Longmont, CO new WFO build - casted over sand

[david s]

That black ring is what I posted about before in my previous post https://community.fornobravo.com/for...204#post399204

The soot burns off at around 300 C, so that black ring indicates that the refractory there is below that temperature. This is quite common on new ovens. If you have an IR thermometer it should confirm this. Don't push the fire too fast until it has all burnt off.

[jonv]

That ring is below the level of the smoke - it'll always be there and shows the layer of clean air drawn in to the oven whilst the smokey hot air exhausts above. Nothing to worry about

[cnegrelli]

So I continue with curing fires, reaching 450 F for long periods, keeping warm overnight. Dome has a distinct ring around bottom about 4" up. I've been using fires contained in a basket that is an inch or so off the floor to boost oxygen. What is this ring line and what does it mean to me? Zero visible cracks from inside so far. Any help appreciated!

[cnegrelli]

Continuing the curing fires with charcoal and seeing some progress in terms of lower temps closer to dome top temps as I move the fire around the periphery. Keeping the dome around 300-350 and just going at it for hours at a time and being patient right now.

Meanwhile, finally have the front of the enclosure the way I want it (the engineer in me knows I should have taken the time over the winter to learn a CAD program, but alas, I was lazy). Plus I'm and Electrical, not a Civil or Mechanical, so there is that. Here's the latest pic.

[cnegrelli]

Yes, that's correct. When the top of the dome reaches around 300 C it burns off the soot and will become dry. This means that it will heat even faster and the temperature difference will be even greater. You can spread the coals out to the sides in an effort to heat the bottom rather than the top. It is always difficult to maintain a fire in a new, wet oven and it's common for the fire to go out or get the charcoal or brickettes to light. You will probably also find it rather smoky. As more of the black burns off you will have a persistent ring of black at the base of the oven which indicates that this part is still not dry, so don't get too eager at that point. Because most of the oven will be dry the fire will gallop away easily.

David - thanks again for all the advice.
My dome is very dark, almost black in color before the fires (that's the color of the Castmax 28 refractory) so I'm going to have a lot of trouble knowing when I've cleared the dome!

It started to sprinkle a few times today for minutes at a time, and I'd cover it with a tarp. When I took it off, there was quite a bit of moisture collecting in just a few minutes, so it's plenty wet in there. It's been 17 days since I cast the dome, 10 days since I cast the gallery/flue, and 5 days since I wet it up to patch. I honestly thought it would be pretty dry given our humidity here has been very low. I was warned.....

Had a charcoal fire going today for about 10 hours at 250F at the top of the dome. 140F about 8" up on sides. Floor stayed about 100.

Working on the enclosure as much as I can. Damn Octogon is driving me crazy!

[david s]

I'm seeing floor staying around 100 degrees yet dome top up at 250. Not seeing steam. When these things are full go (later) what sort of differential is to be expected? Heat rises, no?

Yes, that's correct. When the top of the dome reaches around 300 C it burns off the soot and will become dry. This means that it will heat even faster and the temperature difference will be even greater. You can spread the coals out to the sides in an effort to heat the bottom rather than the top. It is always difficult to maintain a fire in a new, wet oven and it's common for the fire to go out or get the charcoal or brickettes to light. You will probably also find it rather smoky. As more of the black burns off you will have a persistent ring of black at the base of the oven which indicates that this part is still not dry, so don't get too eager at that point. Because most of the oven will be dry the fire will gallop away easily.

[cnegrelli]

I'm seeing floor staying around 100 degrees yet dome top up at 250. Not seeing steam. When these things are full go (later) what sort of differential is to be expected? Heat rises, no?

[fox]

I managed to do two small fires a day for the first few days but then the oven would not cool down enough so I went to one fire every 24 hours.
I used kindling for the first few then added a few blocks of wood but kept the fire going for an hour or so after around 8 fires I was getting 250c on the floor then just feeding it for around 1/2 an hour.
I made the first cooking fire after 7 days & got the floor to 400c.
The dome went white alter my second cooking fire, I held around 400c for two hours.

[cnegrelli]

small fire late yesterday - but didn't have much success in getting the charcoal going.
This morning, I rigged it up to get it off the floor and get some oxygen and I've got a nice charcoal fire going.
Large differentials between dome peak and lower walls, which I've heard David state many times means there's moisture down below. No doubt.
So I'll be going at this slow.

Current Temp readings:
Floor: 100 F
6" up Wall: 140 F
Top: 220F

[david s]

The thicker it is the slower you need to go. Avoid direct flame impingement on the dome in early fires by using a combo of small sticks and BBQ fuel. If you see visible steam, back off you are going too hard.

[cnegrelli]

Finally can start doing some fire today. Casting has been dried out fo a few weeks now, just haven't had any time.

david s the link you sent me for Refractory suggests: Firing

A slow fire can be applied and the temperature raised at the rate of 50șC approx per hour per 25mm thickness of lining until working temperature is reached.

For 50mm, does that mean, half that rate or double that rate?

I'm assuming since it's about 30 degrees C outside, I can take it up 50șC, every two hours (half the rate).....

[cnegrelli]

[cnegrelli]

I think that you need to think about how long until you will have this enclosed. Turns out squirrels, mice, & birds love to pick out fibers for their nests. As Russell noted, since you are enclosing and adding vermiculite there are other jobs that should have higher priorities...but that assumes you are going to get your enclosure built & filled & closed soon .

As for venting, I don't think you need to worry about it since your enclosure will probably have a built-in screened soffit or two and that will keep out the rodents and let any moisture escape. Looking good on having curing fires pretty soon (if you haven't already ).

No soffits. It's really an octogon shape. 3D. Just like a dome is half a sphere, my enclosure is half of a complete 3D octogon. We will see!

[cnegrelli]

Since you are enclosing and adding dry vermiculite, your labor resources might be better spent on other aspects of the oven. Your oven is really insulated well. FYI, you can drill some Tapcons into the hearth to fasten your wire to hold down the CF blanket.

I have lots of wire crisscrossing the outside of the insulation as suggested. But I do have a massive squirrel problem. By the way, I left the gas can out last night, and they ate thru the plastic spout on it. Unbelievable.

The enclosure is a total PITA, as it's a complete octogon. Not like Octoforno, but simliar (picture posted in this thread earlier). I'm struggling with how to frame some of the tidbits, but I think I will just have to do it. The gallery area ended up bigger than I had planned, so I'm trying to not make the enclosure bigger than I need to.

I am trying to jump on the enclosure part, as my wife wants to see that done asap. Really the whole reason I went with cast vs firebrick build. Her tolerance is waning thin after just a month or so. The good news is she is not a shopper, but that's also the bad news!

I think I will start with a slow and low curing fire tomorrow with some lump charcoal from my smoker.

[SableSprings]

I think that you need to think about how long until you will have this enclosed. Turns out squirrels, mice, & birds love to pick out fibers for their nests. As Russell noted, since you are enclosing and adding vermiculite there are other jobs that should have higher priorities...but that assumes you are going to get your enclosure built & filled & closed soon .

As for venting, I don't think you need to worry about it since your enclosure will probably have a built-in screened soffit or two and that will keep out the rodents and let any moisture escape. Looking good on having curing fires pretty soon (if you haven't already ).