Remnants of the Once Mighty Hudson Valley Brick Industry

I’m pretty sure any home excavation in the Hudson Valley will reveal old bricks. We have found about 5 or 6 different bricks each with the makers’ name. They are rather attractive and we will keep them, I will include some photos, but first a bit of history. By the way, most of this is new to me and I find it fascinating, I hope you do too.

At the turn of the 20th century, the Hudson Valley was the brickmaking capital of the world, producing more than a billion bricks a year and employing nearly 10,000 people in more than 120 brickyards. By the late 1970s, the once-mighty molded-brick industry was no more. How and why did this industry become so mighty in the Hudson Valley and why the decline?

I have found what I think to be the major reason for the Hudson Valley brick boom, they are:

  • The raw materials. The raw materials for clay are found in abundance in Hudson Valley. During the last Ice Age in the Hudson Valley area, blankets of ice weighing millions of tons crushed the rocks of many of the mountains into a deposit of flour-textured, rich blue clay. This came to rest in the bays and coves of the newly carved Hudson River. In 1928, test borings made in the Hudson off the old Cofferdam in southern Haverstraw, drilled 100 feet deep and still did not drill through the clay. The Hudson valley clay deposits were known to be the most extensive in America.

  • James Wood’s revolutionary practice. In 1829 James Wood introduced a revolutionary practice into the production of Hudson River bricks. In that year Wood patented the use of crushed coal as a new ingredient in the brick clay mixture. This innovation had the result of reducing the brick firing time as well as fuel consumption by half.

  • Easy access to coal. The Rondout Creek in Kingston is part of the Delaware & Hudson Canal which was the main route for anthracite coal from the Carbondale coalfields in Pennsylvania. As mentioned above coal was an important ingredient to the clay recipe as well fueling the kilns.

  • The great fire of New York city. New York city’s demand for brick skyrocketed after a night watchman noticed smoke coming out of a dry-goods store in the city’s business district on December 16, 1835. Although 56 engines and 1,000 firemen fought the blaze for 16 hours, the Great Fire of 1835 burned more than 52 acres, destroying 674 buildings and driving 14 of the City’s 25 fire insurance companies into insolvency. It was the largest, most costly fire America had ever seen.

    Lawmakers unwilling to risk another such tragedy passed a series of building codes requiring fireproofing. Although marble, brownstone, cut stone and brick all played major roles in New York construction after wood dwellings were outlawed, brick was the least expensive. It became the most frequent choice of architects and builders. As the City’s population increased, the demand for brick also rose. Hudson Valley brickmakers rushed to heed the contractors’ calls, and the local brickyards prospered.

And then the decline (from the hudsonvalleyone.com).

New materials, new standards.

The good times for Hudson Valley brickmakers came to an end around the advent of World War I. New construction material such as steel and concrete began to cut into the brick market. The market price of brick hovered slightly higher than the cost of production. To combat the slump, the brickmakers modernized their plants, cutting down on their labour needs. Only technologically progressive plants with new marketing strategies survived. By the end of World War II, only ten brick plants were left in the Hudson Valley.

Attempts by the industry to hold on ultimately failed. By the 1940s, new transportation options meant that New Yorkers could live in the suburbs and still work in the City. The suburban single-family dwellings they built weren’t subject to the City’s stringent fire codes, and brick was no longer required.

The Hudson Valley brick industry lost its transportation edge, too, and designers and architects became more precise when ordering building materials. The high compression standards handed down from the American Society for Testing Materials – unnecessarily high, local brickmakers insisted – were generally beyond the reach of Hudson Valley molded brick. That was the final blow.

Ponckhockie housed a lot or the European migrant workers for the Hutton Brickyard which is half a mile away. If you visit the nearby beaches they are littered with bricks.

Below are some of the bricks which we dug up in the garden. The history of all these local brickworks can be found at brickcollecting.com. Sorry, I can’t give you links to direct links for each brick, still, it’s a very useful and informative site.

Travelling in and around Kingston there are many relics from both the brick and the cement works. I hope some of these can be preserved, I know I have my eye on a beautiful chimney stack on the Rondout which desperately needs some TLC. So if there is anyone out there with more money than sense, come talk to me.

These facts were cobbled together from these far more informative data sources:

HV1
Never Sink Museum
Wikipedia
brickcollecting.com

Hidden Mason Marks

After I had removed all the concrete from the path there was left a lovely thick slab of blue stone which we would obviously repurpose somehow, possibly a step or part of a path. You can see this stone sticking up, two-thirds along the path towards the end of the “Jack hammer” video.

This evening I started work on removing some of the tree stumps we have in the garden and towards the end of the evening, as I was walking up the back path, I saw something on the above mentioned slab which looked like something carved. I knelt down and it was indeed a stone masons mark of some sort and after I cleared some plants away I noticed another one.

What these marks are for I have no idea, in the UK you often see mason marks to depict boundaries but they also seem to have other uses including religious. Maybe it was as simple as “this way up” or the masons initials? Seeing as this stone was an isolated stone amongst concrete I suspect that this stone has been recycled from another building or structure.

I do like these marks and as we have a stone mason friend, Paulo, I may ask him to teach me how to make similar.

Our friend Derrick thinks that this may be a horse carriage steeping stone which would help occupants disembark with style and grace.

If anyone has any information on these marking, please post a comment.

What a jack hammer

Yesterday we demolished a lot more of the concrete block walls. It poured down most of the day but cleared up round about 5pm so we went down and worked till dark. I didn’t bother filming it, but it was quite hard work swinging the hammer and filling up the skip.

Today was better weather so I tried out our new jack hammer, the best $145 I have ever spent, apart from the round on Jasons stag night but that’s another story. If I had to do todays work with sledge hammers and chisels it would have taken me four times as long. The jack hammer took a little time to setup as the instructions were in poor English with lots of warning about things being fatal! Anyway sorted it out, just had to get the oil level correct. Pretty easy to use and not too noisy, only effort involved clearing away the lumps of concrete. Drill itself weights about 35lbs and once you have it going you just have to keep it vertical which is pretty easy.

In case you are wondering how these time lapse relate to real-time. The camera takes a picture every 10 seconds. The software I use then combines them together at a frame rate of 20 – 30 per seconds (depending on how many days I am recording over). Anyway this relates to roughly 15 – 25 seconds of time lapse to one hour real-time.

Next job will be to remove the concrete steps. We want at least once entrance which is ADA accessible, so no steps.

If I look a little bedraggled at the end, well that’s because I am. I was pleased with the cooling breeze today and on the second time lapse don’t the trees look like they are dancing with the sound track?

Today I offer you:

Mystery of the stairs

I know we are biased but isn’t the balcony and front entrance beautiful? In the earlier pictures from public record office the balustrade extends the full width of the balcony. So how do you get up there? If you look closely at the public record photographs you’ll see the stairs coming up from the left. We took this for granted until Derrick (friend and advisor) mentioned that he thought it was an odd location for the stairs. To get to the front stairs you have to go all the way around to the left. Does this seem the most sensible position? Notice also the room on the far left has a door opening out onto the balcony which partially opens over the stairwell. This seems poor design and a little unsafe.

Derrick had suggested that we should have the stairs coming out and down from the center, for which we do have a few options. A center stairs would enhance the front view and at the same time give us more balcony space (no more stairwell). We liked this idea but I think I was struggling with keeping the house as original as possible. Last weekend Derrick stumbled on something which has changed my view point completely.

Look at the first picture below and you will see two green squares (I added the color in Photoshop) which seem to line up with the vertical supports above. Why on such a beautiful balcony would this front boarding be interrupted by two small squares? Well Derrick and I also now think that these were very likely all that remains of a front staircase. This staircase would have been exposed to the full elements and as this house is about 150 years old, you can easily imagine them deteriorating over the years to a point where they were completely removed and replaced with the steps to the left. The points at which they were originally attached were patched up with two small squares of wood.

This is another reason why we are very keen on finding early pictures of our house. There must be pictures out there somewhere and we just need to find them.

We do have Dave from Bolder Architecture working on the house so we will mention this.

By the way the lower vertical pillars are newer and don’t match up with what’s above. These will be replaced one day as will the ugly lower front door.

Demolition hammer

There are quite a few large concrete blocks and steps that I’d like removed. I could have rented a top quality tool from the local DIY place or, for the price of a day and a half rental I could buy something cheap.

Seeing as I’m a pretty slow worker (note how much time I am sitting down) I bought this Jack hammer. I have no idea whether this is any good. Funnily enough I got an extended guarantee and it was cheaper to get 4 years ($7) rather than 3 years (maybe $10). The “extremo python blaster jack hammer, like a fine wine it matures with age. Probably…”.

Like they are trying to make it attractive for all genders to use 🙁

Clearing up the back area (chortle, chortle)

This involved the removal of the rotten timbers of the rear deck, clearing away mucky soil and starting to remove the concrete block walls. I was hoping to find a Roman mosaic under everything, but alas no.

I did find quite a lot of old blue stone so we’ll use that for paths or garden walls in the future. The concrete blocks are a bit of a pain especially near the house as you can’t get a good swing of the 15 pounder, which might be a blessing in disguise as it’s hard work.

I know these videos aren’t very exciting but they give us something to look back on. All I have to do is set the camera up and forget about it, no need to go and grab a camera at key moments etc. By the way the cameras I use have a battery life of a few hours so to keep them running all day I have to use an ethernet cable (Power over Ethernet/POE) to provide the power. You will see the ribbon ethernet cable in quite a few shots. I have been using this product, there maybe better solutions but this works and I haven’t the time and energy to find an alternative. For these days jobs I should use a USB power pack, but for longer recordings POE will be handy.

The last ten seconds were filmed on Wednesday evening. We have had the skip for almost two weeks (which is really nice of Tom & Kingston Roll Offs), so I was trying to fill it up. It was taking too long to break up the concrete walls so I decided instead to remove the concrete block wall at the rear left of the garden, hence why you see me all over the place.

I’m using royalty free music so you have the choice of:

or

Giovanna visits the Public Records Office

Our friend and advisor Giovanna went to Kingston Public Record Department and requested the property record cards for our house. The cards are quite small so the photographs are probably 2″ square, hence why the quality isn’t that great when enlarged. That said it’s great to see the house looking finer in earlier years. Thank you Giovanna.

By 1994 the house is looking a little sad and it’s pretty much been downhill from there 🙁 I feel we are still going downhill but Aimee and I have our heels down and dug in [spfx: sparks flying] and are trying to decelerate the decline.

The date of the photograph with all the sun shades is unknown, the 1956 and 1994 property cards all have a list of owners and dates, so maybe this card is a precursor.

Update 5-28-18 I was talking to the Mama Dot who is the lady who lives opposite. Mama Dot has been living in the same house for 60 odd years and she remembers the house when it has sun shades, which is around 1958.

The sun shades in the undated photograph were probably installed to keep the rooms cool and it would be interesting to know how well they worked. I like this simple approach that people had before electrical AC took over. Maybe we can try something similar.

We are appealing for any photographs people may have of this house. One of next projects is an enquiring letter to all people with the surname of Gill listed in our local public property tax roll.

Skip Four Joy – the Movie

Literally and the fourth skip to be filled!!! I rather like these skip/dumpster movies, even if they are a little disjointed. It’s like the worker bees going about their duties. We also like the cars that suddenly vanish and the moving shadow that the house casts.

The first thing that goes into the skip is our last piles of garden waste, poison ivy, and all (for now). If it looks like we are putting small sticks into the skip, then we are, those are the last of the hundreds of sapling trees we dug up. Next to go in was the rear stairs etc, followed by our rear patio excavation and lastly wall demolition.

Filling up these skips is a pretty good work out, digging, lifting, pushing, arms, legs, back, up and down steps etc. It’s nice in the evening just to feel that nice fatigue sleep slowly envelope you.

The skips/dumpsters are from Kingston Roll Offs, I have no complaints and the Tom the owner seems a great chap and always manages to maneuver the skip onto our drive way. Thanks Tom and thanks to the Major of Ponckhockie, Barry who introduced us.

By the way the two guys in white shirts that appear on the street at around 30 seconds are not having a boxing match as some viewers have suggested.

Another snake

Found another snake today, this time when I was digging up the old deck. It was underground and under a stone. If it was still in hibernation, it’s not now, but it wasn’t a bad day to wake up. Lucky I didn’t cut it in half with the shovel. It was a cute little snake about the size of a pencil with a beautiful orange underside. If you look closely you can see an orange ring around the neck, hence the name ringneck. We let it go in a safe pile of leaves away from where we were working.

You can see from these photos that the soil is full of debris and junk, hence why we were clearing off the top six inches.

More info about the ringneck can be found on Wiki.

Clearing up back path and deck

The back deck was gross and the first picture in the gallery pretty much shows how we found it, at least a foot of junk in some places (old plaster boards, kitchen units, roofing materials just rotting and compressing over the years).

The deck is now gone and will never be replaced with a deck. I see a deck as a cheap alternative to a beautiful stone patio which will always look great and never rot (note, I do see how a deck can make perfect sense when you want to get some height or on a slope etc.). Also, this deck was built directly onto bare earth so no wonder it rotted. If they had lifted it up a few inches, supported by concrete blocks, it probably would have been still okay today.

This area is rich with bluestone and as we know a good stone mason, we will eventually be making stone patios. This will be while off until we have the time, money and more importantly how we want the garden laid out. As it is we need to fill the skip and this is good fill 🙂

We are hoping to grade the garden such that the rear windows in the basement have as much light coming in as possible. It won’t be a lot but we can improve on what we currently have.

Going also are the finely crafted cement block walls, skillfully laided by Bodge Builders and Sons. In the UK these people are referred to as “Cowboys”. No disrespect meant to ranch Cowboys.

[UK informal] someone who is not honest, careful, or skilful in their trade or business, or someone who ignores rules that most people obey and is therefore not considered to be responsible:

Those builders are a bunch of cowboys – they made a terrible job of our extension.

I have a 3lb Estwing pound hammer and a Stanely concrete chisel which does take a long time, but you get there in the end. Oh yes, always wear safety glasses when doing this sort of work. I do also have a proper 10lb sledgehammer if needed and today arrived a 30mm x 1.5m monster of a crowbar. In the last picture in the gallery, you’ll see a huge concrete block. I want somehow to get this into the dumpster. It doesn’t look big but I doubt Aimee and I could lift it.

By the way, the walls are really at that angle.