Chapter 2 ‘CHAPTER 2/ METHODS OF KILN CONSTHLCTION 18 Methods of Kiln Construction The laying of rebrck in kiln construction i 2 specialized masonry sil There ae rules that must be followed to ensure + strong, monolith structure that will function eficeny at high temperatures and be ‘Surabl, STRAIGHT-WALL CONSTRUCTION ‘There are thee vital rules in straght-wall con- struction’ (1) An supported wall 4112" thick ean not be higher than 3 feet (2) an unsupported wall ‘thick, ed by alteest header and stetcher courses, ‘ant be higher than 8 fet (3) an unsupported wall IDI? tice, ted by alternate header and stretcher ours, cannot be higher than 12 feet "There ate five base methods of laying staight wall header coure, seetcher course, altemate Reader and stretcher rowiock course, and. soldier HEADER COURSE Tn header course, bricks are Ini engthwise cose the wall withthe 2 U2" x9" debuting gaint ‘he next brick (Fig 2-1). AU header courses develop 3 ‘esonably sabe wall with minimum ho face expo fore (4 12° x2 U2) and the back side ofthe Brick ‘Subject oelatively low temperature, Header courses fe good for bricks facing near temperature limits, Fig. 2—1: Header course, with bricks aid across the wal. ‘Awall aid mainly of headers, which normally consis of hee or four rows of header courses to one tov of stretcher courses (Fig. 2-2) as the advantages ofan all Reader wal but has greater igi. Fig. 2-2: Alternating four header rows with (oe recher row gives eater rigidity. STRETCHER COURSE Sretcher couric are lid lengthwise, running swith the wall so thatthe 212" 9" surface Becomes the hot face (Fig. 2-3) An allstrecher wall isnot Tigi and isnot recommended for ove 3 fet In Fight unlesit ha other meas of suppor Fig. 28: Stretcher course, with Bricks raming along the wal. ‘A vrll aid msinly of stretchers, which normally consnts of three to fut 1s of stetcher courses fone header row a showin Fig. 2-5 a much ston: fer wll and has an important advantage In 2 kn Inet bricks ae subject slagging or ster exosive {ction suchas occurs in a wood-fired kn or salt lane ln, the exterior fe canbe easly repaed by feplacng the # 1/2" x 9" hace brick with another, ona 1/2" skin wall (am mix) ed into the remain Ingrid, ALTERNATE HEADER AND STRETCHER courses ‘Alternat headers and stretches in walle of" and 13 112 thicknesses ate exterely stable. This is con sidered good price in beckayingFig. 2—A: Alternating four stretchers with one adr makes it easy t replace a hot fce brick Itis alo considered good practice to have alter- nating joints on each row, which means no joints run inastraigh line above cach other (Fg. 2"). Fig. 2-5: Alternating joints produc a stable wall. ‘This alternate header and stretcher walls some- times refered to at "English bond” ands the mort, ‘common method of construction uring dense ite ‘brik T begin 9" wall 9" 6 large Bick 1/2" Dat and straight bricks are used to setup the ot pat tern for subsequent rows (Fig. 2-8) Fig. 2-8: Layout for bac of" altrnate header and stretcher wall ROWLOCK AND SOLDIER COURSES In rowiock course bricks ae lad on their Sides (2 12° X9") side to-ide or end to-end (Fig. 2 ‘Dana solder course, bricks are laid on end (4 U2" 21/2), Sdetoside o end-toend (Fig 28) Rowlock course: left) side-to-side (right) end-o-end oe Fig. 28: Soldier course (eft) side-to-side: (ight) end-sovend, WALL CONSTRUCTION 13:1/2" WALLS “There are thee usual methods fr lying 13 1/2 wall: 1 One may use standard 9" x 4 U2" x 2 2" bricks with "36" 2 U2" bricks. The 13 1/2 wal (Ghoven in Fig. 2-9) has no joints running through it ‘Also (shown in Fig. 2-9) alternating heade/stretcher ‘with suetchectheader, use 9° x 6" 2 12" brick fr ‘Staggering joins. Fig. 2—9: Method 1 for lay ing 1312" wal, 2. In the second method, the wali laid with four rows of hot-face stretchers backed by headers, and one row ofheades, which, in tun, sbacked with Stretchers (ig, 2-10). The advantage ofthis eonstuc- ‘oni that ie makes for eae rept.Fig. 210: Method 2 or layinga 13 1/2" wal. 3. In the third method of lying 13 1/2" wall, ‘very fith-tow header course has 4131/2" brick init ‘with alternating joints on each row. “Ths type of construction makes an extremely stable wall ha easy repair. Its also good for set- ting sprung arches Pimow — MexT stows SR ROW Fig, 211: Metso 3 for laying a 1312" wall, FLUES ‘When building flues into the lla wall, the nor- ral distance between flues will be 9, or one brick ‘The average sie of Tues wl bone brick standing on end (974 129). (Fasng the? 12" brick sere, our rows of bricks wil tse the Ave hoes tobe 41/2" CumPren 2/MEMI0B OF KAN CONETIVCTION-3¢ 10" Thre bricks ofthe 21/2 series wil be sufficient in almost ll cases however itt better to erin bat= ing flues too large, rather than too smal.) All fue holes shouldbe but on aheader couse with the ue opening directly sbove a header (Fig, 212). The rex fon iz thatthe header brick becomes a knockout brick incase the fue bo smal. tn ain the 9° five separator, alternate header and stretcher courses Should be weed CURVED WALLS Cursed wall are found in domed, downdraft and beehive Hlne. The exon curved wal ae ed that they ate much stronger and mote stable than a ‘night wall The curve creates 3 wedging aco, which hegpe the brick fram fling inva. The only Timing ftctor on height he compression strength of the bottom bricks. This ie why many early Kine ‘with walls 18-22 1/4 hick (n some cases up to 3to5 Tet) cou ary the thru ofthe dome without rein forcing suppor. Material choices for curved wall 4 "wall thickness (rch brick can be sed, but not recommended) wall hicknes-fy (or combination ofcirle and key bik) A713 1/2 and greater wall thicknes-key (or combination of lr snd key brick: wedge bricks not recommended) ‘Carved walls ae laid with the same alternating Soins straight walls (213). SE EE Fig. 2-13: joints are aerated in curved wall, Neo