History of the steel industry (1850–1970)
Before 1800 A.D., the iron and steel industry was located where raw material, power supply and running water were easily available. After 1950, the iron and steel industry began to be located on large areas of flat land near sea ports. The history of the modern steel industry began in the late 1850s. Since then,
Technology
Steel is an alloy composed of between 0.2 and 2.0 percent carbon, with the balance being iron. From prehistory through the creation of the blast furnace, iron was produced from iron ore as wrought iron, 99.82–100 percent Fe, and the process of making steel involved adding carbon to iron, usually in a serendipitous manner, in the forge, or via the cementation process. The introduction of the blast furnace reversed the problem. A blast furnace produces pig iron — an alloy of approximately 90 percent iron and 10 percent carbon. When the process of steel-making is started with pig iron, instead of wrought iron, the challenge is to remove a sufficient amount of carbon to reduce it to the 0.2 to 2 percentage for steel.
Before about 1860, steel was an expensive product, made in small quantities and used mostly for swords, tools and cutlery; all large metal structures were made of wrought or cast iron. Steelmaking was centered in Sheffield and Middlesbrough, Britain, which supplied the European and American markets. The introduction of cheap steel was due to the Bessemer and the open hearth processes, two technological advances made in England. In the Bessemer process, molten pig iron is converted to steel by blowing air through it after it was removed from the furnace. The air blast burned the carbon and silicon out of the pig iron, releasing heat and causing the temperature of the molten metal to rise. Henry Bessemer demonstrated the process in 1856 and had a successful operation going by 1864. By 1870 Bessemer steel was widely used for ship plate. By the 1850s, the speed, weight, and quantity of railway traffic was limited by the strength of the wrought iron rails in use. The solution was to turn to steel rails, which the Bessemer process made competitive in price. Experience quickly proved steel had much greater strength and durability and could handle the increasingly heavy and faster engines and cars.[1]
After 1890 the Bessemer process was gradually supplanted by
Britain
19th century
Britain led the world's Industrial Revolution with its early commitment to coal mining, steam power, textile mills, machinery, railways, and shipbuilding. Britain's demand for iron and steel, combined with ample capital and energetic entrepreneurs, made it the world leader in the first half of the 19th century. Steel has a vital role during the industrial revolution.
In 1875, Britain accounted for 47% of world production of pig iron, a third of which came from the Middlesbrough area and almost 40% of steel. 40% of British output was exported to the U.S., which was rapidly building its rail and industrial infrastructure. Two decades later in 1896, however, the British share of world production had plunged to 29% for pig iron and 22.5% for steel, and little was sent to the U.S. The U.S. was now the world leader and Germany was catching up to Britain. Britain had lost its American market, and was losing its role elsewhere; indeed American products were now underselling British steel in Britain.[5]
The growth of pig iron output was dramatic. Britain went from 1.3 million tons in 1840 to 6.7 million in 1870 and 10.4 in 1913. The US started from a lower base, but grew faster; from 0.3 million tons in 1840, to 1.7 million in 1870, and 31.5 million in 1913. Germany went from 0.2 million tons in 1859 to 1.6 in 1871 and 19.3 in 1913. France, Belgium, Austria-Hungary, and Russia, combined, went from 2.2 million tons in 1870 to 14.1 million tons in 1913, on the eve of the First World War. During the war the demand for artillery shells and other supplies caused a spurt in output and a diversion to military uses.
20th century
Abé (1996) explores the record of iron and steel firms in Victorian England by analyzing Bolckow Vaughan & Company. It was wedded for too long to obsolescent technology and was a very late adopter of the open hearth furnace method. Abé concludes that the firm—and the British steel industry—suffered from a failure of entrepreneurship and planning.[6]
Blair (1997) explores the history of the British Steel industry since the
Australia
There were various iron-making ventures during the 19th Century, and steel was made but only on a very small scale.
The first commercial scale production of steel in Australia was by William Sandford Limited at the Eskbank Ironworks at Lithgow, New South Wales, in 1901. The plant became Australia's first integrated iron and steel works in 1907. It was later expanded by Charles Hoskins. The first steel rails rolled in Australia were rolled there in 1911. Between 1928 and 1932, the operations at Lithgow were transferred, under the management of Cecil Hoskins, to a new plant at Port Kembla, still the site of most of Australia's steel production today.
The Minister for Public Works, Arthur Hill Griffith, had consistently advocated for the greater industrialization of Newcastle, then, under William Holman, personally negotiated the establishment of a steelworks with G. D. Delprat of BHP. Griffith was also the architect of the Walsh Island establishment.[7][8]
In 1915, BHP ventured into steel manufacturing with its
Germany
The
The leading firm was
By 1913 American and German exports dominated the world steel market, and Britain slipped to third place.
In iron and steel and other industries, German firms avoided cut-throat competition and instead relied on trade associations. Germany was a world leader because of its prevailing "corporatist mentality", its strong bureaucratic tradition, and the encouragement of the government. These associations regulated competition and allowed small firms to function in the shadow of much larger companies.[22]
With the need to rebuild the bombed-out infrastructure after the Second World War, Marshall Plan (1948–51) enabled West Germany to rebuild and modernize its mills. It produced 3 million tons of steel in 1947, 12 million in 1950, 34 million in 1960 and 46 million in 1970. East Germany produced about a tenth as much.[23]
France
The French iron industry lagged behind Britain and Belgium in the early 19th century.[24] After 1850 it also lagged behind Germany and Luxembourg. Its industry comprised too many small, inefficient firms.[25] 20th century growth was not robust, due more to traditional social and economic attitudes than to inherent geographic, population, or resource factors. Despite a high national income level, the French steel industry remained laggard.[26] The industry was based on large supplies of coal and iron ore, and was dispersed across the country. The greatest output came in 1929, at 10.4 million metric tons.[27] The industry suffered sharply during the Great Depression and World War II. Prosperity returned by mid-1950s, but profits came largely from strong domestic demand rather than competitive capacity. Late modernization delayed the development of powerful unions and collective bargaining.[28]
Italy
In Italy a shortage of coal led the steel industry to specialize in the use of hydro-electrical energy, exploiting ideas pioneered by Ernesto Stassano from 1898 (Stassano furnace). Despite periods of innovation (1907–14), growth (1915–18), and consolidation (1918–22), early expectations were only partly realized. Steel output in the 1920s and 1930s averaged about 2.1 million metric tons. Per capita consumption was much lower than the average of Western Europe.[29] Electrical processes were an important substitute, yet did not improve competitiveness or reduce prices. Instead, they reinforced the dualism of the sector and initiated a vicious circle that prevented market expansion.[30] Italy modernized its industry in the 1950s and 1960s and it grew rapidly, becoming second only to West Germany in the 1970s. Strong labour unions kept employment levels high. Troubles multiplied after 1980, however, as foreign competition became stiffer. In 1980 the largest producer Nuova Italsider [now dubbed Ilva (company) lost 746 billion lira in its inefficient operations.[31] In the 1990s the Italian steel industry, then mostly state-owned, was largely privatised.[32] Today the country is the world's seventh-largest steel exporter.[33]
United States
From 1875 to 1920 American steel production grew from 380,000 tons to 60 million tons annually, making the U.S. the world leader. The annual growth rates in steel 1870–1913 were 7.0% for the US; 1.0% for Britain; 6.0% for Germany; and 4.3% for France, Belgium, and Russia, the other major producers.[34] This explosive American growth rested on solid technological foundations and the continuous rapid expansion of urban infrastructures, office buildings, factories, railroads, bridges and other sectors that increasingly demanded steel. The use of steel in automobiles and household appliances came in the 20th century.
Some key elements in the growth of steel production included the easy availability of iron ore, and coal. Iron ore of fair quality was abundant in the eastern states, but the Lake Superior region contained huge deposits of exceedingly rich ore; the Marquette Iron Range was discovered in 1844; operations began in 1846. Other ranges were opened by 1910, including the Menominee, Gogebic, Vermilion, Cuyuna, and, greatest of all, (in 1892) the Mesabi range in Minnesota. This iron ore was shipped through the Great Lakes to ports such as Chicago, Detroit, Cleveland, Erie and Buffalo for shipment by rail to the steel mills.[35] Abundant coal was available in Pennsylvania, West Virginia, and Ohio. Manpower was short. Few Native Americans wanted to work in the mills, but immigrants from Britain and Germany (and later from Eastern Europe) arrived in great numbers.[36]
In 1869 iron was already a major industry, accounting for 6.6% of manufacturing employment and 7.8% of manufacturing output. By then the central figure was
In the 1880s, the transition from wrought iron puddling to mass-produced Bessemer steel greatly increased worker productivity. Highly skilled workers remained essential, but the average level of skill declined. Nevertheless, steelworkers earned much more than ironworkers despite their fewer skills. Workers in an integrated, synchronized mass production environment wielded greater strategic power, for the greater cost of mistakes bolstered workers' status. The experience demonstrated that the new technology did not decrease worker bargaining leverage by creating an interchangeable, unskilled workforce.[39]
Alabama
In Alabama, industrialization was generating a ravenous appetite for the state's coal and iron ore. Production was booming, and unions were attempting to organize unincarcerated miners. Convicts provided an ideal captive work force: cheap, usually docile, unable to organize and available when unincarcerated laborers went on strike."[40] The Southern agrarian economy did not accommodate convict leasing as well as the industrial economy did, whose jobs were often unappealing or dangerous, offering hard-labor and low pay. The competition, expansion, and growth of mining and steel companies also created a high demand for labor, but union labor posed a threat to expanding companies. As unions bargained for higher wages and better conditions, often organizing strikes in order to achieve their goals, the growing companies would be forced to agree to union demands or face abrupt halts in production. The rate companies paid for convict leases, which paid the laborer nothing, was regulated by government and state officials who entered the labor contracts with companies. "The companies built their own prisons, fed and clothed the convicts, and supplied guards as they saw fit." (Blackmon 2001)[40] Alabama's use of convict leasing was commanding; 51 of its 67 counties regularly leased convicts serving for misdemeanors at a rate of about $5–20 per month, equal to about $160–500 in 2015.[41] Although the influence of labor unions forced some states to move away from the profitable convict lease agreements and run traditional prisons, plenty of companies began substituting convict labor in their operations in the twentieth century. "The biggest user of forced labor in Alabama at the turn of the century was Tennessee Coal, Iron & Railroad Co., [of] U.S. Steel"[40]
Carnegie
Andrew Carnegie, a Scottish immigrant, advanced the cheap and efficient mass production of steel rails for railroad lines, by adopting the
Lauder would go on to lead the development of the use of steel in armor and armaments for the Carnegie Steel Company, spending significant time at the Krupp factory in Germany in 1886 before returning to build the massive armor plate mill at the Homestead Steel Works that would revolutionize naval warfare.[43]
Carnegie's first mill was the
Lauder would go on to lead the development of the use of steel in armor and armaments for the Carnegie Steel Company, spending significant time at the Krupp factory in Germany in 1886 before returning to build the massive armor plate mill at the Homestead Steel Works that would revolutionize naval warfare.[43]
By 1889, the U.S. output of steel exceeded that of Britain, and Andrew Carnegie owned a large part of it. By 1900, the profits of Carnegie Bros. & Company alone stood at $480,000,000 with $225,000,000 being Carnegie's share.
Carnegie, through Keystone, supplied the steel for and owned shares in the landmark Eads Bridge project across the Mississippi River in St. Louis, Missouri (completed 1874). This project was an important proof-of-concept for steel technology which marked the opening of a new steel market.
The
Carnegie sold all his steel holdings in 1901; they were merged into U.S. Steel and it was non-union until the late 1930s.
US Steel
By 1900 the US was the largest producer and also the lowest cost producer, and demand for steel seemed inexhaustible. Output had tripled since 1890, but customers, not producers, mostly benefitted. Productivity-enhancing technology encouraged faster and faster rates of investment in new plants. However, during recessions, demand fell sharply taking down output, prices, and profits.
US Steel combined finishing firms (American Tin Plate (controlled by
The
Earnings were recorded at $2.650 billion for 2016.[47]
Bethlehem Steel
Charles M. Schwab (1862–1939) and Eugene Grace (1876–1960) made Bethlehem Steel the second-largest American steel company by the 1920s. Schwab had been the operating head of Carnegie Steel and US Steel. In 1903 he purchased the small firm Bethlehem Steel, and in 1916 made Grace president. Innovation was the keynote at a time when U.S. Steel under Judge Elbert Henry Gary moved slowly. Bethlehem concentrated on government contracts, such as ships and naval armor, and on construction beams, especially for skyscrapers and bridges.[48] Its subsidiary Bethlehem Shipbuilding Corporation operated 15 shipyards in World War II. It produced 1,121 ships, more than any other builder during the war and nearly one-fifth of the U.S. Navy's fleet. Its peak employment was 180,000 workers, out of a company-wide wartime peak of 300,000. After 1945 Bethlehem doubled its steel capacity, a measure of the widespread optimism in the industry. However the company ignored the new technologies then being developed in Europe and Japan. Seeking labor peace in order to avoid strikes, Bethlehem like the other majors agreed to large wage and benefits increases that kept its costs high. After Grace retired the executives concentrated on short term profits and postponed innovations that led to long-term inefficiency. It went bankrupt in 2001.[49]
Republic Steel
Unions
The American Federation of Labor (AFL) tried and failed to organize the steelworkers in 1919. Although the strike gained widespread middle-class support because of its demand and the 12-hour day, the strike failed and unionization was postponed until the late 1930s. The mills ended the 12-hour day in the early 1920s.[51]
The second surge of unionization came under the auspices of the militant
Apogee and decline
Integration was the watchword as the various processes were brought together by large corporations, from mining the iron ore to shipping the finished product to wholesalers. The typical steelworks was a giant operation, including blast furnaces, Bessemer converters, open-hearth furnaces, rolling mills, coke ovens and foundries, as well as supported transportation facilities. The largest ones were operated in the region from Chicago to St. Louis to Baltimore, Philadelphia and Buffalo. Smaller operations appeared in Birmingham, Alabama, and in California.[53]
The industry grew slowly but other industries grew even faster, so that by 1967, as the downward spiral began, steel accounted for 4.4% of manufacturing employment and 4.9% of manufacturing output. After 1970 American steel producers could no longer compete effectively with low-wage producers elsewhere. Imports and local mini-mills undercut sales.
Per-capita steel consumption in the U.S. peaked in 1977, then fell by half before staging a modest recovery to levels well below the peak.[54]
Most mills were closed. Bethlehem went bankrupt in 2001. In 1984, Republic merged with Jones and Laughlin Steel Company; the new firm went bankrupt in 2001. US Steel diversified into oil (Marathon Oil was spun off in 2001). Finally US Steel reemerged in 2002 with plants in three American locations (plus one in Europe) that employed fewer than one-tenth the 168,000 workers of 1902. By 2001 steel accounted for only 0.8% of manufacturing employment and 0.8% of manufacturing output.[55]
The world steel industry peaked in 2007. That year, ThyssenKrupp spent $12 billion to build the two most modern mills in the world, in Alabama and Brazil. The worldwide great recession starting in 2008, however, with its heavy cutbacks in construction, sharply lowered demand and prices fell 40%. ThyssenKrupp lost $11 billion on its two new plants, which sold steel below the cost of production. Finally in 2013, ThyssenKrupp offered the plants for sale at under $4 billion.[56]
Legacy
The President of the United States is authorized to declare each May "Steelmark Month" to recognize the contribution made by the steel industry to the United States.[57]
Asia
Japan
Yonekura shows the steel industry was central to the economic development of Japan. The nation's sudden transformation from
The government's activist
India
The Bengal Iron Works was founded at Kulti, Bengal, in 1870 which began its production in 1874 followed by The Tata Iron and Steel Company (TISCO) was established by Dorabji Tata in 1907, as part of his father's conglomerate. By 1939 it operated the largest steel plant in the British Empire. The company launched a major modernization and expansion program in 1951.[60]
Prime Minister Jawaharlal Nehru, a believer in socialism, decided that the technological revolution in India needed maximization of steel production. He, therefore, formed a government owned company, Hindustan Steel Limited (HSL) and set up three steel plants in the 1950s.[61]
The Indian steel industry began expanding into Europe in the 21st century. In January 2007 India's Tata Steel made a successful $11.3 billion offer to buy European steel maker
China
Communist party Chairman Mao Zedong disdained the cities and put his faith in the Chinese peasantry for a Great Leap Forward. Mao saw steel production as the key to overnight economic modernization, promising that within 15 years China's steel production would surpass that of Britain. In 1958 he decided that steel production would double within the year, using backyard steel furnaces run by inexperienced peasants. The plan was a fiasco, as the small amounts of steel produced were of very poor quality, and the diversion of resources out of agriculture produced a massive famine in 1959–61 that killed millions.[63]
With economic reforms brought in by Deng Xiaoping, who led China from 1978 to 1992, China began to develop a modern steel industry by building new steel plants and recycling scrap metal from the United States and Europe. As of 2013 China produced 779 million metric tons of steel each year, making it by far the largest steel producing country in the world. This is compared to 165 for the European Union, 110 for Japan, 87 for the United States and 81 for India.[64] China's 2013 steel production was equivalent to an average of 3.14 cubic meters of steel per second.[65]
See also
- American Iron and Steel Institute
- British Steel Corporation
- Dominion Steel and Coal Corporation, in Canada
- Steelmaking
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