Experimental IRON SMELTING

Norse Bellows Air
 
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.
This is a record of the ongoing series by Darrell Markewitz,
assisted by members of the Dark Ages Re-creation Company.

A specific element of historic iron smelting methods is that of air supply. For the Norse this especially a problem, as there are no surviving artifact bellows of any kind. There are only a couple of illustrations known depicting bellows, and those related to blacksmithing, not iron smelting. These images show a pair of individual chambers, linked to a single output. The operator is seen alternating the action, raising and filling one chamber while the other is collapsed and providing blast.

bellows
bellows
Drawing of the Ramsund Stone Carving (1030?)
Sweden
Wood Carving (c 1150?)
Hyllestad Stave Church  - Norway


Along with investigations into the underlying physical methods, and specific regional variations, this team has undertaken experimental use of several bellows constructions based on the Norse model.

smiths
ubberbellows
smelt bellows
Blacksmith's Bellows
(several variations used)
E 120 LpM (@60 strokes / minute)
Ubber Bellows
E 700 LpM (@60 strokes / minute)
Smelting Bellows
E 425 LpM (@60 strokes / minute)

Generally, the tests of Viking Age Bellows / Air would overlap with other test series. The Blacksmith's bellows was used 4 times, plus once in combination with a bladder. The Ubber Bellows was used only 3 times, as it was found too punishing for workers. The Smelting Bellows as used 6 times, plus partially for 2 others. The standard electric blower was used twice at reduced volume (to mimic measurements from the Smelting Bellows. This blower limited both in volume and by a sliding gate to mimic the plusing delivery flow from Norse twin bellows equipment was used 4 times.


Commentaries on Norse Bellows Air

Air Flow Rates
A table of measured rates from our standard equipment  (Revised October 2007)

Bellows Air Test
Measuring Operator rates using a reconstructed Norse blacksmith's bellows  (Report October 2007)

It is worth noting that the blog posts are sometimes repetitive.
Links to blog postings are off this web site

July 2007, 'Viking Age Blacksmith's Bellows' :
https://warehamforgeblog.blogspot.com/2007/07/viking-age-blacksmiths-bellows.html

October 2007, 'Bellows Test' :
https://warehamforgeblog.blogspot.com/2007/10/bellows-test.html

January 2008, 'Bellows Reconstruction 2' :
https://warehamforgeblog.blogspot.com/2008/01/bellows-reconstruction-2.html

November 2008, 'Air Delivery Test - Norse Smelting Bellows' :
https://warehamforgeblog.blogspot.com/2008/11/air-delivery-test-norse-smelting.html

January 2008, 'Bellows Reconstruction 3' :
https://warehamforgeblog.blogspot.com/2008/01/bellows-reonstruction-3.html

March 2008, 'Bead Bellows Reconstruction' , (this bellows similar to the Blacksmith's bellows, and would be used for Peterson's presentation given below) :
https://warehamforgeblog.blogspot.com/2008/03/bead-bellows-reconstruction.html

November 2008, 'Air Delivery Test - Norse Smelting Bellows' :
https://warehamforgeblog.blogspot.com/2008/11/air-delivery-test-norse-smelting.html

October 2009, 'Piston Bellows', (although this is a Chinese Box bellows, the intent was to mechanically deliver the same kind of pulsing air flow as with the twin chamber type) :
https://warehamforgeblog.blogspot.com/2009/10/piston-bellows-1.html

August 2019, 'Viking Age Iron Smelting Systems' :
https://warehamforgeblog.blogspot.com/2019/08/viking-age-iron-smelting-air-systems.html

October 2020, 'Iron Smelting with Human Power' :
https://warehamforgeblog.blogspot.com/2020/10/iron-smelting-with-human-power.html

February 2021, 'Bellows Test - Norse Iron Smelting Bellows', YouTube video :
https://youtu.be/d3TRdE_kSZg

February 2021, 'Sometimes, a Great Notion - Bellows Delivery' :
https://warehamforgeblog.blogspot.com/2021/02/sometimes-great-notion-bellows-delivery.html

July 2021, 'You Mean ONLY with more Air?' :
https://warehamforgeblog.blogspot.com/2021/07/you-mean-only-with-more-air.html

September 2021, 'Mind the Blast - Correcting Air Volumes' :
https://warehamforgeblog.blogspot.com/2021/09/mind-blast.html

Neil Peterson, 2021, 'A Lot of Hot Air - Exploring Air Production in Viking Era Bellow', presentation for the EAC12 conference as narrated YouTube video : https://youtu.be/d3TRdE_kSZg



Detailed Smelt Reports

Overview Report / Smelt Sequence / Furnace Layout / Additional Materials

Some of these links will take you off this web page

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

Furnace
image

#2 / D1 - Boxed Bowl 'Vinland'
May 25 - 2002
Blacksmith's Bellows
Brief Written Report

Furnace
image
Detailed Overview
DARC - Neil Peterson
#4/ D3 - Low Stack
12 June - 2004
Blacksmith's Bellows
Detailed Overview
DARC - Neil Peterson
Smelt Sequence
table by Neil Peterson
Front Elevation
field drawing

#5 - Early Iron One
10 October - 2004
Cooperstown NY
Blacksmith's Bellows

Smelt Sequence
experimental data
Front Elevation
field drawing
Visual Overview
one / two / three
#10 / D5 - CANIRON Norse Test
June 11, 2005
Ubber Bellows
Detailed Overview
DARC - Neil Peterson
Smelt Sequence
experimental data
Front Elevation
field drawing

#11 / D6 - CANIRON V Norse Demo
September 1, 2005
Annapolis Royal NS
Ubber Bellows
Detailed Overview
DARC - Neil Peterson
Smelt Sequence
experimental data
Front Elevation
field drawings

#18 / D9 - DARC at Bonfield
September, 2006
Bonfield ON
Ubber Bellows
Draft Report
blog posting
SmeltSequence
Experimental Data
Working Layout
image

#42 / D20 - Vinland 3
November 7, 2009
Smelting Bellows
Written Report
detailed overview
Smelt Sequence
experimental data
Furnace
image
Theoretical
work layout drawing
#43 / D21 - Vinland 4
June 12, 2010
Smelting Bellows
Written Report
detailed overview

Front Elevation
field drawing
Theoretical
work layout drawing
#44 / D22 - Vinland 5
August 23 , 2010
Smelting Bellows
Brief Report
blog posting
Smelt Sequence
experimental data
Front Elevation
field drawing
Debris Field
Comparison with Archaeology
detailed report
#63 - Multiple Bellows Test
SCA 50th event
June 20, 2016
3 Blacksmith's + Bladder
Bladder Concept
illustration
Smelt Sequence
experimental data
Front Elevation
field drawing
Working Smelt
image
#71 - Norse Bellows Test / Demo
ReARC, Williamsburg VA
November 19, 2016
Smelting Bellows

Smelt Sequence
experimental data
FrontElevation
field drawing
Smelt in Progress
short video clip
#73 - Dark Ages Iron Smelting
SCA 'Fruits of Our Labours'
June 21, 2017
Dumbo ON
Smelting Bellows

Smelt Sequence
experimental data
Front Elevation
field drawing
#74 / D31 - Iron at Vinland
L'Anse aux Meadows NHSC
July 16, 2017
Smelting Bellows
Experiment Overview
blog posting
Smelt Sequence
experimental data
Front Elevation
field drawing

# 90 / D35 -
Wind & Weathering
October 2021
Smelting Bellows (partial only)
Part One : the Smelt
detailed report
Smelt Sequence
experimental data
Overall Layout
Elevation
field drawings
Part Two : WIND
detailed report

Experiments with Reduced / Pulsing Air

Blower - reduced
are smelts with air deliberately reduced to the volume produced by the Smelting Bellows (via #90 measurements).
Blower - pulsing
are smelts using a mechanical sliding gate to mimic the variable flow from the Smelting Bellows.

# 91 / D36 -
LAM, Lower & Longer
June 2022
Blower - reduced
Experimental Outline
detailed report
Smelt Sequence
experimental data
Elevation & Plan
scaled drawing
Remains - Compaction
formal report PDF
# 92 / D37
Lower & Longer 2
October 2022
Blower - reduced
Experimental Outline
detailed report
Smelt Sequence
experimental data
Elevation & Plan
scaled drawing
Bellows Air Comparison
data table
#94 / D37 - Pulsing Air Test
October 2023
Blower - pulsing
Experimental Outline
the Build
detailed reports
Smelt Sequence
experimental data
Furnace layout
field drawing

#95 / D38 - Pulsing Air 2 Baron's 7 Demo
June 2024
Tiverton ON
Blower - pulsing
+ Smelting Bellows (partial)
Experimental Outline
brief report
Smelt Sequence
experimental data
Furnace layout
field drawing

#96 / D39 - Pulsing Air 3
October 2024
Blower - pulsing

Smelt Sequence
experimental data
Furnace layout
field drawing 

#98 / D40 - Return to Icelandic
November 2024
Blower - pulsing
Experimental Outline
detailed report
Smelt Sequence
experimental data
Furnace layout
field drawing



Supporting Publications

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'

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'

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