AMHOP 2008 Kacheloven Workshop,

Oxford, Maryland

The Swiss craftsmen and stove builders of 250 years ago would certainly have been astonished to find one of their masterworks being reconstructed from the original kacheltiles in Oxford, Maryland last summer. During a workshop sponsored by AMHOP, Rod Zander of New England Hearth & Soapstone, with Austrian Master Stove Builder Richard Jussel led a group of seven masons in the rebuilding of the antique stove. The project provided a perfect opportunity to employ the techniques of masonry stove building as practiced and perfected over hundreds of years in Northern and Central Europe, while learning and using sophisticated software developed by the Austrian Kacheloven Verband to redesign the stove’s firebox and flue passages. Further, the design calculations specify perfectly matched wood loadings, chimney sizing, and air inlet sizes, all working together to create a state of the art stove.

The participants, from all over the US, as well as Canada and Austria, began the course by learning the use of the calculation software, which allows any mason making use of it to build an extremely efficient stove, while satisfying diverse customer-specific requirements. This software has been perfected in Vienna to the point that the Austrian government provides substantial subsidies to homeowners contracting stoves built to its parameters.

After a thorough immersion in the theoretical aspects of masonry stove building, the actual stove reconstruction was begun. The foundation of the very heavy stove had been readied, so work began by resetting the original base on its legs. Then, the firebox was constructed, while simultaneously the original kacheltiles were positioned. Once placed, work on the flue passages began, care being taken to allow differing rates of expansion between different materials, as well as between the inner and outer workings. The kacheltiles were wired together, as has always been done to create a rigid exterior casing, while using clay mortar to allow for future reconstruction work. In this way, all courses were laid, until the stove top could be built, and stove and chimney connected. Thus, traditional techniques and materials were blended with modern ones to create a learning opportunity offering a wide range of experience. The resulting heater, that to all appearances seemed a museum piece, was also built to be exceptionally comfortable, healthy, and environmentally responsible.

Almost amazingly, the challenging project was completed on schedule, and without hitches! It attracted much interest from everyone on the jobsite, and was the setting for an exceptionally enjoyable and friendly working environment for everyone involved in the building.

Although , because of the need for more drying time than was available, only a small fire could be built at the end of the job, we hear that the performance of the stove has been superb, so much so that the owners have contracted for a second stove to be built . Many thanks to Ron and Richard for their organizing, teaching, and leading this workshop, from all of us there.

Jim Apollonio