The Magazine of the CLEMSON BRICK FORUM and the National Brick Research Center

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Volume 8 • Number 4 • October 2009 The Magazine of THE CLEMSON BRICK FORUM and The National Brick Research Center

In This Issue

Pine Hall Brick Paver Plant #5

A New Beginning for J. B. Cooper, General Shale Brick

Stedman Machine Company’s 175 Years of Service

Analysis of Mortars

Fun in the Break Room

C Exceeds B

Yard Talk

National Brick Research Center – Key Dates for 2010 Executive Committee Meeting and Research Reports, April 6-7 56th Clemson Brick Forum, October 3-5 Executive Committee Meeting and Research Reports, October 6 On the Cover: J. B. Cooper is just the kind of guy you would want as a boss. He is calm, thoughtful, intelligent, and dedicated to his people. He is certainly a “mentor” to everybody who comes into his path. It has not been easy for J. B. with the budgetary restric- tions brought on by the GREAT RECESSION. He sat across the table from a number of good people and explained that there are just no jobs. Wonderful plants have been idled. It just takes a toll on a person, and it is a scenario that makes retirement seem “OK” – even desir- able. Now J. B. and Becky Cooper can explore the world We ARE Traditional Ceramic’s Classically Trained Engineers with a well-earned freedom With the disappearance of ceramic engineering degrees in North America, the Center’s staff that countless hours in the brick constitutes a continuing resource in ceramic engineering for the ceramic industries’ needs. Here is the track record (given in alphabetical order) of almost 110 years of experience: plant have earned. We wish our Denis Brosnan, Ph.D., PE – 12 years refractories, 6 years technical ceramics and building friends the Coopers bon voyage. products, and 20 years brick industry problem solving or 38 years total. —The Editor. Jim Frederic – 42 years brick plant and problem solving experience. Greg Grabert, Ph.D. – 15 years brick plant and technical service plus two years with the Center (Greg worked for the Center prior to and after his brick industry experience). John Sanders, Ph.D., PE – 2 years ceramic tile, 2 years refractories, and 12 years ceramic and brick industry problem solving or 14 years total. Features Plant & Laughs In Sales The Break 5–7 A New Beginning for 8–13 Room J. B. Cooper Pine Hall Paver Plant

14–16 17–19 20 Stedman Has 175 Year Analysis of Mortars Stick It or Ticket History of Service 21 Yard Talk

2 • BRICKYARD • October 2009 Just Down “Brickyard Road” . . . The Aftermath of the Great Recession

Denis Brosnan

T Is an unusual privilege to eat breakfast with We welcome brick sales and marketing personnel to Richard Bickerstaff, retired president of the former a meeting traditionally dominated by manufacturers. IBickerstaff Clay Products and scion of the Broken Arrow properties near Columbus, GA. Mr. Richard is a We welcome architects from along the I-85 corridor and model of what anybody should be as a senior citizen – still elsewhere. thinking, active physically, surrounded by family, etc. We must recognize that we are on the same road toward We had a pretty good discussion of the aftermath of greener and sustainable buildings, so let’s work together. THE GREAT DEPRESSION and what it would be like after I suspect that this is a permanent direction for the Forum, the eventual end of THE GREAT RECESSION. With the and it will be interesting to see how sales people and GREAT RECESSION, the answer was amazingly simple – architects respond to the practical type of education that it will be DIFFERENT. we have been offering to brick manufacturers for the last 54 years. I can promise manufacturers this – we will Everything will be DIFFERENT. Not only will our continue to present our topics related to plants emphasizing nation be in debt up to its nostrils, construction and con- “how to make better clay products at lower cost”. struction products will likely be different. The peak of the clay products industry of a couple of years ago will not So, welcome to the 55th Forum! We are trying to posi- likely be duplicated in the short term. We will move toward tion it for the aftermath of the GREAT RECESSION. May sustainable buildings and sustainable construction practices this thing be over soon! at an increasing rate. Incidentally, if Mr. Richard can morph at his age, The Forum will be DIFFFERENT. The Forum is NOT anybody can. He has been busy selling gravel to the Atlanta approaching the end of its “life cycle” – not on my watch. Airport and turning clay pits into landfills. I’ll just bet he is What we will see is an outreach using technology and calculating what the landfill gas will be worth in 25 years involving new participants. This year we have done the fol- or so. n lowing things to re-engineer the Forum:

We are continuing to offer the delayed webcast of Forum talks – this year reducing the price for the international audience.

October 2009 • BRICKYARD • 3 The Preacher’s Corner

Harold Newman Chairman, Executive Committee The National Brick Research Center (Pine Hall Brick Co., Inc.)

he Clemson Brick Forum this year is I was asked recently by one of our sales people to look a timely one: Greener Brick Manufacturing. We over a LEED Product Data Sheet to see how we could Thave heard a lot about being “Green” and being help “fill in the blanks”. I saw items such as recycled able to help projects qualify for LEED certification. content, regional materials, low-emitting materials and rapidly renewable materials, but I did not see anywhere on BIA has reported that leaders in the movement toward the form where we could get credit for using alternative sustainability in housing say that the marketplace is in a fuels such as sawdust, land fill gas, or biomass materials. period of transition and that home builders need to gear I guess we have a lot to learn, but I think we can also edu- up to fill demand for energy-and-resource-efficient homes. cate the LEED council about the advantages of utilizing BIA has developed Builder Notes on Brick: Green Building these renewable materials in the production of “Green” Design and Sustainability and also Tech Note #48 entitled products in the construction industry. Sustainability and Brick for our edification. Before closing, I need to encourage all of you to attend Needless to say, we as manufacturers have a lot to the “Jim Frederic Roast” on Monday afternoon prior to the learn about this topic, and the Forum this year is a great steak cookout. I invite anyone who wishes to say a few venue to expand our knowledge. We have been asked words of thanks to Jim for his service to the industry to by our sales staff to tell them about the manufacturing step forward when the time comes. I am sure there are process and what, if any, recycled materials are utilized some good stories about Jim that need to be shared before in production. The National Brick Research Center has he moves on to retirement. n established a program for Product Certification for Recycled Content and Reduced Resources. Dr. Greg Grabert is on the program this year to tell us all about it.

4 • BRICKYARD • October 2009 A New Beginning for J. B. Cooper

Denis Brosnan

here was a sense of J. B. credits George Sells as being excitement for the future yet another important example, as Twhen I interviewed J. B. George was a believer in neatness, for this “retirement article” last organization, and work rules. Of April. Retirement will be a new course, George was the driving beginning, a fresh start, and a time force behind coal firing, and J. B. of discovery for J. B. and Becky was in on the first coal firing Cooper – well deserved after 27 experiment in Johnson City in years in and around the brick- 1973, when coal granules were yards. In fact, talking to dropped through a hole drilled J. B. that day, I had the sense in a tunnel kiln. I did not know of one of my grandkids anticipat- Mr. Sells, but I suspect that he and ing a trip to the ice cream store. J. B. might have been on different ends of the personality spectrum. It is fair to say that the Great Recession has been a burden for Finally, J. B. credits Dick J. B. He was the guy who had Green, President of General Shale to decide who stays and who Brick, as also being a mentor. It doesn’t. It is not an easy task to turns out that both Dick and J. B. tell a man or a woman that there started together at the Johnson just is not a job for them – espe- City plant in 1972. Dick and cially when you consider them J. B. in his Office at the New “Roundhouse” J. B. rose through the ranks your friends. And, J. B. was together, although Dick eventu- a friend to everyone who worked in production at General ally went toward marketing. Crediting your boss as being Shale Brick. It is also fair to say that it “hurts” to see plants a mentor isn’t just being nice by J. B. – I believe Dick that you have nurtured suddenly idle. If you have manufac- and J. B. have been through a lot together including the turing in your blood, you have to admit that an idle plant is acquisition by Wienerberger AG, the world’s largest pro- something hard to look at or think about. ducer of clay bricks. J. B. said, “Wienerberger has done a lot of good things since 2000”. J. B. and Becky are “anticipating that trip to the ice cream store” in the form of a drive to Alaska. Other travel All this talk about mentors, with little talk about men- and lots of hiking are planned too. J. B. admitted to me last toring, I believe that J. B. has been mentor to countless pro- April in working on some long-delayed patio improvements. duction people at General Shale. J. B. did not want to talk My memory is that this included an outdoor cooking and about that – but I know the people – the Dan Green’s of the fireplace area so the Cooper’s could enjoy their backyard world. J. B. is leaving behind a tight ship. His influence will year around. There just wasn’t time for that kind of thing be felt for a long time. in the past. Of course, Becky retired as a nurse a couple of years ago, and she probably has a long list for J. B. Growing up in Erwin, TN, J. B. attended East Tennessee State University in Johnson City – where he met Becky Our discussion centered on J. B.’s good fortune to have and where they eventually married. After two years, he some excellent mentors during his career. One was the joined the Air Force and served three and a half years in late Phil Garland who insisted that things were done “the Vietnam as a weapons mechanic on F-4 fighters. On his right way”. Phil was responsible for hiring J. B. away from return, he finished his degree program with graduation in a position as a plant manager so that J. B. could become 1972. He started with General Shale at the Johnson City a regional production manager. It was a classic case of plant in January of ’73. mentor becoming “promoter” starting J. B. on the road to becoming Vice President of Production. A year later he went to Knoxville to work under Don Ward. In ’77, he was back at the Johnson City plant as Another of J. B.’s mentors was Don Ward – now retired Assistant Plant Manager. In 1980, he became Plant from General Shale Brick. Don was always a pretty matter Manager in Johnson City. Is it easy to be a plant manager of fact kind of guy - Straight shooter - Reliable as the sun in the same city as the corporate headquarters? J. B. did coming up tomorrow. Can’t we all see that in J. B. as well? not comment on that.

October 2009 • BRICKYARD • 5 Dan Green (left) and J. B. at the Forum

Brick people learn how to move from place to place. whole industry – professional assistance –friend, kind of Next, J. B. went to Marion, Virginia in 1981. In 1988, Phil sums it up. Garland hired J. B. as regional production manager meaning J. B. and Becky could “come home”. Along the way, sons There are the accomplishments that cannot be over- Jeremy and Ryan arrived in the world. looked, in addition to coal firing, to include: • Advent of robotic unloading – where General Shale was J. B. is rightfully proud of the team that made coal fir- cautious to adopt the new technology but now is a great ing a reality at General Shale and his participation in this advocate of the productivity gained with robots. fundamental company accomplishment. From the simple experiment in 1973 at Johnson City to bottom fired stokers, • Environmental gains – a natural outcome of coal firing a lot of work was done until the system was “perfected” by where General Shale was perhaps better prepared for con- 1975. The first operational system was in Knoxville when trols than most other brick companies. J. B. was working there. I believe some other folks I know were part of that development team for coal – to include the • Expansion – acquisition of Robinson Brick, Arriscraft late Joe Edwards and currently retired Bob O’Quinn, both in International, and four new block plants. the engineering and research area. There is a lot in this story for young production folks to learn from the career of J. B. Cooper, and that’s why I write I first met J. B. in the early 1990’s when Joe Edwards, them. One thing is to encourage mentoring from others in a founding member of the Center, asked that J. B. become the company and to study the characteristics of the leaders. involved. J. B. rose to Vice Chairman in 2001 and Chairman Technology is sure to change – but you have to be trust- in 2003 of the Center’s Executive Committee. This year, worthy to become a leader. Look at the words I have used he received the Center’s Director’s Award. Here is the cita- or implied in this article – steady, straight forward, reliable, tion on that award, “In recognition of years of distinguished distinguished, etc. I believe that these things will continue service to the brick industry and in appreciation for profes- to work in the real world for you to advance in your career. sional assistance and participation in efforts for research, It was not just luck that landed J. B. Cooper with a senior testing, and service, this Director’s Award is presented to management position. our good friend with our best wishes for the future.” Writing things like that is the best part of my job – service to the

6 • BRICKYARD • October 2009 Now, J. B. attends his last Forum before qualifying for the “retiree rate”. I hope he will come back in the future. Regardless, J. B. has been an excellent example for me, and I can only say again to J. B. and Becky Cooper – best wishes for the future. n

J. B. Cooper’s Service to the NBRC

• Chairman, 2003-2005

• Vice Chairman, 2001-2003

• Executive Committee

• Management Subcommittee

• Strategic Planning Subcommittee

• Representation of General Shale Brick, 2004-2009

• Service Award, 2005

• Director’s Award, 2009

John Sanders (left) and J. B. at a Plant Tour

October 2009 • BRICKYARD • 7 Be Careful What You Ask For! Pine Hall Brick Company’s Decision to Focus on the Paver Market Pays Dividends.

Greg Grabert

ost of us, at one time Well, maybe it wasn’t put exactly Today, Pine Hall Brick Company or another, have been that way, but in 1994 Pine Hall Brick is still a family owned company that Minvolved in a manufactur- Company decided to do just that, build manufactures quality face brick, paving changeover. If you haven’t, con- a plant dedicated to making quality ers and special shaped brick. It oper- sider yourself lucky. I understand there pavers instead of a face brick plant ates three plants in Madison, NC and are plants that exist which run one that made pavers as a side item. They two plants in Fairmount, GA, with its raw material body, in one size, maybe did however have a backup plan. The Corporate Offices headquartered in changing a sand coating every now plant could always be converted to Winston-Salem, NC. The plants have and then, and never make solids or a face brick plant if the additional a rated capacity of 500 million brick shapes. If you work at that plant, keep share of the paver market did not come per year and have employed as many it to yourself, and maybe no one will to fruition. The plant was started in as 300 people at capacity. Their prod- find out about it. Whenever a change- late 1995 and was sold out by June ucts are distributed to over 38 states over occurs, and whether it occurs in 1996. Phase 2, which began in 1998, through more than 200 distributors. grinding, blending, manufacturing or added a second kiln, dryer, holding packaging, no matter how good a job room, fired storage track and kiln cars. This is a long way from the com- you or your crew has done chang- In 2000, an ASI/Ceric robot setting pany Flake Steele started in 1922 when ing your equipment over, it has hap- machine was added to increase the he purchased a dormant Consolidated pened at a productivity level of zero. setting rate and increase the number Brick Company, located in Pine Hall, Even with the best planning, the best of thin pavers that could be put on NC and formed the Pine Hall Brick crew, the best equipment, the best a kiln car. The Artech Dehacker was Company. His company started with tools, the best ….and so on, things do replaced with a new Artech Dehacker seven round beehive kilns and with the not always seem to go as planned and that would create a convention brick help of his father’s company, J. C. frustration often sets in. Some of the package. The original dehacker pack- Steele & Sons, maker of automated best ideas come from these moments. aged the pavers on pallets. brick making equipment since 1889, I do not know how many times I have heard when things aren’t going so well, “we should have a special line to run those shapes” or “we’re changing from modular size brick to utility size brick for how many cars?” If you ask the right questions to the right person at the right time, you might just get the answer you think you want. This follows the old adage, that sometimes you should be careful what you ask for, because you might just get it. In late 1993, someone in Madison, NC, may have asked the following question to the right person at the right time.

If we are ever truly going to be able to compete in the paver market against concrete pavers, don’t we need a plant dedicated to making pavers instead of a face brick plant that sort of dabbles in pavers as a side item? Ground Storage Bays

8 • BRICKYARD • October 2009 Flake was determined to make this new brick company one of the top quality producers in the state of North Carolina. In 1936, the company purchased the Madison Brick Company and eventually consolidated all their operations to Madison, NC. In the early years, the company maintained fifty company-owned houses and two grocery stores for its employees. The original headquarters in Salem was just two doors down from the Firehouse and the Old Salem Cafe. In those days, each man was responsible for produc- ing 1,000 brick per day and most of the product was sent to Winston (now Winston-Salem). The brick were sent by railcar to the public dock and unloaded by hand via conveyers. Then, brick would be hand loaded English Edge Paver Extrusion Showing Spacing Nimbs onto a truck, with layers of straw between them to prevent chippage, and shipped to the job site. Today, if you Production The blending operator loads a hop- look at manufacturing capacity verses per which feeds two sixty ton storage total employees, each employee, even The first thing you notice when visiting silos using material from all three the sales and delivery employees, are plant #5 is there is no grinding equip- Madison storage bays. The blending responsible for manufacturing more ment. Since plants #3 and #4 are less area was set up this way to provide than 6,000 brick per day. than 5 miles away and the grinding several different transfer points to get facility had extra capacity, the decision as much mixing of the Triassic shale as Most of the decisions for the build- was made to hold off on installing any possible since raw material consistency ing and design of the plant were based grinding equipment, but leave room on is very important in size control. From on Pine Hall’s signature paver, English site to build one just in case. The raw the storage silos, the materials are fed Edge®. This was the unit that was materials storage and blending build- into a small surge bin before head- going to compete with the concrete ing has five 1,080 ton storage bays, ing to the mill room. If there are any pavers in sizing and quality. In the face two of which were part of the phase body additives, those are added on the brick market, if the dimensions of the 2 additions in 1998, which are filled conveyor headed to the mill room. In brick are a little off, this difference can via an overhead conveyor system con- the mill room, the incoming raw mate- be made up with the 3/8” mortar joint. nected to an outside truck dump. Three rial enters a J. C. Steele double shaft However, since pavers are laid on the bays hold Madison Triassic shale and mixer, which is also fed with scrap 4” x 8” bed with little to no spacing, the other two currently hold imported from the mill and setting machine by sizing is much more critical. clays. a J. C. Steele 88C even feeder setup

English Edge Texture Unit Stacked Pavers being Indexed Onto the Marshalling Belts

October 2009 • BRICKYARD • 9 ting rate for those units that were not textured. The rate on this machine is 18,000, 4”x 8” pavers per hour. The ASI/Ceric Setter features two Fanuc M-410 Robots.

One interesting facet of the Artech Setter was the equipment designed to apply the texture to the English Edge® paver, since the plant was designed around it. A column enters the textur- ing unit and is imprinted on all four sides; it then goes to the wire bank where those indentions must line up with the wires to obtain a clean edge. Another interesting feature of this setting machine is the wire cut. The wire bank moves while the pavers are being pushed through to give the appearance that they were cut with a reel cutter. Forklift Type Pickup Head Taking Two Hacks of Pavers to the Kiln Car Once through the wire bank, the key is to stack and set the pavers on the kiln car without damaging the spacing with variable speed control. The water From the mill, the pavers go to one nimbs on the pavers or wrecking the is also added in the double shaft mixer of two setting machines depending on kiln car. This is accomplished using and is controlled by an E. H. Wright the product type. The original setter is a setting head that looks like a modi- Pugmaster water control system. an Artech Flexible Automatic Setting fied forklift. Six forks on bottom and The double shaft mixer feeds System, which is now used primarily five stabilizer bars on top pick the pav- a J. C. Steele 758D Pug Sealer and for the textured products. This machine ers up and set them on the kiln car. The a J. C. Steele 75AD extruder. Both is rated to set 15,000, 4”x 8” pavers key is that the six forks not only fit in the pug sealer and the extruder are per hour. For the more commercial between the marshalling belts, but that equipped with variable speed controls, square edge pavers, the second setter is they also fit in between the refractory and the extruder has a hydraulic tele- an ASI/Ceric Robot Setting Machine, block on the kiln car. Once the kiln car scoping die changer and load control. which was installed in 2000 to increase is set, it is transferred to the holding the number of thin pavers that could room. be set on a car and increase the set-

Harrop Kiln

10 • BRICKYARD • October 2009 End View of the Harrop Kiln During a Flash Cycle

The plant started with one 27 car an additional holding room, dryer and The original design of the pack- holding room, one 28 car dryer, and kiln were added. These were basically ing department was taken from the one 26 car kiln designed by Harrop. the same design with a few exceptions European method of packaging The kiln cars do not touch in the hold- based on the knowledge gained from clay brick pavers on pallets. Artech ing room, and each car is indexed running the plant in the first two years. designed an automatic unloading sys- using a special haulage system, The kiln is computer controlled using tem that employed a palletizer unit designed by Star Engineering, which software from Kil-Tel Systems, Inc. with a Signode Cobra 2100 Stretch leaves about six inches of clearance Wrap Assembly to accomplish the between cars. The dryer has six recirculation zones and each zone has its own independent heat input supply and is controlled by temperature and humidity. At a push rate of 34 cars per day, the resident time in the dryer is 19.8 hours. The Harrop tunnel kiln is 295 feet long with a cycle time of 18.5 hours at 34 cars per day, continuous push. This works out to 30 million pavers per year. The kiln cars are set either three or four brick high, depending on the product, and the number of units on a car range from 1800 heavy duty 3 pavers (2 /4” x 4” x 8”) to 3600 thin pavers (1 3/8” x 4” x 8”) with the stan- 1 dard 4” x 8” pavers (2 /4” Thick) at 2340. The kiln is natural gas fired with propane/air backup and is an over/ Side View of the Forklift type Pickup Head Taking two Hacks of Pavers under deck pulse fired design. In 1998, to the Dehacker

October 2009 • BRICKYARD • 11 Dehacker goal. During the plant expansion in employees from Pine Hall started train- parts more efficient. All tool and part 2000, Artech removed the palletizer ing sessions and were able to begin to areas are labeled and if something and replaced it with a dehacker for take advantage of the lean manufactur- is missing a tag is put in its place to a more conventional brick package. ing principles. Currently, all of the pro- explain the situation. More emphasis The pavers were strapped with duction employees have had at least is placed on housekeeping and inspect- a Signode MHT-80 main strapper and the 5-S training and some employees ing equipment and areas for possible cross-strapper. This equipment change have had an opportunity to further their downtime. The plant is still running was needed to keep up with the pro- training by taking additional classes. two shifts, one 10-hour shift, seven duction of both kilns and reduce over- Lean manufacturing is a process used days per week and one eight hour time. The plant was originally setup to to increase profits by making the pro- shift, five days per week. However, the run one 10-hour shift, seven days per duction process more efficient, reduc- second shift, which consists of four week. When the plant was expanded ing costs, and maximizing quality. This employees cross trained in every aspect in 1998, it went to two 10-hour shifts, is accomplished by eliminating waste of manufacturing and packaging, now, seven days per week. and reducing incidental work. Waste is relieves the first shift, both manufac- considered to be anything that does not turing and packaging, for lunch and add value to the process. breaks. They also work on specialty Lean Manufacturing products and projects, and handle most One of the areas of training dealt of the changeovers in manufacturing. To help improve the competitiveness with manufacturing changeovers. The Preston McMillan, Regional Manager of North Carolina businesses, North employees were videotaped while for the North Carolina Operations of Carolina State University started pro- making a changeover and then viewed Pine Hall Brick Company, believes all viding customized on-site applications the tape to determine how they could of this training and implementation has and public workshops on understand- improve their efficiency. Every area really benefited the employees and the ing and implementing the lean enter- in the plant is labeled and cataloged Company and will put them on the right prise business systems. In April 2006, to make documentation and ordering path coming out of this recession. n

12 • BRICKYARD • October 2009 Plant Features

• Extrusion • J. C. Steele Double Shaft Mixer • J. C. Steele 88C Even Feeder, Variable Speed • J. C. Steele 758D Pug Sealer, Variable Speed • J. C. Steele 75AD Extruder, Variable Speed, Hydraulic Telescoping Die Changer, Load Control • E. H. Wright Pugmaster Water Control • Setting • ASI/Ceric Robot Setting Machine - 18,000 units/hour • Artech Flexible Automatic Setting Cube Building Stacker Showing The Void Course and Automated System - 15,000 units/hour Board Placement Head • Holding Rooms • (2) Tracks, 27 Cars each, 315’-4” Long • Star Engineering Indexers and Haulages • Harrop Tunnel Dryers • (2) Tracks, 28 Cars each, 315’-4” Long • 19.8 hours cycle time • 34.0 Cars per Day • Six Recirculation Zones with Independent Heat Input • Star Engineering Hydraulic Single Car Index Pusher • Harrop Tunnel Kilns • (2) Tracks, 26 Cars each, 295’Long • 18.5 hours cycle time • 34.0 Cars per Day • 60,000,000 Pavers/Year Example of the Lean Manufacturing System • Harrop Natural Gas Fired Over/Under Deck Pulse System with Propane/Air Backup • Star Engineering Inside/Outside Hydraulic Continuous Push • Kil-Tel Systems Inc control software • Star Engineering Transfer Cars • Dehacking and Packaging • Artech Automatic Unloading and Packaging System - 18,000 units/hour • (2) Signode MHT 80 Heads

October 2009 • BRICKYARD • 13 Stedman Has 175 Year History of Service Company is a Proud Partner with the Brick Industry

he brick industry has a special place engines for the booming construction and river traffic mar- in Stedman’s 175 year history. 2009 marks a major kets. The Stedman engine was a favorite through the West Tmilestone for this Aurora, Indiana based manufac- and South, as well as with various manufacturers in Aurora. turer of bulk material crushing and processing equipment. Nathan P. Stedman, the son of the company’s founder, 1834: The beginning… invented an innovative new crushing machine called the cage mill. The first cage mill was shipped April 22, 1886 to Stedman owes its origin to the market created in the Oakland Pressed Brick Company in Zanesville, Ohio. The South for iron nuts and screws for first cage mill shipped overseas was delivered in December, use by farmers and others in assem- 1890 to Kennedy Brick Machinery Manufacturing in bling their cotton and hay presses. In Liverpool, England. 1834, Andrew Jackson was President of the United States (all 24 of them), On April 10, 1894, the United States Patent Office Cyrus McCormick received a patent for granted patent #518.011 to Nathan Stedman for the “disin- his mechanical reaper, and Stedman tegrator”, as the patent named the cage mill. The machines Foundry and Machine Works was soon became known for their performance under the most established in Rising Sun, Indiana, severe crushing conditions. Stedman’s first pan mixer was by Nathan R. Stedman. In 1840, the shipped to a customer in Chillicothe, Ohio, in 1897; and company moved to Aurora, Indiana, to a site near the old the Stedman family continued to search for new markets B & O Railroad Depot. Initially, the company produced for their products. One such market for the company was castings for cotton gins, hay and cotton presses, saw mills furnishing the castings for the Vine and Sycamore Street and various types of farm equipment. As the business devel- cable lines in Cincinnati and similar castings for the cities oped, the company began manufacturing sawmill and steam of Denver and New York City.

Circa 1892

14 • BRICKYARD • October 2009 In 1912, the business In 1985, Stedman signed a technical licensing moved to accommodate agreement with Otsuka Iron Works Ltd., Tokyo, growth. A new plant Japan, to manufacture the G Series cage mills. was built in the Cochran Later, the agreement was expanded, allowing neighborhood of Aurora, Stedman to manufacture and market Otsuka the site still occupied by jaw crushers. the firm. That same year, the Stedman family sold On September 1, 1990, the company was the business to Cincinnati purchased by Eagle Crusher Company, industrialists Stuart Inc., Galion, Ohio. Today, Stedman P. Sutphin, Chester still operates as a division of Eagle. A. Peebles and Perin In January, 1993, administra- Langdon. The com- tive, sales and engineering pany began operating personnel moved into as two divisions, the a newly erected office foundry division and building in Aurora, the machinery division. IN. The company The foundry continued to produce designed a larger, castings for manufacturers of machine heavier second- tools, valves, pumps, presses, motors, ary impactor, and in blowers and tool and die equipment. The 1994, shipped its first machinery division’s product line expanded to “Mega Slam” primary impactor to Ohio include crushing, pulverizing, disintegrating, mixing Ready Mix, Forrest, Ohio. and screening equipment for the fertilizer, chemical, meat packing, crushed stone, sand and gravel and glass industries. Early company history indicated the company’s focus The company was conveniently located for the delivery of on the future. This approach has continued throughout the goods to the boat landings and the railroad. years. In 1996, the company began focusing on marketing new products. Stedman crushers are well established in the In 1949, the company was acquired by United aggregate industry and many different industrial applica- Engineering and Foundry Company, Pittsburg, tions. The company is very confident that ongoing product Pennsylvania. The parent company merged with Wean development will result in new and improved machines, Industries in 1968, and Stedman became a Wean United further increasing customer value. Evidence of this is the company. In 1966, a major expansion of the machine July, 2009 granting of a US Patent for a new rotor design for shop was completed. At that time, the company employed Stedman’s VSlam vertical shaft impact crusher. Stedman’s 220 persons. New designs were added, and in 1972, the line of crushers is marketed worldwide. Many of the earliest company shipped the first of its newly designed flared F crushers manufactured by the company are still in operation. Series™ cage mill to Webster Brick, Roanoke, Virginia. The foundry division continued to operate, and in 1970 Stedman Brick Industry installed equipment for cupola emission control. Milestones In 1978, a new test lab was constructed. The company st continued to design new equipment and improve the current 1886 – 1 ever cage mill shipped to Oakland product line. In spite of the growth of the machinery divi- Pressed Brick, Zanesville, Ohio sion, the foundry division would have to undergo substantial 1890 – The first cage mill shipped overseas to further expenditures to bring it into conformance with EPA, OSHA and other agency regulations. No longer economi- Kennedy Brick Machinery, Liverpool, England cally feasible to continue, foundry operations were termi- 1972 – 1st ever Flared Series cage mill is shipped to nated on June 30, 1980. Webster Brick, Roanoke, Virginia The machinery division now represented the company’s 1994 – Grand Slam with heaters and air cannons total activity, and the company name was changed to introduced to the market Stedman Machine Company. New additions to the crusher line were added. In 1980, the first “G” series multi cage 2003 – 1st ever H Series Cage mill with heaters mills were shipped to ADM, Decatur, Illinois. In 1983, the and air cannons shipped to Brampton Brick, first “Grand Slam” secondary impactor was shipped to Ohio Brampton, Ontario Asphaltic, Hillsboro, Ohio. 2007 – 1st Mega Slam shipped to Australian brick plant via J C Steele Australia

October 2009 • BRICKYARD • 15 output is cut by 50% or more. Today, the Grand Slam is the lead- ing crusher in North American brick plant grinding rooms.

As crusher sales to the brick industry grew in the late1990’s, Stedman recognized a customer need for installation and start up service. In 2002, Stedman formed an affiliate company, Innovative Processing Solutions, to help Stedman Test Lab Stedman customers properly install their crushers. Innovative Stedman maintains a test facility utilizing full-size Processing Solutions addresses each brick plant’s unique crushing equipment. Every year, over one-hundred different material and requirements to successfully design, install customers test bulk samples of their material. ASTM tests and commission a retrofit crusher through complete, turn- methods combined with Stedman experience result in reli- key grinding rooms. Project elements typically include able scale up in the field. Customers are welcome to witness crushing, screening, apron and testing of their product before purchasing Stedman equip- belt feeders, conveyors, dust ment. Visitors to Stedman not only see their material tested, control, and material storage. but also have a chance to meet and talk with the dedicated Innovative continues to deliver employees throughout the company. customer value through solid engineering, quality manufac- Community service is a strong element of Stedman’s turing and best-practice, techni- corporate personality. Stedman employees, retirees and their cal leadership. families support community events such as Indiana’s oldest street festival, the Aurora’s Farmer’s Fair. Charitable con- Customer satisfaction is the reason for Stedman’s 175 tributions of time and money go to the annual United Fund/ years of success. Stedman employees appreciate their United Way, Relay for Life, 4-H programs and the Boy responsibility to make great products and offer great service Scouts of America. for stronger, more profitable customers. Stedman is proud to be a partner in the brick industry. n Industry service and partnership are also a part of Stedman’s corporate fabric. Stedman belongs to no less than 12 state and national industry associations. Stedman is proud of active membership in the brick industry associations: The National Brick Research Center, Brick Industry Association and the Western States Clay Products Recent Stedman & Innovative Association. Stedman’s partnership approach supports healthy manufacturing industries. Processing Solutions Projects

In the 1990’s a brick industry partner challenged • Glen-Gery Brick: Primary Crushing System York, PA Stedman to use our engineering know-how and test plant • Watsontown Brick: Turnkey Complete Grinding Room, to develop a better crusher for clay, shale and grog (scrap Watsontown, PA brick.) The resulting modifications to Stedman’s Grand Slam led to an innovation that has revolutionized grinding • Interpace Brick: Turnkey Complete Grinding Room, rooms. The installation of Stedman crushers in brick plants Ogden, UT has resulted in significant savings and unexpected improvements in finished product quality. The key to the Grand • US Tile: Crushing and Screening Equipment, Ione, CA Slam’s success is simple economics. One Grand Slam typically replaces two or three old-style crushers. The Grand • Interstate Brick: Primary Crushing System, West Slam’s features help keep acceptable production levels on Jordan, UT wet and sticky materials when other grinding machines’

16 • BRICKYARD • October 2009 Analysis of Mortars

John Sanders

hen dealing with customer complaints, it 1329. The procedures described here assume that the mortar is sometimes necessary to determine if the spec- is a PLC type mortar. Even if the mortar to be examined is Wified type of mortar was used in the job. There masonry or mortar cement, useful information can still be are four types of mortar defined in ASTM C 270 “Standard obtained with this method. Specification for Mortar for Unit Masonry”. The specification for each of the mortar types is summarized in Table 1. To fully understand the composition of a mortar sample, The data in Table 1 assumes that the mortar is a ”PLC” mor- several analytical techniques are required. A summary of tar which means that it is formulated from Portland Cement, these methods used to analyze a mortar is given in Table 2. Lime and Sand. This is the traditional way that mortars were Mortars can be very complicated for several reasons. prepared. Type M mortar has the most Portland cement and Firstly, the composition of the Portland cement changes the least sand while Type O has the most sand and the least as it hydrates. The extent of hydration can vary depending cement. Each type has its advantages and disadvantages. For on the curing conditions of the cement which will affect example, Type M has the highest strength, but it also has the final chemistry of the mortar. Similarly, the hydrated the most shrinkage. On the other hand, Type O has the low- lime converts to calcium carbonate over time as the mortar est strength and the least shrinkage. Type N is used for most is exposed to the atmosphere. The degree of conversion general construction, but Type S is sometimes specified depends on the age of the mortar. Finally, the composi- where higher strength is required. tion of the aggregate can also complicate the analysis. For example, if a relatively pure sand was used to formulate the The mortar proportions in Table 1 are reported on mortar, the determination of the aggregate portion of the a volumetric basis. Mortars batches are usually prepared mortar is fairly straightforward, but if limestone, granite or by combining a certain number of shovels of sand to bags mica, to name a few, were part of the aggregate, the analysis of the cementitious materials. Because mortars are batched becomes much more complicated. by volume and not weight, it is easy to make mistakes, and the actual composition of the mortar can vary significantly. Table 2. Analysis Methods The procedures described in ASTM C 1324 “Standard Test Method for Examination and Analysis of Hardened Masonry Analysis Analytical Technique Description Mortar” offer a series of procedures that can be used to esti- Step Used mate the original batch proportions of the mortar. Identify the Crystalline Petrographic (Microscopic) 1 Components in the Evaluation or X-ray Diffraction Table 1. Mortar Proportions by Volume Mortar Determine the Mortar Portland Hydrated 2 X-ray Fluorescence Masonry Sand Chemistry of the Mortar Type Cement Lime Measure the Amount of M 1 ¼ Calcium Carbonate and Thermal Analysis (TG, DSC, 3 Magnesium Carbonate Evolved Gas Analysis) S 1 ¼ to ½ 2¼ to 3 times the sum in the Mortar of the cementitious Determine the Insoluble N 1 ½ to 1¼ 3 Acid Wash materials Residue (Sand Content)

O 1 1¼ to 2½ Measure Chemistry of 4 X-ray Fluorescence the Insoluble Residue Currently, mortar or masonry cements can be purchased which already have the cementitious materials The first step in analyzing the mortar is to determine pre-packaged. The cementitious materials are the materi- what minerals are present. This can be done with petro- als that hydrate and give strength as the mortar cures. In graphic analysis which uses a microscope to visually iden- masonry and mortar cements, these cementitious materials tify the minerals present in the mortar. This can also be done may include other materials in addition to or as a replace- with X-ray diffraction. An example of the analysis of a mor- ment for Portland cement and lime. The qualifications for tar with X-ray diffraction is shown in Figure 1. The miner- the materials used to formulate masonry cement are speci- als that are present in mortar were identified with a simple fied in ASTM C 91 while the qualifications for the materials search match analysis. In this analysis, quartz was the most used to formulate mortar cement are specified in ASTM C prevalent mineral. Calcite (calcium carbonate), dolomite,

October 2009 • BRICKYARD • 17 Figure 1. Typical X-ray Diffraction Analysis of Mortar clay and a feldspar mineral were also identified. The calcite After determining which minerals are present, the next and dolomite probably came from the lime used to batch the step in the analysis is to simply determine the chemistry of mortar while the quartz, clay and feldspar were part of the the mortar by X-ray fluorescence. The use of this informa- sand. The cement phases typically do not show up in XRD tion will be described in a following section. After deter- because for several reasons: they are present in small con- mining the chemistry, a sample of the mortar is analyzed centrations, they are very small crystals (cryptocrystalline), with thermal analysis. This step reveals the amount of or they are amorphous (not crystalline). Other analysis gypsum in the mortar, the dehydration of the hydraulic or techniques are, therefore, required. cementitious components and the decomposition of the

Figure 2. Typical Thermal Analysis of Mortar

18 • BRICKYARD • October 2009 carbonates. The amount of weight lost for each step can be cement, lime and sand which are given in ASTM C 1324. used to estimate the quantity of each of these components. The volumetric ratios can then be used to estimate the mor- An example of the thermal analysis of a mortar is shown in tar type using Table 1 in ASTM C 270. The mortar example Figure 2. was found to be a 1:1:3 cement/lime/sand mixture.

To complete the mortar analysis, it is necessary to break down the mortar into its various constituents following the Table 3. Calculated Mortar Proportions procedure in ASTM C 1324 (paragraph 8.3.2). To do this, it is first necessary to separate the sand or aggregate from Calculated Values Mortar Example the cementitious materials. This is done with an acid wash which dissolves the cementitious materials, but does not Portland Cement, % 24.60 affect the sand. The material that is not dissolved by this Hydrated Lime, % 11.00 procedure is the “insoluble residue” or the sand content Sand, % 62.81 shown in Table 1. An example of the insoluble residue after acid washing is shown in Figure 3. Volumetric Ratios Portland Cement 1.00 Lime 1.05 Sand 3.00 ASTM C270 Type N Sanding Normal

Using the techniques described in this article, it is possible to estimate the type of mortar used on a job. The description of the method given in this article is a very simple one in comparison to standard petrographic techniques, which use analyses similar to those, reported above to augment microscopic identification of minerals and may employ laborious methods to quantity mineral content. n

Figure 3. Insoluble Residue Determination

After the sand content is determined by the insoluble residue, the chemistry of the sand is measured by X-ray fluorescence. The difference in chemistry between the sand and the bulk mortar can be used to determine how much Portland cement was present in the mortar. The quantity of remaining silica after the contribution of the sand has been subtracted from the bulk chemistry is used to determine the Portland cement content according to the following equation:

Portland Cement Content = ((Silica content of the bulk sample) – ((Silica content of the insoluble residue)*(insoluble residue fraction)))/0.21

According to ASTM C 1324, Portland cement contains 21% silica, so the factor 0.21 is used in the equation above.

Once the amount of Portland cement has been determined, the quantity of lime can be determined by difference. This estimation of the lime content can be verified with the thermal analysis data described previously. The final result of this analysis is shown in Table 3 for an example mortar. The weight fractions reported in Table 3 can be converted to a volumetric basis using standard density values for Portland

October 2009 • BRICKYARD • 19 When C Exceeds B In C Over B

Stick It or Ticket

Denis Brosnan

ampus life without parking regulations and enforcement would Cbe chaos. We offer our admiration to those brave souls who have to deal with enforcement by daily threading their way though students endlessly chatting on their cell phones or texting – oblivious to the world around them. Then, there are those that work in the parking office daily meeting with argumentative violators. It is an “airline counter” type of job where a person receives little thanks. All of these people have my admiration.

Having said that, it can be a daunting task to be an employee and have to buy a parking sticker. You have the choices of payroll deduction, online purchase, and actually coming to the parking office – choices in decreasing order of convenience. It just goes against my grain to charge an employee to park, but that’s the way it is. I don’t mind charging students, as they are fundamentally the reason for the regulated system. What if I just call AMEX and have them refuse the charge. Oh, you can’t do that – as it will mess up our system. Here’s the deal for employees. There are graduated rates Am I the only one who sees the convenience of an on-line based on your income ranging from $35 to $150 a year. Not system messed up with bureaucratic procedures? If the com- true for students – they all pay $134. The graduated scale puter can recognize my salary, why can’t it recognize an off- with employees seems suspiciously a result of pure liberal campus office address? faculty thought processes – ironic in that the senior faculty members pay the maximum rate. Thus, some senior employ- When I received the permit recently, I dutifully drove ees pay more than students. Those with offices off-campus over to the parking office. I had to put money in the park- pay $35, with the thinking apparently that they are only ing meter – OK, it was only 25¢. After standing in line and infrequently needing to park on campus. For your fee, you meeting with several people, I was able to have the mess get to stick a permit on your windshield. straightened out. I should receive my refund within 60 days! That means my excess payment has been tied up as much as This year I chose to buy my permit on-line. The fee for 150 days. popped up as $150. I just entered my AMEX number thinking the permit would arrive in the mail, and I was done It was clearly my fault since I did not sign up for payroll with it. It seemed odd that the fee for me was so high, since deduction thereby automating the entire process. Let’s see- I have an off-campus office – but ALL FEES SEEM TO $35 over nine months or $3.88 a month. What would it have HAVE GONE UP THIS YEAR. Over the next two days, cost to set up that deduction? I’ll bet more than thirty-five I steamed about this and called the parking office. Oh, they bucks. said, you qualify for the off-campus rate but can’t get it online. WHAT? Further, we can’t refund the money and do this Excuse me, I have to apply my permit to my windshield— over. You have to wait to receive the permit and bring it in stick it or ticket. n for a refund.

20 • BRICKYARD • October 2009 YARD TALK

(expert) was Matt Blashaw. They filmed air cannon test- Jim Frederic ing (shooting 2 x 4’s at walls) with Civil Engineering and all sorts of ASTM testing with us – the louder and more violent the better! Some of you who make very low absorp- ere it is almost October, and I know that tion, high compressive strength brick may see your prod- all of you have been sitting around anxiously ucts (unidentified, of course) on TV. We filmed each test Hwaiting on the latest update on the “snake” story MANY times and from every angle. I was the “local host” I started in June. In case you have forgotten, it all started (resident expert, as we TV guys call it), but many of the lab when my wife saw this 18” monster garden snake in our guys were also included so you will be able to see some of front flower bed. I was told to either capture it or else to call them on TV. If you are coming to the Forum, we will be the movers! Please notice that hurting the poor snake was glad to provide autographs as time allows. not an option. Well, it seemed that whenever I was around, the snake was hiding. It only came out when I wasn’t there. The Center has also recently been involved in some It almost got to be a game for everybody to look out the other high profile testing that you may see reported in the front window at the snake and to see what it was doing near future. Denis has spent a lot of time with the National today. It even got to the point that my grandson would run Park Service and has been able to put together a project straight to the window when he came over to see if (get about testing the brick at Fort Sumter in Charleston. Testing this!) “SLINKY” was there. Yes, they even gave it a name. at other national historic sites could follow. The purpose of Now, it was becoming almost a pet. the project is to analyze the brick and mortar at the fort and to access their condition as far as any deterioration and res- Well, all went okay until that disastrous day on July toration might be concerned. While providing some income 23rd (I even remember the exact day). My wife had for the Center, the testing is providing some valuable infor- a meeting with a group of ladies at our house. And, as luck mation for the Park Service. For you history buffs, I’m sure would have it, “SLINKY” decided to put in an appearance there will be some future magazine articles about the work just as all the ladies were leaving. He slithered across the and the background of the materials used to build the fort. sidewalk just as they were coming down the front steps. It Or, I guess we could ask “Mr. Richard” – I think he may wasn’t a pretty sight – women, pocket books, and makeup have been around when it was built! (my wife sells Mary Kay) going in all directions. I was IMMEDIATELY issued orders that “SLINKY” had to go, Now, if any of you happen to be hungry, I have a recipe this time, one way or the other. I put on my pith helmet for you. This comes from Teresa Smith in our office, and (for you young guys and gals - jungle hat, sun helmet, I bet you haven’t heard about it before. It’s called “soppin’ safari helmet, etc.) and found a pitch fork and a large plas- chocolate” (spelling?). It’s made like regular gravy except tic trash can. The hunt was on! It took about an hour, but it has chocolate and some other sweeteners in it. She says I was finally able to corner “SLINKY” up and get him in that you put it on bread or biscuits, or you can dip in it. the trash can. At this point, everybody that was around had Remember, now, that Teresa hails from Seneca, SC which to come out, look, and pose for pictures. The snake was is north of here in the foothills of the mountains. They have almost a celebrity. I finally got away and took the trash a lot of “recipes” there (most are liquids!), but I haven’t run can across the street to an empty lot and proceeded to let across “soppin’ chocolate” before. Let us know if you have, “SLINKY” go. As he slithered away, he took one last strike or if you are brave enough to try it! at me just to let me know he wasn’t too happy with the whole affair. As he did, I noticed a couple of things. First, I want to end up with a quick note on one of our “brick he was now a lot BIGGER than when this snake watching family” in Texas. I talked with Keith Alves from the got started. And, second, he really looked a lot more like Hanson Plant in Elgin, TX this week. He told me that he a copperhead than a garden snake. You don’t suppose he had just received a serious diagnosis for a condition that he could have actually been….. ? Don’t even mention this to has. Keith has not been in the brick industry that long, but my wife - the idea of moving might come back up (Because he came to our Short Course a few years ago and has stayed those things have babies! Right?). in touch about testing ever since. Please keep Keith and his family in your prayers as they make some decisions about The Brick Center will hopefully get some national TV possible treatments. If you know him, please get in touch exposure in either September or October (exact date not and let him know that we are all supporting him. known at this time). We recently had a visit from the DIY network. They spent a day with us and the Clemson Civil Thanks for reading YARD TALK (since you have Engineering Department at their wind tunnel facility. The made it this far). There won’t be too many left (do I hear network was interested in filming the testing of brick and applause?) with retirement looming in the near future. Hope wall sections as part of their deconstruction series. The host to see you all at the Forum! n

October 2009 • BRICKYARD • 21 1889 2009

Our founder, James Columbus Steele, built J.C. Steele & Sons on honesty and integrity, while striving to meet the customer’s equipment needs. Today, we’re still devoted to building upon what he created. PASSION FOR Committed to personalized service and technical support RELIABLE Committed to providing equipment made for a CUSTOMER provided by dedicated, capable people with 24/7 emer- AND RUGGED lifetime. We provide long-lasting value to our cus- SERVICE gency assistance. These cornerstones of our company EQUIPMENT tomers by manufacturing dependable equipment, are supported by detailed customer records since 1889. backed by complete and prompt parts support. Our goal is to be a partner to our customers. We will always strive to meet their needs and those of the Brick Industry.

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22 • BRICKYARD • October 2009 AE Quality USA neu 07.09.2009 9:13 Uhr Seite 1

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October 2009 • BRICKYARD • 23 24 • BRICKYARD • October 2009 Green products are greener with sustainable packaging solutions

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October 2009 • BRICKYARD • 25 26 • BRICKYARD • October 2009 08-MC-0410.SnglRllCrshr:08-MC-0410.SnglRllCrshr 8/21/08 11:24 AM Page 1

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28 • BRICKYARD • October 2009 October 2009 • BRICKYARD • 29 Energy Saving Systems for the Ceramic Industry Burton is your No. 1 partner worldwide for complete tunnel kiln systems. Our kiln car designs offer a solution for an optimized firing product Boral Bricks, Union City, USA (Harrop kiln): and simultaneously for an efficient firing process. a total saving in energy consumption of 9.5 % thanks to our BurcoLight material Modern energy computing programs show the remarkable energy savings with BurcoLight. Visit us at CERAMITEC 2009 Hall B5 – Stand 317/416

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30 • BRICKYARD • October 2009 October 2009 • BRICKYARD • 31 October 3–5 The 2010 Clemson Brick Forum