Chester Rolling Mill
Encyclopedia
The Chester Rolling Mill was a large iron (later steel) rolling mill established by shipbuilder John Roach
in Chester, Pennsylvania
, United States
in 1873. The main purpose of the Mill was to provide metal hull plates, beams and other parts for the ships built at Roach's Delaware River Iron Ship Building and Engine Works
, also located at Chester.
Amongst the mill's notable achievements, it manufactured the steel plates for the first steel-hulled steamship built in the United States, Alaskan, and for the U.S. Navy's first four steel ships, the so-called "ABCD ships". Production of the latter vessels drove Roach's shipbuilding empire into receivership after the government unexpectedly repudiated the contracts, and Roach was forced to sell the Chester Rolling Mill and most of his other companies to satisfy creditors. The Chester Rolling Mill later became part of the Wellman Steel Company.
at Chester in 1871. He had two reasons for establishing the Chester Rolling Mill. Firstly, the locality of Chester lacked facilities for the large-scale production of iron plates and frames as required by his shipyard. Secondly, by establishing his own rolling mill, he could dispense with ironmaking subcontractors and thus reduce his overall costs. Roach's ownership of a network of companies supporting his shipyard, which included the Chester Rolling Mill, the Chester Pipe and Tube Company
and later the Standard Steel Casting Company
and the Combination Steel and Iron Company
made John Roach & Sons one of the first large companies in the United States to adopt the vertical integration
model.
The connection with the Houston family was of particular importance to Roach as the Houstons had investments in Pennsylvanian iron and coal mines, virtually guaranteeing the new company a reliable supply of raw materials. The Houstons also controlled Chester's only newspaper, the Chester Times, and they in turn shared business interests with Samuel A. Crozer, whose extended family—the wealthiest in Chester—owned the city's largest textile mills. Collectively, the Roach, Houston and Crozer families employed 25% of Chester's working population and accounted for 35% of its payroll, their partnership ensuring dominance of the city's politics.
and 300 tons of iron ship plate. Pig iron, beams, and hull and boiler plates were produced both for Roach's main shipyard in Chester and for his other shipbuilding facility, the Morgan Iron Works
in New York City
.
With the establishment of the Mill, Roach was able to introduce a number of innovations into the industry which reduced time and cut costs. To begin with, he rejected the standard ship plate size of 12 x 4 feet (48 squ. ft) and rolled larger plates of 14 x 5 ft (70 squ. ft). This simple innovation reduced the time spent in planing, punching and chipping plates by 40%, reduced handling times, and had the added advantage of producing a stronger ship with fewer butts to strain. Roach also endeavoured as far as possible to roll plates to their finished dimensions, saving time which other companies spent on reworking plates at the shipyard.
By this time, the Mill included two puddling mills with 11 furnaces and a total output of 50 tons per day, a mill for boiler and ship plate with a capacity of 45 tons per day, and a mill for angle, beam and skelp
iron with a daily capacity of 35 tons. Included in the above were two large gas-operated furnaces and a mill which could produce plates from ⅛ to 6 inch thickness and 27 feet wide. Roach's milling machines incorporated both vertical and horizontal rollers which allowed plates to be finished with parallel edges, eliminating the necessity of shearing ragged edges to size. Some of the new machinery was capable of rolling steel as well as iron ingots.
Power to operate the milling machines was provided by four large Corliss steam engines and eight smaller ones. A five ton steam hammer
was also installed. After the expansion, the mill could produce 300 tons of steel plate a day in addition to the 300 tons of iron plate and 700 tons of pig iron already produced. The mill as a whole consumed 1,400 tons of iron ore, 600 tons of limestone and 1,000 tons of coal per week. The workforce was also expanded to 500 people, with a weekly payroll of $6,000.
A notable achievement for the company following the addition of the steel milling facilities was the production of steel plates for America's first steel-hulled ship, the cargo ship
Alaskan, built by the Roach shipyard for the Oregon Railway and Navigation Company and delivered in August 1883.
On July 2, 1883, John Roach & Sons won the contracts for all four of the Navy's first steel ships—, , , and —or the "ABCD ships", as they came to be known. The only bidder with his own steel mill, Roach was able to undercut the other bidders by a total of $270,000 on the price of steel alone. The final contracts were signed on July 23 and Roach began construction of the ships shortly thereafter.
Roach was initially confident that he would have no difficulty supplying the steel for the four ships. To ensure the minimum of delay, he subcontracted with several other steel manufacturers, including the Norway Iron and Steel Company of South Boston, the Park Brothers' Black Diamond Works of Pittsburgh, and the Phoenix Iron Company of Phoenixville, Pennsylvania
, for the supply of various steel parts. So exacting were the specifications however, that a third of all the parts produced were rejected by Navy inspectors, leading to cost overruns which eventually persuaded the subcontractors to renege on their agreements with Roach. Roach was left having to manufacture all the steel parts himself, although the situation was somewhat alleviated by the fact that another Roach company, the Standard Steel Casting Company
, had recently begun production.
Delays in production of the steel along with additional unexpected delays prolonged construction of the ships past the 1883 Presidential election, and by the time Roach was ready to deliver the first ship, Dolphin, the new Democrat administration of Grover Cleveland
, hostile to the staunchly Republican Roach, had assumed office. In what many regarded as a politically motivated act, the new Cleveland administration found reasons to void Roach's contract for Dolphin. With another three Navy ships still unpaid for in his shipyard whose contracts might also be declared void, Roach was unable to secure loans to continue his business and was forced into receivership. In the subsequent liquidation of assets, the Chester Rolling Mill along with the rest of Roach's companies, with the exception of his Chester shipyard and the Morgan Iron Works in New York, were sold to pay off creditors.
In 1890, the Mill was purchased by Samuel Taylor Wellman, becoming part of the Wellman Steel Company. This venture proved unsuccessful, and Wellman dispensed with his holdings in about 1896.
John Roach
John Robert Roach was an American clergyman of the Roman Catholic Church. He served as Archbishop of Saint Paul and Minneapolis from 1975 to 1995.-Biography:...
in Chester, Pennsylvania
Chester, Pennsylvania
Chester is a city in Delaware County, Pennsylvania, United States, with a population of 33,972 at the 2010 census. Chester is situated on the Delaware River, between the cities of Philadelphia and Wilmington, Delaware.- History :...
, United States
United States
The United States of America is a federal constitutional republic comprising fifty states and a federal district...
in 1873. The main purpose of the Mill was to provide metal hull plates, beams and other parts for the ships built at Roach's Delaware River Iron Ship Building and Engine Works
Delaware River Iron Ship Building and Engine Works
The Delaware River Iron Ship Building and Engine Works, often referred to by its parent company name of John Roach & Sons, or just known as the Roach shipyard, was a major late–19th century American shipyard founded in 1871 by John Roach...
, also located at Chester.
Amongst the mill's notable achievements, it manufactured the steel plates for the first steel-hulled steamship built in the United States, Alaskan, and for the U.S. Navy's first four steel ships, the so-called "ABCD ships". Production of the latter vessels drove Roach's shipbuilding empire into receivership after the government unexpectedly repudiated the contracts, and Roach was forced to sell the Chester Rolling Mill and most of his other companies to satisfy creditors. The Chester Rolling Mill later became part of the Wellman Steel Company.
History
Roach established his shipyard, the Delaware River Iron Ship Building and Engine Works, on the Delaware RiverDelaware River
The Delaware River is a major river on the Atlantic coast of the United States.A Dutch expedition led by Henry Hudson in 1609 first mapped the river. The river was christened the South River in the New Netherland colony that followed, in contrast to the North River, as the Hudson River was then...
at Chester in 1871. He had two reasons for establishing the Chester Rolling Mill. Firstly, the locality of Chester lacked facilities for the large-scale production of iron plates and frames as required by his shipyard. Secondly, by establishing his own rolling mill, he could dispense with ironmaking subcontractors and thus reduce his overall costs. Roach's ownership of a network of companies supporting his shipyard, which included the Chester Rolling Mill, the Chester Pipe and Tube Company
Chester Pipe and Tube Company
The Chester Pipe and Tube Company was a company incorporated in 1877 in Chester, Pennsylvania by shipbuilder John Roach for the manufacture of iron pipes and boiler tubes for the steamships built at his Chester shipyard, the Delaware River Iron Ship Building and Engine Works.Incorporated for a sum...
and later the Standard Steel Casting Company
Standard Steel Casting Company
The Standard Steel Casting Company, commonly referred to as Thurlow Works, was a steel production and steel casting facility founded in Chester, Pennsylvania in 1883 by shipbuilder John Roach...
and the Combination Steel and Iron Company
Combination Steel and Iron Company
The Combination Steel and Iron Company was a steel mill founded in Chester, Pennsylvania by shipbuilder John Roach in 1880. Unlike Roach's other companies, Combination Iron and Steel was initially established not to support the operations of his Chester shipyard, but to produce steel rails and...
made John Roach & Sons one of the first large companies in the United States to adopt the vertical integration
Vertical integration
In microeconomics and management, the term vertical integration describes a style of management control. Vertically integrated companies in a supply chain are united through a common owner. Usually each member of the supply chain produces a different product or service, and the products combine to...
model.
Organization and structure
The Chester Rolling Mill was incorporated with a capital of $300,000 on March 10, 1875 by John Roach and a number of partners including Roach's sons John B. and Garrett, and local Chester business identities John Q. Denny and Charles B. and David Houston. The elder Roach became President of the new company, and Charles and David Houston were made general manager and paymaster respectively, while their brother Thomas also received a management position. Roach and his sons held the majority of shares.The connection with the Houston family was of particular importance to Roach as the Houstons had investments in Pennsylvanian iron and coal mines, virtually guaranteeing the new company a reliable supply of raw materials. The Houstons also controlled Chester's only newspaper, the Chester Times, and they in turn shared business interests with Samuel A. Crozer, whose extended family—the wealthiest in Chester—owned the city's largest textile mills. Collectively, the Roach, Houston and Crozer families employed 25% of Chester's working population and accounted for 35% of its payroll, their partnership ensuring dominance of the city's politics.
Early period, 1875-1879
The Chester Rolling Mill was established on the site of an old bridge and steel works at the foot of Wilson and Hayes Sts., Chester, incorporating the area between Townsend to Highland Ave., and from Front St. to the Delaware River. Construction of the main rolling mill, a building with dimensions of 160 x 185 feet, began in 1875. In 1879, the building was doubled in size, from 160 to 320 feet. Initial output was 700 tons of pig ironPig iron
Pig iron is the intermediate product of smelting iron ore with a high-carbon fuel such as coke, usually with limestone as a flux. Charcoal and anthracite have also been used as fuel...
and 300 tons of iron ship plate. Pig iron, beams, and hull and boiler plates were produced both for Roach's main shipyard in Chester and for his other shipbuilding facility, the Morgan Iron Works
Morgan iron works
The Morgan Iron Works was a 19th century manufacturing plant for marine steam engines located in New York City, United States. Originally founded as T. F...
in New York City
New York City
New York is the most populous city in the United States and the center of the New York Metropolitan Area, one of the most populous metropolitan areas in the world. New York exerts a significant impact upon global commerce, finance, media, art, fashion, research, technology, education, and...
.
With the establishment of the Mill, Roach was able to introduce a number of innovations into the industry which reduced time and cut costs. To begin with, he rejected the standard ship plate size of 12 x 4 feet (48 squ. ft) and rolled larger plates of 14 x 5 ft (70 squ. ft). This simple innovation reduced the time spent in planing, punching and chipping plates by 40%, reduced handling times, and had the added advantage of producing a stronger ship with fewer butts to strain. Roach also endeavoured as far as possible to roll plates to their finished dimensions, saving time which other companies spent on reworking plates at the shipyard.
Expansion of facilities, 1880-81
In 1880, Roach embarked on a substantial upgrade of the mill's facilities. A second blast furnace was constructed above the original rolling mill, along with new buildings covering about 1¼ acres, including a new 90 x 140 ft steelworks. The new furnace commenced production on November 1, 1881. In order to pay for the expansion, the firm was recapitalized at $600,000.By this time, the Mill included two puddling mills with 11 furnaces and a total output of 50 tons per day, a mill for boiler and ship plate with a capacity of 45 tons per day, and a mill for angle, beam and skelp
Skelp
Skelp is iron or steel rolled or forged into narrow strips and ready to be made into pipe or tubing by being bent and welded. It is most commonly used in the traditional terminology of smithing and in the iron and steel industries. Before the 20th century, the welding was likely to be forge welding...
iron with a daily capacity of 35 tons. Included in the above were two large gas-operated furnaces and a mill which could produce plates from ⅛ to 6 inch thickness and 27 feet wide. Roach's milling machines incorporated both vertical and horizontal rollers which allowed plates to be finished with parallel edges, eliminating the necessity of shearing ragged edges to size. Some of the new machinery was capable of rolling steel as well as iron ingots.
Power to operate the milling machines was provided by four large Corliss steam engines and eight smaller ones. A five ton steam hammer
Steam hammer
A steam hammer is a power-driven hammer used to shape forgings. It consists of a hammer-like piston located within a cylinder. The hammer is raised by the pressure of steam injected into the lower part of a cylinder and falls down with a force by removing the steam. Usually, the hammer is made to...
was also installed. After the expansion, the mill could produce 300 tons of steel plate a day in addition to the 300 tons of iron plate and 700 tons of pig iron already produced. The mill as a whole consumed 1,400 tons of iron ore, 600 tons of limestone and 1,000 tons of coal per week. The workforce was also expanded to 500 people, with a weekly payroll of $6,000.
A notable achievement for the company following the addition of the steel milling facilities was the production of steel plates for America's first steel-hulled ship, the cargo ship
Cargo ship
A cargo ship or freighter is any sort of ship or vessel that carries cargo, goods, and materials from one port to another. Thousands of cargo carriers ply the world's seas and oceans each year; they handle the bulk of international trade...
Alaskan, built by the Roach shipyard for the Oregon Railway and Navigation Company and delivered in August 1883.
ABCD ships and Roach receivership
Roach was initially confident that he would have no difficulty supplying the steel for the four ships. To ensure the minimum of delay, he subcontracted with several other steel manufacturers, including the Norway Iron and Steel Company of South Boston, the Park Brothers' Black Diamond Works of Pittsburgh, and the Phoenix Iron Company of Phoenixville, Pennsylvania
Phoenixville, Pennsylvania
Phoenixville is a borough in Chester County, Pennsylvania, United States, northwest of Philadelphia, at the junction of French Creek with the Schuylkill River. The population is 16,440 as of the 2010 Census.- History :...
, for the supply of various steel parts. So exacting were the specifications however, that a third of all the parts produced were rejected by Navy inspectors, leading to cost overruns which eventually persuaded the subcontractors to renege on their agreements with Roach. Roach was left having to manufacture all the steel parts himself, although the situation was somewhat alleviated by the fact that another Roach company, the Standard Steel Casting Company
Standard Steel Casting Company
The Standard Steel Casting Company, commonly referred to as Thurlow Works, was a steel production and steel casting facility founded in Chester, Pennsylvania in 1883 by shipbuilder John Roach...
, had recently begun production.
Delays in production of the steel along with additional unexpected delays prolonged construction of the ships past the 1883 Presidential election, and by the time Roach was ready to deliver the first ship, Dolphin, the new Democrat administration of Grover Cleveland
Grover Cleveland
Stephen Grover Cleveland was the 22nd and 24th president of the United States. Cleveland is the only president to serve two non-consecutive terms and therefore is the only individual to be counted twice in the numbering of the presidents...
, hostile to the staunchly Republican Roach, had assumed office. In what many regarded as a politically motivated act, the new Cleveland administration found reasons to void Roach's contract for Dolphin. With another three Navy ships still unpaid for in his shipyard whose contracts might also be declared void, Roach was unable to secure loans to continue his business and was forced into receivership. In the subsequent liquidation of assets, the Chester Rolling Mill along with the rest of Roach's companies, with the exception of his Chester shipyard and the Morgan Iron Works in New York, were sold to pay off creditors.
Later history
After selling their shares in the company, Roach and his sons resigned from their positions in February 1886, and the Chester Rolling Mill appears to have been taken over by Roach's former partner Samuel A. Crozer, who became the company's new President.In 1890, the Mill was purchased by Samuel Taylor Wellman, becoming part of the Wellman Steel Company. This venture proved unsuccessful, and Wellman dispensed with his holdings in about 1896.