Sagar Works At Caughley 2005

Project No 13 The Saggar works at Caughley

EXCAVATION OF THE WORKS Spring 2005

Chris Robinson

Contents 2005 Excavation at an early industrial site ...................................4 Summary .....................................................................................................................................4 Introduction .................................................................................................................................4 Aim ..............................................................................................................................................4 Acknowledgements.....................................................................................................................4

Historical Background .......................................................................5 Geology .................................................................................................5 Topography...........................................................................................6 The WAG team .....................................................................................6 Archaeology .........................................................................................7 Methodology ...............................................................................................................................7

Excavations..........................................................................................8 Bro 05/A1/T6 Plan 1 Bro 05/A1/T7 Plan 2

North end of the Tee building.........................................................8 Wall feature and floor near to tip area .......................................... 10

Conclusion ..........................................................................................14 BRO 05/A1/T7......................................................................................................................... 14 BRO 05/A1/T7......................................................................................................................... 15

The Context layers............................................................................16 Bibliography .......................................................................................19 Appendix .............................................................................................21 Clay tobacco pipe. Caughley, April 2005. ............................................................................. 21 A Caughley time line............................................................................................................... 21

PLATES................................................................................................25

Table of figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5

Location of the Saggar Works.........................................................................................3 Bro 05/A1/T6 Plan 1 Brick feature to the north of the tee building........................9 Bro 05/A1/T7 Plan 2 Wall feature and floor near to tip area............................... 11 Caughley and Swinney 1790........................................................................................ 12 Contour map 1987 ..................................................................................................... 24

PLATES Plate Plate Plate Plate Plate

1 2 3 4 5

Picture……………………… ………………………………….. Picture…………………………………………………………… Picture……… …………………………………………………… Picture…………………………………………………………… Picture…………………………………………………………….

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2

Figure 1 Location of the Saggar Works

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The Saggar works at Caughley 2005 Excavation at an early industrial site Summa r y Another exciting and successful investigation of the Saggar works. Wall foundations were revealed that provide conclusive evidence for the existence of the tee shaped extension of the works shown by the Thomas Bryan map (SRO1224/1/47) in 1780. A further feature was excavated at the northern end of this building and although at first seemed to be a kiln like structure, has proved to be intriguing. This excavation has provided a good basis for continuing with a further investigation, to discover the use of this feature and further remains of the associated buildings. Introduction These excavations follow four previous reports into the area. The 1988 report by the Ironbridge Institute, the 2002 report by Wolverhampton Archaeology Group looking at geophysics and the excavation reports carried out in July 2003 and November 2004. Aim To produce a detailed study of the works, provide good evidence of the operation of the works and its relationship to the Caughley Porcelain works and other local potteries. Acknowledgements These excavations were undertaken with the kind permission of Lady Forester during March and April 2005. Thanks to Phillip Morris for permission to uncover various amounts of turf within his tenancy, and for the unrestricted access to the fields around the site. Thanks also to Nigel Williams of Parkhill for use of the secure car park, site survey and maps freely provided. To Robin Morris of Ibstock Bricks for his help in getting the equipment to the area and his in depth knowledge of the area. To Roger Edmondson for his help and input before and during the four investigations. We must also thank the staff especially, Sarah, of the Forester Arms for a log fire and sustenance during some of the coldest days of the winter.

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Historical Background It is thought a Pottery may have existed at Caughley as early as 1754. The works was run by Ambrose Gallimore, who had taken leases from the Caughley estate owned by Edward Browne. 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 and China clay 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 is a Fireclay container that protects the delicate porcelain from the direct heat and smoke of the kiln. The name is a corruption of "safe guard". A map of 1780 by Thomas Bryan (SRO1224/1/47) shows the existence of a saggar works approximately a quarter of a mile south of the site of the Porcelain works.

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 previously 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.

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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 eastern 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 "Honey pot" and several ruined outbuildings.

The WAG team CHRIS ROBINSON SANDRA VINT MARTIN HOLLAND JAN HOLLAND SUE FOSTER CLIVE WESTWOOD EMMA HUGHES MIKE DURRANT ANDY PEARSALL PAUL HADFIELD GLYN DAVIES

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Archaeology Methodology The new phase of work involved using the existing site grid, within which the previous excavations were carried out. A temporary bench mark was also designated for the area, from which all heights were recorded. This was 100m. The bench mark is at point 369205E299540N. This point is derived from measurement on a map (Parkhill 2003, CY/D044/21), and not measured at the site using a known O.S. benchmark. The grid was 20m by 15m , the south west point designated 100E,100N an arbitrary figure for use within this document,(369184E299520N).

Scale work from A. Pearsall was used to determine the position of a circular feature thought to be a second kiln. A scale of 1:2500 was derived from the comparison of measured excavation versus Bryan’s map of 1780.

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Excavations Bro 05/A1/T6 Plan 1

North end of the Tee building

The location of foundation walls running north from the body of the building excavated in 2004 ( The saggar works at Caughley WAG November 2004 )gave good evidence for the existence of a tee extension. This concurred with the map by Thomas Bryan (SRO1224/1/47) 1780. Some doubt as to the scale of the map was raised. In shape there was a clear similarity. The gradient of the land to the north was getting steeper. This meant that to excavate further would mean removing at least 0.50m of soil, probably clay, to extend trench four (Bro 04/A1/T4) in the direction of the second circular feature shown on the map. This was clearly not possible given the size of the excavation team, and the winter weather conditions. Scale work was undertaken from known dimensions of the previous excavation. (Pearsall 2005). This scale was transposed onto the field area adjoining the previous work. Trench 5 (BRO 05/A1/T6) was marked out at the point where the tee extension ended and the circular feature started. Position 115E120N. The topsoil was removed and quickly revealed a hard surface made up of saggar wasters context 132. This area was joined by an area of firebricks worn smooth as if part of a heavy traffic area context 133. The 5.00 x 1.00 metre trench extended west, but no significant archaeology was present in the upper level of the progress west. The archaeology was deeper if present at all. A sondage was sunk at 110E120N, the intention being to test the depth and reveal any remains at that level. A course of bricks, forming a square, running north to south was uncovered at a depth of 99.14 or approximately .50 m below topsoil. Cleaning revealed a square of bricks abutted another course running east to west laid on bed and apparently circular. This gave clear evidence of a structure at a point where the two map features came together. This feature was excavated to level 99.07 where it met a brick floor 134. The full removal of clay within the trench revealed a sub-circular feature that straightened out as it moved to the west. No mortar was used in the construction of this brick feature. This means that a structure of a hovel or kiln was unlikely. It simply would not have stood the weight of masonry bearing down. The area of paved floor was bounded by wall foundations. The bricks had tie courses and mortar. There was also alignment with the foundations of the tee extension building running north. The paved floor area falls within the area bounded by these foundations and seems certain that the circular feature lies at the north of the area shown as circular on the 1780 map. The general area condition was wet. Natural yellow clay 135 appeared to be retained by the brick feature. Water ran into the site from the north and filled the square brick feature.

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+109E 119N

114 100

99.16

+110E 120N

99.09 99.04

134 135 99.07

135 Drawn by Emma Hughes Do not scale 99.14 99.00

Key Limit of excav. 135

Brick

99.92

100

Fire brick S

137

Saggar

Context 133 100

Topsoil

114

Foundation of the works building.

99.50 99.07

114

132

Area of saggar fragments

133

Firebrick worn smooth by wear similar to cobbles

99.10

99.06

132

S

134

Brick paved floor area.

135

Natural yellow clay infill of possible drain.

137

Sub circular feature. Possible retaining wall for an area of clay preparation.

99.66 115E 120N

115E

+

1m

+ 121N

N Figure 2 Bro 05/A1/T6 Plan 1

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Brick feature to the north of the tee building

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Bro 05/A1/T7 Plan 2

Wall feature and floor near to tip area

Investigation of the area of trench 7 was instigated by the discovery of a very hard surface below the turf. A fence pole would not penetrate this area. It was decided to open a trench 2.00m x 2.00m at 115E125N and hopefully discover a floor surface below. A surface 136 was uncovered and appeared to be a threshold into or out of a building. It was made up of firebricks laid as paving on bed. Further removal of turf revealed two foundation walls. Wall 130 orientated north – south appeared to bound the area of the paved surface. A single course wall 129 laid at 45 º to wall 130 runs south west. This wall is similar to the airway found into the kiln base 112 (WAG 2003) and may have served a heating device of some sort. There was no evidence to support the idea of a firebox into a second kiln. The firebrick paving is at odds to this idea. Two saggars appear to have been used to store sand to the north of wall 129. However if these were wasters placed to create an area of hard standing, the sand fill of these may have been decomposed fired clay of the fabric of the same saggars. There was also an area to the west of the paving made up of saggar fragments again to create a hard area. Context 128 contained approximately 150 small items of kiln furniture. These small fire clay items appear to have either been stored or discarded in an area of about .030m x .030m. The reason is lost to history. This area requires further detailed investigation at a later date. It may be an associated work area or possibly an office. The area lies near to the tip of wasters within the quarry area to the west. designated area 2.

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N +119.00E 124.80N

100 105 131 99.95

130

99.95

128 Drawn by Emma Hughes Do not Scale

123

Key 99.95

136 Limit of excav. Brick Fire brick

99.95

S

129

Saggar

Context

2M

S 132

100

Topsoil

105

Hard compact coal/clay

123

Area of soft grey clay. Internal area.

128

Spread of kiln furniture.

129

Possible airway to firebox. Similar to 112

130

Wall of possible office.

131

Spread of demolition.

99.95

S + 115 E 125 N

132 136

Figure 3 Bro 05/A1/T7 Plan 2

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Area of saggar fragments Fire brick roughly laid to form threshold or work area.

Wall feature and floor near to tip area.

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Figure 4 Caughley and Swinney 1790

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Conclusion

All of the excavations so far have proved Bryan’s drawing to be accurate, but he seems to have used two scales. Approximately 1:5000 for the general area and 1:2500 for the detail of the saggar works. This allows more detail to be recorded. Less exciting are the few finds. Iron nails have been found. There has been only one find in a sealed context that would conclusively date the commencement of the operation. A Broseley clay pipe was excavated from Test pit 15 within Area 1 (BRO 05/A1/TP 15). The pipe lay below turf level but was probably at a contemporary level with the life of the works. Analysis by Durrant (2005) suggests a span of 1740 – 1780 and the pipe to be of local manufacture. BRO 05/A1/T7 The sub-circular wall feature 137 is of the greatest interest. Initial thoughts that a second kiln had been located were quickly dispelled. The wall was not mortared and the three courses of bricks were dry laid. It would not support the weight of a wall. The feature, if complete, appeared to hold back an area of natural material. This appears to make good sense. The site is naturally sloping to the south. To create a level area for the operation of the works across the whole site would have meant an enormous amount of earth moving. The use of a retaining wall would have been easier and achieved the same result i.e. two level work areas. The discovery of a floor surface 134 certainly supports this idea. The floor falls within two foundation walls 127, probably the outer walls of the tee shaped building. This would be the lower area of the works. Since the floor area is so good, it suggests an area that was important to the works operation. The hypothesis is that this was an area of moulding. The floor area would have needed to be kept clean and relatively dry. The feature forming a square to the retaining wall 1 3 4 was collecting water during the excavation via two apparent inlets to the east and west respectively. This gives good evidence of it’s purpose during the lifetime of the works, a drain or well which gathered water for use, clay must be softened prior to moulding, or allowed the collected water to soak away. This would have kept the work area free from water. This idea means that the building containing the moulding area must have had access to the higher level beyond the retaining wall. The higher level may have been an area of clay preparation. The clays may have been brought by barrow or cart from the adjacent quarry. Grinding may then have taken place at the higher level. The prepared material then delivered into the work area at the lower level for or use. The prepared material may also have been stored outside which allowed prolonged weathering or decomposition of the clay. There may have been an animal powered mill that would have produced finely prepared material for moulding.

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Clay preparation may have improved progressively. The excavation in 2003 revealed varying quality of saggars. Very coarsely made saggars to fine body wares. This suggests that as experience was gained a finer material produced a more durable saggar and less waste. This may have been instrumental in the acquisition of a mechanical technology. Animal power was the only available method. Power was a problem due to the elevated position of the works and distance from a water supply that could have provided power. The method and layout of a clay manufacturing operation is very much the same today. The scale is massively larger but principles are the same. In simple terms clay must first be won, then stored or weathered. This weathering is a process that is little seen today. Machinery does the work of the weather, crushing and pulverizing the material before use. Clay is then ground in pan mills and reduced to a fine particle size. 4.5 mm for more general bricks. 1.5 to 2.00mm for a more dense product such as blue bricks where the strength may be a factor. Clay is then mixed with water to allow shaping and then dried and fired. This progression exists at the saggar works just as it still does at modern factories. BRO 05/A1/T7 This trench is very complex and difficult to interpret. A wall foundation 130 exists at the east of the trench that requires further work before a realistic attempt at interpretation can be made. It may be associated with a work area of some kind. There is however another wall 129 running at approximately 45 degrees to wall 130. This angularly laid wall gives the appearance of an airway into a heating device of some kind. It is similar to feature 112 that formed an airway into the kiln (BRO 03/A1/T1). An area of firebricks laid as paving exists in the centre of this trench. There is obvious disruption of this surface. Discussions with Phillip Morris have revealed that ploughing was attempted which may have caused this. The area was also tree covered until recent years and tree roots may also have caused this damage. This paving suggests access into a building or an exit from a building to adjacent the tip area where most fired waste has been found. Feature 128 is a spread of 150 pieces of kiln furniture within an area 0.30m square. The form is similar to a button and has been found all over the site but not in this great concentration. It is thought that its use was to keep saggars apart whilst being fired. The Saggar works has yielded some of its secrets but has not given many clues regarding dates of occupation. It seems unlikely that this situation will change. There are still some questions to be answered. Did an animal powered mill exist? How difficult will this be to prove given the lack of documentary evidence? Thomas Bryan’s map of 1780 shows a fully circular shaped building at the north of the works. A sub-circular feature has been found. Was this feature open to the elements as proposed by the clay preparation theory? As usual more questions are raised.

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We are now more knowledgeable of the Saggar works, but there is a thirst for more still to be quenched!

The Context layers Each level of the excavation has been designated a context number. This enables similar layers to be identified as continuous within an area. This may define shape or depth of the area. Context will also define changes in layers as depths change, which is essential when any dating evidence is found.

Context 100 Topsoil 101 Hard compact floor surface. Clay imbedded with waste burnt material and coal. 102 Kiln hearth bricks laid in radial pattern with an infill of brick paving laid in the opposite direction. 103 Clay layer overlying the hearth surface 104 Loose hardcore layer 105 Hard surface heavily compacted with Coal and clay and similar to 101 106 Spare 107 Light brown soil containing poorly fired Coal. Some saggar wasters. Tree roots prevalent. 108 Grey soil, saggars and coal. Very soft and contains bricks. 109 Crushed bricks and ash from hearth. 110 Sandstone cover of possible drain channel 111 Drain channel.

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112 Firing point of the kiln or air intake. 113 Drain walls in brick. 114 Foundation of works building 115 Grey soil and compact saggars. Coal and nodules of natural clay. Red and yellow in colour. 116 Natural clay 117 Wall to the north of possible building. Bricks laid in a single course. 118 Sondage. Sub surface of kiln hearth, clay and fine particles of fired materials. 119 Drain fill. Grey clay with Coal fragments 120 Subsoil. Sandy orange natural material found in the present quarry operation. 121 Corner of foundation. Bricks laid over Red sandstone. 122 Area of bricks laid into paving. Firebricks and red bricks possible entrance of building. 123 Area of soft grey clay with frags. of brick and tile possible internal surface. Soft now due to exposure but would have been a hard beaten dry surface when the works was roofed. 124 Soft grey clay and mortar frags. Heavy with tiles possibly from roof slippage after disuse of the building but prior to demolition when all reusable materials would have been recovered. 125 Soft grey silt possible water run off from site. 126 Buttress on south wall supporting return of the building. 127 Possible Tee extension of the works.

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128 Spread of kiln furniture. Approximately 150 small button sized clay objects. Possibly used to keep wares apart in the kiln whilst firing. 129 Possible airway into a heating device, Firebox 130 Wall of work area or office. 131 Spread of demolition outside the area of work area. 132 Area of saggar fragments 133 Area of firebricks. Apparently worn smooth by heavy traffic around this area. Similar to cobble wear. 134 Brick paved floor area. Within the area bounded by the walls of the tee extension building. 135 Natural yellow clay infill of drain and apparently retained by the sub circular wall feature. 136 Fire bricks laid crudely to form a threshold into the work area suggested by wall 130. 137 Sub circular wall feature. This wall appears to retain an area of natural clay. At about the centre is a crude square of bricks which appears to gather water from the area to the north.

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Bibliography

Black, J.

2001

British Tin- glazed Earthenware. Aylesbury, Shire pub.

Broseley History 2003

China: Caughley and Coalport

Brunskill, R.

1974

Vernacular Architecture.

Part 2 Glossary. P67.

Bryan, T.

1780

Survey map

SRO 1224/1/47.

Clark, Mcleod.

1988

Dixon, J.L.

1952

The Saggar works, Caughley: "An Archaeological Evaluation." Ironbridge Institute Research Paper No 31. Ironbridge Gorge Museum. th English porcelain of the 18 Century. Caughley. Faber and Faber. London

Draper J.

2001

Post medieval pottery 1650-1800."Local earthenwares". P7-15 . Aylesbury, Shire publications.

Edmundson, R.

2002

Personal communication.

Edmundson, R.

2003

Personal communication.

Edmundson, R.

1999

Caughley Porcelains c1775 – 1799. A bicentenary Review.

Hammond, M.

1981

Bricks and Brickmaking. Aylesbury, Shire publications 1981.

Honey, W.B.

1945

English Pottery and porcelain. Worcester and its offshoots at Caughley and Liverpool. Adam and Charles Black. London.

Mackenzie, Compton 1951

The House of Coalport. Thomas Turner. Collins. St James. London.

Muggeridge, A.J. 1997

Twelve mines in Broseley. Gazetteer "Known mines in Broseley". Published A.J.Muggeridge .

Multi Maps

Aerial photograph. Multimaps.com 2002.

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Perry, S.

2001

Caughley society magazine. Newsletter No.8 December 2001. "Contemporary references to Caughley". P18-21

Randall J.

1871

" A history of Broseley"

Toghill, P.

1990

Geology in Shropshire. The Carboniferous period. "The Shropshire coalfields". P125-129. Shrewsbury, Swan Hill press .

P.A. Thornes

1963

Barrow parish pack. Shropshire Record office. Article: Thomas Turner brought Frenchmen to his Caughley China works and lived in a mock chateau.

.

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Appendix Clay tobacco pipe. Caughley, April 2005. A clay pipe was found within Area 1. Test pit 15. Approximately 0.015m below topsoil, within a spread of Sandstone blocks. This is the first pipe bowl found to date and is less than 20% complete. A stem of 0.005m pipe stem was found nearby and mated with the bowl. The stem was 5/16”(7mm) in diameter with a bore of 5/64”(1.93mm). The bowl has a mark where a spur has been broken off. th Spurred pipes occur through out the 17 Century and at the close had replaced flat heel pipes. From this information and form it is possible to date the pipe to circa 1740 – 1770 and of a Broseley type 7b. (Oswald’s typology). Without any markings to identify the manufacturer it would be hard to argue against it as that of Broseley. M. Durrant 2005

A Caughley time line 1066

Caughley is recorded as Kakeleg in the Doomsday Book.

1586

Caughley is sold to one Dawes of Shrewsbury

1650

Caughley is acquired by Ralph Browne of Caverswall in North Staffordshire.

1680

Browne builds a new Caughley Hall to the east of the existing Hall.

1687

Ralph Browne is made sheriff of Shropshire.

1709

Ralph Browne dies and the estate passes to Edward Browne.

1720

Benthall passes to Browne via his wife.

1729

The Benthall and Ironbridge Pottery co. is started.

1754

Ambrose Gallimore purchases a 62 year leases from Mistress Jane Browne at Caughley.

1749

Thomas Turner is born the son of a scholarly vicar at Little Comberton Elmley Castle near to Evesham.

1750

Ralph Browne starts a pottery at Linley on the Caughley estate. The manager is William Thursfield. Saggar making was probably included. The coal and clay are only 20 feet below the surface. There is a pathway to the River Severn.

1771

John Rose senior and Martha are married at Shipton. The move to a farm at Swinney on the Caughley estate. They have 10 children including John jr and Richard.

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Thomas Turner is now a skilled designer and engraver for transfer printing. He has been taught by Robert Hancock at Chamberlains Worcester works. 1772

Turner comes to Caughley and persuades Gallimore to open a new manufactory for the production of Soft Paste porcelain.

1774

Robert Hancock comes to Caughley after a disagreement at Worcester. He brings designs with him.

1775

Turner moves to Caughley Hall. The new works starts production.

1779

R.B. Welde inherits the Caughley estate.

1780

“Wheels, implements, etc for converting and grinding materials for Caughley” are mentioned in a lease. Caughley was only approachable by a narrow lane. Turner kept his processes secret. He mixed the clays himself. Engravers were kept away from others locked in a work room.

1781

Turner visits France to study China making. French craftsmen return with him. Turner builds Caughley place to a Chateau style.

1783

Turner marries Dorothy niece of Gallimore after an 11 year engagement.

1783

The Caughley enterprise opens the Salopian warehouse in London. Large quantities of Blue and White china are held in stock. Willow pattern, Blue dragon, Nankin and Broseley fluted were sold. The products were extremely popular as they bridged the gap between individually made items and mass produced wares. It was very competitive.

1793

Turner develops a distinctive Violet blue glaze. Three kilns are shown on Powells map (SJ 2925 0002) of the Caughley estate.

1794

John Rose is apprenticed to Caughley along with Thomas Minton.

1795

The Saggar works closes.

1798

John and Richard Rose with Edward Blakeway start a china works.

1799

Turner retires. The stock is auctioned off at Shrewsbury. The lease for Caughley is acquired by Rose, Blakeway and company.

1800

Reynolds (later Anstice) and Horton start a works at Coalport on the west bank of the river Severn.

1803

Rose and Blakeway are bankrupt but are re- formed as J. Rose and company.

1809

Turner dies and is buried at Barrow.

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1814

John Rose takes over Anstice and Horton. The Caughley porcelain closes. Caughley place is demolished. Only one small cottage remains.

1823

The Foresters of Willey purchase the Caughley estate.

1833

Caughley Hall demolished.

1841

John Rose dies and is buried at Barrow.

1844

Benthall is sold to Lord Forester.

1879

Original Caughley copper engraving plates are still listed at Coalport.

1840

Caughley drift mine closes.

1960

Clay and coal mining starts but this time for bricks and power stations. A record is made by Grant Davidson. Glyn Davies 2005

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Figure 5

Contour map 1987

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PLATES

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