[William Byrd with Mr. Chiswell on 26 September 1732.]
"At our return we saw near the furnace large heaps of mine [ore] with charcoal mixed with it, a stratum of each alternately, beginning first with a layer of charcoal at the bottom. To this they put fire, which a little time spreads through the whole heap and calcines the ore, which afterwards easily crumbles into small pieces fit for the furnace. Then was likewise a mighty quantity of limestone brought from Bristol by way of ballast, at 2s. 6d. a ton, which they are at the trouble to cart hither from Rappahannock River, but continue to do it when the carts return from carrying of iron. They put this into the furnace with the iron ore, in the proportion of one ton of stone to ten of ore, with design to absorb the sulphur out of the iron, which would otherwise make it brittle. And if that be the use of it, oyster shells would certainly do as well as limestone, being altogether as strong an alkali, if not stronger. Nor can their being taken out of salt water be any objection, because 'tis pretty certain the West Indian limestone, which is thrown up by the sea, is even better than that imported from Bristol. But the founders who never tried either of these will by no means be persuaded to go out of their way, though the reason of the thing be never so evident.
"I observed the richer sort of mine, being of a dark color mixed with rust, was laid in a heap by itself, and so was the poor, which was of a liver or brick color. The sow iron is in the figure of a half round, about two feet and a half long, weighing sixty or seventy pounds, whereof three thousandweight make a cartload drawn by eight oxen, which are commonly shod to save their hoofs in those stony ways. When the furnace blows, it runs about twenty tons of iron a week. The founders find it very hot work to tend the furnace, especially in summer, and are obliged to spend no small part of their earnings in strong drink to recruit their spirits.
"Besides the founder, the collier, and miner, who are paid in proportion to their work, the company has several other officers upon wages: a stocktaker, who weighs and measures everything; a clerk, who keeps an account of all receipts and disbursements; a smith to shoe their cattle and keep all their ironwork in repair; a wheelwright, cartwright, carpenter, and several carters. The wages of all these persons amount to £100 a year [seems too low]; so that including Mr. Chiswell’s salary they disburse £200 per annum in standing wages. The provisions, too, are a heavy article, though they are the charge of a general overseer. But while corn is so short with them, there can be no great increase of stock of any kind.
"27 [September 1732]. Having now pretty well exhausted the subject of sow iron, I asked my friend some questions about bar iron. He told me we had as yet no forge erected in Virginia, though we had four furnaces. But there was a very good one set up at the head of the bay in Maryland, that made exceeding good work. He let me know that the duty in England upon bar iron was 24s. a ton, and that it sold there from £10 to £16 at ton."
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