1. History
     Beginnings    Early years    War time    1950s - 1970s    1980s    1990s    2000s    2010s  

2. References

Sherman + Reilly is an American manufacturer of tools and equipment for underground and aerial transmission, and distribution of electrical power and communications systems, including a complete line of bundle blocks, pullers, tensioners, reel trailers, and lineman construction and maintenance tools. They also manufactured wreckers in the 1980s.

History

Beginnings

Sherman + Reilly was founded on April 12, 1927^[1], by D. C. Sherman and F. W. Reilly Sr. “Doc” Sherman was a very talented engineer with an excellent technical background coupled with good common sense enabling him to arrive at workable solutions and designs.He became an expert in wind induced vibration on overhead power lines. He developed and received a U.S. patent for a preformed wire damper. This technology is still used today. General Reilly was also a very talented engineer with a passion for detail and perfection, which attracted him to aviation. He was an active pilot and aircraft owner for many years. His passion in aviation was the Civil Air Patrol, an auxiliary of the U.S. Airforce. During his many years of service in the CAP he became the National Chairman, which carries the rank of Brigadier General.

Both were former employees of Street Brothers Machine Company in Chattanooga. The founding of this company was made possible by the award of engineering work for their former employer, Street Brothers Machine Company, and Williamsport Wire Rope Company. Work for other clients was undertaken during the first several years; however, the principal efforts of this engineering concern were for the clients mentioned above.

F. Ward Reilly, Jr. died in a Chattanooga hospital on August 25, 1997 at the age of 68. Ward was the son of F.W. Reilly, Sr., one of the founders of Sherman + Reilly. Ward joined Sherman + Reilly in 1954.

He, along with his brother Jim, pioneered the company’s entry into the manufacture of “The World’s Finest Line of Conductor Stringing Equipment.” Ward became President and then Chairman of the Board. He was a graduate of the Georgia Institute of Technology and served as an officer in the United States Air Force.

Early years

Early work for Street Brothers consisted of design and field engineering work on hoisting machinery, derricks, and cableways, which Street Brothers produced. Williamsport Wire Rope Company^[2] engaged the services of Sherman & Reilly to design a complete line of aerial tramways, apparatus, and equipment and arrange for the equipment to be manufactured by subcontractors with field erection supervised by the company.

The company was also commissioned by Williamsport to design for it a complete line of wire rope blocks and the necessary patterns, dies, jigs and fixtures, and arrange for the manufacture of these wire rope blocks by suitable fabricators. At this same time, Williamsport also contracted with the company to do the early development work on the pumping of oil wells by means of wire rope in addition to developing other uses for which wire rope had not been previously used. In pursuing additional markets for wire rope, the company developed a line of small suspension bridges using prefabricated wire rope for the cables.

These bridges required special fittings that were not readily available on the commercial market because of the small quantities involved on any one order. To satisfy this demand, the company installed a small manufacturing shop and undertook the fabrication of these items for Williamsport. Work in this field broadened, and Sherman & Reilly began designing the suspension bridges, estimating the cost for Williamsport, fabricating the necessary special fittings, and supervising the construction and erection of these bridges.

Another early development by Sherman & Reilly in the wire rope industry was a flexible roof for large grain elevators.

A firm in Minneapolis, Minnesota, utilizing wire rope manufactured by Williamsport and fittings designed by Sherman & Reilly under the Williamsport name, manufactured these flexible roofs.

During the depression both Street Brothers Machine Company and Williamsport Wire Rope Company went into receivership. At that time, Williamsport owed the company a substantial sum of money for engineering services and manufactured goods. The Williamsport receivers decided to continue the manufacture of wire rope but to discontinue the sale of wire rope blocks, small suspension bridges, tramways, and other items that had been designed and manufactured by Sherman + Reilly.

The Williamsport receivers did not have funds available to pay its debt to Sherman & Reilly, and desiring to continue the goodwill of Sherman & Reilly and its engineering services, proposed to turn over to the company all of the drawings, patterns, jigs, and fixtures connected with the wire rope blocks, suspension bridges, and tramways in settlement of its debt. This put Sherman & Reilly in a position of having the necessary tooling to produce these items under its own name.

Since clients for engineering services were very scarce at this time, the company began concentrating on the manufacturing phase of the business utilizing the Williamsport designs and tooling. As the company’s manufacturing business increased, additional space and equipment were required. In 1934 the company moved to First and Broad Streets leasing property from the City of Chattanooga. In most instances, a new manufacturing business needs a good financial break to put the business on solid ground. This opportunity presented itself when the Tennessee Valley Authority issued invitations for bid on a three-span suspension bridge to be used in the construction of Watts Bar Dam across the Tennessee River. The only other previously erected multiple span suspension bridge was a two-span bridge in Germany; however, for the Watts Bar project, a three-span bridge was needed, and the company undertook the design of this bridge.

In addition to Sherman & Reilly, there were two other bidders on this project: American Bridge Company and John A. Roebling & Sons. However, neither American Bridge Company nor Roebling bid on the three-span suspension bridge but offered alternatives. The alternatives offered by these bidders required piers at points that were not suitable for the construction planned. Even though the Sherman & Reilly bid was considerably higher than the other two, the Tennessee Valley Authority Engineering Department was convinced that Sherman & Reilly’s three-span suspension bridge design was sound and practical, and the contract was awarded to the company. This contract carried both a premium and penalty provision for completion within the allotted time. As construction on this bridge progressed, it was evident that cost estimates were quite conservative, and, as a result, this three-span suspension bridge was completed, tested, and accepted 60 days ahead of schedule. This project, which was completed in 1938 with a considerable profit and during favorable tax years, greatly enhanced the financial position of the company.

The company continued to pursue the suspension bridge market and also turned its marketing efforts towards shipyards and the manufacture of ship rigging. An excellent opportunity presented itself in the ship rigging market when quite suddenly the Tampa Shipbuilding Company had a very urgent need for special ship rigging blocks equipped with steel wire rope sheaves. At that time steel sheaves were made from steel castings, and, traditionally, delivery on steel castings had always been very slow since the steel casting process requires a lot of time.

To satisfy the requirements of the Tampa Shipbuilding Company, Sherman & Reilly initiated the manufacture of synthetically forged steel sheaves, which were made up of forged weldments. This new method of manufacture placed the company in the position of making almost immediate delivery on steel sheaves to meet the shipyard requirements. A constant demand for these wire rope sheaves developed, and the shipbuilding industry became a most important market. A short time later the United States Navy became extremely interested in Sherman & Reilly’s method of manufacturing steel sheaves and requested that the company greatly increase the manufacturing capacity for these items.

War time

As the United States entered World War II, an invitation to bid requiring a large quantity of these steel sheaves was received from the Navy. The company’s bid specified that one ship set of rigging would be delivered within 60 days of receipt of the award and six ship sets per month thereafter. As soon as this bid was opened, the following telegram was received: “You are hereby directed to commence manufacture under this contract number comprising the ship sets of rigging as per your bid, and you are further directed to deliver 50 ship sets within 60 days from this date and 50 ship sets per month thereafter. Signed J. Joseph Whelan, Secretary of War Production Department.”

The company telegraphed Mr. Whelan back acknowledging his telegram and telling him such a schedule was impossible. Mr. Whelan wired back, “Nothing is impossible, do it.” This, of course, required immediate and substantial enlargement of facilities in addition to a great deal more working capital than was available. The Navy was very cooperative and arranged a deal with the Smaller War Plants Corporation to secure the necessary equipment on a rental purchase agreement. A local bank agreed to provide whatever financing was necessary to meet the payrolls and material purchases.

A short time thereafter the Navy wanted to locate a plant for the manufacture of minesweep paravanes. Inconnection with this, D. C. Sherman of Sherman + Reilly was called to Washington to meet with the Navy to discuss plans and methods of production for such a plant.

Mr. Sherman made some very valuable suggestions, not only in the design of the plant but also in the design of the paravane equipment and the launching systems for this project. The plant was ultimately located in Ottumwa, Iowa; however, Sherman & Reilly received contracts for the production of all the non-magnetic wire rope blocks required in this paravane program. As the intensity of World War II increased, Sherman & Reilly was awarded numerous additional contracts for ship rigging and minesweep equipment. In addition, U.S. Army Ordinance awarded the company a contract for the design and manufacture of an entire line of wire rope snatch blocks for use on military vehicles.

A significant contribution was made to the war effort as a result of a contract for ship rigging to be used on LST’s. The company was advised that this was one-third of a total requirement and that production and delivery schedules must be met. The company delivered its share of rigging ahead of schedule and as a result was awarded an additional one-third of the total program. At the time of this additional award, a telegram was received from the War Production Board advising, “Without regard to any rule or regulation of the War Production Board, delivery as specified must be effected.”

To meet this delivery, it was necessary for the company to appropriate needed materials from other manufacturing companies in the Chattanooga area, with this action being sanctioned by the War Production Board. The company was later advised that it had produced two-thirds of all the necessary ship rigging for the LST’s that were used during the Normandy Invasion.

The award of these wartime contracts necessitated a considerable expansion of manufacturing facilities resulting in the company’s occupying the entire square block of property owned by the City of Chattanooga at First and Broad Streets, which had originally been constructed for a river terminal.

1950s - 1970s

After World War II and Korean War years, the company began exploring commercial markets to maintain a level of production suitable for its greatly expanded manufacturing facilities. During the war years, the electrical utilities had not been able to purchase conductor stringing equipment and tools due to material shortages. This appeared to be an extremely bright market provided a line of products could be developed that were suitable for the manufacturing facilities.

Sherman & Reilly began working with the Tennessee Valley Authority’s Power Line Construction Department in an effort to determine the type of tools and equipment needed for the construction of electrical transmission and distribution power lines. Manufacture of special conductor stringing blocks and tools was undertaken for TVA’s use, and the company began working in the field with TVA to gain additional experience and determine the need for additional products. Shortly thereafter work was begun with a contractor doing construction work for TVA, and suitable equipment was manufactured for these two customers to fit their needs. As the company’s experience in the electrical construction field increased, many improvements were made in the construction equipment and tools. The design of a complete line of conductor stringing equipment for both transmission and distribution line construction was in process. After a new product was designed, pilot models were manufactured and the product taken into the field for tests on actual construction projects prior to marketing the products. In many instances, valuable comments and suggestions were received from personnel actually engaged in the construction work enabling the company to greatly improve the product line.

A fairly complete line of conductor stringing equipment had been developed by Sherman & Reilly by 1958; however, in closely watching the electrical construction market, it was evident that transmission and distribution voltages would be greatly increased, which would necessitate the use of larger electrical conductors. To accommodate the larger conductors, much larger conductor stringing blocks would be required, which would prohibit the use of steel and other heavier materials that had been used in the previous manufacture of these

blocks. The company undertook the study of lighter materials that would make the product more acceptable to the industry and which would greatly enhance the utility of the product and expand its market potential. As a result of these engineering studies, the company produced the first complete line of lightweight conductor stringing blocks incorporating aluminum and/ or aluminum-magnesium alloy parts throughout. Many of the previous designs that had been used became obsolete with the introduction of these new lighter weight conductor stringing blocks.

In 1959 the company began marketing the first permanently bonded neoprene sheave linings for conductor sheave grooves. These linings were produced on vulcanizing machines designed and manufactured by Sherman + Reilly. The immediate acceptance of neoprene lined sheaves by the industry opened up additional potential, and eventually this type of sheave became the standard for transmission line construction and today is also widely used in the construction of distribution lines. In addition to the trend of larger conductors, the company was aware that consideration was being given to the use of multiple or bundle conductors per phase in extra high voltage transmission line design. Preliminary designs of a bundle conductor stringing block were made, and a contract was secured for a quantity of these new blocks for export to Brazil. The work in Brazil was closely followed, and, as a result of this experience, design improvements were made. This placed the company in the position of offering field tested and proven bundle conductor stringing equipment.

Increasing domestic and international business necessitated an expansion of the company’s office and manufacturing facilities. In 1971 Sherman + Reilly moved into its present General Offices and Manufacturing Plant at 400 West 33rd Street in Chattanooga. This location provides 6,000 square feet of office space and approximately 100,000 square feet of manufacturing and storage areas. Additionally, complete field testing facilities are located behind the manufacturing plant and include various aluminum conductoring in different configurations simulating both 345kv and 500kv extra high voltage power lines.

Bundle conductors became the norm for the extra high voltage network for North America. These designs varied with two, three, four, and occasionally more conductors per phase requiring special tools and equipment. Many customers, particularly contractors, wanted tools and equipment that could be used on one, two, three, or four conductors. Relying on its earlier experience, the company introduced the revolutionary Multiversal, which could accommodate everything from one to four conductors. However, in some configurations, the very abrasive steel pulling lines had to ride in the same groove as the delicate aluminum conductors that followed. The neoprene sheave linings that had been developed earlier would not stand up under the abrasion of the steel pulling line. An experimental program was initiated to develop a lining that would take the abrasion of the steel pulling line and also provide a cushion for the aluminum conductor. The new lining that answered this tough job turned out to be urethane. Again, the company designed the equipment and molds to actually cast in place the urethane lining and ovens to cure the material to the proper hardness. After a considerable investment, Sherman + Reilly introduced fully lined urethane conductor stringing sheaves in January 1966. As anticipated, these urethane-lined sheaves offered many advantages, but depending on the circumstances, neoprene, which can be made electrically conductive, is the lining of choice. Sherman + Reilly became the only manufacturer offering both urethane and neoprene sheave linings.

In addition to designing and manufacturing the world’s most complete line of conductor stringing equipment, the company has also developed systems of construction utilizing these products. These construction systems offer customers a cost saving method of building electrical power lines. A continuing program of research and development will introduce new systems, new methods, and new products in the years ahead. One of these systems allows for totally reconductoring distribution lines without an electrical outage. This allows the electric utilities to maintain even better relationships with their customers.

With the new, larger facilities, the company decided to pioneer the development of pullers and tensioners for distribution line construction. The idea was to take the same approach that had been used in construction of the much larger transmission lines: tension stringing under positive control. Tension stringing keeps the pulling lines, usually synthetic rope, and the electrical wires (aluminum conductors) in the air above other lines, traffic, etc. This led to the first ever Puller/Tensioner: one machine that did both jobs with hydraulic circuitry that enables accurate positive control. On one end of the job is a P/T with a reel of conductor, and on the other end is another P/T with a drum of pulling line. One machine acts as a puller and the other one as a brake (tensioner). This not only is cost effective but much safer. Since its introduction in the early 70s, it has developed into a complete system of construction that has become the standard.

1980s

As the 80s approached, so did a new trend in electrical power line construction, UNDERGROUND. The word was that “overhead lines were for the birds.” To answer this need, Sherman & Reilly formed a partnership, a working agreement, with Plumettaz, S.A., a Swiss company that had already developed machines for underground. Putting electrical lines underground in Europe was already the norm. The challenge was to “Americanize” these designs and manufacture as much in the U.S. as practical. The Underdawg was introduced and eventually accepted in North America. This was followed by the Superdawg, the Megadawg, even a Puppydawg and later a Housedawg. By the end of the 80s, the family of “Dawgs” had become somewhat famous in the underground world!

A system was developed for blowing steel pulling lines through PVC conduit. Sherman & Reilly pioneered the first and most successful dedicated underground cable placing system that is second to none worldwide. This system allowed the steel pulling line on the underground puller to be blown through the various sizes of PVC conduit without damage to the conduit and/or the cables being installed. Since steel pulling line dissipates heat, unlike synthetic rope that builds up heat, there is no damage to the conduit. The most recent development is called the House Dawg, primarily used for installing power cable inside of commercial buildings. By making available everything from the House and Puppy Dawgs to the Super and Mega Dawgs, S+R has by far the best and most complete line of underground pulling equipment. Many accessories, such as electronic recorders, load limiting devices, and air compressors can be furnished.

As the overhead line tension stringing business tends to be somewhat seasonal, an effort was made to diversify the Sherman & Reilly product line and to maximize the existing quality work force. Market research indicated that the addition of products related to the automotive towing and recovery industry could be a “good fit” for the company to fill this seasonal need. In 1986 it was decided to follow this course, and within a few months and the addition of a few employees specializing in this field, a new division of the company, Reilly Towing Systems, was born. The springboard for the launch of this new division was the development of a unique wheel lift known as Power-Trac, which allowed for the retrieval and damage-free towing of the new-style aerodynamic cars of the 1980s. Power-Trac was an innovation that would have a definite positive impact upon the industry, which had become known for towing cars and trucks with tow slings and tow bars. The new Power-Trac System gave RTS the entry it needed to enter the towing and recovery industry with significant recognition introducing its series of light duty tow trucks in 1986.

In 1988, after much success with this light-duty product, RTS introduced a medium duty tow truck for towing motor homes and other large vehicles. Over the next four years, RTS would go on to become one of the most recognized brands in an industry with over 20 competitors. In 1990 however, Jerr-Dan Corporation made an offer to buy RTS and the product line complete. It was decided to accept the offer and invest the capital back into the core business of the company while looking for other areas of diversification more in line with the utilities industry.

During the 1980s, the relationship between Sherman + Reilly and Plumettaz, S.A. continued to grow with the on-going success of the UD Series underground pulling equipment for the power industry. This was also a time in which the world was beginning to build an insatiable appetite for fiber optic networks for communications.

1990s

In 1991 Plumettaz became the worldwide licensee for a revolutionary new line of equipment called CableJet Systems for the installation of fiber-optic cables primarily for the telecommunications industry. Sherman + Reilly became the North American partner of Plumettaz in this venture, again bringing the company diversification in its expanding product line. The CableJet, used for small fiber-optic cables, and SuperJet^[3], used for large cables, became the products that would open the door to the telecom industry for Sherman & Reilly. CableJet Systems were very revolutionary in that it replaced traditional cable pulling methods with the ability to “float” cables through duct systems utilizing air, thereby providing a virtually stressfree installation.

The CableJet method proved to install cables faster, safer and more efficiently than other methods and therefore was key to the successful installation of fiber optics in the early 1990s.

Sherman & Reilly was the first company to introduce HASB (High Air-Speed Blown) cable technology to North America and became the leader in this arena. These systems have been used primarily for long haul and city ring fiber-optic networks. CableJet and SuperJet have become the “method of choice” for installing fiber cables, and the product line continues to grow with other specialized products. The company designed the Rapid Fiber Deployment Truck (RFDT), DC-10 airtight duct coupler, and SLRT- 56 Series self-loading reel trailers, as well as many ancillary products surrounding CableJet Systems.

2000s

In 2000 Sherman & Reilly introduced MicroJet Systems to the North American market. This smallest version of CableJet Systems focuses on Fiber to the Business (FTTB) access market and Fiber-to-the- Home (FTTH) taking fiber optics all the way to the end user. The Telecom-CATV Division of Sherman & Reilly has become a very important part of the core business allowing for diversification and the expansion of existing product lines to meet the needs of the telecom companies, as well as bringing many innovative products to that market.

2010s

In 2011, Sherman + Reilly was sold to a private group of investors and launched the Revolution series of utility equipment to modernize the equipment. All machines were upgraded to CANBus technology along with some other improvements in order to increase safety, performance, reliability, and to reduce complexity of operation. They also partnered with ZECK^[4] to produce their transmission equipment under license.

In 2013, Greenlee (subsidiary of Textron then) purchased Sherman + Reilly along with HD Electric.^[5]

In June 2018, Greenlee along with all of its subsidiaries was acquired by Emerson Electric Co.^[6]

References

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• AT&T Challenger of Dallas
• AT&T City Center