In an effort to take a quick break from my normal posting, I feel as though I should introduce people to my art which is sculpture. Many people wonder exactly why it is I do what I do and all I can respond with is that I simply enjoy every minute of it. I love my art and I’m genuinely happy during the entire process of fabrication.
This past Saturday RIT hosted a university wide innovation festival called Imagine RIT. Each college, along with many of our numerous clubs, had exhibits and demos to show off exactly what happens here at RIT. I belong to the College of Imaging Arts and Sciences being a Fine Art Sculpture major. What better demonstration could we have done but have an iron pour?!
So what’s an iron pour? An iron pour is a highly intensive activity that involves tending to a red hot kiln, scrapping and melting iron in the kiln, catching the molten iron in a ladel, and pouring the molten iron into casted moulds.
The process started several days earlier when the preparations took place. The fuel used to heat the kiln is called coke, a purified state of coal which burns hotter and cleaner. This fuel needed to be hammered into varying sizes ranging from grapefruit size down to lime size pieces. We also needed to hammer our iron into more manageable sizes seeing as they came in the form of brake pads. The machine used to get the iron broken apart into smaller pieces was the human body equipped with a sledge hammer. I had almost as much fun doing this as I did actually pouring the molten iron. We needed about 900-1100 pounds of iron, 400 of which was contributed solely by me (I substituted this as a Cross Fit work out. Believe you me, I was sore).
The kiln is prepped by cleaning it out, then placing all the largest pieces of coke on the bottom rack. These are then torched and set a flame. Medium size peices are added and a leaf blower is turned on to further fuel the fire. After several hours, the kiln reaches it’s designated temperature of 3500 degrees fahrenheit. In smaller pours, the metal to be melted is usually placed inside the the ladel and the ladel placed in the kiln until the metal is liquified. Because iron is usually poured in hundreds or thousands of pounds at a time, the kiln used is slightly different. Iron is tossed in freely along with lime sized pieces of coke and is melted and sinks to the bottom of the kiln where it is caught in a well. The iron continues to fill up in the well until the well is filled. The ladel crew is then called to grab the ladel and prepare to catch the flowing iron.
Because the ladel is not heated in the kiln with the iron, it must be heated separately with a leaf blower and a torch. A ladel is a small bowl made up of refractory and heat resistant materials. A pole is inserted on either side of the ladel and is handeled by two people: the live end and the dead end. The live end is the person who actually controls the pour while the dead end is just there to hold the dead weight on the opposite end. This duo grabs the ladel when the sound is called and moves it to the kiln and prepares to catch the iron.
Once the ladel crew is in place, the tapper uses a very large metal rod and breaks the seal of the tap at the bottom of the kiln’s well which allows the iron to flow out. Once the ladel is filled (about 100 pounds of iron worth) the tap is sealed with a sand and resin cork. The iron is now about 2800 degrees.
During the melting process, all the impurities float to the surface of the liquified metal which is then scraped away by the pushbacker. The ladel crew then runs over to pour the moulds with the caught iron. Once all the iron is poured, the ladel is cleaned out and returned to the torch to be pre-heated for the next pour. Once we got going, we were pouring about 150 pounds of iron every 15 minutes.
All in all it was a good day and one of the best demonstrations of exactly what it is that I do. I loved every minute of it.
-Charles Moreland






