#21  
Old 04-28-2010, 12:01 PM
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Default Re: spalling hearth

"Even if the brick are not refractory, which I don't believe is the case,"

I am not doubting you, I was just raised the possibility because this type of spalling is definably unusual.

Last edited by Neil2; 06-05-2010 at 05:32 PM.
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  #22  
Old 04-28-2010, 06:36 PM
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Default Re: spalling hearth

No worries, Neil. It's always a good thing to question and investigate. I appreciate all your input. Everyone's.
Kim
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  #23  
Old 04-28-2010, 07:42 PM
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Default Re: spalling hearth

Quote:
Originally Posted by Neil2 View Post
"Even if the brick are not refractory, which I don't believe is the case,"

I am not doubting you, I was just raised the possibility because this type of spalling is defiantly unusual.
I've been following this thread for quite some time and I have to agree with Neil. It is very unusual for refractory brick to act in this manner. In the pizzeria I used to work at, we would cook a number of things in the oven. Sometimes if not frequently stews and boiled potatoes/vegetables would boil over and liquid would hit the floor. Mind you the cooking floor has suffered different types of abuse and not to mention constant cleaning with a wet rag. Never has it chipped or spalled in its 9 (going on ten) years of operation. Therefore, I can only think of two reasons on why the brick has degraded in this manner.

1. If you live in cold climate, liquid or any type of moisture from the food or other source has penetrated the surface of the brick and has frozen causing the spalling.

2. You were sold inferior manufactured brick. This is easier to test by buying brick from another supplier to replace the ruined bricks.

Hope this helps.

Yours truly,
Raffy
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Last edited by Raffy; 04-28-2010 at 08:07 PM.
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  #24  
Old 06-04-2010, 08:00 AM
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Default Re: spalling hearth

Just an update: I finally got around to replacing the damaged bricks. Getting them out was easy, done as suggested above. I had a layer of sand mixed with fire-clay under the bricks and some of this had stuck to the removed bricks. So I scraped it off and saved it. But I had a lot left over even after making sure all bricks were level and flush.I had several bricks left unused from when I purchased my brick, so they came from the same lot - or close to it. But when I replaced the older bricks, size was an issue somehow. Nice sized gaping all over. I tried switching bricks to compensate for a lack of uniformity in manufacturing but that was a dead end, nightmare, useless endeavor. Everything is back in place now but, as I said, there are gaps bigger than I ever had. Not cast, but I could probably get a pencil in a couple of them. I'm not overly worried though.
The only draw back I can see is that one or two spalled bricks are the ones underneath the soldier course so they remain. Fortunately, these are on the perimeter and won't be a huge issue, if at all.
As always and ever, I want to thank you all for your input and passion. I tell people I built this oven all by myself in that I was the only person to so much as lift a tool or a brick. But I was helped by good people all over the planet. And that feels like a good connection.
Ain't Life grand!
Thanks,
Kim
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  #25  
Old 06-05-2010, 05:55 AM
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Default Re: spalling hearth

I do have a question, though, about those gaps. It's as though the bricks I took out had shrunk and so the areas where I put the new ones were bigger than they were when those bricks were new. I don't actually believe the bricks shrunk, just that it seems that way. Each brick I took out was, of course, the same size as the ones I put back in. But they didn't really fit the same. All I can think of is that due to the irregularity of bricks, their inconsistent measurements from one brick to the next, just means that I likely would not ever get new ones to match old ones anyway.

So, with these gaps and the fact that I'm not mortaring them in place, is there anything to be concerned about? Such as their being loose and becoming wobbly and moving as I bake? Or will heat and ash eventually "cement" them in place?
Thanks,
Kim
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  #26  
Old 06-05-2010, 06:48 AM
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Default Re: spalling hearth

I can assure you the brick dd not shrink. Possibly the ones in the floor expanded, the gaps filled with ash, and when you removed the spalled brick it left a slightly larger opening. So long as you bed the new brick in they should be fine.
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  #27  
Old 06-05-2010, 07:01 AM
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Default Re: spalling hearth

Oh, I know they didn't shrink. It just looked that way. What do you mean by "bed the new brick?" I just took up old ones and replaced them with new.
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  #28  
Old 06-05-2010, 08:13 AM
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Default Re: spalling hearth

What did you use to lay them originally?
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  #29  
Old 06-06-2010, 04:11 AM
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Default Re: spalling hearth

I haave a bed of sand mixed with fire clay that I had mixed with water to even out the surface. It was that mixture that was clinging to the bricks I removed. I scraped off that and used it as a dry bedding.I wasn't sure if I should wet it again so I didn't. I had a bit left over too. Still, everything is flush and level with all other bricks.
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