Iron Trails

Overview of plantation National Park Service, J. Kenneth Townsend, illustrator

A Pennsylvania Iron Plantation
—Hopewell Furnace

By Tom Straka  

Hopewell was an iron plantation, or a self-sustaining village that focused on iron making. It operated from 1771 to 1883 and it exists as a National Park Service historical site for the unique insights into the earliest days of America's iron industry it provides.

Sketch of Hopewell Furnace  National Park Service, Richard Schlecht, illustrator

An iron plantation was centered on a furnace that produced iron, a furnace that almost never stopped. An iron plantation had a rhythmical sound, a waterwheel that turned unceasingly and the constant roar of the blast furnace as air rushed in. During the day a cloud of black charcoal dust surrounded the furnace, but at night the furnace produced a constant glow. And it had its own smell; the workers thought it smelled like prosperity.

Early iron making activities were located where its main ingredients abounded; the four essentials were iron ore, forests, water, and limestone. Pennsylvania was rich in these ingredients and in the 18 th and 19 th century was the center of the nation's iron making industry. Much of the iron making took place on these plantations that were owned and managed by an ironmaster. They were organized somewhat like the southern cotton plantations, but without the slaves. The ironmaster employed workers for the various tasks on the plantation, especially the iron making, paid them a moderate wage, but also supplied housing and for other basic needs

The Furnace

Hopewell miners digging iron ore from mine pit. NPS illustration

In the colonial period and the early United States these iron plantations produced cast iron products. Iron ore came from nearby open pits; limestone from quarries; and charcoal from the hardwood forests. Teamsters carried the iron ore and limestone to the furnace. Charcoal was stored in the charcoal house. The founder or furnace supervisor was responsible to see the blast furnace was constantly charged. The furnace was a tall stone structure, shaped like a flattened pyramid. Every half-hour iron ore, limestone, and charcoal were fed into the furnace. Water drove a pair of blowing tubs that produced blasts of air into the furnace and raised the inside temperatures to 3,000°F. This was hot enough to turn iron ore into iron. Molten iron was tapped from the front of the furnace. The furnace only stopped for repairs and when charcoal ran out.

High quality iron could be cast into products (ever hear of a cast iron stove?) and produced higher profits. The founder controlled quality by regulating the inputs. When he tapped the furnace, he had to determine the quality of the iron; high quality went into casting and low quality (impurities) had to be further refined. This low quality iron was run into beds dug in the sand of the casting house. The pattern formed by these beds reminded many of a litter of nursing piglets (ever hear of pig iron?). The pig iron was sent off for further refining. When high quality iron was tapped, the casting house bell was rung and moulders came and cast the iron into products. Hopewell produced pots, skillets, flat irons, wheels, hammers, grates, and a high quality Hopewell stove. By 1844 over 65,000 Hopewell stoves were produced.

The Plantation

Most of the colonial buildings have been restored.  The closest one in this photo-graph is the charcoal house. Sometimes just the roofs show in the morning mist. Shades and tones change during the day.   This is unique colonial architecture you won't see many other places. Photo credit Pat Straka

An iron plantation was a self-sustaining community, usually of 200-300 people, all with direct or indirect employment tied to the furnace. They lived in tenant houses. The plantation was also a farm where crops and livestock were raised for food. A company story provided what could not be produced locally. A social order prevailed. The ironmaster was at the top and shared in profits. His lived in the "Big House" and his mansion also served as the company headquarters and social center.

The founder was second to the ironmaster and was responsible for the furnace and the iron workers. The furnace clerk was next. He kept the books and served as paymaster. Plus, he had procurement duties and had to see supplies were delivered as needed. Skilled craftsmen followed, like moulders and colliers, and at the bottom were the less-skilled workers, like woodcutters, miners, and teamsters.

Even the path between buildings contain vistas.  The plantation is seen via a walking tour, but what  wonderful  paths flow around the plantation. Photo credit Pat Straka

Today, the closest thing you will ever see to the original iron plantation is Hopewell Furnace. It is maintained as an 848 acre historical site, specifically to preserve this aspect of American industrial history and the lifestyle on an iron plantation. There are about a dozen major buildings on site and, of course, the furnace. When you hear the casting house bell, you can walk down to the casting house to see actual casting take place. Many of the original store clerks, craftsmen, cooks, charcoalmakers, ironmakers, and plantation inhabitants are still there in costume. Even the animals are still are the farm. In season, you can see sheep shearing, harvest apples, or see an Iron Plantation Christmas. There is a visitors center with displays and short movies on ironmaking. The plantation is visited via a self-guided walking tour.

The National Park System contains many "gems" that don't get the publicity of Yellowstone and Gettysburg. This is one of them and you can spend a fascinating day there.

Author: Thomas J. Straka is a professor of Forestry at Clemson University in South Carolina.

For more information:

http://www.nps.gov/hofu/index.htm

http://www.nps.gov/nr/twhp/wwwlps/lessons/97hopewell/97hopewell.htm

http://explorepahistory.com/story.php?storyId=29&chapter=1

http://explorepahistory.com/viewLesson.php?id=81