Okay, so here’s the deal with my kiln brick replacement adventure. It all started when I noticed some serious wear and tear on the bricks inside my kiln. I mean, this thing has seen some action over the years, but it was getting to the point where I was worried about its performance and safety.
First off, I started by assessing the damage. Some bricks were cracked, others were chipped, and a few were just plain crumbling. It wasn’t a pretty sight. I knew I couldn’t just ignore it, so I decided to take matters into my own hands.
I did some digging online, you know, just browsing around to see what other folks have done. Turns out, replacing kiln bricks isn’t rocket science, but it does take some patience and elbow grease. I found some discussions online which said some folks paid like $4 to $25 per square foot just to fix the mortar, some other guys said it probably cost $187 – $244 to repair one brick. I guess the price is not that cheap.
And I thought, “Man, I ain’t got that kind of cash to splash around, and I ain’t payin’ somebody else to do somethin’ I can do myself.” So, I rolled up my sleeves and got to work.
I gathered my tools – a hammer, chisel, some safety goggles, and gloves. The safety goggles are key, trust me. You don’t want any of that brick dust flying into your eyes. Then I carefully removed the old, damaged bricks. Some were easier to get out than others, let me tell you. There were a few stubborn ones that put up a good fight.
With the old bricks out, I cleaned up the area. Got rid of all the dust and debris. You want a nice, clean surface for the new bricks to sit on. Then came the fun part – putting in the new bricks. I carefully placed each one, making sure they were snug and level. It was kind of like putting together a puzzle, except the pieces were heavy and dusty.
These bricks are fragile, someone said it was made by mixing refractory materials with wood pulp and then firing it to burn out the wood pulp, I am not sure if it’s true, but when I hold the brick, it’s really not that solid.
- Assess the damage and decide which bricks need replacing.
- Gather your tools and safety gear.
- Remove the old bricks carefully.
- Clean the area thoroughly.
- Place the new bricks, ensuring they are level and secure.
After all the new bricks were in, I inspected my work. Not too shabby, if I do say so myself. It wasn’t perfect, but it was a heck of a lot better than before. And the best part? I saved myself a ton of money by doing it myself. I heard that those kilns with advanced insulation and energy-saving features cost more initially. Kiln costs vary a lot, from $700 to over $20,000. Mine is not expensive, luckily.
My takeaway?
Don’t be afraid to tackle these kinds of projects yourself. With a little research and some good old-fashioned hard work, you can save yourself a bundle and keep your equipment in top shape. Plus, there’s a certain satisfaction that comes from fixing something with your own two hands.
