Author Archives: Colby

Alliance Brick Industry

This article was written for and first appeared in a local newspaper.  The name of the paper and publication date are unknown.

by Gary Miller

They stand like sentinels at attention, three decrepit and timeworn red brick buildings, in a row, looking down on what once was.  Their windows broken and boarded-up, they give little indication of the half-century of enormous productivity that took place below them.

These three buildings stand at the edge of a multi-acred section of property bordered by U.S. Route 62 and South Mahoning Avenue in Alliance.  Extending out from them, in a northeasterly direction, stand the structural remains of a once-thriving brick and clay products industry that helped make Stark County the paving brick capitol of the world in the 1920’s.  As early as 1907, James Wilcox’s Alliance Clay Products Company was turning out 18,000 brick a day from a single plant at 1500 South Mahoning Avenue.  By 1924, Wilcox had three plants in operation at the same location and was capable of producing 275,000 bricks a day, or about 50,000,000 a year!  But Mr. Wilcox was not the first.

Brickmaking actually started in Alliance during the 1860’s, just before the civil war.  The distinction as the first successful brickmaker in Alliance goes to Josiah Rosenberry who garnered the clay for his bricks from a pond on what is now known as the Glamorgan Estate.  In 1867 he furnished 650,000 bricks for the construction of Alliance College (now Mt. Union).  Unfortunately, Rosenberry also supplied brick for the construction of the Alliance Opera house, which collapsed without warning on June 2, 1886.  Mr. Rosenberry was out of business shortly thereafter.

The manufacture of clay products did not become an important industry to Alliance until after 1900.  There were five brickmakers and two clay products companies before that time buy only two made it through the turn of the century.  One was Rosenberry.  The other was John Auld and Sons who started in business in 1889 and continued until 1906 when they reorganized and became Alliance Builders Supply Company.  Coincidentally, 1906 was the year of incorporation of the Alliance Brick Company by F.A. Hoiles.  Hoiles built his first plant in 1909 on a 150 acre tract of land between Alliance and Sebring with a production capacity of over a million bricks per month.  But the demand for bricks was on the rise so Hoiles built a second plant on 35 acres of land adjacent to Wilcox’s Alliance Fire Clay Products Company and extended his capacity to almost three million bricks a month by 1926.  By the mid-twenties two major brick producing companies were operating out of that corner section of property bordered by South Mahoning and U.S. Route 62 with a capability of producing upwards of 70,000,000 bricks per year.  Nearly all of this brick was used for road surfacing and building facing.  And it was a very high quality product.

Stark County was, and probably still is, a brickmaker’s paradise.  Thanks to the last glacial period, Stark County is endowed with tremendous quantities of clay, coal, sand and gravel.  For thousands of years, mile-high layers of ice compacted the soil into clay and shale strata that can be found, in varying amounts, almost everywhere in the county.  The glacial period provided us with something else too.  Surface vegetation was compressed and compacted by immeasurable forces into accompanying coal strata.  So the early brickmakers could, and did, find all the raw materials, including fuel, they needed to manufacture their product on the same small parcel of property.  They were, in fact, self-supporting.  An advertisement for Alliance Fire Clay Company in 1868 reads, ‘Most of all the ware manufactured from Fire Clay can be burned with coal, which makes this company almost independent in the nominal cost of mining – while it takes only from five to twenty days for them to turn their raw material into cash, from the time they strike the pick into the clay and coal.’  That is just about any manufacturers’ dream-come-true.  Stark County’s brick industry blossomed to a peak period in 1925 when they contributed substantially to a national production of over 10 billion bricks.

For about seventy years, the clay products industry was of considerable economic importance to Alliance.  The 1960’s saw a change in the industry as Alliance Clay Products began closing plants and Alliance Brick Company began modernization to compete in a changing market.  Alliance Brick held out through the fifties and sixties, employing about 50 men, but eventually sold out to another very old name in Stark County’s clay products industry: Whitacre-Greer.  This situation, however, was not unique to Alliance.  According to the Department of Commerce, paving brick production dropped by 95% from 1925 (the peak period) to 1947.  This was due, in large part, to the development of smoother road surfacing materials needed for the burgeoning automobile industry and the frenzied highway construction efforts of post World War II.  In 1925 there were 13 active brick companies in Stark County; in 1975 there were 5.  Company failures were caused by everything from labor problems to the inability to adapt to new trends.  Marketing savvy began to playing an increasingly important role in business survival.  A 75 percent failure rate for the clay construction products industry with a 50 year period pointed unerringly to centralization of the industry.  The day of the small operator was over.  Now, just a few plants that have been modernized and streamlined equal, and exceed, the output of the many smaller companies of yesteryear.  For many, the dream ended.

Today, the Whitacre-Greer Fireproofing Company is the lone flag-bearer of a vanished industry that was once the pride of Alliance.  They purchased the Alliance Brick plant in July of 1972 and are carrying on a tradition that began in 1916 with the founding of their company in ‘the Paving Brick Capitol of the World.’

Air Quality Districts in Utah and Oregon Require EPA Qualified Fireplaces for New Construction

Air quality districts in Utah and Oregon have adopted the use of EPA Qualified fireplaces as one strategy to attain National Ambient Air Quality Standards for PM2.5.  EPA Qualified fireplaces are qualified through the voluntary wood-burning fireplace program, an initiative of the Federal Environmental Protection Agency.  The program encourages the development and sale of lower-emitting wood-burning fireplaces.  The EPA’s fireplace program covers new masonry and prefabricated (low-mass) fireplaces and retrofit devices for existing fireplaces. Fireplace retrofits can reduce pollution up to 70% if installed properly.  Additional information on the program is available at http://www.epa.gov/burnwise/participation.html#fireplace.  The site-built masonry Whitacre Greer MFR-100 fireplace with HearthCAT catalytic technology is EPA Qualified.

The Klamath County Code, Klamath County, Oregon, section 406.100(3)(f), requires that ‘any newly constructed fireplaces must comply with fireplace ASTM standards. Any retrofitted fireplace must meet fireplace ASTM standards.’  Fireplace ASTM standards are defined in the code as fireplaces emitting less than 5.1 g/kg as measured by ASTM E2558.  Additional information on the Klamath County Code is available at http://www.klamathcounty.org/depts/countycounsel/CountyCode.pdf.  The Whitacre Greer MFR-100 fireplace is EPA Qualified and complies with the requirements of the Klamath County Code.

The Utah Department of Environmental Quality, Division of Air Quality, Rule R307-302 for Solid Fuel Burning Devices for all or portions of Box Elder, Cache, Davis, Salt Lake, Tooele, Utah and Weber Counties requires that all fireplaces installed or sold after September 1, 2013, be EPA Qualified.  The masonry EPA Qualified Whitacre Greer MFR-100 fireplace meets this requirement.  Information on the Utah Department of Environmental Quality rule may be viewed at http://www.rules.utah.gov/publicat/code/r307/r307-302.htm#E8.

The EPA Qualified Whitacre Greer MFR-100 fireplace with HearthCAT catalytic emission control technology has a tested emission rate of 4.3 g/kg.  The fireplaces is a traditional site-built masonry fireplace constructed to prescribed dimensions with concrete masonry units, firebrick and clay flue liners purchased separately.  The catalytic emission control device is installed with included stainless hardware, out of the sight of the homeowner, against the back wall of the fire box just above the lentil and below the damper.  Additional information on the MFR-100 fireplace is at https://www.wgpaver.com/mfr-100-series-fireplace/.

Whitacre Greer Creates New Position, Hires Director of Quality Sly Kodrin

As the new Director of Quality, I am excited to join the Whitacre Greer Team. The opportunity to be a part of a historical and dedicated team was one of my top priorities in looking for my next success opportunity.

Sustained improvements, training, and process documentation are high on my list of tasks that need to be accomplished quickly. However, I want to reassure everyone that quickly is relative…I would rather make sure that the tasks are completed in a timely, measured, and a manageable pace.

To date, we have been able to define, empower, and begin implementing a Total Quality Management System (TQMS). This system will define “How We Do Business” throughout the entire organization. Through the efforts of the Executive Team, the framework of this system has already been identified and put in place as a repository for newly created policies, procedures, and work instructions. Our Quality Policy is listed below.

Whitacre Greer is committed to providing its customers with both quality products and exceptional customer service.

We will conduct our business in an ethical manner that enhances the business partner relationships between Whitacre Greer, our customers, and our suppliers.

In addition, Whitacre Greer defines “quality” as continuously meeting or exceeding customer requirements in products produced and in service while continuously improving the operation of our organization at all levels through the:

  • Development and Improvement of the Total Quality Management System.
  • Establishment of the Quality Policy and its objectives.
  • Continually Improving the Effectiveness of the Total Quality Management System.
  • Conducting Management Reviews of the Effectiveness of the Implementation of      the Total Quality Management System.
  • Ensure the availability of resources.
  • Challenge the effectiveness of established processes.
  • Provide competence based education and training to support the TQMS.

I look forward to input and feedback from all of you. Inclosing, please view me as a resource. As a Tool and Die Maker, I learned how to build things with my hands. As a Mfg. Systems Professional, I learned the importance of data accuracy, inventory planning and control, and documented processes. As a Operations professional, I learned the importance of managing resources, both personnel and capacity, to drive operational performance excellence. As a Quality professional, I learned the importance of meeting and/or exceeding customer expectations. As a Lean Six Sigma Black Belt, I was able to shrink wrap all of my experience with a vast array of tools to drive change both in behavior and performance to be the best at what we do. I am here to serve. I look forward to the challenges and the opportunities.

Plan with Attitude, Prepare with Aptitude, Participate with Servitude, Receive with Gratitude, and that should be enough to Separate you from the Multitudes…
Krish Dhanam

Bituminous Set Pavers Perform Well in University of Waterloo Study

The University of Waterloo Centre for Pavement and Transportation Technology (CPATT) recently released a 150?page report evaluating the performance of interlocking concrete pavement (ICP) in crosswalks. Headed by Professor Susan Tighe, Ph.D., P. Eng., the CPATT research quantifies the structural performance of four typical crosswalk designs and recommends the maximum expected design life for each assembly. Design life is expressed as the total number of 18,000 lb (80 kN) equivalent single axle loads (ESALs) the pavement can withstand before major rehabilitation is required. ESALs standardize or equalize the spectrum of lighter axle loads from cars to that from heavier truck and bus loads into a composite single axle load. ESALs inflict damage to pavements typically measured as rutting in ICPs.  The report indicates that pavers set on a bituminous setting bed over a concrete base performed better than the other systems tested.

Download the a summary of the report from the Interlocking Concrete Pavement Institute here.

Gilmore & Associates Test Whitacre Greer Permeable Paver Installation

This letter summarizes the results of the surface infiltration testing conducted on Whitacre Greer’s permeable Boardwalk brick paver system at the above referenced site. To facilitate the study, Gilmore & Associates, Inc. (G&A) performed single-ring infiltration tests at three locations in Hawthorne Park on July 30, 2012. The Whitacre Greer permeable Boardwalk brick paver installation was completed in March 2012. The purpose of this investigation was to establish post-construction infiltration rates for stormwater passing through the pavement surface into the open-graded base materials. This testing did not examine infiltration of water into the soil subgrade.

Hawthorne Park is a flat, relatively open site along 12th and Catharine Streets in Philadelphia. The brick walkways are bordered by grass and planting beds, with small trees located sparsely throughout the site. See the attached Location Plan for the testing locations.

The brick pavement system at Hawthorne Park was installed on a compacted section of three aggregate layers listed from bottom to top as follows: a minimum of 12 inches of open-graded No. 1 aggregate placed over the soil subgrade; a 4-inch layer of No. 57 aggregate; and a 2-inch bedding layer of No. 9 aggregate. Non-woven geotextile fabric was placed on top of the soil subgrade prior to placing the No. 1 aggregate. No. 9 aggregate was placed within the paver unit joints. Based on information provided by the brick manufacturer, the herringbone brick layout of the pavement has 11 percent void space. A detailed design-and-build pavement cross-section taken from the site civil plans, prepared  by LRSLA Studio, is attached for reference.

A single-ring infiltrometer was used to test the surface infiltration rate of the clay brick pavement per ASTM C1701. This testing method was developed for pervious concrete applications, but can be utilized for other permeable systems such as brick pavement systems. The single-ring infiltrometer consisted of a 0.25-inch gauge, 12-inch diameter, 10-inch high steel cylinder. The ring was placed on the pavement so that a representative infiltration area was exposed at the cylinder base and then sealed to the pavement surface with plumber’s putty. Water was added to the single-ring per ASTM C1701 and the time was recorded when the required amount infiltrated into the pavement system. The surface infiltration testing was performed two times at each location in accordance with the ASTM
standard.

An average surface infiltration rate of 561.6 inches per hour was observed at Location A. An average surface infiltration rate of 965.7 inches per hour was observed at Location B. An average surface infiltration rate of 870.3 inches per hour was observed at Location C. The average post-construction surface infiltration rate for the permeable Boardwalk paver system is 800 inches per hour. The infiltration results for the three locations are outlined in the Appendix.

This testing supports the use of these clay brick pavement systems as a pervious (permeable) infiltration surface. The initial surface infiltration rate of the pavement system is significantly faster than what can be expected of most surface soils. Additionally, these results confirm that the pavement surface has an initial flow-through rate greater than 5 inches per hour, as specified in the site civil drawings.

Like all permeable surfaces, clay brick pavements can become clogged with sediment over time, leading to reductions in the surface infiltration rate. As stated in ICPI’s Permeable Interlocking Concrete Pavements Manual, traffic and sedimentation can vary widely with every project; therefore, regular surface cleaning is recommended at least once or twice in the first year, with more or less cleaning being performed as needed thereafter.

G&A recommends that infiltration testing be completed again in one year, so as to document the brick pavement’s performance and refine system maintenance recommendations as needed.

G&A appreciates the opportunity to provide Whitacre Greer with engineering consulting services.

Please contact us with any questions.

Download the full report from Gilmore & Associates

Whitacre Greer Plans Expansion

Land replats for two area businesses approved by Alliance Planning board

By Ruth Lang, The Alliance Review

 

The Alliance Planning Commission approved land replats for two area businesses during its regular meeting on Wednesday.

Concerning property along South Mahoning Avenue, Surveyor Bob Akins testified that brick-making business Whitacre-Greer wishes to purchase a parcel of an outlet in order to formally expand its available storage space.  He said the portion, owned by Jacob Maendal, is within city limits but the business property is within Smith Township limits, so creation of a landlocked outlot is required.

“This outlet will be transferred to Whitacre-Greer, then immediately following that transfer, there will be another transfer combining it into Whitacre-Greer’s 10 acres,” he explained.

Chairman John Gross, city safety-service director, read a letter from Assistant Law Director Robert Hunter Jr., which indicated “this is a landlocked parcel; it may not be conveyed or conferred, unless it is adjoined with a property that abuts on a street right-of-way.”

It was noted that since Whitacre-Greer owns other portions of the parcel that abut city street rights-of-way, the subsequent transfer should not be an issue.

City Engineer Curtis Bungard, who was not present Wednesday, recommended via correspondence approval of the replat on the condition of the above-mentioned language correction.

Board member Mark Locke moved for approval, and the issue was unanimously approved for recommendation to Alliance City Council.

The Alliance Review, Thursday, August 16, 2012

Whitacre Greer’s Pauline Whitacre Featured in Golf Digest Article

The following article appeared in GolfDigest.com.

Professional clubfitter Jim McCleery thought he’d seen every type of golfer in his shop (McGolf Custom Clubs in Waverly, Ohio). Then one day in June, 85-year-old Pauline Whitacre walked through his door. “That woman, what a treat it was to get to spend time with her,” McCleery says. “I can only imagine what she was like back in the day. Competitive, to say the least.”

Whitacre, of Canton, Ohio, doesn’t just like golf, she loves it and lives it almost every day, even though she’s been suffering from emphysema for the last three years. “I still play about three or four times a week all year, both here and in Florida, so I guess that’s over 150 rounds a year,” she says. Whitacre picked up the game as a 10-year-old at her parents’ club in Canton back in 1937, and broke 80 for the first time at age 14. She went on to play college golf (long before there really was such a thing) at Ohio State, where she lost to LPGA co-founder Marilynn Smith in the semifinals of the National Intercollegiate. After getting married, she won the Ohio State Amateur Championship three times and the Ohio Invitational Senior Championship at least six times (she can’t quite remember). To this day, she competes regularly, and she hasn’t lost an ounce of drive (she was even featured on the local news at last year’s Ohio Senior Women’s Amateur Championship, where she competed in the Super Seniors division).

But lately, Whitacre’s scores had been inching up, and she just wasn’t hitting the ball as far as she used to. And even though she keeps shooting her age or better on a regular basis (she estimates she’s done that at least 70 times by now), she wasn’t happy with her 13.5 handicap. So her daughter, Janet Kaboth, booked her a clubfitting session with McCleery to see if a new set of clubs might help.

“I’m really not that into equipment,” Whitacre said before her fitting. “Some of my friends get new clubs every year, but I think mine are about 10 years old, except for the driver, which I got for my 80th birthday.” Like most golfers (women especially), Whitacre always figured it wasn’t the clubs that mattered when it came to performance, but the operator. In fact, the first set she ever played with — hand-me-downs from her father — didn’t have a a club higher-lofted than an 8-iron, so she learned to play without wedges and continued that way for a long time. But since her daughter insisted that she give clubfitting a try — and since she was given the fitting as a Mother’s Day present — she reluctantly agreed to visit McGolf.

McCleery began the fitting by looking at Whitacre’s putter, a center-shafted blade that he quickly determined was about two and a half inches too long for its owner. The centered shaft was also detrimental to her arc stroke. “She has the traditional screen-door type of putting stroke, so she needed something more heel-shafted,” McCleery says. A new putter was assembled on the spot, and it turned out to be instrumental in the 86 Whitacre shot the day after her fitting.

The remainder of the four-hour fitting session (“We made sure she took a lot of breaks between swings, because we didn’t want her to get too exhausted,” McCleery says) was spent on the launch monitor identifying Whitacre’s best driver and iron specs. “She had been playing with irons that measured out super soft on the shaft flex and had too much offset for her swing type — she flips her wrists a lot through impact, and was missing to the left,” says McCleery. “So we determined that she needed something lightweight but slightly stiffer, and clubheads with a bit less offset.” When testing clubs that fit those criteria, Whitacre started hitting 6-irons farther than her own 5-iron. To compensate for her diminishing clubhead speed, McCleery put her in easy-to-launch hybrids rather than mid and long irons. The club brand they finally landed on was a big name that McCleery ordered with un-cut shafts so that he could customize them for Whitacre (women’s clubs that he cut to men’s length, with standard men’s grips because she has large hands).

The driver fitting was an eye-opening experience, both for player and fitter. When McCleery measured Whitacre’s current driver, he found that it was almost 46 inches long with an extra-stiff shaft (the flex most PGA Tour players use) and only had nine degrees of loft. “It’s no wonder she couldn’t get it up in the air,” McCleery chuckles. The launch-monitor data showed that she got almost 70 yards of roll out of her old driver but only carried it 79 yards. “That’ll work in Florida, but up here in Appalachia, it’s not going to do you much good,” says McCleey. With a higher-lofted driver head and a lighter, shorter and much more flexible shaft, Whitacre immediately gained 30 yards of carry.

At the end of the day, a tired but happy Whitacre went home with a new putter and an order placed for the rest of her set. “The whole experience was so enjoyable,” she told me the next day. “I’d never had anything like that happen before. It was strange to have somebody giving me clubs to fit my swing rather than the other way around.” Three weeks later, Whitacre proudly told me about the 80 and 81 she’d just scored with her new clubs. “I’m doing very well especially with the woods, and really the whole set. It’s taken me some time to learn the new distances, especially with the irons because they go farther. But I feel so much more confident now that I know I have the right clubs for my swing.”

The fitting bug has spread through Whitacre’s family — her daughter and son-in-law have both gone through the same procedure since seeing what it did for Pauline. “I would recommend it to anyone,” she says.

For Golf Digest’s ranking of America’s100 Best Clubfitters, click here.

–Stina Sternberg (Photos by Michael Nemeth)