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2022 Furnace ('Phoenix') and Lehr at Quarley - Vesuvius Superstructure - Outer Wall Build

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

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Inner Wall Build and Firing One   Outer Wall Build   Upper Wall Build   Flat Roof Build and Stoke Hole Collar

Building the Outer Wall

The building of the outer wall went smoothly and quickly, incorporating the ceramic fibre blanket insulaton as it was built. We kept to a thickness of 2", but widened the wall at the top to create a shelf. (In the event, this could have been either about 1" wider or not created at all, except for under the mullite slabs we used as gathering hole floors.)

The problems appeared as it dried! We had not allowed nearly enough shrinkage space, naïvely thinking that compressing the ceramic fibre blanket would fully compensate. It turned out that we should have allowed about another inch or inch and one-half of space around the wall - both for shrinkage on drying and on firing (even though the outer wall did not fire to a high temperature in subsequent firings).

Nevertheless, we were able to fill the cracks that appeared as the wall dried, although we had to do this several times).

We also had to work on the top of the wall, filling in several dips and generally keeping it horizontal and at the same height as the inner wall (even though we had built the outer wall higher than the inner wall). We also needed to adjust the slots for the floors of the gathering holes that we had cut into the outer wall. Clearly, adjustments when building an outer wall around a fired inner wall need to be carefully thought through.

At this time, we also made two slots under the front of the gathering hole tunnel. These were to allow for the insertion of a steel bar which functioned as a support for the wood during firing, allowing air to reach the underside of the wood.

Making the stoke hole tunnel Making the stoke hole tunnel
Building the stoke hole tunnel outer wall Making the stoke hole tunnel
The stoke hole tunnel The stoke hole tunnel
Fitting the insulation Fitting the insulation
Starting the outer wall Building the outer wall
Building the outer wall Building the outer wall
Building the outer wall Building the outer wall
Building the outer wall Preventing the wall from drying
Preventing the wall from drying 'Vesuvius'
Working on the top of the wall The finished outer wall
The finished outer wall The finished outer wall
The first cracks The first cracks
The cracks at their widest The filled cracks
The filled cracks Using fire cement to build up one of the gathering hole floor slots
Building up the top of the outer wall The finished lower walls with the bars in place

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