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The mill operation was enormous during its heyday 1908 to 1922. It ran two 11-hour shifts six days per week, cutting 125,000 board feet of lumber each shift, an impressive 1.5 million feet of lumber per week. The Cass mill also had drying kilns using 11 miles of steam pipe to dry 360,000 board feet of lumber on each run.
The adjoining planing mill was three stories high, measuring 96 by 224 feet. Massive elevators carried up to 5,000 feet of lumber to the separate floors and machines. Some of the flooring machines were so big that it took 15 men to operate them. There were two resaws here that could accommmodate boards up to 35 feet long. The large surfacing machines finished all four sides of a board in one operation.
Roy Clarkson, in Tumult on the Mountain, estimated that in 40 years the Cass mill and the mill at Spruce turned more than 2-14 billion feet of timber into pulp or lumber. The town of Cass was named for Joseph K Cass (left picture), Chairman of the Board of W.Va. Pulp & Paper Co. Each morning the C&O dispatched a 44-car pulpwood train for the paper mill at Covington. At its peak, West Virginia Pulp and Paper employed between 2,500 and 3,000 men. In an average week six to 10 carloads of food and supplies traveled over the railroad to 12 logging camps. Indeed, the ruined mill is a symbol and a reminder of a past resplendent with human achievement. But the story of the mill is also a story of the rails that linked that mill with the timber in the nearby mountains. At the turn of the century lumbermen eyeing the large tracts of virgin timber on Cheat Mountain, west of Cass, decided to route the timber east through a mountain gap and down the steep grade to the planned mill. An interchange between the Greenbrier and Elk River Railroad at Cass and the C&O was most economical but it called for the building of a difficult mountain railroad. In 1900 Samuel Slaymaker, a timber broker, set up a construction camp at the mouth of Leatherbark Creek (the present site of the Cass shops). He and his hardy men pushed the rails up and along Leatherbark Creek, and gained altitude by constructing two switchbacks. Tracks were laid around the face of the promontory -- up and up along the ridge, winding until at last the rails reached the gap between the mountains. Here a camp named Old Spruce was established.
Around 1904, 1-1/4 miles of track were laid from Old Spruce to Spruce, a new town on the Shavers Fork on the Cheat River. At 3,853 feet, Spruce became the highest town in the eastern United States. From Spruce, the track eventually ran 35 miles south into the Elk River Basin to the town of Bergoo and 65 miles north, along Shavers Fork of Cheat River. Spruce became the hub of the rail empire. The main lines (Cass to Spruce, Spruce to Bergoo and Spruce to Cheat Junction) were 82 miles long. During the 1920s there were many miles of branches in use at once, but the total length was probably about 140 miles at maximum. Altogether the logging railroad built about 250 miles of track. At Spruce a large pulp peeling rossing mill was constructed. Billions of board feet of logs passed through Spruce and eventually went over the mountain behind the tanks of big 4 ton Shays like Number 12.
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