along buy Front. The area in which these houses arc to be constructed id.ll be Icnoin as the : econd Addition to Point (. o .fort Villa<-c. Order lor the nocessiry encineerin- and field survey vorV. was riven to Johnston, Johnstcn and Levis of Victoria, Texas, on October 2. Contract for the slopin': of the i-luff alor.- Lay Front was awarded to Jack altor. of Victoria, Texas, on Leconber 3 and work started iuwediately. Irawin;-s for utility work have been co .pletcd and are at present oat for bids. `uthoricatian TR-26j05 was received on 7 eceiber 11 tc cover additional punning capacity for the existin'* Sewar disposal Plant. Irawin-'S for t:is work are Lcinr .rerarc-d in Pittsbur-'.. :o t'iat tills vori. nry be submitted for Lids. Point Comfort Village now ia: a total of 21 Company built leases and cr:o additional house built by tic baptist Church for their Parsonage. Ticrc arc four Churches, baptist, Lutheran, dethodist and Catholic, as well as one Illlin- tation aid a Grocery rtore. The population of tho Village remains at approximately 1200 persons and a Tra nuxr hchool enrollment of 175 pupils. 15-5 APC 000405 A poe.'? cok:of.t war.Kr HOJPEr. L?P/Lr:TIL::.T 1951* Lynnhavcn The. 19;-3 Jliriory cmcred the purchase of sixty two lots in t;ie upper Lynnhavcn area Ly John Peeler and Associates of Port Lavaca from /. Fochler. These lots have no;: ix.en completely developod ty tho owners and a total of ten horses have been completed vith i'our additional ho.aen under construction. 1. rawin'*r for seven more horses have been approved by the building committee. The First Christian Church of Port Lavaca purchased one and ono-.half acres of lane on April 23* at the corner of Houston and Calhoun Ctreats in Lynnhavcn for their church site, l.'o work 112s as yet been started on this project. On April 20, an agreement was signed ly Aluminum Company of America with The Equitable Life Insurance Company of Iowa to finance all future real estate sales to Coapany employees through the I'irEt .lortrapo Company of rrourton, Inc. Construction work on the baptist Ch.urch in Lynnhavon was started in January and completed in Septc:-i>er vith opening services held tlie same month. In 1953 o roup of local people were interested in securin'- land in Lynnhnven for the construction of a modern boulinr alley. This project has been abandoned due to the inability of tho local parties to arrange the necessary financing. A tot:J. of sixty one homes have been sold to Alcoa employees to date, with four of those homos having been sold by t!ie original, owners to non-employees. 15-6 APC 000406 195U Continued There tire sixteen homos in Iynnhaven occupied under a rental apreerjant. There were also three new hones built in the original tynnhaven develop ment by other than Company employees, brinrinp the total of hones built by other than Alcoa employees to fifteen* / total of five developed lots arc- allj that remain available of tho one hundred twenty lots in tho orifinal Lynnhaven development, with a total of ninety two homes bavin,~ been built in this area* I Point Comfort Sloping of the bluff'alonr the Lay front was awarded to L. Jack lalton of Victoria, Texas', in December,1953* Dork on this portion of t/so project was started at once and completed in January, 195U* In February, Heldenfcls Lros. of Corpus Christi, Texas, were awarded J , 'J the contract for tho utility vork requirecljj rhich covered streets, storm and sanitary sewers and t-jater lines* ' ork was started on February 22 and completed June 20* \ Authorization TR-2oli51 was revised in }ebruary to cover tho construction [\ of one additional staff house in the lay front .'dcSition. ; uthorisetion 11.-26803. was also issued in February to cover construction of a residence in the Lay- Front Addition for tho Plant i'hyeician, Lr. J. Tom..ic who will also . maintain | officer in the City of Point Comfort. On February 19, Acne Electric Company of Port Lavaca was awarded tho contract to install the aluminum street lirhtin^ standards for the Lay front Addition, including tho underground service for the street liyhts and under ground power service for tho homos located on the bay Front* V.ork on this portion of the project waa started in April and completed July 21* 15 - 7 APC 000407 195 b Continued On February 25j the Houston Natural fias Corporation commenced laying rar mains for the lay Front Addition and completed it June 1. Cn ;arch 23, The Anchor Umber Company of Victoria, Texas, was awarded the Contract for the construction of all the staff houses on the aav Front Addition. . ork was started on April 3, end completed Aurust 1$. Central Power and Lirht Company started installing power linos for the lay Front Addition on April 5 and completed it in one week. In April, Authorization TF.-270U3 was issued to cover tise construction of a Shoppinr Center in Point Comfort. . Plans and specifications for this project were drawn by Frank C. Dill, architect of Houston, Texas. As the City of Point Comfort required additional office space, tho Tfoucinr; Lopartrcnt vacated their offices in the Kecreation Luilainr; in Point (o. tort and ovod to tho office building at Point Comfort Forks. Purchase Order was issued to L. Jack : alton of Victoria, Texas, on May 13, -o furnish and install water and sower lino extensions to serve the net: -hopping Center, v ork was started ay 21 and completed June ? In June, on Authorization TF-26605, Purchase Order was issued to the Lushnell i-achinery Company of Pittsburgh, Pennsylvania, for the necessary equipment, and Contract issued to iicldenfcls , roc. of corpus Christi, Texas, coverin- the installation of the equipment for the Point Comfort ewa c Lisposal riant. orl: was started on July 6 and completed Fovo..:ber 7 Also in June, Contracts cure issued to the Commercial Contractin': Company of Pan Antonio, Texas, For the: general construction of tho chopping Center in Point contort anc' to u I. Cook Air Conditioning Company of Victoria, Texas, covering t!;e air conditioning and heatin- for the Shopping Center, l.orif on this project was started Juno 22 with final completion December 5. 15-8 APC 000408 195 L Continued In July, Authorization TF-27317 was issued to cover the extension of Alamo -troet from Austin Street in Point Comfort to Toxas State Highway "o. 35* Knrineerine on this project was done by Johnston, Johnston end Davis of Victoria, Texas. On August 1C, order vas r;ivon to ... Jack 1 alton of Victoria, Texas, to construct the Alano Street extension. Dork was started on September 1 and completed November 12. In September, Authorization TE-27C27 was issued to cover the construction of a lire station with living quartors for a resident fireman for the City of Point C oifort. Plane and specifications for this project were prepared by Trank C. Dill, Architect of ifeuston, Texas. Authorization 7E-27616 was issued in Uovonbcr to cover the furnishing and installinr of pressure valves on tho hot water heaters in Company ouned hones. On liovertoor 22, Lot 1 in I lock 21 of Point Corifort was sold to the General Telephone Company of the southwest as a site for the Point Comfort Lial hxchan~c Tuildinr. This tuilciinr- lias been completed, ana the installa tion of facilities for the net dial cyrte ; is ur.dorway. On December 1, ceromonioc vcrc held to officially o;>cn the new : hoppinr; (enter, 'n estimated 2,500 persons attended tho opening. All rpaco ir. the new center toe leasod, with all retail establishments ready for business on opening ni"ht. -pace in the buildIn- has been leased to a Lcauty Shop, iarber fhop. Post Office, Doctor's Office, Druf: Store and a Super i-iarket. Tho space ori-inally providod for a Dry 'oods Ttoro has been taken over for offices of tho Lavaca Pipe line Company and Alcoa Kousinr Lepartnent. 15-9 APC 000409 I?pli Continued On beconber 2, the 1-Jercer Construction Company of Edna, Texas, was awarded the Contract for the general construction of the Fire I'tatior. for the City of Point Comfort. Voile was started December 8. The City of Point Comfort now has a total of two hundred ninety five Company built houses, and three additional houses built by others in the original Point Comfort Village area. A total of forty nine of the Company built hones have been sold to employees. The balance are an rental. The original Village store buildin-* is now occupied by an applianco and T. V. dealer. The Calhoun County Independent School District constructed a new school buildin-, adjacent to the existing building in Point Comfort, containing six classrooms and an auditorium. The latest sc tool enrollment figures for Point Comfort show a total of two hundred sixty six pupils, an increase of ninety one over last year. The school census figuros taken the early part of 195U showed a total of five hundred fifty six children in Point C omfort under eighteen years of age, with two hundred seventy one of school age. 15-10 APC 000410 A POINT COMFORT WORKS HOUSING DEPARTMENT 1955 Lynnhaven During March, seventy five lots were sold in the upper Lynnhaven area. Ten of these were sold to Alton White of Port Lavaca, and sixty five to the Victoria Realty Company of Victoria, TexaB. This sale, plus the sixty two lots sold in 1953, disposed of all lots in this area except six which are being retained by Alcoa. The entire upper Lynnhaven area has now been completely developed with streets, curb and gutter, water, sanitary sewage lines, etc. A total of sixty four homes have been completed in this area. Seven additional homes are under construction with plans for five additional homes having been approved for construction. The original Lynnhaven development has had new streets constructed by the City of Port Lavaca as well as curbs and gutters installed. Our 1954 History covered the purchase of one and one*half acres of land by the First Christian Church of Port Lavaca. Plans for construction have been approved and work is scheduled to get underway January 3, 1956. Of the seventy seven homes built by Alcoa in Lynnhaven, fifty five are owned by Alcoa employees, five owned by other than Alcoa employees. Seventeen are under rental contract to employees. 15 - 11 /^PC 000411 1955 Continued Three additional homes were built in the original Lynnhaven area during the year, bringing the total of homes built by other than Alcoa to eighteen. A total of three developed residential lots are all that remain available in the original Lynnhaven development. Point Comfort On January 13, the Calhoun County Independent School District purchased 5.6 acres of land adjacent to their present school buildings for future expansion. Our 1954 History covered the awarding of a contract to the Mercer Construction Company of Edna, Texas, for the construction of a Fire Station and residence for the City of Point Comfort. This project was completed on February 19, and a new Fire Truck was purchased through Alcoa for the City of Point Comfort. In February, Authorisation TR-27974 was issued to cover landscaping for the new Point Comfort Shopping Center. This work included the installation of an underground sprinkling system for the lawn in front of the Shopping Center, sodding of the area, and the installation of a six-foot high Redwood basket-weave fence in the rear of the building. This work was completed in April. In March, Aluminum Company of America deeded to the City of Point Comfort, Lots 17 and 18 in Block "A" of Point Comfort in return for 25/100 acres of land in Block "D" of Point Comfort, which had been previously 15 - 12 APC 000412 A 1955 Continued dedicated to the City of Point Comfort. The 25/100 acre tract was sold in May to the Point Comfort Boat Club as a site for their Club House. On June 13, Aluminum Company of America donated to the Calhoun j County Independent School District, four one-jbedroom houses for their use in housing teachere at the Point Comfort School. On September 23, a Request for Authorization was written to cover i the purchase of approximately 26l acres of land, adjacent to the City of Point Comfort, from Miss Susie Coates, et al. On October 7, a Request for Authorisation was written to cover the purchase of approximately 55 acres of land from S. G. Sample. This acreage is also adjacent to the City of Point Comiort. 1 ji Authorization TR-28909 was issued in October to cover the development of approximately fifty six lots in the Bay Front Addition and the First ' Addition to the City of Point Comfort. Bids were taken on December 9, and contract for utility work awarded to Wade Bros, of Edna, Texas. The contract for installing the underground street lighting system was awarded to Power Electric Company of Port Lavaca, Texas. Work under this authorization is scheduled to get underway January 3, 1956. In December, Alcoa donated to the First Assembly of God, Point Comfort, Texas, two lots on which to erect their church building. This group is now holding church services is the Union Hall in Point Comfort. The Church of Christ is also holding regular services in the Recreation Building In Point Comfort. 15 - 13 APC 000413 A 1955 Continued A total of eighty one homes built by Alcoa have been sold to employees to date, with two hundred and thirteen on rental contracts. A total of twenty homes have been built this yoar by others, seventeen of which are in the new Bay Front Addition. This represents a total of twenty three new homes by others to date. Included in these totals arc parsonages constructed by the Baptist and Lutheran churches. The Point Comfort school census as of September 1, 1955, showed a total of five hundred ninety four children from birth to seventeen years of age, with three hundred twenty one children of school age. This represents an increase of fifty school age children during the past year. 15 - 14 APC 000414