Chapter 12: Firing
Roland stood at the kiln in the backyard and waited.
The brick building he had designed for cement production was fifteen meters long, four meters wide, and built with a deliberate asymmetry: the front door wide enough to wheel a barrow through, the rear door barely a man’s breadth — a door meant for one person only. Anna’s door. A half-wall enclosed the yard, and Carter’s men guarded both entrances, their loyalty the kind that didn’t require examination.
The production process itself was simple enough that Roland could recite it in his sleep. Grind limestone to powder, blend it with clay and iron dust, calcine the mixture, grind the clinker a final time with gypsum. The raw materials were common. The iron was harder to stockpile. The critical difficulty was heat — specifically, sustaining a temperature near the melting point of iron without an infrared thermometer, without a thermocouple, without anything built after the first century.
In this era, an ordinary open furnace bled heat faster than it generated it. Maintaining twelve hundred degrees was not merely difficult; it was essentially impossible by conventional means. A high-temperature resistance furnace would require firebrick, and firebrick was its own project. A blast furnace could reach the right temperature but its chamber was too narrow for calcination. The months before the Demons’ arrival were not long enough to solve all of that.
So his kiln had no heating system. He was relying on Anna entirely.
The limestone and clay had been slurried together and spread evenly inside the chamber. The knights locked the front door and withdrew. Anna went in through the back. Her fire baked the slurry until it fused with the iron powder, particle by particle, at a temperature no furnace in the kingdom could produce.
Roland’s jaw was set. He had been telling himself for days that cement was only the first step, that the wall was only the first step after that — but the reasoning felt thin now, standing in the cold, waiting. If the calcination failed, three months would vanish and the wall would remain the fantasy Carter’s men probably already thought it was.
“Your Highness.” Carter appeared at his shoulder. “Can this material truly bond stone?”
“The Graycastle alchemists say it can.” Roland spread his hands. “We’ll know shortly.”
The art of alchemy enjoyed an inflated prestige in the kingdom — not undeserved, as a point of social engineering. Nobles kept alchemists on retainer the way they kept astrologers: for the feeling of standing at the edge of the unknown. Roland had cited their authority freely. Carter didn’t question the source; that was enough.
Through the soot-darkened window the last of the flame guttered and went still.
He sent Carter out of the yard before going to the back door himself. Anna emerged into the cold air, her face gray with dust. The wet processing had kept the particulate low, but the calcination itself produced a hot pall that had clearly settled on her — her hair, her eyelashes, the creases at the corners of her eyes.
Roland draped his robe over her shoulders and handed her the water cup before she could ask.
“The slurry changed into powder,” she said, and coughed once.
He waited until the kiln cooled enough, then wrapped a wet cloth around his head and went in with a shovel. The heat hit him like a physical wall — his skin tightened and his lungs balked at the first breath. He worked fast: one shovelful, two, then out. The interior would cause heat shock within minutes.
Back in the cold air, he spread the powder flat on the ground and pressed his fingertip into it to check the temperature. Ash gray. Lighter than he had expected, because he had omitted the iron powder in this test batch.
“What is it for?” Anna had changed back into her witch’s clothes. She was watching him.
“Houses. Roads. Bridges.” He looked up. “If this works, people in Border Town will live in walls that wind and rain cannot take apart.” He reached up and touched the top of her head, lightly. “It only works because of you.”
Her breathing changed — or he thought it did, a quickening too slight to name.
He mixed the powder with sand at three different ratios and had Carter spread the mortar between bricks, two bricks per test, nine tests total. The hardening time would be approximately four hours, but Roland was conscious of the instability inherent in a first batch. He set the tests aside, covered them with cloth, and left them for the night.
The next morning they went out at first light, all three of them — Roland, Carter, Anna.
The mortar had set. The bricks were bonded. In the corners a white effloresce had formed where mineral salts had migrated to the surface, but when Roland crouched and scraped it away with his thumbnail, the cement beneath was solid and cool. He pressed his finger into the surface: nothing. Dragged a nail across it: no mark.
Carter tried to lift the bonded pair. They did not separate. He put his knee against them and shoved. Still nothing. He kicked the join from the side until the contact with the ground broke, but the two bricks held to each other. He drew his sword by the hilt and struck the corner of one brick. A chip of brick broke away. The join did not.
“Yesterday it poured like a candle.” Carter turned the bonded bricks in his hands, genuinely puzzled, the way a man is puzzled by something he cannot disbelieve. “This morning it is stone.” He looked at Roland. “With this material we could wall the entire border in five years. As long as we have enough—”
“That’s not what it’s for.” Roland stood. “A tall wall cannot stop an enemy who is already inside it. I would rather give every family in Border Town a room that a winter storm cannot flatten.”
Carter was quiet for a moment. In all his years guarding the fourth prince — the gambling, the late nights, the unfortunate incidents with the daughters of minor lords — he had never heard him say anything like that.
Roland did not notice the silence. He was already thinking about the next batch, the next ratio, the rate of production, how many kilns he could build before the Demons came. Science and technology were the first productive force. He had believed it abstractly for a long time. Standing in the cold yard with the bonded bricks in his hands, he believed it in his chest.
And here, in this town, the witch was the first technology of all.
Chapter 12 Firing
Roland stood by the kiln in the backyard, waiting for the first batch of cement
being released.
The brick house he had designed for the cement production was fifteen
meters long and four meters wide. The front and back had each a door, the
front door was as spacious as possible, so that people could easily transport
materials into the house. Instead the back door was only one person wide, the
only use was to let Anna secretly into the firing room.
Therefore, he also built a wall halfway around the house, the import and
export arrangements were guarded by knights — they were Carter’s men,
loyalty was beyond doubt.
The cement production process was very simple. First the limestone would
be grinded into powder, afterwards mix it with clay, iron powder, and then it
would be calcined with a dry or wet method. It can be used after the final
grinding with plaster. The raw materials were very common, only iron could
be difficult to obtain and hold in a large number, the critical fact lies in the
process to reach the right calcine temperature.
Roland did not remember the specific temperature needed to produce cement,
even if he did remember it, he had not the possibility to measure and control
the temperature – whether it was an infrared thermodetector or a
thermocouple temperature measuring gun both were not available, this made
the production of the cement countless times more complex. He only knew
that the temperature was almost similar to the melting point of iron, and the
calcination process was also a difficulty in the production of cement.
In the era of the less advanced smelting technology, maintaining the
temperature of the furnace has been a problem for all people. The heat loss
of an ordinary open furnace was too great, it was difficult to maintain the
temperature at 1200 degrees. But he would also need a high temperature
resistance furnace, he would have to figure out how to make firebrick. The
traditional iron making blast furnace would be forced to the point of melting,
temperature may be up to the standard, but the narrow chamber was to small
for the cement calcination, Roland was afraid that the time until the Months
of the Demons was not enough.
Therefore, Roland’s design for the kiln had no heating measures, he purely
relied on Anna.
The broken down particle of limestone and clay were mixed together with
water into a slurry, this was evenly spread within the kiln. Then the knights
locked the door and walked away. Anna entered from the back door, her fire
baked the earth slurry until it melted together with the iron powder.
Roland was somewhat restless, this was his first step to upgrade Border
Town. If he couldn’t produce cement, building a wall within three months
would be empty talk. Without the wall, there would be no people willing to
stay in this place. Whether it was real life or fictional literature, if you want
to progress forward, a stable base is essential.
“Your Highness, this kind of product can really hold the stones together?”
Carter, who was at the side of the fourth prince asked. Although the prince
had told him this was the latest research results of the alchemists of
Graycastle, but he was still skeptical. After all, those people really haven’t
made any useful products.
“Who knows? Anyway, they said it would, “Roland spread out his hands.
The world of alchemy and astrology were known as the sage art,
in the mainland these professions were very popular. In general the royal
family would develop their own alchemist and astrologers, for refining and
predict the fate. For ordinary people, these studies were too classy. In view
of this, Roland naturally set the source of cement formulations to the
alchemical head. As for the chief knight, he didn’t matter.
Through the window they could see the flame gradually stopped to burn, it
seemed the calcination was done.
When Roland stood up and went to look, Carter was driven out of the garden,
so he waited alone in front of the backdoor for the brick.
The gates creaked open and Anna walked out. First thing Roland did was to
drape a robe over her, and brought her a cup of water, “how are you?”
The face of the witch was full of dust, due the wet processing system the
amount of dust was low, but the hot air needed for calcination produced still
some dust. She was not wearing a mask, staying inside for more than 10
minutes was obviously not too comfortable. She coughed and nodded, “the
slurry already changed into powder.”
Roland waited until the temperature in the kiln dropped low enough, still then
he wrapped a wet towel around his head, he grabbed the shovel and got into
the back door.
He was instantly surrounded by the hot air, for some time he felt it was
difficult to breath, the skin on his hands was roasted immediately.
Fortunately, taking a shovel of powder took not much time, otherwise if
staying for a few minutes in this environment would cause a high temperature
shock.
“Is this what you wanted?” asked Anna, who was now wearing the witch
outfit.
“It looks very much like it,” Roland spread out the fine powder flat on the
ground, using his finger to sense the temperature, “to know it definite we will
need to test it.”
“What’s the use of it?”
“It is for building houses, or repairing bridges and the roads, it can be used
in many other places too. If it is successful, afterwards the people will be
unafraid of the wind, or that their homes could be destroyed, by the cold, rain
or snow.” With the other hand he patted the girl’s head, “this was only
possible thanks to your ability.”
Anna lowered her head, Roland did not know if it was or wasn’t an illusion,
but he felt that the girl’s breathing got faster after he patted her.
According to the theory, it is important to fire the grinded materials together
with the gypsum, with this it would possible to adjust the hardening time. But
now it would be needless to think so much, after a short break Roland took
the shovel again and grasped to more, then he called Carter who stood
outside the courtyard over, letting him prepare three different mixtures of the
powder with the sand to compound cement mortar.
The chief knight completely didn’t mind this manual work, for him, doing this
kind of matter was many times better than the substitute fights for his
Highness, when he got into a brawl with other young lords while he was on
an outing with young ladies (prostitutes) in Graycastle.
Because in the raw material was not added any iron powder, the color and
luster that came out were lighter than the average, appearing to be ash gray.
Roland spread the grout on a brick, and then putting down another brick upon
it. The cement solidification time would be around four hours, but taking into
account the preproduction of instability, he intended to simply wait until
tomorrow to see the results.
The second day early in the morning, Roland, Carter and Anna hurriedly
rushed to the firing place in the backyard. When he opened the door, he saw
that the cement had the appearance of the solidification condition, the two
pieces of brick were tightly bound together. The consolidation appeared to
be uneven, on some places appeared hoar frost.
Roland crouched down, scraping off the aroused hoar frost, trying to press
his finger into the hardened cement, the touch made his heart feeling pleased,
the cement surface was solid, completely different from the touch of rammed
earth, namely, the use of the nail to scrap didn’t leave any traces.
Carter repeated the action of the fourth prince, attempting to move the rock,
but he also did not succeed. He even resolutely kicked against the side with
his foot, until the connection between the cement and earth broke, but the two
pieces of bricks were still firmly bonded together. At last, he swung the hilt
of his sword against the brick, but only a small piece at a corner broke away
“This is the effect of ‘cement’, “Carter immediately realized its role,” it is
incredible. Yesterday it could also flow like a melted candle, just one night
later, it’s like a rock. With this kind of material, with this building the city
wall would go much faster. As long as we have enough stones, we could
even build a wall around the border in five years!”
“What’s the use of that?” Roland did not accept it as the correct way, “the tall
wall would be unable to stop any enemy who comes from the inside. I would
rather turn the old wooden homes of Border Town into solid concrete rooms,
so that my people no longer need to worry about a natural disaster turning
them homeless. “
“……” the Chief Knight was speechless, he really did not expect the fourth
prince with all his kinds of bad habits would say this.
“In the future, you will see, Roland reaffirmed himself one more time about
the important of the road he would walk — with regard to the numerous
battles he needed to fight, science and technology was the first production
capability. And here, the witch was the first productivity.
TN: This image would shorten the chapter a lot xD