​Cement Manufacture, Leading Industry in Southern Ulster. Part 1 of 2.

"Cement Manufacture, Leading Industry in Southern Ulster" by Will Plank. Published August 14, 1969 in Perspective section of "Southern Ulster Pioneer" newspaper.

1875 Ulster County Atlas.

​Cement Manufacture, Leading Industry in Southern Ulster by Will Plank. Perspective, Southern Ulster Pioneer, August 14, 1969, part 1
The construction and development of the Delaware and Hudson canal led to the creation of Southern Ulster's greatest manufacturing industry in the 19th century --- that of the famous Rosendale cement. Considered the best cement manufactured in this country, it was used in the construction of the Brooklyn bridge, the Croton Aqueduct which supplied New York City with water, the dry-dock of the Brooklyn Navy Yard, hundreds of the city's largest buildings, and principal construction projects of the Hudson River Railroad.

During the life of the industry from 1825 to the turn of the century it led all activities on the west side of the Hudson from New Jersey to Albany, employed thousands of men in one way or another. At least a dozen plants for the manufacture of cement were in operation as well as numerous quarries and kilns for burning cement rock. The business attracted capital from New York City, Newark, Long Island and upstate, resulting in heavy investments which paid well as the demand for this favored product increased. The heyday of success in this industry was from 1870 to 1890, after which cheaper cement from Pennsylvania, the west, and Greene and Columbia counties dominated the markets and sent Rosendale black cement into decline. Produced at a greater cost, the local produce was considered superior for construction work and some mills continued to operate for the next twenty years – in fact the industry is still [1969] represented by at least one producer in the area north of Rosendale.

Thousands of local people today (1969) know little or nothing about this industry which contributed so much to the wealth and population of the county, although there are still many physical reminders of the days of its fame. Dozens of quarries and tunnels through the solid rock along Rondout Creek from Kingston to High Falls and the areas on either side, stone construction work covered by brush and weeds and occasional ruined smokestacks of once busy cement-burning kilns attest to the importance of the industry. For many years of the 20th century the yawning cavern mouths of the tunnels were an interesting tourist attraction of this region – mute witnesses of the work of men burrowing under the hillsides following the strata of cement rock which was so valuable. Today (1969) a few of these are in evidence but some of the most important ones have been closed, except for doors which give access to the tunnels which were used for years to four decades ago in the cultivation of mushrooms. The coolness of the long tunnels made them excellent for this purpose, but now the caverns are used for storage of government documents.

Canal construction work led to the discovery of cement-bearing rock in the United States. When the Erie Canal was being built hydraulic cement had to be imported from Europe for stone work under the water, but in 1818, the same type stone was discovered in Chittenango, Madison County. Use of it in making durable cement resulted in more economical construction in the completion of the canal. When the Delaware and Hudson Canal was about to be built to carry Pennsylvania's anthracite coal across Southern Ulster to deep water navigation on the Hudson at Rondout, engineers discovered the same type of cement rock at High Falls. The first was burned at a blacksmith's forge at that village, reduced to powder by pounding and when tested, proved to be of excellent quality. Thus the Ulster County hydraulic cement industry was born, and the product was used in the construction of the 14-year-old locks and bridges which excite the admiration of canal visitors today. In 1826 John Littlejohn contracted to furnish all the cement needed for the construction of the canal. In the spring of that year, he commenced quarrying, burning the grinding the cement-bearing stone and established a kiln near the Sulphur spring below High Falls. The burnt stone was hauled to the Simon DePuy grist mill and ground, thence delivered in tight wagon boxes to the places where it was to be used. When the demand for the product increased other grinding mills were erected and a good business resulted.
The industry was permitted to die after the canal work was completed, but some years later, Judge Lucas Elmendorf, for whom the Lucas Turnpike, existing today (1969) was named, saw a future in commercial manufacture of this high quality cement. He began quarrying and burning cement on land he owned a mile or so west of Rosendale on the canal, and had it crushed at the old Snyder Mill on Rondout Creek. He met with ready demand for his product and soon others followed his example. The Hoffmans began operating a plant at what became later known as Hickory Bush. They were followed by Hugh White who built extensive plants at Whiteport which took his name. He had a big contract for supplying cement for the Croton Aqueduct and had four mills in and about Whiteport.

Watson E. Lawrence may well be considered the father of the cement business, for he not only developed the business through the experimental stages, but later became one of the two principal operators. At Lawrenceville, just west of Rosendale, where his plants and the hamlet providing homes for some of his employees bore his name was one of the largest industrial plants in Ulster County. Remains of his huge kilns and stone buildings may still be seen just south of the highway between Rosendale and High Falls and an examination of the size of the kilns   gives one an idea of the size of the industry. Lawrence took over the business originally started by Lucas Elmendorf. In 1828 he made an agreement with the judge for manufacturing cement and built two kilns and a waterpower mill near Rondout Creek. Here he operated on a small scale for several years filling the limited number of orders that came in for hydraulic cement, learning from experience how to perfect his manufacturing process. Hs first kilns were small and used wood for fuel. The kilns were filled with stone, after which a fire was started at the bottom under an arch which contained the wood and allowed to burn for six days and nights by which time the cement rock was supposed to be well cooked and ready to be ground. Frequently rains and inexperienced burning caused the whole batch to come out as worthless cinders or raw stones. By this slow process of burning a week's output was not more than 25 barrels per kiln.

Other cement manufacturers in the area included the Rosendale Cement Co., one of the earliest firms operating under the guidance of Watson Lawrence, the pioneer in the industry. Another good producer was the Lawrence Cement Co. which retained the name of its founder long after it passed from his control. Although its quarries were located at Hickory Bush, its mill was established at Eddyville, where it had the advantage of tidewater navigation. Among other smaller operators was Martin and Clearwater's cement works located at Rock Locks where, like other larger plants, they operated about 250 days a year.
The Hudson River Cement Works was located on high ground half a mile from Rondout Creek and the canal near Creek Locks, where they operated six kilns burning cement rock near their quarries. The firm had its cement ground at Flatbush, and the stone was conveyed to the canal by a double-track railroad operated by gravity. The loaded cars descending to the canal provided enough impetus to carry the empty back up the grade to the quarries at little expense. Their kilns burned 80 to 90 tons of rock per day.

The Warner Lime and Cement Co. had its quarries and kilns at Hickory Bush. The burned stone was shipped to Troy, N.Y. where it was reduced to cement for northern markets.

The New York Cement Co., owned by Long Island men, had a capacity of 115,000 barrels of cement annually at its plant near LeFevre Falls, later knowns as Rock Lock. One hundred thirty men were employed at its quarries and its seven kilns which were so located as to eliminate a large working force. This firm also took advantage of its location to send its product to its mills and the barreled cement to the canal loading docks by means of a gravity railroad.

Conley and Shaffer had six kilns burning cement rock from their quarries just south of Bloomindale Reformed Church, but were handicapped by being obliged to haul their product to their mills near the mouth of the Greenkill by teams. Their mills were on the site of the old grist mills, of Smedes and DuBois who operated them at the time of the Revolution on the stream which takes its name from the color of its water.

In addition to the cement manufacturing many men were employed and fortunes were made in operating quarries for mills here or elsewhere. Quantities of desirable stone for making hydraulic cement have been found in strata twenty feet thick on both sides of Rondout Creek from south of High Falls to Eddyville. In several cases kilns were operated for burning the stone but no mills for crushing it. Most of the stone, however, was sold by individuals who owned the land and engaged men to work their quarries. Some rough land unsuited for agriculture sold at high prices because of the stone strata in the rocky hillsides. As an example 53 acres of otherwise nearly worthless land sold for $30,000. And "That ain't hay" – not in those post Civil War days!

The largest cement manufacturers, the Newark Lime and Cement Co., was actually located in the Rondout-Wilbur area, rather than the Rosendale district, but because of its importance an article about this industry would be incomplete without mentioning it. During the 1880's this was the largest industrial firm in Kingston and operated 23 kilns for burning stones, as well as mills and other buildings which made it possible to produce1200 barrels of cement daily. The strata of cement rock were worked on both sides of Rondout Creek where rich deposits in the bluffs were so close to shipping facilities by water the finished produce could be produced at minimum cost. The bluffs were honeycombed by caverns, some high up on the hillsides, others at the level of the creek and one level worked was 90 feet below tidewater. Motive power was supplied by three steam engines, one of nearly 300 horse power. A copper shop turned out 300 barrels daily and storage space was provided for 30,000 barrels of cement.

Organized in New Jersey in 1840 the company originally shipped local cement rock to Newark where it was ground.  Ten years later the demand for cement caused the company to operate at the source of supply and when the mills on Rondout Creek began running in 1851 a new era of prosperity began for the firm. For some forty years later this firm led the field in industrial activity.

The Rosendale Cement Works owned and operated by F.O. Norton of New York operated a plant at Keator's Corners where 150 or more employees were kept busy getting out about 150,000 barrels of cement annually. Two quarries were operated, one just in the rear of the mills and other nearly opposite the railroad station, from whence a narrow gauge horse railroad carried the stone to the kilns and mills for grinding. Norton was a big operator and also had well equipped cement mills at High Falls.
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The Bruceville Cement Works was one of the early industries of its type. It was founded by Nathaniel Bruce, who operated it for many years and give his name to the settlement. In 1860, the business was taken over by James H. and Jacob D. Vandemark, who used both steam and waterpower to operate the mills which were near the kilns. At first, the firm bought its rock from other individuals who operated quarries, but later opened an extensive quarry of its own on the old Schoonmaker property.

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