Steelmaking at Carnforth

There have been several books, papers, and newspaper articles which have reported on activities at Carnforth ironworks over many years. They have corroborated much of the known facts yet few have appraised or questioned why the major investment in steelmaking was so short lived. No images or illustrations of the steelworks have been published apart from aerial photographs of the site. 

Research has shown that the steelworks had a relatively short and problematic existence and a history is emerging that they were a £30,000 financial disaster, notwithstanding the impact on 200 steelworkers hired and fired by the company.

There are occasional references to the steelworks not having operated at all. It would not be the first time that huge investments in steelmaking plant were overtaken by a rapid decline in market conditions.  Meanwhile the known published evidence comprises:

1 Alan Harris in his "Carnforth 1840-1900: The rise of a North Lancashire Town".  The Historic Society of Lancashire & Cheshire Vol 112

 The steelworks had a curious history. Walduck (who was in a position to know) said in 1881 that up to that time they had never worked. The Mineral Statistics suggest sporadic operation. In 1884 they were reorganized, apparently to produce steel wire, and were working during 1885 and 1886. In 1890 they were "disused" and in 1898 were dismantled and sold by auction. 

2     Van Nostrand's Engineering Magasine Vol 23  July - December 1880  page 238

"......In England we have four new vessels [Bessemer converters] building at Bolckow, Vaughan's works, two at Erimus, and two at Darlington, and one at Rhymney, with a total capacity of say 155,000 tons - we do not count the Carnforth plant, which is really an old one, though it has never been at work............"

3      The Mourholme Magazine of Local History  1992 No1    Jean Chatterley and John Findlater. The article quotes local papers in 1884 .

"The company intends to put their large converting plant which has lain idle since its construction to profitable use. It was realised that it was a waste of money sending pig iron from Carnforth to Sheffield to be made in to steel............" .

The authors comment  "............it seems to imply that, despite the installation of Bessemer Convertors some fourteen years before, the company had never used them, but had continued to send their pig iron elsewhere for conversion to steel."

Equipment

In 1866 the company arranged for Warton Road to be straightened (called Mill Lane at the time) and then built a row of terraced houses for their employees naming it Bessemer Terrace. The location was roughly opposite the present day Railway Club (vacant and deteriorating as of 2022). In 1871 the houses were removed to yield space. The terrace was rebuilt at the South end of the town on Lancaster Road not far from the Canal Turn Public House. The new steelworks building was erected behind a tall stone wall which largely remains today (albeit considerably lower in height and much modified). 

The Steelworks comprised:

• A new brick chimney to vent the waste gases from the Cupola furnaces 

• Two large Woodward's steam jet Cupolas for pig iron.

• Two small Cupolas for spiegel.

• Two 6 ton Bessemer Converters (not six 2 ton converters as has been wrongly reported elsewhere). formerly at Henry Bessemer's own East Greenwich works.  An additional pit was built in anticipation of an additional 2 converters, if required.

• Plate Mill

• Rail rolling mill, complete with horizontal engines, hot saw, straightening machines.

• Ingots, crane, ladle crane

• Two new blowing engines by Messrs. Galloway were installed in the Blower house 

We know from contemporary reports that steelmaking had not commenced by 1881 which is an extraordinarily long time, given the magnitude of the investment. Further research will be necessary to determine if and when it began.

Phil Grosse states that  ..... the works were leased out to Albion Ironworks of Warrington and operated under the management of Robert Pemberton, and that rails and plate had been manufactured previously. In January 1885 the works were reorganised to make steel wire until its closure. In December 1889 the manager, W. D. Houghton of Albion ironworks stated that he would not operate the steelworks again. 

It appears to have laid dormant for some 9 years.

The plant was put up for sale by auction in 31st March 1898.   The building and all the process equipment was removed excepting the chimney.

Opinion

Such was the pace of change in Bessemer Steelmaking, the two 6 ton converters were already out of date and too small by the time they were installed. There were several factors which combined to squeeze out smaller steelmaking plants:

1. Foreign steelmakers, particularly in America were quick to introduce larger capacity converters and alternative processes which did not rely on low phosphorus haematite ores. American productivity was vastly superior to English steelmakers. 

2. The market was fluctuating wildly.  American steelmaking was moving from net imports to net exports. 

3. The Carnforth ironmaking process was still competitive, there was still demand but worldwide demand was already switching in favour of steel based products.

4. There were bigger and more advanced steelmakers in close proximity with developed port facilities.

5. Undoubtedly there were many other factors such as international trade tariffs, raw materials, home market size and other cultural and economic factors.

6. This wasn't the only white elephant that Walduck was involved with, and ultimately he amassed, and lost, a huge personal fortune in his lifetime. He died penniless.