[Clayart] Part of my problem with firing soda kiln - need a solution for how to attach hardbrick to hotface Hiof kiln

[Helen Stone]

HI folks, this continues my earlier commentary today about the soda kiln
disaster and how I am now considering using salt in addition to soda
mixture.  I want more texture on my clay and am hoping for more volatility
from the salt.  But my soda kiln needs a retrofit, as most of the interior
is made of K23 insulating bricks, also the outside layer, arch, etc.  I
need to line the hotface with skinny cuts of hardbrick, ad my question is -
how can I get the hardbrick to adhere to the softbrick, or is there another
option to protect the softbrick from salt.  The bottomt 5 layers of
interiorwall  brick are hardbrick, but I still have to start from the
exusting hardbrick floor upwards to the sprung arch.  The sprung arch is
another issue, how to adhere the hardbrick skinny pieces to that.
Insulating softbrick is notoriously difficult for refractory mortar to
adhere to , it sucks out all the moisture immediately, I found when
building the chimney.  So, is there a way to make it easier to use
refractory mortar to glue the skinny hardbrick pieces to the hotface?

 I thought about using Nichrome or Kanthal wire to shape little nails, and
nailing the hardbrick to the vertical walls.  Especially I thought about
trying this on the arch.  Thought about using that wire to weave a loose
mesh at the arch, to somehow  make it not fall down from the arch.  There
must be of course a little buttress of hardbrick for those arch hardrick
skinny pieces to rest on.  HOpe that this is making sense.

 Or, could I avoid completely putting in skinny pieces of hardbrick
somehow  , i.e. could I use somehow a type of refractory mortar which could
bond to the insulating softbrick and save a lot of trouble?  My Ecuadorian
friend suggested that I use perhaps a spray of some liquid, immediatley I
thought of ITC, but this is not available here, and it likely would not
work on softbrick to protect it from salt, do not know.  For the interior
walls, I thought of trying to use the refractory mortar to attach the
skinny pieces of hardbrick and also use Kanthal or Nichrome wires in shape
of nails for extra security.  I am getting nowhere.  I would appreciate
your input!  You guys are experts, I am a soda neophyte obviously, since I
screwed up so badly..  Could I use some kind of coating  of zircopax mix?

Remember that the protective homemade coating for the combustion chambers
actually separated from the bag wall and the kiln wall during the firing at
cone 10 or 11.

Hoping to hear from you folks!  Rather, praying...
Helen in Ecuador, on Rio Yambala
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