#11  
Old 08-10-2011, 04:51 AM
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Location: Easley, SC
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Default Re: Jeff's 42" Pompeii in Easley, SC (near Greenville,SC)

Ok, I spent the weekend at my cousin's on the lake and didn't get anything done! Last night I did remove the forms from the hearth slab. I really wanted to see how the poured arch turned out. It looks good! I got all the supports out from underneath and can start working on the perlcrete hearth insulation.


I also added a vent on the backside to help with ventilation in humid South Carolina.

Jeff
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  #12  
Old 08-12-2011, 04:26 PM
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Default Re: Jeff's 42" Pompeii in Easley, SC (near Greenville,SC)

Ok... I'm about to make progress - grin!
I bought 3 bags (12 cuft 54#) of perlite today (15/bag) and 3 94# bags of portland cement. Also picked up some 5.5" hardboard for inside the forms to make the circle for under the floor.

I was reading Jake's (Jake's In Mass (Started July 3, 2011)) build and he had 30% volume loss with vermiculite.
I'm estimating 9.1 cu.ft. with my 5.5" floor. With the 12 cu.ft. of perlite and 3 bags (1.5 cu ft) of portland cement, I'll wind up with somewhere between 6:1 and 8:1 which will be ok.
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  #13  
Old 08-20-2011, 11:40 AM
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Default Re: Jeff's 42" Pompeii in Easley, SC (near Greenville,SC)

More progress today. I was able to put in the forms for the perlcrete (1h) and even got the perlcrete 'poured' (+ 2h with clean up).
I used about 11 cu ft of perlite and just under 1.5 cf of cement, so about 7:1. I was trying for 6:1, so the water I added was 1.8.

The volume I was trying to fill I estimated as 8.0 cu ft so there was about 25% compaction.

Now to let it cure for a week which gives me a time to get some 4x8x2.25 light duty firebricks (all I can get locally (Boral Brick)) and to decide on homebrew or Alsey Flueset.

Time for a cold beverage!
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Jeff's 42" Pompeii in Easley, SC (near Greenville,SC)-photo-0007-1-crop.jpg   Jeff's 42" Pompeii in Easley, SC (near Greenville,SC)-photo-0008-1-crop.jpg   Jeff's 42" Pompeii in Easley, SC (near Greenville,SC)-photo-0009-1-.jpg   Jeff's 42" Pompeii in Easley, SC (near Greenville,SC)-photo-0011-1-.jpg   Jeff's 42" Pompeii in Easley, SC (near Greenville,SC)-photo-0012-1-.jpg  

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  #14  
Old 08-21-2011, 06:41 AM
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Default Re: Jeff's 42" Pompeii in Easley, SC (near Greenville,SC)

The thickness of my insulation slab is 5". I thought I had enough 2x6s, but I didn't. I did have lots of 2x4s from the frame supporting the concrete hearth, so I laid 1 flat and another on its side (1.5 + 3.5 =5").

I checked on it this morning and am surprised how hard it is already. After reading other stories about how crumbly it can be even after two days, I was pleasantly surprised by its structural integrity. It certainly helps that it has been in the 90s yesterday afternoon and low 70s last night.

In any case, I haven't bought any firebricks yet, so I won't be putting weight on it until next weekend.
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  #15  
Old 08-21-2011, 07:27 AM
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Default Re: Jeff's 42" Pompeii in Easley, SC (near Greenville,SC)

Nice job Jeff. I had a little trouble with crumbling edges, etc so I put a layer of homebrew all around the ends. Now the real fun starts, have a ball.
Leigh
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  #16  
Old 08-22-2011, 06:41 PM
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Default Re: Jeff's 42" Pompeii in Easley, SC (near Greenville,SC)

Thank Leigh - looking forward to the bricks!

It looks like I'll be doing homebrew.
I called the local Heatstop distributor: $120 / 50 pounds - ouch, and that's if I pick it up.

Still have to go back and check on the Alsey Flueset. I don't remember it being that expensive.

Home brew is certainly cost-effective
Fireclay: $15-22/50 pounds depending on supplier
The lime and sand are certainly cheaper too and I still have 140+ pounds of portland cement
With oh sooo many people happy with the homebrew I'll probably become a convert.

Now I need to talk with my neighbor who said I can borrow his brick saw.
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  #17  
Old 08-25-2011, 07:29 PM
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Default Re: Jeff's 42" Pompeii in Easley, SC (near Greenville,SC)

I picked about 1/3 of my firebricks today and 50# of fireclay. It turns out the 50# of fireclay is not much, only about 1/2 cu ft. I joked with the guy at Boral Brick in Greenville asking where the rest of the bag is. It's a bag as big as 94# of portland cement, but only half full.
Still looking for hydrated lime. Will pick the white sand tomorrow at Home Depot.

Moving forward...slowly.
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  #18  
Old 08-26-2011, 03:20 AM
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Default Re: Jeff's 42" Pompeii in Easley, SC (near Greenville,SC)

Quote:
Originally Posted by PizzaIdiot View Post
I picked about 1/3 of my firebricks today and 50# of fireclay. It turns out the 50# of fireclay is not much, only about 1/2 cu ft. I joked with the guy at Boral Brick in Greenville asking where the rest of the bag is. It's a bag as big as 94# of portland cement, but only half full.
Still looking for hydrated lime. Will pick the white sand tomorrow at Home Depot.

Moving forward...slowly.
As you cut your firebricks you will get PLENTY of fireclay from the wet saw tray. I was amazed at the amount I wound up with after cutting the last brick. I think it was over a 5 gal bucket full!
Good Luck on your build!
John
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  #19  
Old 08-26-2011, 01:59 PM
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Default Re: Jeff's 42" Pompeii in Easley, SC (near Greenville,SC)

Jeff - I built my 42 inch with the one 50# bag of fireclay. You'll use a half bag of portland as well. The big volume is the "fine sand", that'll be 150 - 200#. Save the fireclay, as John suggests, from the wet saw for use in cladding the dome. If you get one of those big bags of lime, you will have more than a half bag left over. I used 5 gallon buckets with sealed lids for the ingredients to make it easier. A bucket full of fireclay, portland, and lime is all I used for building the dome and entry along with 3 bucketfulls of sand. As I say, this does not include any leveling or dome cladding materials. Make sure to use only "fine sand" and not playground sand. You will find as I did the homebrew is great stuff. Good luck!
Leigh
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  #20  
Old 08-26-2011, 03:05 PM
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Default Re: Jeff's 42" Pompeii in Easley, SC (near Greenville,SC)

Time for stupid questions:
LIME:
Can I use quicklime or does it need to be hydrated lime? (Did you know there was a lime website National Lime Association) It just confused me further. Neither Lowe's or HD had hydrated lime.
SAND:
Is quickcrete all-purpose sand 'fine'? I saw it at lowes and HD, butI didn't figure it was. Is the fineness the primary consideration.
I bought premium play sand (Short Mountain Silica - Mooresburg, TN) because is looked finer than the quikcrete sand. It's been washed and screened (but the bag doesn't say the screen size).
@RODEAIR - thanks for help. The five gallon buckets sound like a great idea too!
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