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^hc CanaMan 5ocict\> of Civil lEnginccrs,

IXCORPORATED J 887.
ADVANCE PROOF— (Subject to revision.)

N.B. — -Tliia Society, jia a body, does not hold itsolf rea])onsiV»]e f<ir
tlie BtHtenienta and <)i)ini'Jii8 advanced in any of its publications.

MODERN WORK-SHOP DESIGN.
By A. Pringle, M. Can. Soc. C.E.

It should be explained at the outset that the writer shall only
attempt to cover the subject in a general way and shall not offer
any lantern slides of modern work-shop structures, or detailr^ of
construction, for although they might be interesting in a manner,
yet no really new features could be presented, and the best that can
be said of most modern work-shop structures in Canada to-day, is
that certain recognized principles have been followed in their con-
struction in possibly a somewhat modified form to suit the existing
conditions.

Generally speaking, it may be said that the advantages of
modern work-shop design have not been appreciated until recently.
The mill or factory engineer, outside of a few special industries,
has been, comparatively speaking, unknown. It was held by many
manufacturers, or their managers, that they knew just what they
required in the way of plant and machinery; and having determined
that an extension of works was necessary, additional land was
secured as near the existing plant as possible, the millwright and
local builder were called in and directed to erect a building to
dimensions that would best suit the property— one, two, three, pos-
sibly four stories in height. The building completed and the
machinery delivered, planning would commence as to how the
machinery could be located to best advantage. Of course, the

siiporintondont had undoubtedly planned the whole arrangement In
his mind at the commencement, but when it came to placing the
machines it would be found that he had quite neglected the detail
that there would be columns and beams supporting the upper floors,
all of which naturally interfered with his mental layout, and pos-
sibly in the end, (he whole arrangement of plant would have to be
changed entirely from what he originally contemplated, and in all
probability some important machine would have to be placed at
some distance from its proper location, in possibly a daric corner of
the shop, necessitating the almost continual use of artittcial light,
also requiring a special line of shafting to operate it. But most
serious of all would be the daily expense of handling materials to
and from this machine, possibly throughout the length of the shop.

MLlI.niXO.

The building also would, in all probability, be defective in many
respects, not necessarily that the materials or worlimanship were
faulty, but rather that they were not arranged or proportioned to
give the best results in the service required of them. For instance,
foundation walls, although properly constructed of good materials,
would be laid upon a poor bottom with inadequate footing courses
for bearing. Thus, frequently, was an expensive building jeopard-
ized in avoiding a few hundred dollars for piling or extra walling
to obtain a solid foundation.

In the construction of the upper floors it would frequently be
found that the joists and flooring were capable of sustaining with
safety flfty to one hundred per cent, greater floor load than the
beams u])on which the joists rested.

Durin.tv the present year the writer had occasion to examine
plans and specifications, and report upon the stability of a factory
structure it was proposed to extend. At the time tenders had been
received for carrying out the worlv. One of the first questions asl<ed
was the approximate floor load to be carried. The owners could
not give this offhand, but advised later that it would approximate
125 lbs. per square foot. In the structure in question we found
that the joisting and flooring specifled would sustain with safety
85 lbs., while the beams supporting the joists were only good for 30
lbs. It is almost unnecessary to add that the factory in question
has not been extended.

Another serious defect was that frequently, roof purlines, beams,
rafters and board covering were too light, and owing, possibly, to
changes in temperature, warped, twisted or shrunk to such extent
that the felt, tar and gravel covering was damaged, causing leaks
and entailing continual expense patching and repairing. But the

maintonance Is inconsequent as compared with tlie Increased cost
oi' operation in sucli a building from loss of power owing to shafting
and maeliiues being out of alignment ; faulty workmanship from
vibration of tools and ineflicient light ; and loss of production from
belts slipping, and expensive and slow methods of handling stock in
urocess.

In old time shop practice it was not appreciated that a few
thousand dollars saved in the cost of construction, probably entailed
double that expenditure annually in the operation and maintenance.
The consideration seems to have been given entirely to the
machines purchased ; they must necessarily be the best possible—
where or how they were housed, or how many hours they operated,
were not of particular consequence. It was apparently sufficient
that they would perform certain operations.

In modern shop practice the conditions are vast'ly different— a
machine is purchased with the understanding that it will do a cer-
tain quantity of work per day if kept in continual operation. Due
allowance is made for placing and removing work from the
machine with the facilities of thr modern work-shop, and the effi-
ciency of the machine is estimated to be seventy, eighty or ninety
per cent., according to the class of stock which it is handling. The
machine hours are recorded as carefully as the operator's, and if the
estimated results are not obtained, either the operator or the
machine must be replaced, for the facilities of the modern work
shop are such that the estimated results should be obtained with
ease.

In modern worl; shop design no standard form of construction
can be laid down since so many conditions are likely to affect it in
one way or another ; for instance, the situation of the property,
transportation facilities, climatic conditions and the class of work
to be produced. Thus each proposition must be carefully thought
out and designed to suit the existing conditions.

The class of work to be produced has a very important bearing
upon the design of building and its apparatus. For instance, it
would be a most 'serious error to equip a foundry for turning out
light work with heavy cranes, as they would necessarily be expen-
sive and slow in operation.

Also in a machine shop arrangement, most careful consideration
should be given to the class of work to be carried out ; some are
operating on heavy castings, others on comparatively light work,
while still again are shops which have to do considerable machine
work on light structural steel shapes. In the latter case a travel-
ing crane may not be at all essential ; an arrangement of trolley
tracks and chain blocks may answer every purpose to even better
advantage than would a crane. In some instances when the oper-

ations are short, the work la secured to the trolley and passed from
process to process until completed before releasing. In the hand-
ling of this class of work it is necessary to eliminate to the fullest
extent possible, building columns and overhead driving belts. In
a one story building the steel truss roof and the independent elec-
trical operation of each machine gives the desired result.

If in a two story structure clear tloor space is required upon the
ground floor, a common construction is to suspend the upper floor
to the roof trusses ; while if the upper floor only is required to have
clear floor space, the columns could be used below, the truss roof
would meet the conditions above, and the machines could, if pre-
ferred, be belt driven from below.

The design most usually adopted for general machine work is a
structure with a centre bay, ranging from forty to ninety feet in
width, and two side bays, usually somewhat narrower. For heavy
worlc all three are equipped with suitable traveling crane. The
machine work of a lighter character is performed in the side bays,
and the heavier work in the centre bay — the product to be worked
up usually being received from the foundry located at one end of
the above described building, and the goods delivered when com-
pleted to the erecting shop, located at the other end of the said
shop, and also at right angles to it.

In shops turning out a lighter class of work, the travellers in the
side bays referred to are occasionally omitted, and an upper or gal-
lery floor constructed to receive ligiiter machine tools.

There are still other classes of light manufacturing which
require neitlier cranes nor trolleys, but owing to the fineness and
the particular care necessary in their production, require an espe-
cially well lighted shop. In such cases what is known as a saw
tooth construction meets with favourable consideration. The name
undoubtedly originated from the form of the roof, which much
resembles a saw tooth, extending the full length or width of the
building over each bay, the short side of the tooth is glazed and
the long side roofed in the usual manner. Of course, this class of
construction is restricted to one story buildings, but there is practi-
cally no limit to the length and breadth of the structure from a
lighting point of view. Doubtless, the object of this form of roof
construction is to give, throughout the shop, uniform distribution
of light and, at the same time, exclude the sun rays. Designers
have varied the form of saw tooth somewhat to suit local require-
ments, but by facing the glass due north and setting it at an angle of
25" to 30° from the vertical, there will be little oportunity for the
sun rays to penetrate the shop during the usual working hours.

In the writer's opinion a modern structure of this design is
more expensive to construct than an equally substantial building

three or four stories In height, containing the same total floor area,
for the reason that the foundations and roofings are more expen-
sive per square foot of floor surface, against which, however, the
walling is much less. Its possibilities of extension in any direc-
tion are limited only by the boundaries of the property. And it is
also contended that for certain cl.isses of work a structure of this
design presents exceptional manufacturing advantages, in which
event the initial cost of the structure is only of secondary import-
ance.

The following features are, however, of the greatest Importance
in work-shop designing : — Good light, good air, steady power, effi-
ciently distributed, solid foundations for buildings and machines,
comfortable temperature, smooth floors, with adequate facilities
for handling the stock from process to process, and the machines
so arranged that the several operations from commencement to
completion shall be in almost continual progression in one direc-
tion. It may be contended that such arrangement of machines is
a detail of manufacturing convenience or economy. Such, how-
ever, is hardly the case, for the object of modern work shop design
is undoubtedly to obtain the maximum production in the least time
&t a minimum cost, and the advantages of a modern work shop
building may be frequently almost entirely lost owing to unnecess-
ary handling of the product in the course of manufacture. And
the designer may not necessarily be at fault, since he may not have
had an opportunity of becoming familar wth the several processes
of manufacture, or may have had only a very indifferent under-
standing of what was expected to be accomplished. For, to many
manufacturers, the idea that any outsider could give any useful
information respecting the machinery in their works, or suggest
how to arrange the plant to handle the product in process to best
advantage would seem preposterous.

Nevertheless the full advantage of the modern work-shop can
only be obtained when the whole process of manufacturing is car-
ried out in detail from beginning to end and the shops designed to
house the arrangement as laid down. The mill engineer should be
engaged long before it is proposed to commence building operations.
He should be given, or placed in a position to obtain, the fullest
particulars of what is being done and the manner in which it is
done, and what it is further contemplated to do. From his natural
ignorance of the business it becomes necessary that he diagram and
work out every operation in detail to thoroughly understand it. In
so doing he will, in all probability, notice features that may not
possibly have received more than passing consideration in the past.
And his asking an apparently absurd question has no doubt on more
than one occasion indirectly attracted the manufacturer's attention

to Home shorlor method or economy whi(3h had not previously been
ol)Ht'rve(i, and In just sui;h accidental manner liavo many of tlie
Hiiort cuts and economies which are now in general use, been ob-
sorvt'd and tui<('n advantage of.

Having diagramed and determined the general procedure for
performing the several operations of manufacture, the engineer
should, witli the assistance of the manufa(!turer and his superin-
tendents, lay down the machinery in a manner to insure continuous
proKression In one direction as nearly as possible with the mini-
mum amount of iiandiing from process to process. This being
accomplished all that remains Is to design buildings to house the
maihlncry as laid down, embodying, of course, to the fullest extent
possible, the essential features previously cited. Without such
preliminary planning it is extremely doubtful if the full advantage
of modern work-shop design will be attained.

Of course, it may be contended that this is all very well in the
case of designing new shops, but that it would bo entirely different
in tlie luatlcr of carrying out extension to works presently in oper-
ation. The plan, liowever, liolds good in either case.

in conlom plating extensions to e^cisting works, manufacturers
very properly fear and try to guard against the consequent inter-
ruption to business. Extreme conservatism in this respect has
Hoiaetimes led to the construction of a new and practically indepen-
dr'ut shop or factory, with the result that establishments may be
found operating several departments or shops performing practical-
ly tlu! same class of work, at, of course, greatly increased cost of
oj)eration. not only in the handling of goods between departments,
but in tlie general management and supervision. More superintena-
encn, foremen, labouring help, power, supplies, etc. being usually
required tlian if tlie departments were concentrated under one roof.
Therefore, in considering a re-arangement and extension of works,
it should be assumed that the existing buildings contain practically
no machinery and tliat the proposition is to arrange therein the
most economical and efficient plant possible of tlie increased capa-
city called for. The plan when completed is compared with the
existing arrangement and modified until a plan is finally determined
upon that may be carried out with the least possible interruption
to the existing works, and which when ultimately completed, will
be modern and up-to-date in most respects, and economical to oper-
ate. Tiie remodelling can then be commenced, carried out irom
time to time and the old plant will gradually evolve into a modern
works of increased capacity without any serious manufacturing or
financial inconvenience.

In connnection with the construction of shop or factory build-
ings, there is a prevalent but mistaken idea with many builders that

thore Is no particular occaHion for accuracy or finish, and If the
work ^ Is fairly substantial it should be sufficient. However, the
a((urac>. finish and detail specified should be closely adhered to
for the reason that without entailing extra expense to anyone they
add greatly to the appearance, stability and durability of the struc-
tures.

Special care must, of course, be taken In securing suitable found-
ations and adequate looting courses to carry the distributed loads
which will be imposed upon them, and the walling must be well
built and thoroughly filled with mortar as the least settlement in
the foundations will surely damage the light brick curtain walls
usually employed in the superstructure— if it does not affect it more
seriously.

Usually there is nothing to be gained in making a foundation
wall less than two feet in thickness, the contractors usually figuring
that the additional labour l)uilding a thinner wall offsets the saving
in material. Frequently, there is so little difference between the
cost of lime mortar and Portland cement masonry that one is war-
ranted in recommending the use of the latter, as it insures a tighter
wall and better bond. In any event, the wall joints should be
SI raped and pointed inside and out with cement mortar, giving a
comparatively smooth surface and tightness, thus minimizing tlie
danger from frost or water penetration.

The use of the stone base course is largely a matter of prefer-
ence. It certainly adds to the cost, but also to the appearance of
the structure, and also has the advantage of giving a level surface
upon which to commence the erection of the steel and brickwork of
the superstructure.

In reference to the brickwork in the modern steel frame struc-
tures—the very thinness of the walls makes it important that they
shall be especially plumb and true in every respect and thoroughly
bonded together and to the steelwork, and flushed full of good
mortar to insure tightness. Portland cement mortar is used to
some extent, but good lime mortar will apparently meet most re-
euirements.

Projections from brickwork are undesirable, but where essential,
should be weathered on top surface and properly throated or
dripped below. Much of the local brick is soft and porous and fre-
quently scales off where severely exposed to the wet and frost, for
which reason a dwarfed stone mulliori is frequently placed at the
lower corners of doors and windows. For the same reason it is
also desirable to carry the masonry up (or use especially hard
brick for the facing of walls) to a height of 30" to 3 feet above the
general ground level.

The Interior face of walls should bo carofully Jointed and made
as Hinooth as poHslble to prevent dust accumulation. Window and
door openings should be accurately and carefully spaced. It means
no extra cost and adds greatly to the appearance of the building.
Wherever possible the frames should be built Into the walls, and In
addition the joints scraped, caulked with oakum and pointed.
Anent this matter of caulklnK : The writer recently heard It re-
marked that Canadians apparently desired their buildings to bo
hermetically sealed.

In so far as uncontrollable events are concerned, this Is probably
quite true for most structures are equipped with sufficient control-
lable vents In the way of doors, windows, etc. to give any ventila-
tion required.

KOOFINO.

In regard to the matter of roofing much could be said, as slate,
terra cotta, concrete, Iron, all find more or leas favour, but arc objec-
tionable owing to their cost.welght, etc. The wooden board roof,
covered with tarred felt and asphalt, is probably more generally
used than any other, Its low first cost being probably its principal
recommendation, although when properly laid it gives good service.
From an insurance point of view it is considered objectionable,
some serious fire damages being attributable to tue board and com-
position tarred roof.

The engineering department of the New England Mutual Insur-
ance Companies recently issued a pamphlet favourably commenting
upon a roof called ' Ferrolndace." Mr. Brown, vice-president of the
Brown Hoisting Machinery Co., is credited with having thought
out this construction. It consists of iron, specially corrugated into
a dovetail form, and plastered upon both the upper and lower sides
with a mixture of two parts of sand and one of Portland cement,
the lower side containing a proportion of lime and hair. When
completed the top surface is painted with two coats of a special
non-drying paint, which renders the roof quite water-tight. The
total thickness of the covering being about VA". This form of roof
is said to cost about twenty-flve to thirty per cent, more than the
ordinary board or plank and composition covering. It is contended
that it resists fire well, but has a conductivity six to eight times
that of 2" spruce plank, from which it may be concluded that there
would be considerable trouble from condensation, and unless the
form could be changed to eliminate this it is a question if it would
be very generally pdopted.

In the matter of flooring it has been found that for ground
covering something more rigid and durable than the 2" or 3" plank
laid upon cerad sills was required. Brick and many forms of con-

Crete have been used with varying n-Bults. but unless laid with
particular car.- they are very lil<e|y to settle, cracit and wear into
holta. becominK Anally very uneven ; in addition being objection-
able from the operator's point or view in that they were hard and
cold to work upon.

Another form of lloor quite generally used at present is concrete
toundatlon with nailing Htripa bedded therein. In some instances
the tops oi: these strips were flush with the concrete, while in other
cases the nailing strips in question projected IW to 2" above the
concrete, thus forming, when the planiv was laid, an air space
between the concrete and the planl<.

Still another form which the writer has used quite ext-3nsivoly
and which he believes compares favourably in first cost, durability,
rigidity and general service with any of the forms above mentioned;
it consists of a 3" cinder ground, well tamped to receive a 3" tar
and cinder foundation, rolled level, over which is then laid hot a
vulcanite composition 1" in thickness, into which are bedded 3"
sound hemlock plank. dre«sed one side and two edges, the rough
side being well tamped into the hot vulcanite so as to give an even
and true bearing. Toe nailing assists In laying plank true, but if
the composition id properly made the adhesion of the plank to the
vulcanite, after a few hours, la such that it Is impossible to separate
them without damaging the plank. The planking Is in turn cov-
ered with two ply of tarred felt cemented at the joints, over which
IS laid, preferably at right angles or diagonally to the planking a
1 matched hardwood flooring, of narrow widths securely blind
nailed.

A floor of this description is so rigid that all but the heaviest of
machine tools may be erected upon and secured to it without other
toundatlon. The composition prevents moisture reaching the wood
thus preserving it to a great extent from decay. The top flooring
will, ot course, wear out, but it can be easily renewed at compar-
atively small cost as there remains a good foundation of plank to
renew upon. • i* «. i-u

To the writer's knowledge one such floor has been In service for
the past six years in a machine shop-all but four or Ave of the
heaviest machines having no other foundation than the floor above

™nH r"'f ' T ^" "''''^'""'' ^''" ^°-^^^y P^'-^^^tly rigid and true,
and the top flooring is not appreciably worn excepting at some few
points where the traffic is heaviest.

For upper floors where brick, terra cotta or concrete steel con-
struction are not used, the 4" plank flooring with 1" hardwood ton
covering is probably more generally used than any other The -'
X 4" flooring laid on edge, instead of 4" plank, also finds some favour.
This torm of flooring is nailed through the side to the adjoinin-

plank and to the running beams. The joints do not necessarily
require to be broken on the beams and, therefore, there is probably
less waste in laying a floor of this description than would be in the
usual plank floor. In casje of an extra heavy floor load or where
an extra long ppan is required, 2" x 5" and evon 2" x G" may be used
in the same manner. The material in question is usually dressed
on four sides, one edgt frequently being beaded or chamfered so as
to give a neat ceiling effect to the floor below.

The writer has found it good practice to lay two ply of tarred
felt, cemented at joints, between the lower and top flooring, for not
only does this make it dust and oil proof, but frequently in case of
a fire it prevents the water dripping down at many points on tha
machines below.

A floor of this description has been known to be flooded to a
depth of 2" with water from the sprinklers, and the only leakage to
the floors below was at the wails and columns.

Although modern work-shop design is doing much to reduce the
cost of handling stock in process of manufacture, yet comparatively
little attention is given to the cost of receiving and delivering to first
process of raw stocks, supples, etc Of course, almost all manufac-
turing establishments are equipped wUh a warehouse or shed in a
comparatively convenient locality adjoining the railroad, but in all
probability the warehouse in question is located some distance from
the point where the material will be required for the fir process
in manufacturing, and thus in nine cases out of ten entailing r'ldi-
tional expenses for handlin,i as the stock might probably have been
placed in the first instance with little, if any, extra expense on al-
most the spot where it was to be used, or at least in such a position
that iTirther movement would be almost by gravity.

For instance, nearly all manufacturing establishments use coal
to a greater or lesser extent, the usual procedure being to deliver it
by team or barrow to the floor of the boiler house, from where
every ton is transferred to the grate bars with shovels by the fire-
man. A coal handling plant would obviate this, but its urst cost
and operation are expensive, and it can thereroie only be favfirably
considered in plants where large quantities of coal are being vsod ;
bUL in almost every caso the boilers in manufacturing plants could
be placed somewhat below the ground level or on an elevated run-
way erected so that the coal could be d-^livered by team into hop-
pers level with or above tlio boiler house rool, from which hoppers
it would flow by gravity to the stokers, these in turn dplivering it, as
required, to the grate bars The hoppers referred to need not neces-
sarily be large, two or three tens' capacity being sufficient in riany
cases.

It may be argued, of course, that such an arrangement entails
increased capital expenditure and that if the fireman did not have
the coal to handle he would be idle. Against this, however it may
be said that an intelligent fireman, with care and attention, can
effect great economy in the use of fuel by noting the fiuctuating
demands or steam and preparing to meet them, and also by Iceep-
ing his plant generally in condition to obtain the best results If
however, he is required to transfer six, eight or ten tons of coal to
h,s l^oilers per day, and in addition remove the ashes, it will be
readily appreciated that he will have little time or desire to give
thought to the matter of economies in the consumption of coaf or
maintenance of plant.

In connection with the handling of raw stock from cars to fir«t

ItZ;, "/T'' ""' ''" ^^^^^ ^^°' '^ -^°-"«" -ith some
o ob^er . fh '"" *" " '"""'' manufacturing plant.had occasion
o ob erve the receiving and warehousing of raw stock and its fur-
thor delivery to first process. The stock was being handled by the
generally recognized method at that time, and although moved
quickly, It required considerable labour. After some carefulTdy

designed for receiving this class of goo.ls and some conveying appa!
ratus provided for handling stock to first process. When the plant
wa. completed and put into operation it was found that it effe ted
a saving of six hundred per cent, in the cost of handling he stock
to the warehouse and from the warehouse to the first process and

r'-lraVd^X"^^^- — -^ — - -fo'r^-

Plant anf 'ffPcTr^''"'"' ''"' ^"''""°' subsequently in another

use tho T.rTr '''"•' ^""^''^ '^''°^' P^^"^'iP-l'y. of course, be-
cause the operation onginally in the second plant was more com-
plicated than in the first.

Of course, such extensive economies in the handling of raw stock

: r n'stTnT thT ^"-^^ ^'"^^^ °^ manufacturing, still l7Jlt
tAcry nstance there is opportunity for Improvement of some
description if the matter be carefuly thought out

In still another manufacturing establishment it was found that

Of 3%r"""r ^^^^"^^ "^^ "^^'"^ -"'--^ in the hand Lg
of goods af er manufacture. m this instance all goods manufac

ured were transferred by teams to a warehouse some distance from
the works Where they ^ere stored, and later shipped to S /est"

a on. Tbe expense of this double handling involving e^ a ship
l>eis teams, etc. amounted to thousands of dollars per annum

Reference ,s simply made to show that the locating «n7?I.-
mg Of the receiving and warehousing buildi:gf t^the raw^a^d

manufactured goods require as important consideration as any of
the other buildings in a manufacturing plant.

Finally, there is the item of power. It must not be lost sight
of in designing and arranging a modern plant, for outside of the
economies to be considered in producing the power there are the
losses in transmission to be considered, and whether water steam
or electricity be used the problem of distribution must be carefully
thought out in order to obtain the best results.

The writer appreciates that possibly he has not treated the sub-
ject of modern work-shop design along the lines generally expected
and in explanation would say that with the movement in manufac-
uring to concentrate, conserve and utilize energy most efficiently
n the production of goods, it became necessary to provide struc-
tures which would accommodate the appliances and features neces-
sary to this end. The flexibility of structural steel construction
commended its almost general use as a frame work best adapted to
meet the varying requirements and thus the building prooer ,s
really only incidental to or a detail in the general arrangement or
design of the modern work-shop.