Ne ws l e t t e r D at e V o l ume 1 , I s s ue 1

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ULSTER HAND PUDDLED WROUGHT IRON
For over a century Ulster Hand Puddled \Vrought Iron has retained its place as the
superior metal for installations requiring long life under difficult service conditions. Year
after year the leading railroads of the nation have specified this material for uses where
the worst conditions of shock, vibration, corrosion, and heai are encountered. Today, Ul-
ster Iron is receiving wider application than ever before in industry. Executives and en-
gineers are specifying Ulster Hand Puddled Wrought Iron because they realize that
Ulster's higher initial cost is more than compensated by its lower cost per year of service.
Wrought Iron's traditional reputation for durability was built by Wrought Iron that was
hand puddled, just as Ulster Iron is made today. Where long life in rough service is re-
quired, Ulster Iron is the most economical material that ca11 be used.
WHAT HAND PUDDLED WROUGHT IRON IS
Genuine Hand Puddled Wrought Iron is a ferrous metal consisting of high purity
iron and iron silicate - a glass like slag. The iron and slag are in physical association, as
contrasted to the chemical alloy relationship that generally exists between the constitu-
ents of other metals. The slag i!l distributed throughout the iron in the form of longitu-
dinal fibers. In ULSTER Wrought Iron there are 250,000 or more of these fibers to each
cross-sectional square inch. These fibers give genuine wrought iron a strucLure si milar to
that of hickory wood, and the presence of these fibers in the iron is in a large part respon-
sible for the desirable characteristics of wrought iron.
QUALITIES OF HAND PUDDLED WROUGHT IRON
Resisfonce fo Vibrofion ond Shock:
Hand Puddled Wrought Iron has superior vibration and shock r esisting qualities.
One of the best endorsements of this quality is the fact that most of the major railroads
use t his material for staybolts in their locomotive boilers. Staybolts must not only stand
vibl'ation, but they are under heavy varying stress, exposed to elevated temperatures and
subject to abrasion from cinders in the fire box.
The ability of Hand Puddled Wrought Iron to combat these conditions results from
the physical structure of the material. The tiny slag fibers threaded t hrough the body Of
the high purity iron give the material a sir ucture like a stranded wire cable. This struc-
ture, in conjunction with the fact that absence of carbon prevents crystilizalion, confers
to genuine wrought iron an unusual resistance to fatigue and shock.
Resistance fo Corrosion:
Genuine Wrought Iron's remarkable resistance to corrosion has been proven by end-
less case histories of marine and architectural installations. Below water line installations
of wrought iron made before the Civil War are in good condition today. Grill work of gen-
uine wrought iron made in Revolutionary times has survived the elements down to these
davs and still is sound.
..
.r
Wrought Iron resists corrosion in two ways. First, the number of slag fibers in the
Wroug-ht Iron is so great that they act as a barrier against the progress of corrosion and
force it to spread over the surface of the metal rather than to pit. Thus the corrosion is
confined to a film on the surface of the metal. Secondly, the ability of Wrought Iron to de-
velop a dense, uniform and adherent film effectively protects the underlying metal from
any further corrosion. Because of its resista nee to corrosion, Wrought Iron is often used
in Marine applications and situations where the metal is exposed to the elements.
Resistance to Heat:
Hand Puddled Wrought Iron stands up under hig-h temperatures and does not waste
or burn away under repeated beatings. Ordinary steel begins to melt at 2100F. Wrought
Iron does not begin to melt before 2800F - a difference of 700 degrees.
Wrought Iron's ability to stand up under high temperatures results from its low
carbon content about .02 to .04 per cent.
HOW ULSTER WROUGHT IRON IS MADE
ULSTER Hand Puddled Wrought Iron is a quality product. "Hand-puddling", as the
term implies, is largely a manual operation and requires a large amount of skilled labor,
with a relatively small output per man. This makes the manufacture costly, but it insures
qualities which no other method or process equals. The important advantage of Hand-
puddling over other processes is that it effects a minute and uniform distribution of the
slag fibers throughout the body of the metal. Besides the skilled supervision and the close
control of raw materials that goes into the making of ULSTER Iron, there is an integrity
of workmanship handed down through the years which guarantees quality beyond any
specification's description.
In the manufacture of ULSTER Hand Puddled Wrought Iron a charge of pig iron is
melted in the shallow hearth of a Reverberatory Furnace. Impurities are oxidized while
the metal is molten. This process is stimulated by the addition of iron oxide and the rapid
agitation of the molten metal by the puddler, who rabbles the bath with a long iron hook.
The oxidizing reaction effects an almost complete elimination of the carbon, silicon, phos-
phorous, sulphur and manganese originally present in the pig iron.
Owing to the fact that the melting point of the metal rises with the decreasing con-
tent of impurities, the purification finally reaches the stage where the temperature in the
furnace is not sufficient to keep the metal molten. The metallic iron then assumes a pasty
state immersed in the surrounding slag. The iron is then gathered into balls by the pud-
dler, and these are commonly known as "puddle balls".
The "puddle ball" is then placed in the "squeezer" which squeezes and kneads the
mass of plastic metal and slag, causing t he excess slag to be squeezed out. The mass
emerges from the "squeezer" in the form of a rough, elongated bloom of correct size to be
passed through the bar mill.
, The material emerges f rom the bar mill in the form of rough bars called "puddle
bars".
The puddle bars are then taken to the Finishing Mills where cutting, piling, heating
and rolling of this puddle bar further refines the material and elongates the fiber of the
material.
GRADES OF ULSTER HAND PUDDLED WROUGHT IRON
ULSTER produces three outstanding grades of Wrought Iron :-ULSTER, t;LSTER
ENGINE BOLT, and ULSTER SPECIAL.
Ulster:
ULSTER Grade is produced from puddle bars cut into short lengths and made into
a pile; such piles are commonly known as Slab or Box Piles. The pile is placed in a fur-
nace, heated uniformly throughout to a welding temperature of about 2500F and then
rolled into finished bars. This Grade of iron is in general use, both by Railroads and In-
dustry for bolts, tie rods, sling chains, forgings, etc.
Ulster Engine Bolt:
Additional working of Wrought I ron by cutting, piling, reheating and rolling in-
creases the fineness of the slag fibers and improves its physical properties, the slag dis-
tribution in the metal being of utmost uniformity. ULSTER ENGINE BOLT Wrought
Iron is twice piled and rolled. ULSTER ENGINE BOLT is produced to meet the strictest
requirements and specifications fot locomotive frame bolts, spring bands, etc., and is
recommended for industrial users where a very high quality material is required.
Ulster Special:
ULSTER SPECIAL Wrought Iron is produced to meet ihe high standards necessary
for use in locomotive stay bolts and boiler braces. The railroads of this country have long
recognized the need for such a material and set up rigid tests for Wrought Iron from
which to make staybolts.
ULSTER SPECIAL Wrought Iron has I ong been the standard o excellence or this
purpose. Where highest quality and uniformity is desired, with high resistance to vibra-
tion or shock, ULSTER SPECI AL Wrought Iron should be used.
CHEMICAL PROPERTIES OF ULSTER HAND PUDDLED WROUGHT IRON
(Combined Metal and Slag)
Carbon Low content Approximately 0.04
Manganese
,
0.03
Phosphorous
,
.12
Sulhpur
,
.025
Silicon
,
.15
On Left, etch of
Ulster Special
Iron.
On Right, nick-
bend test of
Ulster Tron.
PHYSICAL PROPERTIES OF ULSTER HAND PUDDLED WROUGHT IRON
Tensile, psi.
Yield point
Elongation
Reduction in Area
47000- 52000
.6 of tensile
in 8 inches
40-48}f
SPECIFICATIONS
ULSTER SPECIAL Iron \viii meet the following speci f:ications:
AAR spec. M305-39; ASTM spec. A84-39; ASME spec. SA84.
ULSTER ENGINE BOLT Iron will meet the folowing specifications :
AAR spec. M302-41; spec. AI89-42.
ULSTER IRON meets the physical and chemical requirements for BOLT
IRON but varies from the specifications somewhat in method of manufacture. In general
ULSTER is offered in sizes of .21fz square inches in cross section or under, but for special
ptuposes is available in larger sizes.
WORKING GENUINE HAND PUDDLED WROUGHT IRON
Forging:
Wrought Iron is easy to forge by any of the common methods. The heat range at
which forging can be done is quite wide, but two extremes should be avoided. At high
heats the slag content of iron becomes liquid and the laminated structure of the iron
may allow the slag to be voided and form cracks. For this r eason it is suggested that
\vhite hot heats be avoided. On the other hand, at a dull red heat a critical temperature is
reached at which point iron becomes "red short" and fractures when worked. For ULSTER
IRON the "red :;hort" range of temperature is narrow and the iron can be bent or other-
wise worked both above and below the critical temperature range. Skilled workmen quick-
ly learn to recognize and avoid this critical temperature and find no trouble selecting t he
proper forging temperature for Wrought Iron.
Threading:
The presence of the silicate fibers in Genuine vVrought Iron is a distinct advantage
in threading operations. In threading, the fibrous structure of the metal produces chips
that crumble and clear the dies rather than ones that form long spirals. This, of course,
promotes the production of clean, sharp threads.
Galvanizing:
As the surface of Wrought I ron is microscopically rougher t ha n other commonly
used metals, hot-dipped metallic coatings or paint v .. ill adhere better and last longer on
Wrought Iron.
Welding:
ULSTER HAND PUDDLED WROUGHT IRON can be welded easily because of ifs
superior welding characteristics by any of the commonly used processes, such as Electric
Resistance Welding; Electric Metallic Arc Welding; Electric Carbon Arc Welding; Forge
Welding; and Gas or Oxy-acetylene Welding.
Sizes:
ULSTER HAND PUDDLED WROUGHT IRO.J BARS (Flats, Rounds, Squares and
Hexagonals) are produced in sizes ranging as follows:
Rounds
Squares
Hexagonals
*Flats
1;2" to 4 ' / ~
1;2" to 4"
%."to 3"
1" X 1,4" to 6" X 4"
* Also in special cases up to 8" x 11/2". Also special shapes and sizes if quantity
of order wartants rolling.
USES OF ULSTER IRON
)
ULSTER Hand Puddled Wrought Iron is being used in all forms and types of prod-
ucts being manufactured by American Industry. It is being used as a major metal material
by the railroads, petroleum industry, chemical industl'y, boiler manufacturing, shipyards,
mines and many others.
Space limitations do not permit the inclusion of a detailed description of all the ser-
vices in which ULSTER Iron is commonly used, but the list below will give an indication
of the more p1ominent ones.
BOILERS
CHAINS
CHEMICAL INDUSTRY
CEMENT INDUSTRY
FOUNDRIES
GLASS INDUSTRY

LOGGING INDUSTRY
MINING
PAPER MILLS
PETROLEUM
QUARRIES
PORT AUTHORITY
RAILROADS
REFRIGERATION
and
ICE MAKING PLANTS
SHIPBUILDING
SEWAGE DISPOSAL
S'TEEL INDUSTRY
Staybolts, boiler braces.
Sling chains.
Spots which must resist attacks by corrosive chemicals.
Rods and bolts.
Stopper rods, stopper rod pins, stirrers, skimmers, sling
chains.
Handles for glass ladles.
Tie rods for wood troughs.
Chains, grates.
Mine car parts and hitchings.
Bands for jordons and beaters, grates.
Sucker rods, heavy machine parts.
Rods, bolts and chains.
Dock fenders, bolts, tie rods.
Locomotive staybolts, engine bolts, spring bands, brake
hangers, spring hangers, passenger and freight car spring
bands and forgings.
Grates, drop forged pipe flanges.
Rivets, fender iron, railings, rudder chains, sling ehains.
Grates, ladders.
Stoppers rods and stopper rod pins, rabbles, sling chains.
New uses are being found every day for ULS'l'ER Hand Puddled Wrought Iron. If
you have a problem concerning its use or application, or desire further detailed informa-
tion, write the ULSTER IRON WORKS, INC., DOVER, NEW JERSEY. We will gladly
furnish this information on request. Our Engineering Department is available at all
times to assist manufacturers and users of Wrought Iron in solving their problems in the
application of ULSTER Hand Puddled Wrought Iron involving corrosion, fatigue, current
design trends and fabrication.
THE ULSTER IRON WORKS

In 1722, Dover was settled and immediately the process of iron production started. Jacksons
Forge was established by John Jackson and located a short distance west of the Dover Iron Works
at Park Heights Avenue near Hurd Park.

In 1745, Joseph Shotwell, the son-in-law of Jackson started the Quaker Iron Works along the Rocka-
way River in what is now downtown Dover. Here Shotwell dammed the river creating the Mill Pond
and processed iron until 1757 when Joseph Beaman took over the operations. Around 1792, Isreal
Canfield and Jacob Losey bought the plant and set up a major forge, nail factory, rolling mills and
slitting mills. The Dover Rolling Mill was a profitable operation until the economic slump following
the War of 1812. Being deeply in debt to New York bankers Henry McFarlan and Joseph Blackwell,
Canfield and Losey abandoned the operations in 1817. McFarlan and Blackwell took over and re-
named the company to the Dover Iron Works and produced much of the equipment and tools need-
ed to dig and construct the Morris Canal. During this time, Dover grew from a small hamlet into a
large village (incorporated in 1827) and eventually to a large industrial town by 1869.

In 1869, following the Civil War, the plant closed because business was very slow. In 1880, Judge
Francis S. Lathrop reopened the plant under the name of the Dover Iron Company and repaired the
buildings, made improvements and revived Dovers economic slump. In 1884, the Ulster Iron Works
of Saugerties, New York moved their operations to the Dover plant to be near the canal and rail-
roads. In 1903, they purchased the plant and renamed it the Ulster Iron Works of Dover. In 1923,
ground was broken for a new $100,000 factory, including a building for drilling hollow staybolts for
trains and a warehouse for box making, packing and shipping. At its peak, the Ulster Iron Works
employed 450 men. Ulster sold the works to J.A. Williams in 1935 and by 1950, the plant shut down
for lack of business. In 1951, the main buildings of the works were torn down and the land cleared
for the eventual construction of the Dover Shopping Center. For over 200 years, the Iron Works of
Dover served the nation with some of the finest Iron products and materials ever produced bearing
the tag Made in Dover.

Iron ore production and the workings of iron were the major support of the settlers of Dover area
from the very beginning. It is estimated that the Dover area had a total iron production of 26 million
long tons up through the year 1950, worth $100 million. In a historical sketch published by the Free-
holders of Morris County in 1937, it was stated that the stores of iron in Northern N.J., chiefly Morris
County, were sufficient to provide all the iron the nation could use in 350 years. Since the iron ore
mined and worked in the Dover area was among the first in America and for many years, this made
an early and significant contribution to the industrial development of our country and to our indus-
trial independence from England prior to and during the Revolutionary War.