 |
 |
 |
 |
 |
 |
 |
|
|||||||||||||||||||
| construction of my latest kiln, near Dorking in Surrey, in Spring 2006 | |||||||||||||||||||
 the foundations were dug out using a mini-digger, then the base was built up using building rubble and old plaster-board. |
 constructing the kiln shed once mini-digger access no longer needed (photo: Yo Thom) |
||||||||||||||||||
 levelling the base with sand |
 a layer of concrete blocks completes the foundation layers |
||||||||||||||||||
 the formers for the highest, and the first and last parts of the arch, make the beginings of the formwork structure which will support the bricks during construction |
 flatmate Laurence modelling the latest in arch-former templates...to achieve the catenary arch build of the kiln, a chain is hung to form the correct width and height of each arch. The shape made by the chain as it hangs in gravity is drawn around and cut out, then used as a template for the wooden supporting arches of the former. This makes the brick arch naturally self supporting |
||||||||||||||||||
 light and shadows inside the finished former |
 the first stage of the walls, supported by the arch former |
||||||||||||||||||
 to make the kiln more efficient insulation bricks were used wherever possible. Stronger heavy firebrick was used around stoke-holes and for lower walls of the firebox - areas where wear is highest |
 building assistant John H plastering up the keystones to ensure they're secure, prior to lowering and removal of the former |
||||||||||||||||||
 the completed arch with the former removed, looking towards the back of the kiln. The heavy brick structures on either side form the flue-exits of the underfloor flues |
 the kiln is clad with insulation 'mud' of vermiculite mixed with sand, fireclay, cement and lime. Chicken-wire mesh put over the kiln prior to cladding acts as reinforcing and helps the cladding hold together despite the inevitable cracks caused by the kiln expanding at high temperatures |
||||||||||||||||||
 |
 the floor seen from the back of the kiln, showing the supports and the underfloor flues. The support walls are made using narrow supports in alternate layers which cause large spaces between bricks. This lowers the mass of the wall so less energy is used just heating kiln structure (and saves a few bricks) |
||||||||||||||||||
| building underfloor air channels to provide the firebox floor and sidestock area with pre-heated air for more efficient burning | |||||||||||||||||||
 cutting holes in the roof to make way for the chimneys (photo: John Harrison) |
 finishing the back wall from inside the chamber flue exit (photo: John Harrison) |
||||||||||||||||||
 the virtually finished kiln. The floors of all but the very first step (in the firebox) were covered with silica sand. |
 the kiln as it was for the first firing, showing the finished stoke-holes. A second (and creamier coloured) layer of insulating 'mud' was added to the outside of the kiln after the first firing (not shown) |
||||||||||||||||||
 |
the back of the kiln features a bread oven. There is a half brick opening from the back of the kiln to below a kiln shelf slab that forms the oven floor. A small gap between slab and oven wall allows heat in. The wall between the kiln and the oven is only one brick thick (as opposed to two bricks thick for the wall above it) to allow some heat in. It needs some improvements; in the first firing it possibly set the world record for longest time taken to cook a pizza. Far more effective was to speed bake them for a few seconds in the front fire-mouth above 1100... to download the plans for this kiln in pdf format click here |
||||||||||||||||||
right: the finished kiln (now known as The Bear), packed and ready to fire, sporting the second coat of insulation and full set of counter-balanced doors on pullies |
 |
||||||||||||||||||
site design and content copyright John Butler, 2001-2007