Visit to a nearby treasure. Colonial Brick kilns at Cayuga.

Driving home to Indiana from Denver, Colorado over the weekend with my wife, my sister and her daughter, I made a short visit to a brickworks in Cayuga, Indiana. Id known about it being in my state for over a year. But never had found time to make the trip to see it.

The 10 or so beehive downdraught kilns are operated by Colonial Brick Co. and still are coal fired to this day. They specialize in recreating old and out of date brick for important historical restorations all over the country.

The sights and smells of the smoke here is a powerful step back in time. If I lived closer, id work for free on the side, just to learn better some of the old ways they made and fired the brick.

I really want to build my next brick kiln like one of these scaled down for my needs. Maybe next year.

Death and rebirth, A new kiln for Wabash and Erie Canal Park in Delphi.

With much excitement and some sadness I report to you the ongoing construction of a new brick and tile kiln in Delphi. I have been honored with the task of building a replica historical brickmaking kiln at the Wabash and Erie Canal Park. There you can find a village with several cabins and period homes and other structures from the 1830's to 1880's time frame. They also have an actual reconstructed canal boat that offers rides. For those of you with an interest in metalworking there is a blacksmith shop as well as two iron bridges nearby that have been restored.

The new kiln is a scaled down simple updraft clamp scove fired by wood. This is much like kilns of that time in this area. It is designed to fire a few hundred bricks or tiles each time. The inner body of the kiln is made out of recycled firebrick. This is surrounded by an outer shell of common red brick. In between is filled with dirt for insulation and to stop cold air leakage into the kiln.

The new kiln is the largest I have ever built so far. Because of that it has put a strain on my supply of brick, requiring me to tear down and recycle both of my other kilns for the needed brick.

The barn kiln wasn't a big loss to me as it never worked out as well as I would have liked. Failing to reach peak temps no matter what I tried.

But to loose my backyard bottlekiln is sad. It more than did as I hoped it would. Its sacrafice for the greater good will not be in vain. I hope to one day bring it back bigger and better.

A fellow brickmaker

I would like to introduce to you Tony Mugridge, a fellow brickmaker and potter.

His work is at least a few years more advanced along than what I am doing now. He is fortunate in that he has access to his very own complete historic brickworks. His work can be found on Facebook as well as his own website. I invite you to take a look at what he has done.

http://www.ajmugridge.co.uk/index.htm

Bridge build photo update #4

My kids became some extra crew help a few weekends ago during the center pier concrete pour.

I pulled the flood damaged bridge frame out of the creek bed with the bulldozer. It will be cut up and used in the contruction of the new bridges steel truss frame.

Here are some more recent photos showing the start of the center pier and the west abutment.

A side shot showing all three now in various stages of construction.

Your name in brick.

I have been kicking around the idea for awhile now. The idea of offering for sale a custom made brick with your name pressed into it. Maybe for promotional stuff, like a town fundraiser. That or the name of your town, club, buisness, maybe even a favorite team name. I dont think anybody has ever offered this in this way before. Yes ive seen engraved brick sold all over the place. But not 3-D "pressed" in names, just like the old time bricks had in them.

It would be very unique.

Wouldn't be near as much written on the bricks. Pretty much a single word or maybe two.

Engraved bricks can offer more words, but not the depth. They just look like they were something added on later. An afterthought. Not like that when its really a part of the brick itself.

Im looking for opinions and feedback on this idea!

Bridge build photo update #3

Here are some more progress photos on the east abutment and the start of the center pier.

More bridge building pics.

More bridge construction photos. East bank abutment. Since these photos were taken I have backfilled the wall, poured concrete for the upstream wing, and begun foundation work on the down stream wing.

Once all of the wing work is done on this side of the creek, I will pour a concrete slab over the wall and backfill. Then its off to the west side of the stream to do this again. I am also thinking of building a center pier to increse the bridge load carring ability.

Pouring concrete today.

I was caught working on the bridge today.

Update photo progress.

Its been awhile since I posted any pics on the my woodfired water boiler project for home heating. Here is the boilerhouse showing the summers progress. Pretty much all the brickwork is now done. I still need to fit the windows in and build a door. Finish the roof and add the firewood chute from the adjacent wood shed are after that.

Ive started on my replacement bridge.

Im finally underway on my replacement bridge. The bridge will cross the small creek on the property that limits access to my workshop and future site of my pole barn. I am building the foundation piers on both banks. Not sure what form the finished bridge will take yet. I first had in mind a concrete or brick arch bridge, but have lately thought a steel pony truss bridge may be quicker and cheaper. i have most of the materials already on site. Either way its gonna be a long project. Probably a year to complete it if im lucky!

This is a small pony truss bridge photo to give you an example of what I want to build. The deck it missing from this old one though.

Here is another pic of a pony truss near my home. It has a poured concrete deck over steel under framework. My plans call for a span of about 32 feet and a deck width of aroun 12 feet.

Here is a stone arch bridge like the one I at first wanted to make. I think it would be to huge a job for me to try this now.

Bottle kiln, firing #2, better but not good

I kept the top temp of the firing down to around 1850'F at the pryometer. But the center of the chamber still got much hotter than that! Gonna have to rethink the kiln and firing cycle some.

Improved results over first firing of the new bottle kiln, but along way from good results.

Can you tell which brick is wood fired and which one is electric fired? Both were fired to 1850'F.

Monster results. Too hot!

The bricks literally MELTED! Wow thats gotta be the hottest kiln Ive made ever.

It took me a few hours with a hammer and chisel to force remove these clinkers.

Heres what it looked like when I first opened it up. You can see that more heat was at the center of the chamber. It was cooler th the edges. Well over 2000 in the middle. Maybe 1800 by the walls.

I do like the wood glazing that occurred on the bricks. The cracking and tearing is most likely from the rapid heating of the clay in the bricks. Need to slow it down to at least double the time on firing. At least 8 to 10 hours. And max temp no more than 1850'F.

Here are a few more pics.

The firebox door.

A look down thru the chimney.

A cutaway diagram.

Progress at the boilerhouse.

Heres a new photo for all of you. As you can see Its comming along now. I still have alot of work to do on the north and east walls. Then its a door and a window along with finishing the roof.

Firing temps and brickmaking

The finished color and hardness of a clay brick has alot to do with the highest temp achieved and length of time held there before cool down. There doesn't seem to be as much effect on outcome if the ramp up time to peak temperatre is varied shorter or longer. Obviously the type of clay will have a profound influence on the finished product as well. But here I will focus on firing temp of a single type of clay.

Below are tiles and bricks of the exact same source of clay, prepaired the same way before firing.

They are identical except for the one brick on the lower left. The three of the same color were fired to 1900 deg F over an 8 hr period in my electric kiln. The darker brick made at the same time as the others, was fired to 2000 deg F over 9.5 hrs in the same kiln. All settings on the kiln were identical.

The surface of the darker brick is closer to that of a paver or clinker. It has a reflective quality to it that the others do not. All the bricks and tiles are fired fully and have a strong 'ring' when tapped together. The darker brick has a higher ptched ring to it.

If I were to ever try to make pavers or outdoor tile, they would be fired much like the darker brick. I believe the water proof qualities should be higher.

Notice the small paw prints on the one tile. My kittens were having fun after I made up the tiles.