Greetings from Steel-Town

I know I’m going to have a blast visiting with people here at Netroots Nation. But I’ve already done what will likely be the coolest thing I do: a tour of a local steel plant. There were about 30 of us who took a bus out into the Monongahela Valley and all dolled up in hard hats, Nomex suits, and safety glasses to see how they make steel (Jane will be posting a photo of us, but I’m sure it won’t give you the proper sense of just how gorgeous Jane looks in an industrial suit). 

The video doesn’t give you a full sense of the size and heat of the process. The ladle that appears in the early part of the video is maybe a story and a half high, all moved around on a giant pulley system.

There were a number of us who left saying, "next time I hear someone complaining about their job, I will tell them to shut up unless they’re a steelworker." It is hot, there are tons of steps everywhere. But the whole trip was a fascinating way to understand something about Pittsburgh–and about where our cars and stuff comes from. 

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55 replies
  1. AZ Matt says:

    You must have been on the same tour as Tula Connell. I am glad you both are highlighting workers who make things as oppose to Wall St that makes things up.

    • readerOfTeaLeaves says:

      I am glad you both are highlighting workers who make things as oppose to Wall St that makes things up.

      I could ponder for an hour about what best to say and never top this comment, AZ Matt.

      Hope EW saw some magnets moving liquid steel around.
      And have a GREAT time!!!!!

  2. dqueue says:

    Go to East End Brewing, if you have a chance. Great beer. All local. Oh, they only fill growlers, but you can make it through a half-gallon of delicious beer, right?

  3. tonycpsu says:

    +1 to East End, and also check out Penn Brewery (just a hop+skip+jump across the Allegheny river) for craft brewed goodness and great German food.

    • scribe says:

      If you can get to Penn Brewery, go. But don’t be surprised if you can’t get in – they had a lease dispute with their landlord earlier this year.

      If it’s open, it’s the best Bierkeller experience this side of the Atlantic Ocean. And astonishingly good true Reinheitsgebot-compliant beer.

      There’s also Church Square Brew Works.

      And the Strip District – the land o’ clubs and bars.

  4. MadDog says:

    Totally cool EW!

    Or should I make that totally hot?

    In my youth, I once worked a summer at a steel plant, but before Nomex existed, so it was my own shirts and jeans that always ended up with holes burned in ‘em. Talk about fookin’ warm!

    And after each and every shift (3:30 to 11:30 PM), each of us looked like we had just come out of a coal mine.

    We were liberally covered in black coke used in the process, and having sweated through another 8 hour shift, that stuff was so embedded in our skin and clothes that normal washing just never got it out anytime soon.

    And I learned that various auto parts are made of Ductile iron and they take hours and hours to cool down (yep, learned the hard way. Ouchie!).

  5. scribe says:

    Speaking as one who actually did work in a steel mill during college (like 30 frickin’ summers ago), I can tell you that no video can capture the enormity and visceral impact of going into a steel mill, especially for the first time.

    You walk through an industrial environment which can be like something out of the chase scenes in the original Robocop, up to a huge, multistory metal barn of a building. Set on the wall is a single generic metal door of the type you’ve all seen. Grey, with a “danger” or “warning” sign or something similar, half peeled off, and a lot of grime on it.

    You walk in, and as the door shuts behind you the darkness is an immediate, stark contrast to the sunlight outside. There is dust and steam and smoke everywhere. There are arc lights five stories or so above your head, casting both light and shadow across the floor. The floor is (or was, anyway) dirt and not concrete. Dirt absorbs those little meteors of molten steel or slag which spray at odd, but predictable, intervals from the ladles and the process. Concrete, they bounce off, then lay around to be slippery like sawdust on a dance floor. The heat smacks you across the face and the cold on the side not exposed to the hot metal feels arctic by comparison. Noise – across the whole frequency range but more toward the low end – bombards you through your protective gear. Sirens, flashing “whoopee” lights, bells, horns, you name it. Every one of them has a meaning but when you don’t know them it’s a cacaphony.

    And then they pour a ladle. What was smoky, steamy, noisy, and hot before just gets turned up past 11. The occasional dust-fleck meteor of metal or slag burns through your shirt and leaves a little mark on you. “Stingers” we called them. After a couple days you no longer notice them.

    You then get a sense that, when that entry door closed behind you, had there been a doorman he would have said “Welcome to Hell.”

    I worked in a relatively modern plant. We used electric furnaces to melt scrap and make ductile iron pipe fittings. My job, most of the time, was either to grind off rough edges, or to slam them with sledghammers as they came out of the sand molds looking like so many model airplane parts, to break them apart into individual fittings. One guy, who had “anger issues”, spent weeks swinging a 5 or 10 pound sledge (depending on the size of the parts being made) to work through them. Kept him out of trouble. The grinders were either hand-held or big, floor-mounted units with 36 inch wheels spinning at 5000 rpm. You wore so much protective gear you felt like an astronaut or something. Hard hat, face shield, safety glasses, earplugs, dust mask, leather apron, long leather gloves, heavy boots. And it was always about 100 deg. F in there.

    One night, they gave me a tryout on the pouring deck. I got aluminized coveralls, special insulated gloves, and a nearly-opaque dark green face shield to replace the normal clear one. The overhead crane would bring me a lidded ladle, about the size of a 10 gallon bucket, attached to a chain hoist. This ladle was full of molten steel. The heat would radiate from under the lid like one of those starship motors in the movies. Yellow-white, with a hint of pink. But this was frickin’ hot.

    Molten iron is so hot, i.e., there is so much energy running around in there, that if you were to spit into it, the energy would disassociate the water into the constituent hydrogen and oxygen, which would then promptly explode back into water. So, you’d get a combination steam and hydrogen explosion. Invariably lethal – so you don’t spit.

    And my job was to line the spout of the ladle up with the holes in the sand moulds as they went by on a conveyor belt and pour the steel into the moulds. In three dimensions, without reference marks. Then, I was to turn a wheel on the frame of the ladle, kind of like a ship’s wheel, and this would tip the ladle to pour. The stream of molten steel – in theory – then went into the moulds, cooled and congealed into pipe fittings or whatever we were making that night. And the next mould came on. And I was to pour again. For eight hours.

    You have no idea how hot this was. I sweated off about 10 pounds that night.

    My tryout was a one-night deal. I missed a little too much. About 2 or 3 cups in the course of the night. Molten iron is nasty stuff, but at least no one got hurt.

    Prior to law school, I once thought about going back from construction to a possible job at a copper foundry. Second thoughts got the better of me when I heard that the labor force was so polyglot that no one spoke in words – it was all whistles and yells. At least in the iron foundry, we communicated pretty well. And, I remembered that I got the best grades of my college career the semester after working in that steel mill.

    I just love it when wingnuts denigrate working in places like that mill as … whatever derogatory term they’re using. Yeah. Like they know.

    • MadDog says:

      Dante’s Inferno comes to mind.

      Dark, smokey and hot as hell. With a cacophony of never-ending noise that meant you had to shout all the time in order to be heard.

      And yes, nobody who hasn’t worked in one can begin to imagine that first couple of days of constant primordial fear buzzing through your blood.

      Yep, those were the days! *g*

      • scribe says:

        I hated the hammer line – they called it the “sprue” line. The pieces which connected the fittings during pouring, called “sprue”, were always about the size of an egg, give or take a bit. You’d hit the damn thing with your hammer to break it off the fitting and invariably the damned sprue would fly back and clock you right in the balls. Or the groin. Or just above your pubic bone. Faster than you could move to get out of the way.

        Imagine getting clocked like that 5 or 10 times a night.

        Fun.

        • MadDog says:

          Spent most of my time swinging that sledge on exhaust manifolds on those always-moving conveyor belts.

          We were considered the low end of the totem pole. My older brother (who got me the job) had progressed to being one of the pourers.

          And the ones with the most seniority got to be the mold makers.

          Like you, I didn’t stay long enough to climb any rung of the ladders, but my brother managed to “enjoy” working there for several years.

        • scribe says:

          I can say that the pay was good and, for a steel mill, it was relatively “safe”.

          Of course, it was a union shop.

          I worked with some guys who I’d attended high school with. Some of us were going back to college in the fall and, for the others, this was the beginning of their working life. As to them, you could see the terror in their eyes, looking forward to 20, 30 or 40 years more of that shop floor. As to us, we got the message, too.

        • Petrocelli says:

          Thanks to you & MadDog for the great insights. I’m going to call in a favor and get a tour of a nearby Steel Plant.

          I’ll definitely make a point of showing extra gratitude to everyone I meet there.

        • MadDog says:

          I can say that the pay was good and, for a steel mill, it was relatively “safe”…

          Ditto on the pay! We made good money for unskilled youngsters.

          As to that relative “safety”, at my steel plant, they had a big scorecard thingie as you walked in the place and I don’t know that we ever made it through an entire “accident-free” week.

          My brother, as a pourer, somehow managed to spill about a teaspoon of molten iron down the back of his steel-toed boots. Got one hell of a nasty burn as you can well imagine.

        • prostratedragon says:

          Actually I think the hottest part was in Purgatorio, where you got most of the last remnants the sin burnt out of you.

          There was always a lot of pride in the family over our steeler (and automaking and -repairing) relatives, a couple of whom remain in shadier parts of Pittsburgh. Next I visit, I must try to get one of those tours.

    • fatster says:

      That is fascinating. And you write so beautifully too, scribe. I’m going to copy it (with all due credit, of course), for it is definitely a keeper. Many thnx.

  6. zak822 says:

    Definitely the Strip District. Bring home sausages from Parma Sausage and get coffee for your hotel room from Prestogeorge! They roast their own, on site. Great deli too.

    I live in Pittsburgh, and catch my bus across the street from the Convention Center hotel, at Tonic (which has a good happy hour–Sam Adams $3).

    I can’t tell you how happy I am that Netroots is in my home town this year! Hope to bump into you; I promise not to gush.

    • scribe says:

      Or just get one sandwich from Primanti’s. You can eat all week off one of those.

      And, EW: there’s plenty of Stiller gear for sale in the Strip District. You can get enough to outfit BMAz head-to-toe for probably 20 or 30 bucks. No problem.

  7. rosalind says:

    ot: “Former U.S. Atty. Debra Yang named to L.A. police commission”

    A prominent attorney has been tapped to join the Los Angeles Board of Police Commissioners, filling out the depleted civilian panel at a pivotal time as it begins the search for a replacement for outgoing Police Chief William J. Bratton.

    and yes, Chief Bratton has been accused of “pulling a Palin”.

    (and praise god, hallelujah! the L.A. Times has done a complete website redesign producing something quite bearable and readable.)

    • bmaz says:

      I can live with Yang on the Commission (easy for me to say, I live in Phoenix). She is qualified to sit as long as the remaining members are diverse. As to Bratton, he was appointed and is 40% through his second term. He implemented his program and the department is on a steady course; he is no Palin. That is a cheap and unearned shot.

    • PJEvans says:

      He’s leaving to run a security company of some kind. Probably easier than trying to run the LAPD, although he’s done pretty well and there aren’t many people who are going to be happy about him leaving (at least they aren’t being happy about it in public).

  8. justiceputnam says:

    But I love the I, steel I-beam
    that my father sold. They poured the pig iron
    into the mold, and it fed out slowly,
    a bending jelly in the bath, and it hardened,
    Bessemer, blister, crucible, alloy, and he
    marketed it, and bought bourbon, and Cream
    of Wheat, its curl of butter right
    in the middle of its forehead, he paid for our dresses
    with his metal sweat, sweet in the morning
    and sour in the evening. I love the I,
    frail between its flitches, its hard ground
    and hard sky, it soars between them
    like the soul that rushes, back and forth,
    between the mother and father. What if they had loved each other,
    how would it have felt to be the strut
    joining the floor and roof of the truss?
    I have seen, on his shirt-cardboard, years
    in her desk, the night they made me, the penciled
    slope of her temperature rising, and on
    the peak of the hill, first soldier to reach
    the crest, the Roman numeral I–
    I, I, I, I,
    girders of identity, head on,
    embedded in the poem. I love the I
    for its premise of existence–our I–when I was
    born, part gelid, I lay with you
    on the cooling table, we were all there, a
    forest of felled iron. The I is a pine,
    resinous, flammable root to crown,
    which throws its cones as far as it can in a fire.

    – Sharon Olds
    “Take the I Out”

  9. Quebecois says:

    Scribe, MadDog, thanks for the stories, potent images.

    Marcy, thanks for the thread, enjoy your time at the Netroots.

  10. readerOfTeaLeaves says:

    Amazing comments on this thread.
    Be careful MD and scribe; if any wingnuts visit, your tales might damage their notions of all libruls as wussy, quiche-eating wimps.

    We wouldn’t want that now, would we?

  11. bobschacht says:

    EW–
    Did they pronounce “Monongahela” as “Mon-gay-la” or maybe even “Mon-gay-lia”?

    Anyway, thanks for taking us into the heart of American industrial power. In some ways, the story of the 20th century was the story of steel. We “won” two world wars in part because we could do steel better than anyone else. So I look forward to your additional commentary on this.

    Bob in HI

  12. PJEvans says:

    One of my great-grandfathers had a glass factory for a while. (They supplied local sash-and-door companies, including one that made revolving doors.) Also hot and messy, but probably not as much as steel.

  13. CTMET says:

    Add me to the list of folks who have worked at a steel mill. I worked at one Bethlehem Steel’s last rolling mills in Lackawanna for my internship in 1985. It is pretty amazing.

    It was also kinda cool that my grandfather worked for Bethlehem Steel at the shipyards in Dundalk,MD during WWII.

  14. Jeff Kaye says:

    That was a beautiful, even poetic vision of a modern hell in a steel plant, scribe. Thanks for the memories.

    Have fun in Steel-town, Marcy. Look how much we still depend upon the Industrial Revolution! Go Steelers!

  15. Sara says:

    Went on a tour of the old Steel plant at Homestead before they tore it down perhaps about 40 years ago. It was even in the 1960’s, very outdated and clearly unlikely to be modernized. Workers had to hand shovel coal into the blast furnace, as well as operate all the overhead equipment. About ten years ago I read a fascinating book on the history of Homestead from the immediate post war “great prosperity” period through the 1980’s downsizing, and ultimate ripping out of the blast furnaces.

    Selected Homestead to tour as a sort of homage to the Homestead strikers done in by the Pinkertons. Also I had a sense of guilt, as I had toured the Krupp Werk in Essen Germany a few years earlier — famous for being located literally on top of the coal mine. Coal came up the shaft, and went into a tipple, and from there directly into the blast furnaces and coke ovens. Of course since the Soviets had claimed and dismantled and hauled away as reperations, the earlier Krupp Werk blast furnaces, what was there in 1960 was a new and very much more modern plant than what I would later see at Homestead. I read that today Essen is all neatly shut down, and the old worker’s housing has become quite the Yuppified community.

    One thing I would love to see in Homestead is the Public Library — one of the first that Andrew Carnagie built, and apparently one of the most elaborate. I think it originally had an olympic sized swimming pool, full gym, and other extras one would normally not find in a public library. The Carnagie Library sentiment is a little too paternalistic for my blood, but the odd duck who originally built the steel industry in the valley did spend most of his substantial fortune on hundreds of libraries, and his Peace Foundation. No Unions — but very fancy Public Libraries.

  16. PJBurke says:

    Pittsburgh. I grew up there in the 1960’s when the late-night pouring of steel lit up the sky with an brilliant orange glow so bright that one could read the paper by it… and the smell of sulphur hung in the air well past daybreak, burning our nostrils as we waited for the school bus. Shortly after graduation from high school in 1976, the year of our nation’s bicentennial, I joined the dispossessed middle-class diaspora… who became the parents, promulgators, and promoters of the now-recognized Steeler Nation phenomena.

    But it was necessary to leave that battlefield in order to gain the wider perspective and learn that Pittsburgh wasn’t the only battleground, perhaps not even the main one, in the long-running war between Capital and Labor… which is really just a subset of the larger war between Big Industry — which is to say Big Money — and ‘We The People.’ Numerous hometowns have been raped, pillaged, plundered, and poisoned — slowly and deliberately — all across this country. And the war rages on today on the healthcare front… Big Money vs. ‘We The People.’

    The callous, deliberate decimation of Pittsburgh by the oligarchs of Big Industry — followed immediately by Reagan’s war on organized labor and the Middle Class generally — is instructive: by their actions we will know them.

    “Them” are profit-predators first, foremost, and always… not citizens of a democratic republic along with numerous, diverse others. They recognize no bonds of civic, contractual, or even moral obligation so there is no negotiated agreement, regulation, or even absolute legal prohibition which can result in anything beyond a mere temporary restraint… a restraint which will last only until a way around it is devised and not one minute longer.

    Bargain with unions? Comply with environmental regulations (etc., etc) ? Sure, sure… but only until we move these plants outta here to the Third World where there are no unions or regulations.

    If you speak to now-elderly middle class folk — quite likely “formerly middle class,” actually — in Pittsburgh, they will blame the unions for for being too greedy, for being too confrontational, and for being corrupt. They will blame government for taxes and regulations, and (again) corruption. But they’ll voice no such blame to the corporations that made the decisions not to modernize — specifically because they’d already decided to relocate the entire industry overseas, while they continued to negotiate labor agreements in bad faith — and they’ll articulate no such criticism of corporate malefactors generally.

    Pittsburgh is a fitting place for progressives to gather… one of the more emblematic “scenes of the crime,” as it were, where many of the witnesses — and victims — still reside… and where the evidence of how a Middle Class can live — did live, once upon a time — still remains.

  17. brendanx says:

    You should have seen Pittsburgh before 1980 when those steel mills still lined both rivers within the city limits of Pittsburgh. They were grim, awesome and beautiful. I believe the population of the city has gone down by half, or even a third, since it’s peak in the last century.

  18. brendanx says:

    I recommend the South Side, which was (obviously) formerly a working-class neighborhood of Eastern Europeans but now has a main strip (Carson St.) of enjoyable bars that have mostly only changed their clientele, from blue collar to college student (I liked Jack’s and Dee’s). The city as a whole is topographically dramatic, but the hills above that neighborhood are particularly interesting, a warren of stairways and alleys overlooking various Catholic and Orthodox churches, the Duquesne brewery and once, alas, those mills.

  19. rapt says:

    This may follow along OK from scribe’s and MadDog’s spill stories.

    I was fascinated years ago by a piece in Saturday Review about a steel plant which had been taken over by a newcomer, Nucor I think is the name of the company; it still exists. It was necessary to pinch pennies in that weakened steel industry. A crane cable suspending one of those story-and-a-half high buckets of molten steel broke, flooding the entire plant floor with white-hot liquid iron. That was the focus of this story. No humans were killed in that incident though as I recall.

    I never saw any followup to learn how or if all that iron was removed after it cooled.

    I too like your story scribe; it created palpable images.

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