Athy's Wallboard factory

One of my earliest memories is of walking with my older brothers to the huge fire which broke out at the Wallboard factory in April 1949. I was a month short of my seventh birthday when like so many other Athy folk we all gathered on the roadside at Barrowford to watch ricks of straw on fire. The Athy Fire Station master made the following entry in the station records; ‘I received a call to fire at Wallboard Factory on 14th April 1949. All members of the Brigade were present. When we arrived we discovered three ricks of straw on fire. We remained working until Saturday 16th May. The Curragh and Carlow Brigades were also there.’ A later entry for the month of May listed as fire members R. Webster, P. Delahunt, Thomas Fleming, Jas Fleming, J. Webster, P. Cowman and P. Doyle who attended a fire at Mrs. Quinn’s house in St. John’s Lane. The Wallboard Mills were located on a 17 acre site approximately one mile north of Athy. Irish Wallboard Co. Ltd. had been formed in 1939 to manufacture hardboard from straw but did not commence production until 1949. Two years later it began to use native timber as the basic raw material for the manufacture of the oil tempered hardboard which was marketed under the trade name ‘Lignatex’. The Irish company had become closely associated with the Bowater organisation in 1950. The timber used in the manufacturing process consisted of forest thinning, while steam power was generated by machine won turf supplied by Bord na Mona. Over 12,000 tons of turf was used each year while 3 or 4 weeks turf supply was always kept in reserve. A major expansion programme in 1957 increased the mill’s production capacity by almost 60% and a further expansion scheme, completed in 1966, trebled the capacity of the Wallboard factory in the space of fifteen years. A report in the Nationalist and Leinster Times of 15th January 1949 noted that while equipment installation work in the new factory was nearing completion two local men, Pat Doyle and Ed Hicks, spent some days at Clondalkin Paper Mills studying the working of the various machines in preparation for their duties at Athy’s new factory. I am uncertain as to whether the factory was in production when the fire started on 14th April 1949. Despite that early setback, with the use of timber rather than straw, and the expansion programmes initiated in 1957 the factory was able to produce 60 million square feet of board annually. Two thirds of the factory output was exported. A press report of the 1960s outlined the steps taken at the Wallboard factory to ensure the production of a high-quality product. The factory laboratory where samples from every part of the production process were tested was managed by Jim Flanagan, assisted by John Murphy, Terry Doyle and many others. Three quality controllers were constantly sampling during every stage of the manufacturing process. This was a responsibility of Pat Daly, John Murphy and Michael Ahern, while Kevin McNulty kept an eye on the quality of the turf and the finished board. In the chemical mixing department Arthur Kavanagh was employed in the preparation of approximately ten tons of aluminium sulphate solution each week. Another laboratory man was George Robinson who assisted the chief chemist Jim Flanagan in research and development. The first manager of the Wallboard factory was Richard Shackleton, while the initial production managers employed were Swedish, the fifth production manager was Andy Coughlan whom I understand was a former RAF flight engineer. With many other local factories the Wallboard staff participated in the annual parochial variety festivals which were initiated by the local curate, Fr. Joe Corbett. In 1964 the Wallboard Variety Show was reported in the local press as ‘a pleasant and colourful presentation which won loud applause from the audience.’ The performers included Ena, Joan and Frances Coughlan, Connie Stafford, M. Dooley, P. Dunleavy, N. Wright, M. Holohan, K. McNulty, T. Dooley, S. Fanning, P.J. Loughman, Tim Ryan, M. Rainsford, F. Ryan, S. Finnerty, B. Finnerty and B. Robinson. The laughter, songs and work stopped in December 1978 when the Wallboard factory closed down. Approximately 220 workers were made redundant when production of wallboard transferred to Sweden where it is today still carried on. When corresponding with my good friend Liam Kenny, doyen of Kildare local historians, I invariably refer to Athy as being in the deep south of the county. For a change this Eye comes from the deep south of the island of Ireland to where I have travelled to greet my latest grandchild, Hannah Rose, born just a few days ago in Cork city. Hannah was the name of her maternal great grandmother who was born and reared in Doneraile, Co. Cork. The circle has now been completed.