After weathering, the clay is carted or conveyed to the clay-grinding
plant, where it is stored under cover until it is dry enough to be
ground on the clay-mill. Here the clay is fed into a revolving pan, and
crushed under heavy iron runners, and, after passing through
perforations in the bottom of the pan, it is elevated on to screens
which sieve the clay to a requisite degree of fineness. It is then
admixed with a large proportion of ground-burnt and the mixture is
tempered with water until it forms a plastic mass of dough, which is
conveyed to the workshops where the furnace blocks or pots are to be
made. These making and drying shops have false or double floors, under
which steam or heated air is passed using pipes or flues below the
floors, giving the steady and uniform heat which is necessary to dry the
goods as they are made. Heavy goods should on no account be hurried in
drying, lest trouble should occur through the goods cracking or warping.
In making the blocks for the furnaces the workman takes a portion of the
prepared clay and tramps the plastic mass into a wooden frame, or mold,
the shape and size of the block required, with due allowance made for
shrinkage. The blocks are made on the warm floor, which is of cement or
overlaid with quarries. When the mold is filled the surplus clay is cut
off and the wooden frame is lifted up, leaving the clay block on the
floor. The empty mold is then cleaned and refilled. The blocks are left
until they attain considerable stiffness from the evaporation of the
water present by the heat of the room. They are then dressed and cut to
the final shape desired, after which they are further dried until they
become quite hard and white. When thoroughly dry the blocks are removed
from the drying sheds to the kiln for burning.
In burning thick and heavy blocks much care and vigilance is required in
expelling the chemically combined water present in the clay, and, as the
temperature rises and approaches red heat, the rate of heating should be
retarded to allow proper oxidation to take place throughout the
structure of the blocks, and prevent black cores from being formed. In
all fire-clays, besides the mechanically admixed water used in preparing
the clay to a plastic mass, which is mostly driven off whilst in the
drying shed, there exists water in a chemically combined state. This the
combined water is not expelled below 250° Centigrade, and is tenaciously
held by many varieties of mild fire-clays. Due care has to be exercised
in dehydrating goods made from such clays; therefore the man in charge
of the burning regulates his fires, keeping the kiln at a moderate heat
for some time to allow this chemically combined water to be properly and
completely expelled. This dehydration stage in burning clay goods occurs
between the temperatures of 300° and 650° Centigrade.
Public-domain text, read in full here on John Shaqi.
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