Terra Cotta, California
Coal, along with clay deposits, was found on the site by John D. Huff in the late 1880s, and the Southern California Coal and Clay Company was formed to mine them. The town site of Terra Cotta was laid out and was given a post office on October 26, 1887. In May 1893 its post office was closed and moved to Lake Elsinore. A plant for the manufacture of sewer and water pipes was built using the coal to fire ceramic pipes in the four kilns. The finished product had to be shipped by wagon six miles through Lake Elsinore to the La Laguna rail station at the mouth of Railroad Canyon until 1896 when a spur line was built through Lake Elsinore and Terra Cotta to the new clay deposits in Alberhill. The coal mined was also used locally as fuel for the stamping mill at the Good Hope Mine and was shipped elsewhere in the state.
Sand casting
The choice of sand has a lot to do with the temperature at which the metal is poured. At the temperatures that copper and iron are poured, the clay gets inactivated by the heat, in that the montmorillonite is converted to illite, which is a non-expanding clay. Most foundries do not have the very expensive equipment to remove the burned out clay and substitute new clay, so instead, those that pour iron typically work with silica sand that is inexpensive compared to the other sands. As the clay is burned out, newly mixed sand is added and some of the old sand is discarded or recycled into other uses. Silica is the least desirable of the sands, since metamorphic grains of silica sand have a tendency to explode to form sub-micron sized particles when thermally shocked during pouring of the molds. These particles enter the air of the work area and can lead to silicosis in the workers. Iron foundries spend a considerable effort on aggressive dust collection to capture this fine silica. The sand also has the dimensional instability associated with the conversion of quartz from alpha quartz to beta quartz at 680 °C (1250 °F). Often, combustible additives such as wood flour are added to create spaces for the grains to expand without deforming the mold. Olivine, chromite, etc. are therefore used because they do not have a phase transition that causes rapid expansion of the grains, as well as offering greater density, which cools the metal faster, producing finer grain structures in the metal. Since they are not metamorphic minerals, they do not have the polycrystals found in silica, and subsequently do not form hazardous sub-micron sized particles.