Oral history of the Malta Dockyard: Frans Scicluna

(00:30) Scicluna joined the dockyard in 1965. The first year was at the training centre. Then after some time he moved to where he was allocated, and this was the foundry fFunderija). He wanted to become a fitter, since a lot of people choose that trade. However, he was sent to the foundry and in a way, he was happy about it, even though he did not know what the trade involved. On the other hand, other workers that he met, were saying negative things about the foundry and as a result, he went half-heartedly.

Education-Apprenticeship process 

(03:00) When he went to the foundry, he realised that this was a small section with about twenty-five workers. He eventually worked there for 43 years. During his apprenticeship, they attended at the Technical Institute for two days a week, the other three remaining days, were practical training at the foundry with an instructor. Scicluna mentions, that those who did well in the T-Course, they would be sent to attend for a full-time course at the Polytechnic for a Technician Diploma. He obtained credit, and merit in all subjects.

 

Safety-Health issues (noise, risks) 

(06:30) When he returned from the course, he became a tradesman, so it was a bit difficult to adapt. Frans states that the environment of the place was not welcoming, due to noise pollution. However, he liked the trade as it required mostly manual work. Then by time, he got used to the environment. 

(07:30) He was disappointed when he wanted to advance in education. The Head of Department at the Polytechnic, Mr. Smith gave him the go ahead to do so, subject to Scicluna’s release by his department at the dockyard. However, the dockyard did not allow him and he could not progress with his studies for Engineer’s Diploma. They told him to either choose to stay with the Dockyard, or otherwise leave and continue with his studies on his own. However, he knew how difficult it was for someone to get a job, and as a result, he remained working at the Dockyard.

Education-Interesting training and skills 

(08:30) He gave details about the sand they used for the moulds which was imported from foreign countries. The sand in Malta was not adequate for this type of work. They had more than one type of sand, one of which had a chemical and when they finished the mould, they injected carbon dioxide which solidified the mould. This was used for bigger moulds. 

They also had very fine sand which was used for small things, such as for cap badges, etc. He also remembers doing the moulds with clay. He describes the process, how they put clay mould in a 40-meter oven to dry it and solidify it, when it is time to pull it out, the clay cracks due to heat, and then they refill the cracks again and repeat the process. This process was very long. Eventually this was substituted by the chemical Sand with CO2. The moulds were also painted with alcohol and put on fire to dry it further.

 

(13:00) For certain works they needed a pattern, and they agreed with the patternmaker how to make the pattern in parts so that the pattern can be extracted from the mould. They worked together with the patternmaker until an agreement of how to carry out the work is reached. According to Scicluna, the work of a patternmaker was like sculpting in wood.

(15:00) The moulds were made in metal mould boxes. They opened the mould to remove the pattern, and its shape was left in the sand. Then they prepared areas from where the metal is poured, so that the empty space left by the pattern is filled with molten metal. This also depended on the metal material included, for example, lead, bronze, zinc, aluminium, etc.  Also cast iron which due to the higher temperatures was the most difficult to cast.

 

Education-Interesting training and skills

(16:30) He recalls some major projects too. He talked about how the dry dock had a big gearwheel, which was used to open and close the dock gate. The gear teeth used to get worn down through working. Basically, the casting came out from the mould finished and only required some machining. It was done with the assistance of the patternmakers. They also used to do sleeves for tail-shafts.  These had to be free from any casting defects.

(20:45) According to Scicluna, some of the melted metal used to evaporate in the furnace. Meaning that they make an allowance for this loss. Each metal had its own evaporation rate. Then there is another process to let the casting cool down in the mould, which could take up to two days depending on the size. Once cooled, the removed the cast items from the mould and the finishing process started by grinding and blasting, etc.

Safety-Health issues (noise, risks)

(25:00) They had no safety, in fact, when they poured metal, they only had light green glasses made of plastic. Their uniform consisted of a boiler suit. By time, they were given shields, safety shoes, fireproof jackets, etc. He mentioned that every time some new safety equipment was being introduced.  Unfortunately, the workers were sometimes reluctant to wear protective clothing.

Education-Interesting training and skills

(26:30) He remembers that they did the lettering on the Freedom monument at Birgu. They also did the casting of the urn for this monument. For this they used part of the decoration of the lamp posts that are in front of Castille and are also in various places around Malta, which were also cast in the dockyard foundry.

(27:30) Major works, in terms of weight, were weight blocks of up to 10 tons. They had a special furnace for these called ‘kupolas’, where they put coal and metal together. First, they burn the coal, then when it heats up, they add the metal and then keep adding on more coal. The forge (forga) had a spout and then the final product would slide into a big pan. The weights of 10 tons were used to test the cranes.

(31:45) He had an apprentice, Raymond Azzopardi, who came from the trade school, and Scicluna states that he was as good as him if not better, especially for doing the fine moulds for small and fine items.  It was work that required a lot of patience.

(33:45) On the whole, work was decreasing at a fast rate and so were the workers. Keeping the foundry active was very expensive. As a result of this, Scicluna was not occupied in full so he started working afloat with the joiners, until he was sent away from the yard with early retirement.