THE following Act passed by
the Scottish Parliament in 1686, throws some light on the origin of working
in cast iron in this country:
"His Majesty and Estates of
Parliament, taking into consideration the great advantage that the nation
may have by the trade of Founding, lately brought into the kingdom by John
Meikle, for casting of balls, cannons, and other such useful instruments,
do, for encouragement to him, and others in the same trade, statute and
ordain, that the same shall enjoy the benefit and priviledges of a
manufacture in all points as the other manufactures newly erected are
allowed to have by the laws and Acts of Parliament, and that for the space
of nineteen years next following the date hereof."
The Carron Ironworks may,
however, claim to be the birthplace of the Scotch iron trade in its most
important form; and long had the reputation of being the most extensive
foundry in Britain. Though now surpassed in extent, they retain their old
reputation for producing work of a superior kind, and in several branches of
production they may be said to have no rivals. The works were established in
1760, under a chartered company, projected by Dr Roebuck, of Sheffield, who
appears to have been the first to appreciate the value of the iron ores of
Scotland. The operations of the Company have all along embraced the digging
and smelting of the ore, the manufacture of the iron into an endless variety
of articles, and the sending of these into every market of the world.
Notwithstanding the great extension of the iron trade that has taken place
in recent years, the Carron Works have not been much enlarged; and though
improved appliances have been introduced, the buildings maintain pretty much
their original appearance, allowance being made for the effects produced by
the smoke and dust which have swept around them for a century. The
establishment is situated on the bank of the Carron River, about two miles
from Falkirk, and may be most conveniently reached from Grahamston railway
station.
The operations carried on
within the works were long kept secret from the outside world, and the rule
which excluded Burns when he went to view the place is yet relaxed only in
the case of persons who are not likely to use to the prejudice of the
company any knowledge they may gain while witnessing what is going on. The
poet gave vent to his feelings on the occasion referred to in the following
lines, which he scratched on. a pane of a window in the inn at Carron:—
Electric Scotland Note:Hi Alastair,
As my Great Great Great Great Grandparents MacLaren lived and worked in
the shadow of the Carron Iron Works, I felt that I should research the
more commercial aspects of that business and perhaps thus add another
dimension to what we already have on ES about its foundation and
development over two and a half centuries.
What I discovered are SHOCKING illegal misappropriation activities by
its Sassenach managers between c. 1790 and 1850.
I attach the evidence for this arising in an 1883 book that also
recounts more south of the border legal stories ….. in addition to the
Carron one, that is relevant to ES.
You can download this account of the Carron
company here
"We cam' na here to view your
warks,
In hopes to be main wise,
But only, lest we gang to hell,
It may be na'e surprise;
But when we titled at your door,
Your porter dought na hear us;
Sae may, should we to hell's yetts come,
Your billy Satan sair us!"
If the history of Carron
Ironworks were minutely written, it would be a record of much interest, as
showing the many stages of improvement through which the manufacture of iron
has passed. It must suffice here to mention the change which has taken place
in the motive power at the works. The site of the establishment was chosen
on account of the abundant and convenient supply of water which could be
made available for driving the machinery. The blast was created, and the
tilt-hammers, lathes, and other machines were driven by water applied over a
large number of wheels. As the premises were extended the supply of water
became inadequate, and somewhat anomalous means of overcoming this
difficulty were devised. While James Watt was working out his improvements
on the steam-engine, he entered into partnership with Dr Roebuck of the
Carron Ironworks, and a joint-patent was taken out for a condenser. This
partnership was not a fortunate one for Watt. During the time he was
associated with Dr Roebuck, however, he erected a large steam-engine at
Carron, and that was the anomalous contrivance alluded to. Instead of the
power of the engine being applied directly to the machinery, it was merely
employed to
pump back into a reservoir the water that had passed over the water-wheels,
and so enable it to be used again and again. The engine was fitted with four
pumps, which raised to a height of thirty-six feet forty tons of water per
minute. This old servaut of the company has been sadly neglected. Though it
has been allowed to remain in its original position, nothing has been done
to prevent it falling into decay. The engine-room is crumbling into ruins,
and the iron-work is black and furrowed by oxidation. As one of the earliest
engines ever made, this piece of mechanism is an object of much interest to
men of science; and it is to be regretted that the very little care
necessary for its preservation has not been taken. The engine, which is on
the atmospheric principle, has a cylinder six feet in diameter, by eight
feet in depth, and the beam is about thirty feet in length. The steam was
supplied by three cast-iron boilers, two of which are globular in shape, and
measure fifteen feet in diameter. About thirty years ago this engine was
superseded by one of improved design, applied directly to the machinery, and
since then the use of water power has gradually died out. The machinery in
the engineers' shops is, however, kept in motion by a powerful turbine
wheel. A few years ago a splendid beam engine was added to the
establishment. It was made by the company's own workmen, and supplies the
blast to all the furnaces. The steam cylinder is six feet in diameter, and
the piston has a stroke of ten feet. The blast cylinder is one hundred and
four inches in diameter, and ten feet deep.
On approaching the works by
the long irregularly built street leading in an almost direct line from
Grahamston, the visitor's eye is first attracted by the flames of five blast
furnaces which stand on the south side of the works. The smaller flames
issuing from the chimneys of the cupola and air-furnaces next arrest
attention; and a nearer approach brings into view a whole forest of
chimneys, shooting up from amid vast ranges of brick-built workshops. On
getting inside the boundaries of the establishment the mere sightseer would
probably be somewhat disappointed. The great extent of the place does not
become apparent until the various departments are visited in succession; nor
can it be said that externally the workshops present an inviting appearance.
But within those ragged- looking and smoke-begrimed structures, processes go
on which illustrate some of the grandest developments of human ingenuity;
and in no individual establishment, in this country at least, can such a
variety of operations in the manufacture of iron be seen. As one passes
through the place, the roar of furnaces, the clash of machinery, and the
clatter of anvils, fall upon the ear from all sides, and combined with the
irregular nature of the roadways, the immense and apparently confused piles
of iron, old and new, and of finished and unfinished articles of every
conceivable form, produce a most bewildering effect on persons unaccustomed
to such sounds and scenes.
Persons who are privileged to
visit the works are first shown the various processes in smelting iron,
which are similar to those already described as being practised at
Gartsherrie, and are then conducted through the other departments,
commencing with the pattern-shop. The latter is a large three-story
building, on the lower floor of which are a saw-mill and other machinery for
preparing wood. On the middle floor the patterns are made; and the upper is
filled from end to end with a vast collection of patterns of articles of all
sorts, from a spittoon to the cylinders of a 200-horse power engine. As the
cost of making the patterns is considerable—those here collected
representing many thousands of pounds—they are carefully preserved. The
patterns are chiefly made of wood, and considerable skill is required for
their construction. When the patterns are completed, they pass into the
hands of the moulders, who take an impression or mould of them in sand. The
more simple the outline and plainer the surface of the article, the more
easy it is to form the mould. For instance, nothing could be more simple
than the operation of making a mould for the heater of a dressing-iron; but
the moulding of a tea-kettle requires considerable skill on the part of the
workman.
A few years ago the Prince of
Wales visited Carron for the purpose of inspecting the works, and expressed
a desire to see the pro¬cess of making a mould. The moulding of a common
three-legged pot was shown him, and no better illustration could be given of
the moulder's work. The patterns for a pot consist of nine pieces—two for
the body, three for the feet, and two for each of the ears. The body pieces
have been formed by taking a completed pot, denuding it of feet and ears,
and cutting it vertically into two pieces. These pieces the moulder takes,
and, placing the severed edges together, lays them down on his bench with
the bottom upward. He then encloses the pattern in a circular casing, which
he fills up with sand. The sand is rammed down all round and over the
pattern, care being taken during this process to insert the feet pieces, and
also a wooden plug to form a "gate" through which to pour the metal. The
moulder then turns the box over, and fills the inside of the pot with sand.
The next part of the operation is to take out the pattern and leave open and
entire the space it occupies. The advantage of having the casing and the
pattern in sections now becomes manifest The upper section of the casing is
unfastened and taken off, when it is seen that the sand bears an impression
of the bottom of the pot. The side pieces are in like manner removed,
leaving the body pattern clear. The latter is carefully lifted off, one-half
at a time, exposing the "core," or globular mass of sand which represents
the interior of the pot. The surface of the sand is next thickly dusted with
ground charcoal, and rubbed quite smooth—a process which makes the iron take
a finer " skin" than it would otherwise do. The feet and ear pieces having
been withdrawn, all that is now necessary is to put the casing together
again, fasten it tight up, and prepare the "gate" by pulling out the plug
and rounding off the edges of the hole. So compact does the sand become,
that the completed mould may be moved about freely without sustaining
injury. An expert hand can mould a pot of the largest size in from fifteen
to twenty minutes.
After a certain number of
moulds have been prepared, the workmen proceed to "cast" them. The molten
metal is carried from the furnaces in huge ladles, and appears to be as
fluid as water. When it is poured into the mould, gas is at once generated,
which finds its way through the sand, and, issuing from the joints of the
casing, becomes ignited, and burns with a beautiful purple flame. Were the
gas not allowed to escape, the mould would burst, and the consequences to
the workmen would be most disastrous. It is a curious fact that, while a few
drops of water would ruin a mould, the boiling metal may be poured in from a
height of a couple of feet without disturbing a particle of the sand. When
the metal has cooled sufficiently, it is dug out of the sand and taken to
the dressing shops, where roughnesses are removed. Articles cast in several
pieces are then carried to the fitting shops, where they are put together.
Kettles and stew-pans, which are to be tinned, are first annealed, and then
passed to turners, who put a smooth and bright surface on the inside. The
tinning is then done, the handles are put on, the outsides japanned, and the
completed goods removed to the warehouse. Portions of many of the articles
are of malleable iron, such as the handles of kettles and pans, and in
making these a large number of smiths are employed.
The division of labour system
is extensively applied in the works, and the result is, that the men in the
various departments display extraordinary expertness. When a boy enters on
his apprenticeship, he chooses, or has chosen for him, the branch of work
which he is to follow, and to that he adheres. Let us suppose that a boy
selects pot-moulding. After some preliminary training, he is entrusted with
the making of pots of the smallest size. As he advances in years, so does
the size of his pots increase; and by the time that grey hairs come, he
finds his hands employed upon vessels so capacious that each might contain a
dozen of those he made in his early days. This is one of the peculiarities
of life at Carron; and though it looks as if designed to remind the men of
the flight of time and the growth of years upon them, it is simply the
result of promotion by seniority. The mould for a small pot requires nearly
as much time to make as that of a large one; but there is a difference of
price in favour of the latter, and these the older hands claim the privilege
of making. Another peculiarity of the pot-making branch is the mode of
payment. A man agrees to make a certain number of pots for half-a-crown, and
he is allowed one shilling of premium on every hundred he produces. Taken
altogether, the men employed in moulding make higher wages than those in the
other departments, and it is no unusual thing for one of them to receive as
much as L.3 for a week's work; but the general wage of the class may be set
down at about 25s. a-week.
Though the reputation of
Carron is now chiefly based on its production of what may be called domestic
iron-work—such as stoves, grates, cooking ranges, boilers, pots, rain-pipes,
&c.—at one time it was closely identified with the manufacture of cannon and
shot. The now obsolete piece of ordnance known as the "carronade" was there
brought to perfection, and derived its name from the works. None of those
guns have been made since 1852, about which time the revolution which has
taken place in the construction of implements of war commenced. Among the
heaps of old iron in the works may be seen one or two condemned castings of
carronades, which show the mode of manufacture. The guns were cast solid, in
an upright position; and in order to ensure closeness of texture, the mould
was filled up for a distance of two feet above the muzzle of the gun. This
superfluous mass was cut off, and the gun bored to the required calibre.
The company possess, and work
for themselves, extensive mines of coal, iron, and lime, some of which are
in the immediate vicinity of the establishment. The raw material is brought
in by a railway which approaches close to the furnaces; and additional
facility for carrying is afforded by a canal three miles in length,
extending from the centre of the works to Grangemouth. For the conveyance of
goods to the east and west, sixteen canal boats are employed. Six
steam-vessels are owned by the company, and chiefly occupied in carrying the
produce of the foundry to London, where the company have an extensive
warehouse. Attached to the works is a farm of four hundred acres; and no
fewer than five villages in the vicinity are dependencies of the company,
and many of the houses have been built by them.
The company employ nearly two
thousand men and boys, whose labours are never affected by fluctuations in
the markets for the productions—as, when a temporary slackening of demand
takes place, the company go on making stock goods; and as a precaution
against any contingency that might interfere with the supply of raw
material, an immense stock is always kept on hand. These circumstances are,
of course, a great advantage to the men; and one of the results is that very
few leave the service of the company, so that the great body of them are
natives of the locality, whose forefathers for three or four generations had
worked in the place. There are no Irish among them; and, in the aggregate,
they are an exemplary body of workmen. They have three principal benefit
societies and a number of minor ones. The most important society has been
in_ existence for many years, has accumulated a considerable amount of
capital, and holds an interest in the company. It has a membership of seven
hundred, mostly heads of families. A co-operative store has flourished in
connection with the works for upwards of forty years. No special provision
for the education of the children of the workmen was provided by the company
until recently, when a large and commodious schoolroom was erected by them.
The Falkirk Iron works, which
are situated in the immediate vicinity of Carron, deserve notice, both on
account of their extent and the kind of goods they produce. They were
started in 1819 by a company chiefly, if not entirely, composed of workmen
from Carron. The beginning was not a pretentious one, but the concern
prospered. In 1848 the establishment was acquired by the present
proprietors, Messrs Kennard, who had been shareholders for many years in the
old company. Since then it has steadily risen in importance, and is now the
largest foundry in Scotland, with the exception of Carron. Nine hundred men
and boys are employed; and when ordinarily busy, upwards of 300 tons of
castings are turned out per week. The buildings, which cover eight acres of
ground, have during the last few years been almost entirely reconstructed,
and considerable additions are being made. The most improved appliances are
in use in every department. During the Crimean war, 16,000 tons of shot and
shell were made at the foundry for Government; and guns of all sizes, from 4
to 18-pounders, for use on board mercantile vessels, are manufactured in
considerable numbers. With these exceptions, the productions of the firm are
associated with the arts of peace, and they range from bridges of the
largest size to ornamental inkstands and fancy castings of the most delicate
patterns possible in cast iron. The castings for some of the principal iron
bridges in India, Italy, and Spain have been made at the Falkirk Ironworks.
The heaviest pieces of work recently executed were the columns for the
Solway Viaduct. This bridge is supported on groups of cast-iron columns,
securely fixed in the bed of the Firth, and strengthened by diagonal
bracings of malleable iron. The columns were cast in ten and twenty feet
lengths, which were readily bolted together, and made as strong as if the
entire column were cast in one piece. A large number of fountains for the
Calcutta Water Company were turned out a short time ago. These were of a
neat design, and bore the arms of the company, and the maxim "Waste not,
want not," in English and Hindustani. Those for the East Indies; sugar-pans
for the West Indies; tubular telegraph-posts for South America; grates,
pots, and pans for the million; and beautiful objects of art for homes in
many lands—might be seen piled side by side in the elegant arcade and
extensive shipping warehouses, testifying alike to the wide connection of
the firm and to the merit of Scottish workmanship.
Messrs Kennard have devoted
great attention to the production of cast-iron goods of an artistic kind;
and it is stated that no establishment in Britain possesses such a valuable
collection of patterns for stoves, grates, umbrella-stands, garden-seats,
verandahs, iron stairs, balconies, and fancy articles—such as inkstands,
card-trays, mirror- frames, statuary groups, &c. The designs of these
articles are without exception beautiful, and they are being manufactured in
constantly increasing variety. When any new article is to be produced, a
drawing of it is first made, and from that a modeller forms a pattern in
wood, wax, or plaster. From the pattern a cast is taken in tin, and from the
tin copy, which is nicely chased up, the moulder makes the impression in
sand from which the iron is cast. A smoother surface is thus given to the
iron than would be the case were a wood pattern used. In all cases the
details of the pattern are sharpened in the iron after casting, by filing.
Though no model seems to be too difficult for the moulder to make in one
piece, yet, as a matter of convenience, most articles of any size or
complexity are made in several pieces. A specimen of work from the moulding-
shop in which the ornamental castings are made was shown at the Exhibition
of 1862, along with a variety of other castings, and excited a great deal of
interest, as showing the capabilities of the sand-moulding process. It was a
small figure of a stag browsing; and, in order to its being cast in one
piece, the mould had to be made in upwards of one hundred parts, each part
being simply a clod of moist sand held together by compression.
There are six other foundries
in the neighbourhood of Falkirk, which give employment in the aggregate to
six hundred men. Glasgow, however, is the centre of the iron trade, as
indeed of nearly all other trades in Scotland, and produces a great amount
of iron goods of every kind. The foundries and machine shops of Edinburgh,
Leith, Dalkeith, Kirkcaldy, Dundee, and Aberdeen, also turn out a
considerable quantity of machinery, &c.
Fire-grates and stoves form a
large portion of the produce of several establishments, and one in the
Falkirk district is devoted exclusively to making stoves after American
patterns. A "ventilating fire-place," recently patented by Mr J. D.
Morrison, surgeon-dentist, Edinburgh, may be noticed here, as it bids fair
to revolutionise the modes of warming and ventilating hitherto in use. Mr
Morrison's invention consists of a combination of the open fireplace and
close stove, possessing the pleasant appearance of the former, and the
active heating qualities of the latter, and yet free from the defects of
both. As applied to a room, it consists of a semicircular apparatus, fitted
into an ordinary fireplace, the centre projecting a little beyond the lintel
of the mantelpiece. This form, besides giving the fireplace a handsome
appearance, serves, as will be seen, a twofold purpose. The grate containing
the fire is brought a little further forward than usual. There are two
sliding doors opening from the centre to right and left, for modifying, as
required, the consumption of fuel and the warmth of the apartment. These
doors, when open, expose a large amount of radiating surface. taking in a
range of 150° of the room. The products of combustion are purified before
escaping to the air, and very little smoke is emitted. On either side of the
cast-iron chimney at the back of the fireplace are two caliducts for
moderately warming fresh air before entering the room. And here the
semicircular form of the apparatus is made to perform its other function. By
means of a perforated opening above the fire, and separated from it, the
warm fresh air is discharged radially into the room. The tendency of the
heated air to ascend is taken advantage of in producing a complete
circulation and continual changes, for, as the air passes over and across
the room, it becomes gradually cooled, and descends by the walls and windows
furthest from the heat. By a simple contrivance, the air which has been
vitiated by respiration is returned to the fire, and freed from its
impurities. By another arrangement in the system, the vitiated air is
conveyed through the ceiling to the fire in a room above. This continual
influx of fresh air, and the abstraction, as described, of the air after
having been used, besides effectually ventilating and heating the room,
serves yet another purpose. The draughts caused by the ordinary fireplace
are completely neutralised by Mr Morrison's apparatus. The weight of the new
grate is very little more than that of one of the ordinary kind, and it is
quite as easily fitted to its place. Mr Morrison intends his system of
warming and ventilating to be applied to hospitals, churches, public
buildings, and ships, as well as to dwelling-houses; but, especially in its
application to rooms, his endeavour has been to realise in this country the
mild and salubrious conditions of a warmer climate. The system is applicable
to all the apartments of private dwellings. Messrs Kemp & Co.,
philosophical-instrument makers, Edinburgh, have arranged with the patentee
to add a supplementary establishment for constructing and introducing the
apparatus in all its applications.
Though cast iron may be
readily formed into articles of complex shape, its brittleness sets a limit
to its use; and in the construction of the working parts of machinery, or
articles in which great strength and lightness have to be combined,
malleable iron must be used. But from the difficulty of working malleable
iron, the cost of articles made of it is much greater. The knowledge how to
treat the metal, so that, while it might be cast into any shape, it should
retain all the qualities of malleable iron, was until recently a
desideratum. The possibility of so treating both iron and steel has, we
believe, been successfully proved, but as yet the process is kept secret.
The conversion of pig-iron into malleable by the "puddling" process was
commenced in Scotland about forty years ago, when a number of workmen from
England and Wales were brought into Lanark-shire for the purpose of
instructing the Scotch ironworkers. The first attempts, however, to
establish this branch of trade were not successful, and it was not until
1836 that it was fairly started. There are now nearly four hundred puddling
furnaces and fifty rolling-mills in operation, which in 1867 produced
143,800 tons of malleable iron, valued at L.1,006,600. The principal firm in
the trade is the Glasgow Iron Company, which has extensive premises at St
Rollox, Motherwell, and Wishaw.
The works for the conversion
of pig-iron into malleable are nearly all constructed on the same plan. The
mill consists of a vast roof supported on iron pillars, so that the sides
are open. The puddling furnaces are built at intervals along one or two
sides of the mill; and the floor, which is paved with iron plates, is
crowded with machinery, a powerful steam-engine occupying the centre.
The work of the puddlers is
probably the severest kind of labour voluntarily undertaken by men. The
puddling-furnace is a compact structure of firebrick cased in iron. It
consists of three parts—the fireplace, the hearth, and the flue. The
fireplace is on the left-hand side, and is separated from the hearth, which
occupies the central place, by a low wall or ridge. To the right of the
hearth is the flue, the entrance to which slopes downward from the hearth,
so that, when a fire is lighted in the fireplace, the flame is drawn close
over the hearth in its passage to the flue. Each furnace requires two men to
work it. One of these is the puddler, who has all the responsibility, and
the other his assistant, who performs the portions of the work in which only
slight skill is required. The quantity of pig-iron operated upon at a time
is about four hundredweight, and is called a charge. One charge is got out
of the furnace every two hours, and the work goes on night and day, from one
week's end to the other, Sunday excepted—the men taking the night and day
shifts by turns. After a charge is withdrawn, the furnace undergoes some
slight preparation before another is put in. A coating of "bull dog"—a
material prepared from the slag of the furnace—is laid on the hearth, to
fortify it against the intense heat. The pig-iron, which has previously been
broken into pieces of convenient size, is then thrown in, and the doors of
the furnace are closed and sealed up with cinders. Intense heat is then
generated; and so fiercely does the fire burn that the flame issues from the
top of the chimney, which is upwards of forty feet high. In about a quarter
of an hour after the furnace has been sealed, the iron shows signs of
melting, and an aperture in the hearth door, about six inches square, is
opened. The puddler, whose eyes seem to be proof against a light as dazzling
as the sun at noon, looks in at the opening, and determines whether it is
time to disturb the iron. So soon as he sees the finer angles of the iron
begin to melt, he thrusts in a stout rod of malleable iron, and moves the
lumps of metal about, so that the entire mass may be equally heated. If this
were not done, the parts which melted first would be burned up and lost, and
the quality of what remained deteriorated. The puddler's assistant takes a
turn at this part of the work; and during its progress the heat is
occasionally moderated by means of the "damper," or by dashing small
quantities of water upon the iron.
At frequent intervals the puddling bar is withdrawn, and cooled by being
dipped into water. The iron dissolves gradually on the hearth, and after a
time begins to heave and bubble, innumerable jets of flame bursting forth
all over its surface. The desired chemical change is now going on. The hot
air from the furnace sweeps over the iron and carries off a great part of
the carbon, sulphur, phosphorus, and silicon contained in the pig-iron. Care
must be taken to prevent the metal from becoming too fluid; and as soon as
it attains a pasty consistency, the heat is moderated. Meantime the puddler
uses his rod vigorously; and as the metal begins to "dry," the labour of
moving it about is increased. The metal at length seems to curdle and become
granular. As it then ceases to give off carbonic oxide, the heat of the
furnace is again raised, and the particles of metal begin to adhere
together. From this point the chief puddler undertakes and completes the
operation. As the metal agglutinates, it becomes very difficult to move. The
puddler has to exert himself to the utmost; and he dare not relax his
efforts for a single minute, else all the previous labour would be worse
than lost. Though the perspiration trickles from his face and arms, and
oozes through his scanty clothing, he must toil on. His eye is never removed
from watching the contents of the furnace; and the expression of anxiety on
his face indicates that the operation has reached a critical point. When the
metal has attained a certain degree of consistency, the puddler divides it
into five or six heaps. He then works each heap into a "ball" or "bloom" The
door of the hearth is opened, and one after the other the balls are drawn
out with a large pair of tongs, and dragged over the floor to the "
shingling" hammer. As the balls are drawn from the furnace they have a
spongy appearance, and slag and other impurities trickle from them. The
various operations described occupy, on the average, about two hours, and
the quantity of mire- fined pig-iron required to make a ton of puddled iron
may be stated at from twenty-two to twenty-three cwt. An invention for
facilitating and making more perfect the work of the pudellers, has recently
been adopted at some of the malleable ironworks. It operates by injecting a
current of air at high pressure into the furnace. This is done by making the
puddling bar hollow, and affixing to the outer end of it an india-rubber
tube, communicating with a powerful air-pump. The patentee is Mr Richardson
of Glasgow; and the advantages gained by the contrivance are, that a charge
of the furnace can be puddled in fifteen minutes less than the time required
by the usual process, and that the iron produced is purer and tougher.
It is the puddler's duty to
convey the "balls" from the furnace, and to place them one by one on the
anvil of the " shingling" hammer. Before the invention of the steam-hammer,
a somewhat clumsy contrivance was used for squeezing the slag out of the
puddled iron, and beating it into shape. Now the steam-hammer is everywhere
employed for those purposes. When the puddler lays a "ball" on the anvil, he
waits to see the result of the first blow, and from it he is enabled to
judge of the quality of his work. The "shingler" then steps forward, and
takes charge of the "ball." His feet and legs are encased in iron armour,
his body is covered by a stout leather apron, and he wears a mask of the
same material. One stroke of the hammer makes apparent the use for this
warlike attire, for it sends out in every direction jets of liquid fire,
which patter against the legs of the workman, and would inflict fearful
injuries were they to come in contact with the skin. The manipulation of the
ball under the hammer is severe work, and requires great expertness. The "shingler"
uses a pair of tongs about four feet in length, and with these seizes the
ball and turns it on the anvil every time the hammer ascends. He so manages
that the iron assumes the shape of a brick; and the operation occupies only
two or three minutes. The "shingler" passes the metal, yet at a white heat,
to the "rollers," who pass it through a series of grooves, in a pair of
solid iron cylinders. By this means it is drawn into bars of the required
size.
The iron produced by the
above process is called "puddled-bar," and has to go through another
operation before it is suited for even the commoner purposes of the
blacksmith. In order to produce what is known in the trade as "common iron,"
the puddled bars are cut up into short lengths, and a number of these are
laid in a heap of sufficient size to make a bar of any stated dimensions.
They are then placed in a "reheating furnace," and exposed to a free
circulation of heat. In about half an hour the iron becomes heated to what
is known as the welding-point, and is then removed and rolled as before.
When the rolling is completed, the bars are taken away by boys, and cut to
the desired length by means of a circular-saw, which passes through the
metal with astonishing rapidity and with a hideous noise. The bars are then
straightened on an iron plate, stamped with the maker's name, and allowed to
cool. From the moment the iron is taken out of the reheating furnace till
the bars are ready for the market, the utmost expedition is required on the
part of the workmen; and their operations, especially when witnessed at
night, form one of the most interesting sights connected with the
manufacture of iron. When a finer quality of iron is required, another
welding and rolling are given to it. These repeated heatings, however,
entail a considerable loss of material—equal, we believe, to eight or ten
per cent. for each heat. In making the best quality of malleable iron, it is
usual to refine the pig-iron before putting it into the puddling-furnace.
The refining is done in a furnace specially constructed for the purpose; and
the process consists in fusing the iron with coke, and thus ridding it of a
large proportion of its impurities.
The quantity of malleable
iron used in making machinery, building ships, and for other purposes, is
immense. From year to year the workers in that material have been called
upon to produce heavier pieces of work than formerly; and it is gratifying
to find Scotch firms occupying the foremost place among the makers of
gigantic smithwork. The heaviest forgings required for the largest war and
mercantile vessels afloat have been made at Glasgow. When the Great Eastern
was building, it was feared that no firm would be found willing to undertake
the forging of her shafts; but the Lance- field Forge Company, of Glasgow,
accepted the task, and executed it in a most satisfactory style. The shafts
of many large war-ships, mail-steamers, and other vessels, have been made at
the splendidly appointed works of this company. The shafts for the steamers
of the Cunard, Peninsular and Oriental, and Royal Mail Companies, as well as
for the Achilles, Black Prince, Monarch, and other ships of the British
navy, and also for the war-ships built by Messrs Napier & Son for foreign
governments, were made at Parkhead Forge, Glasgow, by Messrs Rigby &
Beardmorp. The heaviest piece of work produced at this forge was the
crank-shaft of the Monarch—an immense war-ship, recently built at Chatham.
When the shaft left the hammer, it weighed thirty-two tons, and when
finished it measured 23i inches in diameter. It was feared that the passage
of such a heavy and compact mass over the bridges on the public road would
not be safe, and some difficulty was experienced in arranging for its
conveyance to Chatham. The North British Railway Company undertook to carry
it, and the journey to the railway station and thence was safely
accomplished, a special train being run for the purpose.
The Parkhead Forge is an
extensive establishment, giving employment to seven hundred men and boys;
but in consequence of the heavy nature of the work, the proportion of boys
to men is smaller than in other branches of iron manufacture. The buildings
cover several acres of ground, and are constructed in a most substantial
style. On approaching the entrance to the forge, the visitor is startled by
the vibration of the ground under his feet, caused by the incessant blows of
the steam-hammers; and a peep inside reveals a scene of extraordinary
activity. The rolling-mill is three hundred. feet in length and one hundred
and fifty in breadth. At one end of the mill are ranged twenty-two puddling
furnaces, and half a dozen reheating furnaces. The rolling and other
machines are driven by a pair of horizontal engines of 300 horse power. The
flywheel of the engines is eighteen tons in weight, and makes one hundred
revolutions a minute. The steam is supplied by fourteen vertical boilers
heated from the puddling furnaces. The iron is first rolled into bars, then
cut up, reheated, and either rolled into ship and boiler plates, or into
pieces suitable for the forge. A number of years ago the firm devoted
attention to making armour plates. Their specimens stood the test of
competition with those of English makers most creditably; and but for the
want of convenience for carrying the plates—the nearest railway being a mile
distant— Messrs Rigby & Beardmore would have obtained a fair share of
patronage from our own and other governments. The machines are capable of
producing plates eight inches thick, and some of the plates made of that
thickness have weighed twelve tons each.
The forge or smithy is nearly
as large as the rolling-mill, and its fittings are on a most gigantic scale.
There are two steam-cranes, capable of lifting fifty tons each; four, forty
tons each; and four, twelve tons each; and these are so arranged that a
shaft or other piece of work may be passed from one to the other all over
the shop. There are fifteen steam-hammers, varying in weight from seven tons
to two. Finished shafts—that is, finished so far as the hammering is
concerned—lie about in all directions, and so delicately have these been
operated upon by the hammers that turning would seem to be almost
superfluous. Yet they are destined, before leaving the place, to be fitted
into a lathe and turned with the greatest exactness. In the heating
furnaces, and under the hammers, forgings may be seen in various stages of
progress, and a glance at these makes plain the whole process of forging. In
making a crank-shaft, for instance, a piece of iron eight or ten feet long,
and of suitable diameter, is used as a "haft" or handle. At one extremity it
is fitted with cross-bars or levers, by which it may be turned on its axis;
and the other end is shaped conveniently for having smaller pieces of iron
welded to it. The welding end is placed in a furnace, and in about an hour
and a-half is raised to a welding heat. The crane by which the iron is moved
about is fitted with a chain collar or sling, in the loop of which the iron
rests. The collar works in a pulley attached to the chain of the crane, and
moves easily, so that the shaft may be readily turned on the anvil. When the
proper degree of heat is attained, the stopping of the furnace is removed,
the steam-crane put in motion, and the gigantic bolt is swung on to the
anvil of the steam- hammer. Several large slabs of iron, similarly heated in
another furnace, are then brought out and laid on the "face" of the "haft."
At a signal from the head forgeman, the hammer drops upon the glowing mass,
and sparks of dazzling brilliancy fly off in all directions. Again and again
the hammer descends, the iron meantime being carefully moved about, so that
the whole may be worked into a homogeneous mass. Gradually the iron assumes
a dull colour, but not before the desired end is obtained. It is then swung
back to the furnace, comes forth glowing, has another addition made to its
bulk, and so on. The most difficult part of the work is the formation of the
crank piece, which is forged solid, and forms a huge square projection on
one side of the shaft. When the shaft has acquired the proper dimensions, it
is allowed to cool, and the haft piece is cut off to be used again. As the
shafts are turned down until a good surface is obtained, an extra inch or so
is allowed in the forging. All shafts are made in lengths of about twenty
feet, each length having flanged ends, so that they may be firmly united.
For dressing and finishing
such huge pieces of iron special and costly appliances are necessary. These
are in the machine shop, an apartment one hundred and fifty feet in length,
and fifty feet in breadth, both sides of which are lined with
turning-lathes, slotting and boring machines, &c., of extraordinary size.
One of the turning- lathes is said to be the largest in the world; and some
idea of its dimensions and form may be obtained from the fact, that the
crank shaft of the Monarch, though weighing thirty-two tons, was turned in
it without taxing its capabilities to the utmost. Iron shavings fully one
inch broad, and one-eighth of an inch thick, are turned off with apparently
as little effort as if the material had been wood, instead of iron. One of
the boring machines is sufficiently powerful to drill a hole ten inches in
diameter through a solid block of iron, and the largest slotting machine can
send off chips a pound or two in weight. When the work leaves this
department, it is generally ready for being fitted into its place.
Messrs Rigby & Beardmore pay
nearly L.40,000 a-year in wages; and in all departments of the
establishment, fifteen thousand tons of iron and sixty thousand tons of coal
are used annually.
The "forehands" employed in
the operations described above earn much higher wages than any other class
engaged in the manufacture of iron; but no one who knows the nature of their
work will say that they are overpaid. When trade is moderately brisk, a
puddler working full time makes from 8s. 6d. to 9s. per "shift" of twelve
hours; but out of that sum he has to pay his assistant or "chap" 3s. or 3s.
6d., so that his weekly earnings, supposing him to work five shifts, are
from 25s. to 28s. It follows that when the puddlers are slack, the men
employed in the other branches of iron- making are equally so. When working
full time, shinglers make about L.4 a-week, and chief rollers £5. All are
paid according to piecework—so much a-ton. The "forehand" shinglers,
rollers, and heaters engage their own assistants, and pay them out of their
joint earnings; but men are so eager to learn the work, in consequence of
the high rate of remuneration obtained ultimately, that they are found ready
to undertake the subordinate position at low wages, so that a liberal share
falls to the "forehands." The work, as may be gleaned from the foregoing, is
of the most arduous kind, and the best constitutions cannot stand it long.
One effect of the severe heat and exertion is the creation of a craving for
stimulants, such as beer, which at once cool and support the workmen; and to
a certain extent no man would grudge them these; but unfortunately, the
craving does not always cease with the work, and the consequence is that a
considerable proportion of them may be set down as being of irregular
habits. When their day's work or night's work is done, they are too much
exhausted to devote attention to anything of the nature of mental culture,
so that they are not so well-informed nor intelligent as the average of
workmen engaged in other occupations. The forehand forgemen are paid at the
rate of from 10s. to 15s. a-day. They require to exercise great care and
skill in the manipulation of heavy forgings. A flaw in the forging of a
crank might be attended by the most disastrous results to life and property.
In order to prevent such a thing, every blow of the hammer has to be
carefully directed, and its effect closely watched. A good forgeman must
know something about the chemistry of iron, and also be well up in figures.
In making machinery, the greatest exactness has to be observed in the
dimensions of the respective parts, and a crank made at Glasgow must be so
nicely finished, that when it is taken to Chatham or elsewhere it will fit
exactly into the bearings prepared for it. |