Part 3

This necessitated, of course, that the cross-passages between that in which the fan was placed and the mouths of the tunnels should be blocked tight. There was some difficulty in keeping this blocking tight, owing to the force of the blasting blowing out the bulkheads. The fan, however, did good service when it and the bulkheads were in good order. The compressed air discharged from the drills kept the headings fairly clear, as well as that part of the tunnel between the headings and the fan. The fan was moved ahead to the next cross-passage at Station 277 when the work had progressed far enough, and was used there for some time; it was found, however, that by the time the excavation had reached Station 280, about 1,500 ft. from the shaft, there was practically no further difficulty from fog and smoke. No satisfactory explanation was found for this, as it would rather be expected that the ventilation and trouble with smoke and fumes from blasting would be worse as the distance increased between the mouth of the tunnel and the working face. One explanation was offered: That the blasting of the softer sandstone tended to create more and lighter dust than the heavier trap rock; whether or not this was so, it is a fact that there was far less trouble with fog and smoke after the sandstone was passed.

At Hackensack, the principal cause of trouble was the smoke from the "dinky" locomotives. As the tunnels progressed, this gradually became worse, until a connection was made with the Central Shaft headings. A fan was installed in the cross-passage at Station 316 (700 ft. in from the portal), but was never worked properly. Apparently, the men, at least the walking bosses and foremen, had little faith in the fan as a means of ventilation; no real attempt was made to keep it in order or operate it properly, and a great deal of time and money was lost groping around in the smoke and fog, the density of which increased, not only with the state of the atmosphere, but also with the direction of the wind. On some days the tunnels easily cleared themselves, and on others the smoke was so thick that a candle held at arm's length could not be seen. At this end, the South Tunnel was generally worse than the North. After the headings were holed through between the portal and the Central Shaft there was very little trouble, there being usually a strong up-draft through the shaft. This was so pronounced when the wind was blowing toward the portal, that the moisture-laden air, as it ascended from the mouth of the shaft, presented the appearance of a heavy rainstorm with the rain ascending instead of descending. When the wind was blowing away from the portal, that is, from the southeast, the effect of the shaft as a chimney was neutralized, and, consequently, the smoke accumulated in the tunnels. To overcome this, a large blower, with a fan 9 ft. in diameter, and with blades 4 ft. wide and 2 ft. 3 in. long, operated by a vertical 12-h.p. engine, was installed at the top of the shaft, and this kept the tunnels reasonably clear of smoke at all times. After the bench and enlargement had passed the bottom of the shaft, the use of the fan was abandoned, as it was found that the tunnels cleared themselves fairly well, probably owing to the larger cross-section reaching all the way to the Shaft. What little fog and smoke there might be did not cause enough trouble to warrant the cost of running the fan, which, owing to its location, required the whole time of a mechanic in attendance day and night.

_Lighting._--During the earlier stages of the work, gasoline lamps and Kitson lights were used. The former, of the familiar banjo type, and a modification of this, with a section of wrought-iron pipe for the reservoir, were very unsatisfactory, and were out of repair and leaking a large proportion of the time. The Kitson lights were given only a short trial, but were found unsatisfactory, owing to the necessity of moving them frequently and having to set them up in insecure positions. Electric lights were installed by Mr. Bradley, on his assumption of the contract.

The number of lamps maintained in each of the tunnels for the excavation was approximately as follows:

At the main working face From 8 to 10 On and around the shovel " 9 to 12 Between the portal and the working face " 60 to 80

The cost of lighting for the whole work averaged about 15 cents per cu. yd., which is quite large. This was mainly due to the fact that current was bought from outside sources during a large part of the time (one-third of the yardage). Part of this current cost 5 cents per kw-hr., and there were fairly heavy charges for connecting the tunnel wiring system with the source of supply. Current bought from the Public Service Corporation cost from 10 to 12 cents per kw-hr. delivered at the mouth of the tunnel.

_Pumping._--The quantity of water encountered during the excavation of the tunnels, measured somewhat roughly, was approximately as follows:

At Weehawken 74 gal. per min. At Central Shaft 1 " " " At Hackensack 18 " " "

The water at the Weehawken end had to be pumped from the bottom of the shaft, a lift of about 90 ft., while at the Hackensack end it had to be pumped back from the face up grade to the portal.

The cost of pumping was about $100 to $125 per month for labor for the whole work, besides the cost of the plant (about $1,200) and the power for running it.

PROGRESS.

The total time elapsed from the time of starting work at the Weehawken end, in May, 1905, to the completion of the excavation, in May, 1908, was almost exactly three years. Of this time about 40 days were lost in February and March, 1906, when work was stopped by the Receiver of the Shields Company, the total number of days actually worked being about 940, giving an average progress of 6.26 ft. per working day in each of the two tunnels, which, omitting the Central Shaft headings, gives an average rate of progress for each working face, of 3.13 ft. per day.

These 940 days include practically all the time elapsed, except Sundays and such few holidays as were observed. For some of this time, work was being carried on at only one or two points; the time, therefore, represents practically the total possible working time during the period covered.

_Progress at Weehawken._--At Weehawken the total number of days worked was 763, divided as follows:

186 days in timbered section, about 426 ft., an average rate of 2.3 ft. per day in each tunnel;

176 days in hard sandstone, about 563 ft., an average rate of 3.2 ft. per day in each tunnel;

112 days in hard trap, about 267 ft., an average rate of 2.4 ft. per day in each tunnel;

289 days in ordinary trap, about 1,316 ft., an average rate of 4.55 ft. per day in each tunnel.

_Progress at Central Shaft._--At Central Shaft the average length driven per day in each of the four headings is shown by Table 4.

TABLE 4.

+----------------+-----------------+---------------------+ Location. | Number of days | Total length of | Average length of | | worked. | heading, in | heading driven per | | | feet. | day worked, in feet.| -----------+----------------+-----------------+---------------------+ | | | | N.E. | 227 | 446 | 1.96 | S.E. | 168 | 346 | 2.06 | N.W. | 272 | 768 | 2.82 | S.W. | 234 | 698 | 2.98 | -----------+----------------+-----------------+---------------------+

_Progress at Hackensack._--At Hackensack the total number of days worked on the tunnels proper, all in trap rock (omitting the cut and cover) was about 792, divided as shown in Table 5.

TABLE 5.

+----------+----------+----------+ |Number of | | Average | Location. | days | Advance. | advance | | worked. | | per day. | ------------------------------+----------+----------+----------+ Station 323 to Central Shaft | | | | headings | 492 | 1,450 | 4.5 | Bench and enlargement of | 159 | { 1,150* | 7.2* | Central Shaft headings | | { 906**| 5.7** | Central Shaft headings to | | | | Weehawken headings | 141 | 620 | 4.4 | ------------------------------+----------+----------+----------+

[* Actual advance.]

[** Equivalent linear feet of full section tunnel.]

The best month's work in each location was as follows, the actual yardage excavated and paid for being reduced to equivalent linear feet of full section. The tunnels were generally taken out to full section, except for a small amount left in the bottom, which latter reduced the equivalent linear feet of full section to about 95% of the actual advance at the face.

_Weehawken._-- Feet Linear per feet. day. Full timbered section, North Tunnel Nov., 1905, 87 = 3.0 Sandstone " " May, 1906, 109 = 3.9 Trap (normal) South " July, 1907, 144 = 5.3

_Hackensack (All trap)._-- Feet Linear per feet. day.

Portal to Central Shaft headings, South Tunnel May, 1907, 139 = 5.0 * Enlargement of headings, " " Nov., 1907, 175 = 6.0 Central Shaft headings to Weehawken headings, North Tunnel Apr., 1908, 145 = 5.2

[* The actual advance of the bench this month was 202 lin. ft.]

_Central Shaft Headings._--During April, 1907, 122 lin. ft. of heading, averaging 3.8 cu. yd. per lin. ft., were taken out in the South Tunnel, west of the shaft. This was equal to 5.0 ft. per day for the 24 days worked.

_The Best Week's Work._--The best week's work at either of the main working faces, when the full section was being excavated in trap rock, was 803 cu. yd., equal to 41.8 lin. ft. of full-section tunnel, or an average of 6.0 lin. ft. of full section per day; this was from the South Tunnel at Hackensack for the week ending January 11th, 1908.

_The Best Yardage._--The largest number of yards taken out in any one week from one working face was 1,087, equivalent to 56.6 lin. ft. of full section, or an average of 8.1 lin. ft. of full section per day. This was bench and enlargement only (Central Shaft headings) in the North Tunnel, Hackensack, for the week ending October 19th, 1907.

The largest yardage for the whole work in any one week was 3,238 cu. yd. from four working faces--two at Weehawken in full section and two at the Hackensack bench and enlargement (Central Shaft headings). This was equivalent to 168.4 lin. ft. of full-section tunnel, or an average of 6 ft. per day from each working face.

_The Best Month's Work._--The best month's work with each of the four methods of drilling the headings, as shown in Figs. 1, 2, 3, and 4, where the work was straight forward and the full section was being taken out, was as follows:

Method No. 1 About 90 ft. in sandstone. " No. 2 " 100 " in trap. " No. 3 " 137 " in trap. " No. 4 " 145 " in trap.

In regard to these figures it should be noted, as stated previously, that the organization of the men and plant was not properly completed until near the time Method No. 4 was put in operation.

In Fig. 9 is shown graphically the relation of the progress to the time elapsed in the North Tunnel, the diagram for the South Tunnel being almost exactly the same.

PLANT.

The plant installed by the John Shields Construction Company, and taken over by Mr. Bradley, was composed very largely of second-hand material, and eventually most of it had to be replaced. Insufficient and inefficient plant and delay in installation were largely responsible for the small progress made by the Shields Company, and Mr. Bradley's endeavor to utilize this plant not only caused much delay during the first 8 or 10 months after he started work, but also involved large expense.

_Power Plant._--At Weehawken the plant installed by the Shields Company consisted of three old locomotive boilers, each having a nominal capacity of about 125 h.p., and one Rand and one Ingersoll-Sergeant compressor, each of a rated capacity of about 1,250 cu. ft. of free air per min. compressed to 100 lb.

To this Mr. Bradley added two more second-hand locomotive boilers, and another Rand compressor of the same type and capacity as the first. The theoretical steam capacity of each of the five old locomotive boilers was about 4,250 lb. per hour, or a total capacity of 21,250 lb. per hour.

Theoretically, the demand on this steam was:

Pounds per hour.

Three compressors, about 5,600 lb. per hour each 16,800 One dynamo About 1,000 One 500-gal. pump " 1,000 One hoisting engine for elevators " 2,000 ______ Total 20,800

Actually, there was considerable deficiency of steam when an endeavor was made to work the three compressors at their full capacity. A separate boiler was afterward installed to run the hoisting engine for the elevators and the pumps, thus leaving a requirement of only approximately 18,000 lb. of steam per hour, but even this was beyond the capacity of the boilers, especially as one was almost always out of commission.

The two Rand compressors were 24 by 24 by 30-in., straight-line, one-stage, steam-driven, with a nominal capacity of 1,250 cu. ft. of free air per min. at 80 rev. per min. The Ingersoll-Sergeant was of similar type and capacity. Therefore, the theoretical quantity available was 3,750 cu. ft. of free air per min.

The theoretical air requirements (as taken from manufacturers' catalogues) were:

Cubic feet of free air per minute.

20 Rand slugger drills (12 by 174) 2,088 2 Little Giant shovels (taking air two-thirds of the time) 1,100 ----- Total 3,188

This estimate, based on the assumption (given in the catalogues) that the drills would be working about three-fifths of the time, and the shovels about two-thirds of the time, left apparently an ample margin between the full capacity of the compressors and the requirements for the drills; as a matter of fact, however, it was seldom that more than 80 lb. of air was available, and the pressure often dropped to 60 or 50 lb. at the compressors. During the time this plant was in use the greatest distance to the drills was about 1,500 ft.

As this plant proved to be entirely inadequate to the demands, an arrangement was made with the O'Rourke Construction Company on August 17th, 1906, whereby they agreed to supplement the air supply by 1,000 cu. ft. of free air per min. at 100 lb. pressure. This arrangement was not altogether satisfactory, and finally (on December 5th, 1906) an arrangement was made with the same company to supply air up to 4,000 cu. ft. of free air per min. at 100 lb., and the old plant was shut down.

The new plant had been in use previously in the construction of the River Tunnels. The air from it was compressed to 40 lb. by low-pressure machines, one being used all the time and two when necessary. These machines were built by the Ingersoll-Sergeant Company, the engines being of the Corliss duplex type, cross-compound steam, with simple duplex air cylinders, each compressor having a capacity of nearly 4,000 cu. ft. of free air per min. This air, at 40 lb., was delivered to an Ingersoll-Sergeant high-pressure machine, having Corliss cross-compound engines, 14 by 26 by 36-in., with air cylinders of the piston inlet type, 13¼ by 36-in., which compressed it to 100 lb. The capacity of this latter machine, taking air at normal pressure, is 920 cu. ft. of free air per min. working at 85 rev. per min.; by taking the air at 40 lb., and working at a somewhat higher speed, this machine alone supplied all the air used at the Weehawken end (approximately 4,000 ft.) from December, 1906, to November, 1907, and, with very few exceptions, the pressure was steadily maintained at from 90 to 100 lb., there being no break-down of any kind.

At Hackensack the plant taken over by Mr. Bradley consisted of six old locomotive boilers and four Rand compressors, all of the same type as those at Weehawken. To this he added two second-hand marine boilers, each of a stated capacity of about 350 h.p., and two more Rand compressors of the same type and capacity as the others, making the total theoretical steam power available approximately 1,450 h.p., with a compressor capacity of approximately 7,500 cu. ft. of free air per min., equal to about 1,500 h.p., allowing for 15% of loss.

Nowhere near the theoretical steam power was ever developed from the boilers. The tubes of the old locomotive boilers were filled with mud in many cases, and were always leaking. The marine boilers were not properly installed to give the best results, and it was seldom possible to work more than four compressors at once, or to keep the air pressure at the power-house much greater than from 70 to 80 lb. at any time.

This plant had been built by the Shields Company on the meadows alongside the Erie and New York, Susquehanna and Western Railroads, and the foundations were not made sufficiently strong to resist the effect of the vibration caused by the passing trains. It was impossible to keep the steam connections tight, and there was not only the loss of steam due to leaky joints, but positive danger of one of the main steam lines breaking entirely. After attempting to operate this plant for nearly 5 months, Mr. Bradley determined to abandon the site and the boilers, and build a new plant, farther back from the railroad, on solid ground, in such a position that a spur track could be built to a coal trestle in front of the boilers.

Two pairs of Stirling boilers, with a total capacity of 2,000 h.p., were installed. As a rule, at times of maximum demand, three of the boilers were in use; after the Central Shaft was stopped, two were generally sufficient, until, toward the latter part of the excavation, the losses in the transmission of the air made it necessary to keep three going.

Eight compressors (the six old ones with two brought from Weehawken), were installed in the new power-house. All were of the same type, namely, Rand, straight-line, steam-driven, 24 by 24 by 30-in., each with a nominal capacity of 1,250 cu. ft. of free air per min. Seven of these were generally worked to their full capacity in order to keep up the necessary supply of air.

The maximum requirements of air at this end were primarily estimated as follows:

Central Shaft, four headings 24 drills. Hackensack, two working faces 20 drills. ---------- Total 44 drills.

Cubic feet of free air per minute.

44 Slugger drills (25 by 174) require 4,350 2 Steam shovels 1,600 Pumps and machine-shop, say 1,000 4 Hoisting engines, placing concrete 2,000 4 Derricks 2,000 ------ Total 10,950

The theoretical capacity of the whole eight compressors was:

1250 × 8 = 10,000 cu. ft. of free air per min.

It was considered that not more than two-thirds of the above equipment would be working at the same time; the actual requirement, therefore, was taken at about 8,000 cu. ft. of free air per min., thus leaving a margin of one spare compressor.

As actually worked out, there were probably never more than eight drills working at any one time at the Central Shaft, and this work was entirely suspended in June, 1907, before there was any demand for power in connection with the tunnel lining. The heaviest actual requirement, therefore, was approximately as follows:

(_A_) _Previous to June 25th, 1907:_

Cubic feet of free air per minute.

40 Drills (22 by 174) 3,828 2 Shovels 1,600 Pumps and machine-shop, say 1,000 2 Derricks 1,000 ----- Total 7,428

(_B_) _After November, 1907_ (_after completion of enlargement of Central Shaft headings_): Cubic feet of free air per minute.

32 Drills (17 by 174) 2,958 2 Shovels 1,600 Pumps, etc 1,000 3 Hoisting engines on concrete, each working one-third time 500 2 Derricks 1,000 ----- Total 7,058

The average number of drillers per shift was about 25 at the two main working faces. There were also from 5 to 10 drills trimming and cleaning up for concrete, say an average of 7, making 32 in all.

After November 1st, it actually required three boilers under steam all the time, and not less than seven compressors running at full capacity, to keep the air at proper pressure, the theoretical capacity of the compressors being 8,750 cu. ft. of free air per min., as against 7,000 to 7,400 cu. ft., the theoretical maximum requirement.

Some of this deficiency was due to losses in transmission, part also was due to the fact that the actual was probably considerably below the theoretical capacity of the compressors.

ACCIDENTS.

Two accidents occurred to the powder magazines, the causes of which were never absolutely determined. The first occurred on January 10th, 1907, when the dynamite burned up without exploding. The second accident was on March 3d, 1907, when an explosion occurred which damaged property over a very large area, but did not involve any serious injury to persons, only one man being slightly hurt.

The only serious blasting accident in the tunnels occurred on January 26th, 1908, and was due to a premature blast, the cause for which could not be ascertained.

_Contractor's Organization._--The work was in general charge of a superintendent, and, during the time it was being carried on at both ends, an assistant superintendent had charge at night. At each end there was a day and a night walking boss, who had general supervision of the men in the tunnels, the day walking boss being the superior, and responsible for the general conduct of the work at his end, both day and night. Two 10-hour shifts were worked, thirteen shifts every two weeks, no work being done on alternate Sundays and Sunday nights. With the exception of the walking bosses and the master mechanic, all the men changed from the day to the night shift every two weeks.

The organization was approximately as follows, for each shift:

_General_--_Both Tunnels._