The virgin clay and chamotte having been intimately mixed, the whole
mass is “wet up” by the addition of a proper proportion of water and
prolonged and vigorous kneading, usually in a suitable pug mill. The
mass leaves this mill as a fairly stiff, plastic dough, but the full
toughness and plasticity of such clay mixtures can only be developed by
prolonged storage of the damp mass. In the next stage of the process,
the plastic clay is passed to the “pot maker” in the form of thick
rolls, and with these he gradually builds up the pots or crucibles from
day to day, allowing the lowest parts to dry sufficiently to enable
them to bear the weight of the upper parts without giving way. The
building of large pots in this way occupies several weeks, and during
this time the premature drying of any part of the pot must be carefully
avoided. After the completion of the pot, drying is allowed to take
place, slowly at first, but more vigorously after a time when the risk
of cracking is smaller; when it is taken into use, the pot is usually
many months old and is thoroughly air-dry. The clay, however, is still
hydrated, _i.e._, contains chemically combined water, and this is only
expelled during the early stages of the burning process. This process
is carried out in smaller furnaces or kilns placed near the melting
furnaces. In these the pot or pots are exposed to a very gradually
increasing temperature, until a bright red heat is finally attained.
This is a delicate process in which great care is required to secure
gradual and uniform heating, especially during the earlier stages,
otherwise the pots are apt to crack and become useless. Finally, when
a bright red heat has been maintained for at least a day, the pots are
ready to be placed in the furnace, and this is ordinarily done while
both pots and furnace are at a red heat, the pots never being allowed
to cool down again once they have been burnt.
Public-domain text, read in full here on John Shaqi.
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