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

In building the upper wall, we again traced the outine of the lower wall onto a plastic sheet and added an inch around it. We built it 8" tall, about 3.75" to 4" thick, and incorporated three clingfilm-covered, corrugated cardboard forms for the gathering holes, each 7" wide by 6.5" high by 4" deep.

As the upper wall was weak in the areas above the three gathering holes, we had to create a method of moving it without stressing it in those areas. This we did by drilling holes through the strongest areas of the wall for two blowing irons arranged in an 'X' formation, and wired them together at their intersections. We could plug these holes later with some ceramic fibre blanket. Using this method, two people could easily and safely lift the wall and move it into place on the furnace.

Before we moved it, we ascertained the positions of the slots in the roof and marked them on a plastic sheet stretched over the top of the wall. See this page for photos of this part of the build.

The final stage before moving the upper wall was to level the top. This we did after it had dried, using one of the 24" by 24" concrete paving slabs to grind it flat.

Marking the inner extent of the upper wall The plan of the upper wall, allowing for some shrinkage
Starting the wall Covered up to hinder overnight drying
Continuing the wall build The finished wall
Planning the position of the lifting rods Drilling the holes for the lifting rods
Drilling the holes for the lifting rods xxx
The lifting rods in position The lifting rods in position
Pinning down the plastic sheet ready for drawing the slots that will be in the roof Using a concrete slab to grind flat the top of the upper wall
Using a concrete slab to grind flat the top of the upper wall

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