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View of soda kiln firing
at night,
February, 2001.
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Castable
Refractory
Used for Soda Vapor Kiln
Built by Greg Stahly, senior.
Marvin Bartel, Consultant, summer,
2000
Goshen College
Materials below are all by
Volume
- NOT
Weight
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Dry mix first until all ingredients are totally blended.
Careless mixing produces defects in the kiln wall.
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When ready to mold it, add just enough water to bind
when tamped in place.
Tamp with end of 2x4 or similar tamper.
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Mixes used for Cone 10 Soda
Vapor Firing Kiln
Interior
Solid Refractory
Hot Face
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has some shrinkage as it dries, but tends to expand when kiln is fired.*
(1 inch thick)
Kyanite
Ball Clay OM4
Fireclay
Kaolin 6-T
P-Grog
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10
parts
1 parts
2 part
3 parts
4 parts
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This mix proves to be very resistant
to vapor glaze deterioration, but the hot face and insulating layers tend
to delaminate in some areas.
It may help to add 1 part portland cement.
See door block mix below.
Interior must be bone dry before firing.
First firing must be
very slow
to avoid pop
outs.
This mix used for 1 inch floor slabs.
They are pre fired to cone 10 and laid
on top of 4 inches of insulating castable.
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Insulating
Refractory Castable
(4 inches thick)
Kyanite
Ball Clay OM4
Fireclay
Portland Cement
Sawdust
P-Grog
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4
parts
4 parts
2 part
2 part
5 parts
4 parts
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This mix is tamped directly
on the hot face mix for the walls and top. Both layers are built
at the same time to attempt bonding of the layers.
Subsequently, the exterior gets an additional
2 inches of mineral block
1900 F insulation, plus 0.5 inch
refractory stucco with wire mesh in
it.
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*SUGGESTION: Add 1 part Portland cement to the hot face mix. It may prevent
drying shrinkage and help bond the hot face to the insulating castable
to minimize the crack between them. CAUTION: Portland cement melts
at cone 10. Too much cement would compromise the refractory.
Mixture for door blocks
The
inside needs to resist the effects of the soda vapor and the outside needs
to provide insulation.
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Make both of the above mixtures, but add 1
part portland cement to the hot face recipe to stabilize it and bond it
to the insulating castable.
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Make the hot face about 1/3 of the thickness
and use the insulating mix
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Before using, door blocks are fired to cone
10 in the stoneware kiln.
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Door blocks are 5 or more inches thick.
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All rights reserved. Goshen College students may make one
copy for their own use. Others need to E-mail
marvinpb@goshen.edu
for permission to publish any part of this document.
photos
©
Marvin
Bartel
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Updated 10-10-01
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