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Fireclay Firebricks
Firebricks line kilns, forges and furnaces because they stand heat that would slump or crack ordinary brick. They are refractory fireclay bound round a large share of grog. Potters' guides give about 20–40 % grog for general kiln bricks and up to 60–80 % for the hottest parts such as fireboxes; the bonding clay should be a little less refractory than the grog. Factory firebricks are fired at about 1,100–1,400 °C.
Make test bricks first, fire them, and check them for cracks before making a whole batch.
Intermediate
A day, plus weeks drying and a firing
Instructions
1
1
Choose the mix
Choose the mix
For general kiln walls weigh about 70 parts fireclay to 30 parts coarse grog; for a firebox about 30 to 70. Write the mix on a label.
Tools needed:
Weighing Scale2
2
Mix
Mix
Mix the dry fireclay and grog in the trough, then add water a little at a time and tread or turn it until it is stiff and holds together.
Materials for this step:
Refractory Clay14 kg
Grog (Crushed Fired Pottery)6 kg
Water3 litersTools needed:
Mixing Trough
Spade
Dust Mask3
3
Mould
Mould
Dust the wet brick mould with sand, throw a lump in hard so it fills the corners, strike off the top with the straightedge and tip the brick out onto a board.
Materials for this step:
Sand1 kgTools needed:
Wooden Brick Mould
Straightedge4
4
Dry slowly
Dry slowly
Dry the bricks on pallets under cover, out of sun and wind, for several weeks, turning them now and then. They must be dry right through before firing.
Tools needed:
Wooden Pallet
Tarp5
5
Fire
Fire
Stack them with gaps in the kiln and fire them slowly at first, then as hot as the kiln will safely go. Note the top temperature on the pyrometer.
Tools needed:
Kiln
Pyrometer
Kiln Furniture6
6
Check them
Check them
When cold, tap each brick: a clear ring means it is sound, a dull thud means a crack. Measure the shrinkage for the next batch.
Tools needed:
Tape Measure7
7
Troubleshooting
Troubleshooting
Firebrick troubleshooting.
Flow
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Materials
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Tools Required
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