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Ironworks

Iron: Element Fe Atomic number 26

Melting Point 1535.00C - 1808.150 K (2795.00F)

Boiling Point 2750.00C - 3023.150 K (4982.00F)

Crystal Structure Cubic

Colour Silvery

1620, the same year that the Mayflower sailed to the New World, Walter Vaughan of Llanelli and his kinsmen were involved in metal smelting when they applied for a patent for ‘Charking’ coal. A Swedish Ironmaster was producing iron near the village of Ponthenry at this time and  Hugh Grundy, a Cornishman, re-opened the same furnace around 1640.

1750 Daniel Shewen of the Stradey Estate is known to have worked an iron furnace around 1750

1784 William Yalden opened his ironworks and smithy in the Wern district.

1791 two industrialists, Givers and Ingman started their furnace, which was probably the one worked by Daniel Shewen more than forty years earlier.

1800 At the beginning of the 19th Alexander Raby (senior) took over the furnace of Givers and Ingman and his furnace gave the nearby village its name (Furnace).

1802 Hugh Waddle had established his ironworks and foundry at New Dock and as the industrial revolution reached Llanelli, small ironworks began to spring up to service the growing industries. These early ironworks and foundries were small compared with the works that were to follow the industrialisation and expansion.

1840 The South Wales Iron Works opened around 1840.

1852 The Old Lodge Ironworks opened.

1860s The Cambrian and Penrhos Ironworks opened.

1861 Marshfield Ironworks opened. As tinplate production arrived in Llanelli the old ironworks either converted to tinplate or closed.

The Old Lodge closed and then reopened as a tinplate works, the Marshfield closed and then re-opened as the Western Tinplate.

1866 The Machynys Iron & Tinplate Company was incorporated on 13 February 1866 for the purposes of establishing a works on a site at Machynys near the New Dock. The company considered various proposals before abandoning their plans for their works at Machynys.

1870 The Cambrian works was purchased by Edmund Morewood and his partner John Henry Rogers around 1870 and the Penrhos survived the slump of the 1870s and was still in existence in 1879.

1874 The Burry Tinplate Company was formed and they erected their works on the site rejected by the Machynys Iron & Tinplate Company in 1866.

1866 According to Slater’s Trade Directory of 1866 – Various manufactures:

The Wern Foundry – Richard Nevill: Iron foundries

The Old Lodge Iron Works – William Henry Nevill: Forge and rolling mills. Capable of making boiler and ship plates, bar and rod iron.

The Marshfield Iron Works – Nevill, Everett & Co.: Made terne or black plate The machinery used capable of turning out plates 1/4000th of an inch thick.

Messrs Tregoning & Co. – Located near the New Dock; Tinplate manufacturers.

Llanmore Foundry – John Roberts Waddle

Glan-Mor Foundry – John Powell

South Wales Foundry – J Maybery & Sons; All on extensive scale and capable of turning out goods of very heavy make.

[Note John Maybery, Joseph Maybery Senior and Joseph Maybery Junior all lived at Greenfield Place]

The Dafen Tinplate Works – Phillips Nunes & Co.; Forge and rolling mills. Two miles from the town manufacture tinplates and merchant iron. The company published a prospectus in which it stated it was proposed to erect a tinplate manufactory, on two acres of land, which formed part of Machynis (sic), near New Dock. The new works would include forges, mills and a tinhouse with the necessary steam power, and every appliance to make 700 boxes of tinplate per week. It was proposed to complete the necessary works in 9-10 months at an estimated cost of £9,000.

The company’s first subscribers were:

David Davies,  Carmarthen Iron and Tinplate Company;

William Rosser, Surveyor;

Benjamin Morgan, Carrier;

David Rees, Ship Broker;

William Evans, Manager;

Lewis Rosser Fitzmaurice, Commander RN;

Benjamin Jones, Colliery Proprietor;

David E Williams, Clerk;

Sebastian Furtwengler, Watchmaker & Jeweller;

Thomas Herbert, Draper;

John Bowen, Engineer;

Thomas Mainwaring, Accountant.

It was proposed to employ David Davies of the Marshfield Works as Manager of the new works. Mr Davies intended to invest capital and he also intended to introduce some friends who would also invest capital in the new venture.

At a meeting held on 3 March 1866, shareholder William Rosser, who was a surveyor, reported to a shareholders’ meeting, that there were three possible sites available for the new works. Three other shareholders, Joseph Hepburn, John Bowen and Joseph Maybery were asked to examine each of the three available sites and to make a detailed report. These three men were well qualified to conduct the survey and make a report because Hepburn and Bowen were engineers, and Joseph Maybery was an experienced iron maker having been involved with the South Wales Foundry with his father (Joseph Maybery senior) and brother (John Maybery). Their report on the Old Castle site stated:

"This appears to us to possess more advantages and fewer disadvantages than either of the other two. The foundation is decidedly better, and there is an ample supply of good water which far more than compensates for the extra cost of haulage and tolls to which the company would be subject on this site as compared with the others.

Comparison of Tolls and Haulage Costs:

Machynis £174 4s 2d; Dolau £185 7s 6d; Old Castle £217 5s 10d.

"The advantages of an abundant supply of good water cannot beover-estimated for use in tinplate works, both for the boilers and picklers, and on neither of the other sites can we get this supply in such purity. The Cille Stream is fed from springs which we understand never dry.

"We are aware that in very dry summers that the watercourse has been dry, this was caused by the fact that the inhabitants of the town (in consequence of the non-supply of water from the Water Works) were compelled to have recourse to those springs. But in order to meet contingency of this kind, we would recommend the construction of a reservoir on the site of the works.

"It would also be desirable to have the use of the Furnace Pond in case of need and this we understand Mr Lewis (the landlord) is prepared to grant. Pipes could also be laid to convey water from the Lliedi through a cutting already formed on Mr Lewis’s property, and in addition to these a supply could readily be obtained from the Water Works and at a considerably greater pressure than at the New Dock but we anticipate that the Cille Stream alone would afford ample supply at all seasons, without incurring the expense of obtaining a supply from the local Board of Health.

"After carefully weighing the advantages and the disadvantages of these several sites, we have no hesitation in recommending that the site at Old Castle as the most desirable for the erection of a Tin Plate Manufactory."

On the basis of the report the shareholders decided to build the new works on the Old Castle site. It was stated that the original Machynys site had been rejected because the water supply was not of sufficient quality for the production of tinplate.

Because it was difficult to raise capital locally, most of the other established industries relied heavily on English investors who were mainly metal merchants and industrialists. The Old Castle Company was the exception and the first to be financed locally.

Early in 1866, the company leased land at the Old Castle site from the Stradey Estate at a low annual rental of £20 per acre. The contract for the buildings was signed on 2 June 1866 and the builders undertook to complete the works within four months and to pay £2 per day for every extra day taken. Richard Jones built the works at a cost of £1,384 15s. 3d.

The building comprised the Mill building; Annealing house; Cold rolls department; Tin house; Assorting room; Warehouse; Stores and Offices.

Thomas Thomas, builder of Cross Inn, carried out the carpentry work and roofing at a cost of £1,424 9s. 8d and Richard Nevill’s Foundry supplied the machinery.

Because the site at Machynys had been rejected, the name of the company was changed on 27 August 1866, to The Old Castle Iron and Tinplate Company. This name was chosen because the works were established near the site of Carnwyllion Castle, thought to have been destroyed by Rhys Grug in 1215.

1866-1870 David Davies was manager and Joseph Maybery (junior) was secretary of the works from 1866 until 1870. In the early years both the manager and the secretary received a salary of £208 per annum.

1866 Llanelly Guardian, 18th October

MARRIAGE FESTIVITIES

Mr and Mrs Tregoning were met on their return from their wedding tour, by their workmen of the Morfa Tinworks, and escorted to their home, Bigyn House, followed by the Rifle Corps with flags flying, and cannons fired along Ann Street.

1867 During the first three months of 1867 management sought to perfect the tinplate manufacturing process and establish profitable business connections. The original shareholders were drawn from a wide section of the industrial community.

Of the 38 persons holding shares in 1867: 18 were engaged in trade and industry including: Edward Bagot later proprietor of Upper Forest Works Morriston and John Powell, founder of Glanmor Foundry; 9 were professional men – accountants, surveyors, and surgeons; 6 were shopkeepers; 1 William Morgan (Lleurwg) – Minister of Religion, Seion Baptist Chapel; 1 Henry Thomas – Farmer, a wealthy maltster and corn merchant; 1 James Buckley – Self-styled gentleman; 1 William Samuel – an important ship owner; 1 Sebastian Furtgwengler – watch & clock maker and jeweller.

Most of the investors were local men: 32 lived at Llanelli; 2 lived at Carmarthen; 1 lived at Llandeilo; 1 lived at Swansea; 1 lived at Briton Ferry.

At the time the Old Castle Company was established, local tinplate manufacturer, John S Tregoning, proprietor of the Llanelly Tinplate Works voiced his opinion as follows: “There seems little doubt that the little concern of parsons, tailors, clerks, tinkers etc; will get into operation, they have scrambled together about £70,000 and expect by perseverance to get still more.”

In 1867 According to Slater’s Directory, Tinplate Manufacturers were:

Boughton, Smith & Co. Ltd: Tinplate Works, Pontardulais. Octavius Williams, Manager [Note He had previously been manager of Tregonings Tinplate Works, Morfa];

Old Castle Iron and Tinplate Company Limited: Joseph Maybery Junior, Secretary;

Dafen Tinplate – Phillips Nunes & Co;

Llanelly Tinplate Works, New Dock: Also Tin smelters (London Office) John S Tregoning & Co.

1867 The Old Castle Works started full-scale production in the third week of April 1867 when 504 boxes of tinplate were made. One box contained 112 sheets which measured 20" x 14" and weighed 108lbs. The company appointed selling agents in Liverpool, London, Manchester, Birmingham and Newcastle. These agents with their expertise and knowledge of the markets and commercial trends provided a valuable service and allowed the manufacturers to concentrate on tinplate production.

After the first year of trading the directors reported: “The operations of the company for the past 12 months of which about nine months have been occupied in manufacturing tinplates, have not been so successful as we would have wished, but the low prices ruling throughout the year and the opening of a new business will account for the result.”

During the early years of the company the proprietors kept tight control of the administration of the new works. This was achieved by selling the shares through the secretary Joseph Maybery Junior who was in the best position to assess their current value. The company resembled the old style partnership rather than the modern limited liability company because ownership and control were not separate. The largest individual holdings in the company were held by directors and it was common practise for the company to offer both old and new issue shares to existing members first, which enabled the directors to consolidate their control.

1868 Until July 1868 the directors met twice a week and after that they held weekly meetings. In this way they knew everything that was going on in the works.

The secretary kept strict control over all the correspondence and all cheques and bills had to be signed by three directors. A sub-committee was appointed to arrange and oversee a system of accounts and three directors were instructed to meet at the works to pay the wages. In this way ownership, management and financial control were closely linked.

1870 Joseph Maybery (junior) who had been secretary of the works from 1866, succeeded David Davies as manager. Maybery was the son of Joseph Maybery (senior), former manager of Richard Nevill’s Wern Foundry, Ann Street who had been trained as an iron maker at Alnwick.

The quality of tinplate produced in the works generally depended on the skill of the workmen and recruiting an efficient labour force was very important when there was a shortage of skilled labour. Experienced mill and tinhouse superintendents were always in demand not only because they had their own particular skills but they could also encourage other skilled men to follow them.

During the expansion of the industry from 1866 the competition for men became intense. Joseph Maybery complained bitterly that his skilled workmen were being ‘poached’ by other tinplate works proprietors and he was not averse to employing the same tactics himself. He is said to have instructed a newly appointed roll-turner from Landore to “look out for two or three rollers – I do not care where you get the men from as long as they are good steady people.” At this time around 75 per cent of the labour force was made up of unskilled workers and recruitment was not a problem.

The high wages paid in the industry encouraged many families to move to Llanelli from the surrounding countryside. One man who came to Llanelli in the 1870s said, “Gaffers were out on the roads looking for men, and asking men from the country whether they wanted work.”

When vacancies could not be filled by direct personal contact, advertisements were placed in South Wales newspapers. The response to these advertisements showed that skilled men were prepared to move around South Wales to find work.

Boom and bust is not a new phenomenon, it also occurred in the 19th century when fluctuation in trade became a traditional part of the “ups and downs” of the tinplate industry. Boom was followed by a depression, resulting in over production, accumulation of stocks, decline in prices, short time and the laying off of men. During the time of adverse trading conditions in this early period the Old Castle Company was frequently over drawn at the bank, either when stocks accumulated or when merchants were slow in settling their accounts, on no occasion, however, was a bank loan found necessary.

During the years from 1867-70 the company made an average profit of £1,660 per year.

In 1870 A forge was supplied and installed by Wern Foundry for £2,000, which included a forge engine costing £925 and a 2-ton hammer costing £500. This equipment had been originally ordered in 1866, but the directors had thought it prudent financial management to delay installation.

1871 The cold rolls situated between the annealing department and the tinhouse were removed and a mill erected in their place. They then had four mills with an engine to work each mill separately, also six pairs of cold rolls and room for another pair should they be required. The new mill came into operation in October 1871, and with demand for tinplate increasing the company was able to increase output from 50,709 boxes in 1871 to 63,329 boxes in 1873. Other additions were made and because of the small initial outlay construction costs were spread over a number of years.

1872 According to Chalinder’s Directory – Iron & Tinplate Manufacturers etc were:

Cambrian Iron & Tinplate Works: Morewood & Rogers

South Wales Iron Works: Morewood & Rogers

Dafen Tinplate Works: Phillips Nunes & Co.

Glanmor Foundry: John Powell

Llanelly Tinplate Works: John S Tregoning & Co.

Lanmore Foundry: John R Waddle

Marshfield Black-plate Works: Richard Nevill, Son & Co.

Old Castle Iron & Tinplate Works: Joseph Maybery Secretary (The Old Castle Iron & Tinplate Company Limited)

Old Lodge Iron Works: Nevill Brothers

Shovel Forge: Richard Nevill

1873 Before the early 1870s there was little sign of active trade-unionism in the Llanelli area, but by 1873, the Independent Association of Tinplate Makers had been formed by workmen from both east and west Wales.

1874 In February 1874 the new union presented the masters with a demand for new wage rates which resulted in the great conflict of the ‘Lock-Out of 1874’. After long protracted discussions the masters gave the workers one month’s notice of lock-out. All the Llanelli works were closed by the beginning of May; the Old Castle closing on April 2. A 20-week struggle ended in complete victory for the masters, with the men returning to work at the old rates of pay. The Old Castle was the last works in Llanelli to re-open on July 13 1874. The struggle was not a complete disaster because it made the employers realise that the extreme diversification of wage-rates in the South Wales tinplate industry would always cause unrest among the workmen. As a result the employers decided to introduce a uniform list of wages which became known as the ‘1874’ list. The list came into force on January 4 1875, and remained the basis of the tinplate wages until the closure of the pack-mills.

1887 The Old Castle Works were extended when another mill was added.

1888 A further 4 extensions were carried out to Old Castle Works making it an 11 mill works. Around this time a reservoir (Pond Twym) was created for the Old Castle Works within the bounds of the former meander of the River Lliedi.

1894 The Llanelly Guardian reported on 19 July 1894:

Old Castle Works

Quite a sensation was created in town on Monday by a rumour, which was freely circulated to the effect that Mr J Maybery the managing partner in the firm of the Old Castle Tinplate Company, had called upon the men for a reduction in their wages to the tune of 25 per cent. As our readers are aware, the Old Castle operatives only resumed operations a week or two after a period of idleness extending over seven or eight weeks. The news circulated on Monday that another stoppage would shortly occur, was, therefore, received with universal disappointment and dismay. The prolonged stoppage at the Old Castle and other tinplate works in the neighbourhood has been most disastrous, both to the operatives and tradesmen.

Indeed, we do not think we are far wrong in stating that the conditions of trade in the town of Llanelly at the present time are worse than they have been for many years past.

1896 The Old Castle Works converted one of their tinplate mills to produce the cheaper alternative of blackplate and sheet.

1897 Old Castle Works made its own iron until the introduction of steel production when it was one of three companies, which contributed financially to the construction of the Llanelly Steel Works.

The Railway network underwent a period of great expansion, and three local companies, the Western, Old Castle, and Briton Ferry Steel, formed the ‘Llanelly Steel Company’ to ensure regular, relatively cheap supplies, of bar.

1898 The end of the century saw other Tinplate Works come under the hammer and Llanelli’s future as a Tinplate centre was described as being in the hands of Richard Thomas & Company and the Old Castle Company.

1906 Joseph Maybery ceased to be Manager of the Old Castle Works and retired to Bournemouth with his wife, Isabella, who was the first matron of the Cottage Hospital on Bigyn Hill.

1907 Between 1907 and 1912 the Old Castle Works Company built 7 mills.

1914-1918 During the war years when supplies of raw materials, shipping and transport were restricted, the Mills were forced to operate at half capacity and a shortage of coal encouraged Old Castle to invest in the coal industry.

1923 Production had increased to about 1,000,000 boxes a year and the main brand was ‘Castell’ Coke.

The Llanelli Official Guide commented on the fact that due to the harmonious relationship between the managers and the employees the company was proud of the long service of their workers and the absence of industrial disputes.

1939 The Llanelly Associated Tinplate Companies Limited were formed and comprised:

Old Castle Iron & Tinplate Co Ltd. (HQ) – 17 Mills

The Ashburnham Tinplate Co Ltd. – 4 Mills

Western Tinplate Company Limited – 9 Mills

The Kidwelly Tinplate Company – 7 Mills

Teilo Tinplate Company Limited (Pontardulais) – 6 Mills

This amalgamation saw the end of the independent tinplate manufacturer in Llanelli. The only Tinplate Works that did not belong to either Richard Thomas & Company or Llanelly Associated Tinplate Companies Limited, were the small Pemberton and Old Lodge Works.

Llanelli remained an important Tinplate centre, but Ebbw Vale with its new Strip Mill was beginning to emerge as a rival.

1953 The Western Works, the Old Castle Extension and the Richard Thomas Mills, all closed.

1957 The Old Castle Works, which at one time was the largest independent tinplate works in South Wales, closed.

A local newspaper report on 13 April 1957:

Old Castle Closing

The Old Castle Tinplate Works of the Steel Company of Wales are to close at the end of June. The decision to close and declare redundant the works was announced yesterday by the Steel Company of Wales. The decision arises from the Company’s continued difficulty in disposing of the product of the old-type works in competition with modern cold-reduced tinplate. The total number of employees involved at the Old Castle is 440, of whom 50 are Italians and 70 are women. The works were built on the site of an old British fortification in 1867. It derived the name Old Castle from the fortification – Hen Gastell. For 20 years or more it made its own iron.

Acknowledgements

Byron Davies, Local Historian;

Chalinder’s Llanelly Directory 1872;

A Llanelli Chronicle compiled by Gareth Hughes;

Llanelly Guardian;

Llanelly Official Guide 1923;

Llanelli Star;

Post Office Directory of Glamorgan 1866;

Slater’s South WalesTrade Directory 1867;

Tinopolis edited by John Edwards;