That the iron and steel industry is especially suited to production in large establishments is indicated by the fact that the value of the product of the steel works and rolling mills of the United States in 1905 averaged nearly four times as much per establishment as that of those engaged in cotton manufacturing.
Even these figures of value of product per establishment at the various dates and in the various industries do not, by any means, measure the degree of concentration of the industry which has come in recent years, because of the fact that under the most recent methods, many of the establishments are managed in groups, many large mills or factories which were considered by the census as separate establishments being, in fact, combined under one management, as is shown in another part of this work in which trusts and combinations are discussed.
This tremendous growth of the iron and steel industry of the United States—of the world, in fact, but more especially of the United States, seems to justify a somewhat detailed historical and descriptive account of iron and steel making, ancient and modern.
The manufacture of iron and steel is older than history. The material is so widely distributed over the surface of the globe that man in every part of the world and in nearly every stage of civilization long since learned its value. There is evidence that it was known to the Egyptians, the Assyrians, the Chaldeans, the Babylonians, the Israelites, the Greeks, the Persians, the Romans. Caesar found the Britons in possession of iron weapons which they had made, and the Scandinavians of that period were also acquainted with its manufacture. The people of Spain seem to have been early and successful workers in iron and steel, if the wonderful stories about the swords and other weapons of the early history of that country are to be believed.
Iron, wherever found in the native condition, is so mixed with rock, dirt and other foreign matter that it can only be utilized by heating and hammering or rolling until the pure iron is separated from the foreign substances. Originally the method seems to have been to heat the ore in fires built on the ground until it became softened, and by hammering it in this condition work out the foreign substances. Then man found that by building the fire in a hole at the top of a hill and leaving an opening at the bottom so that air could be forced into it, the heat could be intensified. Then he learned to build up a wall of mud and stones with an opening at the bottom, and by placing in it alternate layers of charcoal and iron ore and forcing in air at the bottom with rude bellows similar to those now used by blacksmiths, he was able to heat the ore until the iron melted and ran together into a mass which he worked into the steel with which the famous “Toledo
blades” and other weapons of that early day were made. Later, the Germans, by building the walls higher and getting a greater mass of the fuel and ore, were able to melt it so that it ran in liquid form into little ditches at the bottom of the furnace. This furnace, which came to be known as the “stuckofen” and “blow oven,” was the precursor of the blast furnace. Meantime the English were developing the process, and before the year 1700 were manufacturing considerable quantities of iron in furnaces in which charcoal supplied heat sufficient, when a blast of air was introduced, to melt the iron. This method of manufacturing iron continued in the European countries during all of the seventeenth century and until the early part of the eighteenth century. Meantime the forests of England were being rapidly destroyed in the sections which produced the iron ore. Prior to that time it had not been found practicable to use coal in smelting the ore, because the weight of the ore was so great that the fire was extinguished as the coal grew soft from the heat. Then, in the early part of the eighteenth century, somebody tried the experiment of treating the coal in a manner similar to that by which wood is turned into charcoal, and coke was produced and found available for smelting the iron ore, the coke being substituted for charcoal. And so the manufacture of iron in Europe went on, developing most rapidly in England which had ore, timber from which to make charcoal, and coal from which to make coke.
Meantime the making of iron began to develop in the United States. The early colonists found ore in Virginia and New England. Small quantities of pig iron were made in Virginia within a few years after the settlement of Jamestown, and in the latter half of the century New England began manufacturing iron from bog ore and charcoal made in the forests which were then so plentiful. Most of these early iron furnaces were “bloomaries,” merely heating the iron so that it formed a lump of 100 to 200
pounds weight at the bottom of the furnace, called a “bloom,” though there were some furnaces which heated the ore until the iron ran into little channels at the bottom and became “pig iron.” Before the year 1800 the State of Massachusetts alone had some 75 iron works, chiefly furnaces, making small quantities of iron. A little later there was built in that state a furnace then declared to be “the finest in America,” having two bellows twenty feet in length and operated by a water wheel. During the next century the size of the furnaces grew slowly and before the year 1800 there were furnaces capable of making two to three tons of iron per day each.
The history of the early iron industry in Massachusetts is not materially different from that of others of the colonies and early settlements. Connecticut, New York, New Jersey, Pennsylvania, Maryland, Delaware, Virginia, and the Carolinas all had numbers of small furnaces capable of making from a half ton to two or three tons of iron per day. They used charcoal altogether as the fuel, and it was estimated in Virginia and Maryland that for one furnace of average size four square miles of woodland and 100 slaves were required. The fact that there were then no means of transportation other than pack trains and that iron was too heavy to transport any considerable distances, encouraged every neighborhood to sustain its furnace and forge, and from these local factories of pig iron and iron bars the local blacksmith and others who aided him in supplying local wants drew their supplies. It is probable that the number of furnaces and forges in the United States at the beginning of the nineteenth century was much greater than at the end of the century, though the product of 1800 was but 40,000 tons of pig iron, against 14,000,000 tons in 1900 and 26,000,000 tons in 1907.
Meantime the English iron manufacturers had learned to smelt the ore with coke instead of charcoal. The quantity of wood required to make charcoal for smelting the ore