Flowing gently before us, the Saugus River whispers tales of industry and innovation. This is the story of the Saugus River at Saugus Ironworks. It is a place where the power of water shaped the destiny of early America.
The Saugus River stretches thirteen miles. It winds from Lake Quannapowitt to the Atlantic. Here at Saugus, the river’s unique contours allowed colonists to harness its power. They built the Saugus Iron Works.
In the 1640s, visionary Richard Leader recognized the river’s potential. He saw ample water power. The river also provided easy access for transporting raw materials and finished goods. Nearby were the resources needed for iron production: bog iron ore, gabbro for flux, and timber for charcoal.
To power the Iron Works’ machinery, the Saugus River was dammed. This created a large reservoir upstream. A waterway channeled water to a holding pond behind the ironworks. From there, sluiceways directed water to each building. The flowing water turned waterwheels. These waterwheels powered bellows, the trip hammer, and rolling and slitting machinery. Afterward, the water vented back into the river.
The Saugus Iron Works dam wasn’t without problems. Agreements stipulated the water level. It was not to exceed a certain point. But under new management, the dam was heightened. This flooded farmland. A horse even fell through a floating bridge. The ensuing lawsuit forced the ironworks to compensate the farmer.
The dam also stopped anadromous fish. Alewives could no longer swim upstream. Settlers relied on these fish for food and fertilizer. After the iron works closed, locals petitioned for the dam’s removal. When that failed, they took matters into their own hands. Under the cover of darkness, they dismantled the dam. Using a dog as an alert, and a musket for signals, they restored the Saugus River’s natural flow.
Bog iron from nearby marshes fueled the Saugus Iron Works. It was layered with charcoal and gabbro in the blast furnace. Burning charcoal extracted oxygen from the ore. This produced carbon monoxide gas and molten iron. The furnace’s height allowed iron particles to absorb carbon. The addition of carbon lowered the iron’s melting temperature. Liquid iron flowed into sand channels. These channels resembled piglets suckling a sow, hence the term “pig iron”.
Cast iron from the furnace was brittle. It was then refined. Workers reheated the “sow bars”. They burned off excess carbon. Sledgehammers removed slag. Finally, a 500-pound hammer shaped wrought iron bars. Blacksmiths used these bars to make axes. These axes felled trees for charcoal. Thus, the cycle of iron production continued.
The Saugus Iron Works represents early American ingenuity. It was the first integrated iron works in the New World. Though forgotten for years, its restoration reminds us of our industrial past.
So, as the Saugus River continues its journey to the sea, remember its role. The Saugus River powered the beginnings of American industry. It shaped not only iron but also a nation’s destiny.