Belco: (not) a blast from the past in the Pinelands

Acres and acres of pitch pines and other evergreens obscure the remnants of industry that once dotted the Pinelands. Land cleared for pig iron foundries and papermills in the 1800s has now been overtaken by regrowth, rendering the old factories difficult to locate. Other, more accessible abandoned industrial sites like the Estell Manor glassworks are easily visited within Atlantic County parks.

What we didn't realize on our original visit to Estell Manor was that there was a larger and more recently-built and abandoned factory community nearby. In fact, a good part of the park now stands on the grounds of the World War I era munitions manufacturing site and proving grounds known as Belco. Just outside of the former blast range, the companion factory town of Belcoville is still alive and well.

New Jersey's contributions to the war effort began well before the United States entered the conflict in April 1917, with several suppliers manufacturing ammunition for our allies. Once we were formally in the conflict, four additional factories were constructed around the state by various defense contractors, including the Bethlehem Loading Company, or Belco. Under the direction and supervision of the U.S. Army, Belco cleared about 10,000 acres of marshy pine forest along the Great Egg Harbor River to build the factory along with the nearby village of Belcoville to house more than 3000 workers and their families. An adjacent proving ground was to be the largest testing site of its kind in the world.

Storage facilities for loaded shells.
Courtesy Atlantic County Government.

War is a great motivator for rapid construction, and Belco is a case in point. Work on the factory site and village began simultaneously in early 1918, continuing non-stop, seven days a week. A subsidiary of the Bethlehem Steel Company, Belco was the only ordinance contractor to supply shells from mining the iron ore through forging the steel, machining, loading and assembling the final product. The site at Estell Manor was responsible for the loading and finishing stages, requiring both factories and complex safety measures to address the highly explosive elements that employees would handle.

The self-contained plant included everything that would be needed to keep production moving, including a power generator, water works, personnel offices, machine shop, blacksmith and carpentry areas, and storage facilities including reinforced powder magazines. A barracks held 1100 soldiers who guarded the plant against potential sabotage, a threat already felt from explosions at Jersey City's Black Tom Wharf and the Canadian Car and Foundry munitions plant in Kingsland.

Safety was paramount. Plants were built at distances to ensure that a fire or blast in one would not set off a chain reaction. A modern water pump and main system included special valves to ensure that firefighters would have adequate water pressure even if part of the system was damaged by explosion. Much of the plant was constructed of wood to prevent sparking that could set off fires, and escape chutes were built into the second floors of the plants, leading to protective ditches. Changing houses were built for both male and female workers to ensure that employees wouldn't track poisonous TNT residue out of the loading areas.

As a result of these measures, Belco was a reasonably safe place to work, and no fires or blasts of note caused significant worker injury or damage to the plant. No employee ever suffered from TNT poisoning though more than 17,000 such incidents occurred at other plants around the country. Nevertheless, a 100-bed hospital stood ready to address injuries and illness.

By July 1918 the first 155 millimeter shells were being filled and rolling off the assembly lines, even as construction work continued on additional factory buildings. Meanwhile, employees enjoyed the benefits of living in modern housing at nearby Belcoville, with running water and heating as well as community amenities like a school, bowling alley, shopping district and YMCA/YWCA.

Belcoville housing ranged from dorms for single employees
to large homes for supervisors with families.
Courtesy Atlantic County Government.

Just four months later, with about 70 percent of the plant built, the war ended, though Belco continued to turn out munitions for several months afterward. Plant buildings were dismantled and sold for scrap, leaving only the concrete foundations. Many of the newly-vacant worker houses were sold, taken down and moved to other locations in the area, while many employees remained in Belcoville to keep the community going.

Belco is listed on the New Jersey and National registers of Historic Places, and Ivan and I visited some of the roads and ruins recently, guided by an informative booklet available at the Estell Manor Park Nature Center. On a warm, sunny day, the gnats were in full force, accompanying us as we walked the broad main path into the complex.

Had we not already known that a busy manufacturing plant had been there less than 100 years ago, we'd never have been able to tell. Roadways are still evident from the long, reasonably straight breaks between trees, but many of the side streets are little more but wide strips of overgrown grass marked with wooden signs.

The booklet points out the sites of several Belco buildings which are a 10 or 15 minute stroll from the visitor center (depending on whether you stop to look for the stray cuckoo or vireo calling from the trees). We found the footings or a water tank and the machine shop, blacksmith and carpenter shop before the gnats got to be too much for us. There's more along the other paths, but from what I understand, most of it is along the lines of "you need an imagination to see it." No doubt, a late fall, winter or early spring visit might be more productive for those wanting to find more of the ruins.

Still, a hike through Belco is thought provoking. If such a busy industrial site can revert to virtual wilderness so quickly, what potential is there for other highly-developed tracts to be reclaimed by nature? So much of New Jersey has been paved over, some to great benefit and some not. Maybe sprawl isn't irreversible after all, and maybe old industrial sites can, with some effort, host wildlife once again.

Oh, and if our experience is any indication, it's a wonderfully reliable place to find Yellow-billed cuckoos. During our visit, we saw at least four, including a pair perched comfortably beside each other not far into the woods from the trail.

The Jersey Devil and the Pot House: glassmaking at Estellville

Fresh from our find at Weymouth, Ivan and I headed a slight bit eastward on the Black Horse Pike. I'd heard about another ancient Pinelands factory nestled within an Atlantic County park. We were so close by, we had some time before we were expected elsewhere, why not go for it?

The former Estellville glassworks operated from 1825 to 1877 and was reportedly among the first to produce both window glass and bottles. About three and a half miles south of Mays Landing proper, it's now surrounded by an expansive parkland of playgrounds, picnic areas and untouched woods. The factory site itself is about halfway along the circular park road, well marked out with wayside signs. Though the buildings have deteriorated to about the same level of falling-apartness as the site we'd just visited, helpful numbered maps direct visitors to various features of importance in glassmaking.

Like the Weymouth Furnace, the glassworks was made up of several buildings, but in this case, each represented a stage of the manufacturing process. We first went to the pot house where workers made the vessels in which sand, potash and limestone would be mixed and melted to make glass. According to the wayside, replacement pots were needed often, as they'd become damaged by the high heat of the melting process.

Several steps away, a three-room building once held the furnace where the raw glass was made. It was also where glassblowers would shape the molten material into cylinders that would be flattened in another building and eventually cut into windowpanes. Here's the wild thing: the blowers would often strap themselves to the wall as a counterbalance against the 80 pounds or so of molten glass they'd pick up from the vat with their blowpipes. Those who chose not to take the safety step might -- and sometimes did -- find themselves falling into the pit to meet an unfortunate and painful end.  

Between the furnace building and the flattening building, I noticed several small objects glistening in the sun. They turned out to be weathered pieces of glass, possibly from the factory itself, as none of it seemed thick enough to have been broken bottle shards from a more recent visitor.

The park signs and online guide led me to believe that foundations of workers' houses could be found in the far reaches of the tract, so Ivan and I followed a path into the nearby woods. As we walked, I remembered something I'd read in the handy WPA Guide to New Jersey, which only mentioned the glass factory as a side note. The writers were more interested in highlighting Estellville as the birthplace of the Leeds Devil, more commonly known these days as the Jersey Devil.

Before we go much further, I want to make a statement: we here at Hidden NJ try to avoid the usual Jersey legends and apocryphal stories in favor of the more obscure yet plausible. I'm rather proud that we've published for nearly a year and a half without making hay of Mother Leeds' thirteenth child, but when you stumble upon the purported birthplace of the ol' JD, you have to say something. Plus, he's got wings, so I figured I could include him as a birding feature.

I mulled the possibilities as we walked farther down the path than my research had indicated the workers' homes would have been. The path was well maintained and lined in places by flowering bushes, but who knew if we were walking into territory where a cloven-hooved flying beast would rather be to himself? Focused on finding some of the birds whose songs he'd been hearing, Ivan ignored my suggestions that maybe I'd misread the map and we should instead be looking for the buildings elsewhere.

We decided to turn around after we reached a small deck overlooking a creek and pilings that once apparently supported a bridge. Walking back to the glassworks, we did find an elusive flying creature, but it turned out to be a yellow billed cuckoo rather than ol' JD.

Given the park's size and diversity of habitat, we'll likely be headed back to Estellville sometime soon for birding at a more productive time of day. I guess that means we'll also have another chance to check in on the state's scariest and most active citizen, the immortal Mr. Leeds.