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2021 Furnace ('Phoenix') and Lehr at Quarley - Furnace Superstructure Build

Projects: 2019 Onwards   Woodshed Build   The Woodpile   IFoG Furnace Removal   Firepit Reconstruction

Furnace Superstructure Build   Phoenix Firing One   Repairs after Firing One   Phoenix Firing Two   Repairs after Firing Two

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Building The Lower Walls   Building The Upper Walls   Drying Out The Furnace   Tunnel Height Adjustment

Drying Out the Furnace

As soon as the furnace superstructure build was under way, it began to dry. This was necessary so the successive daub layers could be built on a stable base, but it also meant that shrinkage would take place.

Using two layers of plastic worked in the IFoG Furnace build, but much less so in this build. No cracks showed until we started to actively dry the furnace. The weight of furnace plus the slight unevenness of the firepit walls inhibited the sliding process, leading to more cracks than we anticipated.

To actively dry the furnace, we lit a fire outside the tunnel and allowed the furnace to draw in the warm air and gases. Later we added the tunnel from the IFoG Furnace and allowed the fire to extend downwards. We kept this fire going for as long as possible during the day for nine days (about 48 hours in total), keeping the temperature low; around 150°C, and burning pallet wood at a rate of c.2kg per hour.

When the tunnel was dry enough to be moved, we inserted a 1" thick ceramic fibre blanket gasket between it and the furnace wall to stop leakage of smoke and heat.

The cracks formed in this initial drying stage were plugged using daub. Many of them occurred at the points where the walls were left for a week or so before they were added to during the building phase, and can be seen in the photos of the back and the top of the furnace (which we had not finished before starting the fire), the floors of the gathering holes, and at the bottom of the front of the furnace where it meets the tunnel.

Another consequence of the drying phase was that the horizontal slots in the large gathering hole were no longer level and the hole itself had distorted. This needed drastic measures to sort these problems out: essentially taking a saw and a chisel to the daub to reshape the hole and correct the slots.

The furnace continued cracking during Firings One and Two (links on this page). Although some of these cracks looked severe, none threatened the integrity of the furnace, especially as they could be repaired after each firing.

Setting the fire and building the roof The fire is lit Drying starts here!
The gathering holes are boarded up to keep more of the heat in and to provide a better draw The gathering holes are boarded up to keep more of the heat in and to provide a better draw
Using old pallet wood Before lighting a fire
Drying the wood A good fire
The first crack in the back wall Along the join between the lower and the upper wall
The crack in the small gathering hole floor width= Along the join with the inner wall in the large gathering hole floor
The first cracks in the roof The first cracks in the roof
The darker grey areas show where the daub is still damp The crack near the tunnel
The filled cracks in the top of the furnace The filled cracks in the back wall of the furnace

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