Construction of a Gas Fired Soda Kiln Part 1

[@quantumofconscience6538]

Just to provide a bit more information about the firebrick if anyone needs it. When he says "insulating firbrick" this is the "soft" firebrick used for forges sold online, that are very expensive. They start at 2300 degrees rated and go up to 2600 and higher. They don't absorb heat, but are NOT structural bricks. You can break them apart, even with your hands. The other "yellow bricks" (most used here) are the standard "hard" 9 x 4.5 x 2.5 inch firebricks sold anywhere that sells brick and sells concrete block. These are about $2.20 per brick... cheaper than the "high heat soft reflective brick," which are also the same exact dimensions.

[@EverythingIsPhysics]

great video, looking forward to part 2!

[@WashingtonStreetStudios]

Great handle EverythingIsPhysics, I'm trying to finish part 2 before Christmas, so hopefully it will release tomorrow around 10am eastern.

[@erikhunsinger4937]

Sound is a lot better. I was thinking you could have just done a voice over. Thanks for redoing.

[@WashingtonStreetStudios]

Thanks Erik, we found a bad cable in our audio setup! Hopefully I'll have part 2 out for Christmas!

[@mikeh6172]

These videos are so in depth and so helpful! I was wondering though, why have you used two layers of brick for the kiln body and chimney? I see a lot of kiln designs with only one layer of bricks. Are there 2 layers because it’s a soda kiln? Does it make the kiln more insulated and efficient?

[@WashingtonStreetStudios]

Since it is a soda kiln we couldn't use insulating brick. Hard brick holds up well to soda but does not insulate very well, so we doubled up the wall. That said, if it were a reduction kiln without soda we would have used two layers, one insulating brick for efficiency and one hard brick for structural integrity. The two layers on the chimney reduces the heat transfer to the exterior wall. I hope this helps!

[@mikeh6172]

@@WashingtonStreetStudios Super helpful! Gave me a lot to think about. Thank you. Would the softer insulating brick on the inside hold up to wood firing conditions as well? I’m hoping to build a hybrid gas/wood kiln. Similar idea to this kiln but I won’t be using soda.

[@WashingtonStreetStudios]

I'm going to send this one to Phil, he has a lot more experience in this arena than I do. I'll post his response.

[@mikeh6172]

@@WashingtonStreetStudios oh that’s great! Thank you so much!

[@andrebraha]

Thanks for great content, definetely the best I've found on KZbin so far. I am planning to build a kiln similar to this in the near future, but I am having some difficult sourcing the right bricks in Brazil. Are the ones used in the inner walls those high temperature insulating bricks (ones that are very light weight)?

[@WashingtonStreetStudios]

The lightweight insulating bricks are only used on the floor of the kiln. All of the bricks exposed to the atmosphere are super duty, very high heat and very hard brick, since it is less susceptible to the soda. This is a soda kiln and soda is very corrosive. If you are building a gas reduction kiln without soda or salt you can use the light insulating bricks. Hope this helps.

[@andrebraha]

@@WashingtonStreetStudios Thanks! It helped a lot. In fact, I am not planning to use soda or salt. I guess i'm going with the light insulating bricks than. Should I use them for both layers? Are they strong enough to hold the weight, specially on the chimney?

[@WashingtonStreetStudios]

The insulating bricks are not strong enough to support any weight. You should only use them on the inside of the chamber. And your arch span must be wide enough to be supported by your outside layer of super duty bricks. The insulating bricks will improve kiln efficiency but structurally they are not 'building' bricks. You can use them to create a door since the door does not support the weight of the arch. Best of luck with your kiln build and if you want to share your plans when they are ready we will be happy to review them and make recommenations.

[@andrebraha]

@@WashingtonStreetStudios That makes sense! Super duty fire bricks on the outer layer and insulating ones on the inside than. We are currently relying on another person to fire our pieces, which I think reduces a lot of the cool possibilities and reproducibility. If all goes well, we should start buiding our own kiln in about 6 months. For now I've been studying some, reading some books and watching all your amazing content. Having you reviewing our project when the time comes and helping with some advice would be of great value, I will definetely be up to that. What is the best way to get in touch when our project gets ready? Best regards.

[@WashingtonStreetStudios]

Email: [e-mail]

[@FinancialHealth88]

Are there plans/drawings available that I can follow to construct one of these kilns?

[@WashingtonStreetStudios]

Leighton Durney, Here is a link to our ebook in our store. It is $10 and has pictures every step of the way. It will be easy to count the bricks to determine what you need to do to build the kiln. www.hfclay.com/product-page/construction-of-a-gas-fired-soda-kiln-at-washington-street-studios-ebook

[@ShopperPlug]

Why do you call them "high heat" bricks?? It's called fire bricks. Also what is the valid reason you are not using refractory mortar? To save on costs?

[@WashingtonStreetStudios]

Max, there are a variety of fire bricks and each type has a different heat tolerance. High Heat is a type of firebrick that is dense and handles temperatures up to ^10. Super Duty bricks are dense bricks that handle even higher heat. We used super duty bricks whenever they would be exposed to the heat and atmosphere in the kiln. Super Duty bricks handle the heat and the corrosive properties of the soda.

[@WashingtonStreetStudios]

And we didn't use mortar for two reasons. Damaged bricks are easier to repair and kilns are easier to rebuild, if there is no mortar. Also refractory mortar can handle the heat but can break down when it comes in contact with the soda atmosphere. When it breaks down it can fall on pots in the firing chamber. Since the kiln is sturdy enough dry stacked and framed, mortar isn't required.