A Buckeye Furnace museum display explains the work, wages, hazards, and company-town economy surrounding
nineteenth-century charcoal iron furnaces in Jackson County, Ohio.
Panel transcript
Work at an iron furnace, like most nineteenth century industrial jobs, was low paying, uncertain, and dangerous. Most workers operated at the edge of bankruptcy and, because nearly all were small-scale operations, they could not weather the storms of economic depression or financial crisis. The Panic of 1857, for example, so squeezed the market for iron that by 1858 production plummeted to one-eighth of pre-panic output. Some 8,000 tons of unsold iron piled up at Ohio furnaces and foundries.
During these times, workers were laid off. They had no unemployment insurance and had little hope of finding other employment. Most companies attempted to keep their workers on and the furnace operating by cutting wages. The average wage was only 50¢ per week in good times. When forced to choose between even lower wages or no job whatever, workers selected the former.
One of the major complaints of workers relates to the widespread practice of paying wages in scrip rather than cash. Hanging Rock furnaces offered store laws and paid their employees most of their wages in paper bills of credit, redeemable only at the company’s store. It was also common for workers to rent company-owned housing. This system tied the workers to the company in a closed economic system. The company regained a large portion of the wages through company store and rental profits.
Work at the furnace was hard and often dangerous. The twelve-hour day was common. Heat, smoke, carbon, eye disease, and “gassing” by the furnace’s toxic fumes were job-related dangers workers faced daily. There was seldom any type of health insurance or pension plan and no government aid or regulations.
Despite these conditions, there was little union activity and few strikes at the Hanging Rock charcoal furnaces. One reason for this was that workers who did attempt to organize or strike found themselves on the “blacklist.” This was an informal agreement between furnace owners not to hire troublemakers.
A more important factor, however, was the working relationships at charcoal iron furnaces. Most furnaces were located in isolated areas where the community of about 50 people all worked at the furnace in some capacity. This bred a strong sense of community among workers. The manager and workers knew each other well, and workers could go to the manager with their problems or complaints. This resulted in informal working agreements that replaced the need for formal groups like labor unions. Additionally, companies often allowed workers to stay on rent-free during hard times and attempted to keep the furnace operating as long as possible. Most workmen preferred a slower pace to a fast one in order to ease their load. They also realized that striking during a depression would hasten the company’s demise.
As the industrial era reached its zenith in the 1870s, workers were displaced. The depletion of forests needed to fuel charcoal furnaces, and the introduction of the new, more efficient coal-burning furnaces transformed the industry. Many charcoal workers moved to the coal furnaces, where they found it necessary to band together into unions to win concessions in a modern industrial environment.
Work force
Manager: Owned the furnace, directly supervised the operation, and was responsible for sales and transportation of the iron to market.
Clerk: Managed the accounting details of the furnace and often was responsible for purchasing supplies.
Founder: Directed all furnace operations and saw to the casting of pig iron.
Keeper: Directly supervised the charging and fueling of the furnace and the flow of iron from the furnace.
Filler: Worked at the top of the furnace, charging it with alternating loads of charcoal, iron ore, and limestone flux.
Gutterman: Supervised the flow of molten iron into channels where it could be directed into molds or the casting house.
Molder / cast house worker: Prepared molds and handled castings made from the iron.
Collier: Cut wood and burned it into charcoal, the chief fuel used in the furnace.
Miner: Dug iron ore and limestone used in the furnace.
Teamster / hauler: Transported ore, limestone, charcoal, supplies, and finished iron.
Laborer: Performed general heavy work around the furnace grounds.
Buckeye Furnace context
Buckeye Furnace was built in 1851-1852 by Thomas Price and investors and operated from 1852 to 1894. It produced charcoal pig iron, with peak production of about 12 tons per day. Its iron contributed to Civil War-era manufacturing, including cannons, munitions, and parts associated with the USS Monitor.
Life around the furnace centered on a self-contained company town of roughly 300-400 residents. During a blast, the furnace ran around the clock. Workers and families lived in company housing, purchased goods at the company store, and often depended on company-issued scrip. The surrounding landscape was also transformed as timber was cut to make the charcoal needed to fuel the stack.
Why this matters
This display helps explain the industrial world behind Isaac McGarvey’s documented census occupations as furnace man and iron furnace laborer. It should not be treated as proof of employment at Buckeye Furnace; confirming that would require a direct payroll, roster, furnace book, or similar record.