Total Time:

8 hours (approximately)

Objectives:

* To identify signs which indicate that kilns are functioning properly

* To identify signs which indicate that kilns are functioning poorly

* To repair malfunctioning kilns

* To discuss the potential health and safety hazards associated with kilns

* To extract a kiln

* To identify grades of charcoal

Materials:

(see "Materials" for "Kiln Construction", Session 11) as desired--tents, sleeping bags, mosquito repellent, candles, lanterns, flashlights, ingredients and utensils for preparing a meal, coffee, tea, music.

Trainer Notes

* The nightwatch activity will continue until the kilns have been extracted. It is estimated that firing the kilns at 6 PM will allow them to be ready for extraction at approximately 1 or 2 AM.

* An appropriate informal atmosphere should be established for this activity. It is recommended:

- that participants set up protection from the elements (i.e., tents, sleeping bags, mosquito repellent)

- that there is an ample supply of light sources (i.e., flashlights, lanterns, candles, etc.)

- that a dinner be prepared on an open fire or using charcoal cookers

- that there be coffee or tea, and music available for the later hours when enthusiasm and energy may be waning.

* This session is designed to allow for considerable latitude in timing and execution, depending on individual trainer styles and the needs of the participants. It is recommended that the trainer remain sensitive to the group's need for both rest and stimulation. For example:

- Part 1, "Monitoring and Trouble-Shooting" should occur in an ongoing fashion as problems or indications arise.

- Part 2, "Health and Safety Factors" can occur at a time when the group seems to need some stimulation (perhaps late in the night).

- Part 3, "Kiln Extraction" will need to occur as a final activity whenever the kilns are ready to be disassembled.

Total Time:

Continuous throughout the 8-hour period.

Trainer Notes

* Invite participants to gather around the kiln and explain why it seems to be functioning well.

* Stimulate discussion and dialogue by asking:

- How do we know that this kiln is functioning well?

- What indications are present?

- What is happening inside the kiln?

* For each kiln, it is important to discuss:

- movement of the front

- the draft system

- color, smell, and volume of smoke

Trainer Notes

* Invite participants to gather around the kiln and explain why it seems to be functioning poorly.

* Stimulate discussion and participation by asking:

- How do we know this kiln is functioning poorly?

- What indications are present?

- What can be done to repair it?

* Some common malfunctions which should be discussed include:

- poor draft

- holes

- fires dying out

- irregular front progression

* It is important that each work group take the necessary steps to repair their kilns. Offer suggestions whenever necessary, but try to rely heavily on the group's problem-solving abilities.

Total Time:

1 hour (approximately)

Trainer Notes

* Mention that, to some degree, all kilns are potentially dangerous, both to those who build them and to by-standers.

* Stimulate discussion by asking the following questions:

- What are some of the most dangerous aspects of this design?

- Who might be most affected by these dangers? (i.e., animals, by-standers, the charcoal makers, etc.)

- What could be done to diminish the potential health and safety hazards represented by this kiln?

* Some common health and safety factors to be discussed include:

- smoke inhalation

- open vents

- burns from hot metal

- sides caving in

Total Time:

2 hours (approximately)

Trainer Notes

* Stimulate discussion and participation by asking:

- How do we know this kiln is ready to pull?

- What indications are present?

* Some common indications which should be discussed include:

- completion of front progression

- cooling of the kiln

- absence or reduction of smoke

- coals visible through vents

Trainer Notes

* Include the following points in your explanation:

- clear an area around the kiln that is large enough to spread the charcoal without stacking it.

- Open the kiln, one small section at a time, and extract the charcoal by pulling it into the cleared area.

- Watch for burning coals and extinguish them with loose soil. (Be careful not to bury the charcoal.)

- Keep the pulling and dragging of the charcoal to a minimum since it fragments easily when hot.

- Stack charcoal in concentric windrows after it has cooled.

- Leave paths between each windrow to prevent walking on the charcoal and to act as firebreaks.

- The design of some metal kilns requires that all the charcoal be removed at once. In these cases it may be necessary to open the kilns and cool them with a spray of water before disassembling. This should be done only in special circumstances since wetting the charcoal reduces its quality.

Trainer Notes

* Offer suggestions and advice whenever necessary.

* Remind the group that they are working with miniatures and that the larger scale of full-sized kilos would necessitate a strict adherence to the basic extraction procedures.

Trainer Notes

* Stimulate discussion by asking:

- Approximately what percent of the wood is completely carbonized?

- What happened to cause some of the wood to only partially carbonize?

* Some important points which should be brought out in this discussion include:

- the importance of re-covering earth kilns

- the causes of ash spots

- the causes of brands

Trainer Notes

* Each of the kilns will be ready to be disassembled at different times. If the work groups seem to be getting extremely tired, it is recommended that they go ahead and extract the charcoal, even though all the wood inside may not be completely carbonized.

* Explain that on the next afternoon, there will be a review of the entire kiln construction activity and that ample time will be provided for participants to examine their charcoal and ask questions.

* Before dispersing for the night, make sure that charcoal is stacked appropriately for cooling and that there is no danger of fire from any of the disassembled kilns.