Roman Pottery Kiln and Workshops at Vindolanda

I'm really excited about this new collaboration with Vindolanda Roman Fort near to Hadrians Wall, the first stage has been to create a reconstruction of a Roman pottery kiln as a permanent feature of the site. Built with the help of a very enthusiastic team of Vindolanda volunteers, the kiln is sited in the valley, beside the burn, near to the museum and visitor centre, so look out for it next time you're there.

This fully functional replica of a Roman up-draft pottery kiln, is based on information gained from the excavation of such kilns at archaeological sites across the North of England. The body of the kiln itself (1) is constructed entirely from a mixture of materials found on site, Clay, Earth and plant matter such as straw. The internal floor and central support, (2) also known as Kiln Furniture are made from specially selected clay which will survive repeated exposure to high temperatures.

While the kiln is cold, dry, raw pots are packed into the Ware Chamber (3) the top of the kiln is closed off with a temporary dome of clay and straw (4), leaving small holes as exit flues. A small fire is then lit in the Fire Box (5) allowing hot gasses and flames to pass through into the combustion chamber (6) then up through the ware chamber. Starting slowly and steadily building up the fire the the pots are brought up to a temperature of between 8000 and 10000 Centigrade.

The first firing took many hours of constant stoking as we not only needed to fire the pots, but to dry out the structure of the kiln itself. Nevertheless we achieved a temperature of between 700 & 800 degrees Centigrade, hot enough to fire the kiln load which included two amphorae.

This type of kiln would have been used by potters working in this region, to manufacture coarse wares such as Black Burnished Ware and Gray Ware cooking pots, indented bakers, plates, bowls, flagons and the like. While fine wares such as Samian Ware, Terra Sigillata and the Aphorae that carried produce around the empire would have been imported from production sites in Gaul and elsewhere in the Roman World.

The latest firing of this kiln is recorded here Firing the Vindolanda Kiln

From now on I will be running regular Roman pottery workshops at Vindolanda where you will be able to learn the techniques and skills that went into making the ceramics of the Roman Empire. Workshops and courses will include: Kiln Building & Firing; Samian Ware; Barbotine Ware; Black Burnished Ware; Lamps & Goddesses; The Potters' Wheel, Roman Head Pots. For more information on these workshops, follow me on Twitter @PottedHistory, visit the Vindolanda website or email me info@pottedhistory.co.uk.

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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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Hebridean Bronze Age Replicas

Just finishing work on a replica Cordoned Urn and Food Vessel for a client.

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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.

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Kiln Floor in Production

You might be forgiven for thinking that it's National Boring Photograph Day but this pic does illustrate the fact that, while we are in the grips of winter here in Rothbury, work on the Roman kilns is going ahead.  These clay bars will form the floor of the firing chamber and will be laid, radiating out from a central support like the spokes of a wheel, allowing the flames to pass up from the firebox and combustion chamber, see Roman Sunken Kiln Under Construction below.

Kiln bars drying in the workshop

  I haven't been back to the Westhills kiln since my last blog on the subject and my work on the York kiln got rained off after three days.  In this time I did however get the sunken part of the kiln dug out and most of the raised chamber wall built and clay lined.  It's actually mixing the clay and soil that takes the time, if I was working on an actual Roman Pottery production site with a high clay content in the soil I would simply add water.  As it is the soil on site is mostly sand and builders rubble so needs careful sorting and clay adding to it.

York kiln - lining the chamber with clay

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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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National Towel Day

I'm not sure that I qualify as a 'Hoopy Frood' but I do always know where my towel is, it's beside my wheel covered in clay.  With respect to the late Douglas Adams.
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