Fireclay

The materials we use are very important in keeping our homes warm and energy-efficient. Fireclay is one such material that has been gaining popularity due to its superior insulation and heating qualities. Refractory clay, also known as fireclay, is a unique kind of clay that can tolerate high temperatures without breaking down or deforming. Because of its special qualities, it is a useful material for many different applications, particularly in the building and upkeep of chimneys, fireplaces, and insulation systems.

The building industry has been using fireclay for centuries because of its exceptional durability and heat resistance. It is mostly made of kaolinite, a mineral that is created during the long-term breakdown of rocks. Fireclay’s extraordinary resistance to extreme heat without losing its structural integrity is a result of its composition. Fireclay can offer dependable insulation, preventing heat loss and guaranteeing economical energy use within a home, when it is prepared and installed correctly.

The versatility of fireclay is one of its main benefits. Because it can be molded into a variety of shapes and forms, it can be used with a range of heating systems and architectural styles. Fireclay is a versatile material that can be used to create insulating barriers inside walls or lined the interior of fireplaces. This versatility enables builders and homeowners to tailor solutions to their individual requirements.

Fireclay’s resistance to erosion and chemical corrosion makes it an enduring material for insulation and heating, which is another noteworthy feature. Fireclay keeps its integrity over time, offering dependable performance for many years to come, in contrast to certain other materials that may deteriorate over time due to exposure to high temperatures or harsh chemicals. Because of its longevity, homeowners can enjoy cost-effective heating and insulation without having to replace or repair it frequently.

It is crucial to select the right materials in our endeavor to build more environmentally and energy-efficient homes. With its exceptional thermal qualities, resilience, and adaptability, fireclay presents a strong choice for insulation and heating. Including fireclay in your heating and insulation plan can help create a more cozy and ecologically friendly living environment, whether you’re renovating an old house or building a new one.

Properties	Uses
High heat resistance	Commonly used in fireplaces and wood stoves

Method of independent preparation

I use chamotte clay mixed with cement as a masonry mortar.

You can use regular clay instead of refractory clay to make decorative items at home. Most of the time, a different substance will function equally well and be equally robust and ductile. However, prior to creating the polymer clay we are discussing, you must get ready the following materials:

• PVA glue;
• Starch (potato or corn starch can be used);
• Vaseline or hand cream;
• Baby oil.

Considering that practically every element can be found in any house, the composition is fairly simple. Additionally, a suitable-sized container and a plastic spatula are required for the mixing process.

The grate is installed in the furnace’s bottom.

Starch, petroleum jelly and PVA are placed in a container and mixed thoroughly. When the mixture becomes homogeneous, add two tablespoons of oil to it and mix again properly. After that, the resulting solution should be sent to the microwave oven for exactly one minute. Then it is necessary to mix the polymer clay again. Next, the surface of the table needs to be lubricated with a cream that does not contain silicone. Put the obtained mass on it and soften it with your hands. After some time, a dough with the properties of polymer clay should be obtained. If it will not be used immediately, the mixture can be wrapped in polyethylene and put in the refrigerator.

Work instructions, consumption per mortar, how long it takes to dry

It’s not easy to work with fireclay; many inexperienced people run into issues such as the masonry proving to be brittle and the plaster crumbling due to cracks. This is due to the fact that kaolin clay nearly entirely loses its plasticity during firing and must regain it when mixing the mortar. This is accomplished by adding regular quartz sand or a specific glue to the mixture.

How to use and dilute

Use regular water to dilute the powdered fireclay. Amounts are determined based on how the final solution will be used going forward.

How to prepare plaster mortar

• Take a packet of fireclay powder.
• Pour it into a special bowl
• Gradually add water until the powder is completely covered with water.
• After that, the diluted clay is infused for at least three days.
• After three days, make the final mixing.
• Add silica sand, if the mortar is liquid; or water, if thick.
• Stir thoroughly by hand or with a special drill.

In order for the ready fireclay mortar to stick to the surface and not run off, it should have the consistency of thick sour cream. You can add cement, up to 2 kg per bag of fireclay, to shorten the mortar’s setting time.

A composition for instant mixing is available for purchase; however, it is much more expensive and does not require waiting three days. Add PVA construction adhesive to both compositions. Fiberglass is sometimes used to reinforce them. Using spatulas, the ready mortar can be applied to the surface.

Because the mixture needs 48 hours to cure, dilute it only slightly.

How to knead mortar for bricklaying with your own hands

Shamot clay is diluted in a big container (you can use this 10-15-liter tank) with sand and water. Stirring the mortar is a more convenient method. Skilled kiln builders advise scooping the mortar with a foreman to ensure it is ready. The mortar is ready to use if it slides down the master slowly and without leaving any trace, without dripping or sticking.

It should completely fill in the masonry’s irregularities when pressed with a brick.

Despite the fact that fireclay is safe, you should exercise caution when mixing it to avoid getting mortar on your face. The office should have adequate ventilation.

The following video demonstrates how to ensure that the mortar is ready before beginning any masonry work:

How to prepare masonry mortar

This brings up a crucial point. The components of the mortar must be mixed independently; there are no set ratios for doing so. Because there is already a certain amount of sand in the clay, too much of it makes the material appear fat, while too much makes it appear lean. As a result, the ratios may vary, ranging from 1:1 to 1:5 by volume.

Note: The binder, in this case clay, always comes first in mortar ratio calculations. The amount of filler (sand) is indicated in the second place.

Maintaining this ratio of clay to sand is essential for performing masonry work, ensuring that the mortar has a medium fatness. It is advised to create a trial mixing in this order in order to accomplish this:

• Take an ordinary bucket and fill it with clay pulp by about one third.
• Fill the remaining space in the bucket with sand and mix thoroughly, adding water if necessary.
• check the condition of the mortar by pouring a small amount onto the trowel and turning it over. At the same time, the mixture should not fall off the trowel. Then the tool is turned 90º and here the mortar should slowly slide off the surface, as shown in the photo:

The percentage of sand and clay in the masonry mixture is preserved going forward when it performs as described. It is necessary to add clay to the mortar and repeat the test if it falls off the trowel when it is inverted. If the mixture sticks to the trowel in the ninety-five degree position, it is excessively oily and needs more sand added.

After drying, too-fat mortar will fracture, and too-lean mortar won’t give the masonry the right strength.

This is the reason it’s so crucial to prepare clay properly.

During the mixing process, the amount of water is also ascertained through experimentation. Brick pores will not be adequately filled by a thick mixture, resulting in an excessively thick joint. The addition of the mixture will only result in an increase in clay consumption; the strength of the joint will not be strengthened as liquid will spread and not provide the usual adhesion between the bricks. To do this, use a trowel with a flat surface to check the mortar and examine the trace that is left behind.

You need to add a little water and properly knead the clay because the mixture in photo #1 is too thick and the trace goes with breaks. Photo #2: Due to the volume of water, the groove swims on the sides very quickly. The clay needs to stand for a while before the extra water can be drained off. The third photo displays mortar that has been properly prepared. How clay is mixed in real life, as seen in the video:

Clay for plastering the oven

, It’s easy to tidy it up quickly and repair any cracks that have developed over time with the same clay. Plastering stove walls is intended to:

• Reduce the risk of smoke penetration when cracking seams in old stoves.
• Give a certain style.
• Smoothing out sloppy masonry.
• Keep the heat in the stove for longer.

Preparation with your own hands

You can use a basic clay composition, lime-clay, lime-gypsum, or a mixture of sand, clay, and cement for plastering. Preparing a mixture for masonry and making this kind of mortar are similar processes. In addition, the clay mass is pre-crushed, soaked, and combined with cement or lime and sand.

One part lime dough is added to two parts sand (pure river sand is preferred) and one part medium-fat clay. The amount of sand is based on the amount of sand when using cement. The more concrete that is added, the more of it there is. One part of the sand must be taken for every three parts.

Prior to mixing with the previously soaked clay, all other ingredients are combined with one another in the clay solution.

To strengthen and reinforce the plaster, add asbestos, fiberglass, hemp, or straw in a ratio of 1:2:0.1 (clay, sand, additives).

How to make the claying correctly

The stove’s surface has been cleared of debris, dust, and old mortar. The masonry joints between the bricks are chosen by 10 mm if this wasn’t done when the furnace was being built. The only tool needed to begin plastering is a pre-melted, warm stove:

1. It is necessary to wet the surface abundantly.
2. First, a layer is applied, called a nabryazhka. A slightly more liquid solution is prepared for it, which can be easily splashed on the stove in a small layer with a brush or a broom. It is better to do it twice. A second thin layer is applied after the first layer has set, in order to seal small cracks and places where too little mortar has been applied.
3. Before applying each layer, the wall must be moistened again.
4. Reinforcement mesh is fixed on nails.
5. It is covered with a thin layer of very liquid clay mortar. After such priming, the main layer will stick better.
6. The primer is dried.
7. Now the main layer is applied. It should be small – 2-5 mm. If a thicker layer is required, it is reapplied after drying.
8. The last layer is a covering, leveling the surface and filling all the small irregularities. Its thickness is 2-5 mm. The mortar for it is prepared as liquid as for sprinkling.

Thus, making clay mortar is not a particularly difficult process. However, the masonry itself calls for knowledge and care. If there is a mistake in the staging (masonry scheme), the stove may smoke violently or may not light at all in the lack of a strong enough draft. As a result, if this is something you’ve never done before, do it with the assistance of an expert stove maker.

We hope you found the article to be interesting. In the space provided below, ask questions and share your thoughts.

What is fireclay

Even seasoned salespeople in big-box construction stores frequently struggle to articulate precisely which fireproof compound you need for a given task and, motivated by the desire to maximize sales, won’t genuinely listen to your concerns. You will learn why there is such a high chance of error a little later, but for now, let’s talk about definitions.

Refractory clay, also known as fireclay, is essentially a billet that can be treated with different additives to become a functional building material. Because of the variety of raw materials, firing temperatures and methods, degree of crushing, etc., it itself has quite a few varieties.

Mertel is an already-made composition made primarily of clay and various aggregates. There are over two dozen major brands within it. The percentage of aluminum oxide in the mixture is indicated by the numbers that come after the abbreviations (MP stands for semi-acidic binder and MSH for fireclay binder).

Everything would be OK, but a lot depends on these acronyms and numbers, most notably the amount of masonry mortar shrinkage and compatibility with specific kinds of fireclay bricks t.ο.

Furthermore, you may find yourself facing a significant issue if you combine all of this with regular burnt red bricks that are placed on mortars that have varying shrinkages. This is because the uneven shrinkage may cause the finished oven or fireplace to crack, the fuel box’s plaster to peel and fall off, etc.

Plastering process

When achieving an exact level surface is required, use a refractory clay mortar. Corners and a specific profile are required during the working process. Plastering a wall perfectly even requires the installation of multiple profiles on that same wall. It is advised to use a construction level or a plumb line during the installation process. Corners are glued straight to the plane in order to create even edges.

A rule ought to be applied in order to create an entirely level surface. In order for every beacon to touch one another horizontally at the same moment, it is fixed across the vertical profiles.

The under-blower and the fire door’s level of extension should be taken into consideration when installing the beacons. In order to achieve a smooth surface free of indentations and protrusions, the profiles and doors should be level.

A specialized tool for leveling can be used to facilitate work with refractory clay mortar more easily. In this instance, obtaining an even plane with minor cracks is possible without any issues. An ordinary wide spatula can be used to solve this issue and smooth the surface all over.

3 How to prepare the mortar for refractory masonry

In the furnace masonry, one kilogram of binding mortar is required for every refractory brick. typically use a 20-kg fireclay bag after laying no more than 30 bricks. Additionally, you need at least five of these bags (or 100 kg of mortar) to make a cube.

Bricks are bound together with mortar using a specific method that is prepared. First, utensils for mixing are chosen. This cookware should have a bottom with the largest possible area and low sides. An old bathtub or trough would be the best choice.

Sand made of quartz and crushed fireclay are added to the trough’s bottom. For masonry fireboxes and chimneys, the composition ratio is one part clay to two parts sand. A different ratio should be used: one part clay to three parts sand. But, it makes no sense to prepare a different composition and then use a 1:2 ratio (fireclay: sand) if the stove builder gathers a small hearth.

You can use the above ratio as a guide for the final volumes: 100 kg for every brick cube (5 standard bags). Additionally, the bags might contain precisely the ready mixture rather than pure fireclay. It is not required to search for quartz sand with such a composition.

Subsequently, the mixture is mixed with water according to the instructions, which should submerge the dry composition to the level of the index finger’s first phalanx. The dry mixture is then given time to absorb moisture by leaving the trough empty for two to three days.

Because of this, the furnace can prepare the entire volume at once, which is sufficient to finish the masonry, without having to make separate portions of mortar as it would with cement and plaster. The composition of absorbed moisture will dry out over the course of two days.

Next, you must knead the mixture with a construction mixer until it has the consistency of thick cream. Additionally, you should add water to compositions that are too viscous, and you can add a little quartz sand or soak the mixture in a separate bowl of thick mortar if it is too liquid.

The masonry process on fireclay is identical to the comparable technology used in wall or foundation construction. It is advised that joints have a maximum thickness of 10 mm.

Research of clay.

Hold a piece of clay in your half-fist. Wet it, work it into a soft dough, then carefully squeeze it between two perfectly level surfaces. The clay is of low quality if the lump split easily. Once the lump had been compressed by one third, cracks started to show up. At least five kilograms of this clay would then be taken home for additional work.

Research on the properties of clay at home.

Water hardness is a significant factor. Water is used only soft or, in extreme situations, medium hard.

For the furnace quartz, sand is used; for the remaining portion, regular construction yellow sand is used. First, a fine wire sieve is used to filter the sand mixture. Afterwards, organics—a variety of organisms that like to settle in the sand—were carefully cleaned with water. Their presence degrades the quality of the masonry mortar, which is why it is undesirable.

Determining the mixture’s component proportions is the next step.

We divide the entire volume of clay into two parts. Part of it is put aside, and the second part is divided into 5 parts. It is best to label the dishes. The clay is evenly distributed in the labeled container and leavened with water, adding one fourth of the amount of clay. During 24 hours it is scattered, after that we mix it, press it through a mesh material with 3 mm cells, stand for 1 day. Then drain the upper layer of water and add sand, starting from the second cup – one fourth of sand, 3 cup ˗ half of sand, 4 cup ˗ three quarters, 5 cup ˗ one to one half of the clay volume. The first cup contains only clay. Stir thoroughly until a homogeneous composition.

Using the obtained solution, samples are created:

1. Sausages or flagons 30 centimeters long, no thicker than a finger ˗ 2 pieces.
2. Roll a ball with a diameter of 5 centimeters.
3. Mold a medium diameter clay mold about a finger thick.

Give the samples labels. Clay cakes and balls can dry for up to twenty days, while sausages can take three days. In the shade, the samples are dried.

When the flagella are extended or coiled around a stick:

• normal clay ˗ only the crust cracks and the mass is damp;
• Fat ˗ cracked crust or no cracking;
• skinny clay ˗ flagellum breaks immediately.

This experiment’s findings are not trustworthy. It is required that cakes and balls be allowed to dry. Check for cracks on the dry samples, then drop them from a height of one meter onto the floor to observe which ones cracked. Samples that escaped the impact are dropped from a greater altitude once more. The samples that passed the tests are the ones we choose. This mortar recipe is what it is.

Using this mixture, a trial mix of the leftover clay is created, and the mortar’s adhesiveness is evaluated. The masonry won’t be strong enough if the mortar is extremely liquid. The joint will be unduly thick if it is too thick. The upper slurry, or sedimented water, is drained, the excess liquid is sedimented, and the amount is measured. This volume is subtracted from the water dilution’s starting volume.

A mortar that has been lightly greased has adhesion. A thin, streaky solution can be seen dripping down when you dip a trowel into it. The clay is greasy if a solid layer is still present.

Description of the material

Typically, fireclay is offered as a dry mass in stores. It is typically combined with mortar for plaster. Furthermore, bricks manufactured using chamotte clay are available for purchase in the construction market. The kaolin after firing takes on a creamy hue. It might also be brown.

The material’s composition is also highly intriguing. Rich in highly dispersed hydroaluminosilicates, clay is used to make fireclay. Usually, it is shaped into briquettes or pieces of various shapes. They are burned at temperatures that rise to very high levels in special kilns.

There are numerous ways to make fireclay mixture. There is a lot of burnt powder added to some compositions, and coarse powder is added to others. There is a lot of water in other masses. Refractory product requirements are outlined in GOST 390-69.

Furthermore, there are variations in the length of time and temperature at which fireclay is fired. The material has a range of colors and textures when it exits the kilns. Refractory clay is composed of alumina ceramics and oxides of calcium, magnesium, potassium, iron, and sodium.

Bentonite clay is a naturally occurring substance with a variety of uses. It selects montimorillonite as its foundation. Refractory clay comes in a wide range of varieties and is utilized in many different industries. Refractory clay PGB is currently in high demand in the construction industry.

Fireclay instructions for use

The production of fireclay bricks and masonry compounds is the most well-known use of fireclay in the construction industry, but there are other uses as well. Fireclay is even used to make stair elements because of its special qualities.

In addition to the facing tiles.

Of course, one of the best uses for these tiles is the lining of stoves and fireplaces, but the distinctive color and texture of fireclay products allow for other applications as well. The material’s characteristics allow it to stick to most concrete and stone surfaces beautifully, which makes it a very attractive choice for exterior finishes.

The following are basic instructions for using fireclay to make such products:

1. Refractory clay is mixed with fireclay in certain proportions.
2. Products are molded.
3. Drying.
4. Primary (low-temperature) firing.
5. Coating the product with glaze.
6. Secondary (high-temperature) firing.

Because fireclay is used in so many other applications besides construction, this recipe is also used to make the majority of products made from fireclay.

In ceramics, refractory compositions are also frequently utilized. Specifically, fireclay flower pots offer several benefits over standard clay or plastic ones. It’s the best plant container, according to florists.

The main factor in this case is most likely chamotte’s lack of dangerous contaminants. Furthermore, these pots can sometimes last longer than fifty years.

Fireclay appears to have similar properties that make it useful for household ceramics, especially when making tableware.

Garden sculpture is one particular kind of decorative art that has made extensive use of fireclay. Because of chamotte’s special qualities, you can create even massive sculptures that have enviable levels of durability, detail accuracy, and environmental friendliness.

Shamotnaya-Glina-14

Shamotnaya-Glina-13

Shamotnaya-Glina-12

And lastly, cooking is yet another fascinating application of fireclay.

Because it mimics the appearance of a natural stone oven or tandoor, fireclay stone (also known as culinary fireclay) enables you to bake food of the highest caliber.

Please use the form below to ask any more questions you may have, dear readers. We are excited to speak with you.

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Fireclay is one of the most useful and adaptable materials for heating and insulating homes. Its natural composition, which is mostly made up of clay minerals, makes it the perfect material for a variety of uses, such as building heat-resistant barriers and lining fireplaces and chimneys. Fireclay assures heating system efficiency and safety with its remarkable thermal properties and resistance to elevated temperatures. Its insulating qualities also aid in controlling interior temperature, saving energy and improving comfort. Whether it is utilized for contemporary furnace linings or conventional brick ovens, fireclay is still a trustworthy ally in the construction of a warm and well-insulated home.

Secrets of choosing the ingredients for a quality clay mortar

Superior clay mortar

The mortar used to lay bricks is made up of the following ingredients:

• water. The main requirement for it – the complete absence of all sorts of impurities, the presence of which can adversely affect the quality of the finished mortar and lead to a noticeable reduction in the strength of the structure. The durability of the binder also directly depends on the quality and purity of the water, so it is necessary to take a responsible attitude to this issue and immediately abandon the idea of using water from the nearest body of water;
• sand. Clean sand should be used, which is free of crushed stone and stones. The best solution is to buy homogeneous sand, which should be sifted through a sieve beforehand. The diameter of the holes in the sieve should not exceed the value of 1.5 mm;
• clay. It is the main ingredient that provides excellent binding properties of the finished mortar and reliability of the furnace construction. The right choice of this ingredient guarantees the longevity of the construction and its excellent tightness.

Take a few quick tests to find out the clay’s quality before deciding on a choice. It is preferable to create multiple combinations by varying the proportions of clay and sand, resulting in tiny tortillas. To ensure there are no cracks and that the mortar ingredient proportions are correct, leave them in a warm room for ten to twelve days.

It is crucial to keep in mind that mortars made of clay and chamotte are only appropriate for use with specific kinds of masonry; otherwise, the intended effects will not be obtained! This mixture works well for laying the foundation and chimney, as well as the furnace and heat storage areas. This characteristic results from the clay mixture’s heightened resistance to both mechanical damage and extended exposure to high temperatures.

However, take note that these structures will not survive for very long; many cracks will appear, and the structure itself will not last for very long when exposed to condensation moisture over an extended period of time.

It is best to use cement-based mortars or mixtures of quicklime and sand for laying the foundation and chimney. They will guarantee the durability of the furnace’s construction and exhibit exceptional resistance to the detrimental effects of elevated moisture. In "hot spots" where the structure needs to be as tight as possible and completely reliable, use clay mortars.

Methods of preparation

For masonry, mortar

A knowledgeable approach to material selection is required. Both the size of the fractions and the technological process have an impact on the quality of chamotte powder. The material is labeled as a result. Should the package bear the letter "Σ," it indicates that defective kaolin bricks were utilized in the manufacturing process. Although the cost is greatly decreased, it is not advised to use this material for precise or significant work.

The composition may take various forms:

1. A mixture of fireclay sand and kaolin in the ratio of 2:1. Fractions should not exceed 0.5 millimeters.
2. A mixture of fireclay sand and blue clay, in a ratio of 4:1.

Ordinary sand will expand as the temperature in the kiln rises, so if it is used to prepare the mortar, cracks might appear. Additionally, since river sand lacks some of the ingredients needed for good adhesion, using it is not advised. The mortar will become much stronger if Portland cement is added. But in this instance, fireclay’s refractory properties will decline orders of magnitude. The following mixture needs to be made in order to lay out the furnace:

1. To begin with, you need to prepare a container, PVA, water, as well as kaolin.
2. To prepare the basis for the mixture, you need to pour the special powder into the container and slowly add water. The liquid should completely cover the kaolin powder. But the water must be added carefully, otherwise, the refractory will not work the mortar will turn out to be liquid. Then it is necessary to wait three days for the prepared mortar to infuse.
3. When the base is sufficiently infused, then you can continue work. It is necessary to check the quality of the prepared mixture and determine its suitability for further treatment. If it is liquid, it is necessary to add a small amount of sand, if it turns out to be too thick, it is necessary to add more water. Fireclay should have a consistency of, similar to sour cream. If the material meets the necessary requirements, then it is necessary to increase plasticity and strength, for this purpose it is necessary to add PVA. Also, experts recommend adding fine-grained glass fiber to the clay, it will give the following properties for additional strength to the mortar.
4. The next step is to prepare the surface, as clay is not characterized by good plasticity. It is necessary to install the mesh, after which it thoroughly primed. It is recommended to purchase a primer with a high degree of heat resistance. In this case, the method of application will be quite simple and easy, and clay bond well with the surface.

You can purchase a composition that is mixed almost instantly if your budget permits, saving you the three days of waiting for it to infuse.

How to properly prepare clay mortar

The chamotte clay should soak before use. The clay powder is fully submerged in the material after it has been filled with water. ingredients well, ensuring that the vessel’s corners are free of dry clay and lumps. Cover the capacity completely and take a three-day break.

Stages of manufacture: dilute the mixture for construction with your own hands

Large containers, cold water, stirrers, mixers, fireclay, fireclay sand (crushed stone), or quartz sand are needed for the preparation. For the formulation of shamotnaya clay, there are various recipes:

Amount of water and take precisely as directed by the fireclay manufacturer. The room’s temperature ranges from plus 5 degrees Celsius to plus 60 degrees.

• The clay is poured into the container.
• Fillers (sand, crushed stone) are poured on top of the clay.
• Pour water over the dry ingredients.
• The mass is mixed with a trowel or a construction mixer.
• The container is closed to avoid excessive evaporation of water, and three days.
• After the specified time, the paste is once again thoroughly mixed and proceed to laying.

Aid. As directed by the manufacturer, pre-made fireclay mixtures are diluted. Long-term soaking is not necessary for complex compositions that contain chemical additives, fiberglass, heat-resistant adhesives, plasticizers, and cement. After mixing, these solutions are ready to use in 20 to 25 minutes.

Thus, a tank, mixer, stirrer, and clean, cool water will be required in order to get ready for work with the "Mixture Masonry Clay-Shamotnaya Clay Heat-Resistant" from the manufacturer Terrakot. As stated on the package, 240 milliliters of water are needed for every kilogram of powder.

• The mixture from the bag is poured into the tank.
• Water is poured into the vessel, the solution is kneaded with a trowel and a mixer.
• paste soak for 20 minutes, once again mixed and used for masonry. If necessary, a little water is added to it to achieve the desired consistency of the solution.

Instructions for use

The building industry makes extensive use of the material. Furthermore, because of its technical qualities, which allow it to adhere flawlessly to any surface, clay is frequently used to produce step elements.

stove laying

When installing stoves or open fireplaces, many experts in masonry use fireproof bricks, which are composed of a clay-shamot mixture.

Keep an eye out for the markings on the material when purchasing it; the letter SH should be present. These bricks are much more expensive, so the material is only used to lay the firebox.

Universal brick makes up the remainder of the apparatus.

If fireclay brick is to be used, only refractory clay should be used as the base for the brick.

Verifying that the coefficient of expansion is the same is crucial.

Plastering process

Typically, the stoves are plastered with this mortar. As a result, special profiles and corners must be used during the cladding process in order to achieve perfectly flat walls. These components will be needed in small quantities. You only need two or three points of support to level out the mortar.

You can apply corners to the edges of the structure, but many find this inconvenient because they are usually glued onto the plane.

Strict fixes are made to profiles on a designated plumb line. Only when the rule is securely positioned across the beacons—which should be in contact with each other both horizontally and diagonally—will a perfectly level surface be achieved.

Since the furnace or blower door is set into the wall, the beacons must be fixed at the level of their extension. It is imperative that the segment generated by the profiles is commensurate with the door.

If none of this is taken care of beforehand, the blowpipe will need to be extended during the project in order to get a clear view of the entire wall.

For masonry stoves, the refractory clay-containing mortar is somewhat viscous. It will adhere to metal, making it impossible to remove like a regular cement mixture. You can use a leveling tool in this situation. Although the plane will be even, it will have a few tiny cracks that are easily fixed with a standard wide trowel.

If desired, the finished plaster’s prepared flat surface can be covered with a lovely decorative ceramic tile.

Other products from clay

Designers frequently use this material to create exquisite ornamental pieces, including tiles, figurines, kitchen utensils, and much more.

Addition of specific ingredients turns fireclay into a plastic material. Because it is a material that is good for the environment, this rock is valued.

How to determine the fat content of clay

The foundation of almost all mortars is clay. There is some sand added to the kiln’s body. You can only "feel" the source material (figuratively) and create a number of trial mixes with varying concentrations to determine the precise amount. The optimal ratio is established based on test results. There is only one way to do this. The kiln will not stand for very long if the mortar is not made properly, which can only be done in this manner.

Where to collect

You can gather the clay from your own location to save money. This is legally permissible (down to a maximum depth of 5 meters). It only takes two to three meters of digging to reach deposits that have qualities that are generally deemed acceptable. Gathering clay in the closest ravine, on a precipitous riverbank, etc., is the second choice. Although it is no longer lawful, many still engage in this. The third option is to purchase clay from stove makers or stores, but in order to assess its quality and prepare it, it must be precisely the same as the extracted independently.

So, we go to the ravine, on the river bank or dig a hole in the vegetable garden. If you look at the structure of a clay pit in section, you will see a certain number of layers. The upper layer is usually fertile, with a lot of organic matter and plant residues. Even though its main component is clay, it is definitely not suitable for us. The required layers are lower down. Maybe under sedimentary rocks, maybe under loam (clay with very high sand content). We go much lower – deeper than the lower edge of the fertile layer by 1.5-2 meters. The color of the clay we are looking for can be anything from whitish and gray to reddish. It"s not important, it"s the characteristics that matter.

You can find clay in a ravine, a river cliff, or a quarry.

Clay layers become more fatty from top to bottom. The middle layers are where the material should ideally be extracted. This area typically has medium-fat clays, which are ideal for the primary mortar. A certain amount of very light and fat clay from the lowest layers will be needed for the fireclay.

Determining the fat content on site

We determine the fatness right on the spot. We take a piece of clay from any layer (smaller than a fist). Wet your hand, clamp the lump, try to knead it. Waiting for the water to soak in. Repeat until the clay becomes malleable. Roll a ball, begin to squeeze it from above and below two smooth flat plates (pieces of wood, metal, etc.).п.). In the process, cracks begin to appear. If they began to appear only after the lump was compressed by 1/3, then the mortar is either normal or fat and this layer can be used. If earlier – the clay is thin, and it is better to try another, because torturing sand – a long and very painful business, requires a large amount of water.

Roll the clay into a ball.

About 5–6 kg of clay will need to be taken from the chosen layer (or layers). They are required in order to calculate the sand content of the mortar used to lay the furnace. The most important thing is to remember which clay comes from where and not to mix them.

How to dilute fireclay

Hearing about chamotte cracking, plaster crumbling, and other such incidents is not unusual. Materials that have expired, been stored improperly, or—the most frequent variation—were mixed compounds incorrectly could be the source. So how can mortar be made correctly for plastering and bricklaying?

Chamotte mortar for bricklaying

The first hit material is inappropriate in this instance. The truth is that the production process and fraction of fireclay powder determine its characteristics. Fireclay comes in various grades, just like cement. If the bag has the letter "U" on it, it indicates that faulty kaolin bricks were used in the manufacturing process. Though less expensive, it is not worth utilizing for significant projects.

The following varieties of mortar are most frequently used:

1. Mortar of 1 part kaolin and 2 parts fireclay sand (fraction up to 0.5 mm).
2. Mortar of 1 part kaolin and blue clay, 4 parts fireclay sand.

Ordinary sand can expand when heated by the stove, which is why using it in the mortar causes cracks. Additionally, river sand is not used because it does not provide the required adhesion for the other ingredients.

Portland cement can be added to the mixture to increase the mortar’s strength. It should be noted that this will lessen chamotte’s refractory properties.

You will need the following to dilute the clay for the stove’s masonry:

1. Select a container of the necessary size (the solution should be stirred without spilling out).
2. Pour out the required composition (choose from the above) and pour in water.
3. Mix the mortar so that there are no lumps in it. It should be thick.
4. Leave it for three days.
5. Add water, the consistency should resemble sour cream. If the mortar turns out to be too liquid – add powder.

The mass can be used if it came out thick and lump-free. If you hold the mortar too short, the clay will crack, so don’t rush to add water again.

There are instant mixing compositions available that don’t require three days to stand, but they cost a lot more. Furthermore, incorporate PVA glue into the mortar and fortify with fiberglass.

Because normal red bricks and special fireproof bricks have different coefficients of thermal expansion, this mortar should not be used to lay regular red bricks.

Chamotte mortar for puttying

In this instance, the mixture is made up of the following ingredients:

• Portland cement – 1 part;
• fireclay – 2 parts;
• quarry sand – 7 parts.

The mortar needs to be blended in the same manner as brickwork.

Use a special metal mesh to reinforce the chamotte plaster.

Plastering with metal mesh

Additives

The following ingredients are mixed into the mixture in order to fortify any mortar properties:

• PVA glue;
• table salt;
• liquid glass.

Glass and table salt are added in increments of up to 100 grams per bucket of mortar, or up to 3% of the mixture’s total mass. Adding additives to chamotte is a great way to enhance its qualities.

Although fireclay is safe, it should not be allowed to get in the eyes or on the face. Make sure there is enough ventilation in the room if you plan to knead mortar there.

How long it takes for the clay mixture to set

The fireclay paste takes 72 hours to fully dry in the air; however, inside brickwork, this time can take longer depending on the masonry’s thickness, the surrounding air’s temperature, and its humidity. Fireclay mortar fossilized at 800 degrees Celsius.

Crucial! Fireclay masonry is not tolerant of abrupt temperature changes.

Three days after construction is finished, the furnace is heated for the first time. Logs that burn thin and quickly are used. During the initial fire, the dampers and under-blowers are fully opened. Following that, the furnace is used to dry for a week, burning small amounts of firewood each day.

Only the firebox is typically constructed of fireclay, but the masonry composed of regular clay-sand mortar and ceramic bricks dries more slowly. As a result, the conditions under which the stove with fireclay masonry will start to operate will be the same as those under which the stove constructed with clay and lime mortar will be used. A new stove should be heated as much as possible in 10 to 14 days in the summer and a month in the winter.

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Fireclay fireclay synthesis of natural and human

The word "chamotte," which is derived from French, has become increasingly popular lately. People are looking for natural materials because they are sick of artificial pleasures and plastic gloss, and chamotte is one of the most popular natural materials. But obtaining such material requires human involvement; unique white kaolin clay needs to be fired in rotary kilns at temperatures as high as 1,500 degrees Celsius, which causes the clay to completely lose its flexibility and all of the water that is attached to its molecules.

As a result, chamotte gains characteristics that are similar to those of stone. The fireclay pieces that are obtained are crushed in specialized mills and sold as construction dry masses or used to make fireclay bricks. It should be mentioned that chamotte favors designers more than builders. This application technique is common because fireclay has an enigmatic, restrained beauty, unique texture, and natural spirit that allow items made of it to adorn even the most exquisite interiors. Create ceramic dishes, tiles, and figurines in the fireclay creative environment.

On the other hand, builders attempt to use textured fireclay not only for facing surfaces that are subjected to high temperatures (such as fireplaces and stoves), but also for home facades!

This is still fireclay; it is also referred to as kaolin in construction supply stores. This material comes in a variety of colors, from creamy white to gray-brown. Chamotte is widely used for plastering projects, mixing bricklaying mortar, and producing mortar for brick laying. When purchasing, make sure the clay hasn’t been sitting on the shelves for a long period of time as this could cause it to lose its properties as clay in stores doesn’t always withstand the right conditions. The same is true of cement: prolonged exposure to humid air can completely ruin chamotte. The cost of using such material is high.

The image is from coldflame.ru/fireclay.

Fireclay powder image from ogodom.ru

The picture shows the chamotte-making process, fb.ru

Image of a fireclay bag from voloku.ru

Methods of determining the plasticity of clay

It is now time to recall the clay samples that were taken in order to determine the suitability of plasticity. Place them in various bowls and mix with water. Add it gradually to the clay dough so that it cools down and doesn’t stick to our palms.

Serial numbers will be applied to the samples so that it is possible to determine the amount of sand added and how that affected the plasticity:

• Leave the first one as it is.
• In the second one we add 10%.
• In the third 25%.
• In the fourth portion 75%.
• To the fifth sample we add 100% sand, t.е. amount equal to the volume of clay.

It is best to add sand in small amounts and mix thoroughly after each addition. Water will need to be added if a significant quantity of sand is added. We should create test samples from every sample, consisting of three × 5 cm balls and the same quantity of flat cakes that are 2-3 cm thick. The samples, numbered one through nine, should be dried in a room shielded from drafts. Once the scones with balls have been in for 8 to 10 days, they should be examined and the sample with the best composition should be identified.

A mortar is deemed appropriate for masonry if it meets the following requirements:

• If the ball dropped from a height of about 75cm-1m above the floor does not break or color when pressed.
• If the dried samples have no perceptible cracks.

To enable multiple runs of the experiment, two or three samples were prepared.

There are two additional methods of calculation that, based on an analogous five-part division and comparable preliminary preparation, are as follows:

• From each sample roll balls of Ø 5 cm. The test pieces are alternately placed between two planks, which act as the working elements of the press. When the planks are compressed, a ball of plastic clay will shrink by 1/2 of its diameter with the appearance of minor cracks. A sample with medium plasticity will "sag" by 1/3 with the formation of noticeable cracks. The lean material will only shrink by 1/4 or less and will crumble.
• From each sample it is necessary to roll out flagellum-colubaski about 1.5-2cm thick with a length of 25cm. They should be slightly stretched and wrapped around a wooden rolling pin or shovel blade Ø up to 5cm. A sample of lean clay breaks off almost immediately, it does not stretch. A medium ductility sausage will break off when the stretch and strain section has decreased in thickness by 20%. It will crack at the folds. A harness made of plastic clay will not break and will stretch smoothly.

The most basic tests ought to provide us with the medium plasticity mixture proportions, which we can use to make masonry mortar. Masonry mortars will need one-tenth or marginally less space than the stove.

How to choose quality clay

Shamot clay, also known as "Kaolin," and pre-made blends available at building supply stores. Positive evaluations are available for both foreign and Russian producers of this heat-resistant substance. The fireclay made by companies in Western Europe is thought to be the best.

Consider the year of production and the quality of the materials when making your selection. Particles larger than the fraction specified on the package are not present in quality mix or clay.

No more than 2.5 mm of crushed stone or sand should be included in the mortar mixture.

The package’s letter "U" designates that secondary, recycled materials are used to make the fireclay. Letter "SH" Masonry fireboxes are a better fit for the material if it hasn’t been recycled.

Building supplies are kept in warehouses with specialized equipment. The shelf life of mixtures and clays is infinite if they are kept in a dry room, in sealed bags, and at temperatures between plus and minus forty degrees Celsius. The material’s qualities will deteriorate after extended storage (more than three years) in an environment with high humidity because of moisture saturation.

Types of clay, its characteristics

It is available in various colors, including blue, white, red, ginger, gray, and black. When granite was broken up, white, or kaolin, was created. Juicy red has metallic impurities, and gray is made up of the same kaolinite minerals as the black mass.

There are various types based on the main component’s presence (clay minerals):

• Greasy;
• Medium fat content;
• Skinny (non-fat).

It is actually devoid of fat, and its presence cannot be detected. However, high plasticity makes it possible to discuss the material’s softness, slipperiness, and soapiness—all of which are nearly invariably associated with fat content.

Determining the fat content of clay

How can I find out how much fat is in clay myself? This is required to determine the behavior of the finished mass. and how to enhance its attributes. Its initial content already contains some sand, which influences its fatness. If it’s present in excess, the clay is lean. You can carry out a quick experiment to make sure.

It is necessary to soak it, you can soak the whole mass, because for the preparation of the solution it is pre-soaked. After a couple of days, roll 2 small balls, leaving fingerprints on them, dry them and look carefully at what has been obtained. If your clumps have decreased in size and cracked, you have a fat variety in front of you. If the lumps are crumbly, this is a lean version of the material. If the lump is not crumbled, but there are no fingerprints or poorly viewed, then the clay is thin. And if your product does not have cracks and is not crumbled, it is almost ready masonry mortar. Having established the level of fatness, you can independently prepare clay mortar for masonry stoves.

Experts assert that the quality of the heating structure will not be impacted by a mixture that is oversaturated with fat clay. However, an excessive amount of sand in the mortar can cause the dried mortar to crumble and disintegrate. Sand and clay must be combined in the proper amounts. Superior clay is the primary requirement for the longevity of the built structure. Plasticity is one of the primary requirements. Plasticity is the capacity to adopt any shape, free from seams, fractures, and cracks, as well as the "ability" to hold onto these shapes in the face of harsh environmental effects.

Plasticity of clay

Every type of clay has some degree of plasticity; there are three types of clay that are associated with this quality:

• highly plastic;
• medium plasticity;
• low plasticity.

How can I measure plasticity in my home? By the way, obesity and plasticity are directly correlated. Therefore, you can independently adjust the mortar’s plasticity. Roll it into a dense ball with your small fist and press it between two boards after kneading it. Apply pressure until fractures start to show. Cracks that developed under light pressure indicate that the material is lean and low-plastic; cracks that developed after the material had traveled half the radius—that is, near the cake—indicate that the material is highly plastic. Medium plasticity is indicated by the occurrence of cracks at one-third of the compression height.

Another method is to roll out and bend into an arc flagons that have a diameter of roughly 20 mm and a length of more than 20 cm. Weakly plastic varieties will tear in bundles when bent slightly. Additionally, greasier products bend more easily without breaking; they can be bent into rings or calacas. The composition can be depleted (by adding sand) or enriched (by adding clay) based on the experiment’s findings. A combination that is blended using precise data about each component will be of the highest caliber.

What masonry mortars are

Mixtures only contain one or two ingredients plus water. Their composition is straightforward. Lime, cement, and clay are binding agents. Sand—which may be silicate or fireclay—is used as a filler.

It is crucial to consume pure water devoid of any artificial additives or contaminants. Water from an open pond, well, or water supply is appropriate.

However, rain or melted water are thought to be the best liquid for the mortar.

Mortars differ in their porosity, thermal conductivity, and gas conductivity. Their high strength after the mortar hardens, good plasticity, and ease of application are what make them all the same. Every kind of mortar needs to have the specified qualities.

Experts in the stove industry divide mortars into the following groups:

• Greasy, with good plasticity, but prone to cracking after curing.
• Normal – with medium plasticity and strength, they are used to create reliable masonry. This is the type of clay that should be sought for construction work.
• Lean – brittle and low-plastic, not durable, crumbles after drying. Such clay is not suitable for the stove, it will immediately put it out of operation at the first heating. It can be used only after bringing it to the desired condition in a pair with other plastic components.

When the composition of the mixture includes one binding component (cement, clay), the mortar is categorized as simple. The ratio of components is designated as follows: 1:1, 1:2, 1:3. These designations help to understand what proportions are used in mortars. The first digit indicates the binding component, the second digit the aggregate. When the mortar is complex, from two binding components (cement-lime mixture), the designation is as follows:1:2:8. The first digit is the most effective binding element. Stove builders use mixtures of normal plasticity and strength. Fat mortars are brought to the desired condition by adding sand, to lean lime or clay is mixed with it.

The following types of mortars are utilized in the construction of the furnace, excluding the reinforced concrete mortar used in the foundation:

1. Lime. It is used for a brick plinth and for a chimney channel. That is, it can be used in the construction of such parts, where there will be no heating more than 450-500 degrees above zero. Joints with such a mortar will be strong, but fire resistance suffers. It can not be used for the construction of the stove pipe, as this part of the structure is exposed to aggressive atmospheric effects. Lime mortar is not wear-resistant.
2. Cement-lime. They are used in the construction of foundations. It is not heat-resistant, it is not suitable for chimneys. Withstands temperatures not exceeding 250 degrees above zero.
3. Cement-chamotte. They are composed of cement and heat-resistant fireclay sand and water. It is used to build a firebox. Such a composition will withstand a free temperature load of 1300 degrees and above and will not collapse. Smoke such a joint will not pass, but condensation through it is able to escape. Heat resistance, refractoriness, convenience in work distinguish cement-chamotte mortars. But it comes out at a high price. Therefore, in the construction of stoves for baths are often bypassed analog, where cement is replaced by clay.
4. Clay fireclay. Such mortars are also used when laying the furnace chamber, as they have fireproof properties. It is much cheaper than the previous option. Clay is often a complimentary element.
5. Clay. Used to build the basic structure of the stove, where the heat is accumulated and transferred to the heated room. On the scale of heat resistance, such mortars stand on the middle position. Clay mixture will withstand a temperature of 1100 degrees Celsius. When water evaporates, the mixture becomes solid, under the influence of liquid it becomes plastic again. Very convenient property, which allows you to take the stove for repair or restoration. For the construction of the chimney clay mortar for the stove can be used, but the upper part of the pipe with its help can not be laid, it will get wet.

The majority of the structure is laid with this mortar, which is the least expensive. Since you will need a large amount of the mixture, the ostensibly inexpensive ready-made clay mixture from factory production will actually cost a lot of money. Furthermore, the component parts are freely available. They have moved. Thus, learning how to make clay mortar for a masonry furnace by hand makes sense and doesn’t require a lot of work. You’ll also need clay if you need to mix something to lay the furnace.

Clay mortar for laying the stove

Only the foundation and chimney cap should be built using a stove cement mixture, which is brittle when exposed to intense heat. Only mortars with a clay base are used for plastering, laying furnaces, and chimneys.

Normal red clay, which is accessible from any quarry, may be used to lay the furnace’s base. Heat-resistant fireclay, which is high-density white kaolin sedimentary rock that is fired in ovens to enhance strength properties, is used to bond bricks in the furnace and chimney. It turns a cream or gray-brown color at high temperatures, and after firing, its strength is on par with that of stone.

All that’s needed for a traditional masonry furnace is clay and sand. Additional components that enhance the composition are added as needed.

The following refractory fireclay mixtures are available from manufacturers:

• "Terracotta": it is made using classical stove technology.
• "Plitonit": with reinforcing heat-resistant fibers.
• "PecnikЪ": in the form of ground fireclay powder.
• "Makarov"s Stove House": chamotte mortar (unformed mass), the composition includes clay and ground refractory brick.
• "SPO": based on chamotte and sand.

Construction stores sell reinforced clay compositions for fireclay furnaces in addition to masonry and plaster mixtures for stoves and fireplaces. Special compositions for masonry sauna stoves that operate in high humidity are also available for purchase.

Compositions: clay, sand, additives

Mortar used inmasonry

The following kinds of mortars are used for stove work:

• Red clay-based: capable of withstanding an average temperature of 1100°C, used for masonry of the body of the stove.
• Fireclay fireclay: for bonding bricks in the furnace or chimney.
• Lime: lower than average fire resistance, can withstand temperatures of only 450-500°; used for the foundation of the stove and chimney above the roof level.
• Sand-cement and cement-lime: used only for the upper part of the chimney and masonry foundation. Cement-lime is stronger than ordinary lime, but can withstand temperatures only up to 200-250°C.
• Clay-lime: used for plastering.

A helpful hint is to strengthen the masonry mortar by adding salt to it. A bucket of ready-to-use clay mortar requires 1.5–2 kg of salt. After firing, the mixture dries for a longer time but solidifies into a monolith after firing.

Proportions and preparation of masonry mortar

Because clay takes a while to set, you can get ready for masonry work on the entire volume at once. About 20 liters will be needed to bind 50 bricks. A Russian oven will require 15-20% more mortar.

Pre-crushing and at least a day of immersion are required for the material. It can be put straight into the container to soak while the mortar gets ready. The necessary quantity of sifted sand is then added, and everything is well combined. A drill, a wooden spatula, or a construction mixer can be used for this.

The ratios of sand to clay can change based on how fat the clay is. One part clay can be mixed with two to five parts sand.

Professional judgment Plasterer Alexander Guryanov

To determine the accurate ratio, mix multiple mortar samples with varying sand contents. Balls measuring 5 cm in diameter and thrown on a hard surface from a height of 1 meter are produced from each roll. A ball constructed with "proper" clay mortar shouldn’t crack or change shape after falling. If it becomes flat, the mixture was made with too much oil. putting in more sand. Add more clay if the mortar has cracks in it.

The video shows how to make a mixture for masonry.

The adaptable substance known as "fireclay," which is made from naturally occurring clay minerals, has shown value in a number of residential heating and insulation applications. It is an invaluable resource in the construction industry due to its remarkable thermal resistance and capacity to tolerate elevated temperatures.

Making refractory bricks is one of the main applications for fireclay in home insulation and heating. The lining of fireplaces, furnaces, and kilns is composed of these bricks, which are created by combining fireclay with additional materials. Their effective heat retention guarantees that the house is kept at the ideal temperature, which lowers energy consumption and saves money.

Apart from its usage in conventional heating systems, fireclay is also utilized in contemporary insulation methods. It is a great option for insulating materials because of its low thermal conductivity, which helps to keep interior temperatures comfortable and minimize heat loss. Whether applied as insulation boards, mortar, or bricks, fireclay offers efficient thermal insulation that raises the home’s overall energy efficiency.

In addition to its heat-retaining qualities, fireclay provides additional advantages for home insulation and heating. It is an affordable alternative for homeowners because it is easily accessible and less expensive than other materials. Additionally, fireclay products are long-lasting and robust, guaranteeing consistent performance over time with little upkeep needed.

To sum up, fireclay is a dependable and adaptable material for insulation and heating in new construction. Both builders and homeowners favor it because of its affordability, durability, and resistance to heat. Fireclay is a material that can be used in both conventional fireplaces and contemporary insulation systems to improve comfort, sustainability, and energy efficiency in residential buildings.

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