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In 1836 John Lysaght was born to a land owning family
in County Cork Ireland. Shortly after his birth the family moved
to Bristol where the young John was educated and formed a friendship
with the oldest son of the Clarke family. The Clarke's were engaged
in galvanizing ironware at "Temple Backs" using the
Crawford hot-dip technique. When Mr Clarke died in 1857 his son
had no interest
in pursing the family business and he offered it as a free gift
to his friend John who renamed the company John Lysaght LTD.
When the company was first formed John Lysaghts employed
6 men and a boy at its Temple backs works continuing the company's
traditional work galvanizing hardware like buckets. Corrugated
iron sheeting had recently been developed and John quickly realised
the potential of galvanised iron sheet and he turned the companies
attention towards this new product adopting the word "Orb" as
his trademark. Initially Lysaght's simply galvanised iron sheet
produced in the foundry's of the midlands and shipped to Bristol
via the country's canal network.
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Orb galvanised corrugated iron sheet became highly
prized in the construction industry for its inherent strength and
resistance
to rust, and it came to the market at a time where the construction
of factories, mills, workshops and railway sheds was growing
rapidly as the country industrialised and the demand for
corrugated iron grew just as quickly. As demand for the companies
products
increased
the
workforce
at
Temple
backs
works had expanded to 29 men and boys by 1869. With demand still
increasing Lysaghts purchased
an additional 4
acre
site at St
Vincent's so the company could continue to grow. The new St Vincent's
works was also used to galvanise
iron sheet, which was still purchased from the foundries of the
Midlands.
By 1878 the company employed 400 men producing 1000
tons of galvanised iron sheet a month, The company had also diversified
into iron making having purchased a 13 acre site at Netham
where they produced constructional iron work to compliment their
corrugated iron sheets. The company's products were becoming
increasingly popular colonial markets, exported
around the globe from the Port of Bristol. However the rate of
expansion in the galvanising business meant that the company was
struggling to find sufficient quantities of raw corrugated iron
from the black countries iron makers. The decision was made
to begin producing their own rolled sheet and the company purchased
the
disused
Swan
Garden Iron Works in Wolverhampton from G.B Thorneycroft & Co.
for £23,000. After Lysaghts installed eight new rolling mills
the Swan Garden Iron Works were capable of producing 25,000 tons
of rolled Iron sheet
a year. An additional 4 mills were added when the company purchased
the neighboring Osier Beds Iron works in 1880 which raised the
company's capacity to 40,000 tons of rolled Iron sheet each year.
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When Lysaght's bought their Wolverhampton Iron works
their Iron "Black Sheets" were made from Puddled
Iron Bars, but the Bessermer Converter process which introduced
the
first cheep method for producing steel was beginning to take
over the countries iron production in 1883 70% of Britain's pig
iron was converted into puddled bar by 1887 this figure had fallen
to
5% the majority was then being converted into steel via the Bessermer
process. Lysaght's had kept pace the development, introducing "Black
Steel
Sheet" in 1895 along side their galvanized iron products.
Lysaght's was very much a family concern John Lysaght
has been joined by his nephew Sydney Royce Lysaght who became the
company's first registered secretary in 1881. He was soon followed
by his younger brother William Royce Lysaght and later by Daniel
Connor Lysaght who joined the company in 1895. During the the same
year the company's founder John Lysaght died and management of
the company
passed to his nephews S.R Lysaght and W.R Lysaght.
The Galvanised trade
was still growing at an exceptional rate, the companies exports
to Australia alone were consuming 30,000 tons a year, andLysaghts
was in need of additional rolling mills. The change to Steel from Iron
sheet had lead to a process of decentalisation in the iron working
industry and the advantages of South Wales with easy access to
the coal
field
and developing ports attracted the directors of the company, who decided
to transfer the company offices and mills from Wolverhampton to
Newport. Lysaghts
purchased the 100 acre "Pill Farm" on the banks of the
river Usk in Newport from the estate of Col. Lockwood with the
intention of
building a new rolling mill called the Orb Iron Works.
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Construction of the iron works took three years to
complete, when it opened in March 1898 Mr D.C Lysaght moved to
Newport from Wolverhampton to oversee the opening with a staff
of Three. Initially three mills were installed manned by nine teams
of men recruited from a small mill at Ynysmeudwy near Neath. These
were soon augmented with the mills from the Oiser beds mill which
was closed. By 1901 the company's move had been completed, the
remaining mills had been moved down from the Swan Garden works
which was converted
for the production of Chilled Cast Iron Rolls. The completed iron
works had a workforce of three thousand including 600 women. Many
of
the workers had migrated from Wolverhampton, the company had offered
employment at the Orb to it's experienced workers and
many chose to follow the company
to Newport rather than find alternative employment.
The influx of workers from Wolverhampton left its
mark on Newport, most of the iron workers settled along Corporation
Road to the north of the Orb, many of the side streets in this
area, Dudley Street, Telford Street, Walsall Street still reveal
the towns links with the black country. The workforce included
many
catholics
from Wolverhampton which led to the establishment of a Parish
Mission on Corporation Road within sight of the Orb.
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When the works were complete Mr W.R Lysaght
arrived from Wolverhampton to take control under his
direction the Orb expanded by 1913 to include 42 mills driven by
six steam engines whose chimney stacks known as the severn sisters
became
a dominant
feature of the Newport skyline. The work force expanded to
over three thousand men producing 175,000 tons per annum of which
140,000 tons were shipped by barge from the works own wharf to
St Vincent's for galvanising.
The works first manager D.C. Lysaght moved on to
lead Lysaght's into the emerging technology of electrical steels,
with
the company forging a technical partnership with the Joseph Sankey
Company to produce "Iron-Silicon" alloys and a special
laboratory called the calendar room was constructed to house a
battery of
forty 24 hour clockwork temperature
recorders which controlled the critical annealing cycle, the first
installation of the type in the world.
Until 1910, all the steel required by the works
for sheet rolling had been purchased from outside companies. With
the developmentand growth
of the black steel sheet business which was gradually taking over
from galvanising, the company became more dependent upon special
steels and decided it would enter the steel making business. Scunthorpe,
Lincolnshire, was chosen as a suitable position for the companies
first steel works as it was located in the center
of an extensive
and easily-mined iron-ore field. Normanby
Park Steel Works were opened in 1912 producing a weekly output
of 6,500 tons the majority of which was shipped to Newport for rolling.
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The outbreak of the First World War in 1914 caused
a major disruption to Lysaght's commercial plans. The Orb's output
was turned over to the production of steel for trench plates, helmets
and other military hardware including vast quantities of cartridge
brass. The war had a severe impact upon the companies export trade
especially in the Australian market which entirely depended
on Britain for steel imports. Once peace returned Lysaght's main
priority was rebuilding its international business.
In 1921 the company established an Australian subsidiary
with a brand new galvanising works in Newcastle, New South Wales.
Many of the experienced workers form the Orb and their families
emigrated to form the nucleus of the work force to operate the
new mills. The company went on to acquire the Dominion Sheet Metal
Corporation, Hamilton, Canada in 1924 and constructed a new galvanising
work in Buenos Aires, South America, in 1930 to which black sheets
were regularly exported from Newport. The foreign plants had little
impact upon the output of the Orb which was busy fulfilling demand
from newly emerging domestic markets, but the loss of foreign demand
for galvanised products which were now supplied from their local
mills had a major impact on the St Vincent's works which
had previously supplied the export trade. In 1930 the St Vincent's
were closed and the companies headoffices were moved to
the Orb.
The 1920's also saw some major changes to the company
at home, in 1921 Lysaght's joined the combine
of Guest, Keen & Nettlefolds, Ltd, although the company was
to remain an independent entity still under the leadership of W.R
Lysaght. The company also benefited from the demand for a
range of newly emerging steel products. The formation of the
Central Electricity Generating Board and the development of the
"National
Grid" for high voltage AC distribution in 1926 led to a
rapid and sustained demand for Transformer grade steels. As one
of
the few works in the country capable of their production the
Orb was quick to take advantage of the new market. The main key
to the works success between the World Wars was the automotive
industrys demand for sheet steel. As
car ownership in Britain became popular for the first time the
demand for automotive grade steels took off. The Orb installed
new 72"
mills in 1928, which produced the widest rolled
steel in the world at the time, which were highly sought after
by car makers.
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As the company flourished, the work force at the
Orb peeked at over 3,500 men and women. Lysaght's prided itself
on
it's worker relations, during the General Strike in 1926 the company
closed the works for 9 days rather than see their workers strike
maintaining its much prized industrial relations record. The company
provided excellent facilities for its workers a small workings
mans club had been provided on Jenkins Street from the first days
of the Orb, It was reconstituted in 1928 in the newly built W.R
Lysaght Institute on Corporation Road. The institute had been
constructed as a memorial of W.R Lysaght's fifty years as the company's
chairman and was financed jointly by the company and workers contributions.
The institute stood in 8 acres of ground near the
work's
main gates
and provided a public bar, smoking room, lounge, billiards room,
skittle alley, reading room and recreation hall within the elaborate
building. Surrounded by tennis courts, bowling green, putting green
and ornamental
garden.
Many industrial concerns had their works football
teams, but the Orb's made a major contribution to the sporting
life of Newport. Almost as soon as the companies football loving
workers from the midlands arrived in South Wales a work's football
team was formed, initially nicknamed the "Iron Sides" in
1912 the team became the core of the newly formed Newport County
AFC, the
majority of the teams early players were Midlanders to be found
in the workforce of the Orb and the team's nickname remained the
"Ironsides"
for
many years because of their links to the works. The club's chosen
colors were amber and black, opinion is divided whether
they were
chosen
in
honor
of
Wolverhampton
Wanderers or Newport Rugby Football Club who both use the same
colors, but for many years copies of the Saturday night the football
edition of the Wolverhampton Express & Star was shipped by
express train to the newsagents along Corporation Road.
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Rising demand for the Orbs products threatened to
outstrip the production capabilities of the works traditional hand
operated rolling mills. To meet the ever increasing demand several
several of the mills were mechanised in 1933 with the installation
of chain driven sheet feeds and elevated returns which increased
the mills production capabilities while reducing the number of
operators. The company also installed the countries first four-high
mechanical cold-reducing mill capable of rolling wide highquality
auto steel.
In january of 1939 the Orb once again became involved
in war work, as the storm clouds of WWII gathered the works were
engaged in the production of heavy corrugated iron sheeting for
anderson shelters and during the course of the next six years the
Orb contributed to the countries war effort by producing jerry
can's, ammunition boxes and landmine's. The work's mills also rolled
large quantities of Duralumin and stainless steels for airframes
along with cartridge brass used in he 20mm shells for the RAF's
fighter aircraft used in the battle of Britain. In recognition
of its contribution to the war effort, the Orb was visited by the
Royal family in March on 1944. King
George the VI, Queen Elizabeth and Princess Elizabeth were shown
around the works by R P Perry MBE the works manager and Mr Tom
Crowther, mayor of Newport. Although the visit was kept secret
for security reasons work had spread into the community and the
Royal Family were greeted by large crowds.
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After the second world war the company
made the decision to specialise in electrical steel production at
the Orb. Electrical steels are specialty steels manufactured in
cold-rolled strips or laminations often less than 0.30 mm thick used
in the laminated
cores of power transformers, and the stator and rotor parts of electric
motors. However the largest change
in works history was just around the corner, In 1949 the post
war Labour government announced its intention to nationalise the
Iron
and Steel industry. When the Iron and Steel act came into effect
on the 15th of February 1951 the Orb Steel Works was taken over by
the
Iron and Steel Corporation of Great Britain. Eventually the Orb
became separated from the rest of the former Lysaght's empire and
found
itself merged into the Steel Company of Wales one of the new
nationalised industries subsidiary companies. The conservative party
had
vigorously opposed the nationalisation of the steel industry and
when they were reelected later in the year they immediately made
plans to return the industry to the private sector.
The Orb remained part of the Steel
Company of Wales when it was sold back into the private sector, specialising
in the production of Electrical steels and a new cold rolling mill
for
their
production
was erected
at the
site during the early 1950's, this mill is still in operation today.
The companies time in private ownership lasted until 1967 when the
British
steel industry was nationalised
for a second time, the Orb
now found itself in the ownership of the British Steel corporation.
The following decade was hard on the steel Industry and the loss
making British Steel decided to concentrate steel making in the
united kingdom
in five areas, one of these was the South Wales which secured
the future of the Orb while many steelworks across the country were
closing. During the 1980's the Conservative government embarked
on
a program
of nationalisation and in preparation for British Steels eventual
sell off the corporation concentrated on its core activities
which lead to the sale of the Orb works which emerged as Orb Electrical
Steels Ltd.
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The new company did not remain independent
long and merged with the expanding European Electrical Steel's group
which was in turn taken over by Cogent a wholly owned subsidiary
of Corus. a move which reunited the Orb with the remainder of British
Steel which had merged with the dutch steel maker Koninklijke Hoogovens
N.V. to form Corus in 1999. In 2004 Cogent embarked on a major restructuring
and investment program at the Orb, the first significant investment
in the works since the 1960's. The project included
the sale of the oldest parts of the works on a 23 acre plot known
as monkey island, included in the sale were the administration building's
which were housed in Pill farm house which had survived since 1895,
the
training
center and steel packaging plant.
I visited the Orb Steel works with
another photographer shorty after the site had been sold off for
redevelopment, I knew very little
about the steelworks before the visit so once on site I was intregued
by the administration buildings I was'nt expecting what looked like
a farm house when visiting a steelworks so we made our way over to
these first. Once in sidethe building we enterd the former reception
area which just like the rest of the offices was striped out shell
of a bland modernised office very little of the buildings original
carachter remained. Out in the offices hall ways a notice board still
had some pinned up greeting cards from staff bidding farewell to
the works, some after 30 years service. Throughout the office were
scattered
reminders of the works centaury of history folders from the 60's
carried the name of the Steel Company of Wales, Reports form the
1970's compiled for British Steel and a Cogent Mug perhaps used
only a weeks before. The real gem of the office building was a dust
filled archive room tucked away at the back of the building apparently
forgotten when the office was cleared, on it's shelves were reports
dating back to 1930's and Lysaghts' ownership.
Alongside the original Pill Farmhouse
a second office building had been built once from the inside this
building appeared to have been built in the 1930's perhaps coincideing
with Lysaghts' headquarters moving to Newport in 1930. This second
office building was just as empty as the farmhouse, even the oak
paneling and marble fireplace in the board room was piled up ready
for removal.
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Outside the administrative buildings
lay a small sports field which was over grown and neglected beyond
this was the training school where we headed next. The training school
was a substantial brick building which appeared to have been built
in the years following the second world war. Inside the training
center contained a large hall flanked on both sides with small classrooms.
The hall was filled with abandoned training tool, lathes, drills
ect along with some more unusual items like a cut away internal combustion
engine possibly from a original Mini. The classrooms were fitted
out for the different trades employed in the steel works one for
the
electricians and another filled with ARC welding benches. Behind
the hall a larger classroom was fitted out as a lecture theater where
the firms apprentices did their training in years gone bye.
Leaving the training center we moved
on to the factory proper, very little had been left behind in the
unwanted buildings, machine pits marked out where where machines
had once stood but all that remained in place was a battered old
generator in one of the halls, apart from this the only indication
of the heavy
industry that once took place within its walls was an over head 10ton
crane. Behind the two machine floors roughly on the site of the original
"race" was a long thin factory floor, there was nothing left to suggest
what its original purpose was but a small office within was labeled
"packaging" and abandoned rolls of Corus packing tape and storage
bays marked out on the floor indicated that this hall was last used
as the goods outward loading bay. The only things left for shipment
were a few milling machines packed up on pallets. Having spent a
few hours within the silent buildings of the Orb disturbed occasionally
by the sound of industry in the active parts of the steelworks next
to us, it was time for us to leave. Not long after our visit the
farm house buildings were gutted by fire and by July of 2008 the
whole site had been demolished and flattened, the oldest parts of
Lysaghts'
Orb Steelworks due to be come the site of 550 homes.
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