Life in a Railway Factory

by Alfred Williams

The only tools, besides hammers, required by the cutters-down, were cold sets to cut off the heads of the rivets and bolts, and punches to force the stems and stays out of the holes. They were held by hazel rods, that were supplied in bundles from the stores for the purpose. To bind them round the steel tools they were first of all heated in the middle over the fire. Then the cutter-out took hold of one end, and his mate held the other, and the two together gave the wand several twists round. After that the rod was wound twice about the set or punch and the two ends were tied together with strong twine. This gave a good grip on the tool, which would not be obtained with the use of an iron rod. The repeated blows on the set from the sledge would soon jar the iron rod loose and cause it to snap off, while the hazel rod grips it firmly and springs with it under the blow.

Formerly all the repair riveting was done by hand. When the hot rivet was inserted in the hole the “holder-up” kept it in position, either with the “dolly” or with a heavy square-headed sledge. Then the riveters knocked down the head of the rivet with long-nosed hammers, striking alternately in rapid succession and making the neighbourhood resound with the blows. Afterwards the chief mate held the “snap” upon it and his mate plied the sledge until the new head was perfectly round and smooth. The “snap” is a portion of steel bar, about ten inches long and toughly tempered, with a die, the shape of the rivet head required, infixed at one end. Now, however, pneumatic riveting machines are used out of doors. These, being small and compact, can be employed anywhere and with much fewer hands than were required by the old method. The air is supplied from accumulators into which it is forced by the engine in the shed, and it is conducted in pipes all round the factory yards.

The repair gangs are an off-shoot of the frame shed that is situated at a distance of nearly half a mile from the field. There the steel frames for the waggons and carriages and all iron-topped vehicles, such as ballast trucks, brake and bullion vans, refrigerators and others are constructed. That is essentially the shop of hard work, heavy lifting and noise terrific. The din is quite inconceivable. First of all is the machinery. On this side are rows of drills, saws, slotting and planing machines; on that are the punches and shears, screeching and grinding, snapping and groaning with the terrible labour imposed upon them. The long lines of shafting and wheels whirl incessantly overhead, the cogs clatter, the belts flap on the rapidly spinning pulleys, and the blast from the fan roars loudly underground. All this, however, is nearly drowned with the noise of the hammering. Hundreds of blows are being struck, on “tops” and “bottoms,” steel rails and iron rails, sole-bars and headstocks, middles, diagonals, stanchions, knees, straps and girders. Every part of the frame is being subjected to the same treatment — riveted, straightened, levelled, or squared, most unmercifully used. Every tone and degree of sound is emitted, according to the various qualities and thicknesses of the metal — sharps and flats, alto, treble and bass. There is the sharp clear tone of the highly-tempered steel in the tools used; the solid and defiant ring of the sole-bar or headstock, strong and firm under the hammer of the “puller-up,” the dull, flat sound of the floor plates, the loud hollow noise of the “covered goods” sides and ends, and the deep heavy boom of the roofs of the vans. Everyone seems to be striking as hard and as quickly as he is able. All the blows fall at once, and yet everything is in a jumble and tangle, loud, vicious, violent, confused and chaotic — a veritable pandemonium. And then, to crown the whole, there are the pneumatic tools, the chipping and riveting machines. It is dreadful; it is overpowering; it is unearthly; but it has to be borne, day after day and year after year.

Yet even the frame shed must yield to the boiler shop in the matter of concentrated noise. The din produced by the pneumatic machines in cutting out the many hundreds of rivets and stays inside a boiler is quite appalling. There is nothing to be compared with it. The heaviest artillery is feeble considered with it; thunder is a mere echo. What is more, the noise of neither of these is continuous, while the operation within the boiler lasts for a week or more. The boiler, in a great degree, contains the sound, so that even if you were a short distance away, though the noise there would be very great, you could have no idea of the intensity of the sound within. Words could not express it; language fails to give an adequate idea of the terrible detonation and the staggering effect produced upon whosoever will venture to thrust his head within the aperture of the boiler fire-box. Do you hear anything? You hear nothing. Sound is swallowed up in sound. You are a hundred times deaf. You are transfixed; your every sense is paralysed. In a moment you seem to be encompassed with an unspeakable silence — a deathlike vacuity of sound altogether. Though you shout at the top of your voice you hear nothing — nothing at all. You are deaf and dumb, and stupefied. You look at the operator; there he sits, stands or stoops. You see his movements and the apparatus in his hands, but everything is absolutely noiseless to you. It is like a dumb show, a dream, a phantasm. So, for a little while after you withdraw your head from the boiler, you can hear nothing. You do not know whether you are upon your head or your heels, which is the floor and which is the roof. The ground rises rapidly underneath you and you seem to be going up, up, up, you know not where. Then, after a little while, when you have removed from the immediate vicinity of the boiler, you feel to come to earth again. Your senses rush upon you and you are suddenly made aware of the terrific noise you have encountered. Even now, it will be some time before the faculty of hearing is properly restored; the fearful noise rings in your ears for hours and days afterwards.

And what of the men who have to perform the work? It is said that they are used to it. That is plainly begging the question. They have to do it, whether they are used to it or not. It is useless for them to complain; into the boiler they must go, and face the music, for good or ill. All the men very soon become more or less deaf, and it is inconceivable but that other ailments must necessarily follow. The complete nervous system must in time be shattered, or seriously impaired, and the individual become something of a wreck. This is one of the many ills resulting from progress in machinery and modern manufacturing appliances.

The personnel of the frame shed is individual and distinct in a very marked degree. Most of the men seem to have been chosen for their great strength and fine physique, or to have developed these qualities after their admission to the work. The very nature of the toil tends to produce strong limbs and brawny muscles. It is certain that continual exercise of the upper parts of the body by such means as the lifting of heavy substances tends to improve the chest and shoulders, and many of those who are engaged in lifting and carrying the plates and sole-bars are very stout and square in this respect. There is a number of “heavy weights,” and a few positive giants among them, though the majority of the men are conspicuous, not so much by their bulk, as by their squareness of limb and muscularity. A proof of the strength of the frame shed men may be seen in the success of their tug-of-war teams. Wherever they have competed — and they have gone throughout the entire south of England — they have invariably beaten their opponents and carried off the trophies.

There was formerly a workman, an ex-Hussar, named Bryan, in the shed, who could perform extraordinary feats of strength. He was nearly seven feet in height and he was very erect. His arms and limbs were solid and strong; he was a veritable Hercules, and his shoulders must have been as broad as those of Atlas, who is fabled to have borne the world on his back. It was striking to see him lift the heavy headstocks, that weighed two hundredweights and a quarter, with perfect ease and carry them about on his shoulder — a task that usually required the powers of two of the strongest men. This he continued to do for many years, not out of bravado, but because he knew it was within his natural powers to perform. Notwithstanding his tremendous normal strength, however, he was subject to attacks of ague, and you might have seen him sometimes stretched out upon the ground quite helpless, groaning and foaming at the mouth. If he had been working in the shed recently, since the passing of the new Factory Acts, he would have been promptly discharged, for no one is kept at the works now who is subject to any infirmity that might incapacitate him in the shed among the machinery. Later on, when work got slack, Bryan was turned adrift from the factory, a broken and a ruined man. All his past services to the firm were forgotten, he was cast off like an old shoe. However valuable and extraordinary a man may have proved himself to be at his work, it counts for little or nothing with the foremen and managers; the least thing puts him out of favour and he must go.

The men of the frame shed are of a cosmopolitan order, though to a less extent than is the case in some departments. The work being for the most part rough and requiring no very great skill, there has consequently been no need of apprenticeships, though there are a few who have served their time as waggon-builders or boiler-smiths. They are not recognised as journeymen here, however, and so must take their chance with the rank and file. Promotion is supposed to be made according to merit, but there are favourites everywhere who will somehow or other prevail. The normal order of promotion is from labourer to “puller-up,” from puller-up to riveter, and thence to the position of chargeman. Here he must be content to stop, for foremen are only made about once or twice in a generation, and when the odds on any man for the post are high, surprise and disappointment always follow. The first is usually relegated to the rear, and the least expected of all is brought forward to fill the coveted position. It may be design, or it may be judgment, and perhaps it is neither. It very often looks as though the matter had been decided by the toss of a coin, or the drawing of lots, and that the lot had fallen upon the least qualified, but there is no questioning the decision. The old and tried chargeman, who knows the scale and dimensions of everything that has been built or that is likely to be built in the shed in his lifetime, must stand aside for the raw youth who has not left school many months, but who, by some mysterious means or other, has managed to secure the favour and indulgence of his foreman, or other superior. Perhaps he is reckoned good at arithmetic, or can scratch out a rough drawing, though more than likely his father was gardener to someone, or cleaned the foreman’s boots and did odd jobs in the scullery after factory hours.

Another reason for the selection of young and comparatively unknown men for the post of foreman is that they will have a smaller circle of personal mates in the shed, and, consequently, a less amount of human kindness and sympathy in them. That is to say, they will be able to cut and slash the piecework prices with less compunction, and so the better serve the interests of the company. The young aspirant, moreover, will be at the very foot of the ladder, hot and impetuous, while the elder one will have passed the season of senseless and unscrupulous ambition.

A feature of the frame shed is the rivet boy. It is his duty to hot the rivets in the forge for his mates and to perform sundry other small offices, such as fetching water from the tap in the shed, or holding a nail bag in front of the rivet head which is being cut away, in order to keep it from flying and causing injury to any of the workmen. The forges for hotting the rivets are fixtures and are supplied with air through pipes laid beneath the ground from the fan under the wall. Several boys usually work from one fire, and there is often a scramble for the most advantageous position in the coals. An iron plate is used to facilitate the heating. This has been perforated with holes at the punch to allow its receiving as many rivets as are required. It is then placed over the whitehot coke in the forge and the rivets inserted. Each boy has a certain number of holes allotted to him and he must not trespass on his mates’ territory.