Edison and the Concrete Boom: Mass Housing
Long before Edison ever thought of going into the business of manufacturing cement he had very pronounced opinions of its value for building purposes. During a discussion on ancient buildings, he remarked: "Wood will rot, stone will chip and crumble, bricks disintegrate, but a cement and iron structure is apparently indestructible. Look at some of the old Roman baths. They are as solid as when they were built."
Thomas Edison with the model for his first (never) realized modern concrete building (1).
And as we stand now in awe of the achievements of the Roman Empire and its great architectural wonders, so will people marvel over Edison pioneer work in creating "city factories" and the kickstart he gave the general automated industry with his numerical controlled machines. However before his big triumph Edison, had to endure some quitet some hardship and costly failure the "Audio War" (2) and the "War of the Currents" only the most prominent among them.
Grinding Mountain to Dust
While walking along the sea-shore some may have noticed occasional streaks or patches of bluish-black sand, somewhat like gunpowder in appearance. It is carried up from the bed of the sea and deposited by the waves on the shore to a greater or lesser extent on many beaches. If a magnet be brought near to this "black sand" the particles will be immediately attracted to it, just as iron filings would be in such a case. As a matter of fact, these particles of black sand are grains of finely divided magnetic iron in a very pure state.
Now, if we should take a piece of magnetic iron ore in the form of a rock and grind it to powder the particles of iron could be separated from the ground-up mass by drawing them out with a magnet, just as they could be drawn out of a heap of sea-shore sand. If all the grains of iron were thus separated and put together, or concentrated, they would be called concentrates.
During the last century a great many experimenters besides Edison attempted to perfect various cheap methods of magnetically separating iron ores, but until he took up the work on a large scale no one seems to have realized the real meaning of the tremendous problems involved.
The beginning of this work on the part of Edison was his invention in 1880 of a peculiar form of magnetic separator. It consisted of a suspended V-shaped hopper with an adjustable slit along the pointed end. A long electromagnet was placed, edgewise, a little below the hopper, and a bin with a dividing partition in the center was placed on the floor below.
Crushed ore, or sand, was placed in the hopper. If there was no magnetism this fine material would flow down in a straight line past the magnet and fill the bin on one side of the partition. If, however, the magnet were active the particles of iron would be attracted out of the line of the falling material, but their weight would carry them beyond the magnet and they would fall to the other side of the partition. Thus, the material would be separated, the grains of iron going to one side and the grains of rock or sand to the other side.
This separator, as afterward modified, was the basis of a colossal enterprise conducted by Mr. Edison, as we shall presently relate. But first let us glance at an early experiment on the Atlantic sea-shore in 1881, as mentioned by him. He says:
"Some years ago I heard one day that down at Quogue, Long Island, there were immense deposits of black magnetic sand. This would be very valuable if the iron could be separated from the sand. So I went down to Quogue with one of my assistants and saw there for miles large beds of black sand on the beach in layers from one to six inches thick—hundreds of thousands of tons. My first thought was that it would be a very easy matter to concentrate this, and I found I could sell the stuff at a good price. I put up a small magnetic separating plant, but just as I got it started a tremendous storm came up, and every bit of that black sand went out to sea. During the twenty-eight years that have intervened it has never come back."
In the same year a similar separating plant was put up and worked on the Rhode Island shore by the writer under Mr. Edison's direction. More than one thousand tons of concentrated iron ore of fine quality were separated from sea-shore sand and sold. It was found, however, that it could not be successfully used on account of being so finely divided.
Magnetic separation of ores was allowed to rest for many years after this, so far as Edison was concerned. He was intensely busy on the electric light, electric railway, and other similar problems until 1888, and then undertook the perfecting and manufacturing of his improved phonograph, and other matters. Somewhere about 1890, however, he again took up the subject of ore-separation.
For some years previous to that time the Eastern iron-mills had been suffering because of the scarcity of low-priced high-grade ores. If low-grade ores could be crushed and the iron therein concentrated and sold at a reasonable price the furnaces would be benefited. Edison decided, after serious hours of deliberation, that if these low-grade ores were magnetically separated on a colossal scale at a low cost the furnace-men could be supplied with the much-desired high quality of iron ore at a price which would be practicable.
He appreciated the fact that it was a serious and gigantic problem, but was fully satisfied that he could solve it. He first planned a great magnetic survey of the East, with the object of locating large bodies of magnetic iron ore. This survey was the greatest and most comprehensive of the kind ever made. With a peculiarly sensitive magnetic needle to indicate the presence of magnetic ore in the earth, he sent out men who made a survey of twenty-five miles across country, all the way from lower Canada to North Carolina. Edison says:
"The amount of ore disclosed by this survey was simply fabulous. How much so may be judged from the fact that in the three thousand acres immediately surrounding the mills that I afterward established at Edison, New Jersey, there were over two hundred million tons of low-grade ore. I also secured sixteen thousand acres in which the deposit was proportionately as large. These few acres alone contained sufficient ore to supply the whole United States iron trade, including exports, for seventy years."
Given a mountain of rock containing only one-fifth to one-fourth magnetic iron, the broad problem confronting Edison resolved itself into three distinct parts—first, to tear down the mountain bodily and grind it to powder; second, to extract from this powder the particles of iron mingled in its mass; and third, to accomplish these results at a cost sufficiently low to give the product a commercial value.
From the start Edison realized that in order to carry out this program there would have to be automatic and continuous treatment of the material, and that he would have to make the fullest possible use of natural forces, such as gravity and momentum. The carrying out of these principles and ideas gave rise to some of the most brilliant engineering work that has ever been done by Edison. (...)
Everything was bright and promising, when there came a fatal blow. The discovery of rich Bessemer ore in the Mesaba range of mountains in Minnesota a few years before had been followed by the opening of the mines there about this time. As this rich ore could be sold for three dollars and fifty cents per ton, as against six dollars and fifty cents per ton for Edison's iron, his great enterprise had to be abandoned at the very moment it was succeding.
It was a sad blow to Edison's hopes. He had spent nine years of hard work and about two millions of his own money in the great work that had thus been brought to nought through no fault of his. The project had lain close to his heart and ambition, indeed he had put aside almost all other work and inventions for a while. For five of the nine years he had lived and worked steadily at Edison (the name of the place where the works were located), leaving there only on Saturday night to spend Sunday at his home in Orange, and returning to the plant by an early train on Monday morning. Life at Edison was of the simple kind—work, meals, and a few hours' sleep day by day, but Mr. Edison often says he never felt better than he did during those five years.
After careful investigations and calculations it was decided to close the plant. Mr. W. S. Mallory, his close associate during those years of the concentrating work, said: "...As to the state of Mr. Edison's mind when the final decision was reached to close down, if he was specially disappointed there was nothing in his manner to indicate it, his every thought being for the future."
In this attitude we find a true revelation of one conspicuous trait in Edison. No one ever cried less over spilled milk than he. He had spent a fortune and had devoted nine years of his life to the most intense thought and labor in the creation and development of this vast enterprise. He had made many remarkable inventions and had achieved a very great success, only to see the splendid results swept away in a moment. He did not sit down and bewail his lot, but with true philosophy and greatness of mind applied himself with characteristic energy to new work through which he might be able to open up a more promising future.
Portland Cement
With such convictions, and the vast fund of practical knowledge and experience he had gained in the crushing and handling of enormous masses of finely divided material, it is not surprising that he should have decided to engage in the manufacture of cement. He was fully aware of the fact that he was proposing to "butt into" an old-established industry, in which the principal manufacturers were concerns which had been in business for a long time. He knew there were great problems to be solved, both in manufacturing and selling the cement. These difficulties, however, only made the proposition more inviting to him.
Edison followed his usual course of reading up all the literature on the subject that he could find, and seeking information from all quarters. After thorough study he came to the conclusion that with his improved methods of handling finely crushed material, and with some new inventions and processes he had in mind, he could go into the cement business and succeed in making a finer quality of product. As we shall see later, he "made good ".
This study of the cement proposition took place during the first few months of his experimenting on a new storage battery. In the mean time Mr. Mallory had been busy arranging for the formation of a company with the necessary money to commence and carry on the business. One day he went to the laboratory and told Mr. Edison that everything was ready and that it was now time to engage engineers to lay out the works.
To this Edison replied that he intended to do that himself, and invited Mr. Mallory to go with him to one of the draughting-rooms upstairs. Here Edison placed a sheet of paper on a draughting-table and immediately began to draw out a plan of the proposed works. He continued all day and away into the evening, when he finished; thus completing within twenty-four hours the full lay-out of the entire plant as it was subsequently installed. If the plant were to be rebuilt to-day no vital change would be necessary.
It will be granted that this was a remarkable engineering feat, for Edison was then a new-comer in the cement business. But in that one day's planning everything was considered and provided for, including crushing, mixing, weighing, grinding, drying, screening, sizing, burning, packing, storing, and other processes.
From one end to the other the cement plant is about half a mile long, and through the various buildings there passes, automatically, each day a vast quantity of material under treatment. In practice this results in the production of more than two and a quarter million pounds of finished cement every twenty-four hours. Not only was all this provided for in that one day's designing, but also smaller details, such, for instance, as the carrying of all steam, water and air pipes and electrical conductors in a large subway extending from one end of the plant to the other; also a system by which the ten thousand bearings in the plant are oiled automatically, requiring the services of only two men for the entire work.
Following this general outline plan of the whole plant by Edison himself there came the preparation of the detail plans by his engineers. As the manufacture of cement also involves the breaking and grinding of rocks, the scheme, of course, included using the giant rolls and other crushing, drying, and screening machinery invented by him for the iron-concentrating work, as mentioned in our last chapter.
Although the older cement manufacturers predicted utter failure, they have since recognized the success of Edison's improvements, and it is now being used quite generally in the trade. We cannot enter into all the details of the numerous inventions and improvements that Edison has introduced into his cement plant during the last eight or nine years. It is sufficient to say that by his persistent and energetic labors during that period he has raised his plant from the position of a new-comer to the rank of the fifth largest producer of cement in this country. Edison's achievements have made a deep impression on the cement industry.
Grosvenor Atterbury and Pre Cast Housing
Encouraged by his previous accomplishments Mr. Edision made a bold annoucenemt in in an after-dinner speech 1906 , in front of New York City high society. Concrete homes, he said, would revolutionize American life. They would be fireproof, insect-proof and easy to clean. Everything from shingles to bathtubs to picture frames would be cast of concrete, in a process that would took just a few hours. Extra stories could be added with a simple adjustment of the molding forms. Best of all, the $1,200-dollar houses would be cheap enough for even the poorest slum-dwellers to afford. Edison intends this house for the workingman, and in its design has insisted on its being ornamental as well as substantial.
As he expressed it: "We will give the working man and his family ornamentation in their house. They deserve it, and besides, it costs no more after the pattern is made to give decorative effects than it would to make everything plain. The walls can be pre-tinted in attractive colors and will never need to be repainted as well."
Grosvenor Atterbury and some buildings of Ilium, NY (In OTL Forest Hill Gardens, Queens NY)
Edison conceived the idea of pouring a complete concrete house in a few hours. He made a long series of experiments for producing a free-flowing combination of the necessary materials, and at length found one that satisfied him that his idea was feasible, although experts said it could not be done. His first draft of the plan was to provide two sets of iron molds, one inside the other, with an open space between. These molds would be made in small pieces and set up by being bolted together. When erected, the concrete mixture would be poured, in from the top in a continuous stream until the space between the molds would be filled.
The pouring would be done in about six hours, after which the molds would be left in position about four days in order that the concrete may harden. When the molds woulde be removed there would remain standing an entire house, complete from cellar to roof, with walls, floors, stairways, bath and laundry tubs, all in one solid piece. As it seems natural for most of these visionary projects the early prototypes proved to be disastrous. Instead of simple molds, the houses required nickel-plated iron forms containing more than two thousand parts and weighing nearly half a million pounds. A builder had to buy at least $175,000 in equipment before pouring a single house.
Mr. Edisons bad fortune turned however around when he had a faithful meeting with the architect of his new summer residence, Grosvenor Atterbury. Aside from being an rewon architect of luxurty buildings he was also an urban planner and writer. Atterbury was born in 1869, and his interest in architecture was piqued in 1887 by Sugar Loaf, the country house his parents built in Shinnecock Hills, hard by the emerging swelldom of Southampton. He was about 19 when Stanford White designed the long series of rolling bays, sheltered by a deep shingled roof, and he soon apprenticed with White’s firm, McKim, Mead & White, following that with study in Paris. He set out on his own in 1895. Atterbury quickly developed a country house practice, especially on Long Island.
In 1897, the sugar manufacturer Henry Havemeyer gave the neophyte a dream commission, to lay out an entire waterfront summer community oriented around artificial canals in Islip, N.Y. Town and country houses were the stock in trade for Gilded Age architects, and what sets Atterbury apart from most is his continued interest in housing and other social issues. Atterbury became convinced that creating humane housing was going to cost money, too much money unless building costs themselves were lowered by scientific research. He described his philosophy after finishing his work at the opening cermony of Edison's model city Ilium, New York:
"While any town, whatever its birth and family history, may aspire to set such a high standard of living that it may be called in a general sense -model-, the word is now taking a new and special meaning, following the beginning of organized attempts to apply scientific, aesthetic, and economic principles and methods to the problem of housing civilized humanity. Now, the conditions that have at last brought this about are largely economic.
As in the case of the increase in the cost of living--or the high cost of high living, as it has been aptly put--the high cost of model housing is due not only to higher standards, but to the cumulative profits of production and distribution common to any retail business.
The individual can escape the penalties of the situation only by going without or by combining for collective action, by means of which the profits of the speculator--the middleman in this instance--can be largely eliminated. Such combined action must be, I think, the most distinctive feature of a model town; and therefore its theoretic definition should be based on the essential element of collectivism. Practically stated, this means collective purchase, design, development, and control."
Atterbury had begun experimenting with precast concrete panels for the construction for houses as early as 1904, two years before Edison had annouced his own plans. After discussing his "concrete quagmire", Edision realized that Atterbury provided him the missing piece of the puzzle. He was comissioned to oversee the construction of the Illium Works Factory which would be used to showcase how an entire city could be mass produced much like cars were by the Ford Motor Company.
For this project Atterbury developed and refined his innovative construction method. Each house in Illium was built from approximately 170 standardized precast concrete panels, fabricated off-site and assembled by crane. The system was sophisticated even by modern standards: panels were cast with integral hollow insulation chambers; casting formwork incorporated an internal sleeve, allowing molds to be "broken" before concrete had completely set; and panels were moved to the site in only two operations (formwork to truck and truck to crane). The whole factory was highly automated, uilizing technology like a sophisicated conveyor belt system Mr. Edision had devised for his iron sand mill and concrete factories.
Introducing mass produced housing to the world would have been a more than statifactory end of any great innovators story, but for Mr. Edision it was only the beginning of something even greater.
Notes and Sources
(1) He actually build those type of houses shown on the picture and they were an utter failure.
(2) Mechanical Sound Recording vs. Magnetic Wire Recording
New York Times:
Designing for High and Low.
William H. Meadowcroft:
The Boy's life of Edison.
Suburban Steel:
The Magnificent Failure of the Lustron Corporation, 1945-1951.
Grosvenor Atterbury:
Model Towns in America.