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Astley Mill Forge Puddling Furnace

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Astley Mill Forge Puddling Furnace © comarkworcester.co.uk Date: 10th November 2017 Author and Editor: CAW Publications Contributors: Terry Chandler, S. Crump (Surveyor), Rollo Gillespie, F. Llewellyn (Researcher and report sections), F. D. Sproat, Tina Virr CAD Drawings: Rod Sproat Bphil. MIED. Illustrations and Colour. Rollo Gillespie. Project reference: Astley Forge Mill. Trench 9. WHAS reference: WSM 41736 Location: SO 806 668 52degs. 17’58.30” N, 2degs. 17’20.44” W ASTLEY MILL FORGE PUDDLING FURNACE 1 Contents Summary............................................................................................. Page 4 Report.................................................................................................. Page 4 • Background.... • Aims • Methods • Conservation • Personnel Excavation... ASTLEY MILL FURNACE ..................................... Page 6 Puddling area Floor 1. General introduction to to trench area .............................,...... Page 7 2. Excavation, overview, definitions, Methods .............................. Page 8 West section/Flooring.......................................................................... Page 10 1. Objects 2. West area brick work in zones, East section ..................................................................................... ..... Page 12 1. Objects 2. Brickwork description., Conclusion. Rising Brickwork ................................................................................. Page 13 1. Construction. in General 2. Slag pan 3. Chimney 4. Western Edge 5. Firebox 6. Ash Layer 7. Metal Object. South Boundary Wall.................................................................... ..... Page 20 Description. Closure of site and conservation.......................................................... Page 20 Metal finds............................................................................................... Page 21 Documentary Evidence for Iron Working at the Forge/Mill Site... Page 25 Historical Weather reports .................................................................. Page 30 Final Demise........................................................................................... Page 33 2 Geology...................................................................................................... Page 35 Confirmed date when still used for Grinding Porcelain materials........ Page 36 Description of the Grinding works........................................................... Page 38 Plans, Photos.............................................................................................. Page 39 Appendices ............................................................................................... Page 51 Iron works References................................................................................Page 51 1. Trench description 2. Appendix 2 ........................................................................................ Page 52 Brick Table and joined site plan Plans form a different publication in association with this report. A3 SITE PLANS. PUDDLING.pdf 3 Summary An excavation was undertaken at Astley Forge Mill, Astley, Worcestershire (NGR SO 806 668) in April to September 2009. Outline of results. Identification of structure. The complete lower brick courses, furnace slag pan, chimney base and fire pit was uncovered. This was resting on the factory floor. Evidence of construction phases were identified. Research gives possible dates of use. Report. This report is not intended to be an authoritative discourse on various iron working methods. Methods are discussed for general guidance. The idea is to place the furnace into a wider industrial landscape. 1. Background A community archaeology group had been aware of the presence of industrial workings associated with Andrew Yarranton along Dick Brook. Yarranton was a canal builder and industrial entrepreneur who was probably a century before his time with his thinking and achievements. Regardless of his impressive history he had supposedly set up an iron smelting furnace at Astley ( WSM 41736 ) A community archaeology group were invited by the owners, Chris and Jo Evans, to undertake an investigation of the site as a whole. Trench 9 forms part of the wider project and is published as a separate report due to its importance in the history of the area. The project conforms to the Standard and guidance for archaeological field evaluation (IfA 2008) The event reference for this project, given by the HER is 41736 2. Aims The aims of the project were to uncover and record the structure and to attempt to assess its position in the site history. 3. Methods The primary method used was with hand trowel and bucket. In parts of the excavation distal to the structure, wheel barrow and shovel was used. Brickwork was carefully cleaned with hand brushes. Initially the structure was unknown and the trench only exposed the West end . The trench was then extended in stages. Over the years the site had become regularly flooded and so this resulted in the accumulations of silt. The silt was not regarded as important. However at floor level some samples were retained for the possibility of finding hammer scale from processes associated with the furnace should funding become available at a later stage. Magnetic sorting produced a negative result. It is likely that flood events had washed any traces of particles away. Years of post industrial use and demolition have also played a considerable part in removal of evidence No structure was removed or disturbed. Site plans were drawn at a scale of 1:50. Context sheets were completed if needed. A full digital photographic record was made. 4 4. Conservation Methodology for preservation of this unique site was discussed with WAS, and their recommendations were followed as far as possible. A community archaeology group were indebted to the generosity of the landowners Chris and Jo Evans who donated the Terram Rootguard that was used to cover the key areas of the site when backfilled. It was felt that the silt had already proved itself to be an excellent preservation material. Prior to excavation soil cover had been minimal over the slag pan so this was substantially deepened. At the same time, due to the closeness of the brook to the structure, heavy block work was emplaced along the bank in the hope this would restrict further lateral erosion. Site monitoring is carried out on an occasional basis. 5. Personnel F. D. Sproat(CAD/excavator), Rollo Gillespie,(Geologist/ excavator) S. Crump (Surveyor), Terry Chandler (Site director/excavator/ recording). F. Llewellyn (Researcher/excavator), David Parker (Deceased/excavator). Tina Virr (Recording /excavator), Diana Huston (Drawing), Photography. Members of a community archaeology group. 5 Astley Mill Furnace Introduction. The presence of a Puddling furnace had been mentioned in papers regarding the mill site over 50 years or so. This will be covered in the historical review and submitted by other authors. In spite of this very little was known about the location and the discovery of it was almost accidental. Really it began with the finding of the bolster chisel and crumbling brickwork at the West end. A wider look at the immediate area revealed a solid lump of slag poking above ground in part and even where covered, this was minimal and supported some small plants and mosses and little else. With the proximity to the brook this area becomes the part most affected by flooding. The sediment load of a channel is dependant on the speed of current and hence the transport energy. This reduces when water flows over the land surface and often results in the formation of levees. Here though the site is subjected to erosion and deposition resulting in stasis and continued recycling of the top layers. There is very little in the way of binding agents like roots due to the thin sandy soil cover and very little moisture in dry periods for plants to take hold. Even more so the West end is subjected to full force of the current in the channel and the erosive period had begun and could only result in the whole furnace collapsing into the brook. The excavation then was essential and the post excavation work done should ensure protection for a considerable period longer. The term “Rising Brickwork”(RB) describes all that is above floor level and includes the slag pan. Reverbatory Furnaces were the main way to convert cast iron/pig iron which was the main output of 17th Century Iron Technology into wrought iron. Wrought Iron is the material used by Blacksmiths and is what can be heated, hammered and bent at will. The idea was not new and it had existed since medieval times, and pre-dating the process, had been carried out in open hearths. The approaching Industrial Revolution caused a rapid increase in demand and spurred a continual review of the Iron Production Processes and a greater scientific understanding of the chemistry underpinning it. The Iron Mines of the Forest of Dean were in full production at this time and fortunes were being made there. Riverside docks such as Lydney, Blakeney, Westbury were enjoying an upsurge also supported later on by the deep coal mines and the technical advances in machines and pumps that would keep the water out. That is not to say that there was any improvement in the working conditions of the miners. Elsewhere similar demands were being fulfilled in the West Midlands and the Industrial Towns of the North. The details of the history of metal working at Astley Forge Mill will probably remain hazy. It is not known when
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