Experimental IRON SMELTING

How did the Norse during the Viking Age make iron blooms from bog ore?
Experimental Archaeology can give insight into the techniques used in Northern Europe to operate direct reduction iron smelting furnaces.

How to build and operate Bloomery Iron Smelting Furnaces

Formally Published Articles
'But If You Don't Get Any IRON...'
Towards an Effective Method for Small Iron Smelting Furnaces.

Published on in the EXARC Journal : issue 2012/1 
Available as a PDF
bloom
Standardized Reporting of
Experimental Iron Smelting
- a modest (?) proposal


This article was sparked by discussions leading up to the orginally scheduled 2020 Woodford Furnace Festival (Ireland). Completed as a 'semi - academic' format, it was submitted and published in the EXARC Journal : issue 2021/1
Available as a PDF
measures
Stacking Up
On constructing clay furnace walls


This report is a consideration of what has been learned from the construction of a large number of clay mixture furnaces over the last two decades.
This includes some observations that relate back to the continuing experimental series based on the Viking Age furnaces excavated at Hals, Iceland. : Prepared August 2021

Continue to : Stacking Up
stacking

Smelting with Sven & Yorgi

A 'thought experiment'


How would the process of smelting iron be described - in the Viking Age?

Download Sven & Yorgi (PDF)
Viking Smelt

Guides on how to build simple test bed and teaching equipment
 - made from easily available materials :

the Econo Norse Smelter
Developed by the DARC smelt team - using standard fire brick packed with sand

Go on to Econo Norse
Download Econo-Norse Handout (PDF)

Econo
                      Norse

the Flue Tyle Smelter
Developed by Lee Sauder & Skip Williams - using a ceramic chimney liner

Go on to Flue Tyle
Download Flue Tyle Handout (PDF)

Flue Tyle

the Norse Short Shaft
A handout developed for courses - historic clay cobb furnace.
(based on 'If you don't get any iron...')

Download Short Shaft Handout (PDF)

Short Shaft
the Aristotle Remelting Furnace
A handout on building and running this table top sized furnace, which can be used to modify the carbon of any scrap iron metals,

Download Aristotle Furnace Handout (PDF)
Building the Furnace
(blog post / photo essay)
aristotle

45 Gallon Drum Charcoal
Developed by Lee Sauder & Skip Williams - a simple method described
Go on to http://iron.wlu.edu/reports/CharcoalBarrel.htm



hammered out bits
Is my BLOG - on it you will find a regular series of short postings on various aspects of Experimental Iron Smelting


smelt smelt
Basics of Bloomery Iron Smelting

ISBN : 978-1-0691597-2-4 
January 2025

This 201 page book outlines the history and functioning methods learned from two decades using small scale smelting furnaces. Topics include ores, furnace builds, air systems, tools, record keeping, and the final bloom to bar. Includes operating instructions for three different furances, everything you need to understand the theory and practice of bloomery iron smelting. With 115 illustrations and colour images (8.5 x 11", colour)
companion to '20 Years Before the Blast'
Introduction to Smelting Iron

This HANDS ON course is dependant on registrations

This roughly 20 hour session will involve the student in the construction and operation of the 'Short Shaft' iron smelter. On Friday evening students will cover the theoretical and historical background of smelting iron: ores, furnaces, process, equipment. Saturday students will build the furnace itself, plus prepare charcoal and ore. An early start for a LONG day Sunday will start with the pre-heating the furnace. The actual process of the smelt takes roughly 6 - 8 hours. After this, the resulting iron bloom will be extracted from the furnace, and given a primary consolidation. The iron produced will be cut to sections and shared between the participants. This program does not require any previous metalworking experience, and is of interest to students of history as well as blacksmiths.

For more details on this special program - go Smelting Course .
charcoal

Unless otherwise indicated :
All text and photographs © Darrell Markewitz, the Wareham Forge.