The Glassmakers Home   Gallery   Contact   Events & Projects   Projects: 2019 On   Film & TV   Archive & Links Quarley 2022 Furnace - 'Phoenix'

2022 Furnace ('Phoenix') and Lehr at Quarley - Repairs to Phoenix after Firing Three (Spring 2022)

Projects: 2019 Onwards   Wood Gathering and Processing   Phoenix Firing Three   Repairs after Firing Three   Phoenix Firing Four

Phoenix Firing Five   The New Shelter Floor   The Electric Kiln   Rebuilding the Lehr   Etna Build and Firings   General Photos

Vesuvius Firepit Build   Vesuvius Superstructure Build   Vesuvius Firings   Repairs after Firing Five   Phoenix Firing Six

Phoenix Firing Three Repairs

The sand on the shelves largely succeeded in preventing molten glass from reaching the shelves, although we had some spills which stuck down a few of the batts that were supporting the pots. The shelves were cleaned up using an angle grinder.

The ceramic fibre cloth used to stop the shelves from rocking did its job, but was virtually completely destroyed by the heat (we now know that the firepit reaches 1200°C).

One of the stops for the bars of the grate had come loose and had to be stuck back with high temperature sealant and fire cement.

Two of the small shelves supporting the ceramic tubes had broken off, so needed to be glued back using fire cement.

Most of the normal cracks on both the hot face and the cold face had opened up, so once again had to be filled with high temperature sealant before giving the hot face another coat of zircon silicate slip.

The firepit cleaned up well, although there were a few small splashes of molten glasss, which was only to be expected.

The upper shelves after removing the pots After removing the sand
The spacer bricks The upper shelves showing the pot supports stuck to them
The lower shelves The lower shelves
All that was left of the ceramic fibre cloth Cracks in the inner wall
Cracks in the inner wall Cracks in the inner wall
The stoke hole The dislodged stop
Repairs around the right-hand side gathering hole Repairs around the left-hand side gathering hole
Filling the cracks in the inner wall Filling the cracks in the inner wall
Filling the cracks in the inner wall After a coat of zircon silicate slip
After a coat of zircon silicate slip After a coat of zircon silicate slip
After a coat of zircon silicate slip After a coat of zircon silicate slip
After a coat of zircon silicate slip The right-hand side of the furnace fully restored

Preparations for Firing Four

The preparations mainly consisted of adapting the left-hand side of the furnace so we were able to use it for making Roman-style window panes.

We did this by using concrete setts to support a 24" x 24" concrete paving slab. On top of the slab we laid two large ceramic kiln batts and and some firebricks to achieve the correct height.

The long-handled metal support (akin to a pastorello) for the batt which would be used for shaping and re-heating the window panes ran on top of the fire bricks by means of a metal roller. The metal support could also be slid to the right, allowing Mark to work on the pane after its re-heat.

We also made some domes from daub which were to be used for slumping window panes to create domed panes. These can be seen in operation in the photos of window pane making during Firing Four.

We used one set of shelves, built a low wall around each shelf and filled the space with sand.

The pot we used for holding the window pane glass was a larger circular one, 9.75" in diameter and 6" deep. It would be easier to gather large double gathers from this pot instead of the large 'swimming pool'-shaped pots that we used in 2019, although they held the same amount of glass (c.7kg).

Finally, we fitted new thermocouples and protected them with some ceramic fibre blanket. This meant that we could now record temperatures both above and below the shelf: effectively in the firepit and in the melting chamber.

The left-hand side gathering hole ready for window pane making Placing the concrete setts on a 24 inch square paving slab
The completed arrangement The completed arrangement
The kiln batt in position The kiln batt in position
A side view showing the relative heights of the components The cleaned-up lower shelves
The newly-made low walls and the covers for the joints between the shelves The dried walls and covers
The shelves coated with sand The new thermocouples
The new thermocouples with their ceramic fibre blanket protection The new thermocouples with their ceramic fibre blanket protection

Home   Gallery   Contact   Events & Projects   Projects: 2019 Onwards   Film & TV   Archive & Links