DSR using Geopolymer Settings

[sksshel]

I am currently building a Cast Double Shoebox Rocket (DSR) mass heater (RMH) using a geopolymer recipe documented here.

I've built a working J-Tube RMH out of geopolymer in order to test the techniques and materials. So far so good. I will attach pics of all the items mentioned in this post as replies to the post.

My primary sources of information in this endeavor are:
- this forum 
- Erica and Ernie Wisner's book "The rocket mass heater Builder's Guide"  ernie
- Peter van den Berg's website: batchrocket.eu/en/    peterberg
- the LTGS website I was using is no longer available.

The primary design components are as follows:
- 6" Chimney and overall system
- The batch box will be made of many cast parts: (Floor, Right side, Left side, Back wall etc.) 10 forms will be used.  3 of them will be used twice.  1 will be used 4 times.  
- Bell will be 3 layers with a 1/4" steel "lid" on top. The layers consist of 1 1/4" LTGS on the inside, 4" concrete bricks outside of that and a decorative stone veneer
- the Batch box will be raised off the floor 12"
- for a Total ISA of 56.9 cu ft meeting the target ISA of 57.1 cu ft
- The bell CSA is 720 sq in. This gives a 20.5/1 ratio greatly exceeding the 5.0/1 minimum requirement.
- a 1 1/2 story class "A" chimney is being installed inside the house through the ceiling and the roof.
- approximately 5.4 cu ft of geopolymer will be needed at a cost of about $220 total (not including the J-tube prototype)  

[sksshel]

Here's a pic of the end goal.  

[sksshel]

The first form has been poured.  It is 22" x 12" x 1.5".  The piece from this form will be cut into 2 pieces to make the back of both the Batch Box and the Shoe Box.  It will be sitting in the curing box for the next few weeks.  There are several more forms to build and pour. 

[sksshel]

The picture above is the "external" view of the Rocket Heater.  It is intended to have the general appearance of a traditional fireplace.  

The pic below is from the Sketchup of the "Internal" structure of the DSR. 

You can download the Sketchup here.  

[sksshel]

The next 3 forms are ready to go. I've adjusted the allowance for shrinkage to 11% after reviewing the first poured form's results.



Left to right they are: Batch Box side, Batch Box floor (cut in 2), Batch Box and Shoe Box roofs (cut in 2)

[sksshel]

6 forms have been poured so far.  At this time there haven't been any visible cracks.

This sample is 21.5" x 12.25" x 1.25". It will function as one of the Batch Box sides. 

This formula for geopolymer has passed all of the tests so far.

[DCish]

Following your build with interest. I had dreamed of something similar but couldn't quite get the time to invest. Kudos!

[travis]

Nice! I was reading the thread about geopolymers, this will be really good to see how it comes together!

[sksshel]

Here's the batch box. Next steps are to add the P-channel, cut the port in the batch box roof, cut the shoe box sides and roof to size and set it all up.

[smarty]

Looks good. I’ve been away from the site for ages and I now have some catching up to do. Can you give me a link to this double shoe box design? What is it? What does it do? I’m familiar with the batch box, but not this shoe box.

[sksshel]

Jun 6, 2018 23:33:59 GMT -8 smarty said:

Looks good. I’ve been away from the site for ages and I now have some catching up to do. Can you give me a link to this double shoe box design? What is it? What does it do? I’m familiar with the batch box, but not this shoe box.

donkey32.proboards.com/thread/2341/different-batch-core-riser-all

[boilermantim]

I have much to learn. The contemporary design looks great. Like Smarty, I will be looking at a lot of posts.
The chimney height sounds like draft will not be a problem.

[sksshel]

"Dry Stacked" Double Shoebox Rocket -

next steps:  mix up some cob to temporarily assemble the heater for testing, weld the metal exoskeleton.   Then I can begin the testing process. 

Longer term, I'll be working on the metal doors with glass inserts.  The p-tube will be trimmed to its final length once the doors have been built.

[firewatcher]

It's looking good!

[sksshel]

peterberg , For DSRs, should the bell top also be 12" above the top of the heat riser?  In other words, is it consistent with your recommendations for the Batch Box Rocket? 

I'm currently planning on using a 16 inch riser on top of the DSR.