george koller on sun 24 nov 02
When we finished our shed I wrote into ClayArt asking if anybody
would have interest in learning how we confronted this interesting
question. Some six clayarters expressed strong interest so here we
go....
I have waited now until we have fired our kiln three times and
while there are still some issues (and inspections) pending I
am satisfied that the project goals have been reasonably met.
First the disclaimers:
1. Our shed design is NOT known or claimed to meet local
regulations or fire ordinances. You are on your own to find
these o ut and interpret them.
2. I'm not associated with Arrow Shed or any other shed mfgr.
How our project evolved:
1. We purchased a 9 cubic foot updraught gas kiln (exit flue on top)
2. We wanted it to be reasonable to move the entire kiln building..
3. For various reasons we wanted to "minimize" the investment, and
for example, keep the shed in working order for other possible
uses.
4. The nature of our kiln is such that hot vapors exit the top flue
at near full temp (2600d F) but at less than 2 feet over this exhaust
stream the temperature is less than 200d F because plentiful quantities
of cool air are drawn into the exiting air currents.
Key points for construction:
1. Our kiln manual suggests that the kiln be kept at least 6 feet from
any combustible material. While thinking about the design of
this shed I came to the conclusion that the shed had to be made of
noncombustible materials.
2. The studio in in NorthWest Michigan and winter weather being
what it is here - no shelter was considered that did not fully protect
the kiln.
After numerous stops at various "building centers" I eventually determined
that I could use a "light metal" shed of modest dimensions if I also used other
appropriate materials. I found just such a shed available from the manufacturer
of a line of sheds at factory closeout prices. This is one of the manufacturers
that supplies Menard's. Their factory direct closeout price was about 30%
less than the best store prices. The overall quality of the shed proved
reasonable, if not exciting. Here is the web site at which I purchased our
shed:
http://www.arrowsheds.com
Below I will detail how we went about the project but let me try to give you
a total cost on the project first:
6'deep by 10'wide by about 6'tall Shed $250
Shipping & Handling for shed $ 75
======
325
2 front-end loader scoops of pea gravel for our foundation
loose laid foundation : 16" by 8" by 4" deep solid blocks
2 courses of 15" by 8" by 8" blocks
4 DuraRock sheets 3' by 5' (a good insulating material)
3 Foundation sliding vents (size of a cement block)
1 Roof vent
3 Boards 2" by 8" by 10' long (achored by poured cement onto
the rows of blocks then screwed into at the shed base)
4 Some misc. sheet metal and metal corner materials for building
our hood and chimney
4 Cement anchor bolts, washers, and nuts.
1 Bag of Ready Mix cement
========
about $300
Time wise this project turned out to be pretty "expensive" as just
assembling the standard shed took some 25 hours, and laying the
foundation and blocks takes some patient work. In all the project
easily consumed more than 60 hours.
I have now fired the kiln 3 times. Even at glaze temperature, just
before shutting down, the shed has been cool to the touch at all points
except at the hood and above it. Even here nothing gets more than a
"good warm".
To my thinking good ventilation has been the key to the design. With
the ventilation we have built into the base and ceiling it has been
possible for me to see my breath while standing just a foot in front of
the kiln at full roar toward maximum (cone 10) temperature.
In part#2 I shall give the construction sequence and share some of
our experiences. I expect to submit yet this week.
Best,
George Koller
Sturgeon Bay, WI - Door County
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