I am primarily an archaeometallurgist, specialising in residues (such as slag) rather than metal artefacts. I undertake commercial archaeometallurgy though my consultancy, GeoArch, for a wide range of clients. GeoArch also offers geophysical surveys. My real passion is the investigation of the technology of early iron production and working - and whenever possible I experiment with the technology.

Making Sense of Analytical Data

After the inital excitement of the arrival of new material in the lab, curiosity had to be curbed and the main task of the day tackled. This task was to process and interpret anayltical data acquired last week during many days work on the SEM. I use many different analytical techniques to investigate the more important archaeometallurgical residues passing through the lab – and the analytical SEM is one of the most useful.

BSEM Roman smelting slag

Backscattered electron image of a tapped Roman iron smelting slag. The field of view is 2.5mm.


The backscattered electron images reveal compositional contrasts through their grey scale. In this image the dominant phase, appearing pale grey, is fayalite (an olivine mineral, approximately Fe2SiO4).

Across the centre of the image is a discontinuity, produced by the chilling of the surface of an individual lobe of slag as it flowed from the surface and cooled in the air.

The crystals are large, suggesting the slag cooled slowly, and the lobe margin is not marked by the development of much iron oxide, so this example probably cooled right in the mouth of the furnace.

As well as producing these images, the analytical SEM also permits chemical microanalyses from tiny spots or areas of the sample.

The second backscattered electron image shows a tiny detail of the first image, with the location of microanalyses.

Detail of Roman iron smelting slag

Detail of Roman tapped iron-smelting slag. Field of view is approximately 0.17mm.


The instrument provides the chemical analyses, but they then have to be recast as mineral formulae – and that was today’s task. With many hundreds to do that was a substantial task in front of the spreadsheet. Gradually a picture emerges of the overall composition of the slag and of its constituent minerals.In this instance, the slag proved to be typical of residues produced during the smelting of iron ores from the Forest of Dean. That is a useful result in itself, allowing one aspect of the economy of this Roman settlement to be understood. As other samples from the same site are interpreted further details will emerge – permitting reconstruction of the yield and efficiency of the furnace as well as aspects of the technology itself.

Spreadsheet of chemical data

Processing microanalytical data, to convert the microanalyses into mineral formulae.


Archaeometallurgical residues provide a very direct link back to a particular occasion in the past, when an artisan did a particular job in a particular way. The waste material provides key evidence for that moment in time. Although studying the waste, rather than the product, might seem perverse, there is often a richer set of evidence about hte nature of the process to be gleaned from the residues than from the artefact. Crucially, the residues also typically remain close to the site of the activity, whereas the products were dispersed after production and may not be able to be linked back to their point of origin.

Careful investigation of such archaeometallurgical residues may allow us to come as close as we ever could do to looking over the shoulder of the Roman smith at his work.

Roman tapped iron-smelting slag

Roman tapped iron-smelting slag. The field of view is approximately 2.5mm. The horizontal line across the centre is the chilled margin of an individual flow lobe.

Following the morning’s excitement of a delivery of new material, it is back to the interpretation of a large dataset collected on the SEM last week. Some of the collections of archaeometallurgical residues that get examined require detailed analysis to reveal their secrets. Various techniques are used to analyse for chemical composition, mineralogy and microstructure. One of the most commonly used tools is the analytical scanning electron microscope.  The analytical SEM allows chemical microanalysis from precise locations in a sample.

From this information the analyses can be converted into chemical formulae, allowing the detailed mineralogy can be established. Analysis of regions of slag also allows the overall chemical composition of the slag determined.Processing of the microanalyses is time-consuming

Spreadsheet of chemical data

Processing microanalytical data, to convert the microanalyses into mineral formulae.

In this example, the chemistry of the slag clearly indicates that the smelters were using iron ore from the Forest of Dean. This ore is generally very pure and produces a slag with a rather simple mineralogy. Here, however, the slag has reacted with the ash of the charcoal fuel, levels of calcium and potassium have been increased, and additional phases formed.

Detail of Roman iron smelting slag

Detail of Roman tapped iron-smelting slag. Field of view is approximately 0.17mm. The image shows the minerals wustite (FeO, white), fayalite (Fe2SiO4, pale grey), kirchsteinite (FeCaSiO4, mid grey) and leucite (KAlSi2O6, dark grey).

So, analysis has, in this instance, clarified not only where the ore was mined, but also provided some subtle indicators that may help with understanding the details of the smelting technique employed.

There are, however, lots more numbers to crunch before the full significance of the material can be understood…



What is in the Post?

One of the delights of specialist post-ex work is that you never know quite what the next delivery from the postman or courier will bring. Today’s delivery was of 15 crates of iron-working residue (almost quarter of a tonne!) from a medieval site in Ireland.

A quick look (its a bit like Christmas…!) shows a beautifully-preserved assemblage of slag and large fragments of tuyères (the ceramic ‘nozzle’ carrying the blast from the bellows into the blacksmith’s hearth).


getting ready for excavation

One of the other tasks for today, was providing Cardiff University with final coordinates for the excavation trenches layed-out yesterday. Besides archaeometallurgy I’m also involved in the provision of services, and of teaching, in archaeogeophysics. Over the last 6 years we’ve been surveying the western side of the Roman legionary fortress at Caerleon as both a major piece of research and as a teaching exercise for students from Cardiff University. For the last few years a joint Cardiff/UCL project has been excavating on sites we surveyed inside the fortress but this year the emphasis switches to our new discoveries outside the fortress.

The will be a season of excavation starting next week, involving nine trenches exploring the enormous buildings we have found between the amphitheatre and the river. The university has produced a website and an ebook all about the project and there will be an excavation blog to follow too!

It’s going to be very exciting – but unfortunately, having layed out the trenches I will be away and missing the first fortnight of the action!


Caerleon 2011 excavation trenches

Location of the 2011 excavation trenches (red) on the magnetic survey of the area SW of the legionary fortress. Image copyright GeoArch


Interpreting Ancient Metalworking

The Day of Archaeology is a pretty busy one in the office – not just the usual need to get specimens analysed and reports out of the door, but also with the added urgency of being almost the last day in the office before holidays.

As an archaeometallurgical specialist, I examine assemblages of metalworking residues (mainly slag…) on behalf of field archaeologists, both in academia and in the commercial world. My particular interest is in iron – so although I undertake projects dealing with all sorts of materials, it is with iron that there is the greatest synergy between my commercial work and my research interests. You might have thought we already know all there is to to know about iron making and iron working – but nothing could be further from the truth. This is a dynamic and rapidly advancing branch of archaeometallurgy and experimental work on various techniques is a key aspect of what I do – at least when the opportunity arises.

The reports I’m completing today include two for assemblages from a pair of adjacent Early Medieval sites in central Ireland. Intepreting such material entails bringing together various strands of data:

– there is the overall make-up of the assemblage, the types of slag, their proportions and distribution within the site. Much of that information is produced during the assessment stage of the project.

– there are detailed observations to be made about the form of individual pieces of slag. Often they can be identified to a general process or technology at this stage.

– there are bulk chemical analytical data. I use information generated by XRF (X-Ray Fluoresence Spectrometry) for the major elements and by ICP-MS (Inductively-coupled plasma – mass spectrometry) for the trace elements – thats over 50 elements altogether.

– and there are also the microstructural and microanalytical data that can be obtained by examining polished blocks of material under the SEM (scanning electron microscope). This gives information on the individual minerals within the slag: what they are, how they formed and sometimes what reactions were taking place in the slag before it solidified.

That, then, are the various sorts of data, but the challenge (and the fun) is in the synthesis of that information into an intepretation. That interpretation needs to be both scientifically rigorous and archaeologically useful. It needs to reflect the place of the metalworking activity in the lives, culture and economy of real people. Its not just a case of what was happening, chemically, within a hearth or furnace – but what that means in a human context.

So where is the synthesis of today’s data going? Well, one of the key observations on the material I’m writing up today is that the morphology of the slag tells me it comes from iron working (rather than primary smelting), but it contains a high proportion of material (particularly the elements manganese and barium) that must have been derived from the original smelting of the iron ore. This means that these slags were generated during the refining of the raw iron bloom to produce a useable material.

Slag under the SEM

A manganese- and barium-rich slag under the SEM

One of the great debates in early ironworking studies at the moment is whether such slags were generated during a bloomsmithing operation (thats to say the smith alternately heated the raw iron and forged it with a hammer to drive out the slag impurities) or by a remelting process (in which the smith completely melted the raw iron to allow the escape of the trapped slag). In the past it has been assumed that all bloom refining was by bloom smithing – now it seems remelting may have been much more important than we thought.

It is to debates such as this that experimental work can make a great contribution.

remelting hearth in operation

An experimental approach to studying bloom refining - a bloom remelting experiment run with friends in Virginia

Today’s  report writing was, at one level, supplying data and interpretation to a developer-funded project – and relates to the interpretation of life in 7th century Ireland. At another level it was another piece of the jigsaw in trying to understand a key early technology used in many parts of Europe. It will be a while before that all comes together as a comprehensive understanding of the technique – but when it does, that information can then be fed back again into the understanding of people’s lives 1400 years ago.