Pottery kiln building project by Peter.

The plan is to build a small kiln using insulating bricks. It will be a gas fired, downdraught, catenary arch kiln, with a chimney.

The internal design of this kiln, one could imagine, is neatly made, with good fitting bricks, and a smooth surface. That is perhaps the good craftpersons instinct. But it has been suggested that by intentionally setting the bricks to randomly jut into the kiln a little, the uneven, erratic surface will increase the play of the flame and gases. This will give some interest and character to the results. Roof cover over kiln foundation.

Kiln foundation constructed from house bricks and sand. Perhaps this base is not absolutely necessary. Insulating bricks for the floor of the kiln will go over this base. Another possible solution is to use sheets of hot face ceramic insulating fibre on the floor. Refractory bricks are hard and durable but take up a lot of heat and transmit heat. If using refractory bricks on the floor then a layer of fibre over them is essential to save on heat loss. The walls will be of insulating bricks. Other additional layers, such as insulating fibre, or a mix of clay and vermiculite, could go on the outside, over the bricks.

Sketch showing draft plan for catenary arch, gas fired kiln. The catenary arch is derived from the shape of a chain hanging between two points. Holding the chain at its two ends, it will hang freely to give the catenary arch. A formwork in the shape of the arch can be cut from cardboard or other construction material. This is made into a support for the bricks until the key brick is set at the top. This is as far as construction has reached. The next step is to get some insulating bricks and start building.

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