Firing The Vindolanda Kiln

On May 31st I, with the help of two of the stalwart Vindolanda volunteers, fired the newly built replica Roman pottery kiln at the Vindolanda Museum: See my earlier post Roman Pottery Kiln and Workshops at Vindolanda.

44 pots of varying sizes were packed tightly into the chamber, tile/amphora sherds (actually roughly made curved slabs of fired clay) were then laid over the pack.  On top of this a very coarse mix of mud, gravel and organic material was spread and finally I plastered a mix of sand and clay over the surface, leaving three exit flues at the back of the kiln, through which hot gasses could escape.

I'd made the decision to attempt a black-burnished ware / greyware firing which involves starving the kiln of oxygen towards the end of the firing causing an intensely reducing atmosphere within the chamber.  This has the combined effect of pushing carbon deep into the pores of the clay and converting iron oxide within the clay body from its red Ferric form to black Ferrous oxide.  In the case of this firing this was achieved by closing down some of the exit flues for the last 200 degrees and, once we had reached the target temperature of 900 degrees, completely sealing the top of the kiln then stoking as much fuel as possible into the firebox and then sealing it closed.

The kiln was lit at 8:30am and we began sealing the kiln at 6pm giving a total firing time of nine and a half hours and an average temperature rise of 95 degrees per hour. Once begun, firing is a continuous process, even being distracted for a few moments can result in a temperature drop. As a 21st Century potter I have the advantage of an thermocouple and pyromenter (High temperature thermometer) my Roman predecessors would have had no such technology at their disposal.  Their temperature measuring techniques would have relied on their senses: in the early stages of firing a potter needs to take things very slowly, ensuring that trapped moisture in the clay doesn't blow his/her pots apart, a hand placed over the exit flue will give an indication of temperature and whether the gasses are moist or not; once the kiln is over 600 degrees C the colour of the pots in the chamber, seen through the exit flues will give the potter all the information they need.

I arrived to open the kiln at noon the following day and upon opening one of the exit flues was surprised to smell smoke, and by the level of heat emanating from the kiln. I realised that the fuel in the firebox had converted to charcoal and that, with the influx of oxygen caused by opening the seal, it was about to reignite.  We therefore opened the firebox and immediately raked out all the accessible fuel which did indeed immediately burst into flame. We then resealed the kiln because the pots were obviously too hot to unpack, unfortunately not having anticipated this turn of events, I had not brought the pyrometer with me and there fore while I knew it was hot, I didn't know how hot!  If fired pots are cooled through the 250 to 200 degrees stage too quickly they can crack, known as "dunting", this is caused by the fact that silica molecules within the clay rearrange themselves at 226 degrees, so it's safest to wait till the kiln is below 200 degrees to open it. After a trip to my workshop to collect the pyrometer, we returned to the kiln at 4pm by which time the temperature was 186 degrees  and the decision was taken to open it.

I think the results speak for themselves, everything was well coloured by the reduction, the variations from pale grey to black being very much in keeping with Roman originals.  If you'd like to own one of the pots from this firing watch the Vindolanda website and my Blog for news, or drop me an email and I'll let you know when they come up for sale.

Visit my website at www.pottedhistory.co.uk

It's been a busy time just recently, to start with I've moved premises, I'm still in Rothbury, Northumberland, and only a few hundred metres away from my old workshop, but with much more space. In addition I now have an assistant, my daughter Sarah Lord, who will not only be expanding the range of replica pottery that we can offer but be bringing her expertise as a costume maker to the business.  Sarah holds a degree in performance costume design from Edinburgh College of Art (ECA) and worked for several years as a costume maker with Scottish Opera. She also has a Post Graduate Certificate of Education (PGCE), and has worked as a Key Stage 3 & 4 (KS 3 & 4) Design Technology Teacher, so is perfectly equipped to deliver school workshops.

Sarah has also been working on our range of retail goods for museum shops, in particular small Neolithic and Bronze Age pots for the Stonehenge Gift Shop.

In the meantime I've been all over the country from Caithness to Wiltshire, from Glasgow to Lincoln delivering workshops and demonstrating, as well as running workshops right here in Rothbury.

I've also been entering the world of Academia by uploading my CBA paper "Mud and Fire" to Academia.edu and having had the honour of being asked by Dr Neil Wilkin to co-present a paper at the European Association of Archaeologists conference in Glasgow.

And last but by no means least, I've been inundated with requests for replicas which I'm now working on, sorry if you've been waiting for yours, it will be with you soon.

 Visit my website at www.pottedhistory.co.uk

Neolithic Carinated Bowl: complex simplicity

At first glance a Neolithic carinated bowl, the earliest type of pottery in Britain, looks like a very simple pot. Certainly they were hand formed often from very coarse natural clay, to function as humble cooking pots. In fact when making an average sized bowl, up to about 20cm in diameter, its form flows almost naturally from the process itself. The curve of the bowl nestles nicely in the hand, the concave form of the upper body conforms to the curve of the thumb, while the fingers stretch down inside to push out the carnation.  All well and good, but when one comes to make a bowl as big as the one I made for Stonehenge, it's a different matter.  For a start there's the weight; at over thirty centimetres in diameter it requires nearly five kilos of coarse clay in its construction. This makes it virtually impossible to hold the soft vessel in one hand.  If I start building on a base (flat stone, grass mat whatever is handy) this gives it a flat base, which can only be expanded out once the clay has stiffened.  Alternatively working into the base of an old broken pot does allow one to make a round bottomed piece but only to a predetermined form and, as clay shrinks on drying it will easily release from its "mould" but will also be considerably smaller than the former.  Once the pot becomes firm enough to support itself it can be picked up and worked on but this brings with it its own problems, the stiffened clay becomes brittle, the least deformation of the rim and the pot will crack, a flaw which, in the firing, could result in total failure.  One possible solution to this is to add organic fibrous material which will act as reinforcement in the unfired pot and one of the most suitable sources of this is animal dung. Finally, once the pot has reached a leather hard stage, the entire inner and outer surfaces need to me slip coated by rubbing with a wet hand and finally burnished all over, again without putting undue stress on the rim.

Firing small pots in an open fire is a relatively simple matter provided a strict set of rules are adhered to, a large pot on the other hand is quite a different matter. That pot needs to be absolutely dry before it comes anywhere near to a flame. In a Neolithic hut it would undoubtedly have spent several days on the outer edges of the hearth, occasionally being turned to present a new face to the warmth of the fire.  Only once the potter was certain that all moisture had left the clay would the firing process begin: The pot would be moved a little closer to the fire, inverted, and with its rim supported on three stones a few embers from the fire would have been pushed underneath its dome, their rising smoke and heat filling the vessel. Replenishing and increasing this small glowing fire over the next couple of hours the potter would have carefully and steadily raised the temperature until, at around about 400 degrees C the organic matter in the clay would have begun to burn, turning the outer surface of the pot dark brown or black.  This would also be an indication that it was ready to move to the next stage of firing, surrounding the pot with embers and eventually immersing the pot into the fire, bringing up its temperature until at seven or eight hundred degrees, in the darkness of the hut interior it could be seen to glow deep red. The firing complete, the fire would have been allowed to burn down and go out and the pot would have been cooled while protecting it from sudden cold draughts that might cause it to crack.

Simple as that!

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Greek Pots for Dr Michael Scott

Having made the replicas used by Dr Michael Scott in his brilliant BBC2 TV series; "Who Were the Greeks", see my blog entry "TV Props, Greek Bronzes Made From Clay" , I was delighted when Dr Scott contacted me and commissioned some replicas to use in his teaching at Warwick University. Now I will say at this point, when Michael contacted me I had anticipated that I'd be making some fairly high status pieces but I wasn't quite prepared for the reference material that he eventually sent me. On a trip to the British Museum he'd taken some photographs of some of the most magnificent Greek pots that he could find: the Douris Cooler, the Berlin Krater, the Phrynos Kylix and the Sharpedon Kylix:

I've replicated Greek red and black figure pottery before but these pieces were the creme de la creme, they were high status when they were first created and they're still high status today. why? Well for the complexity of their manufacture, the refinement of their form and by no means least, the skill of the painter who decorated them. The pots shown here are my, or should I say our replicas not the originals. I made the pots, but my wife Lynda Taylor, a professional artist, decorated them, they required the best! 

The precision with which the pots are made, the perfect alignment of the stem of the kylix and the crispness of the foot, shoulder and rim of the krater, tell me not only that they were made by a highly skilled potter, but that the potters' wheel on which they were thrown was very stable indeed. This was no rough stone disk pivoted on a point of rock, it was a precise piece of machinery with smooth running bearings. The same is true of all of these pots and while the potters making cups and bowls for everyday use may well have made use of primitive wheels these craftsmen had access to the very best tools. They have used that technology to push the making process to new heights, creating forms that say "Look what I can do".

More to come later, watch this space.

Visit my website at www.pottedhistory.co.uk

Potted History Public Events 2012

It's been a hectic summer and I've been all over the country demonstrating ancient pottery techniques, here are some of the main events I attended.

I had a great weekend at  the Bedford, River Festival on 21^st and 22nd July making replicas of ancient Greek Rhytons, Amphorae and Epinetrons. On Friday 3^rd August  I was on the Solway, at Senhouse Roman Fort, Maryport, Cumbria.  Demonstrating Roman pottery making with both the Potter’s Wheel and moulds, including the Senhouse Samian bowl. quite a few children had a go at making their own Samian Ware bowl.

On a very rainy Sunday 5^th August I was at Paxton House, celebrating Paxton "Before the House" with some Prehistoric, Neolithic and Bronze-Age pottery demonstrations.  I showed how the beakers discovered last year at Fishwick had been created, from the making of stone, bone and antler tools through processing the clay to decorating pots. I was joined by Kristian Pedersen the archaeologist leading the excavation, who demonstrated the ancient craft of flintknapping.

From Saturday 11^th to  Monday 19^th August, I worked my way along the middle section of Hadrian's Wall in the guise of Bellicus the itinerant Roman Potter demonstrating how the Romans made many different types of pottery and answering questions on how they used these pots.

Saturday 25^th to Monday 27^th August I was atop the dizzy heights of Dover Castle demonstrating Roman pottery making and giving children the chance to make a Roman Gladiator votive plaque.

Kirknewton Festival, in Northumberland on Saturday 1^st and Sunday 2^nd of September was an absolute joy and here you'd have found me  making and firing Prehistoric Bronze-Age pottery, While Paula Constantine demonstrated ancient spinning, dying and weaving.

On the 22nd & 23rd September I had my first opportunity to work at Beamish Open Air Museum.  In the wonderful surroundings of the Home Farm I made country slipware jugs, bowls and platters in the style of !8th and 19th Century potters.

And continuing the theme of Victorian Pottery on Sunday 30^th of September I’ll be at Preston Hall for their Parkmade Event, where I’ll be demonstrating the skills of a Victorian country slipware potter and even offering you the opportunity to have a go and possibly purchase some of my wares.

Visit my website at www.pottedhistory.co.uk

Roman Pottery Kiln Progress

Installed the Ware chamber floor today and started applying the clay lining.  Unfortunately there won't be any further work on it until Monday at least.

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Roman Sunken Kiln Under Construction

I can't believe that it has been so long since I've recorded my work here, it's been a very busy summer so there's lots of catching up to do, but I'll get to that over the winter.

 

Over the past couple of days I've been building a sunken type Roman kiln for my own use not far from my workshop.  The site was kindly offered by retired potter (I'm not sure that such a thing exists) Alastair Hardie & his wife Kate at Westfield Farm, Thropton Northumberland.  It is situated at the rear of the farm on a raised sand bank about two meters above the flood plain of the Wreigh Burn.  The ground consisted of about 50cm of compacted soil and building rubble, the residue of the concrete floor of an agricultural building which once stood on the site, over natural compacted sand.  This has proved to be an ideal situation, the compacted surface gives strength to the structure while the sand is relatively easy to work and provides a very well drained base for the kiln.

Although I was working alone, the digging of the ware chamber, stoking pit and fire box and the lining of the latter with ceramic brick took less than eight hours.  For the sake of speed I have used some recycled fire brick in the lining of the firebox.  This is the area of the kiln that most archaeologists would refer to as a flue, this is an incorrect use of the term, as the function of a flue is only to carry gasses from one part of a kiln or furnace to another, as in 'exit flue' which as the name suggests carries waste gasses out of the kiln.  The firebox by contrast is where the fuel is burned.  

Today I'll be setting the floor, again for the sake of speed, using modern refractory but I may replace this later for experimental purposes.  I'll report back later today.

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Bronze Age Pots for Perth

Working on some bronze age pots to accompany me on my workshop in Perth, Scotland, Saturday and Sunday 19th & 20th June 2010.  

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Ancient Firing Technology

Most books one reads talk about 'bonfire firing'; fast open firings using large quantities of wood and accepting a quite high percentage of loss. But it's my belief that large open outdoor fires would have been used only for very large pots and even then the fire would have been very carefully controlled. People in subsistence economies do not waste fuel resources or their own labour. Most beakers would have been made in the house while sitting around the fire, they would then have been placed on the perimeter of the hearth and left there for several days, turning them occasionally, until they were absolutely dry. The pot would then be moved closer to the fire to begin preheating. Fine pots like beakers require a relatively slow firing and the best way to start is to invert the pot with its rim on three small stones over a small amount of hot charcoal, replenishing this until the pot reached about 400C; with most natural clays this will be indicated by a visible darkening of the body. At this stage hot charcoal can be built up around the pot and after a further few minutes small kindling added and the pot fired up to red heat, best seen in the darkness of a hut interior.

Come along to one of my workshops and help make the magic happen.


Visit my website at www.pottedhistory.co.uk

TRIAL BY FIRE

With any ceramic piece the firing is always the most risky part of the making process but this is particularly the case with prehistoric, open fired pots.  This weekend has seen me firing a Neolithic bowl, beakers, food vessels, canopic jars and a 17th Century slipware wedding plate although this last item I have to confess is in the electric kiln.  It's needed for a wedding in a week's time and there's no margin for error

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Workshop Nearly Ready

The workshop is ready to go and there are many workshops planned for the future. I don't suppose that a collection lof different types of ancient potters whee like this, , can be seen anywhere else in the country.

ROMAN POTTERY WORKSHOP

In this workshop you will learn to make and decorate pots, just as the Romans did, on both stick and kick wheels. In addition you will have the opportunity to create your own Roman Head pot using a pre prepared pot and you will make your own Roman oil lamp and Goddess figure.

Day 1:

Looking at the Pots: Using replicas and original potsherds we will look at making methods, clay bodies, tools used, firing methods, potential uses, methods of deposition, preservation vs. decomposition, etc

Raw Materials: How to find and prepare your materials. We will look at the types and sources of raw materials and their storage. All participants will prepare their own clay with appropriate inclusions.

Demonstration of the various types of potters' wheel and mould making techniques

Wheel practice working in pairs and with lots of assistance

Day 2:

Making & Decorating: With lots of information, hints, tips, help where needed and encouragement, all participants will have the opportunity to make at least two pots, possibly many more. You can choose from a variety of techniques.

All materials and equipment will be provided. All pots and tools that you make during the workshop are yours to keep. As it is not possible to dry the pots sufficiently to be able to open fire them during the two day course, firing is offered as a separate one day event. This will be an optional third day of the workshop at a later date, at no extra charge, if you can't attend, your pots will be fired for you and can be shipped to you by DHL at cost. Photographs of the firing will be taken. The cost of the workshop includes lunch at the Coach House, delicious home made soup and a roll with a choice of deserts, coffee and home made cakes at break time. If you have any special dietary requirements please inform us in advance.

Accommodation and travel are not included, but a list of local accommodation providers is available on request.

Phone 01669 622890
email ap2010@pottedhistory.co.uk
Visit my website at http://www.pottedhistory.co.uk/

Ancient Pottery Workshops

The first workshop went really well, on the Monday we even managed to fire everything we had made, in the hearth of an Iron-Age Rondhouse, at Brigantium. So on to the next workshops and they are as follows:

Ancient pottery workshops by GRAHAM TAYLOR at the Coach House, Elsdon.

ROMAN SAMIAN WARE
May 15th & 16th.
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ROMAN WHEEL MADE POTTERY –One day workshop
June 22nd.
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PREHISTORIC POTTERY
July 24th & 25th.

MANY OTHER DATES WILL BE AVAILABLE.

GROUPS CAN BOOK ADDITIONAL DATES AND WORKSHOPS CAN BE DESIGNED SPECIFICALLY FOR YOUR REQUIREMENTS, PLEASE CONTACT ME

NO PREVIOUS EXPERIENCE IS REQUIRED FOR ANY OF THESE WORKSHOPS.

The cost of all workshops includes: Rita’s great home made Coach House Lunches, coffee/tea breaks, all materials, and firing of the pots.

These workshops are intended for adults, although some young Advanced Learners may benefit from them, but must be accompanied by a paying adult. Please ask about suitability before booking for a young person. Payment for the workshop can be made by cheque, debit/credit card to secure a booking.

All materials and equipment will be provided. All pots and tools that you make during the workshop are yours to keep. Information sheets will be provided to help you continue potting once you return home.

Accommodation and travel are not included but list of local accommodation providers is available on request. Elsdon is situated in the Northumberland National Park and you will need your own transport as it is virtually impossible to reach it by public transport.

ROMAN WHEEL MADE POTTERY: Learn the ancient skills of the potters’ wheel using an authentic reconstruction of a Roman wheel.

ROMAN SAMIAN WARE: The most prestigious pottery of the Roman era Samian Ware was produced on the wheel and in moulds. This workshop will teach you the techniques of mould making and pot making.

BRONZE-AGE POTTERY WORKSHOP: This workshop will equip participants to; prospect for natural clay and prepare it for pot making; make their own prehistoric tool kit; make and decorate replicas of prehistoric pots and fire them in an authentic manner.

Visit my website at www.pottedhistory.co.uk

Samian at Last

I have finally managed to find the time to fire the batch of Samian Ware that I made over a month ago! Much to the relief of some of my customers!

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Replica Pots for Christmas....what else?

I am guessing that all the people who ordered from me, replica pots for their loved ones, will by now have given them so that I can now reveal a couple of my favourites. Firstly I there's this replica of a Bronze Age food vessel excavated from the Bawearie Cairns at Old Bewick, Northumberland, by Canon William Greenwell in 1866, which I made for one of the Archaeologists involved in the More recent excavations of the same cairns. The original pot is in the British Museum.



Then there is this replica of a Neolithic, Mortlake Bowl made for another Archaeologist:

This one is decorated using a whipped cord tool to produce what are known as "maggot marks". Both have been open fired in a "bonfire" firing just as their archetypes would have been.

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Mediaeval Pottery Kiln at Shotton

A few days ago I was invited to visit the archaeological excavation of a pottery production site at Shotton, to the north of Newcastle upon Tyne. This site is sceduled for surface coal extraction by Banks Development and has been excaveted in advance of this by Tyne and Wear Museums. What they have found is a small medieval settlement with evidence of pottery production including a kiln and clay extraction pits. The whole site is on solid clay a fact that has made the conditions in the trenches less than pleasant. As you can see in this photograph of the kiln mud and ice were the order of the day but they were kind enough to remove the ice and pump out the water so that I could inspect it. These conditions suggest that some of the post holes around the kiln must surely have been supports for a roof, otherwise the kiln would have been inoperable during most of the year.

I have taken clay samples from the site with the intention of firing them under an assortment of different firing conditions so that they can be compared with the potsherds from the excavation.

Prehistoric firing

Last week you'd have found me bent over a small fire in the corner of a Northumbrian field, replicating the firing techniques of the Neolithic in order to complete several commissions before Christmas. I've had several orders this year from the partners of archaeologists wanting replicas of pieces that their loved ones had been instrumental in excavating or that had come from Archaeological site in which they had an interest. So several new beakers, food vessels, Mortlake and Fengate bowls have come into existence thousands of years after the originals upon which they were based.