Steelworker

“ Clean-up man in the pit was my first job, which I held until I passed to third-helper on the open-hearth. Later I worked in the cast-house, became a member of the stove-gang, and at length achieved the semi-skilled job of hot-blast man on the blast-furnace. I acquired the current Anglo-Hunky language and knew speedily the grind and the camaraderie of American steel-making. In these chapters I have put down what I saw, felt, and thought as a steel-worker in 1919.
Steel is perhaps the basic industry of America. ”

“ The songs of the band-saw and the planer were stilled and in their stead rose the metallic clamor of steam hammer and turret lathe, and the endless staccato reverberation of an army of riveters. Ponderous machines to bend, twist, or cut a bar or sheet of steel filled the vast workrooms. An army of steel workers, Titans of the past reborn to fulfill a modern destiny, fanned the flames in their furnaces and released the leash of sand blast, air hose, and gas flame. ”

“ He may be in Scotland, or where he will, the production of steel goes forward just the same. His mills at Pittsburg, Duquesne and Homestead, where these tools are located, are thronged with thousands of toolless wage-workers, who work day and night, in winter’s cold and summer’s heat, who endure all the privations and make all the sacrifices of health and limb and life, producing thousands upon thousands of tons of steel, yet not having an interest, even the slightest, in the product. ”

“ Wherever there is a stream with a fall, there is the grinding-wheel at work: and in hundreds of workshops the nicer labour of the artificer is fashioning the steel into every instrument which the art of man can devise, from the scythe of the mower to the lancet of the surgeon. The machinery that made the steel has called into action the skill that makes the file-cutter. No machine can make a file. ”

“ One portion of the works which seldom fails to interest visitors is the steel works, which, at the time of their opening in 1864, consisted of a converting house with two converters, a cogging shop, and a small forge, but have since been greatly enlarged, the steel-making plant being now capable of producing 50,000 tons of steel per annum, besides which there have been added a large forge, iron, brass and steel foundries, rail- rolling mills, a boiler shop, and several repairing and other shops. ”

“ There is a great fascination, too, in standing near the furnace and watching the sparkling, hissing mass of metal being withdrawn by the crane, or seeing the heated bars removed from the oil forge and clapped quickly on the steel dies to be beaten into shape. No one can withstand the attraction of the steam-hammers; even those who have spent a lifetime in the shed like to stand and watch the stampers and forgers at work.
Forging and smithing are, without doubt, the most interesting of all crafts in the factory ”

“ A careful workman uses a steel die for only a short service before he returns it to the annealer, well assured that the metal, despite its seeming wholeness, has suffered severe internal strain at every blow, which, were no caution exercised, would soon reveal itself in fracture of the die, or ruined work. Facts of this kind, which every day confront the mechanic and engineer, convey a prophecy of the sensibility and memory which dawn with life. ”

“ Castings and Forgings.—There are two distinct ways of making the steel objects actually used in the arts, such as rails, gear wheels, guns, beams, &c., out of the molten steel made by the Bessemer, open hearth, or crucible process, or in an electric furnace. The first is by “steel founding,” i.e. casting the steel as a “steel casting” in a mould which has the exact shape of the object to be made, e.g. a gear wheel, and letting it solidify there. The second is by casting it into a large rough block called an “ingot,” and rolling or hammering this out into the desired shape. ”

“ Underneath his thin, shrunken cheeks and skinny arms are sinews almost as tough as steel itself. In the most blinding and deadly heat of the furnace, with three or four tons of dazzling metal exactly in front of him and the sweat pouring out of the hollows of his grimy cheeks and running down his nose and chin to drop in a continual stream on the ground beneath, he still pushes, heaves, and shouts loudly to his mates, and works and slaves quite unconcernedly. ”

“ Born and raised in a city of mills, he had, from the age of fourteen, played his little part in the making of steel. For three summers and at every other available hour he had toiled at steel. Bare to the waist, brown, heat-burned, perspiring, he had dragged at long bars, raking away at steel bars, but recently formed by rushing, crashing rollers, that were still smoking hot. Other hours he had spent on the gridiron. The one helped the other. Struggling with steel, he had become like steel himself, hard, elastic, resisting. ”

“ In the steel industry the most skilled men are to be found in those trades actually engaged in the making and rolling of iron and steel—the melters, puddlers, shearmen, rollers, roughers, heaters, Bessemer blowers, etc. These men are paid upon a tonnage basis and generally receive considerably higher wages than the mechanical tradesmen—bricklayers, machinists, boilermakers, riggers, firemen, engineers, electrical workers, blacksmiths, etc., who build, maintain and generally operate the plants. It is among the favored tonnage trades that the Americans are especially intrenched. ”

“ The ladlefuls ceased as steel, becoming thirty minutes' sledging through stoppage for four men, the weight of manganese in my shovel, and the clatter of the pieces that hit the rail, sparks on my neck burning through a blue handkerchief, and the cup of tea I had with Jock, cooked over hot slag at 4.00 A.M.
A battle certainly, to make an ingot—trench work in a quiet sector, perhaps, but a year-after-year affair. ”

“ I see miles of smoking chimneys where steel is made for all these uses in unimaginable quantities. And spanning the prismal chasm I see a series of great steel bridges, multiplying as I look, seeming to cast themselves in air across the void like cobwebs. But reflect! We have not yet discovered the way to make this steel. Unless we find it quickly we shall fail that unborn host. It cannot get across; if it did it could not live. The iron bridge cannot bear its weight. Nor can the world be prepared with iron. ”

“ Inseparable from the twelve-hour day in the open-hearth where I worked were the twenty-four-hour shift, and the seven-day week.
What does it mean to make steel twenty-four hours a day? to your muscles, to your thoughts, to the production of steel? Sunday morning, at 7.00, you begin work. There is an hour off at 5.00 P.M. Front-wall, fix spout, tap, back-wall, front-wall, fix spout, tap, back-wall—the second half is something [Pg 148] of a game between time and fatigue. ”

“ There may be miles of underground pipes bringing gas for fuel. Amid these scenes flit strong men, naked to the waist, unharmed in the red pandemonium, guiding every process, superintending every result; like other men, yet leading a life so strange that it is apparently impossible. The glowing rivers they escape; corruscating showers of flying white-hot metal do not fall upon them; the leaping, roaring, hungry, annihilating flames do not touch them; the gurgling streams of melted steel are their familiar playthings; yet they are but men. ”

“ No matter how we try, probably none of us ever realizes the immensity and importance of the iron and steel industry with approximately 460 huge blast furnaces here, 5000 cast and malleable iron foundries, about 1000 Bessemer and open-hearth steel and some 3000 puddling furnaces, and the many thousands of factories which each day are turning the products of these into rails, plate, wire, pipe, and the infinitude of finished articles which enter into and are mighty factors of our civilization. ”

“ A trip through one of the large steel plants with its furnaces, its blooming and slabbing mills, its rail, plate, structural and rod mills is one of the most interesting that can be taken. If the visitor is not afraid of smoke or dust or of what seems to him an uncomfortable heat 276on a warm day he will discover new worlds. No particular attention is paid to the casual visitor to the plant, but, for those who show real interest, steel men have a warm welcome, from manager to the sample boys. ”

“ We still speak of boiler iron, railroad iron, iron ships, etc., but these names are reminiscent, for in the construction of modern boilers and modern ships, steel is used exclusively. In the past decade it is probable that no railroad rails even for the smallest and cheapest of tracks have been made of anything but steel.
The last half of the nineteenth century has been one of triumph of steel manufacture and production in America, and at the present time the United States stands head and shoulders above any other nation in this industry. ”

“ There are several plants of independent steel companies that run on a three-shift, eight-hour basis; [Pg 153] and the steel mills in England, France, Germany, and Italy operate with three eight-hour shifts. The long day is not a metallurgical necessity, therefore. The metallurgical explanation of the twelve-hour day, however, is this. The process of making iron or steel is necessarily a continuous one, because the heat of the furnaces must be conserved by keeping up the fires twenty-four hours a day. ”

“ Its glare lights up the countryside for miles around, and the hissing and roaring of the molten iron, or rather of the steel groaning in its birth throes, forms a fitting accompaniment. It is a sight that once seen will never be forgotten. ”

“ The Steel Factory or Rolling-mill. One of the foremost pictures in the Metropolitan Museum of Art in New York is a picture of a steel-mill. It seems to be a prosaic subject but it makes an appealing picture, and one typical of our modern world. Some one has described a steel-mill as a modern materialization of Dante’s Inferno. The sky above Pittsburgh, Birmingham, and other steel centers is aflame at night as the process of manufacturing is carried on in the miles of buildings that contain the workers and the machinery. ”

“ The felling of a tree would occupy a workman a month, unless helped by the destructive action of fire. Dwellings could not be built, the soil could not be tilled, clothes could not be fashioned and made, and the hewing out of a boat was so tedious a process that the wood must have been far gone in decay before it could be launched. It was a great step in advance to discover the art of working in metals, more especially in steel, one of the few metals capable of taking a sharp edge and keeping it. ”

“ In the fierce and bitter struggle that was the steel trade only the most daring or the most unscrupulous manufacturer could survive, and under the strain for production that it necessitated only the strongest workers could live. No one, unless he has been through a steel plant, can imagine the conditions under which the steel maker works. ”

“ Then the steam-hammer shed, in which nothing but forging is done, was a flourishing place. All the wheels for the engines and waggons, together with piston rods, driving gear, axles, and cranks, were made there. These are obtained elsewhere now, some in England and Scotland, and other parts from abroad. Steel has superseded iron in a great degree, too, being harder, tougher, stronger and cheaper. The combined skill of the chemist and scientist has simplified the manufacture of it, and it is to be obtained in large quantities. ”

“ A further process is the manufacture of the metal thus treated into SHEAR STEEL, by exposing a fasciculus of the blistered steel rods, with sand scattered over them for the purposes of a flux, to the heat of a wind-furnace until the whole mass becomes of a welding heat, when it is taken from the fire and drawn out under a forge-hammer,—the process of welding being repeated, after which the steel is reduced to the required sizes. ”

“ Of the forging and the rolling of the steel a whole book might be written. It is enough now to say that of the 50,000,000 pounds of steel, every pound was made on honor. The railroad had its inspectors everywhere, but the rolling-mill men held to their formulas for perfect steel, and perfect steel was the result. A slight flaw in the metal, and possibly at some unexpected day, a great catastrophe. The safety of human life was upon the men who forged the steel, and they forged honor into every great girder, into every rod and bolt and plate. ”

“ Scrap from anywhere in America; a broken casting, the size of a man's trunk, down to corroded pipe, or strips the thickness of your nail, salvaged in bales. The overhead crane gathers them all from arriving flat cars by a magnet as big as a cart wheel, and the pieces of steel leap to meet it with apparent joy, stick stoutly for a moment, and fall released into iron [Pg 32] charge-boxes. By trainloads they pass out of the stockyard and into the mill, where the track runs directly in front of the furnace-doors. There the charging-machine dumps them quickly into the belly of the furnace. ”

“ Since no man who has worked in an American steel mill, whatever his sympathies or his indifference, can fail to have opinions on these points, I have decided to set down mine, for what they are worth, as simply and informally as I can.
There is a proper apology, I think, that can be made for the presumption of conclusions based upon an individual experience. An intimate and detailed record of processes and methods and the physical and mental environment of the workers in any basic industry is rare enough, I believe, except when it is heightened or foreshortened for a political purpose. ”