knoelle2@yahoo.com on wed 6 dec 06
I have an old electric kiln which needs new elements
so I thought it would be a good time to repair the
soft-brick which is in bad condition. The bottom is
cracked and sagging, several bricks have big chunks
missing, other bricks have crumbling around the edges.
I'm not sure how to proceed - I feel nervous about
replacing actual bricks - and I wonder to what extent
I can build up with refractory cement? I'm considered
about holding the elements in place and also about
providing adequate insulation. I wonder if I can lay
fibre on the bottom?
I'd be grateful for any advice....
Kathleen in Boston
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Arnold Howard on thu 7 dec 06
From: "knoelle2@yahoo.com"
>I have an old electric kiln which needs new elements
> so I thought it would be a good time to repair the
> soft-brick which is in bad condition. The bottom is
> cracked and sagging, several bricks have big chunks
> missing, other bricks have crumbling around the edges.
I visited a studio a few months ago, and someone showed me
photos of his used kiln. He wondered if the kiln was
salvageable because it had damaged bricks.
I told him that the kiln appeared to be in pristine
condition. What he considered extensive damage was to me
only minor wear. Something to consider: The brick damage may
be less serious than you think it is.
There is an art to using repair cement. Years ago when I
first came to Paragon, we held maintenance seminars for
distributors. They would not receive their certificate
unless they could cement two pieces of firebrick together.
It seems logical that you could build up broken bricks with
solid masses of repair cement. However, it usually doesn't
work. The repair cement will break out. It is most effective
applied as very thin seams between bricks. The thinner the
seam, the better.
You can build up damaged areas on the brick bottom with
repair cement and grog (powdered firebrick). Add just enough
cement to keep the grog together, and fill in low areas on
the bottom.
If the bottom is cracked but none of the firebricks are
missing, I might not even replace the bottom. Just slide a
heavy sheet of galvanized steel between the kiln stand and
brick bottom.
Most wall brick damage is along the top edge where the lid
rests. Those bricks are easy to lift out and replace. Loosen
the case and lift out the brick. Sand the new brick along
the top surface so that it matches the other bricks. But
sand only enough to make the surface even. If you sand too
much, you will form a gap where the lid rests on the wall.
After sanding, apply a coating of repair cement watered down
to the consistency of coffee cream. Wipe off with a rag
immediately after applying the cement.
Removing a wall brick that is farther down the wall can be
difficult, even if you are replacing the element anyway.
When you remove one brick, you often damage the adjacent
bricks.
An alternative to replacing a brick is to cut out the
damaged section and slide in a new section. The brick repair
piece must fit precisely. To shape it, file with small
sanding "blocks." You can make miniature firebrick sanding
blocks by gluing self-adhesive 285 grit sandpaper to wood or
to strips of banding steel (the type of banding used in
crating).
If you decide to replace firebricks, there are two methods:
1) Slide the firebrick upward temporarily removing all the
bricks above it; 2) Peel back the stainless steel case and
pull the brick outward.
When you replace a brick, it may be necessary to sand the
new one along the mitered edges.
Sincerely,
Arnold Howard
Paragon Industries, L.P., Mesquite, Texas USA
ahoward@paragonweb.com / www.paragonweb.com
William & Susan Schran User on thu 7 dec 06
On 12/6/06 10:00 PM, "knoelle2@yahoo.com" wrote:
> I have an old electric kiln which needs new elements
> so I thought it would be a good time to repair the
> soft-brick which is in bad condition. The bottom is
> cracked and sagging, several bricks have big chunks
> missing, other bricks have crumbling around the edges.
You don't mention what brand/type of kiln you have, but if it is a sectional
kiln and the bottom is separate from the walls, may be able to get a piece
of sheet metal cut to the same dimensions of the floor, put that on the
stand and flip the floor upside down the reveal a "new floor".
If the wall brick are in sad shape (not enough brick to hold element in
place), take apart the sections, remove electric control box, take a digital
photo or tag each wire location, remove old elements, loosen metal banding,
slip out bad brick, replace with new (that you ordered ahead of time) brick,
reassemble and install new elements. I have also done temporary repairs by
cutting pieces of brick and pinning in place with old element pins.
--
William "Bill" Schran
wschran@cox.net
wschran@nvcc.edu
http://www.creativecreekartisans.com
Rogier Donker on fri 8 dec 06
Well now Kathleen...
Sounds like you are looking for a major rebuilding of an old hobby
kiln. New elements, new brick.... unless you know what you are doing
(and it sounds like you do not know...) I would thrash the old kiln
and find another used one. Replacing all the brick, or most of them,
runs into money and you already know that the element replacement
might be as much as
$ 390.00, depending on the model, bricks cost anywhere from $ 6.00 to
$ 11.50 a piece, again depending on the model.........
choice ,choices...
Rogier
Andy Misner on mon 11 dec 06
$6 - $11 WOW I sell them for only $3.50 each in quantities of 25, less if
buying in quantities for 2600 deg f insulating brick. I know that this
archive isn't really for posting of advertisments but I thought that I'd let
you know that some places are alot cheaper.
Andy
www.indfirebrick.com
On Fri, 8 Dec 2006 08:52:32 -0500, Rogier Donker wrote:
>Well now Kathleen...
>
>Sounds like you are looking for a major rebuilding of an old hobby
>kiln. New elements, new brick.... unless you know what you are doing
>(and it sounds like you do not know...) I would thrash the old kiln
>and find another used one. Replacing all the brick, or most of them,
>runs into money and you already know that the element replacement
>might be as much as
>$ 390.00, depending on the model, bricks cost anywhere from $ 6.00 to
>$ 11.50 a piece, again depending on the model.........
>choice ,choices...
>Rogier
>
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