Saggar Works at Caughley 1
Saggar Works at Caughley 1
by
Christopher Robinson
JANUARY 2003
Contents
Contents 2
List of Figures 3
Summary 4
Introduction 4
Aims 4
Historical Background 4
Geology 5
Topography 5
Archaeology 6
Methodology 6
Location of the Saggar works by measurement survey 6
Geophysics. 6
The East field 6
The West field 7
Field collection 7
Summary of other evidence. 7
Results 8
Geophysics Survey in the East Field. 8
Geophysics survey in the west field 9
Discussion 10
Location of the saggar works 11
Discussion of field collection 11
Conclusion 13
Figures 14
Bibliography 19
Previous surveys 19
Ironbridge 19
Edmundson 2002 19
Acknowledgements 20
Appendices 21
Finds Catalogue 21
Field collection BRO 02 zone 1 21
Field collection BRO 02 zone 2 21
Field collection BRO 02 zone 3 22
Bricks 23
Geophysics Technical Information 24
Site Visits 31
Site visit to the hamlet of Darley 1/06/2002 31
Site visit to Darley 22/07/2002 31
Site visit to Darley 5/08/2002 32
A successful re-evaluation of the location of the saggar works associated with the
Salopian China Works. The Geophysical surveys concur with previous studies but
provide good evidence for the position and type of kilns used. This study will provide
the basis for a programme of excavation subject to permission from Lady Forester
and the local tenants.
Introduction
Aim
The aim was to produce a study of an early Saggar works. To prove its location,
discover the type of kilns, and the extent of the works.
Historical Background
A pottery existed at Caughley as early as 1754. Ambrose Gallimore, who had taken
leases from the Caughley estate owned by Edward Browne, ran it. This pottery is
thought to have manufactured functional wares, but there is no evidence to support
this.
The Caughley Porcelain Manufactory was built between 1772 and 1775. Gallimore
and Thomas Turner were co – proprietors of the Caughley Manufactory, although
Turner would later become "sole master". Turner was apprenticed to his Father as a
writing master and is known to have dealt in Worcester porcelain. He adapted the
works for the manufacture of soft paste porcelain.
The site was well supplied with coal and fireclay. The River Severn was close by and
easy access was gained for Soapstone to be brought from Cornwall. Leases were
owned in Cornwall at Gewgraze and later at Predannack Wollas. The local clays
were used for the production of saggars, which were an essential part of Porcelain
manufacture.
A saggar was a Fireclay container that protected the delicate porcelain from the direct
heat and smoke of the kiln.
Geology
The Lower Coal Measures outcrop from east to west across the investigation area.
The strata dips down towards the north. Ganey coal outcrops across the southern
boundary of the quarry currently being worked. The sequence of coals and clays is as
follows: Ganey, Clunch, Two foots, Best and Randles, Clod and finally Little Flint.
The Little Flint Coal has been exploited, the 2002 win of clay revealed a gallery or
tunnel during excavation. The Caughley mine was worked in the pillar and stall
method, with working sites as low as 45cm in parts of the revealed gallery. Siliceous
sandstone known as YFM (Yellow Firing Material) forms lenses between the
sequences of strata. Dense Little Flint rock outcrops at the surface near the eastern
boundary of the investigation area, due to uplifting known as the Symon fault. The
clays are all usable and were probably exploited for brick and tile as well as for
Saggar production.
Topography
The study site is in the Parish of Barrow, near Broseley, Shropshire. The site is
bounded to the south by a small tributary of the River Severn known as the Dean
Brook and to the north and west by the Parkhill quarry. The western boundary
consists of a poor field of grass and scrub, known locally as the "pig run".
There is dense coniferation in the East and some ancient woodland beyond.
The study area falls steeply to the south towards the brook. In this area lies the
deserted hamlet of Darley. There is one derelict cottage called the "Honeypot" and
several ruined outbuildings. At the site designated the western gate (figure 8.), there
are several house platforms.
Methodology
Two maps were used, Thomas Bryan's tenancy survey of 1780 (figure10), showed
the location of the saggar works and some dwellings in the ruined hamlet of Darley.
The second map was a 1:2500 scale OS map of the site in 2000, which showed
current field boundaries, and also the position of some of the dwellings. Since field
boundaries on the two maps could not be correlated, it was decided to visit the site to
establish some accurate measurements. Measurements were made on the ground
from the western gateway E368760 N299610 to the Honeypot E368870 N299500
(125m), and also to a collection of two buildings at the top of the elevation E368890
N299670 (143m). The same points were then measured on the 1780 map and the
2000 map. This gave a ratio for the scales of the two maps of 0.38 so the scale for
the 1780 map is 1:6580. Using this scale, the saggar works was found to be 486
metres from the western gate. Transferring this distance to the 2000 map, and
aligning with the positions of the dwellings, placed the saggar works at the eastern
end of the West field. This is marked as point A in figure 8, which is redrawn from
an aerial photograph.
Geophysics.
Preliminary discussions centred on an aerial photograph of 1996 that was taken prior
to excavations at that time. The area known as the East field in the original document
appeared to show angular crop marks. Excavation of clays in this area was proposed
in July 2002 and in view of the crop marks it was decided that an area across this
field would have a geophysical survey carried out
Geophysics in the west field centred on the measurement survey, and the Ironbridge
document, which both locate the site of the works at the eastern end of the west field.
Field Collection
Three areas were selected for surface collection. These are identified as Zones 1,2,3
and are shown on figure 9.
Survey by Edmundson (2001). This survey related bricks found in a trial excavation
to features on the ground. Although there is now no trace of the excavation, the
original measurements were transferred to a modern map. This location is shown as
point B in figure 8.
The Gradiometry survey (figure 2), shows little of any significance except for an
anomaly in grid 8, which could be investigated further by excavation of a small test
trench.
Figure 6 is an interpretation of the Resistivity plot in the West field. There are three
main focus areas, which all have similar dimensions, and are circled in white. The
lower area with concentric circles is in agreement for a kiln building with the map
evidence of 1780. The central area of high resistance would also be consistent with
this map. The hot spot on the Gradiometry, which is significantly above the general
background noise, is in exactly the same position (Fig.5). This may indicate an area,
which has been heated and may be the location of the kiln. This area is also the
location of in situ radial brickwork (Edmundson 2001).
The main feature is the alignment of R.Edmundson's radial brickwork with a
complete circular anomaly in the projected position from the landscape survey
conducted on 22/7/2002. There are other anomalies shown which are of extreme
interest. Concentric rings of high resistance show a feature of approximately 5.00 m
diameter, which is similar to the kiln size at the Coalport site.
The upper circle is also similar in size, possible a third kiln or drying area. The white
arrows indicate two areas of sandstone outcrop.
Using direct measurement of the distances between the dwellings, a scale for the
1780 map was obtained, the position of the saggar works was estimated to be at the
eastern end of the West field.
It was also possible to superimpose the old map over the aerial photograph. By
suitable rotation, resizing and scale (Figure 11), it was possible to place the Western
gate and the saggar works in position. The overlay also shows that a small section of
the original field boundary is in alignment at the top of the gully running from Darley
meadow. There is good agreement between the map and aerial for other features such
as the river and buildings.
The pottery collections made from zone 2 and 3 are mainly connected with domestic
activity. There are some fragments of Salopian blue and white. It would be hard to
believe that these wares did not get into everyday use given the proximity of the
manufactory. Wasters would have also been spread over the soils to improve the
quality and drainage given the amount of clays outcropping locally at the surface.
There are however, 3 fragments of earthenware, which appear to have been made
from the local clays. This could keep open the option of a former pottery on the site.
It is more likely that the former pottery existed on the site of the Salopian works and
that the saggar works was purpose built to service the needs of Turners' Porcelain
kilns.
This study has suggested the location of a feature with the dimensions o f a
contemporary kiln, in the area known as the West field. The map evidence from 1780
suggests that two kiln like structures were in use. The 2002 geophysics and radial
brickwork (Edmundson 2001) support one with clarity. The possibility of another
kiln area is expected however the exact location by geophysics is hampered by the
spread of debris that confuses definition.
The location of the works was known from the 1988 survey and has been
substantiated by the new study. Evidence from the two reports supports the need to
take the investigation to its next phase.
Excavation is required to define the location and type of kiln. This would lead to full
protection by scheduling on the Sites and Monuments Record.
A composite showing the Resistivity surveys in the east and west fields
superimposed on an aerial photograph of the area is shown in Figure 1,3. The
Resistivity surveys are detailed in figures 12,14 and 15 and the Gradiometry survey
in figures 13 and 16, all to be found in the Appendix.
KEY:
TREES
IRONBRIDGE INSTITUE
GEOPHYSICS SURVEY
Dean's BROOK
A SAGGAR WORKS
B SAGGAR WORKS
X WESTERN GATE
SCALE metres
KEY:
TREES
IRONBRIDGE INSTITUTE
GEOPHYSICS SURVEY
Dean's BROOK
A SAGGAR WORKS
B SAGGAR WORKS
X WESTERN GATE
SCALE metres
LOCATION OF FINDS
Z1 ZONE1
Z3
Z2 ZONE2 Z2 Z1
Z3 ZONE3
Clark, Mcleod. 1988 The Saggar works, Caughley: "An Archaeological Evaluation."
Ironbridge Institute Research Paper No 31. Ironbridge Gorge
Museum,
Muggeridge, A.J. 1997 Twelve mines in Broseley. Gazetteer "Known mines in Broseley".
Published A.J.Muggeridge .
Previous surveys
Ironbridge 1988
Edmundson 2002
Thank you to Lady Forester who gave written consent for these investigations to take
place.
To Philip Morris who helped gave permission to access his tenancy about Darley.
Thanks to Robin Morris for his in-depth local knowledge of the site.
Roger Edmundson
Ibstock
Parkhill Estates
Caughley Society
Catherine McLeod et al (Ironbridge Institute)
WAG Team
Annie Saunders
Martin Holland
Chris Robinson
Jan Holland
Sandra Vint
Emma Hughes
Carole Griffiths
Finds Catalogue
One of the questions to be answered is whether or not this works served other
purposes before switching to saggar production.
There is a hypothesis that an earthenware pottery preceded saggar production but as
yet no firm evidence exists.
The up draught kilns which are presumed to have existed, supported by Bryans
Tenants map of 1780, could have been used in brick production to satisfy local
demand as it arose. (New Porcelain works?). This theory is supported by close
inspection of bricks used in ruined buildings nearby E369125 N299625 and various
samples found in field survey area zone 1, near the saggar works area.
The fabric of clay used in these bricks has a very coarse body. It consists of two clays
that have been poorly prepared with many inclusions. The clay outcropping in the
adjacent working quarry, at near surface level, are red marl and ganey buff clay,
which is overlain with glacial Till.
The Till or boulder clay is formed as the glacier retreats. It grinds, mixes and finally
deposits top surfaces of the underlying soils. The layer has glacial erratics included,
which have been carried many miles and are consequently worn smooth by the action
of the ice. These small pebbles are present in the brick fabric.
This layer, being near the surface, may have been dug and used in early brick
production at Caughley.
The usual method for firing bricks would have been to build a clamp. This type of
kiln was widely used and was a semi – permanent structure in which bricks were
carefully stacked and spaced. The whole was covered with turf. There were fire
channels formed under the bricks to allow hot gases to be pulled through the clamp
and burn the bricks. A fire was lit at one end and coal fed into a firebox. An opening
at the opposite end of the clamp draws heat.
(Close clamps are still used today but the bricks contain fuel and so burn themselves
once an initial temperature has been reached..)
The most obvious method of firing bricks however would have been to use a kiln
which was already in existence i.e. the saggar works.
Gradiometry
The group uses a Geoscan FM18 Fluxgate Gradiometer (Geoscan Research). This
consists of two sensors at right angle to each other. The upper sensor detects the
earth’s magnetic field; the lower sensor detects the earth’s magnetic field plus any
other field resulting from buried features. The signal from the earth’s magnetic field
can thus be electronically removed leaving the signal from buried objects. Readings
are usually taken at half metre intervals along a fixed grid where the grid lines are
spaced at one metre (traverse interval).
Resistivity
The group uses a Geoscan RM15 unit, which measures the electrical resistance of
soils. This is done using 4 electrodes, 2 current probes and 2 potential probes. They
can be configured in various ways, but this unit uses a twin probe array. With this
system, one current and one potential electrode (spaced 0.5 metres apart by means of
a frame) are used to take the measurements by sampling over a grid pattern, whilst
the other two are situated at least 15 metres away and form the pair of fixed probes.
The readings are captured by a datalogger and can be later downloaded into a
computer for subsequent processing. This method can detect buried objects about
1.5 times the spacing of the electrodes; in this case it is about 0.75 metres.
The resistance of soil depends upon its nature. The electrical current is passed by
means of dissolved salts in the soil so wet soils pass electricity more easily than drier
areas such as stone walls. Resistivity can be expected to detect the remnants of
human activity such as walls, pits and ditches.
Data Processing
The geophysical data produced in this report was processed by a combination of the
following 3 methods.
Geoplot (Geoscan Research) this DOS programme runs under Windows.
Geophys (M R Holland) this is a Windows data analysis programme of limited
functionality
Wolverhampton Archaeology Group, Caughley 24
Chime (Molecular modelling plugin for Internet Explorer by Chime) this uses XYZ
data produced by Geoplot or Geophys to display the data in 3-dimensional form
Display options
The following display options are used in this report. Unless stated to the contrary,
no filtering or smoothing has been used except interpolation. This process generates
a median value in between each pair of measurements. It has the effect of smoothing
out large changes in values and reducing the unit size of the blocks in the display.
Dot density: data are displayed as blocks of randomly placed dots where the density,
or number of dots, depends on the value of the data at that point. Usually, maximum
and minimum cut-offs are chosen so data above the maximum appears totally black
and data below the minimum, white. Although this is the most popular form of
display, multiple plots may be needed to show the full range of the data and it is
difficult to know the true strength of an anomaly without referring to the raw data.
This option is available in Geoplot.
Shade: this is similar to dot density, but the readings are displayed as blocks of
varying shades of grey or colour. Features are seen as areas of light or dark colour
on the printout. This option is available in Geoplot and Geophys.
Trace: this method presents data as horizontal stacked lines in which the height is
given by the value of the data at that point. The effect is similar to a 3 dimensional
display and is particularly useful for looking at the relative heights of features and
allows the full range of data to be viewed, showing the shape of individual
anomalies.
3-dimensional: this is viewed with Internet Explorer using the Chime plugin
(originally designed to show molecules in 3 dimensions). Data from Geoplot or
Geophys is exported as an XYZ data file (i.e. x and y co-ordinates and a z co-
ordinate proportional to the Resistivity or magnetometry reading) This provides a 3
dimensional view of a surface which can be rotated and resized, This option is only
available with the Chime plugin and needs additional software to translate the XYZ
data to the format required for molecular modelling.
Interpretation: Red is high resistance, blue low. Some spikes seen in grids 1 and 5, broad diagonal
band of relative high resistance may reflect surface topography. Diagonal feature in grid 1 marks the
position of a known pipeline and ditch on the ground.
On the southern elevation of the quarry workings, is an area known as Honey pot.
There is a derelict, cottage and several out buildings along side the Dean Brook.
Several tracks run on the slopes of this area. Although overgrown these tracks radiate
from a gateway at the west end of the area, and are clearly visible with very mature
Oak trees in a linear alignment to the tracks.
Clearly visible at the gate are field boundaries; fallen stone walls form angular
divisions of possible field boundaries, at the lower end of the elevation. A house
platform is clearly visible in the next field to the west.
Several trees have grown over walls, some minor excavation of the soils under the
trees, revealed sherds of pottery suggesting domestic occupation over many decades.
Earthenware, Midland Purple ware, slipware, blue and white are all present.
A site visit was made to establish some accurate measurements. The map of 1780
shows linear alignments of buildings parallel to field boundaries from the Saggar
works, to the boundaries discussed above.
Measurement was made from the west gateway E368760 N299610 to the Honey pot
E368870 N299500 (125m), and a collection of two buildings at the top of the
elevation E368890 N299670 (143m). The same points were then measured using the
map of 1780, the scale of the 2000 map is known, and a scale was worked out for
1780 map. A factor of 0.38 was calculated. A measurement was taken from the 1780
map using a scale rule, between the Saggar works and the west gate. Using the factor
it gave a measurement of 486m. An arc was then drawn onto the map of 2000. The
distance was then measured. The location for the Saggar works approximates to the
west field on the 1988 survey.
This area at the southern end of the current clay workings was apparently a level area
when viewed in context with the surrounding topography.
Contact was made with Roger Edmundson via Martha Ledgard of Much Wenlock
Museum. Roger supplied two photographs of in situ brickwork laid in a radial layout.
Roger also supplied detailed notes that he and Stephen Perry had made on a visit in
2001. It recorded the approximate location of the brickwork.
It was decided to try and find the bricks from the details. This proved to be easy as
the details were accurate and there have been no changes in the use of the land. In
locating the bricks, one datum was the corner of East field and West field. In the
plantation adjoining this point, earthwork depressions of two Bell pits are visible
which Roger suggests is the final resting place of the demolition rubble of the Saggar
works. It was uncommon for these pits not to have been filled in after exhaustion of
coal.