THE ROLLING MILL INDUSTRY A Condensed, General Description of Iron andJSteel Rolling Mills and their Products BY F. H. Kindl, Engineer Pittsburgh, Pa. Penton Publishing Company Cleveland, Ohio 1913 Copyrighl, 1913 By The Penton Publishing Company The Penton Press Cleveland Preface In this work the author has endeavored to give a condensed, general description of iron and steel rolling mills and their products, without discussing the details of roiling any special material. Essentially, it is a summary of American rolling mill practice, its development being traced from the beginning to the present day. An effort has been made to define more closely the various mills and their products and the various classifications herein presented have been approved by leading manufacturers and many of the country's foremost iron and steel engineers. The charts which graphically show the production of semi-finished and finished products, from 2,000 pounds of iron ore, 1 000 pounds of coke and 600 pounds of limestone, represent modern practice at some of the largest open-hearth plants and rolling mills. Charts also are included to clearly illustrate the amounts of material charged and produced in making one ten of pig iron; the distribution and production of iron and steel in 1907 and 1911; the conversion of pig iron into the various finished products, etc. For those interested in the economies of the iron industry, a table has been prepared in which a comparison has been made of the general fundamental factors dictating the production of pig iron in the United States, Germany and Great Britain, with particular reference to the Pittsburgh district of the United States, the Rheinland-Westfalia district of Germany, and the Cleveland district of Great Britain. The author wishes to extend his thanks to the several companies and individuals who kindly furnished some of the necessary data for this work ; to the United Engineering and Foundry Co., Pittsburgh, for the views cf the various rolling mill installations and to the American and foreign iron and steel trade associations from which the statistics largely were obtained. F. H. KINDL Pittsburgh, June 2, J9J3 Contents *,. ;-*-tW;*.~\,:n ! '-.T ' ^ - ; CHAPTER I PAGE Historical 1 CHAPTER II Classification of Rolling Mills 9 CHAPTER III Finished Products ..... 21 CHAPTER IV The Wire Industry 37 ' *>% CHAPTER V ..& ~ . *. .. 3 < . . , Tube and Pipe Industry 51 CHAPTER VI -v - ' >& Tin and Terne Plate Industry 57 Statistical .' .' . .' .' .' .' .".".' 60 Index.. 69 Illustrations Interior of Blooming Mill Building, American Tube & Stamping Co., Bridgeport, Conn Frontispiece 40-Inch Blooming Mill, Youngstown Sheet & Tube Co., Youngs- town, 2 34-Inch Blooming Mill and Tables, Andrews Steel Co., Newport, Ky 4 Bloom Shear and Tables, Andrews Steel Co., Newport, Ky 6 Blooming and Sheet Bar Mill, Andrews Steel Co., Newport, Ky. 10 Motor-Driven, Continuous Billet Mill at the Plant of the Indiana Steel Co., Gary, Ind 11 28-Inch Rail Mill and Tables, Bethlehem Steel Co., South Bethlehem, Pa 12 28-Inch Rail Mill and 28-Inch Structural Mill, Bethlehem Steel Co., South Bethlehem, Pa 14 Chart Showing Graphically the Conversion of Pig Iron Into Ingots, Castings, etc., and the Subsequent Finished Pro- ducts 15 Amounts of Material Charged and Produced in Making One Ton of Pig Iron 16 Production Conversion Chart for the Years 1907 and 1911 17 Rail Mill Finishing Department, Bethlehem Steel Co., South Bethlehem, Pa 18 Production Conversion Chart Showing the Weight in Pounds of Open-Hearth Steel Products Obtained From 2,000 Pounds of Ore 22 Production Conversion Chart Showing the Weight in Pounds of Open-Hearth Products Obtained From 2,000 Pounds of Ore . 23 Tilting Frame Hot Saws for Rail Mill 24 Hot Saw Run For Rail Mill 26 Hot Bed for Rail Mill 28 Rail Cambering Machine, Bethlehem Steel Co., South Bethle- hem, Pa 30 84-Inch Plate Mill, La Belle Iron Works, Steubenville, 32 Plate Mill and Tables, La Belle Iron Works, Steubenville, O. . . 38 30-Inch Universal Plate Mill 40 24-Inch Sheet Bar Mill, Andrews Steel Co., Newport, Ky 42 24-Inch Sheet Bar Mill, Andrews Steel Co., Newport, Ky 44 16-Inch Morgan Continuous Mill at the Plant of the Dominion Iron & Steel Co., Cape Breton, N. S ^. .. 46 Motor-Driven, 20-Inch Merchant Mill, Singer Mfg. Co., Eliza- beth, N. J 48 16-Inch Merchant Mill, Illinois Steel Co., Milwaukee 52 Motor-Driven, 10-Inch Merchant Mill, Singer Mfg. Co., Eliza- beth, N. J 54 Tables PAGE Production of Iron and Steel Plates and Sheets 31 Production of Rolled Iron and Steel 35 Total Production of Finished Rolled Iron and Steel 36 Production of Cut and Wire Nails 41 Production of Tin and Terne Plate 59 Production of Tin and Terne Plate in the United States Since 1891 60 Iron and Steel Imports and Exports 61 Basic Factors of Pig Iron Production in the United States, Ger- many and Great Britain 62 Summary of Statistics for 1910 and 1911 64 The World's Leading Iron and Steel Producers 65 The World's Production of Coal, Coke, Iron Ore, Pig Iron and Steel in 1910 66 World's Iron and Steel Production, 1850 to 1910. . 67 Illustrations PAGE Interior of Blooming Mill Building, American Tube & Stamping Co., Bridgeport, Conn Frontispiece 40-Inch Blooming Mill, Youngstown Sheet & Tube Co., Youngs- town, 2 34-Inch Blooming Mill and Tables, Andrews Steel Co., Newport, Ky 4 Bloom Shear and Tables, Andrews Steel Co., Newport, Ky 6 Blooming and Sheet Bar Mill, Andrews Steel Co., Newport, Ky. 10 Motor-Driven, Continuous Billet Mill at the Plant of the Indiana Steel Co., Gary, Ind 11 28-Inch Rail Mill and Tables, Bethlehem Steel Co., South Bethlehem, Pa 12 28-Inch Rail Mill and 28-Inch Structural Mill, Bethlehem Steel Co., South Bethlehem, Pa 14 Chart Showing Graphically the Conversion of Pig Iron Into Ingots, Castings, etc., and the Subsequent Finished Pro- ducts 15 Amounts of Material Charged and Produced in Making One Ton of Pig Iron 16 Production Conversion Chart for the Years 1907 and 1911 17 Rail Mill Finishing Department, Bethlehem Steel Co., South Bethlehem, Pa .; 18 Production Conversion Chart Showing the Weight in Pounds of Open-Hearth Steel Products Obtained From 2,000 Pounds of Ore 22 Production Conversion Chart Showing the Weight in Pounds of Open-Hearth Products Obtained From 2,000 Pounds of Ore. 23 Tilting Frame Hot Saws for Rail Mill . . 24 Hot Saw Run For Rail Mill 26 Hot Bed for Rail Mill 28 Rail Cambering Machine, Bethlehem Steel Co., South Bethle- hem, Pa 30 84-Inch Plate Mill, La Belle Iron Works, Steubenville, 32 Plate Mill and Tables, La Belle Iron Works, Steubenville, O. . . 38 30-Inch Universal Plate Mill 40 24-Inch Sheet Bar Mill, Andrews Steel Co., Newport, Ky 42 24-Inch Sheet Bar Mill, Andrews Steel Co., Newport, Ky 44 16-Inch Morgan Continuous Mill at the Plant of the Dominion Iron & Steel Co., Cape Breton, N. S 46 Motor-Driven, 20-Inch Merchant Mill, Singer Mfg. Co., Eliza- beth, N. J 48 16-Inch Merchant Mill, Illinois Steel Co., Milwaukee 52 Motor-Driven, 10-Inch Merchant Mill, Singer Mfg. Co., Eliza- beth, N. J 54 Tables PAGE Production of Iron and Steel Plates and Sheets 31 Production of Rolled Iron and Steel 35 Total Production of Finished Rolled Iron and Steel 36 Production of Cut and Wire Nails 41 Production of Tin and Terne Plate 59 Production of Tin and Terne Plate in the United States Since 1891 60 Iron and Steel Imports and Exports 61 Basic Factors of Pig Iron Production in the United States, Ger- many and Great Britain 62 Summary of Statistics for 1910 and 1911 64 The World's Leading Iron and Steel Producers 65 The World's Production of Coal, Coke, Iron Ore, Pig Iron and Steel in 1910 66 World's Iron and Steel Production, 1850 to 1910. . 67 1 .8 AL mm. *iM THE ROLLING MILL INDUSTRY Chapter I Historical WITHOUT discussing the details of rolling any special product, it must be of interest, at least to those engaged in the iron and steel business, to have a comprehensive knowledge pertaining to this important branch of the iron and steel industry, and with that in view, the writer will give a con- densed general description of rolling mills and their products. It will be conceded that the most valuable factor in the progress of the art of forming various sections from wrought iron and steel was the introduction of the rolling mill. Its devel- opment can be traced back to the time of Henry Cort, of England, who, in the latter part of the 18th Century, took out his patent for puddling, and mills with plain grooved rolls were first used for the manufacture of bar iron. These bars subsequently were welded and forged into various articles such as chains, hooks, etc., and were used largely for suspension bridges. In the course of development, the practicability of the plate mill was recog- nized, and the process of rolling wire became known, wrought 1 Historical iron plates took the place of wooden planks for ship construc- tion, plate iron boilers were substituted for cast iron boilers, and wire cables displaced chains in suspension bridges. The First Plate Mill In 1780, the first plate mill was built at Neuwind, Germany, and in 1820, John Berkinshaw, of Belington, Eng., rolled the first practical rail, although angles and T-iron were rolled at an earlier date. As the process of rolling plates became better known, the plate box-girder and lattice-girder were introduced, and wrought iron bridges began to replace those built of cast iron and wood. Concurrent with the growing requirements for wrought com- pression members in bridges (introduced in the United States first), came the demand for suitable structural shapes. Thus we might credit England with having rolled the first rails, angles, T and Z-shapes; Germany with rolling the first plates; France with designing and rolling the first I-beams and channels, and the United States with designing and rolling the first segmental shapes so much found in the older designs of built columns. The use of wrought iron shapes for compression as well as tension members in connection with plates caused a more general distribu- tion of their use for other constructions than bridges, such as cars, ships, buildings, etc., until today, with the exception that the material is no longer wrought iron, but steel, rolled struc- tural shapes and plates form the very skeleton of all our modern structures. American Supremacy While the supremacy of the United States in the iron and steel trade is generally recognized, there is no other branch of the iron and steel industry, perhaps, in which the United States has more reason to take pride than this, for on no other have we stamped our national individuality so deeply. The American bridge, the American steel skeleton building, the Amer- ican rail, the American wire, and the American steel 3 Historical car are those forms of construction that are recognized the world over as having received their most marked development in this country and are a direct result of the American rolling mill indus- try. Although the fundamental features of the supremacy of the United States in the iron and steel industry are to be found in the marvelous resources of our country, too much cannot be said in praise of the intelligence and skill with which the Amer- ican iron master has risen to his opportunities. It is to the remarkable ingenuity shown in the production of labor-saving machinery that much of the low cost of production is due, to say nothing of the broad administrative ability shown by the manage- ment of the great steel works in laying out the component parts of their establishments in such a manner that the heavy tonnage which passes through these plants, day after day, shall proceed from the ore to the finished product with the minimum amount of handling and trans-shipment. Finally, the more prominent iron and steel men, early in the history of the development of the industry, perceived and acted upon the fundamental economic principle that for cheap production of iron and steel, large oper- ations and combinations of capital are essential. Labor-Saving Equipment The ingenuity and resourcefulness displayed in handling and transporting the large tonnage of raw material, such as ore, coal, coke, etc., required in the production of a constantly increas- ing tonnage of rolled material, was ably followed when it came to the recovery of the iron in the blast furnaces and the subsequent conversion into steel and its fabrication into the thousand forms in which the finished material is offered for sale upon the market. In no single branch of any industry has more thought been given to labor-saving devices than in the manufacture of iron and steel. First, to reduce the handling and trans-shipment to a minimum, the processes are made as continuous as possible. The erection of a modern, typical steel works calls for a plot of ground preferably parallelogram in shape, and many plants can 5 Historical be found today occupying land having a width of one-half mile by more than a mile in length, along the borders of a navigable stream or lake, from which the necessary supply of water is derived and the transportation by water made possible. At one end of a typical steel plant are located the blast furnaces with their artificial mountains of ore, coke and lime- stone; then the mixer, followed by the Bessemer or open-hearth furnaces; next in line is the ingot-stripper building with its adjoin- ing soaking pits or furnaces for heating the cast ingots. Directly connected with these, stretch enormous buildings, 1,000 feet or more in length, with their blooming, cogging and slabbing mills, followed directly by the various finishing mills, shears, transfers, hot beds, saws and straightening departments, succeeding each other in progressive order up to the stock yard and shipping department, from which the finished product is loaded upon cars almost before the last trace of furnace heat has left it. Furthermore, in its transit through the mills, the material has been rolled and heated and rerolled without the use of manual labor, and for many forms of material, the continuous processes are carried on with such rapidity that the entire rolling from the ingot to the finished shape is accomplished in a single heat. Electrical Age in Steel Plants In summing up the causes of the success in the manufacture of steel, great importance must be given to the early varied appli- cation of electricity as a motive power in the thousand uses to which it has lent itself so admirably. This valuable accessory to our steel works practice was formerly generated entirely from coal-fired boilers and steam engines connected to electric gener- ators, but today it is derived from the by-product of the blast furnace which supplies the necessary gas for heating the boilers and generating high pressure steam to be used in turbines direct- connected to electric generators, or is directly converted into power by means of gas engines connected to electric generators. Large buildings in which thousands of kilowatts of electricity are thus 7 The Rolling Mill Industry generated hourly and known as central power plants, are indis- pensable to the modern steel works. Applications of Electricity Among the most useful applications of the electric cur- rent in iron and steel plants are the electric skip-hoist for charg- ing the blast furnace ; the electrically-operated bridges spanning the stock yard of the blast furnace department; the overhead electric traveling cranes, covering in their range the entire length of both charging and pouring sides of the open-hearth furnaces and entire mill buildings; the electric charging machine that picks up a box containing a ton or more of mixture, which is thrust into the furnace, emptied and withdrawn therefrom; electric strippers which strip the ingot mold from the cast ingot; electric soaking pit cranes for depositing the ingots in the heating furnaces and withdrawing them; electric buggies that receive the heated ingot after it has been lifted from the soaking pits and run it to the rolls; electric pushers for pushing the blooms into the furnace to be reheated, and electric tongs for gripping the blooms and pull- ing them out at the other end; electric motors for driving the rolling mills; electric traveling tables on either side of the mills for conveying the material to be rolled to the various passes of the rolls and to receive it after passing through the rolls for transfer to the hot beds, which also are electrically-operated. These are a few of the uses of electricity in the steel works without mentioning its many applications to other operations in the mines, railroad and ship transportation, and its direct use in the conversion of iron to steel, where, with ingenuity, forethought and administrative skill, it has enabled the American manufac- turer to compete with the world, while paying the highest wages to labor and returning immense dividends on capital invested. Chapter II Classification of Rolling Mills THE production of rolled forms of iron and steel is accom- plished in rolling mills. A rolling mill consists of a train of rolls, which in turn is composed of roll stands; each stand consists of at least two rolls set between and carried by frames called housings. The rolls are cast iron or steel cylinders with their axes set parallel and horizontally above each other, and held in the hous- ings so that a fixed space is left between the surfaces of the rolls. The rolls are driven by electric motors or steam engines, through gear transmission, in such a manner that they rotate in opposite directions ; the gears are connected to the motive power and rolls (by means of spindles, or short shafts and coupling boxes. The operation of rolling consists in passing between the rolls a tough and pliable material, such as heated steel, having greater thickness than the space between the rolls, the result of which is a compression and reduction of cross-section of the material and its consequent elongation. The process is similar to that used by the blacksmith in the elongation of a piece of hot steel by means of the hammer, except that the same result is accomplished much more rapidly on account of the continuity of work by means of rolling. Iron or steel is either rolled direct from its initial heat or is reheated in furnaces suitable for this purpose, to such a temper- 9 The Rolling Mill Industry 10 Classification oj Rolling Mills 3o s e s 5 ^ a $* || S o ature as to soften and render it plia- ble. Notwithstand- ing its soft condi- tion, the resistance to change of form is considerable and r e q u ires numerous passes of the ma- terial through the rolls before the de- sired final shape is obtained. Classes of Rolling Mills Rolling mills can be divided into two fundamental classes, namely, reversing and non - reversing mills. The reversing mill, types of which are shown in Figs. 2 and 3, has two rolls, one above the other, or two-high, which are stopped after each pass; the engine then is reversed and the material is passed through the rolls in the opposite direc- tion. Owing to the impossibility of using a fly-wheel, stored 11 12 Classification of Rolling Mills energy to equalize overloads cannot be used and the engines of such mills must be exceedingly heavy and powerful, making such installations very expensive, and generally restricting them to mills rolling heavy ingots, difficult to raise and handle. The non-reversing or continuous running mill, types of which are illustrated in Figs. 7, 23, 25 and 26, consists of three rolls, one above the other, or three-high, in which the piece passes between the lower and middle rolls in one direction and between the top and middle in the return pass. It is self-evident that this arrangement is the more productive, as the rotation of the rolls is not interrupted and thus the use of a heavy fly-wheel is not excluded. Rolling mills are generally distinguished by the name of the product which they are designed to roll. They may be referred to by their size, or rating, which, for everything except plates, is based upon the diameter of the rolls; in the case of plates, the maximum width which can be rolled fixes the size of the mill. They may be named with reference to the arrangement of the individual stands to each other, also with reference to the kind of material rolled, such as steel, tool steel, copper, lead, brass, etc. Classification of Rolling Mills Mills classified in accordance with the name of the product which they roll, follow: 1. Blooming, cogging and slabbing mills, being the prepara- tory mills to rolling finished rails, shapes or plates, respectively. If reversing, they are from 34 to 48 inches in diameter, and if three-high, from 28 to 42 inches in diameter. Blooming mills are shown in Figs. 2 and 3, and a universal plate mill is illus- trated in Fig. 21. A plan view of a blooming and sheet bar mill is shown in Fig. 5. 2. Billet mills, three-high, rolls from 24 to 32 inches in diameter, used for the further reduction of blooms down to 1^ x 1^-inch billets, being the preparatory mills for the bar and rod 13 The Rolling Mill Industry Jo\i ;= ~ ~~ " s _ "o C/5 "I 14 Classification of Rolling Mills BARsfwi L [_BA RE RODS, WIRE, WIRE MAILS BANDS, HOOPS SHAPES RAILS, SPLICE BARS AXLE BLANKS, FORGED AXLES PLATES, SHEET BARS, SHEETS, TIN PLATE SKELP, TUBES WHEEL BLANKS, FORGED WHEELS BARS fw'RE R ODS, WIRE, WIRE NAILS L BANDS, HOOPS SHAPES RAILS, SPLICE BARS AXLE BLANKS, FORGED AXLES PLATES, SHEET BARS, SHEETS, TIN PLATE. SKELP, TUBES WHEEL BLANKS, FORGED WHEELS BLOOMS BILLETS ("SINGLE REFINED IRON, SKELP, TUBES MUCK BAR! DOUBLE REFINED IRON, SHAPES FRIPLE REFINED IRON ji PLATES [BARS [CRUCIBLE T SEMER SCRAP :N HEARTH SCRAP! STEE:L L ("FORCINGS INGOTS [BARS STRUCTURAL MACHINE PIPE POTTERY ORNAMENTAL AGRICULTURAL Fig. 9 Chart which Graphically shows the Conversion of Pig Iron into Ingots, Castings, Etc., and the subsequent finished products. 15 The Rolling Mill Industry 'W%X'''B ,38 i 267 .304 I22 084 o ELECTRIC STEEL a a .0233 .0140 o. IRON CASTINGS NO i \ 3LAST FURNACES ACTIVE 1 442 167 465 231 IDLE YEAR, 276 raor 234 1911 Fig. 11 Production Conversion Chart for the Years 1907 and 1911. Production in millions of tons 17 IS Classification of Rolling Mills 8. Small merchant bar mills with finishing rolls from 8 to 16 inches in diameter, generally arranged with a larger size roughing stand. Such a mill is shown in Fig. 27. 9. Rod and wire mills with finishing rolls from 8 to 12 inches in diameter, always arranged with larger size roughing stands, Fig. 24. 10. Hoop and cotton tie mills, similar to small merchant bar mills, Fig. 27. 11. Armor plate mills with rolls from 44 to 50 inches in diameter and 140 to 180-inch body. 12. Plate mills with rolls from 28 to 44 inches in diameter, Figs. 19 and 20. 13. Sheet mills with rolls from 20 to 32 inches in diameter. 14. Universal mills for the production of square-edged or so-called universal plates and various wide flanged shapes by a system of vertical and horizontal rolls, Fig. 21. 15. Tube mills for the production of tubes. 16. Special mills, such as slitting, piercing, tire wheel mills, etc. 17. Cold mills. Mills in classifications Nos. 1 to 10, inclusive, have grooved rolls Mills in classifications Nos. 2, 3, 9, 10, 13 and 15, for large tonnage production, are preferably built of the continuous type, which consists of a number of stands of two-high, non-reversing rolls, one behind the other, which are driven at progressively increasing speeds. A plan of a continuous billet mill is illustrated in Fig. 6, and Fig. 24 is a Morgan continuous mill. Rolling Mill Layout The general layout of a rolling mill is dependent upon many conditions, but it will be found here, as in all up-to-date manufacturing establishments, that the arrangement is such as 19 The Rolling Mill Industry to provide for a logical, continuous, progressive and economical operation, so that the material to be rolled enters at one end of the mill and leaves it as a finished product at the other end. Ample space is provided so there may be no overcrowding, and provisions are made on all mills to roll the greatest possible finished length in one heat. The arrangement of various types of mills is shown in Figs. 5, 6 and 8. The progressive steps in a complete plant to convert the ore into the finished product are as follows: From the blast furnace to the mixer, to the steel works, to the soaking pits, to the blooming, cogging or slabbing mills, to the various finishing mills, to the hot beds, through the saw and straightening departments to the shipping yards. The conversion charts, Figs. 9, 11, 13 and 14, graphically illustrate the conversion of ore to the finished products. Semi-Finished Products The products of a rolling mill are divided into semi-finished and finished rolled material. To the first belong rolled blooms, slabs, billets and sheet bars. This material is produced by roll- ing an ingot to square, rhomboidal or flat sections having more or less rounded corners. When an ingot has been reduced to a section 6 inches square or larger, it is called a bloom ; if rolled flat to a section having a thickness not less than 2 inches and a width of at least 12 inches, it is called a slab; if from \ l / 2 inches square or round and less than 6 inches square or round and cut into lengths, it is called a billet. A sheet bar is a section having a thickness less than 2 inches and a width from 6 to 12 inches. Semi-finished material is commercial only as such, and not being straightened or cut square on the ends, it is only adapted for use for further rolling or working into more highly finished products. 20 Chapter III Finished Products THE finished rolled material includes all iron and steel rolled to finished forms. It is the product or forms pro- duced by rolling semi-finished material in finishing mills. This class may be divided into the following groups : First. Bars, rods, wire rods, bands and hoops, Fig. 13. Second. Shapes, structural shapes, rails and splice bars, Fig. 13. Third. Plates, sheets, skelp and nail plates, Fig. 14. Fourth. Forgings, armor plate, axles, wheels, tires and drop forgings, Fig. 14. First Group Bars, rods, wire rods, bands and hoops, constituting the first group, are produced from blooms, slabs and billets" by reduc- ing this material to the simplest forms, such as squares, rounds and flats. These forms resemble the cross-section of the material from which they are rolled, and their final section determines their nomenclature. The materials of this group have great length compared with their width and thickness. The steel from which they are rolled is prepared to conform to certain specifica- tions, and the section must be within certain limits as to size and weight, and must be suitable for further fabrication into bolts, nuts, spikes, chains, rivets, wire, wire nails, hoops, cotton ties, 21 The Rolling Mill Industry COTTQM TIE*, Fig. 13 Production Conversion Chart showing the Weight in Pounds of Open-Hearth Steel Products Obtained from 2,000 Pounds of Ore. 22 Finished Products BUTT -WELD TUBES 740 LAP-WELD| TUBES 7!O - 73O" 910 I TIRE?, HEAVY AXLES 'AND FORCINGS SHEET BARS THIRD GROUP SEMI - FINISHED PIG IRON THIRD GROUP SEMI - FINISHED Fig. 14 Production Conversion Chart showing the Weight in Pounds of Open-Hearth Steel Products 'Obtained from 2,000 Pounds of Ore. 23 24 Finished Products springs, etc. Bars may be either square, round or flat; the sizes to which they are commercially rolled being 3/16 to 7*4 inches square or round. Sizes ^J to 3 1/16 inches are known as base or standard. Flats are commercially rolled ^ inch wide by l /% inch thick up to 6 x 4 inches ; sizes ^ x ]/% inch to 6 x 3/16 inch are classed as light bars and bands, and sizes 1 x y% inch up to 6x4 inches are commercially classed as flat bars and heavy bands. Sizes from 1 to 6 inches wide x ^ inch to 1 inch thick are known as base or standard. A rod is generally understood to be a round bar. Standard wire rods are round bars having a section 0.2 to 0.3 inch in diame- ter, which are coiled in bundles. The United States government limits the size of wire rods to No. 6 B. W. G., or 0.203 inch, and if thinner than this, the product is termed wire. Hoops are very thin flats having a thickness from No. 13 B. W. G. to No. 23 B. W. G., and from ^ to 8 inches in width. Owing to their general length, they are coiled the same as wire rods, but are subsequently annealed, cut to length and shipped in bundles. Cotton ties is a product made from hoop iron or steel cut to certain lengths and used for fastening bales of cotton. They are generally shipped in bundles, each containing 30 ties and weighing 45 pounds per bundle. Second Group Shapes, constituting the second group, are reduced from blooms, slabs or billets to forms having more or less irregular section. In the process of rolling, the original material is not only reduced in section, but it is also developed into a definite shape. The various shapes are given commercial names, such as rails, splice bars, I-beams, channels, zees, tees, angles, etc. The heavier and larger sizes of these shapes are frequently rolled direct in one heat from the ingot to the finished material. After leaving the rolling mill, shapes are cut to length and are cooled on cooling beds, shown in plan in Fig. 7. Fig. 25 Finished Products 17 is a rail mill cooling bed. The shapes are subsequently straightened by means of straightening rolls or presses, the latter work being performed in suitable shops adjoining the rolling mill, and in this condition they are known commercially as struc- tural shapes. These shapes are further developed and worked into various products at shops specially adapted to carry out the character of the work for which they are intended. For example, the fabrication of products built for building construction is carried on in architectural iron works; bridges at bridge works; ships at ship yards, and railroad construction at car shops. The steel from which structural shapes are rolled is pre- pared to conform to three kinds of specifications, namely, for buildings, bridges and ships. Rails Rails are rolled shapes used for guiding and car- rying the wheels of railroad cars, and are produced in rolling mills specially designed for this purpose and known as rail mills. A plan view of a rail mill is shown in Fig. 8, and the various rail mill departments are illustrated in Figs. 7, 12, 15, 16, 17 and 18. The steel from which rails are rolled is prepared to conform with standard specifications for steel rails, and the sec- tions of rails in the United States are largely made in accord- ance with the American Society of Civil Engineers' standards. Rails are divided into light and heavy rails, light rails being those weighing less than 40 pounds per lineal yard. Rails, in addition to being sawed square and straightened, are drilled at their ends for holes to receive the bolts used for splicing or joining the ends of two rails. While rails are rolled to 120 feet and more, the standard length when shipped is 30 to 33 feet. Splice bars are rolled shapes used for joining the ends of rails. They are cut accurately to length and must fit perfectly to the rails for which they are intended. They are punched to match the holes drilled in the rails as well as notched to receive the spikes fastening them to the wooden ties. 27 28 Finished Products Third Group Plates and skelp, of the third group, is the material obtained by rolling slabs and blooms in mills known as plate and skelp mills, respectively, shown in Figs. 19 and 20. A sheet is the product ob- tained by rolling sheet bars in sheet mills. While bars and shapes have great length compared with their other dimensions, this does not apply to plates and sheets where the width is also well devel- oped ; this form of product is known as sheets when rolled to a thickness less than No. 12 gage. The United States govern- ment limits this thickness to No. 10, United States standard gage. With reference to quality and use, plates may be divided into tank, bridge, ship and boiler plates. The steel entering into the material from which plates are rolled is prepared to conform to standard specifications governing the above classes. Boiler plates are further divided (with reference to the grade of steel to be used for certain parts of the boiler) into flange, fire box and extra soft steel. Plates, after being rolled, have frequently an uneven surface, which is flattened by passing them through straighten- ing rolls. Long plates are straightened by being held in place against guides and are hammered flat with wooden hammers. Plates, after being straightened and cooled, are transferred to the shearing department, usually adjoining the plate mill, where they are cut to size. Plates having irregular edges must be sheared. Universal mill plates have their edges rolled and need only be sheared on the ends. Universal mill plates are rolled from 18 to 60 inches in width. Skelp Skelp plate is a material used for the manufacture of tubes and pipes. It is rolled to such width and thickness as may be necessary to produce a certain diameter and strength of tubing. The edges of skelp plate are generally sheared for large sizes of pipe. When the edges of plate are rolled or cut to a beveled shape, it is called scarfed skelp, and is used for the manufacture of lap-welded pipes. Grooved skelp are plates rolled in a mill 29 30 Finished Products having grooves cut into the rolls the width of the plates to be rolled. Sheets Sheets are rolled from sheet bars of such thickness and are sheared into such lengths that each piece will be of the exact weight to make the sheet required. The sheet bars are heated and rolled into sheets of the required thickness in mills called sheet mills. They are also, when specified, cold-rolled or pickled and cold-rolled, to meet special requirements. As the sheets be- come hard in the process of rolling, they must be annealed. This is accomplished in suitable furnaces. Sheet mills, as a rule, do not roll thinner than No. 30 gage. Black sheets is a term gen- erally used to differentiate between sheets that are uncoated and those that are coated. TABLE I PRODUCTION OF IRON AND STEEL PLATES AND SHEETS Plates, No. 12 and thicker. Sheets, No. 13 and thinner. Years. 1905 Iron, gr. tons. 10,022 Steel, gr. tons. 2,031,184 Total, gr. tons. 2,041,206 Iron, gr. tons 62,134 Steel, gr. tons. 1,428,890 Total, gr. tons. 1,491,024 1906.. 1907.. 1908.. 1909.. 1910 ...23,333 ...30,277 ...31,679 ...32,332 37,763 2,508,219 2,629,783 1,239,342 2,346,766 2,769,965 2,531,552 2,660,060 1,271,021 2,379,098 2,807,728 51,040 43,761 22,354 43,870 53,355 1,599,564 1,545,011 1,356,318 1,811,378 2,094,401 1,650,604 1,588,772 1,378,672 1,855,248 2,147,756 1911 46,147 2,288,194 2,334,341 43,280 2,110,428 2,153,708 1912 33.349 3.001.851 3.035.200 41.695 2.798.185 2.839.880 Nail plates are used for the manufacture of cut nails. The plates must be of uniform thickness. This product is being rapidly eliminated owing to the increasing use of wire nails. Table I gives the production of iron and steel plates and sheets from 1905 to 1912. Group Four By forgings, group four, is understood the product obtained by the various steps or stages of heating, pressing or hammering an ingot, bloom, slab and other rolled products into a definite form 31 ^r 7 32 Finished Products or shape. Work performed on forged articles, after the com- pletion of the forging process, such as machine work, advances them beyond the class of product known as forgings, although such finishing process or work is frequently performed in the same shops where the forging of the article takes place. Armor plate is a specially heavy plate, forged from a large ingot by means of powerful hydraulic presses. It is used for the protective sheathing of war vessels to withstand the penetration of projectiles. After being forged the plates are finished to exact dimensions in machine shops with specially equipped tools and appliances for this class of work. There are many patented processes for the treatment of armor plate for producing a tough material with .a hard surface, the most notable being the Krupp and Harvey processes. The manufacture of armor plate is carried on in works close to the steel works, where the armor plate ingots are cast, and is an industry requiring great skill and careful manipulation so that the product will meet the exact requirements of ordnance specifications. Railroad Axles Railroad axles are forged shafts having wheel seats and journals carrying the wheels, and supporting the truck or frame of locomotives, tenders or cars. Steel entering into the material from which axles are forged is made to conform to special speci- fications depending upon whether the axle is to be used for car or tender trucks, driving or engine trucks. Railroad axles are forged in one heat, from blooms or billets, under a steam hammer, or high-speed forging press. After the forging process, they are transferred to the machine shop, where they are cut to length and centered. Frequently, axles are rough- turned in the same shop, and sometimes finished complete ready to receive the wheels. Axles are tested for strength before being shipped, and must conform to certain specifications. After being tested, they are stamped with the melt number and initials of the maker. 33 The Rolling Mill Industry The plants manufacturing this class of forgings are called axle works, and are located close to the steel works, where the blanks or blooms are rolled. Forged Wheels Wheels, like axles, are produced in works specially equipped for this class of forging. There are numerous processes for forging wheels, but the common practice consists in pressing an octagonal ingot into a round slab. The slab is reheated, punched and pressed to the form of a wheel; this form is again reheated and placed in a specially constructed rolling mill, which gives the wheel its final shape. These various operations are shown graphically in Fig. 14. After leaving the rolling mill, the wheel is machined, bored and finished ready to be pressed on the axle. Special specifications govern the quality of steel from which the wheels are produced, and tests are made similar to those for axles. Tires are circular forgings used to form the treads of wheels. They are shrunk to the outer rim of the wheels, and securely fastened thereto. They are forged from ingots of octag- onal shape by pressing and punching to an annular form, and subsequently expanding the ring in a hydraulic press, and are finally rolled to shape. After rolling, the tire is turned to exact size in the machine shop, and finished ready to be shrunk upon the wheel. The manufacture is carried on in separate shops with tools and appliances specially designed for the purpose, similar to that of wheels and axles. Drop Forgings Drop forgings is the product obtained by forging a suita- ble piece of steel between dies under a hammer, the lower die being attached to the anvil block, while the upper die is fastened to the hammer itself, and moves up and down with it. From the drop hammer, the forging is placed in a trimming press to remove the excess metal, called flash, before being machined. The pro- cess is used for the manufacture of articles in large quantities. 34 Finished Products PRODUCTION OF ROLLED IRON AND STEEL The following table gives the production, in gross tons, of all leading articles of finished rolled iron and steel in 1911, and total production from 1904 to 1910, inclusive : Article. Rails Iron, gross tons 234 1911. Steel, gross tons 2822556 Total, gross tons 2 822 790 T't'lgross tons in . 1910. 3636031 Structural shapes... Plates and sheets... Nail and spike plate \Vire rods 811 89,427 9,951 610 1,911,556 4,398,622 38,571 2 449 843 1,912,367 4,488,049 48,522 2 450 453 2,266,890 4,955,484 45,294 2241,830 Rolled forging bl'ims and 'billets 363 230,752 231,115 459,933 Merchant bars Bars for reinforced concrete work.... Skelp, flue, etc 835,625 2,388 322,397 2,211,737 256,353 1,658,276 3,047,362 258,741 1,980,673 3,785,731 241,109 1,828,194 Splice bars . . 14694 148 876 163 570 223,022 Hoops 225 074 225 074 262 214 Bands and cot'n-ties Sheet piling 12 342,798 22,827 342,810 22,827 424,979 26,598 Railroad ties . . . 39197 39197 49048 A 1 1 other finished rolled product.... 184,103 821,518 1,005,621 1,174,922 Total for 1911.. . Total for 1910.. . Total for 1909.. . Total for 1908.. . Total for 1907.. . Total for 1906.. . Total for 1905.. . Total for 1904.. . 1,460,615 1,740,156 1,709,431 1,238,449 2,200,086 2,186,557 2,059,990 1,760,084 17,578,556 19,881,123 17,935,259 10,589,744 17,664,736 17,019,911 14,780,025 10,253,297 19,039,171 21,621,279 19,644,690 11,828,193 19,864,822 19,588,468 16,840,015 12,013,381 21,621,279 PRODUCTION OF FORGED IRON AND STEEL The production of forged iron and steel axles, shaft- ings, anchors, armor plate, gun carriages, etc., by rolling mills and steel works from 1906 to 1911, was as follows, in gross tons of 2,240 pounds: Production. Total, gr. tns. Yr. 352,636 1909. 380,805 1910.. 20,410 299,452 319,862 131,143 1911.. 4,034 214,202 218,236 Iron, Steel, Yr. gr. tns. gr. tns. 1906.. 19,148 333,488 1907.. 23,772 357,033 1908.. 13,646 117,497 Production. Iron, Steel, Total, gr. tons. gr. tns. gr. tns. 25,523 223,741 249,264 35 The Rolling Mill Industry iO\00' i VO 1 vo co o ^ .28 cnio CM 00 O i CM C tx vO Q w 2 CO O>OOCMCMCOCMtOt^'*tOOiOioOvOCMi iCM- | f^l'xVOT$-CM ON O CM i '"3-i-HvOoocOiOOO iTj-iocoOO T *'- H CMTfTj-ONCM OO^Tl^OO^co^CM *-i, c H > O *-^O i O CM 00 O^'-^VO *O CM^O fv. *^CM "^ C\ O\ ' ' co i i VO 00 irf CM ^t" O * , 'IS' C * rt oT rt C *-* ^ -a -a S ""^ ^ C CJ <4J ^ QJ _i *r^ rt i is he > 5-- rt QJ rz* c 2 o 8 00 CVJ 10 O CM f-i Q ( to t^ co r^ ^ rj- o i i O oo CM lx 10 ^H O o5 -H CM co 00 ON SN CM^co ON vq^bS^C^ CM" CM" CM" CM" CM" CM" co" co" co" '-T co" 1 co CM' co bjo o as 2 r 03 H o - O CM <5 13 ^ &- 2 ^ c o en 1-1 *Z ^ en g " t n 1-1 Countries. If o fD 3 fD 3 37 fD 3 i-h 3 fD p o fD 3 o'" Is o 3 3 O 3 g oj? en O o O en United States. .454,630*39.2 38,418 43.3 57,800 39.0 27,740 41.7 26,512 45.6 Germany .221,976 19.2 23,600 26.5 28,710 19.4 14,793 22.3 13,699 23.5 Gt. Britain .... .264,505 22.9 12,116 13.5 15,470 10.8 10,380 15.6 6,107 10.5 Aus. - Hung'y- . 49,000 4.2 2,156 2.4 4,666 3.1 2,010 3.4 2,155 3.7 France . 37,862 3.3 2,272 2.6 14,500 9.8 4,001 6.0 3,390 5.9 Russia . 24,572 2.1 2,678 3.1 5,638 3.8 3,040 4.5 2,350 4.1 Belgium . 23,927 2.1 3,111 3.4 123 0.1 1,804 2.7 1,450 2.5 Japan . . 14,799 1 3 51 japan China . 14,591 1 ?, 203 01 Canada . 13,011 1.1 819 0.9 213 0.1 752 1.2 835 1.4 Australia . 12,246 1 1 286 04 176 01 India 12092 1 1 56 . 6,538' OS 1,065 2 07 Spain . 3,550 0.3 521 0.6 8,667 5.9 367 0.6 220 0.4 Holland .... . 1,200 01 Italy . 400 397 0.5 551 0.4 215 0.3 635 1.1 Sweden . 302 5,184 3.5 594 0.9 470 0.8 Norway Newfoundland 1,127 07 Cuba 1,452 1 Greece 608 04 Other countries 4,000 0.3 2,500 2.8 1,591 1.1 525 0.8 315 0.5 Total 1 ,159,201 100 88,974 100147,851 100 66,221 100 58,138 100 Transvaal and Natal. 2 Algeria. Statistical WORLD'S IRON AND STEEL PRODUCTION 1850 TO 1910 Growth of the world's pig iron and steel production, 1850- 1910. Steel. . Production Increase, in 1,000 in 1,000 Per metric tons, metric t'ns. cent 1 . 85 120 35 41 200 80 66 422 222 111 683 261 60 1,926 1,243 183 4,235 2,309 120 6,041 1,806 43 11,881 5,840 97 15,651 3,770 32 28,734 13,083 84 44,296 15,562 54 58,138 13,842 31 ilndicates per cent of increase in tonnage from year previous. Year. 1850 Pig Iron Production, in 1,000 metric tons, r 4401 Increase in 1,000 netric t'ns. Per cent 1 . 1855 6 150 1 749 40 I860 . . . . 7,400 1,250 20 1865 . . . . 9,481 2,081 28 1870 1875 1880 ....12,146 ....13,920 18331 2,665 1,774 4411 28 14 32 1885 19792 1 461 8 1890 . . ..27,627 7,835 40 1895 29,387 1,760 6 1900 41 032 11 645 40 1905 ... 54053 13021 32 1910.. ..66.321 12.268 23 67 Index PAGE American Tube & Stamping Co.'s Blooming Mill, Frontispiece Andrews Steel Co.'s Bloom Shear and Tables 6 Andrews Steel Co.'s Sheet Bar Mill, Plan of 10 Andrews Steel Co.'s 24-inch Sheet Bar Mill 42, 44 Andrews Steel Co.'s 34-inch Blooming Mill 4 Armor Plate, Definition of 33 Armor Plate, Manufacture of 33 Armor Plate Mill, Definition of 19 Axles, Rolled, Definition of 33 Axles, Rolled, Manufacture of 33 Bale Ties, Definition of 45 Bands 21 Barbed Wire, Definition of 41 Bars 21 Bars, Definition of 25 Bars, Merchant Production of 64 Beam Mill, Definition of 16 Bethlehem Steel Co.'s Rail Cambering Machine 30 Bethlehem Steel Co.'s Rail Mill Finishing Department 18 Bethlehem Steel Co.'s 28-inch Rail Mill and Tables 12 Bethlehem Steel Co.'s 28-inch Rail Mill, Plan of 14 Bethlehem Steel Co.'s 28-inch Structural Mill, Plan of 14 Bessemer Steel, Production of 64 Billet, Definition of 20 Billet Mills, Definition of 13 Billet Mill, Motor-Driven, Continuous, at Gary, Ind 11 Bloom, Definition of 20 Bloom Shear and Tables, Andrews Steel Co 6 Blooming Mill Building, Interior View of, Frontispiece Blooming Mill, Definition of 13 Blooming Mill, 40-inch, Youngstown Sheet & Tube Co 2 Blooming Mill, Plan of Andrews Steel Co.'s 10 Blooming Mill, 34-inch Andrews Steel Co 4 Bolts, Definition of 45 Butt- Welded Pipe 51 Butt- Welded Tubes 53 Castings, Open-Hearth Steel Production of 64 Castings, Steel, Total Production of 64 Chain, Cast 49 Chain, Driving 49 Chain, Hand-Made 49 69 Index PAGE Chain, Machine-Made 49 Chain, Plate 47 Chain, Welded 49 Chain, Weldless 49 Chain, Wire 47 Chains, Classification of. 47 Chains, Definition of 47 Chart, Production Conversion for 1907 and 1911 17 Chart, Production Conversion, Showing Weight of Open-Hearth Steel Products Obtained from 2,000 Pounds of Ore 22, 23 Chart Showing Amounts of Material Charged and Produced in Making One Ton of Pig Iron 16 Chart Showing Conversion of Pig Iron into Finished Products.... 15 Classification of Rolling Mills 9 Coal, Anthracite, Production of 64 Coal, Bituminous, Production of 64 Coal, Exports 64 Coal, Imports 64 Coal, Total Production of 64 Coal, World's Production of 66 Cogging Mill, Definition of 13 Coke, Connellsville Shipments 64 Coke, Production of 64 Coke, World's Production of 66 Cold Mill 19 Comparison Basic Factors Pig Iron Production in the United States, Germany and Great Britain 62 Continuous Mill, 16-inch . . 46 Conversion of Pig Iron into Finished Products 15 Corrugated Sheets, Definition of 58 Cotton Tie Mill, Definition of 19 Cotton Ties, Definition of 25 Crucible Steel, Production of 64 Cut Nails 39 Dominion Iron & Steel Co.'s 16-inch Morgan Continuous Mill 46 Drop Forgings, Definition of 34 Drop Forgings, Manufacture of 34 Electric Steel, Production of 64 Electrical Age in Steel Plants 7 Electricity, Application of, In Iron and Steel Plants 8 70 Index PAGE Enameling 59 Exports, Iron and Steel 61 Fabrics, Wire 45 Fence Wire, Definition of 43 Ferro-Manganese, Production of 64 Finished Products 21 Finished Rolled Iron and Steel, Total Production of 36 Finishing Department, Rail Mill, Bethlehem Steel Co 18 Flats, Definition of 25 Forged Iron and Steel, Production of 35 Forged Wheels, Definition of 34 Forged Wheels, Manufacture of 34 Forgings, Definition of 31 Forgings, Drop, Definition of 34 Forgings, Drop, Manufacture of 34 Forgings, Manufacture of 31 Galvanizing, Hot 58 Glanced Sheets 59 History of the Rolling Mill Industry 1 Hoop Mill, Definition of 19 Hoops 21 Hoops, Definition of 25 Hoops, Wire, Definition of 45 Horse Shoes 50 Hot Bed for Rail Mill 28 Hot Saw Run for a Rail Mill 26 Hot Saws, Tilting Frame, for Rail Mill 24 Illinois Steel Co.'s 16-inch Merchant Mil! 52 Imports, Iron and Steel 61 Indiana Steel Co.'s Motor-Driven Continuous Billet Mill 11 Iron and Steel, Finished, Total Production of 36 Iron and Steel Imports and Exports 61 Iron and Steel Production, World's, 1850 to 1910 67 Iron Ore Imports 64 Iron Ore, Production of 64 Iron Ore, World's Production of 66 La Belle Iron Works' 84-inch Plate Mill 32 La Belle Iron Works' Plate Mill and Tables 38 Lap-Welded Pipe 51 71 Index PAGE Lap-Welded Tubes 53 Layout of Typical Steel Plant 7 Layout, Rolling Mills 19 Machine, Rail Cambering 30 Manufacture of Structural Shapes 27 Materials Charged and Produced in Making One Ton of Pig Iron 16 Merchant Bar Mill, Definition of 16 Merchant Bar Mill, Small, .Definition of 19 Merchant Mill, 16-inch 52 Merchant Mill, 10-inch, Motor-Driven 54 Merchant Mill, 20-inch, Motor-Driven 43 Mill, Merchant, 16-inch 52 Mill, Merchant, 10-inch, Motor-Driven 54 Mill, Merchant, 20-inch, Motor-Driven 48 Mill, Morgan Continuous, 16 inch 46 Mill, Sheet Bar, 24-inch 42, 44 Motor-Driven, 20-inch Merchant Mill 48 Nails, Cut 39 Nails, Cut and Wire, Production of 41 Nails, Definition of 39 Nails, Wire 39 Nomenclature of Rolling Mills 13 Non-Reversing Mills 11 Nuts, Definition of 45 Open-Hearth Steel, Production of 64 Open-Hearth Steel Products Obtained from 2,000 Pounds of Ore... 22, 23 Piercing Mill 19 Pig Iron and Steel Producers, World's Leading 65 Pig Iron, Material Charged and Produced in Making One Ton of 16 Pig Iron Production, Basic Factors of, in Germany 62 Pig Iron Production, Basic Factors of, in Great Britain 62 Pig Iron Production, Basic Factors of, in United States 62 Pig Iron, Production of 64 Pig Iron, World's Production of 66 Pipe and Tube Industry 51 Pipe, Weight of 56 Pipe, Butt-Welded 51 Pipe, Cast Iron 51 Pipe, Definition of 51 Pipe, Lap-Welded 51 72 Index PAGE Pipe, Riveted 51 Pipe, Welded 51 Pipe, Wrought Steel 51 Plan of Andrews Steel Co.'s Blooming Mill 10 Plan of 28-inch Rail Mill 14 Plan of 28-inch Structural Mill 14 Planished Sheets, Definition of 58 Plate, Armor, Definition of 33 Plate, Armor, Manufacture of 33 Plate Chain 47 Plate Mill and Tables, La Belle Iron Works 38 Plate Mill, Definition of 19 Plate Mill, 84-inch 32 Plate Mill, First 3 Plate, Nail, Production of 64 Plates, Definition of 29 Plates, Manufacture of 29 Plates, Nail, Definition of 31 Plates, Production of 31, 64 Plates, Universal, Definition of 29 Plates, Universal, Manufacture of 29 Primes, Definition of 58 Process of Wire-Drawing 39 Production Conversion Chart for 1907 and 1911 17 Production of Cut and Wire Nails 41 Production of Forged Iron and Steel 35 Production of Iron Ore 64 Production of Rolled Iron and Steel 35 Production of Terne Plate 59 Production of Tin Plate 59 Production of Tin and Terne Plate Since 1891 60 Production, World's Iron and Steel, 1850 to 1910 67 Products, Finished 21 Products, Open-Hearth Steel, Obtained from 2,000 Pounds of Ore 22, 23 Products, Seamless Steel Tubes 55 Products, Semi-Finished 20 Rail Cambering Machine 30 Rail Mill, Definition of 16 Rail Mill, Finishing Department, Bethlehem Steel Co 18 Rail Mill, Hot Bed for *.'. 28 Rail Mill, Hot Saw Run for 26 73 Index PAGE Rail Mill, Tilting Frame, Hot Saws for 24 Rail Mill, 28-inch, and Tables, Bethlehem Steel Co 12 Rail Mill, 28-inch, Plan of 14 Rails, Bessemer Steel, Production of 64 Rails, Definition of 27 Rails, Light, Definition of 27 Rails, Open-Hearth Steel, Production of 64 Rails, Standard, Definition of 27 Rails, Total Production of 64 Reversing Mills 11 Riveted Pipe 51 Rivets, Definition of 45 Rod, Definition of 25 Rod Mill, Definition of 19 Rods 21 Rods, Production of 64 Rolled Iron and Steel, Production of 35 Rolled Iron and Steel, Total Production of 64 Rolling Mills, Classification of 9 Rolling Mill, Definition of 9 Rolling Mill Industry, History of 1 Rolling Mill Layout 19 Rolling Mills, Nomenclature of 13 Rope, Wire, Definition of 43 Russian Sheet Iron 58 Screws, Definition of 47 Seamless Steel Tube Products 55 Seamless Tubes, Definition of 53 Semi-Finished Products 20 Shape Mill, Definition of 16 Shapes, Definition of 25 Shapes, Structural, Production of 64 Sheet Bar, Definition of 20 Sheet Bar Mill. Definition of 16 Sheet Bar Mill, Plan of Andrews Steel Co.'s 10 Sheet Bar Mill, 24-inch, Andrews Steel Co 42, 44 Sheet Mill, Definition of , 19 Sheets, Black 31 Sheets, Cold Rolled 31 Sheets, Corrugated, Definition of 58 Sheets, Corrugated, Use of 58 Sheets, Definition of 31 74 Index PAGE Sheets, Manufacture of 31 Sheets, Planished, Definition of 58 Sheets, Production of 31, 64 Singer Mfg. Co.'s Motor-Driven 10-inch Merchant Mill 54 Singer Mfg. Co.'s 20-inch Motor-Driven Merchant Mill 48 Skelp, Definition of 29 Skelp, Grooved 29 Skelp, Manufacture of 29 Skelp, Production of 64 Skelp, Scarfed 29 Slab, Definition of 20 Slabbing Mill, Definition of 13 Slitting Mill 19 Spiegeleisen, Production of 64 Spikes 39 Splice Bars, Definition of 27 Statistics, Summary of, for 1910 and 1911 64 Steel Plant, Layout of Typical 7 Steel, Total Production of 64 Steel, World's Production of 66 Structural Mill, Definition of 16 Structural Mill, 28-inch, Plan of 14 Structural Shapes, Definition of 25 Structural Shapes, Manufacture of 27 Taggers, Definition of 58 Taggers, Use of 58 Telegraph Wire, Definition of 43 Telephone Wire, Definition of 43 Terne Plate, Definition of 58 Terne Plate Industry 57 Terne Plate, Manufacture of 58 Terne Plate, Production of 59 Ties, Bale, Definition of 45 Tilting Frame Hot Saws for Rail Mill 24 Tin and Terne Plate Production since 1891 60 Tin Plate, Definition of 57 Tin Plate Industry 57 Tin Plate, Method of Manufacture 57 Tin Plate, Production of 59 Tin Plate, Standard Sizes of 58 Tire Wheel Mill. 19 75 Index PAGE Toe Calks 50 Total Production of Finished Rolled Iron and Steel 36 Tube and Pipe Industry 51 Tube Mill, Definition of 19 Tubes, Butt-Welded 53 Tubes, Cold Drawn 55 Tubes, Definition of 51 Tubes, Lap- Welded, Definition of 53 Tubes, Lap-Welded, Method of Manufacture 53 Tubes, Seamless 53 Tubes, Seamless, Definition of 53 Tubes, Seamless, Manufacture of 53 Universal Mill, Definition of 19 Universal Plate Mill, 30-inch 40 Washers, Definition of 45 W'aster, Definition of 58 Welded Chain 49 Welded Pipes -. 51 Wheels, Forged, Definition of 34 Wheels, Forged, Manufacture of 34 Wire Barbed, Definition of 41 Wire Chain 47 Wire, Definition of 37 Wire Drawing 39 Wire Fabrics 45 Wire Fence, Definition of 43 Wire Hoops, Definition of 45 Wire Industry 37 Wire Mill, Definition of 19 Wire Nails , 39 Wire Production 37 Wire Rope, Definition of 43 Wire, Telegraph, Definition of 43 Wire, Telephone, Definition of 43 Wire, Woven, Definition of 43 World's Iron and Steel Production, 1850 to 1910 67 World's Leading Pig Iron and Steel Producers 65 Woven Wire, Definition of 43 Wrought Steel Pipe 51 Youngstown Sheet & Tube Co.'s 40-inch Blooming Mill 2 76 7/Ul I rs UNIVERSITY OP CALIFORNIA LIBRARY