CAHABA
IRONWORKS AND ITS SUCCESSORS
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message from Bob Yuill - see Mail / Genealogy /
Alabama / Bob Yuill / Irondale Furnace 10/31/12009
Wallace
S. McElwain, Eliza G. Barney, and W. A. Jones
constructed the Cahaba Iron Works, also referred to as the Irondale Furnace, in
1863. The furnace site, located along the southeast side of a branch feeding
Shades Creek, was secured on February 27, 1863 with lands purchased from Willis
Eastis.70
Previously,
McElwain operated a furnace in Holly Springs, MS. At
the time of his departure from Holly Springs, which was acquired by the
Confederate Government, McElwain was producing arms
for the war effort.
The Irondale
Furnace operated up until the time it was destroyed on March 30th,
1865, when Major General James H. WilsonÕs troops, lead by Colonel Emory Upton,
moved through Shades Valley enroute to Montevallo.
After the war McElwain found the required capital to
rebuild the furnace through Abel D. Breed, (A. D. Breed), of Cincinnati, Ohio,
and in March of 1866 the deal was finalized. The capital secured from A.D.
Breed allowed the Irondale Furnace to be back in operation in early 1866, well
before the Oxmoor Furnace, which too was destroyed in
1865. Along with investment money came plans for expansion. A rolling mill was
to be constructed, the building was erected by the rolling mill was never
installed.262 Major improvements
to the furnace plant included the replacement of the water powered blower with
2 boilers, a horizontal steam driven blower for the blast, and Ôhot blast
pipesÕ. The hot blast was provided by the blast wind passing under the 2
horizontal boilers, thereby gaining heat radiated from the furnaces, before
entering the furnace. Other improvements made to the furnace plant were the
blacksmith shop, foundry, and carpentry shop.
The capacity of the
open top stone furnace was generally 5 - 7 tons a day. After the war the
products pig iron and castings, for the domestic and agricultural markets as
well as equipment for the railroads.
These were taken by wagon to the Alabama and Chattanooga Railroad in
Irondale, about 2 miles distant. Markets for pig iron, other than that used
locally were Cincinnati, Louisville, and Charleston. During the war the product
went by wagon to the Selma, Rome and Dalton Railroad, then to the Arsenal in
Selma for the war effort.
The Montevallo Star, December 18, 1866
reported that ÔBreedsÕ Ironworks will be manufacturing
iron railsÕ, to facilitate the completion of the Selma, Rome and Dalton RR.
E.G. Barney and A. D. Breed, both partners with McElwain,
were contracted to complete of the railroad from Dalton, GA. to Rome, GA.
To enhance the
transportation of product from the furnace to Selma and points south, a rail
spur from the South and North Railroad to the furnace was considered in the
1860Õs. The South, April 15, 1873 reported this route as having been
graded, but the line was never built. The South and North did not reach the
location of Birmingham until 1871. The projected railroad spur line would have
been about 9 miles long; one land deed to McElwain
stipulating a right-of-way may place the railroad in the vicinity of Our Lady
of Sorrows on Oxmoor Road, in Homewood.
A. D. Breed (also known
as A. D. Breed & Co., Crane Breed & Co.)
and the newly reorganized Cahaba Iron Works operated
the furnace until the late 1860`s or early 1870`s;
the property afterwards was leased to McKee, Fuller
and Co. in May of 1871.71 The
Selma County Guide reported the furnace would
be in blast the first week of December 1871.
James
H. McKee and James W. Fuller Jr. were the principles of McKee, Fuller &
Co., also referred to as McKee, Thomas & Co. McKee, Fuller and Co., was
organized during 1866, and operated the
"Lehigh Car, Wheel and Axle Works" at the Fullerton Station of the
Lehigh Valley Railroad in Catasauqua, Pennsylvania. Catasauqua was the
site of the Crane Iron Works where the first commercially successful
anthracite-fired blast furnaces were put in operation in the early 1840Õs. Two
separate (unrelated) Thomas families were active in the Catasauqua iron
industry – David Thomas, who erected the Crane Iron Works and his
child-hood friend, Hopkin Thomas, who served as Master Mechanic (Chief
Engineer) at the Crane from 1852 to 1871.
It was James Thomas, son of Hopkin, that came
to the Irondale furnaces in 1872. It was Samuel Thomas, son of David, that
later came to Jefferson County in 1886 to construct furnaces at a place which
became named Thomas, Alabama -- after the David Thomas family.
James
Thomas, trained at the Crane Iron Works by his father Hopkin, was the superintendent at the
anthracite furnaces of the Carbon Iron Works, Parryville,
Pennsylvania when he was contacted by his brother-in-law about heading up a new
operation in the Alabama iron and coal district. The company thus formed was to
be known as McKee, Thomas & Co. although name of the parent company, McKee,
Fuller & Co appears in many of the records.
Thus James Thomas
moved his family from the Lehigh Valley of Pennsylvania to Jefferson County,
Alabama to assume the position of General Manager of the Irondale Furnace, and
later the Oxmoor Furnace.
The
lease of the Iron Works was for 5 years, the entire property was leased, which
consisted of about 500 acres of iron ore land and mines, limestone, coal, and
timberlands, together with the furnace, machine shops, foundry, pattern and
carpentry shop, machinery, blacksmith shop, stables, stores, and office. The
lessors paid $2.00 per gross ton of pig iron or scrap pig iron produced within
the first two years of the lease, and $2.50 per gross ton of pig iron or scrap
pig iron within the last three years of the lease.72
McKee,
Fuller and Co. purchased in excess of 200 acres of additional timber, coal, and
red ore properties in 1871.
Apparently,
McKee, Fuller & Co. tried out the furnace as they received it and after the
first run of the furnace found the hot blast to be ineffective. James Thomas
made a number of changes to the furnace; perhaps the most important was the
installation of his automatic bell and hopper for closing the tops of blast
furnaces, for which he received a patent for in 1870263. This allowed the
use of the hot furnace gases that with an open top furnace are wasted, to be
used to provide a hot blast. With this arrangement, the hot furnace gases were
sent to a heat exchanger called a Stove in the furnace industry. The stove was
heated by the furnace gases and indirectly heated the blast wind. Eventually,
three brick stoves were built. These modifications enlarged the furnace from a
40Õ height to 46Õ the bosh was 10Õ 6Ó in diameter. The method of charging the
furnace was also changed; previously to get the raw materials to the furnace
wagons were used to haul the iron ore, charcoal and limestone to the top of the
furnace. To eliminate this expense a water elevator, or water hoist, was used
to raise the required material to the top of the furnace. The new hot blast
stove system raised the output significantly, to 15 tons per day.
The
brick rolling mill building constructed by McElwain
was used by McKee, Fuller as a blacksmith shop and foundry.264
On
May 16 1873 the lease between the Cahaba Iron Works (still controlled by A. D.
Breed) and the McKee, Fuller and Co. was cancelled. The Jefferson Iron Co. was
incorporated in September 1872 by more or less the same individuals in McKee,
Fuller and Co.; with this reorganization the Jefferson Iron Co. appears to have
acquired all of A. D. Breed's interest in the Cahaba Iron Works. 73
After
the five-year lease of the iron works expired the operators did not renew the
lease, and the production of iron at the Irondale Furnace ceased forever. In
July of 1874 the Birmingham Iron Age states the furnace is shipping
iron, but by December of the same year mules from the furnace were listed for
sale in the Birmingham Iron Age. Alabama Blast Furnaces mentions
the boilers from the Irondale Furnace went to Oxmoor
in 1876 and the blowing engine went to the Edwards Furnace at Woodstock, Al. in
1877.
A
company called the Irondale Co., whose principals were James Thomas, James
McKee, and V. W. Weaver, were granted the most of the property and
rights of the Jefferson Iron Co. through a consolidation of the two firms in
April of 1890.74 The business of the Jefferson Iron Co. and Irondale Co. is
not known.
Note from Bob Yuhill on 11/9/09: The statement that V W Weaver was co-signer on deed is
incorrect! I went back to that deed, he is listed as a
stockholder but not a co-signer on the deed.
After McElwain left the Irondale Furnace, he was the
Superintendent of the Alabama Iron Company, who planned to build a furnace on
Turkey Creek, near Pinson. The furnace was never built; the company may have
furnished iron ore from their property to local furnaces. Later, in 1874 McElwain was involved in the rebuilding and renewed
operation of the Cornwall Furnace, Cherokee County near Centre. This furnace
ceased operation in 1875.
After the operations at Irondale were abandoned,
James Thomas and James W. Sloss leased the Oxmoor
Furnace beginning in 1875/1876. While James Thomas
was General Manager, and Levin Goodrich was Superintendent
at the Oxmoor Furnace,
the first coke iron at Oxmoor
was produced in late 1876.
The
Irondale Furnace in 1863 attempted to replace charcoal with coke, with
unsuccessful results, however by the early part of 1864 coke pig iron had been
produced at Irondale. This early coke experiment was at the request of Major
Wm. R. Hunt, Officer in Command at Selma. As the Confederate Government
desperately needed iron, the use of coke was seen as a means to increase
production, coke as fuel at Irondale increased the output from 7 to 10 tons per
day. Woodward, in Alabama Iron Manufacturing, 1860-1865, cites a Nitre and Mining Bureau report of the coke pig iron
produced at Irondale: "Éthis iron was rated as excellent."
McKee, Fuller and
Co. also tried their hand at producing coke iron at Irondale. Although the furnace was modified by Thomas and capacity of the
furnace was increased, the old stone furnace was not the optimum design or
shape for coke, also the quality of the coke suspect. When Goodrich modified
the Oxmoor Furnace to burn coke in the mid 1870`s,
changes were incorporated "Éto avoid the Irondale fiasco in trying to burn
coke in a furnace designed to burn charcoal only."76
This 24Ó diameter cast iron wheel is
believed to be from an Irondale Furnace tram car. The large diameter of the wheel provided
less rolling resistance for the heavy tram cars. This
wheel is on display at the Birmingham-Jefferson History Museum.
Group
of men posing in front of three ore cars lead by three mules. This photograph
is labeled, ÒMen employed at ore mines and team drivers, Irondale 1872Ó265, Gordon
Crawford Collection, Stamford University, Special Collections.
The operation of
the Irondale Furnace by McKee, Fuller & Co. was an opportunistic experiment
to determine if a coke fueled furnace using the red hematite ores of Birmingham
could produce pig iron. With information and lessons learned at
Irondale, the Oxmoor Furnaces
were then used to further develop the concepts of a coke-fired furnace. The
location of the Oxmoor Furnaces placed them very
close to the South and North RR, providing good transportation of raw materials
(coal and limestone) and finished goods. Iron ore for the Oxmoor
Furnaces came via tramway from the mines on Red Mountain about 2 miles north of
the furnaces.
CAHABA
IRON WORKS ORE MINES
Histories
of the Cahaba Iron Works often cite the Helen Bess mine as the source of red
hematite ore used in the furnace. During the course of the research for this
paper, evidence was found that suggests a different location for the ore mines
of the Ironworks.
When
studying the topography of the area lying to the northwest of the furnace,
there is a natural, easy route to the SE 1/4 of the SE 1/4 of section 28 Twp 17
R2w. It is here that initial Cahaba Iron Works iron ore mine was located, on
property McElwain acquired from the United States
government in November, 1862. The location of the tramway to the mine
was more or less along the current route of Leach Drive and Kingsbury Drive;
three land deeds place the Iron Works tram road as passing through this area.
This route also corresponds to a stream feeding Shades Creek from the north.
The McElwain commissary is located within 100 feet of
this stream. 77
McCalley, in Report of the Valley Regions of Alabama describes
the McElwain mine as being located in the SE 1/4 of
the SE 1/4 of section 28. The
Irondale seam was mined with drifts; the seam thickness was 2 feet 6
inches. Wm. B. Phillip's Iron
Making in Alabama locates "McElwain's"
mine in the same location.78
"An
outcrop of the Pelham limestone appears on the top of Red Mountain about
opposite the old McElwain or Irondale Furnace, or in
the SE 1/4 of sec 28 Twp R2w. These
limestones have been burnt some into lime and were
used some as a flux in the old McElwain or Irondale
furnace." The outcrop of lime
is about 70 feet thick.79
IRON ORE MINING IN SECTION 28
A
tramway entered the ravine on the west side, and is visible in the backyards of
the homes on Art Haines Circle.
After the tramway reached the two lowermost drifts on the west side of
the ravine, the location of the tram grade crossed to the center of the
ravine. At this point the inclined
grade began. The lower portion of the incline grade has been eroded by a wet
weather wash that now occupies the same place as the inclined grade once did.
The upper portion of the incline grade is still intact, as are the stacked
stone piers located at the end of the tramway outside of numerous drifts
adjacent to the incline. At the top
of the incline is a flat cut that was the location of some form of hoisting
device that is either a hoist of a balance-plane sheave.
There
are 16 drifts in this ravine; the upper four are traceable across the ridge and
into the ravine located to the east.
McElwain drift mine on west side of ravine,
the stacked stone in the foreground is at the end of the trench leading to the
drift. The incline was located in the near foreground and adjacent to the
stacked stone retaining wall.
70 Jefferson County Probate
Records, Deed Book vol. 14 p.52 and 54, February
1863, Willis Eastis to
W. S. McElwain.
71 Jefferson County Probate Records,
Deed Book vol. 17 p. 217, Agreement Between Abel D. Breed `et al', dated May
16 1871.
72 Ibid.
73 Jefferson County Probate Records,
Deed Book vol. 18 p. 198, The
Incorporation
of the Jefferson Iron Co., September 1872.
Deed Book vol. 17 p.712, Cancellation of Lease
from A. D. Breed to Thomas McKee and
Co.
dated May 16 1873.
74 Jefferson County probate Records,
Deed Book vol. 144 p. 199, Irondale Co. and Jefferson Iron Co. Merger, 1890.
76 Joseph H. Woodward, II, Alabama
Iron Manufacturing, 1860-1865, The
Alabama Review vol. 7 #3, July 1954, p.204
262 The Mineral Region of Alabama, The
South, April 5, 1873. Samford Univ,
Special Collections Dept., Gordan Crawford
Collection, box 3495-94.
263 U.S. Patent 103,391 dated May 24,
1870 "Improvement in Apparatus for Opening and Closing the Tops of Blast
Furnaces, James Thomas of Perryville, PA
264 Letter "Furnace at Irondale,
Alabama" written by Samuel Davis, 1918. Samford
Univ. Special Collections Dept., Gordan Crawford
Collection.