5 Jul 85 FOREWORD This Handbook is issued under the authority of DoD Directive 4160.21, "DoD Personal Property Utilization and Disposal Program," 5 December 1980. Its purpose is to outline practical, cost-effective methods for the recovery and recycling of scrap by providing technical guidance on scrap identification and segregation, scrap yard operations, and merchandising of scrap. DSAH 4160.1, TM 755-200, NAVSUP PUB 5523, AFM 68-3, MCO P4010.2A, "Defense Scrap Yard Handbook," June 1966, is hereby canceled. The provisions of the Handbook apply to the Office of the Secretary of Defense (OSD), the Military Departments, the Organization of the Joint Chiefs of Staff, the Unified and Specified Commands, the Defense Agencies, and activities administratively supported by OSD (hereby called "DoD Components"). The Handbook is effective immediately and is mandatory for use by all DoD Components. Heads of DoD Components may issue supplementary instructions only when necessary to provide for unique requirements within their respective components. Send recommended changes to this Hanbook through DoD Component channels to: Director Defense Logistics Agency ATTN: DLA-SMP Cameron Station Alexandria, VA 22304-6100 DoD Components may obtain copies of this Handbook through their pulbications channels. Other Federal Agencies may obtain copies from HQ Defense Logistics Agency, ATTN: DLA-SPD, Cameron Station, Alexandria, VA 22304-6100. -signed- James P. Wade, Jr. Assistant Secretary of Defense (Acquisition and Logistics) ACKNOWLEDGEMENT Acknowledgment is made to the following sources of information used in compiling this handbook: Institute of Scrap Iron and Steel, Inc., Handbook, published by the Institute of Scrap Iron and Steel, Inc., 1627 K Street, N.W., Washington, DC 20006 Metal Statistics, 1980 edition, published by Fairchild Publications, a division of Capital Cities Media, Inc., 7 East 12th Street, New York, NY 10003 Metallic Materials Specifications Handbook, third edition, by Robert B. Ross, published by E. & F. N. Spon Ltd. in association with Methuen, Inc., 733 Third Avenue, New York, NY 10017 Mines Above Ground, published by the Institute of Scrap Iron and Steel, Inc., 1627 K. Street, N.W., Washington, DC 20006 Recycling In Your Community, published by the National Association of Recycling Industries, Inc., 330 Madison Avenue, New York, NY 10017 Recycling Resources: Priorities for the 1980's, published by the National Association of Recycling Industries, Inc., 330 Madison Avenue, New York, NY 10017 Recycled Metals Indentification and Testing Handbook, published by the National Association of Recycling Industries, Inc., 330 Madison Avenue, New York, NY 1001 Standard Classification for Nonferrous Scrap Metals, Circular NF-82, published by the National Association of Recycling Industries, Inc., 330 Madison Avenue, New York, NY 10017 Paper Stock Standards and Practices, Circular PS-83, published by the National Association of Recycling Industries, Inc., 330 Madison Avenue, New York, NY 10017 Concise Guide to Plastics, Second edition, published by Reinhald Publishing Corp., 430 Park Avenue, New York, NY 10022 Health and Safety Guide for Scrap Processors, DHEW Publication No. (NIOSI-1) 76-125, 4676 Columbia Parkway, Cincinnati, OH 45226 TABLE OF CONTENTS Page FOREWORD2 ACKNOWLEDGEMENT3 TABLE OF CONTENTS5 DEFINITIONS RELATING TO METALS AND METALWORKING8 DEFINITIONS RELATING TO PLASTICS35 CHAPTER 1 - INTRODUCTION51 C1.1. GENERAL51 C1.2. PURPOSE51 C1.3. OBJECTIVES51 C1.4. RESPONSIBILITIES OF DoD ACTIVITIES52 CHAPTER 2 - A SCRAP OVERVIEW57 C2.1. GENERAL57 C2.2. FERROUS SCRAP57 C2.3. NONFERROUS SCRAP60 C2.4. NONMETALLIC SCRAP60 C2.5. SCRAP RECYCLING CONSERVES NATURAL RESOURCES61 CHAPTER 3 - SCRAP YARD ORGANIZATION63 C3.1. GENERAL63 C3.2. FACILITY LAYOUT63 C3.3. EQUIPMENT70 C3.4. SUMMARY83 CHAPTER 4 - SEGREGATION AND IDENTIFICATION84 C4.1. SEGRATION AT THE SOURCE84 C4.2. IDENTIFICATION OF METALLIC SCRAP85 C4.3. SIMPLIFIED METAL TESTING AND SORTING PROCEDURES89 C4.4. PROCEDURE FOR CHART 1102 C4.5. PROCEDURE FOR CHART 2103 C4.6. PROCEDURE FOR CHART 3105 C4.7. PROCEDURE FOR CHART 4107 C4.8. PROCEDURE FOR CHARTS 5A THROUGH 5G116 C4.9. LABORATORY ANALYSIS OF METALLIC SCRAP130 TABLE OF CONTENTS, continued Page CHAPTER 5 - STANDARD SCRAP SPECIFICATIONS159 C5.1. GENERAL159 C5.2. FERROUS SCRAP159 C5.3. NONFERROUS SCRAP160 C5.4. PAPER, CARDBOARD, AND CORREGATED SCRAP173 C5.5. PLASTIC SCRAP176 C5.6. USED PETROLEUM PRODUCTS186 C5.7. USED SYNTHETIC LUBRICANTS186 C5.8. INDUSTRIAL DIAMONDS/RESIDUE186 C5.9. WOOD SCRAP187 C5.10. RECYCLABLE AGRICULTURAL PRODUCTS187 C5.11. ACCOUNTING FOR SCRAP187 CHAPTER 6 - RECOVERY OF PRECIOUS METALS217 C6.1. GENERAL217 C6.2. PROCESSING PRECIOUS METAL-BEARING MATERIALS217 C6.3. SALE VERSUS RECOVERY218 C6.4. EXAMPLES OF PRECIOUS METAL-BEARING PROPERTY218 C6.5. RECYCLING OF SCRAP REMAINING AFTER PRECIOUS METAL RECOVERY222 CHAPTER 7 - SCRAP MERCHANDISING223 C7.1. GENERAL223 C7.2. PRINCIPAL TYPES OF SCRAP SALES223 C7.3. OPTIMUM LOT SIZE224 C7.4. SALES DESCRIPTIONS225 C7.5. SCRAP MARKET RESEARCH230 CHAPTER 8 - SAFETY AND HEALTH IN THE SCRAP YARD231 C8.1. GENERAL231 C8.2. OCCUPATIONAL HEALTH, SAFETY, AND ENVIRONMENTAL CONTROL232 C8.3. PERSONAL PROTECTIVE EQUIPMENT (PPE)235 C8.4. MATERIAL HANDLING EQUIPMENT237 C8.5. MACHINERY AND MACHINE GUARDING240 C8.6. TORCH CUTTING242 C8.7. DEMILITARIZATION244 C8.8. ENVIRONMENTAL CONSIDERATIONS244 CHAPTER 9 - RESERVED245 APPENDICES AP1. PRIMARY SCRAP RECYCLING ORGANIZATIONS246 AP2. BIBLIOGRAPHY247 DL1. DEFINITIONS-METAL DL1.1. DEFINITIONS RELATING TO METALS AND METALWORKING These definitions apply to the scrap industry and to mill products in any form as supplied by the mills. Materials in process in the mills are sometimes referred to by terms other than those applied to the materials as supplies. DL1.1.1. Age Hardening. A process of increasing the hardness and strength by the precipitation of particles of a phase from a supersaturated solid-solution alloy. The hardening cycle usually consists of heating or annealing at a temperature sufficiently high to maintain solid solution, rapid cooling or quenching to retain the supersaturated solid solution, and subsequent heating at a temperature lower than the solution anneal to effect the precipitation. DL1.1.2. Alloy. A substance having metallic properties and composed of two or more elements, at least one of which is a metal. DL1.1.3. Angle. A shape consisting of two straight legs meeting in a right angle (usually, but not necessarily) of equal length and with a sharp or slightly rounded corner and with or without fillets. DL1.1.4. Annealing. A process involving heating and cooling designed to effect: DL1.1.4.1. Softening of a cold-worked structure by recrystallization or grain growth or both; DL1.1.4.2. Softening of an age-hardened alloy by causing a nearly complete precipitation of the second phase in relatively coarse form; DL1.1.4.3. Softening of certain age-hardenable alloys by dissolving the second phase and cooling rapidly enough to obtain a supersaturated solution; and DL1.1.4.4. Relief of residual stress. DL1.1.5. Anode DL1.1.5.1. In corrosion processes, usually the metal that has the greater tendency to dissolve. DL1.1.5.2. In electroplating, the positive electrode used in a plating bath. DL1.1.6. As-Hot-Rolled. A condition of a metal mill product resulting from hot rolling, soft, not cleaned nor drawn or rolled to size. DL1.1.7. As-Is-State. Represents that the quality of the lot is based on the analysis findings in the "As is" state without predetermination or accountability for the burning loss (B/L). DL1.1.8. Billet. A solid cylindrical casting used for hot extrusion into rod, bar, tube, or shape or for hot piercing into tube. DL1.1.9. Blades. Refer to the turbine rotor blades or bucket blades associated with the jet engine or the steam engine, and which is the motive part on which the gas or pressure steam impinges and transmits the power to create motion. DL1.1.10. Blanking. The process of cutting metal blanks by a die and punch set in a press, or by sawing or shearing. DL1.1.11. Blister. A void in, or raised spot on the surface of a metal, caused by expansion of entrapped gas in the metal. DL1.1.12. Brass. Any copper-base alloy with zinc as the principal alloying element, with or without small quantities of some other elements. DL1.1.13. Brasses. Copper alloys: DL1.1.13.1. Admiralty. A tin brass containing nominally 70 percent copper; 1 percent tin and 29 percent zinc, orginally developed by the British Admiralty and generally available in tube, flat products, and wire. Its principal use is in heat exchanger and condenser tubes. An inhibitor may be added to increase the resistance to dezincification. DL1.1.13.2. Admiralty, Inhibited (antimonal, arsenical or phosphorized). Admiralty modified by the addition of .02-10 percent of antimony, arsenic or phosphorus to inhibit dezincification. DL1.1.13.3. Aluminum Brass. A brass containing nominally 76 percent copper, 2 percent aluminum and 22 percent zinc with an inhibitor, available in tube form. Its principal use is in heat exchanger and condenser tubes. DL1.1.13.4. Architectural Bronze. A brass containing nominally 57 percent copper, 3 percent lead, and 40 percent zinc, generally available in extruded or drawn shapes and rod; used for architect trim and for some mechanical applications. The alloy is not technically a bronze, but because of long usage the term "Architectural Bronze" has gained widespread acceptance. DL1.1.13.5. Cartridge Brass, 70 Percent. A brass containing nominally 70 percent copper and 30 percent zinc and generally available in pin products, rod, wire and tube. DL1.1.13.6. Clock Brass. A term sometimes used to designate high-leaded brass suitable for specific uses. It is recommended that this alloy be identified by the term "high-leaded brass" properly qualified for the specific use. DL1.1.13.7. Collet Brass. A term sometimes used, but not recommended. See High-Leaded Brass and Free-Cutting Brass. DL1.1.13.8. Commercial Bronze, 90 Percent. A brass containing nominally 90 percent copper and 10 percent zinc, generally available in flat products, wire, rod and tube. The alloy is not technically a bronze, but cause of long usage the term "commercial bronze" has gained widespread acceptance. DL1.1.13.9. Core Brass. See Radiator Core Brass. DL1.1.13.10. Deep Drawing Brass. A term sometimes used, but not recommended, to denote nonleaded brasses of nominal copper content ranging from 65 to 70 percent. See Yellow Brass, or Cartridge Brass, 70 percent. DL1.1.13.11. Engraver's Brass. A term sometimes used, but not recommended. See High-Leaded Brass. DL1.1.13.12. Etching Brass. A term used to indicate quality of material rather than chemical composition. The term signifies a flat product having unusual freeedom from surface defects; very flat and usually of quarter-hard or half-hard temper. DL1.1.13.13. Extra-high-leaded Brass. A brass containing nominally 63 percent copper, 2.5 percent lead, and 34.5 percent zinc, generally available in flat rolled products, and used for engraving and other operations requiring considerable cutting. DL1.1.13.14. Eyelet Brass. A term sometimes used, but not recommended. See Cartridge Brass, 70 percent. DL1.1.13.15. Forging Brass. A brass containing nominally 59 percent copper, 2 percent lead, and 39 percent zinc, generally available in rod, bar, tube and tapes and recommended for fabrication by hot-forging and hot-pressing. It has excellent machinability, approaching that of free-cutting brass. DL1.1.13.16. Free-Cutting Brass. A brass containing nominally 61.5 percent copper, 3 percent lead and 35.5 percent zinc, generally available in rod and drawn bar and in extruded shapes. It is the most commonly used alloy for automatic screw machine work, or for other applications where material of maximum machinability is desired. DL1.1.13.17. Free-Cutting Muntz-Metal. A brass containing nominally 60 percent copper, 1 percent lead, and 39 percent zinc. Generally available as tube. It is used for automatic-screw machine-products where maximum machinability is not necessary. DL1.1.13.18. Gilding, 95 percent. A brass containing nominally 95 percent copper and 5 percent zinc. This alloy is generally available in flat products, rod and wire. DL1.1.13.19. High-Leaded Brass. A brass containing nominally 65 percent copper, 2 percent lead, and 33 percent zinc, generally available in flat products and rod. It is used where easy stamping and machining are desired, as for instance, in clock and notch backs and gears and for engraving. DL1.1.13.20. High-Leaded Brass (tube). A brass containing nominally 66 percent copper, 1.6 percent lead, and 32.4 percent zinc. It is recommended for automatic screw machine operations. DL1.1.13.21. Jewelry Bronze-87.5 percent. A brass containing nominally 87.5 percent copper and 12.5 percent zinc having a rich golden color. It is used for costume jewelry, slide fasteners and as a base for gold-filled articles. Variations may contain small amounts of tin. DL1.1.13.22. Leaded Commercial Bronze. A brass containing nominally 89 percent copper, 1.75 percent lead, and 9.25 percent zinc, generally available in rod, shapes, and bar, and used extensively for hardware. The alloy is not technically a bronze, but because of long usage the term "leaded commercial bronze" has gained widespread acceptance. Hardware bronze is a term formerly used to designate any one of a broad range of similar alloys; this term is not recommended. DL1.1.13.23. Leaded Muntz Metal. A brass containing nominally 60 percent copper, 0.6 percent lead, and 39.4 percent zinc generally used for condenser tube plates. DL1.1.13.24. Leaded Naval Brass. A brass containing nominally 60 percent copper, 0.75 percent tin, 1.75 percent lead, and 37.5 percent zinc, generally available in rod, shapes, and bar. This alloy has the equivalent strength and corrosion resistance of naval brass, plus considerably improved machinability. DL1.1.13.25. Leaded Red Brass. A brass containing nominally 85 percent copper, 2 percent lead and 13 percent zinc, generally available in rod and drawn bar. Hardware bronze is a term formerly used to designate any one of a broad range of similar alloys; this term is not recommended. DL1.1.13.26. Low Brass, 80 percent. A brass containing nominally 80 percent copper and 20 percent zinc and generally available in flat products, rod and wire. DL1.1.13.27. Low-Leaded Brass. A brass containing nominally 65 percent copper, 0.5 percent lead, and 34.5 percent zinc, and generally available in flat products. It is widely used for stamping and light drawing operations. DL1.1.13.28. Manganese Bronze. A brass containing nominally 58.5 percent copper, 1 percent tin, 1.4 percent iron, 0.1 percent manganese, and 39 percent zinc, generally available in rod, flat products shapes, and wire. This alloy is appreciably harder and stronger than naval brass and is, therefore, preferred to the latter for many structural uses. It is also an excellent brazing alloy. DL1.1.13.29. Muntz Metal. A brass containing nominally 60 percent copper and 40 percent zinc and generally available in flat products, rod, wire, and tube. DL1.1.13.30. Naval Brass. A brass containing nominally 60 percent copper, 0.75 percent tin and 39.25 percent zinc, generally available in rod, bar, wire, shapes, tube and to some extent in flat products. It is used in marine construction where a strong, hard material is required. DL1.1.13.31. Plater's Brass. A term sometimes used, but not recommended, to indicate specific alloys used as anodes for brass plating. These vary in composition from 30 to 90 percent copper, 10 to 20 percent zinc, and sometimes 1 to 2 percent tin. DL1.1.13.32. Primer Brass. A term sometimes used, but not recommended, to denote a specific alloy used for making primer caps and tubes. Primer caps are made from cartridge brass, 70 percent; commercial bronze, 90 percent; or gilding, 90 percent. Primer tubes are made from lowleaded or highleaded brass. DL1.1.13.33. Radiator Core Brass. A term used to indicate strip brass of suitable characteristics for forming radiator cores. It is sometimes used, but not recommended, to designate a specific alloy. DL1.1.13.34. Red Brass, 85 percent. A brass containing nominally 85 percent copper, 5 percent tin, 5 percent lead, and 5 percent zinc. DL1.1.13.35. Reflector Brass. A term used to indicate strip brass with suitable characteristics for forming into reflectors. It is sometimes used, but not recommended, to designate a specific alloy, usually yellow brass or cartridge brass, 70 percent, having a small grain size that will take a moderately deep draw and a very high polish. DL1.1.13.36. Yellow Brass. A brass containing nominally 65 percent copper and 35 percent zinc and generally available in flat products, wire and rod. DL1.1.13.37. 7-30 Brass. A term sometimes used, but not recommended, for cartridge brass, 70 percent copper, and 30 percent zinc. DL1.1.14. Braze Welding. A method of welding whereby a groove, fillet, plug or slot weld is made using a nonferrous metal having a melting point below that of the base metals, but above 800°F. The filler metal is not distributed in the joint by capillary attraction. (The term "bronze welding," formerly used, is a misnomer for this process.) DL1.1.15. Brazing. A joining process wherein coalescence is produced by heating to suitable temperatures above 800°F, and by using a nonferrous filler metal having a melting point below that of the base metals. The filler metal is distributed between the closely fitted surfaces of the joint by capillary attraction. See also Soldering. DL1.1.16. Bronze. Originally a term for copper-base alloys having tin as the only or principal alloying elements. In modern usage the term "bronze" is seldom used alone, and the terms "phosphor bronze" or "tin bronze" are considered preferable for indicating copper-tin alloys. In fact, the term "bronze," together with a suitable modifying adjective, has in recent years been extended to apply to any of a great variety of copper-base alloy systems, and such usage has gained widespread acceptance. The more important alloys designated as bronzes are as follows DL1.1.16.1. Aluminum Bronzes. Copper-base alloys with aluminum as the principal alloying element, normally in the range of 3 to 11 percent with or without the additions of other elements. DL1.1.16.2. Architectural Bronze. See Brasses. DL1.1.16.3. Commercial Bronze, 90 percent. See Brasses. DL1.1.16.4. Leaded Commercial Bronze. See Brasses. DL1.1.16.5. Manganese Bronze. See Brasses. DL1.1.16.6. Phosphor Bronzes. Copper-base alloys with tin as the principal alloying element deoxidized with phosphorus. Various types are available in flat products, rod, tube, wire and shapes, the most common ones containing nominally 1.25 percent to 10 percent tin. DL1.1.16.7. Silicon Bronzes. Any copper-base alloy with silicon as the main alloying element, with or without additions of such elements as zinc, manganese, aluminum, iron or nickel. The more commonly used silicon bronzes are: DL1.1.16.7.1. High-silicon bronze, nominally containing 96 percent copper and 3 percent silicon; and DL1.1.16.7.2 Low-silicon bronze, nominally containing 97.7 percent copper and 1.5 percent silicon. DL1.1.16.8. Tin Bronze. See Phosphor Bronzes. DL1.1.17. Burning Loss (B/L). Refers to the percentage of water, oil, other extraneous moisture and combustible matter which, by ignition or evaporation method, is determined as a separate part of the analysis procedure. DL1.1.18. Bus Bar and Bus Conductor. Rigid, high-conductivity copper electrical conductor of tubular or solid section. DL1.1.19. Button Analysis. The meltdown of a sample, usually in the "as is" state, and the casting of the molten metal into a button or bar-shape mold, whereby the metallic content is determined by the difference between the input and output weight. The button is then assayed for the required elements and, by calculation, the analysis may be deduced and reported either for the "as is" state or on the metallic yield basis. DL1.1.20. Casting. By trade history, "castings" are considered a distinct physical form of solids. It is accordingly described here to convey the understanding that this form of scrap does not originate from rolled, forged, or extruded source. DL1.1.21. Channel. A shape having two straight flanges or legs of equal length, extended at right angles from same side of the edges of a web or base, the legs and base having sharp or slightly rounded without fillets. DL1.1.22. Circle. A completely round, commercially flat, solid blank made from a flat rolled product. DL1.1.23. Clean. Meaning a state or condition of cleanliness; namely, free of paint, insignificant in moisture content, or deleterious external matter. DL1.1.24. Clipping. The operation of trimming or cutting off uneven edges of forgings or articles drawn or formed from sheet or strip. DL1.1.25. Cold Working. The process of changing the form or cross section of a piece of metal at a temperature below the softening or recrystallization point, but commonly at or about room temperature. It includes rolling, drawing, pressing, and stretching. DL1.1.26. Condenser Tube. See Tube, Heat Exchanger Tube. DL1.1.27. Condenser Tube Plate. Plate manufactured to special thickness tolerances and furnished in various contours as tube sheets or head plates in condensers and heat exchangers. DL1.1.28. Copper. Commercially pure copper-metal for which the specified minimum copper content is not less than 99.88 percent, silver being counted as copper. Modified copper-metal for which the specified minimum copper content is less than 99.88 percent and more than 99.3 percent, silver being counted as copper. DL1.1.29. Copper Types: DL1.1.29.1. Arsenical, Tough-pitch Copper (ATP). A modified tough-pitch copper containing substantial amounts of arsenic regardless of origin or treatment. DL1.1.29.2. Cathode Copper. A commercially pure copper electrolytically refined in cathode form. DL1.1.29.3. Coalesced Copper. A commercially pure oxygen-free copper formed in a protective atmosphere at elevated temperature, but below its melting point by application of mechanical pressure to particles of electrolytic cathode copper. DL1.1.29.4. Deoxidized Arsenical Copper (DPA). A modified deoxidized copper containing the designated element (arsenic) in amounts as agreed upon between the supplier and the consumer mainly for the purpose of increasing corrosion resistance. DL1.1.29.5. Deoxidized Copper Low Residual Phosphorus (DLP) High Conductivity. A commercially pure copper that has heen deoxidized with phosphorus in such a manner as to leave a very low residual phosphorus content. It is not readily susceptible to hydrogen embrittlement, and has a conductivity approximately equivalent to that of tough-pitch copper. DL1.1.29.6. Deoxidized Copper, Silver Bearing (DPS). A commercially pure deoxidized copper containing the designated element (silver) in amounts as agreed upon between the supplier and the consumer. DL1.1.29.7. Deoxidized Copper Tellurium Bearing (DPTE). A modified deoxidized copper containing the designated element (tellurium) in amounts as agreed upon between the supplier and the consumer to improve machinability The conductivity is somewhat lower than that of electrolytic tough-pitch copper. DL1.1.29.8. Electrolytic Tough-Pitch Copper (ETP). A commercially pure copper of any origin that has heen refined by electrolytic disposition, then melted, oxidized and brought to tough-pitch or controlled low-oxygen content, and finally cast into cakes, billets, wire bars, etc., suitable for hot or cold working, or both. DL1.1.29.9. Fire-Refined Copper (FRHC and FRTP). A commercially pure copper of any origin or type that is finished by furnace refining without, at any stage, having been electrolytically refined. DL1.1.29.10. Lake Copper. A commercially pure copper from the Lake Superior district, generally fire refined and containing variable, but controlled, amounts of silver and arsenic. Such copper of low-arsenic content is called Prime Lake Copper, while that of higher arsenic content is called Arsenical Lake Copper -- also low, medium and high Arsenical Lake Copper. Also see Arsenical Copper and Silver-Bearing Copper. DL1.1.29.11. Oxygen-Free Copper (OF). A commercially pure copper that has heen produced in such a manner as to contain no oxide or residual deoxidants. It has very high resistance to hydrogen embrittlment and has equal or better conductivity than tough-pitch copper. DL1.1.29.12. Oxygen-Free Silver-Bearing Copper (OF). A commercially pure high-conductivity copper containing the designated element (silver) in amounts as agreed upon between the supplier and the consumer for the purpose of raising the softening temperature. DL1.1.29.13. Phoshorus Deoxidized Copper, High-Residual Phosphorus (DHP) (Low Conductivity). A commercially pure copper that has heen deoxidized with phosphorus, leaving a relatively high-residual phosphorus content. It is not susceptible to hydrgen embrittlement, but is of relatively low conductivity due to the amount of phosphorus present. DL1.1.29.14. Silver-Bearing (Argentiferous) Copper. Any copper containing substantial amounts of silver, regardless of origin or treatment. DL1.1.29.15. Silver-Bearing Arsenical Tough-Pitch Copper (SATP). A modified tough-pitch copper containing the designated elements (silver and arsenic) in amounts as agreed upon between the supplier and consumer mainly for the purpose of increasing corrosion resistance and raising the softening temperature. DL1.1.29.16. Silver-Bearing Tough-Pitch Copper (STP). A commercially pure high-conductivity tough-pitch copper containing the designated element (silver) in amounts agreed upon between the supplier and the consumer for the purpose of raising the softening temperature. DL1.1.29.17. Tough-Pitch Copper. Commercially pure or modified copper, either electrolytically or fire refined, containing a controlled amount of oxygen for the purpose of obtaining a level set in the casting. DL1.1.30. Copper Anode. See Anode. DL1.1.31. Copper-Base Alloy. Metal for which the specified minimum copper content is less than 99.3 percent and not less than 40 percent and having no other element specified in excess of the copper content. DL1.1.32. Copper-Beryllium Alloy. A heat-treatable copper alloy containing 1.50 - 2.25 percent beryllium and sometimes small amounts of cobalt, nickel and chromium. It is capable of being formed readily when in the soft condition and heat treated to hardnesses approaching those of steel. DL1.1.33. Corrosion. The deterioration or failure of metals and alloys by chemical or electrochemical processes. DL1.1.33.1. Cavitation. The damage caused to a material by moving liquid and associated with the formation and collapse of cavities in the liquid at the solid-liquid interface. DL1.1.33.2. Dealuminification. A phenomenon somewhat similar to dezincification involving loss of aluminum. DL1.1.33.3. Denickelification. A common phenomenon somewhat similar to dezincification involving loss of nickel. DL1.1.33.4. Dezincification. Corrosion of an alloy containing zinc (usually brass) involving loss of zinc. DL1.1.33.5. Erosion. The abrasion of metal or other material by liquid or gas, usually accelerated by presence of solid particles of matter in suspension, and sometimes by corrosion. DL1.1.33.6. Impingement Attack. A type of localized corrosion caused by the striking of a liquid containing entrained gasses on a metal surface. DL1.1.33.7. Stress Corrosion. Spontaneous failure of metals by cracking under combined action of corrosion and stress, residual or applied. DL1.1.34. Corrosion Fatigue. The deterioration of properties resulting from repeated stressing of a metal in a corrosive medium. The rate of deterioration is greater than that resulting from either repeated stressing or corrosion alone. DL1.1.35. Cupro-Nickel (Copper Nickel). A copper-base alloy composed of copper and nickel with nickel content usually being 10, 20, or 30 percent and with small additions of elements such as iron and manganese. DL1.1.36. Deoxidized. A term applied to any metal or alloy to indicate that it has been treated to remove oxygen. It is specifically applied to copper and refers to removal of oxygen by means of phosphorus or other strong deoxidizing agents. DL1.1.37. Diced Turning. Synonymous to "short shoveling," describes the treatment of machine shop turnings reduced through the attrition of a hammer or cog mill to a state of under 2 inches in length. DL1.1.38. Drawing DL1.1.38.1. The process of pulling flat products, rod, wire, tube, shapes, etc., through a die. This effects a reduction in size or change in shape of the cross section and hardens the metal. DL1.1.38.2. The process of making articles in a press from blanks cut from flat products in which the gage is reduced by pushing the metal between a punch and die to develop the sidewalls of the part. DL1.1.39. Dryweight. Represents the payable weight of the material content as determined by analysis and after allowance or deduction of the B/L. DL1.1.40. Ductility. The property of a metal that permits permanent deformation before fracture by stress in tension. DL1.1.41. Extruded Bar, Extruded Rod, Extruted Shape, Extruded Tube, Extruded Wire. Stock brought to final dimensions by extrusion. DL1.1.42. Extrusion, Hot. The process of shaping metal into a chosen continuous form by forcing it from a closed container through a die of appropriate shape. DL1.1.43. Extrisopm Pipe. A defect that occurs during extrusion and is located internally at the back end of the extruded piece. This defect is removed by cropping off the back end. DL1.1.44. Eyelet-Brass. See Brasses. DL1.1.45. Fatigue. The tendency for a metal to break under conditions of repeated cyclic stressing considerably below the ultimate tensile strength. DL1.1.46. Ferrule. Metal ring or collar used in installation of boiler flues, condenser tubes and similar applications. DL1.1.47. Filler Metal. A metal or alloy that is melted down in a welding or brazing operation to supply metal for the joint. DL1.1.48. Finish. The condition of the surfaces of the products, produced by normal or special mill procedures. Several types of finishes can be produced as follows: DL1.1.48.1. Acid Dipped Dry Rolled Finish. The finish obtained by cold dry rolling on polished rolls of material, previously bichromate dipped or bright dipped, giving a burnished appearance and retaining the color obtained by dipping. DL1.1.48.2. Bright Annealed Finish. The finish obtained by annealing under conditions of controlled atmosphere to prevent oxidation and to retain the original luster of the product. See also Annealing. DL1.1.48.3. Bright-Dipped Finnish. A bright finish having the true color of the metal obtained by immersion in an aqueous solution of sulfuric acid and nitric acid, using the following formula: Sulfuric acid, 2 gallons; nitric acid, 1 gallon; water, 1 to 2 quarts; hydrochloric acid, 1/2 fluid ounce. DL1.1.48.4. Bright Rolled Finish. See Dry Rolled Finish. DL1.1.48.5. Brush Brass Finish. A frosted finish obtained on brass by brushing with a Tampico (Bristol brush) wheel treated with brush rouge and rotating at high speed. DL1.1.48.6. Buffed Surface Finish. The finish obtained by buffing with rouge or similar abrasive, resulting in a high gloss or polish. This may be applied in one operation or two, commonly known as cutting and coloring operations. DL1.1.48.7. Clean Annealed Finish. A finish characterized by a light iridescent film generally obtained on copper-base alloys that have been annealed in a controlled atmosphere. DL1.1.48.8. Cold Rolled Finish. The finish obtained by cold rolling of plain pickled strip with a lubricant; causing a relatively smooth appearance. In the case of sheet or strip, cold rolling may be done without any lubricant, the finish then being similar to that described under Dry Rolled Finish. DL1.1.48.9. Drawn Finish. The finish obtained on tube, wire, and drawn rod, bar and strip by drawing through a die resulting in a relatively smooth and bright appearance. DL1.1.48.10. Dry Rolled Finish (Bright Rolled Finish) DL1.1.48.10.1. The finish obtained by cold rolling on polished rolls without the use of any coolant or metal lubricant on material previously plain pickled, bichromate or bright dipped; DL1.1.48.10.2. The finish obtained by the rolling or tumbling of brass articles in a barrel with either dry sawdust, leather or scrap cork. DL1.1.48.11. Extruded Finish. The finish obtained on tube, wire, and rod, bar and strip by hot extrusion through a die, resulting in a slightly oxidized and dull appearance. DL1.1.48.12. Hot Rolled Finish. The finish obtained by rolling metal while hot resulting in a dark oxidized and relatively rough surface. DL1.1.49. Flat Product. A product with rectangular or square solid section and relatively great length in proportion to thickness. DL1.1.49.1. Drawn Flat Product. Flat product brought to final dimensions by drawing through a die, and burnished in flat straight lengths, on spools, or in rolls. The corners or edges may be square or of other contours. DL1.1.49.2. Rolled Flat Product. Flat product brought to final thickness by rolling, and furnished in flat straight lengths, on spools, or in rolls. Longitudinal edges may be those resulting from final rolling to thickness or the product may he brought to final width by shearing, slitting, sawing, machining or rolling. The corners or edges may be square or of other contours. DL1.1.50. Flattening. The mill operation performed on rolled flat products to reduce departure from flatness, such as curl and dish. DL1.1.51. Flux DL1.1.51.1. In melting, a substance added to the melt to promote removal of foreign materials, and protect the surface. DL1.1.51.2. In brazing or welding, a substance introduced to remove oxide and impurities. DL1.1.52. Foil. A term often applied to a thin flat rolled section usually .005 inch or less in thickness. DL1.1.53. Foundry Spills, Splatters and Skulls. Refers to the characterstic foundry salvage resulting from the surface oxidation of the melting operation that is skimmed off. It may result from the spilling of metal in the casting operation, the metal skullings that cling to the walls of the pouring ladle or furnace walls, the runoff of the accumulated furnace bottoms, or it may consist of such metal of porous oxidized condition unsuited for further foundry reuse. Usually foundry skulls, spills, and spatters may range from a high of 95 percent metallic content and dependent on the cleanliness or freedom of adhesive scale, oxide, dirt, and brick matter termed "silicous matter," may dip to a low of 50 percent of metallic content. Accordingly, it is vital that the metallic yield should be noted for any parcel of this nature. DL1.1.54. Fourdriner Wire. Wire used in making the Fourdrinier screens used in the manufacture of paper. DL1.1.55. Free Machining. The quality of an alloy that enables it to be cut in automatic machines at relatively high speeds, yielding a short brittle chip. DL1.1.56. Gage DL1.1.56.1. Term sometimes used to designate thickness of flat products, wall thickness of tube or diameter of wire. DL1.1.56.2. The instrument used to measure thickness or diameter. DL1.1.57. Gage Number. A number in a specific series used to designate a dimension. There are several series of such gage numbers, of which the most familiar are the American Wire Gage or Brown & Sharpe and Birmingham or Stubs. DL1.1.58. Gassing DL1.1.58.1. A phenomemon in metal caused by absorption of gas while molten and partial evolution as the metal cools, resulting in voids. DL1.1.58.2. A condition in oxygen-bearing copper which has been heated to elevated temperatures in a highly reducing atmosphere. DL1.1.59. Grain. A solid polyhedral (or many-sided) crystal consisting of groups of atoms bound together in a regular geometric pattern. In mill practice, grains are usually studied only as they appear in one plane. DL1.1.60. Grindings. The occurrence of grindings derived from the processing termed "metal dressing." The friction of a high-speed grinding wheel results in a conglomerate Byproduct consisting of somewhat oxidized metal particles and grinding wheel matter. The particles usually are under cinch in screen size and tend to curl and intertwine to form a condition termed "dumpiness." The term "free flowing condition" merely signifies that the grindings can be worked by hand shoveling or pitchfork. The term "frozen condition" implies that the grindings have been exposed to water inclusion and have become congealed or surface crusted. Such condition does not bear on the quality of the material and, in effect, indicates that the grindings may require hammer mill treatment to reduce to free shoveling state. DL1.1.61. Half Hard Temper. See Temper. DL1.1.62. Hammer Forging. A forging process in which the piece is deformed by repeated blows. DL1.1.63. Hand Straightening. See Straightening. DL1.1.64. Hard Temper. See Temper. DL1.1.65. Hardness. The resistance of metal to plastic deformation by indentation. The most common method of measurement is Rockwell. Other methods are Brinell, Scleroscope, Tukon, and Vickers. DL1.1.66. Hardness Number. The number used to designate the hardness of metal. The number is related to the scale of values of a particular hardness test, as Rockwell B 80 or Brinell 150. DL1.1.67. Heat Treatment. A combination of heating and cooling operations applied to a metal or alloy in the solid state to produce changes in physical and mechanical properties. See also Age Hardening and Annealing. DL1.1.68. Ingot Maker. A nonferrous manufacturer who heats secondary material (scrap) in a furnace, melting into ingots of a prescribed specification. DL1.1.69. Inhibitors. Elements added in small amounts to alloys to increase the resistance of the alloys to corrosion. DL1.1.70. Lake Copper. See Copper Types. DL1.1.71. Lap. A surface defect appearing as a seam, caused by folding over hot metal, tins, or sharp corners and then rolling or forging, but not welding, them into the surface. DL1.1.72. Leaded Brasses. Copper-base alloys, generally of copper and zinc to which lead has been added to improve machinability. See Brasses. DL1.1.73. Lengths. The terms employed to designate lengths are as follows: DL1.1.73.1. Mill Lengths. Certain uniform lengths subject to established tolerances with short lengths included according to established schedule. DL1.1.73.2. Multiple Lengths. Lengths of integral multiples of a base length, with suitable allowance for cutting, if and as specified. Several different multiples of the base length may be included in any lot, at the mills' discretion. DL1.1.73.3. Random Lengths. Run-of-mill lengths without any indicated preferred length. DL1.1.73.4. Specific Lengths. Indicated uniform lengths subject to established length tolerances; for example: 12'-0", 9'-7" or 0'-41/2" is a specific length. DL1.1.73.5. Specific Lengths with Ends. Indicated uniform lengths of 6 feet or over, subject to established length tolerances and with ends included according to established length schedules; for example: 10'-0" with ends or 6'-5" with ends. DL1.1.73.6. Standard Lengths. Standard lengths are lengths that have been recommended in a simplified practice recommendation or established as a Commercial Standard by the National Bureau of Standards, Department of Commerce, as standard lengths for certain products. Products such as copper and red brass pipe, copper water tube, copper threadless pipe (TP), copper refrigeration, and general service tube and copper drainage tube (DWV) are furnished in standard lengths. DL1.1.73.7. Stock Lengths. Normally certain uniform lengths subject to established tolerances (including standard lengths) actually carried in mill and warehouse stocks. The nominal length actually carried will vary considerably with the product, alloy, size,and mill source and warehouse location. DL1.1.74. Machine Shop Turning. To denote a condition of turnings, consisting mainly of long streamers intertwined and interlocked in an unwieldy clump-like mass. DL1.1.75. Magnet. This form is too well known to require descriptive amplification: Magnets may range from the miniature (under 2 ounces) to the electronic magnetrons that may weigh upward to 25 pounds. All magnet scrap should be free of insulation or outer shielding covers. NOTE: Magnets, in the magnico category, are highly friable. The examination of the resulting fracture offers some clue to the recognition of the "alnico" V (five) grade in that the fracture of this particular allow will reveal a large crystalline appearance. The other alnicos show a distinctive smaller lattice or grain due to the lower cobalt content. Tape shielding contains high sulpher and antimony, and should be removed before melting to prevent contamination. DL1.1.76. Malleability. The property of a metal that permits deformation by rolling, heading, hammering or extension by pressure without fracturing. DL1.1.77. Manganese Bronze. See Brasses. DL1.1.78. Millings. As distinct from turnings, consist of a finer particle of metal. Usually under three-eighths inch in width or length of thickness, and which is generated through the finishing machining to fine tolerances. Especially prevalent to the close final machining and drilling of bucket blades. DL1.1.79. Naval Brass. See Brasses. DL1.1.80. Naval Brass Welding Rod. See Welding Rod. DL1.1.81. Nickel Silver. Copper-base alloys containing nickel and zinc, formerly sometimes called German silver. These alloys are primarily used for their distinctive colors, which range from yellow to silvery white. DL1.1.81.1. Nickel Silver, 55-18. An alloy nominally containing 55 percent copper, 18 percent nickel, and 27 percent zinc. DL1.1.81.2. Nickel Silver, 65-10. An alloy nominally containing 65 percent copper, 10 percent nickel, and 25 percent zinc. DL1.1.81.3. Nickel Silver, 65-12. An alloy nominally containing 65 percent copper,12 percent nickel, and 23 percent zinc. DL1.1.81.4. Nickel Silver, 65-15. An alloy nominally containing 65 percent copper,15 percent nickel, and 20 percent zinc. DL1.1.81.5. Nickel Silver, 65-18. An alloy nominally containing 65 percent copper,18 percent nickel, and 17 percent zinc. DL1.1.82. Non-Refractory. A term applied to those copper-base alloys which, because of a lack of hardness or abrasiveness, present relatively little difficulty in maintaining standard dimensional tolerances. DL1.1.83. Oxygen-Free Silver Bearing Copper (OFS). See Copper Types. DL1.1.84. Pellets. Synonymous with "Shot," "granulars," a pebble-like shape of irregular size and shape, usually under 2 inches, produced by controlled casting of the stream of hot metal into a tank of water. DL1.1.85. Pickling. The process of removing surface oxide and scale from copper alloys with a mill pickle solution consisting of approximately 12 to percent sulfuric acid in water by volume. DL1.1.86. Piercing DL1.1.86.1. The process, also known as "Mannesmann Process," by which seamless tubes are made from solid billets. A heated billet is rapidly rotated and driven ahead by drive rolls, the action of which is to form an opening in its center. The forward movement imparted by the rolls carries the shell over a freely rotating mandrel, which shapes the inner surface of the tube. DL1.1.86.2. Punching holes in sheet or strip, or walls of shells. DL1.1.87. Pin Test. See Tests, Expansion (Pin). DL1.1.88. Pipe. Seamless tube conforming to the particular dimensions, commercially known as standard pipe sizes. DL1.1.89. Prepared. Signifies that the physical dimensions of the scrap are in conformance to trade-practice such as "prepared" into bales, or drums, crucible shape, open-hearth size, etc. DL1.1.90. Radiator Core Brass. See Brasses. DL1.1.91. Random Lengths. See Lengths. DL1.1.92. Ready-to-Finish. A general mill term applied to size and condition of a product prior to the final drawing or rolling operation. DL1.1.93. Refinery. A nonferrous manufacturer who heats secondary material (scrap) in a furnace for the base metal content, melting the metal into intermediate shapes. DL1.1.94. Recrystallization. The change in grain structure that occurs when the metal is annealed, during which the deformed grains, strain-hardened by working, become new unstrained grains. DL1.1.95. Rolling. The process of passing metal between rolls under pressure to reduce its cross section. DL1.1.95.1. Cold Rolling. This process is carried out below the softening point of the metal and, with copper alloys, usually at room temperature. DL1.1.95.2 Hot Rolling. This process is carried out above the softening temperature and, with copper alloys, usually at temperatures from about 1,200°F. to1,700°F., 650°C. to 927°C. DL1.1.96. Rotating Band Blank. An unfinished tubular blank for making rotating bands for use on artillery projectiles. Sometimes termed driving band blank or projectile band blank. DL1.1.97. Sawed Bar. A bar brought to finished width by sawing. DL1.1.98. Sawed Edges. The edges resulting when a product is brought to final width and length by sawing. The edges are parallel and at right angles to the rolled surface. DL1.1.99. Scale DL1.1.99.1. A heavy oxide coating on copper and copper-base alloys resulting from exposure to high temperatures in an oxidizing atmosphere. DL1.1.99.2. A product resulting from the corrosion of metals. DL1.1.100 Scrap Broker. A scrap broker is a buyer and seller of scrap for his own account, but does not physically handle the material. DL1.1.101. Scrap Broker-Dealer. A broker-dealer performs primarily the functions of a broker, but also maintains a physical inventory of scrap and processes material for his own account. DL1.1.102. Scrap Dealer. A scrap dealer is an operator of a scrap yard taking physical possession of the material for the purpose of sorting and preparing scrap to meet mill specifications and requirements. DL1.1.103. Short Shoveling. When applied to scrap solids or turnings, means material of such dimensional size that can he manually handled by a shovel. DL1.1.104. Slab. A casting in the form of a bar used for rolling into strip. DL1.1.105. Sludge. A mud-like material originating from the chemical industry or the ceramic industry, in the form of a residue scrap byproduct, or as a spent catalyst, or in the form of other chemical substances. Sludge, or such type of scrap should be offered in the following indicated manner: DL1.1.105.1. Moisture content. DL1.1.105.2. Assay to be established on dry content. DL1.1.105.3. When feasible, the metallic yield for the dry content should be supplied. DL1.1.106. Smelter. A nonferrous manufacturer that produces a shape wherein the prime ingredient is ore. DL1.1.106.1. Custom Smelter. Melts secondary material (scrap) into refined copper. DL1.1.106.2. Secondary Smelter. Melts scrap material into specification ingots. DL1.1.107. Soldering. Joining metals by fusion of alloys that have relatively low-melting points--most commonly, lead-base on tin-base alloys, which are the soft solders. Hard solders are alloys that have silver, copper or nickel bases. Use of these alloys with melting points higher than 800°F., 427°C. is properly called "brazing." DL1.1.108. Solids. Trade term "solids" covers almost every conceivable shape manufactured for commercial or military application. It applies to the trade term titled "generated scrap" in solid form. Also, see "Specifics." DL1.1.109. Spaghetti. Pertinent to solids, conjures an optical or mental picture of a jumbled mass of voluminous condition, unprepared scrap, irregular and numerous varied large shapes and sizes. Particularly, pertinent to long streamers of sheet cuttings, slittings, wire, and cable whereby one end of the piece is at one part of the pile and the other end is intertwined. DL1.1.110. Specifics. The following enumerated descriptions are indicative and exemplify the proper meaning of the term "solids." DL1.1.110.1. Blades. Shall refer to the turbine rotor blades or bucket blades associated with the jet engine or the steam engine, and that is the motive part on which the gas or pressure stream impinges and transmits the power to create motion. Blades are produced from forgings or are casted to critical dimensions. Bucket blades may range in weight from an ounce to several pounds. DL1.1.110.2. Clippings. Refers to cuttings, stampings, trimmings, resulting from the fabrication and working of new sheet metal. NOTE: "New," by trade custom refers to plant generated scrap. DL1.1.110.3. Jet Solids. Occurring mainly from sheet stock fabricated parts utilized in the hot section of the jet engine and found mostly in the form of shrouds, outer casings, braking flaps, tail cones, after burners, nozzles, and other engine parts. NOTE: The weight saving requirement of the jet engine necessitates using thin gage metal, (8 to 22 gage) which often is stiffened by bracing sections to avoid metal warping under extreme heat conditions. Often the braces are made of other nickel containing heat-resisting alloy. These braces or other attachments are usually of minor ratio and since the metal content is of a non-harmful nature, a small tolerance of such braces or attachments may be included in the overall lot. DL1.1.110.4. Old Sheet. Salvage in the form of sheet occurring from obsolete, rejected or Service-retired scrap. May include material with brazed seams, also some slight attachment of non-harmful metal attachment. DL1.1.110.5. Solids, Other. The following are usually present in the scrap delineation and need no elaborate further description, namely: rod and bar ends, pipe ends, plate cuttings, bolts and nuts, billet ends, forgings, flashing, etc. DL1.1.111. Spelter. Mill term for cast zinc. Spelter usually is produced in the form of flat slabs for re-melting. DL1.1.112. Spill. A defect that originates during casting and after rolling or drawing appears as a discontinuity either on the surface or as a faint streak which, on distortion, becomes opened or blistered. DL1.1.113. Spot Plate. A non-reactive nonporous glass or mineral plate with one or more shallow depressions in which to perform chemical reagent identification testing of metal filings, chips, or borings. DL1.1.114. Steel Mill: DL1.1.114.1. Integrated Steel Mill. A manufacturer of steel who owns or controls all of the ores, materials, and physical facilities for manufacturing steel from raw material to the finished steel, with the exception of purchased scrap. DL1.1.114.2. Non-Integrated Steel Mill. Lacks ownership or control of certain phases of manufacturing steel and usually purchases from other firms the necessary ingredients as phases of operation rerquired to complete the cycle of the steel manufacturing process. DL1.1.115. Straightening. Any process applied to tube, rod, bar, or wire that eliminates any general or local curvature resulting from mill processing. DL1.1.115.1. Hand Straightening. The process of straightening by bending or twisting by hand with the aid of adjustable supports and suitable hand tools, usually applied to shapes and to large diameter tubes. DL1.1.115.2. Inclined Roll Straightening. (Such as Medart). The process of straightening round rod or tube by passing the product through a machine with rolls having special contours and whose axis are at a slight angle so as to give the product a helical forward motion with repeated flexing in all planes through the axis. DL1.1.115.3. Roll Straightening. The process of straightening tube, rod and bar by passing lengthwise through a machine with suitable rolls so as to repeatedly flex the product in two planes at right angles. DL1.1.116. Straightening and Flattening. Any process applied to flat-rolled products to eliminate any general or local curvature, either with respect to flatness or edgewise curvature. DL1.1.116.1. Roll Flattening. The process of flattening a product by machine with a number of small diameter cylindrical rolls so positioned as to repeatedly flex the product and thus remove certain irregularities in shape. Roll flattening practically eliminates longitudinal curl, burr, and dish. It reduces edge-wise curvature of narrow strip. This operation reduces buckles, but is relatively ineffective in eliminating wavy edges, ripples and twist. Roll flattening is ordinarily applied to a flat-rolled product within the approximate size range .010 inch to 1/8 inch thick and in widths to about 48-inch, and is particularly effective on annealed tempers, but is prgressively less effective wih increase in degree of rolled temper. DL1.1.116.2. Stretcher Straightening (Patent Leveling). Applicable to flat straight lengths. A process that simultaneously flattens and straightens a product by longitudinally stretching it beyond its elastic limit. This process removes buckles, ripples, wavy edges, twist and edgewise curvature, is partially effective in removing longitudinal curl, but is ineffective in removal of crown, dish and burr. It is commonly applied to flat-rolled products within the approximate size range of 3-inch to 48-inch wide and 0.012 inch to 0.050 inch thick. It is particularly effective on all annealed tempers and on rolled tempers up to half hard. DL1.1.117. Stretcher Straightening. See Straightening and Flattening. DL1.1.118. Stresses: DL1.1.118.1. Applied Stress . Stresses that are set up and exist in a body during application of an external load. DL1.1.118.2. Residual Stress. Stresses that remain within a body as the result of plastic deformation, casting, or rapid temperature change. DL1.1.119. Stress Corrosion. See Corrosion. DL1.1.120. Strip. A flat product, other than flat wire, up to and including thickness and generally furnished as follows: DL1.1.120.1. With slit, sheared or slit and edge rolled in widths up to 20-inch inclusive. DL1.1.120.2. With finished drawn or rolled edges in widths over 1 1/4-inch to 12-inch inclusive. DL1.1.121. Temper. The condition produced in a metal by mechanical or thermal treatment and having characteristic structure and mechanical properties. DL1.1.122. Tensile Strength. The value obtained by dividing the maximum load observed during tensile straining by the specimen cross-sectional area before straining. Also called "ultimate strength." It is usually expressed in pounds per square inch. DL1.1.122.1. Bend. A test sometimes made to indicate ductility or bending a suitable specimen about a predetermined radius through a predetermined angle. DL1.1.122.2. Brinell Hardness. A test made to determine hardness on relatively thick sections of metal by pressing a steel ball of specified diameter into a test specimen under a specified load. This test is seldom used on copper and copper-base alloys. DL1.1.122.3. Creep. A test to determine the extension of metallic materials due to the combined effects of temperature, tensile stress and time. Inherently, it is a long-term test, not suitable for specification purposes. DL1.1.122.4. Cup. A test to indicate the ductility of sheet or strip wherein a cup is drawn from the metal until it fractures. Several modifications of the original Erichsen method are now in use. DL1.1.122.5. Endurance. A test to determine the endurance limit of a metal's resistance to fatigue by subjecting a specimen to repeated alternating or pulsating stresses. DL1.1.122.6. Expansion (pin). A test used to determine the capacity of the tube for expansion, to reveal surface defects of the tube for expansion and to reveal surface defects by pushing a tapered pin into the open end of a specimen. DL1.1.122.7. Flattening. A test made on annealed tube to indicate ductility and freedom from mechanical defects. DL1.1.122.8. Hydrostatic. A test to prove soundness and resistance to leakage of tube and pipe under internal water pressure. DL1.1.122.9. Impact. A test made to determine the resistance of metals to failure by sudden shock load. DL1.1.122.10. Mercurous Nitrate. An accelerated test to indicate the resistance of copper-base alloy products to season cracking. DL1.1.122.11. Pneumatic. A test used to prove resistance to leakage of tube or pipe by the application of internal air pressure to the product while submerged in water. DL1.1.122.12. Rockwell Hardness. A test to measure hardness by determining the depth of penetration into a specimen of a penetrator under predetermined conditions of test. DL1.1.122.13. Tension. A test to determine one or more of the following: tensile strength, yield strength, elongation, and contraction of area. DL1.1.122.14. Torsion. A test to determine the strength in torsion by measuring the torque required to twist a specimen of given length through a predetermined angle. DL1.1.123. Tolerance. The amount by which any characteristic, such as dimensional, chemical, physical, or mechanical properties, may vary from that specified. DL1.1.124. Tube. A hollow product of round or any other cross section having a continuous periphery. DL1.1.124.1. Copper Service Tube. Bandable copper water tube for underground water services. See Copper Water Tube. DL1.1.124.2. Copper Water Tube. Seamless copper tube conforming to the particular dimensions commercially known as copper water tube and designated as types "K", "L", and "M." DL1.1.124.3. Heat Exchanger Tube. Tube manufactured to special requirements as to dimensional tolerances, finish, and temper for use in condensers and other heat exchangers. DL1.1.124.4. Lock Seam Tube. Tube made from sheet or strip, with a longitudinal, mechanically locked seam. DL1.1.124.5. Oil Burner Tube. Small diameter seamless copper tube of soft temper in coils intended for use in oil burner installations. DL1.1.124.6. Open Seam Tube. A shape, other than extruded shape, of generally tubular form of nominally uniform wall thickness, but having a longitudinal unjoined seam or gap of width not greater than 25 percent of the outside diameter or greatest overall dimension. DL1.1.124.7. Pipe, Seamless. Tube conforming to the particular dimensions commercially known as standard pipe sizes (SPS) and designated as regular and extra strong. DL1.1.124.8. Reeded Outside, Plain Inside Tube. Tube having reeded outside periphery and plain inside periphery. DL1.1.124.9. Reeded Tube. Tube of nominally uniform wall thickness having regular longitudinal convex corrugations, either with rounded or sharp cusps between corrugations. DL1.1.124.10. Seamless Tube. Tube produced with a continuous periphery at all stages of the operation, in contrast to "brazed," "welded," "open seams," and "lock seam" tube. DL1.1.124.11. Welded Tube. Tube made from sheet or strip, with a longitudinal welded joint. DL1.1.125. Turnings. Likewise trade described as "borings" and "shavings." Results from machining operation and processing of bars, rods, castings, billets, or the machine dressing or finishing of any metal product that results in the occurrence of the usual sliverlike or curlicue shapes. This is generic to the term "turnings." The term "machine shop turnings" indicates that the scrap is voluminous and in bulky condition. DL1.1.126. Welding. Process of producing localized coalescence of metal by heating to suitable temperatures, with or without the application of pressure, and with or without the use of filler metal. The filler metal either has a melting point approximately the same as the base metal, or has a melting point below that of the base metals, but above 800°F. Common welding processes are: DL1.1.126.1. Carbon arc welding; DL1.1.126.2. Metal arc welding; DL1.1.126.3. Oxyacetylene welding; DL1.1.126.4. Resistance welding; and DL1.1.126.5. Shielded arc welding. DL1.1.127. Welding Rod. Filler metal, in wire or rod form, used in gas welding and brazing processes, and those arc-welding processes wherein the electrode does not furnish the filler metal. Some commonly used welding rods are: DL1.1.127.1. Aluminum Bronze. A copper-base alloy having aluminum as the major alloying element with or without a small amount of iron. DL1.1.127.2. Copper. Deoxidized copper containing minor additions of other elements. DL1.1.127.3. Cupro-Nickel, 30 percent. Copper-base-alloy -- having nickel as the major alloying element (about 30 percent) with minor additions of other elements. DL1.1.127.4. Low Fuming. Manganese Bronze type welding rod to which a small amount of silicon has been added to reduce the evolution of zinc oxide fumes in welding or brazing. DL1.1.127.5. Manganese Bronze Welding Rod. A copper-base alloy in which manganese is present in small amount. Usually also contains small quantities of iron and tin. A typical analysis would show about 57 percent copper, 0.7 percent tin, 0.7 percent iron, 0.10 percent manganese, and the remainder zinc. DL1.1.127.6. Naval Brass. An alloy of approximately 60 percent copper, 0.7 percent tin, and the remainder zinc. DL1.1.127.7. Phosphor Bronze. A copper-tin containing residual phosphorus. DL1.1.127.8. Silicon Bronze. A copper-base alloy having silicon as the major alloying element up to 4 percent with or without lesser amounts of any of several elements such as zinc, tin, manganese, and iron. DL2.1. DEFINITIONS RELATING TO PLASTICS There are numerous terms that are peculiar to the plastics industry. Following are definitions of some of the most common terms used in this Handbook (see C5.5.) or that will be found in researching plastics data through most sources: DL2.1.1. Ablative Plastics. This description applies to a material that absorbs heat (while part of it is being consumed by heat) through a decomposition process known as pyrolysis, which takes place in the near surface layer exposed to heat. DL2.1.2. Acetal Resins. The molecular structure of the polymer is that of a linear acetal, consisting of unbranched polyoxymethylene chains. DL2.1.3. Acrylic Ester. An ester of acrylic acid, or of a structural derivative of acrylic acid, e.g., methyl methacrylate. DL2.1.4. Acrylic Resin. A synthetic resin prepared from acrylic acid or from a derivative of acrylic acid. DL2.1.5. Acrylonitrile. A monomer with the structure (CH2:CHCH). It is most useful in copolymers. Its copolymer with butadiene is nitrile rubber, and several copolymers with styrene exist that are tougher than polystyrene. It is also used as a synthetic fiber and as a chemical intermediate. DL2.1.6. Acrylonitrile-Butadiene-Styrene (abbreviated ABS). Acrylonitrile and styrene liquids and butadiene gas are polymerized together in a variety of ratios to produce the family of ABS resins. DL2.1.7. Aliphatic Hydrocarbons. Saturated hydrocarbons having an open chain structure. Familiar examples: gasoline and propane. DL2.1.8. Alkyd Resin. Polyester resins made with some fatty acid as a modifier. DL2.1.9. Alloy. Composite material made up by blending polymers or copolymers with other polymers or elastomers under selected conditions, e.g., styreneacrylonitrile copolymer resins blended with butadiene-acrylonitrile rubbers. DL2.1.10. Allyl Resin. A synthetic resin formed by the polymerization of chemical compounds containing the group CH-CHCH2-. The principal commercial allyl resin is a casting material that yields allyl carbonate polymer. DL2.1.11. Alpha-Cellulose. A very pure cellulose prepared by special chemical treatment. DL2.1.12. Aromatic Hydrocarbons. Hydrocarbons derived from or characterized by presence of unsaturated resonant ring structures. DL2.1.13. Biodegradables. Those plastics which, because of their chemical structure, are susceptible to being assimilated by microorganisms such as fungi and bacteria through enzyme action. This mechanism requires heat, oxygen and moisture. DL2.1.14. Blown Tubing. A thermoplastic film that is produced by extruding a tube, applying a slight internal pressure to the tube to expand it while still molten, and subsequent cooling to set the tube. The tube is then flattened through guides and wound up flat on rolls. The size of blown tubing is determined by the flat width in inches as wound rather than by the diameter as in the case of rigid types of tubing. DL2.1.15. Bushing (Extrusion). The outer ring of any type of a circular tubing or pipe die that forms the outer surface of the tube or pipe. DL2.1.16. Caprolactam. A cyclic amidetype compound, containing 6 carbon atoms. When the ring is opened, caprolactam is polymerizable into a nylon resin known as type-6 nylon or polycaprolactam. DL2.1.17. Casein. A protein material precipitated from skimmed milk by the action of either rennet or dilute acid. Rennet casein finds its main application in the manufacture of plastics. Acid casein is a raw material used in a number of industries including the manufacture of adhesives. DL2.1.18. Cast DL2.1.18.1. To form a "plastic" object by pouring a fluid monomer-polymer solution into an open mold where it finishes poIymenzing. DL2.1.18.2. Forming plastic film and sheet by pouring the liquid resin onto a moving belt or by precipitation in a chemical bath. DL2.1.19. Catalyst. A substance that markedly speeds up the cure of a compound when added in minor quantity as compared to the amounts of primary reactants. DL2.1.20. Cellular Plastics. See Foamed Plastics. DL2.1.21. Celluloid . A thermoplastic material made by the intimate blending of cellulose nitrate with camphor. Alcohol is normally employed as a volatible solvent to assist plasticization, and is subsequently removed. DL2.1.22. Cellulose. A natural high polymeric carbohydrate found in most plants; the main constituent of dried woods, jute, flax, hemp, ramie, etc. Cotton is almost pure cellulose. DL2.1.23. Cellulose Acetate. An acetic acid ester of cellulose. It is obtained by the action, under rigidly controlled conditions, of acetic acid and acetic andride on purified cellulose usually obtained from cotton linters. All three available hydroxyl groups in each glucose unit of the cellulose can be acetylated, but in the material normally used for plastics it is usual to acetylate fully and then to lower the acetyl value (expressed as acetic acid) to 52-56 percent by partial hydrolysis. When compounded with suitable plasticizers it gives a tough therm plastic material. DL2.1.24. Cellulose Acetate Butyrate. An ester of cellulose made by the action of a mixture of acetic and butyric acids and their anhydrides on purified cellulose. It is used in the manufacture of plastics that are similar in general properties to cellulose acetate, but are tougher and have better moisture and dimensional stability. DL2.1.25. Cellulose Ester. A derivative of cellulose in which the free hydroxyl groups attached to the cellulose chain have been replaced wholly or in part by acidic groups; e.g., nitrate, acetate, or stearate groups. Esterification is effected by the use of a mixture of an acid with its anhydride in the presence of a catalyst, such as sulfuric acid. Mixed esters of cellulose; e.g., cellulose acetate butyrate, are prepared by the use of mixed acids and mixed anhydrides. Esters and mixed esters, a wide range of which is known, differ in their compatability with plasticizers, in molding properties, and in physical characteristics. These esters and mixed esters are used in the manufacture of thermoplastic molding compositions. DL2.1.26. Cellulose Nitrate (Nitrocellulose). A nitric acid ester of cellulose manufactured by the action of a mixture of sulfuric acid and nitric acid on cellulose, such as purified cotton linters. The type of cellulose nitrate used for celluloid manufacture usually contains 10.8-11.1 percent of nitrogen. The latter figure is the nitrogen content of the dinitrate. DL2.1.27. Cellulose Propionate. An ester of cellulose made by the action of propionic acid and its anhydride on purified cellulose. It is used as the basis of a thermoplastic molding material. DL2.1.28. Centrifuge Casting. A method of forming thermoplastic resins in which the granular resin is placed in a rotatable container, heated to a molten condition by the transfer of heat through the walls of the container, and rotated such that the centrifical force induced will force the molten resin to conform to the configuration of the interior surrfce of the container. Used to fabricate large diameter pipes and similar cylindrical items. DL2.1.29. Chlorinated Polyether. The polymer is obtained from pentaerythritol by preparing a chlorinated oxetane and polymerizing it to a polyether by means of opening the ring structure. DL2.1.30. Condensation. A chemical reaction in which two or more molecules combine with the separation of water or some other simple substance. If a polymer is formed, the condensation process is called polycondensation. See also Polymerization. DL2.1.31. Condensation Resin. A resin formed by polycondensation; e.g., the alkyd, phenolaldehyde, and urea formaldehyde resins. DL2.132. Copolymer. See Polymer. DL2.1.33. Decorative Sheet. A laminated plastic sheet used for decorative purposes in which the color and/or surface pattern is an integral part of the sheet. DL2.1.34. Degradable. Plastics that will environmentally decompose to a powder or liquid form through biodegradation, solubility, and photodegradation mechanisms. DL2.1.35. Dielectric. Insulating material. In radio frequency preheating, dielectric may refer specifically to the material that is being heated. DL2.1.36. Dimensional Stability. Ability of a plastic part to retain the precise shape in which it was molded, fabricated, or cast. DL2.1.37. Elastomer. A material, which at room temperature, stretches under low stress to at least twice its length and snaps back to the original length upon release of stress. See also Rubber. DL2.1.38. Epoxy Resins. Based in ethylene oxide, its derivatives or homologs, epoxy resins form straight-chain thermoplastics and thermosetting resins; e.g., by the condensation of bisphenol and epichlorohydrin. DL2.1.39. Ester. The reaction product of an alcohol and an acid. DL2.1.40. Expanded Plastics. See Foamed Plastics. DL2.1.41. Fiber. This term usually refers to relatively short lengths of very small cross-sections of various materials. Fibers can be made by chopping filaments (converting). Staple fibers may be 1/2 to a few inches in length and usually 1 to 5 denier. DL2.1.42. Filament. A variety of fiber characterized by extreme length, which permits its use in yarn with little or no twist and usually without the spinning operation required for fibers. DL2.1.43. Film. An optional term for sheeting having a nominal thickness not greater than 0.010 inch. DL2.1.44. Flake. Used to denote the dry, unplasticized base of celluloisic plastics DL2.1.45. Flame-Retarded Resin. A resin that is compounded with certain chemicals to reduce or eliminate its tendency to burn. For polyethylene and similar resins, chemicals such as antimony trioxide and chlorinated paraffins are useful. DL2.1.46. Flexibilizer. An additive that makes a resin or rubber more flexible; i.e., less stiff. Also see plasticizer. DL2.1.47. Foamed Plastics. Resins in sponge form. The sponge may be flexible or rigid, the cells closed or interconnected, the density anything from that of the solid parent resin down to, in some cases, 2 pounds per cubic foot. Compressive strength of rigid foams is fair, making them useful as materials for sandwich structures. Both types are good heat barriers. DL2.1.48. Furan Resins. Dark colored, thermosetting resins available primarily as liquids ranging from low viscosity polymers to thick, heavy syrups. DL2.1.49. Granular Structure. Non-uniform appearance of finished plastic material due to retention of, or incomplete fusion of, particles of composition, either within the mass or on the surface. DL2.1.50. High-Pressure Laminates. Laminates molded and cured at pressures not lower than 1000 p.s.i. and more commonly in the range of 1200 to 2000 p.s.i. DL2.1.51. Honeycomb. Manufactured product consisting of sheet metal or a resin impregnated sheet material (paper, fibrous glass, etc.) that has been formed into hexagonal shaped cells. Used as core material for sandwich constructions. DL2.1.52. Hydrogenation. Chemical process whereby hydrogen is introduced into a compound. DL2.1.53. Hydrolysis. Chemical decomposition of a substance involving the addition of water. DL2.1.54. Hygroscopic. Tending to absorb moisture. DL2.1.55. Impact Resistance. Relative susceptibility of plastics to fracture by shock; e.g., as indicated by the energy expended by a standard pendulum type impact machine in breaking a standard specimen in one blow. DL2.1.56. Inhibitor. A substance that slows down chemical reaction. Inhibitors are sometimes used in certain types of monomers and resins to prolong storage life. DL2.1.57. Insulation. A coating of a dielectric or essentially non-conducting material whose purpose it is to prevent the tranition of electricity. DL2.1.58. Ion Exchange Resins. Small granular or bead-like particles containing acidic or basic groups, which will trade ions with salts in solutions. Generally used for softening and purifiying water. DL2.1.59. Isocyanate Resins. Most applications for this resin are based on its combination with polyestors (e.g., polyesters, polyethers, etc.). During this reaction, the reactants are joined through the formation of the urethane linkage--and hence this field of technology is generally known as urethane chemistry. DL2.1.60. Lacquer. Solution of natural or synthetic resins, etc., in readily evaporating solvents, which is used as a protective coating. DL2.1.62. Laminated Plastics (Synthetic Resin-Bonded Laminate, Laminate). A platics material consisting of superimposed layers of a synthetic resin impregnated or coated filler that have been bonded together, usually by means of heat and presure, to form a single piece. DL2.1.62. Marcromolecule. The large ("giant") molecules that make up the high polymers. DL2.1.63. Melamine Formaldehyde Resin. Classified as a synthetic resin derived from the reaction of melamine (2,4,6 triamino 1,3,5, triazine) with formaldehyde or its polymers. DL2.1.64. Melt Index. The amount, in grains, of a thermo-plastic resin that can be forced through a 0.0825 inch orifice when subjected to 2160 grams force in 10 minutes at 190°C. DL2.1.65. Metalizing. Applying a thin coating of metal to a non-metallic surface. May be done by chemical deposition or by exposing the surface to vaporized metal in a vacuum chamber. DL2.1.66. Monofilament (Monfil). A single filament of indefinite length. Monofilaments are generally produced by extrusion. Their outstanding uses are in the fabrication of bristles, surgical sutures, fishing leader, tennis racquet strings, screen materials,ropes and nets; the finer monofilaments are woven and knitted on textile machinery. DL2.1.67. Monomer. A relatively simple compound that can react to form a polymer. See also Polymer. DL2.1.68. Nonpolar. Having no concentrations of electrical charge on a molecular scale, thus, incapable of significant dielectric loss. Examples among resins are polystyrene and polyethylene. DL2.1.69. Non-Rigid Plastic. A non-rigid plastic is one that has a stiffness or apparent moduus of elasticity of not over 50,000 p.s.i. at 25°C. when determined according to ASTM test procedures D747-43T. DL2.1.70 Novolac. A phenolic-aldehyde resin which, unless a source of methylene groups is added, remains permanently thermoplastic. See also Resinoid and Thermoplastic. DL2.1.71. Nylon. The generic name for all synthetic fiber forming polyyamides; they can be formed into monofilaments and yarns characerized by great toughness, strength and elasticty, high-melting point, and good resistance to water and chemicals. DL2.1.72. Organosol. A vinyl or nylon dispersion, the liquid phase of which contains one or more organic solvents. See also Plastisol. DL2.1.73. Parison. The hollow plastic tube from which a container, toy, etc., is blow molded. DL2.1.74. Phenolic Resin. A synthetic resin produced by the condensation of an aromatic alcohol with an aldehyde, particularly of phenol with formaldehyde. DL2.1.75. Photo-degradation. The breaking down of a plastic molecular structure by absorption of ultraviolet energy. The plastic absorbs high-photon energy, which breaks the bond between carbon and hydrogen, forming oxygen reactive free radicals that promote decomposition. DL2.1.76. Plastic. One of many high-polymeric substances, including both natural and synthetic products, but excluding the rubbers. At some stage in its manufacture every plastic is capable of flowing, under heat and pressure, if necessary, into the desired final shape. Made of plastic; capable of flow under pressure or tensile stress. DL2.1.77. Plasticate. To soften by heating or kneading. Synonyms are: plastify, flux, and, (imprecisely) plasticize. DL2.1.78. Plasticity. The quality of being able to be shaped by plastic flow. DL2.1.79. Plasticize. To soften a material and make it plastic or moldable, either by means of a plasticizer or the application of heat. DL2.1.80. Plasticizer. Chemical agent added to plastic compositions to make them softer and more flexible. DL2.1.81. Plastics Tooling. Tools; e.g., dies, jigs, fixtures, etc., for the metal forming trades constructed of plastics, generally laminates or casting materials. DL2.1.82. Plastigel. A plastisol exhibiting gel-like flow properties. DL2.1.x83. Plastisols. Mixtures of resins and plasticizers that can be molded, cast, or converted to continuous films by the application of heat. If the mixtures contain volatile thinners also, they are known as Organosols. DL2.1.84. Plastometer. An instrument for determing the flow properties of a thermoplastic resin by forcing the molten resin through a die or orifice of specific size at a specific temperature and pressure. DL2.1.85. Polyamide. A polymer in which the structural units are linked by amide or thioamide groupings. Many polyamides are fiber-forming. DL2.1.86. Polyblends. Colloquial term generally used in the styrene field apply to mechanical mixtures of polystyrene and rubber. DL2.1.87. Polycarbonate Resins. Polymers derived from the direct reaction between aromatic and aliphatic dihydroxy compounds with phosgene or by the ester exchange reaction with appropriate phosgen derived precursors. DL2.1.88. Polyester. A resin formed by the reaction between a dibasic acid and dihydroxy alcohol, both organic. Modification with multi-functional acids and/or bases and some unsaturated reactants permit cross-linking to thermosetting resins. Polyesters modified with fatty acids are called Alkyds. DL2.1.89. Polyethylene (Polythene). A thermoplastic material composed of polymers of ethylene. It is normally a translucent, tough, waxy solid that is unaffected by water and by a large range of chemicals. It is a particularly good insulating material with low power factor and low dielectric constant, high resistivity, and high dielectric strength. DL2.1.90. Polyisobutylene. The polymerization product of isobutylene. It varies in consistency from a viscous liquid to a rubber-like solid with corresponding variation in molecular weight from 1,000 to 400,000. DL2.1.91. Polymer. A high molecular-weight organic compound, natural or synthetic, whose structure can be represented by a repeated small unit, the mer; e.g., polyethylene, rubber, cellulose. Synthetic polymers are formed by addition or condensation polymerization of monomers. If two or more monomers are involved, a copolymer is obtained. Some polymers are elastomers, some plastics. DL2.1.92. Polymerization. A chemical reaction in which the molecules of a monomer are linked together to form large molecules whose molecular weight is a multiple of that of the original substance. When two or more monomers are involved, the process is called co-polymerization or hetero-polymerization. See also Condensation and Polymer. DL2.1.93. Polymethyl Methaciylate. A thermoplastic material composed of polymers of methyl methacrylate. It is a transparent solid with exceptional optical properties and good resistance to water. It is obtainable in the form of sheets, granules, solutions, and emulsions. It is extensively used for aircraft domes, lighting fixtures, decorative articles, etc. It is also used in optical instruments and surgical appliances. DL2.1.94. Polypropylene. A tough, lightweight rigid plastic made by the polymerization of high-purity propylene gas in the presence of an organometallic catalyst at relatively low pressures and temperatures. DL2.1.95. Polystyrene. A water-white thermoplastic produced by the polymerization of styrene (vinyl benzene). The electric insulating properties of polystyrene are outstandingly good and the material is relatively unaffected by moisture. In particular the power loss factor is extremely low over the frequency range 103-108 c.p.s. DL2.1.96. Polyvinyl Acetate. A thermoplastic material composed of polymers of vinyl acetate in the form of a colorless solid. It is obtainable in the form of granules, solutions, latices, and pastes, and is used extensively in adhesive, for paper and fabric coatings, and in bases for inks and lacquers. DL2.1.97. Polyvinyl Alcohol. A thermoplastic material composed of polymers of the hypothetical vinyl alcohol. Usually a colorless solid, insoluble in most organic solvents and oils, but soluble in water when the content of hydroxy groups in the polymer is sufficiently high The product is normally granular. It is obtained by the partial hydrolysis or by the complete hydrolysis of polyvinyl esters, usually by the complete hydrolysis of polyvinyl acetate. It is mainly used for adhesives and coatings. DL2.1.98. Polyvinyl Butyral. A thermoplastic material derived from a polyvinyl ester in which some or all of the acid groups have been replaced by hydroxyl groups and some or all of these hydroxyl groups replaced by butyral groups by reaction with butyraldhyde. It is a colorless, flexible, tough solid. It is used primarily in interlayers for laminated safety glass. DL2.1.99. Polyvinyl Chloride (PVC). A themoplastic material composed of polymers of vinyl chloride; a colorless solid with outstanding resistance to water, alcohols, and concentrated acids and alkalies. It is obtainable in the form of granules, solutions, latices, and pastes. Compounded with plasticizers it yields a flexible material superior to rubber in aging properties. It is widely used for cable and wire coverings, in chemical plants, and in the manufacture of protective garments. DL2.1.100. Polyvinyl Chloride Acetate. A thermoplastic material composed of co-polymers of vinyl chloride and vinyl acetate; a colorless solid with good resistance to water, concentrated acids and alkalies. It is obtainable in the form of granules, solutions, and emulsions. Compounded with plasticizers it yields a flexible material superior to rubber in aging properties. It is widely used for cable and wire coverings, in chemical plants, and in protectve garments. DL2.1.101. Polyvinylidene Chloride. A thermoplastic material composed of polymers of vinylidene chloride (l,l-dichloroethylene). It is a white powder with softening temperature at 185-200°C. The material is also supplied as a co-polymer with acrylonitrile or vinyl chloride, giving products that range from the soft flexible type to the rigid type. Also known as saran. DL2.1.102. Prepreg. A term generally used in reinforced plastics to mean the reinforcing material containing or combined with the full complement of resin before molding. DL2.1.x103 Pulp. A form of cellulose obtained from wood or other vegetable matter by prolonged cooking with chemicals. DL2.1.104. Resiliency. Ability to quickly regain an original shape after being strained or distorted DL2.1.105. Resin. Any of a class of solid or semi-solid organic products of natural or synthetic origin, generally of high molecular weight with no definite melting point. Most resins are polymers. DL2.1.106. Resinoid. Any of the class of thermosetting synthetic resins, either in their initial temporarily fusible state or in their final infusible state. DL2.1.107. Rigid PVC. Polyvinyl chloride or a polyvinyl chloride/acetate co-polymer characterized by a relatively high degree of hardness; it may be formulated with or without a small percentage of plasticizer. DL2.1.108. Rigid Resin. One having modulus high enough to be of practical importance; e.g., 10,000 p.s.i. or greater. DL2.1.109. Rosin. A resin obtained as a residue in the distillation of crude turpentine from the sap of the pine tree (gum rosin) or from an extract of the stumps and other parts of the tree (wood rosin). DL2.1.110. Rubber. An elastomer capable of rapid elastic recovery after being stretched to at least twice its length at temperatures from 0°F to 150°F. at any humidity. Specifically, Hevea or natural rubber, the standard of comparison for elastomers. DL2.1.111. Scrap. Any product of a molding operation that is not part of the primary product. In compression molding, this includes flash, culls, runners, and is not reusable as a molding compound. Injection molding and extrusion scrap (runners, rejected parts, sprues, etc.) can usually be reground and remolded. DL2.1.112. Sheet (Thermoplastic). A flat section of a thermoplastic resin with the length considerably greater than the width and 10 mils or greater in thickness. DL2.1.113. Shot. The yield from one complete molding cycle, including scrap. DL2.1.114. Silicone. One of the family of polymeric materials in which the recurring chemical group contains silicon and oxygen atoms as links in the main chain. At present these compounds are derived from silica (sand) and methyl chloride. The various forms obtainable are characterized by their resistance to heat. DL2.1.115. Sintering. In forming articles from fusible powders; e.g., nylon, the process of holding the pressed powder article at a temperature just below its melting point for about 1/2 hour. Particles are fused (sintered) together, but the mass, as a whole, does not melt. DL2.1.116. Sizing. The process of applying a material to a surface to fill pores and thus reduce the absorption of the subsequently applied adhesive or coating or to otherwise modify the surface. Also, the surface treatment applied to glass fiber used in reinforced plastics. The material used is sometimes called "size." DL2.1.117. Solubility. Plastics that become completely soluble in water forming nontoxic homogeneous solutions. The degree of solubility varies considerably with plastic formulation, temperature, solvent concentration and solvent. DL2.1.118. Solvent. Any substance, usually a liquid, which dissolves other substances. DL2.1.119. Stabilizer. An ingredient used in the formulation of some plastics, especially elastomers, to assist in maintaining the physical and chemcial properties of the compounded materials at their initial values throughout the processing and service life of the material. DL2.1.120. Stereo-specific Plastics. Implies a specific or definite order of arrangement of molecules in space. This ordered regularity of the molecules in contrast to the branched or random arrangement found in other plastics permits close packing of the molecules and leads to high crystallinity (e.g., as a polypropylene). DL2.1.121. Tenacity (gpd). The term generally used in yarn manufacture and textile engineering to denote the strength of a yarn or of a filament for its given size. Numerically it is the grams of breaking force per denier unit of yarn or filament size; grams per denier, gpd. The yarn is usually pulled at the rate of 12 inches per minute. Tenacity equals breaking strength (gms) divided by denier. DL2.1.122. Tensile Strength. The pulling stress, in p.s.i., required to break a given specimen. Area used in computing strength is usually the original, rather than the necked down area. DL2.1.123. Thermal Conductivity. Ability of a material to conduct heat; physical constant for quantity of heat that passes through unit cube of a substance in unit of time when difference in temperature of two faces is 1°. DL2.1.124. Thermoforming. Any process of forming thermoplastic sheet that consists of heating the sheet and pulling it down onto a mold surface. DL2.1.125. Thermo forms. The product that results from a thermo-forming operation. DL2.1.126. Thermoplastic. Capable of being repeatedly softened by heat and hardened by cooling a material that will repeatedly soften when heated and harden when cooled Typical of the thermoplastics family are the styrene polymers and co-polymers, acrylics, cellulosics, polyethylenes, vinyls, nylons, and the various fluorocarbon materials. DL2.1.127. Thermoset. A material that will undergo or has undergone a chemical reaction by the action of eat, catalysts, ultra violet light, etc., leading to a relatively infusible state. Typical of the plastics in the thermosetting family are the aminos (melamine and urea), most polyesters, alkyds, epoxies, and phenolics. DL2.1.128. Thixotropic. Said of materials that are gel-like at rest, but fluid when agitated. Liquids containing suspended solids are apt to be thixotropic. Thixotropy is desirable in paints. DL2.1.129. Transfer Molding. A method of molding thermosetting materials, in which the plastic is first softened by heat and pressure in a transfer chamber, then forced by high pressure through suitable sprues, runners, and gates into closed mold for final curing. DL2.1.130. Ultrasonic Sealing. A film sealing method in which sealing is accomplished through the application of vibratory mechanical pressure at ultrasonic frequencies (20 to 40 kc.). Electrical energy is converted to ultrasonic vibrations through the use of either a magnetostrictive or piezoelectric transducer. The vibratory pressures at the film interface in the sealing area develop localized heat losses that melt the plastic surfaces effecting the seal. DL2.1.131. Unsaturated Compounds. Any compound having more than one bond between two adjacent atoms, usually carbon atom, and capable of adding other atoms at that point to reduce it to a single bond. DL2.1.132. Urea Formaldehyde Resin (Urea Resin). A synthetic resin derived from the reaction of urea (carbamide) with formaldehyde or its polymers. DL2.1.133. Urethane. See description under Isocyanate Resins. DL2.1.134. Vacuum Forming. Method of sheet forming in which the plastic sheet is clamped in a stationary frame, heated, and drawn down by a vacuum into a mold. In a loose sense, it is sometimes used to refer to all sheet forming techniques, including drape forming, involving the use of vacuum and stationary molds. DL2.1.135. Vacuum Metalizing. Process in which surfaces are thinly coated with metal by exposing them to the vapor of metal that has been evaporated under vacuum (one millionth of normal atmospheric pressure). DL2.1.136. Vinyl Resin. A synthetic resin formed by the polymerization of chemical compounds containing the group CH2=CH-. In particular, polyvinyl chloride, acetate, alcohol, and butyral, are referred to (though most addition polymers are within the above definition, it is seldom applied to any but the ones listed). DL2.1.137. Viscosity. Internal friction or resistance to flow of a liquid. The constant ratio of shearing stress to rate of shear. In liquids for which this ratio is a function of stress, the term "apparent viscosity" is defined as this ratio. DL2.1.138. Welding. Joining thermoplastic pieces by one of several heat softening processes. In hot-gas welding, the material is heated by a jet of hot air or inert gas directed from a welding "torch" onto the area of contact of the surfaces that are being welded. Welding operations to which this method is applied normally require the use of a filler rod. In spin welding, the heat is generated by friction. Welding also includes heat sealing and the terms are synonymous in some foreign countries, including Britain. DL2.1.139. Wet Strength. The strength of paper when saturated with water, especially used in discussions of processes whereby the strength of paper is increased by the addition, in manufacture, of plastics resins. Also, the strength of an adhesive joint determined immediately after removal from a liquid in which it has been immersed under specified conditions of time, temperature, and pressure. DL2.1.140. Working Life. The period of time during which liquid resin or adhesive, after mixing with catalyst, solvent, or other compounding ingredients, remains usable. C1. CHAPTER 1 INTRODUCTION C1.1. GENERAL The security and defense of the United States requires a massive expenditure of our natural resources; and the rapid pace of technological advances in military equipment and repair parts will generate even greater resource requirements in the future. Efficient recovery and recycling of this property, after it is no longer usable, is of the utmost importance to recover strategic and critical materials and precious metals needed for manufacture of essential military material and consumer goods and to conserve our natural resources and energy in the production process. C1.2. PURPOSE The purpose of this Handbook is to outline practical, cost-effective methods for the recovery and recycling of scrap (defined as personal property that has been discarded for use and that appears to have no value except for its basic material content). By providing the best available technical guidance to all interested components of the Department of Defense on scrap identification and segregation, scrap yard operations and merchandising of scrap, it is intended that this Handbook will result in worldwide DoD implementation of proven methods to increase the payback from the DoD Scrap Recycling Program. C1.3. OBJECTIVES The broad objectives of the DoD Scrap Recycling Program are to: C1.3.1. Ensure that no property with utilization or sales value that exceeds the value of its material content is processed as scrap. C1.3.2. Optimize procedures for cost-effective recovery, recycling, or sales of scrap, including precious metal-bearing materials. C1.3.3. Ensure processing of scrap is in strict compliance with all applicable safety, health regulations and environmental protection guidelines. C1.4. RESPONSIBILITIES OF DoD ACTIVITIES C1.4.1. General. The Federal Property and Administrative Services Act of 1949, as amended, assigned to the Administrator of General Services responsibility for the disposition of excess and surplus personal property (including scrap) generated by Federal Agencies in the United States. The Administrator delegated responsibility for disposition of all DoD generations of such property to the Secretary of Defense, who subsequently assigned overall command and management of the Defense Personal Property Utilization and Disposal Program to the Defense Logistics Agency. Specific responsibilities of the DoD activities primarily concerned with scrap recycling are outlined below. C1.4.2. Military Services' Responsibilities: C1.4.2.1. Provide administrative and logistics support to tenanted Defense Property Disposal Regional Offices (DPDRs) and to Defense Property Disposal Offices (DPDOs) and their Off-Site Branches, in consonance with applicable Interservice Support Agreements (ISAs). The U.S. Army Logistics Management Center also provides specialized training support by conducting the Defense Scrap Management Course. C1.4.2.2. Establish and operate the DoD Resource Recovery and Recycling Programs, Deputy Secretary of Defense Memorandum, Sales of Recyclable Materials (10 U.S.C. 2577), 28 Jan 83. C1.4.2.3. Establish Qualifying Recycling Programs at DoD installations including those that operate under the industrial fund. C1.4.2.4. Ensure that those installations and Defense Agencies with Qualifying Recycling Programs make concerted efforts to divert or recover scrap or waste from the waste streams, as well as efforts to identify, collect, properly segregate and maintain the integrity of the recyclable materials in order to maintain or enhance the marketability of the materials. C1.4.2.5. Report/turn in all authorized scrap generations to their servicing DPDOs. C1.4.2.6. Prepare disposal turn-in documents, DTID (DD Form 1348-1 DoD Single Line Item Release/Receipt Document) and accurately identify all scrap listed thereon. C1.4.2.7. Indicate on DTID that DoD Qualifying Recycling Program material is identified as such with funds to be deposited to the Budget Clearing Account **F3875--- (xx 17 Navy, 21 Army, 57 Air Force and 97 for DoD Activities). No other account is acceptable. C1.4.2.8. Properly containerize all hazardous property in scrap condition before turn-in. Identify by labeling containers and annotate DD Form 1348-1 accordingly. C1.4.2.9. Monitor, with DPDO personnel, all property sent to landfills to ensure no economically salable or recyclable property is discarded. C1.4.2.10. Request DPDS provide sales services, as needed, for recyclable marketable materials generated as a result of resource recovery programs. C1.4.3. Defense Logistics Agency (DLA) Responsibilities: C1.4.3.1. Coordinate DoD policy guidance (developed by the Assistant Secretary of Defense (Manpower, Installations, and Logistics) or other organizational elements of the Office of the Secretary of Defense) with the Military Services and other DoD Components, and with Federal Civil Agencies, as appropriate. C1.4.3.2. Program, budget, fund, account for, allocate and control personnel spaces and other resources required to support DLA scrap recycling activities. C1.4.3.3. Provide Agency-level command and control of the Defense Personal Property Utilization and Disposal Program (including scrap recycling and precious metals recovery) worldwide. C1.4.4. Defense Property Disposal Service (DPDS) Responsibilities: C1.4.4.1. Manage the DoD Scrap Recycling Program (including precious metals recovery) and related financial records. C1.4.4.2. Command and control DPDRs. C1.4.4.3. Implement applicable policies, develop procedures and techniques, and initiate other appropriate actions to ensure cost-effective and environmentally safe implementation of scrap related programs. C1.4.4.4. Comply with DoD guidance on demilitarization of scrap generations. C1.4.4.5. Provide technical guidance to DPDRs regarding equipment procurement and development of facilities required to enhance program effectiveness. C1.4.4.6. Maintain and control the Consolidated DoD Bidders List. C1.4.4.7. Respond to private and public sector inquiries pertaining to the recovery and sale of scrap. C1.4.4.8. Provide sales services and marketing advice to the Military Services on the operation of DoD Directive 4165.60, "Solid Waste Management-Collection Disposal, Resource Recovery Recycling Program." C1.4.5. Defense Property Disposal Regions (DPDRs) Responsibilities: C1.4.5.1. Supervise and provide administrative and technical support to assigned sales office(s) and DPDOs. C1.4.5.2. Coordinate, develop and implement required ISAs with DoD Components. C1.4.5.3. Conduct sales and provide related contracting support. C1.4.5.4. Provide appropriate command guidance and technical assistance to DPDOs. C1.4.5.5. Assist all assigned organizational elements to obtain needed equipment and facilities. C1.4.5.6. Ensure that scrap is handled and stored in strict compliance with applicable safety, health, and environmental protection guidelines, as well as security procedures. C1.4.5.7. Monitor compliance with DoD guidance on the demilitarization of scrap. C1.4.6. Defense Property Disposal Offices (DPDOs) Responsibilities: C1.4.6.1. Provide technical assistance to generating activities in the identification, segregation, collection, and storage of scrap at its source and, where feasible, provide containers to the scrap generator. C1.4.6.2. Receive authorized scrap generations. C1.4.6.3. Ensure adequate storage and security for scrap receipts. C1.4.6.4. Dispose of scrap in such a way as to maximize net return to the Government. C1.4.6.5. Perform market research to determine best sales method and optimum lot sizes. C1.4.6.6. Inspect DoD Component landfills to ensure that no salable property or recyclable scrap (including precious metal-bearing scrap) is abandoned. C1.4.6.7. Optimize procedures for recovery of strategic and critical materials (including precious metals) from scrap generations. C1.4.6.8. Ensure that scrap is handled and stored in strict compliance with applicable safety, health, and environmental protection guidelines, as well as security procedures. C1.4.6.9. Comply with DoD guidance on demilitarization of scrap. C1.4.7. Defense Property Disposal Precious Metals Recovery Program: As operational manager for recovery aspects of the Precious Metals Recovery Program (PMRP), DPDS provides recovery equipment to generating activities on a non-reimbursable basis, issues disposition instructions for the movement of precious metal-bearing materials to collection/recovery sites, and performs contracting and contracting support functions regarding the recovery of precious metals by commercial refiners. As secondary-level field activities reporting to DPDS, the DPDRs, through assigned Precious Metals Area Representatives (PMARs) provide technical support to DoD and participating Federal Civil Agency-generating activities and DPDOs and assist them in improving the cost effectiveness of the PMRP. C1.4.8. Defense Industrial Supply Center (DISC) Responsibilities: As integrated DoD manager for fine precious metals, DISC is responsible for storage and issue of refined precious metals recovered through the PMRP. Costs incurred by DPDS are totally reimbursed by DISC from the Defense Stock Fund. C1.4.9. Defense Contract Administration Services (DCAS) Responsibility: DCAS and its subordinate Defense Contract Administration Services Regions (DCASRs), Defense Contract Administration Services Management Areas (DCASMAs), and Defense Contract Administration Services Plant Representative Offices (DCASPROs), under the direction of the Director, DLA, administer assigned contracts, including those that require contractors to dispose of scrap generated from work specified in their contracts. C2. CHAPTER 2 A SCRAP OVERVIEW C2.1. GENERAL Thus far the term "scrap" has been used in a general sense. In the scrap recycling industry, the word "scrap" usually applies only to ferrous metal materials (iron or steel), which have no value except for their basic material content. "Metals" is the term the scrap recycling industry uses to describe nonferrous scrap, such as brass, copper, stainless steels, high-temperature alloys, lead, zinc, aluminum, magnesium, manganese, cobalt, chromium, tin, nickel, cadmium, tungsten, titanium, mercury, and the precious metals. Other scrap, such as textiles, paper, plastics, chemicals, used or contaminated petroleum products, used synthetic lubricants, used solvents, rubber, leather, wood, and food residue are referred to as nonmetallic scrap. In the Department of Defense, the term "waste" means used or unused property, residues, by-products, sludges, and other materials that have no known utility and, therefore, must be discarded. C2.2. FERROUS SCRAP C2.2.1. Although the terms iron" and "steel" are frequently used interchangeably, they are not the same. Both iron and steel belong to the ferrous family, and their basic content is the element iron, but iron and steel are quite different materials. C2.2.2. Iron has a rather high carbon content; and it is cast into molds to produce such items as automobile motor blocks. It tends to have a granular structure, like an apple. C2.2.3. Steel is also iron, but has been refined to eliminate most of the carbon. Steel can be either carbon steel or alloy steel. Carbon steel, the most common type of steel, varies in carbon content, the higher the carbon content, the harder the steel. Alloy steels are iron-based, but contain varying amounts of other elements (such as chromium, nickel, manganese, silicon, vanadium or molybdenum) that are added to provide heat, wear, and/or corrosion resistance. Stainless steel, for example, is an alloy steel that contains various percentages of nickel and chromium. Steel is generally fibrous, something like celery. It may be produced in the form of steel castings or rolled into such products as bars, structural shapes, plates, sheets, pipe and rails. C2.2.4. Use of iron and steel scrap, which has a much lower carbon content than raw pig iron produced from iron ore, shortens the melting process in all types of furnaces and thus, significantly reduces energy requirements and other costs involved in the manufacture of iron and steel products. Moreover, iron or steel manufactured from recycled ferrous scrap usually results in a better end product than that produced solely from raw pig iron, no matter how old or rusted the scrap may be. C2.2.5. Four types of furnaces--open-hearth, electric, basic oxygen, and blast--constitute the principal producing units of today's steel industry. (See Figure C2.F1.) C2.2.5.1. The blast furnace is primarily used to reduce iron ore into pig iron or "hot metal." When iron from the blast furnace is cast and chilled into molds, it is called pig iron. When it is tapped into a ladle and conveyed directly to an open-hearth furnace for refining into steel, it is called hot metal. C2.2.5.2. Ferrous materials are loaded into open-hearth furnaces either as a "cold" charge (usually iron and steel scrap) and/or a "hot metal" charge of molten iron. About 41-43 percent of the total ferrous input to open-hearth furnaces is scrap. Limestone is used for the bottom layer of the furnace to draw off impurities. Then iron ore, scrap, and hot metal are added, in that order, on top of the limestone. Before the melting process is completed, more scrap and hot metal are usually added. The tremendous heat that passes over this molten bath vaporizes impurities or attracts them to the top as slag. After 8 or 9 hours, the slag on top is tapped off and the steel is poured into a ladle for casting into ingots. Figure C2.F1. Ferrous Scrap Cycle C2.2.5.3. Basic oxygen furnaces that employ the Linz-Donawitz (L-D) process (in which the bath of molten metal is lanced with a jet of oxygen) use only about 25-30 percent scrap. Because of their relatively low cost of construction and operation (as compared to open-hearth furnaces) and the fact that they require less than 1 hour per heat, L-D capacity throughout the world is increasing. C2.2.5.4. Electric furnaces that use electric energy for heat are operated as a non-oxidizing melting furnace that can accept up to a 100 percent charge of scrap under certain conditions. (Normally, however, a charge of about 96 percent scrap and four percent pig iron is used.) Because of their low energy consumption and the low initial capital outlay required, these furnaces are also assuming an increased share of world steel production. C2.2.6. Segregation of most ferrous scrap (iron and carbon steel) is based more on the physical dimensions of the scrap rather than on the chemical composition of the scrap. However, in the case of alloy steel scrap (see Chapter 5), segregation should be based primarily on its alloying constituents. C2.3. NONFERROUS SCRAP C2.3.1. The term "nonferrous scrap" applies to all metallic scrap, except that which consists primarily of iron and steel. Because of the fact that we must depend on foreign sources for supply of a large portion of our requirements for nonferrous metals, and because of the high market price of nonferrous scrap per unit of weight, the handling of nonferrous scrap deserves top priority attention by all concerned. C2.3.2. Nonferrous metals have unique individual properties and characteristics, such as high corrosion resistance, lightness with strength, high reflectability, electrical and thermal conductivity; excellent bearing qualities, and spark resistance. The strength, hardness, and elasticity of nonferrous metals varies with the type of alloying constituents and the exact percentage of each used in the alloying process. A variation of only a few tenths of one percent in one element of the alloy may significantly change the physical characteristics of the alloy. C2.3.3. Most of the complexity that smelters encounter when using nonferrous scrap is a result of contamination caused by improper segregation and classification. When nonferrous scrap is kept clean, properly classified, and free from contamination with other materials, it can be used to produce an ingot that compares favorably for many purposes with a virgin ingot. Conversely, any degree of contamination will seriously degrade the value of otherwise good scrap for use in producing a fully acceptable alloy. Specifications for all nonferrous alloys are very definite and strict. The mixture of any quantity of off-grade scrap can contaminate a pile of otherwise good quality scrap. When this occurs in the remelting process, the entire melt must be upgraded by adding more precisely identified metals (e.g., copper, tin) to bring the alloy up to standard specifications. C2.4. NONMETALLIC SCRAP The recovery of this type of scrap is a vitally important element of the DoD Scrap Recycling Program since it is continuously generated in large quantities at all DoD installations. Although it may not appear to be as glamorous to handle as other types of scrap, it provides much greater benefits (in terms of sales proceeds) because of its higher value per ton than does ferrous scrap. Those segments of the scrap recycling industry concerned with processing nonmetallic scrap are, in many ways, more complex and varied than those concerned with metallic scrap. C2.5. SCRAP RECYCLING CONSERVES NATURAL RESOURCES C2.5.1. As indicated at the beginning of Chapter 1, the most important reason for recycling DoD scrap generations is to conserve our rapidly dwindling natural resources, including those required for the production of energy. In addition, the DoD Scrap Recycling Program can contribute significantly to reducing the net cost of other DoD programs by reducing outlays otherwise required to effect environmentally safe abandonment or destruction of hazardous scrap through costly service contracts. This effort returns millions of dollars generated from scrap sales to the U.S. Treasury and DoD activities, and utilizes precious metals recovered from scrap for authorized internal purposes or as Government-Furnished Material (GFM) to DoD contractors. C2.5.2. A ton of recycled ferrous scrap can replace over one and one fourth tons of iron ore in the production of steel; and recycled nonferrous scrap currently fulfills 25 percent of the aluminum, 50 percent of the copper, 50 percent of lead, and 14 percent of the zinc requirements of the United States. Our metallic scrap resources can therefore truly be considered as "mines above ground." Similarly, paper scrap can be considered as a "secondary forest" since each ton of waste paper replaces over eight-tenths of a ton of wood pulp, and each ton of wood pulp saved by recycling paper scrap is equivalent to an annual growth of pulpwood timber on 1.6 acres of timberland. Thus the total benefits from paper recycling in the United States currently equates to saving 200 million trees annually or 20 percent of the total raw materials used in paper production. If we could increase this rate to 50 percent, each year we could conserve a forest equal in total area to the states of New Jersey, New York, Pennsylvania, and Maryland. Recycling of other nonmetallic scrap, such as textiles, rubber, oil, and chemicals, has a comparable potential for making a significant contribution to our national economy. C2.5.3. In the area of energy conservation, recycling of ferrous scrap, in lieu of refining iron ore, generates a 60-percent energy savings. For example, the energy saved in producing 1000 tons of steel from ferrous scrap is equivalent to that contained in 140,000 gallons of gasoline. Energy savings resulting from the recycling of nonferrous scrap, in lieu of refining nonferrous ores, range from 60 percent for lead and zinc to 80 percent for copper and 96 percent for aluminum; and recycling of paper and rubber scrap is 60 to 70 percent more energy efficient than is the production of paper and rubber from raw materials. Overall, the National Association of Recycling Industries estimates that at least two percent of total United States energy demand could be met from energy saved simply by recycling available steel, aluminum, and paper scrap. C2.5.4. Despite the substantial benefits of scrap recycling, as outlined above, in reality the DoD Scrap Recycling Program to date has only addressed the "tip of the iceberg." It is therefore of vital importance that the Department of Defense, as one of the world's major consumers of scarce natural resources, takes the lead in enhancing the efficiency of its recovery and recycling of scrap. C3. CHAPTER 3 SCRAP YARD ORGANIZATION C3.1. GENERAL The organization and mission of each DoD scrap recycling activity varies depending on the quantity and type of scrap recovered, the layout and quality of available physical facilities and equipment, the varying requirements of scrap buyers, and the presence or absence of special legal, political, or environmental constraints. Therefore, rather than arbitrarily suggesting specific scrap yard models to which each DoD scrap yard should conform, this Handbook classifies scrap yards into three broad, general categories, as follows: C3.1.1. Type "A" Scrap Yard--Small. This type of scrap yard usually serves small activities (such as recruiting stations, Reserve units, small remote communication stations, or auxiliary air stations), which generate up to 500 tons of scrap per year. The suggested layout of a Type "A" scrap yard is a smaller scale version of the Type "B" yard. C3.1.2. Type "B" Scrap Yard--Medium. (See Figure C3.F1.) This type of scrap yard serves slightly larger activities that generate from 500 to 2000 tons of scrap per year. C3.1.3. Type "C" Scrap Yard--Large. (See Figure C3.F2.) This type of scrap yard supports major installations, including those that have large production or repair activities (such as shipyards, supply centers, air bases, large ammunition depots or ordnance plants) that generate more than 2000 tons of scrap per year. C3.2. FACILITY LAYOUT Each scrap yard should be designed to minimize scrap handling and to enhance cost effectiveness, wherever feasible, by mechanizing scrap yard operations. Each time a piece of scrap is moved, the cost of handling that piece of scrap increases. Therefore, whenever possible, the "handle it once" rule should apply. Off-loading material from delivery trucks direct to the appropriate scrap pile or lot will eliminate unnecessary duplicate handling. The model layouts of Type A and B yards (Figure C3.F1.) and a Type C yard (Figure C3.F2.) are meant only as guides. In designing new facilities or improving existing facilities, consideration should be given to the following factors: C3.2.1. Access to Water or Rail Transportation. This will not only facilitate mechanization of scrap yard operations, but may significantly increase sales proceeds by making it possible to market scrap in shipload, bargeload or railcar lots. C3.2.2. Scrap Yard Office. The scrap yard office should not only provide suitable administrative space, but may also include secure covered storage for high-value scrap (e.g., that containing precious metals), a break and lunch area for scrap yard personnel, and a suitable reception and display area in which to receive customers. C3.2.3. Truck/Railroad Scales. (See Figure C3.F3.) Since scrap should be weighed when received or released, consideration should be given to locating the scale close to the scrap yard entrance. However, this may not be essential, particularly in a small scrap yard, if a nearby scale is available for scrap yard use. Yards that normally receive and release scrap in small quantities (generally less than 10,000 pounds) should consider the use of accurate platform scales or forklift scales as a substitute for a truck scale. C3.2.4. Storage Space. One of the most important considerations in scrap yard layout is to identify the quantity arid type of inside and outside storage required. Inside storage is needed for certain types of hazardous material, for high-value scrap requiring special security arrangements, and for scrap that must be protected from exposure moisture or to temperature extremes. C3.2.4.1. Examples of specific types of scrap that require covered storage include the various grades of paper and textile scrap that must be sold dry, small arms brass that should be protected from corrosion and exposure to undesirable contaminants that substantially reduce their value for reloading, precious metal-bearing electronic scrap, high-temperature alloys, and copper scrap that require storage under controlled conditions of temperature and humidity. (See Figure C3.F4.) C3.2.4.2. Some forms of scrap (e.g., scrap tires, ferrous scrap) are best stored in open storage because of their bulkiness, low value, or the quantity of generations. (See Figure C3.F5.) Bulky items that are most efficiently stored when palletized may require some form of improved surface to facilitate safe loading, unloading and placement by forklift. Although ferrous scrap can be stored on an unimproved surface, storage on an improved surface will minimize dirt and gravel contamination from loading operations. Figure C3.F1. Type B Scrap Yard Layout Figure C3.F2. Type C Scrap Yard Layout Figure C3.F3. Truck Scale. Scalehouse Located Immediately Adjacent to the Scale Figure C3.F4. High-Value Scrap Is Accorded Inside Storage When Space Is Available Figure C3.F5. Open Storage Is a Necissity for This Quantity of Ferrous Scrap. Figure C3.F6. A Modern Scrap Recyclilng Facility With Concrete Bins C3.2.4.3. When expected generations of scrap are known and predictable, bin storage is usually the preferred type of storage. Where bins are used, reinforced concrete bins constructed on concrete pads have the advantage of being able to withstand damage inflicted during loading operations, minimize contamination with dirt, and facilitate zeroing-out of scrap inventory. Such bins can also aid in converting yesterday's "junk yard" into today's modern scrap recycling facility. (See Figure C3.F6.) The resulting improvement in the image presented by a DoD scrap yard will be helpful in promoting better public and host-tenant relations, attracting increased buyer participation in DoD scrap sales, and improving the morale of scrap yard employees. Bins may also be constructed of wood, pierced steel planking (PSP), or other locally available materials. (See Figures C3.F7. and C3.F8.) In some cases, where generations fluctuate greatly, it may be desirable to make use of movable dividers, set on concrete pads, to delineate the backs and sides of scrap bins. C3.2.4.4. Other movable storage devices (such as hoppers, drums, engine or Conex containers) may be used, in addition to scrap bins, in order to minimize manual handling of scrap, store small amounts of high-value scrap, promote source segregation of scrap, and facilitate subsequent segregation of scrap. (See Figures C3.F9. through C3.F22.) C3.2.4.5. In determining an optimum facility layout, each scrap yard must carefully evaluate its unique functional needs, considering types and amounts of scrap to be handled, types and amounts of equipment needed, geologic and climatic conditions, and locations and suitability of available buildings and grounds. When physical improvements are appropriate, scrap yard personnel must work closely with host engineers to define their construction requirements. Since each new construction project must be well documented, thoroughly justified, and processed through lengthy and time-consuming coordination and approved channels, it is imperative to identify and quantify all costs and benefits, both tangible and intangible, to ensure that it is cost-effective before preparing and submitting a formal project request. Figure C3.F7. This Scrap Yard, Although Functional, Has Recently Been Upgraded. (See Figure C3.F8.) C3.3. EQUIPMENT C3.3.1. Identifying Equipment Needs. Each scrap yard must identify its equipment needs based upon thorough analysis of the following factors: C3.3.1.1. Safety and health requirements. C3.3.1.2. Environmental practices conforming to all Federal, State, and local environmental laws. C3.3.1.3. Type of scrap received. C3.3.1.4. Frequency and magnitude of scrap generations. C3.3.1.5. Topographical and climatic conditions. C3.3.1.6. Facilities layout. C3.3.1.7. Legal and political constraints. C3.3.1.8. Availability of qualified equipment operators and suitable equipment maintenance support. C3.3.1.9. Costs versus benefits. C3.3.2. Safety Equipment. It is mandatory that every DoD scrap yard be provided with appropriate personal protective equipment (PPE); and the scrap yard manager must ensure that other needed safety equipment is readily available and in continual use. PPE includes items such as safety clothing, gloves, goggles, face shields, hard hats and safety shoes. Included in the category of other needed safety equipment are signs designating areas where the use of PPE is either mandatory or recommended and signs marking the locations of fire extinguishers, eyewashes, and safety showers. Since safety is everyone's business, it is the responsibility of every scrap yard employee to ensure that appropriate PPE is available and properly used. Equipment with safety features (e.g., cages, roll bars, kill switches) should be placed in an inoperative status whenever safety features are not fully functional or effective. C3.3.3. Equipment Determinations. Equipment for Type A, B, or C scrap yards is not determined solely on the basis of size of the yard, but rather by need. If a Type B yard, which normally would not require a cable stripper, can justify the need and show a cost payback from sale of large quantities of stripped copper wire, that Type B yard should initiate action to obtain this equipment. C3.3.4. Equipment List. It is not feasible to separately identify the specific equipment needed by a particular scrap yard, since each scrap yard must tailor its equipment inventory so as to optimize its own scrap operations. This means that only needed equipment should be retained, that it meets specific needs of that scrap yard, and that it be efficiently utilized. Tabulated below is a list of basic scrap yard equipment from which each DoD scrap yard should develop its own requirements: C3.3.4.1. Safety Equipment. There should be sufficient personal protective equipment on hand to meet the needs of all scrap yard employees and scrap yard visitors. In addition, each scrap yard must have its own eyewash unit(s) and shower(s), fire extinguishers, first-aid kits, and signs marking locations of the safety equipment. C3.3.4.2. Material Handling Equipment (MHE): C3.3.4.2.1. Cranes, truck/rail-mounted and/or crawler, equipped with magnet(s) for handling ferrous scrap and other appropriate lifting accessories. (See Figures C3.F9. through C3.F12.) C3.3.4.2.2. Forklifts (see Figures C3.F13. through C3.F15.), in appropriate sizes (e.g., 4,000 lb., 6,000 lb., 15,000 lb.), equipped with puncture-proof tires and appropriate accessories (e.g., rotary head, barrel grabber). Sizes and numbers of forklifts at each location should be determined by the type, size, and amount of scrap being handled. Local scrap yard facilities and topographic conditions will determine the mix of rough terrain models with standard models, and electric models with internal combustion models. C3.3.4.2.3. Front-end loaders, wheeled or crawler. In some instances, it may be more cost-effective to use front-end loaders to move scrap than to use cranes. C3.3.4.2.4. Warehouse tugs may supplement fork lifts, in some instances, for moving and spotting hoppers, engine containers, drums, boxes, and pa