Architectural Iron Work 1000085624

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258 M_A_KK;ET ST.,ARCHITECTMITtfONORK.A PRACTICAL WORK

WORKERS,ARCHITECTS, AND ENGINEERS,

AND ALL WHOSE TRADE, PROFESSION, OR BUSINESS CONNECTSTHEM WITH ARCHITECTURAL IRON WORK.

THE ORGANIZATION AND MECHANICAL AND FINANCIALMANAGEMENT OF A FOUNDRY AND SHOPS

VOB THE KAKUFACTCKE OP

IRON WORK FOR BUILDINGS,WITH

SPECIFICATIONS OF IRON WORK,

USEFUL TABLES,

VALUABLE SUGGESTIONS FOR THE SUCCESSFUL CONDUCTOF THE BUSINESS.

BT WM. J. FRYER, JR.

NEW YORK:JOHN WILEY " SONS.

1876.


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COPYKIOHT, 1876, B*

JOHN WILEY " SON"

JOHN F. TROW " SON,STKREOTYPERS AND PRINTERS,

205-213 East iztk St.,NEW YORK.


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DEDICATED

TO

CA.PITAL,

IN THE PERSON OF

(Eugene Kelly, (Esq.,

BANKER,

A CHRISTIAN GENTLEMAN, A TRUE

FRIEND, A WISE AND SAGACIOUS

COUNSELOR.

AND

TO

LA^B O R,

IN THE PERSONS OF

fttn former felloto It) orkmen,

WHO EXTENDED TO ME THEIR SYM-ATHY

IN THE MOST TRYING

PERIOD OF MY LIFE.

THE AUTHOR.


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CONTENTS.

PAGEA Model Shop " Buildings 3

" Location 2Amount of One Year's Business, etc 18Angle Iron, Weight of 200Apportioned Expenses of Shops 10Arch Girders 37

Example of Cost 43" Table of

;39-42

Arches of Floors '. 91Areas of Circles 208Ashler Fronts 90Balls, Cast Iron, Weight of 204Bar Iron, Quotations of 139

u Tables of Cost 16" To Test the Quality of 194

Blacksmith Shop 15Blank Form of Contract 173

Proposal 172Request for Estimate 172Testing Girders 169

Boiler Iron, Weight of 199Bolts and Nuts, Weight of 203Box Columns, Example of Cost 30

44 Cost of 28Table of Weights 29Table of Workmanship 29

Beams I, and Channels 9144 Condensed Table of Weights and Strength 1184 4 Moulded 12244 Notes for Engineers 11644 Prices of 11844 Relative Efficiency of Ill44 Setting and Connecting Ill44 Unsupported Side-Ways 112"4 Used as Pillars, etc 115" Tables of 93-110" Weights and Co efficients 113-114


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VI CONTENTS.

Beams T, Cast Iron ............................................... 30" " Example of Cost ................................. 37" " Rule for Strength of ............................. 31

" Table of Weights .............................. 32-36Building Law, Extracts from ....................................... 154Building Materials,Weights of .................................... . 206Bundle Iron,Number of Feet in .................................... 198By-Laws ................ . .......................................... 145Capital........................................................... 9Cast Iron Arch Girders .............................................. 37

" Hollow Columns, Table of Safe Load ...................... 24-26" " Table of Weights .......................... 23" T Beams ................................................. 30" " Rule to Determine Strength of .................... 31" " Table of Weights ............................... 82-36

Castings,ost of ..................................... . ............. 14" Shrinkage of ........................ .................... 190

Channels and I Beams .............................................. 911 ' Prices of .................................................. 118

Circles,reas ...................................................... 208" Circumferences .............................................. 207

Coal .............................................................. 12" Prices of ..................................................... 140

Colors of Iron caused by Heat ..................................... v 205Columns, Box, Cost of ............................................. 28

" " Example of Cost ...................................... 30" " Table of Weights ............ . ......................... 21)" " Table of Workmanship ................................ 29" Round, Deep Fluted, Cost of ............................... 27" " Sharp Fluted, Cost of .............................. 21" " Tables of Safe Loads ............................. 24-26

" Table of Weights .................................. 23Company A, Stock .................................................. 140Conducting Power of Building Materials .............................. 206Contract,Blank Form of ........................................... 172Cornice and Lintel,Example of Cost ................................. 43Corrugated Iron .................................................... 201Cost,Example of,Arch Girder ........................... ............ 43

" " Box Columns ...................................... 30" " Gratings......................................... 50" " Lintel and Cornice ................................. 43" " Newel Post ....................................... 47" " Oat Manger ....................................... 47" " Railing........................................... 46" " Roof Cresting. . . ................................. 49" " Shutters

........ .................................48

" " T Beams .......................................... 37" " Window Lintel

.. ,44


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CONTENTS. Vll

PAGE

Cost,Example of,Window Sill 44" " Wrought Iron Plate Girder , 45' ' Illustrations 20

Cost of Box Columns 28u Castings 14

Melted Iron 12-13Cost of Round Columns, Deep Fluted 27

Sharp Fluted 2144 Tile Floors 1284 ' Workmanship on Box Columns 29" Wrought Bar Iron 10

Cylinders,Solid Cast Iron,Weight of 205Department of Buildings,Blank Forms 169Engine and Boiler Expenses 10Engineers'Association,War Prices 184Erecting and FinishingShop 15Estimate, Blank Form of Request 172Estimate of One Year's Business,etc 18Example of Cost " Arch Girder 43

" Box Columns. 3044 Gratings 50

Lintel and Cornice 43Newel Post 47

" Oat Manger 47Railing 40

" Roof Cresting 49u Shutters 48" T Beams 37" Window Lintel 44" Window Sill 4444 Wrought Iron Plate Girder 45

Exhaust Steam Traps 187Expenses,Engine and Boiler 10

44 Office 9" Shop, Apportioned 10

Extracts from the Building Law 154Financial Management 5Finishingand Erecting Shop 15Fire Proof Floors 91

44 Tile Floors 125" " Cost of 128" " Specification 12744 44 Test of Strength 129

Flat Bar Iron,-Weight of , 196-197Floors,Fire Proof " 91Founding 173Foundry 10Galvanized Sheet Iron,Weight of 200


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Vlll CONTENTS.

PAQK

General Remarks 1Girders,Arch 37

" " Example of Cost 43" " Table of 39-42'k Plate,Example of Cost 45" Riveted, Table of Strength 119-121" Testing,Blank Form for 169

Gold, Prices of 140Gratings,Example of Cost 50

" Table of Weights 51-56Hoop Iron,Weight of 199I Beams and Channels 91

" Condensed Table of Weights 118Moulded 122

"' Notes for Engineers 116" Prices of 118" Relative Efficiencyof Ill4 ' Settingand Connecting Ill" Unsupported Side-Ways 112" Used as PiUars,etc 115" Tables of 93-110" Weights and Co-efficients 113-114

Illustrations of Cost 20Iron Founders' Association,War Prices 186Iron Fronts 80

A Representative 81" Ashler 90

Iron,Mixtures of 12" Quotations of Bar Iron 189

Pig Iron 138-139Labor and Materials,Prices for 20Labor Question 209Lintei and Cornice, Example of Cost 43Lintel,Window " Example of Cost .44List of Machinery, Tools,etc 17Machinery, Tools, etc. , List of . 17Management, Financial 5Manger, Oat, Example of Cost 47Mansard Roof 136Materials and Labor, Prices for 20Materials,Building,Weights of . . 206Melted Iron, Table of Cost 12-13Melting Point of Metals 206Mixtures of Iron .' 12Moulded Iron Beams 122Moulding 178Newel Post,Example of Cost 47Oat Manger, Example of Cost 47


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CONTENTS. IX

Office Expenses ........................................... ......... 9Pattern Shop ..................................................... 1?Pig Iron,Quotations of ......................................... 138-139Plate Girder,Example of Cost ....................................... 45Plates for Round Columns ........................................... 22'Port-Holes ......................................................... 189Post,Newel, Example of Cost ....................................... 47Prices for Labor and Materials ...................................... 20

" Bar Iron ............. ........................................ 139" Coal ..................................................... 140" Gold ................................................... 140" of I Beams and Channels ...................................... 118' ' Pig Iron ... ........... ...................................... 138" War .................................................. ...... 183

Profit .............................................................. 19Proposal,Blank Form of ............................................ 172Railing, Example of Cost ............................................ 46Relative Conducting Power of Materials .............................. 200

" Weights of Metals ......................................... 204Riveted Girders ............................................... 1 19-121Rivets, Weight of ....... ........................................... 201Rolled Iron I Beams and Channels ................................... 91

" " u Condensed Table of Weights ......... 118" " Moulded ..................

,...................

122" " Notes for Engineers ............................. 116" " Relative Efficiencyof ........................... Ill** u Settingand Connecting .......................... Ill" " Unsupported Side-Ways ......................... 112" " Used as Pillars,tc .............................. 115" " Tables of .................. ................... 93-110" " Weights and Co-efficients .................... . . 113-114

Roof Cresting,Example of Cost ...................................... 49Roofs.. ............................................................ 129

" Mansard ...................................................... 136Round Columns, Deep Fluted, Cost of ............................... 27

" Sharp Fluted, Cost of ............................... 21" Tables of Safe Loads ............................... 24-26" Tables of Weights ................................. 23

Round Iron,Weight of .......... ................................... 195Rule to Compute the Weight of Box Columns ........................ 192

"" " Cast Iron, Wrought Iron, etc ..... . . . . 191" " Plates .............................. 191" u Round Columns ...................... 193" " T Beams ............................ 193

Rule to Determine the Strength of T Beams .......................... 31u to Find Weight of Casting from the Pattern ...................... 191

Sheet Iron, Weight of ............................................... 199Shop, a Model ...................................................... 2


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X CONTENTS.

PAGEShop, Blacksmith 15

% ' Finishing1Shop 15" Pattern Shop 174 ' Expenses Apportioned 10

Shrinkage of Castings 190Shutters,Example of Cost 48Specificationf Iron Work 62

u Anchors 70" Arch Girders 60" Balconies 77" Beams and Girders 7144 Book Vault Doors 7144 Bridle Irons 70" Chimney Caps 76" " Shafts 76" Coal Cover 74" " Vault Door 77" Columns, Fire Proof 67u " Interior 6("u " Plates for Wooden 7344 Coping 7644 Cornice,Galvanized 724fc Crestings 7244 Dimensions 624w Doors for Book Vault 71" Doors for Coal Vault 7744 " Flue 7344 Door Saddles 73" Dowels 7344 Drill for Carpenter 7444 Elevator

,75

44 Eyes for Shutters 6944 Fire Escape 7544 Fire-Proof Columns 6744 u Floors 12744 Floor Beams and Girders 7144 Floor-Lights 6844 Flue Doors 73'4 " Rings 7444 Front 6244 Fuel Room 7644 Galvanized Cornice 72

General Requirements 7944 Girders, Arch 6644 44 and Floor Beams 7144 4C Vault, and Columns 6544 Gratings,Wrought Iron , '7244 44 Ventilating 74


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CONTENTS. XI

PAGE

Specificationf Guards to Windows 7014 Hooks 7944 Illuminated Platform 64" Interior Columns 6041 Ladder to Scuttle 75" Lining of Fuel Room 7014 Lintels and Sills for Windows 76" Painting 79

Plates for Wooden Columns 64*' Platforms, Illuminated 64" Port-Holes 77** Rings and Covers for Flues 73" Rolling Shutters 6444 Roof Cornice 7244 " Cresting 7244 Saddles 7344 Scrap 6244 Screen Work 73"4 Scuttle 7544 44 Ladder to 7544 Shutter Eyes 61)44 Shutters, Rear Outside (55)" Rolling 64

Sills and Lintels for Windows. 7644 Sky-Lights 67

Stairs 7744 Trimmings 7744 Vault Doors, Book 7144 44 Coal 7744 Vault Girder and Column 65

VentilatingGratings 7444 Window Guards 7044 44 Lintels and Sills 7644 Wrought Iron Gratings 72

Square Iron,Weight of 195Steam Traps, Exhaust 187Stock Company 140Strength of Riveted Girders 119-121

T Beams, Rule for 31Table of Cost of Melted Iron 12-13

Workmanship on Box Columns 29u Wrought Bar Iron 10

Table of Safe Load on Round Columns 24-2644 Strength of Riveted Girders 119-121

Table of Weights of Angle Iron 20044 Arch Girders 39-4214 Boiler Iron 199" Bolts and Nuts.

. .203


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Xll CONTENTS.

PAGETable of Weights of Box Columns 29

" Building Materials 206" Cast Iron Balls. 205" Flat Bar Iron 196-197" Galvanized Sheet Iron 200

Gratings 51-56" Hoop Iron 199" I Beams, Condensed , 118" Relative Weights of Metals 204*' Rivets 201" Round Columns 23** Round Iron 195" Solid Cylinders 205u Sheet Iron 199

Square Iron 195" T Beams 32-36

Tee Iron 200" Various Metals 204" Washers 204

Taritf of Prices for Labor and Materials 20T Beams, Cast Iron 30

" Example of Cost 37" Rule to Determine Strength of 31" Table of Weights 32-36

Tee Iron, Weight of 200Tension Rod Girders 37Testing Girders,Blank Form for 169The Labor Question 209Tile Floors and Ceilings 125-129Tools, Machinery, etc. , List of 17To Young Men 215Traps for Exhaust Pipes 187Value of Iron 198Various Metals, Weight of 204War Prices of Iron Founders' Association 184

' ' Engineers' Association 186Weights and Measures 202Weights of Angle Iron 200

" Arch Girders 39-42" Boiler Iron 199" Bolts and Nuts ; 203" Box Columns 29" Building Materials 206" Cast Iron Balls 205" Cylinders 205" Flat Bar Iron 196-197" Galvanized Sheet Iron 2004t Gratings 51-06


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CONTENTS. Xlll

pxon

Weights of Hoop Iron 199I Beams 118

"' Relative Weights of Metals 204" Rivets 202

" Round Columns 23

" Round Iron 195

" Sheet Iron 190

" Square Iron 195" T Beams 32-30

" Tee Iron 200

" Various Metals 204u Washers 204

Window Lintel, Example of Cost 44u Sill, Example of Cost 44

Wrought Bar Iron, Table of Cost 16Wrought Plate Girder, Example of Cost 45


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UNIVERSITY

"ORK.

GENERAL REMARKS.

ESTABLISHMENTS devoted exclusivelyo the manufacture ofiron work for buildingsre of comparativelyecent growth.Almost without exceptionthe largerones now existingavegrown from small beginnings,uildingafter buildinghavingbeen added to the originalhopuntil theybecame greatwork-hops

without proper plan for the economical working andhandlingof materials. Formerlythere were two distinctdivi-ions

in contractinghe ironwork requiredfor a building;the wrought iron was given to a blacksmith,nd the cast ironwork to a foundryman. The custom now is to givethe entirework to one establishment.

This branch of iron manufacture has increased enormouslywithin the past fifteen years, and the probabilitiesre that thefuture will develop stillgreaterproportionalrowth. It is acommonplace sayingthat as a nation we have but justbegunto use iron. This is,indeed,very true as regardsits use forbuildingpurposes. Good construction, economy of material,and beauty of form in architectural iron work have madegreater progress in this country,and particularlyn ^Jieityof New York, than elsewhere in the world. A knowledgeofthe subjectequiresiffusion. Years of study,observation,ndhard practicaloilwere the priceof the author's thoroughknowl-dge

of this class of work,as it must be to every man whowould qualifyhimself for this business.

The aim in givingpublicityo this knowledgeis largelyorthe enlightenmentnd advancement of workingmen. Theyneed to have placedbefore them in plainand intelligibleorms


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2 ARCHITECTURAL IRON WORK.

an outline of how the works in which theydailytoil are man-ged,and so to helpeducate up operativemechanics to become

competent to command and control the coming great industrialworkshopsof our land.

To proprietorsof works new lightwill be thrown on theirbusiness,and enable them more thoroughlyo understand theprincipleshich govern their every-daydoings.The knowledgeherein impartedwill enable a manufacturer to correctlyscer-ain

what his productscost,and to establish priceswhich willallow fair profits.It is a generalcomplaintthat the cost ofwork almost invariablyexceeds an estimate,and the yearlybalance-sheets too often indicate that a business has failed topay a reasonable reward for the labor and use of capitalm-loyed.

The cost of the various items givenin the followingpages will differ more or less in every establishment;ut if theprinciplesaid down will induce manufacturers of iron workfor buildingsto make similar statements of actual costs,indetail,pplicableo their own shops,there will be littledangerthat their productswill be sold without profit,r that the bal-nce

at the end of the year will be found on the wrong side.

A MODEL SHOP.LOCATION.

In selecting site for the shopsmany essential thingsare tobe considered. The land should have a water frontagen anavigablestream, be convenient to railroad depotsand steam-oat

landings,have good telegraphicnd mail connections,and be where skilled labor is easilybtained,and where homesfor workingmen are numerous. A good-sizedlotof groundis desirable,ot alone for the immediate present,but to ac-ommodate

the future growth and requirementsof the busi-ess.The land must be of moderate value,and selected with

an eye to its prospectivencrease in value. Look ahead to aprofitn the land purchase. It is well to have the location


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ARCHITECTURAL IRON WORK. 3

away from other shops in the same line of manufacture, so asto draw employes to the neighborhoodand secure their per-anency

; and yet be not so far away as to greatlynconve-iencetemporary hands.

Selectingsuch a plot of ground,of a size not less than300 x 250 feet,uppose its cost to be $15,000.

BUILDINGS.

The buildingsill all be of brick,with double-pitchrameroofs,covered with slate,nd put up in a good and substantialmanner. Their cost may be taken at $40,000.

The shopsare arranged in relation to each other as to insurethe least handlingand inconvenience from the time the raw ma-erial

islanded on the dock until the manufactured article is runout for shipment one succession of advances. By reference tothe planitwill be seen that the buildingsform a hollow square.This secures the greatestamount of lightand ventilation,hegreatest securityo valuable materials,he least danger fromdestructive fire,nd the best control of the employes.

The engine and boiler are situated at the centre, the powerradiatingo all quarters. The cupolasre placedat the centreof the lengthof the foundry,and the run way for chargingthe same is in the yard. The foundryis 60x180 feet. Aportion of it,fiftyeet in length,s railed off for lightwork.The remainder,for heavy work, is furnished with four cranes.Sheds for sand run alongsidethe foundry,and the sand isthrown directlyn as required. Two cupolasare provided,each with a maximum capacity ofx twenty tons, enablingacast to be made every workingday in the year without havingto layby duringrelining,tc. By usingboth at once sufficientiron can be melted for almost any purpose. The erectingshop,in which to laydown iron fronts and other work is 60 x 180feet. The blacksmith shop is 30 x 60 feet,nd opens out intothe erectingshop,so that the latter may be used for purposes


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4r ARCHITECTURAL IKON WORK.

connected with the former. A finishingshop is made twostories in height,in which to make shutters,railings,nd litup small work. The second stdryfloors will be suspendedbyiron rods from the roof trusses,so that the firststoryshall beentirelyfree from columns. The oppositebuildingis alsomade two stories in height, portionof its first floorbeingused for a carpenter and a flask-makingshop,and the upperstory,40 x 105 feet,for pattern making. The stairs thereto ison the outside of the build ino;. On the firstfloor of this build-Oing is arranged the offices ; a main counting-room, privateoffice,nd a drawing-room,the latter connectingwith thepattern shop by a circular stairway.From the windows ofthe privateffice a generalsurvey of the premisesis obtained.Drive-waysthrough the shops are plentifullyrovided,andweighingscales are so placedas to accommodate incoming andoutgoingmaterials,nd for the weighingof rough castingsntransit from the foundryto the finishinghop. The core oven,14 x 20 feet,is placed near the cupolas,ogetherith a housefor, core-making. On the other side of the cupolasis a smallhouse for brushingand cleaningcastings.It will be advisablein localitieswhere winters are severe to roof over the yard orcourt, taking care to provide as much lightas possibleandliberal ventilation. The roof can then be made use of forstorage of small flasks and similar things. A stable,0 x 50feet,is placedwhere shown in the side yard. This yardgivesspace for flasks,ord- wood, etc. The workmen in goingoutand in dailyall pass through the entrance way alongsideofthe office. When being paidoff theypass through the hall-ay

and main office.Enlarged capacityto the shops can be had by adding a

wing on the foundry,coveringmore or less of the side yard.The erectingshop may have a galleryadded, fifteen feet wide,running around on all sides,suspendedfrom the roof trusses,and used for vice work. In due time a two or three story


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ARCHITECTURAL IRON' WORK. 5

buildingfor storageof patterns will be required; this will bebuilt on a portionof the space of the side yard,and will bedisconnected from the other buildings.

An iron-works planned as shown and described would, forits purpose, be superiorto any existingat the present time,and its capacity,n proportiono its cost,be far ahead of any.

FINANCIAL MANAGEMENT.The iron business is a heavy business,nd to manufacture in

a first-classway requires largecapital.Whatever amount ofmoney is put into the venture " and it is a venture, as all busi-ess

operationsre " be it remembered that this capitals worthseven per cent, per annum, for that interest can be obtainedwithout risk and without trouble. Then there are expensesconnected which are inevitable and constant, whether much orlittle is done. Taxes,insurance,ffice employes,expenses ofrunning engine,pay to foremen, etc. ; these go on about thesame whether 100 or 300 men are employed as producers thesame on $100,000 as on $300,000 worth of work. Above acertain limit oa a giveninvestment,the difference between thecost of the raw materials and labor employed,and the pricesobtained for the finished articles,s the profit.Therefore, oneof the secrets of making money is to keep the works filled totheir utmost capacity.

To illustrate this principle,uppose that a lot of columns,twelve inches in diameter and three-quartersf an inch inthickness,re to be made at a givenprice say, four cents perpound. Now, if these same columns were to be made one-and-a-half inches thick,and the rate per pound was the same, theheavier weightswould afford by far the best profit,ecause thecost in both cases are alike as to mouldingtime,and materials,cleaning,chipping,turning off ends, etc., and the heavierweightsrepresent simplymelted pig iron poured into the mould.

There is danger,however,of these facts leading contractor


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astray,and tempting him to take work too low. A limit must,therefore,e established ; and when a man is steeled to refusework below that limit,and yet has the energy and abilityokeep the shops well filled with contract work above thatJimit,good results may confidentlye looked for at the end ofthe fiscalyear. If a job be taken at an unprofitableigure,oamount of drive can overcome the error, whether intentionalor unintentional,ade at the start. But whether a job istaken at a good price or a poor one, never slighthe work.Always do the best that can be done,both in material and inexecution. A reputationfor good castingsand true fittingwill,in due time, become extensivelyknown, and turn thescales of owners' preferencein givingsuch an establishmentwork where estimates run close. The expense of doinggoodwork is no greater,and perhaps not as great,as to do botchwork. If the workmen are held up to a proper standard,andwhenever a mechanic shows himself incompetent or careless,he be dischargedand replacedwith a better man, the entireforce will do their work in a thoroughand expeditiousanner.If any journeyman be addicted to drink,no matter how gooda mechanic he may be,or if he is disputativer loud in hispoliticalreferencesr religiousiews,it is well to weed outall such and be free of them.

The cost of ground and buildingshas been set down as$55,000. The machinery will require an expenditure of$45,000,and a working capital,ver and above all,of $50,000.Thus the establishment is supposed to represent $150,000.Expenses will commence with the organization,nd go on,unceasingly. These are to be taken into account and appor-ioned

to the different shops. They become what will betermed shop expenses " so much on the foundry,so much onthe finishinghop,etc.,in proportiono the room they occupy.

The cost of castingsin the foundry wants to be got at. Toone unfamiliar with a foundry perhapsto many familiar with


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8 ARCHITECTURAL IRON" WORK.of the castingss they came out of the foundry; their cost perpound of finishingn the shop; and the cost per pound of set-ing

up and finishingt the building the cost of paintingthetotal cost per pound and the total cost in dollars for the front ;also the cost per lineal foot and per square foot superficial.

With records like these there is little room left for guess-ork.The lack of them accounts for the wide difference in

bids from contractors,and affords an explanationfor the disap-ointingresults obtained at the end of a year'sbusiness on find-ng

little or no profitsade or actual losses incurred. Manyconcerns take work at losingpricesthroughsheer ignoranceofwhat the actual cost is. Every article in the business,nd eachparticularontract,should be reduced in detail to its cost perpound,or per superficialoot,r both. Certain classes of workcost more for the finishingabor than the castingsthemselves"cost. What would seem to be a largepriceper pound wouldnot give back the manufacturer his money. A contract jobmay show a loss,r particulararts of it a loss. But futuresimilar mistakes are thus guarded against.Be governed byfacts,esults actuallybtained,and never be influenced by whata competitorakes work at, other than to impel a closer scru-iny

into the correctness of the cost or a more economical man-erof doing such work. Sooner or later those who defy the

teachingsf figures,s well as the teachingsf experience,illcome to grief.

A man goes into this business for the dollars and centsprofithich is in it,not for glory. It is a noble business,ndaffords scope for the best talents " the astuteness of the lawyer,the sound judgment of the merchant,the geniusof the mech-nician,

and the generalshipf the soldier. Fame, however, isbut incidental to the business,nd surelyit will not attach tohim who fails to make a financial success of his work. In theeagerness and anxietyto secure contracts,and the liabilityfmistakingr omittingitems,the tendency is to figureoo low.


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ARCHITECTURAL IRON WORE. 9

Rather do without work than have it at a loss. Let energyand constant attention to business be the levers which secureto an establishment its complement of work at good prices.The argument that work had better be taken at'cost than notat all,will do for the indolent man, or the man who has out-ived

his energy. An iron works requiresto be kept con-tantlygoing, or it becomes self-consuming.Work at cost

pays the interest and taxes and office hire,and keeps the mentogetherand the tools from rusting,nd the establishmentgenerallyfrom running behind. But when the manager can-ot

find sufficient work at remunerative prices,he establish-entis too largefor that man, or the man too small and in-ompeten

for the establishment. This is a growing country,and foundries can hardlykeep pace with the demand for ironwork for buildings.The live man can always find work, evenin dull times,duringpanicsand wars. It is of the firstimpor-ance

to get remunerative prices.A good credit would attach itself to an establishment paid

for and providedwith a working capitals stated ; indeed,analmost unlimited credit,f the manager be known as a compe-ent

and reliable man.

The sum invested is a largeone, and is representednd usedas follows :

CAPITAL $150,000.Ground cost- $15,000Buildingscost 40,000Machinery 45,000

Interest on capital $10,500Taxes 1,500Insurance 800

Working capital 50,000

$150,000

$15,000

Gas 700Repairs to buildings 500Incidentals 1,000

OFFICE EXPENSES.

Wages " Manager. $5,000Book-keeper 1,500Time-keeper 800


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10 ARCHITECTUEAL IRON WORK.

Amount brought forward $7,300 $15,000Two boys 600Draughtsman 1,200Night watchman 900Incidentals 1,000

~ " 11,000ENGINE AND BOILER EXPENSES.

Coal, per day $4 00Oil,tallow, waste, etc 1 00Repairs, etc 2 00Wages of engineer 3 00Incidentals.. 1 00

$11 00is. per annum (300 days), 3,300 14,300

Expenses $29,300APPORTIONED AS FOLLOWS :

Foundry" 7-16 of $29,300 is $12,818.75 per annum, or per day $42 72Erecting and finishingshop " 7-16 of $29,300 is $12,818.75 per annum,

or per day 42 73Blacksmith" 1-lfi of $29,300 is $1,831.25per annum, or per day 6 10Pattern" 1-16 of $29,300is $1,831.25 per annum, or per day 611

FOUNDRY.Shop expenses, as stated above, per day $42 72Coal for cupola,H tons at $6 9 00Common sand % 00White sand 0 75Sea-coal;fire-clay,tc 2 00Flour 2 00Repairs to ladles,cupolas, etc 2 50Wood and coal for core oven 2 00Flasks, material in and wages making 10 00Wages " 1 foreman $6 00

1 melter 4 502 helpers,$1.75 3 5010 moulders, $3.50 \25 " 3.00Vsay 133 0015 helpers, 1.50 ) - 147 00

219 97Iron"Per ton $30 00 "^U

Interest,four months 0 70Lighterage 1 00Cartage,handling,and short weights. . . 1 00 32 70x8 tons, 261 60

*

$481 57


35/260


Amount brought forward $481 57Cartages,etc - 5 00Contingencies 3 00

Cost of melting 8 tons, with iron included $489 57Or, per ton $61 20

A gross ton of iron (2,240Ibs.)ields 2,000 Ibs. in castingsthe rest is wastage, and sprues, gates,etc.,which makes thecost,without moulding :Melting,per ton $28.50, or per Ib c. 1.425Iron, " 32.70, " c. 1.635

Cost per Ib c. 3.060

If ten tons is melted,then the cost will be :Melting per ton, $22.80, or per pound c. 1 .140Iron " 32.70," " c. 1.635

Cost per pound without moulding c. 2.775

It will thus be seen that the cost of meltingproportionatelydecreases as the amount of iron increases. The heavier thecastingsthe cheaperthey can be made. To melt ten tonsrequiresscarcelyany additional expense over meltingeighttons, with the exceptionf a littlecoal.

The shop expenses of the foundryare covered when a cer-ainamount of iron is beingmelted. But the business becomes

profitablenlywhen a greater amount is being melted. Inmanufacturingiron work for buildings,there are very fewarticles that can be made up into stock or made in advance.Most of the work is taken under contract,and the differentparts made just before they are required at the building.Payments are made by the owners of buildingsfor whom thework is for,as the work progresses. The money turns veryquickly,ay for finished work being usuallygot before the pigiron of which it is made has to be paidfor,if bought on theusual four months' credit. Few bad debts are incurred wherethe contracts are direct with owners, as new buildingsformercantile purposes are rarelyuilt except as investments or to


36/260


supplythe prosperous demands of commercial firms. A man-gercan, therefore,ake close and safe calculations in arrang-ng

his finances. There is no heavy stock of articles to be car-iedwaitingfor purchasers.

It will be observed that in the foregoingalculation made forthe cost of melted iron,the price of pig iron is taken at $30per ton. This priceis merelytaken as an illustration,or theobjectof these tables and the views given are to offer correctprinciplesnd a guide in making up tables and costs applica-le

to any particularron works.The mixtures of iron will vary greatlyaccordingto location,

availabilityf certain brands of iron,and foundrymen'sideasand experience. The followingmixtures are not given withany great degreeof confidence as the best,but simply whathas been found to work well in practice.

MIXTURES OF IRON.For heavy work " No. 1 American Iron 3 parts.

No. 2 u " 2 "Scotch. Iron 1 part.

For medium work " No. 1 American Iron 1 "No. 2 ." " 1 "Scotch Iron 1 "

For small work " No. 1 American Iron 1 k'Scotch Iron 2 parts.

COAL.

Amount to be used will differ in accordance with hardnessand kind " say one ton anthracite coal to six tons of pig iron.

TABLE.Cost of melted iron with foundryexpenses added on same :

Iron at $25 per ton.1 ton iron (2,240Ibs.) $25 004 months' interest.

,0 58

Lighterage 1 00Cartage,handling,and short weight 1 00

$27 58Yields 2,000Ibs. good castings; the rest is wastage, etc.


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ARCHITECTURAL IROX WORK. 13

Iron costs per pound c. 1.38Melting (as obtained under the head of " Foundry") per paund c. 1.64

Cost per pound without moulding expenses c. 3.02

COST OF MELTED IKON.

The followingtable shows the cost of melted iron,with pigfrom $20 to $50 per ton, includingfoundry expenses :


38/260

14 ARCHITECTURAL IRON WORK.'

COST OF CASTINGS.When cost of.moulding does not exceed 1 cent per pound.

Moulding c. 1.00Facings, cores, ;ind chaplets .20Cleaning and chipping .20Labor and handling .05Cartage 10Losage on bad castings(10per cent, of above items) 15

c. 1.70Melted iron, with shop expenses added (as obtained under head of

" Foundry "). Pig iron calculated on a basis of $30 per ton. Seetable, u Iron at $30 per ton " 3.27Cost,per pound c. 4.97

Sell (20 per cent, profit)6c. per pound.

When cost of moulding is f c. per pound.Per Ib.Moulding c. 0.75

Facings, cores, and chaplets 20Cleaning and chipping .20Labor and handling .05Cartage 10Losage on bad castings(10 per cent of above items) 13

c. 1.43Melted iron. (See table," Iron at $30 per ton ") 3.27

Costs c. 4.70Sell (20 per cent, profit)5|c. per pound.

"When cost of mouldingis IJc.per pound.Per Ib.

Moulding c. 1.25Facing, cores, and chaplets .20Cleaning and chipping .20Labor and handling .05Cartage 10Losage on bad castings(10 per cent, of above items) 18

c. 1.89Melted iron. (See table,"Iron at $80 per ton ") c. 3 27

Costs c. 5.25Sell (20 per cent, profit)Jc. per pound.


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40/260


Cost,per day,of blacksmith and two helpers thus :1 blacksmith $3 002 helpers,$1.75 each 3 50Shop expenses, 3 men each, $1.18 3 54

Say $10 00Charge, per day $12 00

TABLE.Cost of wrought bar iron,with cartage and interest added,

and wastage allowed. Showing rate per pound.Bar iron at $50 per ton.

1 ton iron (2,240Ibs.) $50 00Interest,four months 1 17Cartage 2 00

$53 17For wastage (intoscrap, etc.),allow 5 per cent. A gross ton (2,240Ibs.)

will yield2,128 Ibs. for finished work. The bar iron will,therefore,cost, per pound c. 2.50

Cost of Bar Iron, at $45 to $85, includinginterest andcartage.

PER TON. PER POUND.


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PATTERN SHOP.Shop expenses (as previouslystated) per day $6 11Wear and tear of machinery, purchase of small hardware, etc 5 00Wages" 1 foreman $5 00

7 pattern makers $3 00 = 21 0044 2 pattern makers 250= 500 31 00

Cartages 2 00Cost per day, say $44 00

On 10 men (producers)Average wages $3 10Shop expenses 1 30

Each workman. $4 40

LIST OF MACHINERY, TOOLS, ETC.,REQUIRED IN THE VARIOUS SHOPS TO BEGIN WORK WITH.

ENGINE ROOM.160 horse-power engine and boiler $4,500Attachments 1,000Fan for cupola 200Fan for smith's shop 100Shaftingthroughout buildings 3,000

8,800FOUNDRY.

2 cupolas, maximum capacity20 tons each $3,7504 cranes 4,000Ladles,shovels,bellows,riddles,sieves,etc 2,000Sandfloors 600Weights, etc.,etc 2,000

12,350ERECTING AND FINISHING SHOPS.

overhead crane $2,500column-turninglathe 3,500lathe 750

: planer 600punch 650shears 500

Vices and small tools 4,5006 drillers 7c 02 emery wheels 250Grindstones 150

14,1502


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18 ARCHITECTURAL IKON WORK.

BLACKSMITH SHOP.6 forgesand tools,anvils,etc $3,500

3,500PATTERN SHOP.

1 wood planer $8002 circular saws 5001 wood-turning lathe 2001 wood facinglathe 1501 jigsaw 1751 band saw 175Benches, etc 500

2,500MISCELLANEOUS.

2 hoistingderricks $5002 hand trucks 2004 horses and carts, etc 1,800

2,500Contingencies 1,700

Total $45,000

ESTIMATED AMOUNT OF ONE YEAR'S BUSINESSAND COST AND PROFIT.

Interest on capital,7 per cent, on $150,000 $10,500Taxes, insurance,gas, repairs to buildings,etc 4,500Office expenses 11,000Engine and boiler (wages and coal excluded) 1,200Cupola lining,repairs,etc 700Tools,small,additions to, etc 3,600Lumber in flasks, patterns, etc 4,000Foundry equipments 5,000Moulding sand, sea coal, etc 2.000Lump coal, 550 tons, at $6 3,300Soft coal for blacksmiths,engine coal,etc 1,500Wood 500Paints,oils,etc 2,000Stable expenses 2,000Truckages of heavy work 1 ,000Freights,railroad expenses, etc 2,000

IRON.

Pig, 2,400 tons, average, $32 $76,800Bar and sheet,400 tons, average, $90 36,000Rolled beams, 100 tons, average, $135 13,500 126,300


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ARCHITECTURAL IRON WORK.

WAGES.

Pattern makers, average number, 10 men " average, $3.10,say ................................................. $31 00

Finishers and helpers, average number, 63 men " average,$2.20, say .......................................... 138 00Blacksmiths and helpers, average number, 12 men" average,

$2.41, say .......................................... 29 00Moulders and helpers,average number, 50 men" average,

$2.73, say .......................................... 136 00Flask carpenters, average number, 2 men " average, $2.50,

say ................................................. 5 00

Painters, average number, 3 men " average, $2.25, say ...... 6 75Cartmen, average number, 4 men " average, $1.87", say ..... 7 50Common laborers,average number, 4 men " average, $1.50,

say ................................................. 6 00Engineer, 1 man" average, $3, say ........................ 3 00Weightman, 1 man " average, $2.75, say ................... 2 75

Total number of men, 150 ; wages per day, say ..... $365 00

300 working days in a year makes the total sum paid for wages ..... $109,500Contingencies ................................................. 10,000Total cost ............................................. $300,000

PRICES REALIZED.

For pig iron made into finished castings,2,400 tons, at $100 ........ $240,000For bar and sheet iron,finished work, 400 tons, at $160 ............ 64,000For rolled beams, 100 tons, at $175 ............................... 17,500

$321,500

PROFIT.Profit,$21.500 on an investment of $150,000, in addition to 7 per cent, per

annum for use of capital.

The generallyprofitableharacter of this business has thusbeen shown. A new establishment,owever, for the firstfewyears, will have to put the largerproportionf its profitsnadditional machinery,testingapparatus, tools,patterns, etc.In this class of manufacture success attends capacityandindustry.


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From the preceding tables is obtained the following :

TARIFF OF PRICES FOR LABOR AND MATERIALS.Cost. Charge.

Blacksmith (forge) and 1 helper $711 $850" " 2 helpers 1000 1200

Finishers, machinists 3 50 5 00" extra helpers 255 350

Patternmakers 440 600Laborers 150 200Drill machine and 1 man 3 50 5 00Small lathe and 1 man 4 00 6 00Planer and 1 man. 4 00 6 00Column-turning machine, etc 6 00 10 00

In making out bills for jobbing work, always charge for the

following :

Pattern materials,Screws, etc., files,Bolts and nuts,

Cast iron, by weight,Wrought iron, by weight.Labor,

Cartage,Pattern makers,Finishers,

Blacksmiths,Machine use,Boxing.

ILLUSTRATIONS OF COST.

It is important that the cost of every article of commonmanufacture be made up in a book to be kept for that pur-ose.

From time to time, as variations arise in prices of laboror materials, these costs must be revised.

As illustrations, the costs of a number of leading articles isgiven in detail. From these the manner of definitely arrivingat the cost of any article will be readily understood.


45/260


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USUAL SIZE OF PLATES.

Diameter of Column. Cap Plate. Base Plate.4 inch lOxlOx " 8x 8x

10

,12x12x1 10x10x1.12xl2xli lOxlOxli.12xl2xH lOxlOxli.14xl4xli 12xl2xl".14x14x1^ 12xl2xli,14x14x1$ 12xl2xl"

The cores of columns should be made in one piece in length,the castings made of a uniform thickness of metal, straightand reasonably perfect,and the ends turned off true in a lathe.The somewhat common practice of making columns with agreater thickness at the ends, where it is observable, than atany other part, should not be followed. The risk that is there-y

assumed is greater than the value of the metal saved war-ants.

It is usual to make round columns a little smaller at the

upper end than at the middle ; this is advantageous in strengthand also in appearance ; the difference should not exceed one-tenth of the diameter.

It has been a common opinion that long-continued vibra-ion,though very small in amplitude, causes a change in the

structure of iron,rendering it more liable to break ; this notionhas been abandoned by those best informed.

For columns, good strong iron must always be used, and thecastings made with at least ordinary care. It is too much toexpect that long columns will be cast quite straight. Somedefects can be readily detected by inspection. Those having'considerable defects in the casting should, of course, be re-ected,


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48/260

24 AJRCHITECTUJBAL IKON WORK.

TABLES OF SAFE LOAD ON HOLLOW CYLINDRI-CAL CAST IKON COLUMNS.

(ONE-FIFTH THE BREAKING WEIGHT.)

The following tables give the safe load in tons of 2,000pounds, which hollow round iron columns will sustain withsafety ; the ends turned off true at right angles with their axis ;level cap and base plates used ; and the columns set upwith reasonable care at the building. For columns not turned,one-half of these amounts should be taken for the safe load.

In estimating the load to be borne by a column, allowancemust be made for any use the building may be put to, and thegreatest weight that may come on any one column. Besidesan allowance for the floors,and the weight to be placed thereon,one-fourth of the total should be allowed, in addition, to makeassurance doubly sure. Great allowance must also be madefor columns that are subject to vibrations caused by machinery,or under the floors of armory drill-rooms, or subject to concus-ion

from bodies falling on a floor above, or liable to lateralblows from goods in transmission being thrown against them.

The castings should be made of a uniform thickness ofmetal, straight and reasonably perfect, and both ends turnedoff true in a lathe.


49/260

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53/260

ARCHITECTURAL IKON WORK. 29

TABLE.

[Arrangedfrom the foregoingdetails.]COST OF WORKMANSHIP ON BOX COLUMNS, INCLUDING LEAP CAPI-ALS,

SAY I

TABLE.

WEIGHTS OF ORDINARY BOX COLUMNS. PANELLED. MADE AS LIGHTAS CAN BE SAFELY RUN, AND WITH OPEN BACKS.

[Platesincluded.]


54/260


EXAMPLE.

What is the cost of a box column 14 inches face,16 inchesdeep,and 12 feet long?Weight, 134 Ibs. to a foot [see above table] = 1608 Ibs. @ c. 3.27 $52 50Workmanship, includingthe capital 20 08

Cost $72 58Add 20 per cent, profit 14 52Sell $87 10

Is $7.27 per lineal foot,or c. 5.42 per pound.NOTE. " If columns are deep panelled or heavy mouldings in panels,theweight will be considerablymore.If shutter grooves are required,add for additional weight and labor. Set-ing

of columns always charged in addition.

CAST IEON BEAMS.

The best form of section for cast iron beams or girderssthat known as T beams. Experimenthas established the rule,that the area of the bottom flangeshould be a little more thansix times that of the top flange,nd the flangesconnectedtogetherby a vertical web curved in the shapeof an ellipse,and sufficientlyigidto givelateral stiffness.

A cast iron beam will be bent to one-third of its breakingweight if the load is laid on gradually and one-sixth of it,if laid on at once, will produce the same effect if the weightof the beam is small compared with the weight laid on.Hence the breakingweightof the beam should not be lessthan three times the greatestload which it has to carry, andfor those exposed to vibrations the strengthhould not be lessthan six times the load imposed, as sudden shocks tend farmore to destroythe cohesion than a permanent load.


55/260


56/260



57/260

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58/260

ARCHITECTURAL IRON WOKK.


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61/260


EXAMPLE OF COST OF CAST IRON BEAM.

Length be-

$2 00

Suitable to sustain three stories of twelve-inch brick wall,tween supports, eighteen feet.Top flange,4" x 1"".Centre web, 21 x If"14 inches at ends.Bottom flange,2 " x 2i".Average cost of pattern, flasks,etcMoulding" 2 moulders 1 day, $3.00 , $6 00

1 helper 1 day 1 50FacingChaplets,etcCleaning.ChippingLabor, bringingin flasks,ettingout castings,etcSundriesPainting.CartageLosage " 1 beam in 15Weight, 3,485Ibs. @ c. 3.27

Cost $135 35Add 20 per cent, profitfor sellingprice.

CAST IRON AECH GIRDERS, WITH WROUGHTIRON TENSION RODS.

Arch girdersare principallysed for the support of thefront or rear walls of brick buildings.They are a cheap andeffective method of securingwide openings. The castingismade in one piecewith box ends,the latter having groovesand seats to receive the wrought iron tie rod. The tie rod is


62/260

SB AECHITECTUEAL IKON WOEK.

made from one-eightho three-eighthsf an inch shorter thanthe casting and has square ends forming shoulders so as tofit into the casting.The rod has usuallyone weld on itslength,and great care should be taken that this weld beperfect.

The rod is expanded by heat,and then placedin positioninthe casting,nd allowed to contract in cooling,hus tieinghetwo ends of the castingtogethero form abutments to receivethe horizontal thrust of the arch. If the tie rod is too longit will not receive the full proportionf the strain until thecast iron has so far deflected that its lower edge is subjectedto a severe tensile strain,hich cast iron is feeble to resist. Ifthe tie rod is made too short,the castingis cambered up and asevere initial strain put upon both the cast and wrought iron,which enfeebles both in carryinga load. The proper proportion of cast iron arch to wrought iron tie ; the proper weldingand shrinkageof the bar are all importantelements. Thegirdersshould have a rise of about two feet six inches ona lengthof twenty-fiveeet. One square inch of cross-sectionof rod should be allowed for every ten net tons of load imposedupon the span of the arch.

In the followingtables the thickness for the castingsreset forth,the proper diameter of tie rods to be used, andother necessary details. The weight of brick work is calcu-ated

as a solid wall equallydistributed,xclusive of floors orany other weight. If window openings occur, deduct onlyhalf weight; that is,take out of the weightof wall onlyhalfthe actual space which the windows will occupy. Should theweightof wall,by piersor otherwise,e placedat or near thecentre of the girder,ouble the weightcalculated to be borne ;in other words,use a girderof greatersustainingapacity.

A cubic foot of brick work weighs 112 pounds ; a foot ofwall sixteen inches thick will weigh 150 pounds.


63/260


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67/260


ARCH GIRDER EXAMPLE OF COST.

Suitable to sustain four stories of 12 inch brick wall.

Length,25 feet.

Average cost of pattern, flasks,tc $2 50Moulding." 2 moulders, 1 day each $3 00" $6 00

2 helpers,1 day each 1 50" 3 00 9 00Cores 1 00Facing 1 00Chaplets,etc 40Cleaning 50Chipping 2 00Labor, bringing in flasks,taking out casting,etc 1 00Sundries 1 00Painting 1 25Cartage 3 00Losage, 1 girderin 10 1 84Weight, 2,700 Ibs. ate. 3.27 88 29Wrought-iron tension rod, 2f inches diameter, includingforging,fit-ing,

etc.,520 Ibs. at 7c 36 40Cost $149 18

Add 20 per cent, profitfor sellingprice.

LINTEL AND CORNICE COURSE " EXAMPLE OF COST.

such as are generallysed above firststorycolumns.Lintel" Weight, say 100 Ibs. to foot, at c. 3.27 $3 27

Moulding, etc 2 00$5 27


68/260

44? ARCHITECTURAL IRON WORK.

Amount brought forward $5 27Cornice" Weight, 45 Ibs. to foot,at c. 3.27 $1 47

Moulding, etc 60Fittingup at shop 2 00Putting up at building 50Screws, bolts,files, etc 30

4 8740ainting

Cartage .Sundries.

2025

Cost per foot $10 99Add 20 per cent, profitfor sellingprice.

WINDOW LINTEL " EXAMPLE OF COST.

of pattern $0 15MouldingFacingCleaningChipping,Labor,PaintingCartage,SundriesLosage, 1 lintel in 10Weight, 90 Ibs. at c. 3.27

Cost.Add 25 per cent, profitfor sellingprice.

WINDOW SILL EXAMPLE OF COST.

Average cost of pattern $0 15Moulding 85Facing 06


69/260


Amount brought forward $1 06Cleaning 12Chipping 15Labor 05

Painting 25Cartage 15Sundries 10Losage, 1 sill in 10 12Weight, 60 Ibs. at c. 3.27 1 96

Cost $3 96Add 25 per cent, profitfor sellingprice.

WROUGHT-IRON PLATE GIRDER " EXAMPLE OF COST.

Web, 20'x-iV.Top plate,10" x "".Bottom plate,8"xf.Top angles,4" x 4* xBottom angles,3"" x

Length, 30 feet.

Weight, say 2,600 Ibs. ; average 3"c $91 00Making" four hours forge and three helpers,$1.30 $5 20

ten hours forge and three helpers,71c 710twenty hours finisher and four helpers, $1 .40 28 00five hours finisher and three helpers,punching, $1.15 5 75five hours finisher and one helper,65c 3 25

49 30Use of punch, shears,etc 10 00Rivets,120 at 7c 8 40Painting 2 00Cartage and handling ^ 4 00

Cost $16470Add 25 per cent, profitfor sellingprice.


70/260


RAILING EXAMPLE OF COST.

Cost of one panel of railing,six feet in length,

Forging $1 00Finishing in shop 1 50Lead" 2i Ibs. at 8c 20Files, chisels, etc 20Painting 25Labor, cartage, etc 25Putting up at building 1 50Sundries 50Weight : Wrought Iron "

Bottom raH, 1" x ", 6 feet. "\Top rail, 1" x f , 6 feet. . . . (Brace, ix", 3 feet V 35 Ibs. at c. 3.22 103Post, 4 x |, 3 feet j

$65 per ton " [see table].Cast iron"Hand rail 20 Ibs.

Railing castings. .60 Ibs.

80 Ibs. at c. 3.27 2 61Pig iron " $30 per ton [see table].Moulding and other costs in foundry 1 60

4 21

Cost of 6 feet $10 64Add 25 per cent, profit for selling price.


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Amount brought forward $2 66Cleaning,chipping,files,tc 12Cartage 08Losage 10

Cost. $2 96Add 33" per cent, profitfor sellingprice.

IKON SHUTTERS EXAMPLE OF COST.

Made in two folds,nd hung to eyes built in the wall.Size,4 feet wide by 6 feet high.Frames, 1"" x "",covered with No. 16 sheet iron.

Weight. Lbg.4 uprights,6' each = 24 feet of H x | 604 crosses, 4' " 16 feet of HX! 402hinges, 4' " 8feetofl|x-" 201 strikingbar,5' of 2 x | 16Latches, rings,etc 3Rivets 5

V 10 per cent 15

159


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Bar iron ($65 per ton) 159 Ibs. at c. 3.22 $5 13Sheet iron,No. 16,4' 3" x 6' 2",includinglaps 69Wastage, 10 per cent. 7

76at5|c.. 4 18Blacksmith and one helperwill forgethree paira day, $7.11,is 2 37Finisher and one helper,with shop expenses on same, making, say . . 3 00Hanging : finisher and one helperwill hang six paira day, say 1 00Cartage (eightpairto a load) and handling,say 50Painting 60Sundries 50

Cost $17 27Cost per square foot,superficial,2aAdd 25 per cent, profitfor sellingprice.

ROOF CRESTING EXAMPLE OF COST.

Average weight per foot,includingtwo finials to each 25 feet, 10 Ibs.ate. 3.27 $0 33

Moulding and other cost in foundry '.,Cleaning,chipping,etcFittingup in shopScrews, files,tcPainting,cartage,sundries,etcPutting up at building

Cost per footAdd 33^ per cent, profitfor sellingprice.

4:

300510030815

$1 04


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GKATINGS.

Example of cost of wrought iron gratings 2' 8" to 4' 0' out,2 inches centres.

Filling in bars, 1" x "} ^Front frame bars, 2 x "" "" Not including platforms or doors.Back frame bars, 8 x " )

On twenty-five feet run.Finisher and helper, with punching machine, 1-^j days at $8 $10 40

" " " " H days at $6 900Forge, straightening bars and cutting off same, 11 hours at 71 c 7 81Painting, 6 hours, and paint 5Cc 3 00Handling 2 00Cartage, 25 feet 2 00Drilling, etc., for thimbles 4 00Putting down at building: Finisher and helper, 2| days at $6.50 16 25

Cost of workmanship on 25 feet $54 46Or, $2.14 per lineal foot.

Cost of iron, say, $65 per ton (as per table), is 3.22c. per Ib.Wastage, 10 per cent 32c.

3^c. per Ib.

A grating of 1| x -J bars 2 inch centres, 4' 0" out, weights 71-,% Ib. tofootat3ic $2 50

Cost of workmanship per foot 2 14

Cost $4 64Or, 6|c. per Ib.

Add additional for cast iron platforms. Add additional for grating to raise

up, ordoors.


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ARCHITECTUBAL IRON WORK,

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ARCHITECTURAL IRON WORK. 57The foregoingillustrations could be carried to the full ex-ent

of showing the cost of every article that pertainso thebusiness. A sufficient number has been givento enable anyfoundryan to adapt these principleso his own particularclass of work, based on the business expenses under which herests.

The pricesf architectural castingso not materiallyluctu-tewith the price of pig iron. The cost of the iron which

enters into many of the finished articles is not twenty-fiveercent. The principaltem is labor. The cost of the labor em-loyed

is probablythirtyo fiftyer cent, greaterthan in 1860-'61. This is due not onlyto the increase in wages, but to thegreater care with which work is done. The number of partsand the difficultyf castinghem are increasingvery year, andmore skilled labor is required,in proportionto the amount ofiron cast,in the work of fittingp. Of still greater impor-ance,

as affectinghe cost of castings,s the largeamount ofcapitallocked up in patterns,flasks,achinery,buildings,tc.,the value of which shrinks every year. Large capitalas to beemployed,and the proprietorsave to work harder than almostany other class of manufacturers. In fact they do doublework as manufacturers and as contractors. Patterns are in-reasing

in varietyand extent,demanding a continual outlayof money. There is a growing discrimination between thetrue and the false in this branch of productiveindustry.Ahigher order of taste is being developed,and the tendencyis toward more perfectlyinished and more artisticallyrna-ented

work. This is an encouragingfact for the future ofthe business,nd though it involves increased expenditure,tis one which manufacturers must recognize.The enterprisingmanufacturer who will meet the popular demand and giveartistic excellence,ven to the smallest detail,ill not lack forpatronage.

The cost of most, if not all,f the articlesgivenin illustra-


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58 ARCHITECTURAL IRON WOEK.

tion may appear excessive. It must be remembered, however,that there are but few of a kind to be made at a time,and atconsiderable intervals of time apart. To get out the patternsand flasks and shiftingf various articles,ll takes time,whichmust be considered. The moulding,time and expenses con-ected

therewith,and risk of losingthe casting,s greaterwhenmaking up a small number than theyare in making up a largenumber. So in the deliveryby cartage: a small number ofcastingsand lightweight have frequentlyo be taken for aload. No one need be told that the cost is much more, propor-ionately,

in making two or three castingsf a kind than it isin making two or three hundred. It would be a waste of timeto recite why the cost is proportionatelyess on a greater thanon a lesser number ; it is self-evident to every foundryman.

This printedinformation and guideis entirelyn the interestof the producer. It is to enable him to fullycover the cost ofevery article,nd not to make a profitn one article and a losson another. Everythingshould be taken out of the realm ofguess-worknd brought down to hard facts. If errors are tobe made at all,theyneed to be made on the winning side.The costs had better be calculated excessivelyhan not enough.It is quiteprobablethat after a foundryman arranges a com-lete

line of costs of the various articles he manufactures,nthe system here laid out,that the result will be a curtailmentof his business by reason of beingunable to compete in priceswith his neighbors.Such a man need have no regrets. Lethim confine himself to such articles as do pay, or raise thestandard of his work so as to command a superiorpriceinmarket. How many men at the end of a year, after doingalargebusiness,re unable to account to themselves for nottaking money? They cannot discover where any materialsavings could have been made or greater economy practiced,and yet there is nothingto show for a whole year'sard laborand anxiety.The fault layin the fact that a considerable


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portionof their manufactures were made at a loss. The thou-andand one small items had not been considered,nd a system

of self-deceptionad been continuouslyracticed,bringing,nthe end,disappointmentnd discouragement.The small itemsmake up a gross sum which is trulyastonishing.A smallerbusiness may be done,but it will be a profitablene, and willsteer clear of bankruptcy. The making up of detailed tablesof costs are generallyonsidered disagreeableuties,nd putoff as long as possible.They are necessary to success, and ifa manufacturer studies his best interest,e will not onlymakethem complete,ut often revise them.

In no department should anything be left to guess-work.In takingoff quantitiesfrom plans,tc.,for the purpose ofmaking proposals,t should be done in such a detailed manneras to be readilyeferred to and compared with the executedwork.

In the foundry, careful and experiencedan should act asforeman. Practical abilityn turningout good castingss theone great requisiten such a man, and not one full of scientifictheories. More money will be made or lost in the foundrythan in any other department. The making of unnecessaryflasks must be guarded against those on hand used as muchas possiblethe stock of weights,arbors,etc.,kept as low asthe limits of work will allow ; wages seen to that nothingabove market rates is paid,and the work properlysorted " thecommon castingso the cheapgrade of moulders,the betterqualitieso the highergradeof moulders. The meltingmust belooked after to see that the mixtures of iron are properlymade,and the cupolachargedwithout waste of material. Economyeverywheremust be enforced.

In the patternshop, foreman of experience,good judgmentand exceedinglyareful and correct must be selected. Mould-ngis rendered difficult or simpleas the patternsare made.The patterns for buildingwork are rarelyintricate,nd the


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60 AKCHITECTUEAL IKON WORK.

shrinkageof iron and the contraction of castingsn coolingregovernedby very simplelaws.

Between the draughtsmanin making working drawingsandthe foreman of pattern-makersnd the foreman of moulders,perfectaccord should reign. It is not always possibletodesignthe castingith equalmasses of metal throughout,ndthen the responsibilityill devolve upon the founder, whomust, by acceleratingoolingof parts by earlyuncovering,rby retarded coolingof other parts,producea simultaneous rateof coolingthroughoutthe casting.Great care must be exer-ised

in making patterns to secure a proper distribution ofmetal. This arises from the fact that in coolingthe thinnestparts of the castingbecomes quitecool,while the heavierparts are yet red hot. The part which has cooled firsthavingcontracted and set,while the other portionis yet soft,theresult is that the castingpullsapart in the mould, or is leftwith a strain and tension which, upon being subjectedto asudden jar,r even to the influences of the weather in expand-ng

or contractinghe iron,will produceafter breakage.In the finishingepartment,he foreman must have a thor-ugh

practicalnowledge of his branch of work, and abilityocontrol the men under him and get out of them all the workpossible.And he must not onlyhave the drive and snap inhim, but the workmanship of his men must be good,as well asexpeditiouslyone.

Over all,he care and watchfulness of the manager must beomnipresent. Waste must be prevented,each departmentmade to work systematicallynd harmoniouslywith everyother,surplusmen cut off,and the pay-rollsept within theclosest bounds. Suppliesmust be boughtat the lowest rulingrates,and every item in liberal quantities.he shop must bekept well suppliedwith work. If good results are to beobtained from journeymen,they must have confidence thatthere is a full quota of work ahead. Otherwise they will


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nurse their task in order not to do themselves out of a job.The work must be regular, and not spasmodic. Men workwith a will and do their best in busy times, and the reverseof this in dull times. The beginning and the end of thebusiness rests on the manager " on his industry, patience, skilland experience.

The' foundry business is peculiar in one respect. The man-gerhas continually to overcome a tendency to name lower

rates per pound in taking orders than the facts of the real costof production warrants. The business is carried on for thepurpose of making money, and that aim needs constantly to beenforced by thorough and systematic arrangement of and ref-rence

to table of costs.The field is broad enough without calling forth an unhealthy

competition. Frequent and friendly intercourse between thoseengaged in the same pursuits, and comparisons of opinions andexperiences, contribute to the common good. What effects theprosperity of one affects more or less the prosperity of all. Itis certainly desirable to know positively what products cost,and to establish prices which allow fair profits. Those engagedin the manufacture of iron work for buildings need to take abroader corp prehension of their business. The magnificentproportions which the manufacture of this class of iron work isto assume in the future can scarcelv be realized.


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62 AECHITECTURAI, IKON WOKE.

SPECIFICATIONOF

IKON WORK AND MATEEIALS AND LABOK

required to build and complete a to beerected on lot No . . . . , Street,or

Mr ,Owner,

in accordance with this specificationnd the accompanyingplans,elevation,ection,nd workingdrawingsmade by

Architect.

DIMENSIONS. " The size of the building,eightsof stories andother dimensions to be obtained from the drawingsandthe figureshereon.

SCRAP. " Take down and clear away all the old iron from pres-ntbuildings,nd allow the value of same in making the

estimate.FRONT. " The front of the building,rom the foundation up to

the roof cornice,ill be made of cast iron,s shown on thedrawings,includingll posts,antaes,columns,piers,ambs,reveals,arches,facias,cornices,capitals,ases, watertables,ills,anels,nd other architectural features. Theposts,columns,etc.,upon which dependenceis placedforstability,ill average three-quartersf an inch in thick-ess.

The remainder of the work will be cast of sufficientthickness to retain their shape,none being less than aquarter of an inch in thickness. And the whole securelybolted,and properlyput togetherin their several parts.The castingso be smooth,straight,harpand clean. Theends of all columns to be turned off true and even in alathe. Columns to have ears cast on at top and bottom,


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64 ARCHITECTURAL IKON WORK.These beams shall be made to fit snugly between the antaes,and be fastenedwith anglepiecesbolted through the web of the beam."

If only the first story is iron " that is a brick or stone front used above " thenspecify: "Over the first story columns a box lintel course will be placed,made, say, twenty inches high on face, say twenty-two inches on bed, andsay, twelve inches on back, and to average one-and-a-quarterinches thick.The lintels jointed over the centre of columns, turned off on ends in lathetrue and even, and bolted togetherthrough brackets cast in lintels,ith twothree-quarter inch bolts and nuts to each joint. Cornice over lintel course tobe thoroughly put up, bolted and bracketed to lintels."

ROLLING SHUTTERS. " The front openingsof first story to befitted with revolvingron shutters of approvedmake, withall shafts,gearings,ranks,chains,counterweights,uides,grooves and all other necessary fixtures complete,put upin the best manner, and left in perfectworking order.

The wooden doors beneath the rollingshutters to becovered with sheet iron on the face and edges,properlyscrewed on. In the panelsplanton cast iron mouldings.

The entrance to loft will be fitted with dwarf doorsmade in four folds,frames of l^xf wrought iron,cov-red

with No. 16 sheet iron,panelledand moulded andhung to the iron columns,and furnished with strong boltsand a $15 lock and two keys.

ILLUMINATED PLATFORM. " The steps,risers,latformsand doorsills covering front area, shall be of approvedmake ofilluminatingtile,consistingf cast iron platesseven-eighthsinch thick with knobs on top, and thirty-threedouble convex lenses set in cement to each square foot oftile. The tile set in cast iron frames,and the latter sup-orted

on strong cast iron bearers,beaded on the loweredge. Coveringthe end walls will be used an iron tile inimitation of the glass.The ends of the walls are to becovered with iron platesextendingdown below the walk.The exterior surface of frames to be grooved,and edgesto be trimmed with nosings.The platformand stepstohave proper pitch to the street of about three-quartersf


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an inch to the foot. That part of the frame which receivesthe wroughtiron doors over elevator will be set on a greaterincline,s shown on the drawings. Let into granitea castiron shoe,from which the firstriser will start. The doorsillswill each be supportedon two 3 x f wrought ironbars, the whole made completeand put down perfectlywater-tight,nd kept so for one year from completionfthe building.

The elevator doors to be hung and secured to the castiron frame,-to be made in two folds,ith frames of 2 x"inch wrought iron and covered with No. 12 sheet iron.Have proper padlockfasteningso secure the doors whenshut,and have guard bar of seven-eighthnch round ironfor protectionhen doors are open. Eyes to receive thisguard bar to be riveted on at both front and back of doors.

Note." Sometimes the door sills are checquered plates. Sometimes therisers are plainiron. Sometimes the first riser only is plain,the others illumi-ated.

Sometimes checquered platesare introduced in front of the basementcolumns, in order to reduce the amount of illuminated work, and so cheapenthe cost. Sometimes a cheaper platform is required. Then specify: k ' Castiron tile glazedwith 5" x 5" x f glass,set in with putty cement, and madewater-tight."VAULT GIRDER AND COLUMN. " Furnish and set in vault,for

support of granitesidewalk, cast iron girderaveragingone-and-a-quarternches thick,made fifteen inches highon the back flange,ix inches on the front flange,ndeightinches on the bed ; the column underneath thegirderto be seven inches diameter and one inch thick,and to have bottom plate 12 x 12 x li thick,with ringcaston to receive and hold column ; the top plateto be cast onthe column, the plateto have a moulded turn-up pieceontop to prevent the column from beingshifted away fromthe girder.

Note." IS. brick arches and stone flagsare used instead of granite,thenthere requires to be specified: " Vault Beams" to be in number as shown on

4


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plai),f cast iron ten inches on the bed, with centre flangeten inches high inmiddle and four inches on ends. Thickness to average one inch. Beams tobe made to hook over and lay into girderso that the bed of the beams will beon the same level as the bed of the girder." Wrought iron beams extendingfrom the front basement columns to the street walls,with headers at the arealine,are often used.

INTERIOR COLUMNS. " Inside columns supportingwood girderswill be as follows : Basement and firststory,twelve inchesdiameter,one-and-a-quarterinches thick. Second story,ten inches diameter,one-and-a-quarternches thick. Allthe foregoingto be deep fluted,nd have full Corinthiancapitalsnd Attic bases,with round shell plinthsfourinches high. Columns in third story,nine inches diame-er,

one-and-a-quarternches thick. In fourth story,eightinches diameter and one inch thick. In fifthstory,seveninches diameter and one inch thick. And these all tohave plainshafts,oose Tuscan capitalsith egg and dartbed moulding,and moulded bases.

The columns are all to be turned off true and even onends. Those for upper stories are to be made with dowelends to pass throughgirders.And all to have top plateseighteeninches long by the width of girders,nd to beone-and-a-half inches thick.

Under the basement columns placecast iron bed plates18 x 18 x 1J inches planedon top,and bedded level under-eath

with a small quantityof cement.The interior columns will be delivered at the building

to the framer, who will set them up in place.Note. " The followingappliesto a double store :

AECH GIRDER. " Furnish and put up for the support of therear wall two cast iron arch girderswith tension rods.The top flangeof girderto be sixteen inches wide and one-and-a-quarternches thick. Centre web twelve inches high


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and one inch thick. To have twenty inch bearing ateach end and skewbacks thereat. Rise of girderat centreto be two feet six inches. Tension rod three inches dia-eter

of best refined wrought iron,with square heads atends, adjustedto the girder in the best manner, andshrunk in while hot. These girdersto be well boltedtogethern the centre,where theymeet with four one-inchbolts. Also to be properlybolted to the fire-proofolumnon which theyrest.

Note. " Sometimes two rods are used instead of one. Then they are smallersize rods, the two making in section about fiftyper cent, more than the singlerod. Sometimes square rods are used instead of round.

FIRE-PROOF COLUMN. " For the support of the arch girders,provide and set up in place a double fire-proofolumnmade as follows : Outside column, sixteen inches diameter,and average three-quartersnch thick,and to correspondin stylewith the other first story columns. Inside col-mn,

twelve inches diameter and one-and-a-quarternchesthick,plainshaft,with top platetwo-and-a-half inchescast on. Bottom plate,4x24x1^. On the inside col-mn

cast on bracket to receive wooden girder. The spacebetween the outer and inner column to be filled in withplaster.

Note. " Sometimes a fire-proofcolumn is used in the basement underneaththe first slorycolumn, instead of a brick pier. If so, specifythis kind of acolumn to be used both in the basement and first story, and to be stronglybolted together.

SKY-LIGHT. " Curved sky-lightver first storyextension to beof illuminated tile supportedon handsome moulded castiron ribs. To have cast iron moulded gutter on top ofextension wall with flangesto fit over the thickness of


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ARCHITECTURAL IRON \VORK. 09

sides to receive ends of bars,and to be well fitted aroundto the floor,and securely screwed down. Glaze withrough plateglass,ne inch thick,well bedded in putty.

Note. " Sometimes where a floor-lights very large,nine inch (or other size)wrought iron beams are used to secure rigidity. The glass used for floor-lights is generally one inch thick, generally twelve inches wide, and fromthirty to thirty-sixinches long. Even size glassshould always be used, thatis,ten, twelve, fourteen inches and the like wide " not ten-and-a-half, eleven,etc.

REAR OUTSIDE SHUTTERS. " Supply to all the rear openingsout-ideshutters,n two folds to each window, three panelsfor

those seven' feet or over in height,nd two panels forthose under seven feet ; made with frames of " x 1",andcovered with No. 16 sheet iron,riveted to frames withrivets placedabout four inches apart, the sheet iron to lapfull one inch on the brick-work ; to have strong wroughtiron straphingesextendingthe full width of shutter,ndto be well riveted to and through the frames ; shuttingbars of ""x If,built in brick-work ; all the shutters to befurnished completewith all requiredrings,atches,taples,turn buckles,etc. ; the shutters of basement, firstand sec-nd

stories to have three-quarternch square bolts at topand bottom, in addition to the other fasteningsthe topbolts to be long enough for convenient reach from thefloor below ; the bottom bolts to shoot over wrought ironstubs,which must be leaded in the stone window sills; allthe shutters to be left in easy working order.

Note. " Double shutters are frequentlyused; shutters having a double cov-ringof sheet iron,with an air space between.

SHUTTER EYES. " Furnish to the mason to build in the wall castiron brick-eyesor all the rear window openings; three toeach jamb for openingsof seven feet or over, and two foreach jamb of openingsless than seven feet in height.


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70 ARCHITECTURAL IRON WORK.WINDOW GUARDS. " Front windows at hoistwayin the s

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Architectural Iron Work 1000085624