Experimental IRON SMELTING

Developing a Bog Iron Ore Analog
 

From the beginning of the investigations into Early Medieval bloomery iron smelting by Darrell Markewitz and members of the Dark Ages Re-creation Company, there was a significant problem. The region around the testing site at Wareham, Central Ontario does not have geography that contains any natural iron ores. For this reason alone, this team has likely used more different types and sources of iron ore than almost any other long duration group of experimenters.

Starting in 2008, Robert 'Gus' Gissing had started research into analogs composed primarily of powdered red iron oxide (Fe2O3). This would lead to the team developing what came to be called 'DARC Dirt', both using red (DD1) and black oxides (DD2 - Fe3O4). The basic method is to mix the oxide powder with 10% whole wheat flour, add water to form a paste, then let this dry in the sun before breaking into small pieces. Beyond easy availability (any ceramics supplier) the analog also has physical properties similar to natural bog iron ores, without the problem of sulphur content. A number of variations on this basic recipe have been tested over the years, primarily differing amounts of silica (S) or hammer scale (F) added, for a total of 14 mixes in all. The standard would become the simple and consistent DD1 (red + 10% flour) which has an available elemental iron content at 55%.

Commentaries on Development and Variants
these links are off this web site

February 2008, 'Bog Ore Crush Test', blog posting :
http://warehamforgeblog.blogspot.com/2008/02/bog-ore-crush-test.html
March 2008, 'DARC Dirt One - Draft Notes', blog posting :
http://warehamforgeblog.blogspot.com/2008/03/darc-dirt-one-draft-notes.html
June 2008, 'Error Correction - Ore Analog Composition', blog posting :
http://warehamforgeblog.blogspot.com/2008/06/error-correction-ore-analog-composition.html
May 2009, 'L'Anse aux Meadows Smelt - Ore Analog', blog posting :
http://warehamforgeblog.blogspot.com/2009/05/lanse-aux-meadows-smelt-ore-analog.html
November 2009, 'Finding Primary Bog Ore', blog posting :
http://warehamforgeblog.blogspot.com/2009/11/finding-primary-bog-ore.html
January 2013, 'Blooming is an Art - Ore Particle Size', blog post :
http://warehamforgeblog.blogspot.com/2013/01/blooming-is-art-ore-particle-size.html
June 2017, 'Mixing Bog Ore Analog (DARC Dirt)', blog posting :
http://warehamforgeblog.blogspot.com/2017/06/mixing-bog-ore-analog-darc-dirt.html
July 2019, 'So Damn Wet...Ore Analog Consideration', blog posting :
http://warehamforgeblog.blogspot.com/2019/07/so-damn-wet-ore-analog-consideration.html

Specific Test Smelt Reports
Overview Report / Smelt Sequence / Furnace Layout / Variant
There is often additional information available with the main Smelt Records.

Only those tests using a full amount of a single mixture are included here.
Smelts using primary bog iron ore are included for comparison (in italics)
It should be noted that most of these smelts also involve other test aspects.
Details on the specific proportions of mixtures and their total elemental iron content is found on the Experimental Data tables.

Some of these links will take you off this web site.

#1 - Smelt in Vinland
June - 2001
Written Report
as scanned text
 one / two / three

Furnace
image
Primary Bog Iron Ore
L'Anse aux Meadows
#2 / D1 - Boxed Bowl 'Vinland'
May 25 - 2002
Brief Written Report

Furnace
image
Primary Bog Iron Ore
St Lunaire
#30 - Smeltfest 08
March 15 - 21, 2008
An Overview
draft - taken from Blog
Smelt Two Sequence
experimental data
Front Elevation
field drawing
DD1S
red / flour / silica
#32 / D14 - 'DARC Dirt' - 2nd Test
April 13, 2008
Written Report
draft - taken from blog
Smelt Sequence
experimental data
Front Elevation
field drawing
DD1S
red / flour / silica
#35 - Iron Smelting at Thy
(Heltborg Museum - Denmark)

April 29 - May 4, 2008
Symposium Overview
illustrated report
Smelt Sequence
experimental data
Front Elevation
field drawing
Primary Bog Iron Ores
'Swedish' / Heltborg / Guldager
#36 / D15 - 'DARC Dirt' - 3nd Test
June 14, 2008
Written Report
draft - taken from blog
Smelt Sequence
experimental data
Front Elevation
field drawing
DD1S
red / flour / silica
#40 / D18 - Vinland 1
May 30, 2009
Written Report
short overview
Smelt Sequence
  experimental data
Front Elevation
field drawing
DD2S
black / flour / silica
#42 / D20 - Vinland 3
November 7, 2009
Written Report
detailed overview
Smelt Sequence
experimental data

 
DD2S
black / flour / silica
#43 / D21 - Vinland 4
June 12, 2010
Written Report
detailed overview
Smelt Sequence
experimental data
Front Elevation
field drawing
DD1s
red / flour / silica
#44 / D22 - Vinland 5
August 23 , 2010
Blog Posting
brief report
Smelt Sequence
  experimental data
Front Elevation
field drawing
DD2S
black / flour / silica
D25 - DARC at CanIRON 8
July 28, 2011
Written Report
detailed overview
Smelt Sequence
experimental data
Furnace
image
DD1Fd
red / flour / scale
#51 / D27 - Return to Icelandic
May 26 , 2012
Brief Report
blog posting
Smelt Sequence
experimental data
Layout
Front Elevation
field drawings
DD1Sb
red / flour / silica
#52 - Earth, Air Celtic Demonstration
August 11, 2012
Brief Report
blog posting
Smelt Sequence
experimental data
Front Elevation
field drawing
DD1Fd
red / flour / scale
#53 - International Congress on Medieval Studies - Demonstration
May 11 , 2013
Brief Report
blog posting
Smelt Sequence
experimental data
Front Elevation
scaled drawing
DD1Fe
red / flour / scale
#56 - Turf to Tools
 Prototype Smelt

June 14, 2014
Smelt Overview
blog posting
Smelt Sequence
experimental data
Front Elevation
field drawing
DD1M
red / flour / special mix
#60 / D28 - Icelandic #6 - 'Grass Sod' Furnace
Fall 2014 - Summer 2015
Experiment Overview
blog posting
Furnace Build
blog posting
Front Elevation
field drawing
DD1Fa
red / flour /scale
#61 / D29 - Icelandic #7 - 'Grass Sod' Furnace
October 12, 2015
Detailed Overview
DARC - Neil Peterson
Smelt Sequence
experimental data
Front Elevation
Base Construction
field drawings
DD1Fa
red / flour /scale
#62 - Production Smelt
May 22, 2016

Smelt Sequence
experimental data
Front Elevation
field drawing

#64 - ARTEfakty Smelt One
Proszkow Poland
September 9, 2016
Experiment Overview
blog posting
Smelt Sequence
experimental data
Front Elevation
field drawing
Primary Bog Iron Ores
Harres / Guldager
#65 - ARTEfakty Smelt Two
Proszkow Poland
September 11, 2016
Experiment Overview
blog posting
Smelt Sequence
experimental data
Front Elevation
field drawing
Primary Bog Iron Ores
Harres / Guldager
#70 / D30 - Icelandic #8 - 'Grass Sod'
Schweitzer / Amaranth
October 29, 2016
Experiment Overview
detailed report
Smelt Sequence
experimental data
Furnace Outline
field drawing
Front Elevation
reconstructed
DD1
red / flour
#71 - Norse Bellows Test / Demo
ReARC, Williamsburg VA
November 19, 2016

Smelt Sequence
experimental data
Front Elevation
field drawing
DD1
red / flour
#72 - Norse Iron Course
Wareham
November 30, 2016

Smelt Sequence
experimental data
Front Elevation
field drawing
DD1Fa
red / flour / scale
#73 - Dark Ages Iron Smelting - course
SCA Fruits of Our Labours event
June 21, 2017

Smelt Sequence
experimental data
Front Elevation
field drawing
DD1Fa
red / flour / scale
#74 / D31 - Iron at Vinland
L'Anse aux Meadows NHSC
July 16, 2017
Experiment Overview
blog posting
Smelt Sequence
experimental data
Front Elevation
field drawing
DD1
red / flour
#75 - Celtic Iron Age
Scottish Crannog Centre, Aberfeldy
August 6, 2017
Experiment Overview
blog posting
Smelt Sequence
experimental data
Front Elevations
field drawings
DD1
red / flour
#77 - Iron Smelting in the Viking Age
Wareham
June 30, 2018
Experiment Overview
detailed report
Smelt Sequence
experimental data
Front Elevation
field drawing
DD1Fa
red / flour / scale
#78 - CAMELOT Conference - demo
St Jerome's University, Waterloo
September16, 2018
Experiment Overview
detailed report
Smelt Sequence
experimental data
Front Elevation
field drawing
DD1Fa
red / flour / scale
#82 - Stone Block
System Test

June 2019

Smelt Sequence
experimental data
Front Elevation
field drawing
DD1Fb
red / flour / scale
#83 - Stone Block
Slag Bowl Test
October 2019

Smelt Sequence
experimental data
as above
DD1Fb
red / flour / scale
#84 - Stone Block
November 2019

Smelt Sequence
experimental data
as above DD1Fb
red / flour / scale
#85 / D31- 'Look at the Bones' Test
June 2020
the Build & Smelt
detailed report
Smelt Sequence
experimental data
Furnace Details
field drawing
DD1
red / flour
#88 / D33 - Icelandic Clay Test (P3-A)
June 2021
Brief Overview
blog post
Smelt Sequence
experimental data
Furnace Plan
Furnace Elevation
field drawings
DD1
red / flour
#89 / D34 - Icelandic Clay Repeated (P3-B)
September 2021
Brief Overview
blog post
Smelt Sequence
experimental data
Furnace Repairs Elevation
field drawing
DD1
red / flour
# 90 / D35 -
Wind & Weathering
October 2021
Part One : the Smelt
detailed report
Smelt Sequence
experimental data
Overall Layout
Elevation
field drawings
DD1
red / flour
#94 / D37 - Pulsing Air Test
October 2023
Experimental Outline
detailed report
Smelt Sequence
experimental data
Furnace layout
field drawing
DD1
red / flour
#95 / D38 - Pulsing Air 2 Baron's 7 Demo
June 2024
Experimental Outline
brief report
Smelt Sequence
experimental data
Furnace layout
field drawing
DD1
red / flour
#96 / D39 - Pulsing Air 3
October 2024

Smelt Sequence
experimental data
Furnace layout
field drawing
DD1
red / flour
#98 / D40 - Return to Icelandic (P3-C)
November 2024
Experimental Outline
detailed report
Smelt Sequence
experimental data
Furnace layout
field drawing
DD1
red / flour
 
smelt 2 smelt 2
'20 Years Before the Blast'
Experimental Bloomery Iron Smelting 2001 - 2024

with Neil Peterson

ISBN : 978-1-0691597-5-5
March 2025

This 212 page volume is a survey of 101 iron smelting tests by the author and his working team, presented in a more formal academic style. Includes assessments of furnace builds, air systems, ore types and bloom qualities. There are overviews of four major experimental series; iron smelt in Vinland, Icelandic turf walled furnaces, the Turf to Tools project, and Norse Bellows equipment.
8 1/2 x 11 paperback format, 99 colour colour photographs, 25 illustrations, 48 charts and graphs.
companion to 'Basics of Bloomery Iron Smelting'


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