When most potters think about kiln maintenance, they think about replacing elements, checking the thermocouple, or cleaning the kiln floor.
Few people think about the top bricks.
Yet after more than 20 years repairing electric pottery kilns, I noticed the same pattern over and over again: the top bricks were often among the first areas to show significant wear.
It wasn't because something dramatic had happened.
It was because of thousands of tiny moments.
A shelf resting against the edge while loading.
A post bumping the brick.
Leaning across the kiln.
Sliding furniture into position.
Resting tools on the rim.
None of these actions seem like a big deal in the moment. But over hundreds of firings, they gradually wear away one of the most vulnerable parts of your kiln.
Why Are Kiln Bricks So Soft?
Many new kiln owners are surprised by how easily kiln bricks can chip.
That's actually intentional.
Most electric pottery kilns are built with lightweight insulating firebrick (often called IFB). Unlike standard construction bricks, insulating firebrick is manufactured with millions of tiny air pockets that dramatically reduce heat transfer.
Those air pockets are what allow your kiln to reach temperatures exceeding 2,000°F while keeping the outside relatively cool.
The tradeoff?
They're much softer than people expect.
That softness makes them excellent insulators—but also makes them susceptible to accidental damage during everyday use.
Why the Top Bricks Wear the Fastest
The top edge of the kiln is exposed every single time you fire.
During loading and unloading, it's common to:
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Rest kiln shelves on the rim
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Lean across the kiln
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Bump the edge with shelves or posts
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Slide heavy pieces into position
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Set tools or furniture on the top while organizing a load
Individually, these moments rarely cause major damage.
Collectively, they slowly change the shape of the brick.
It's Not Just About Chips
Most people notice large chips or cracks.
But those aren't the only signs of wear.
Over time, repeated contact can:
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Round over sharp brick edges
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Wear down sealing surfaces
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Deepen existing chips
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Enlarge small cracks
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Remove material from high-contact areas
These changes often happen so gradually that they're easy to overlook.
How Worn Bricks Can Affect Your Kiln
As wear increases, damaged brick surfaces may no longer fit together as cleanly as they once did.
Depending on the location and extent of the wear, this can contribute to:
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Less effective sealing between kiln sections or between the lid and kiln body
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Heat loss around damaged areas
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Escape of hot gases or fumes through gaps
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Greater stress on heating elements as the kiln works to maintain temperature
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The need for more extensive brick repairs over time
Not every small chip will affect kiln performance.
However, preventing wear before it becomes significant is much easier—and less expensive—than repairing damaged brick later.
A Better Way to Protect Your Kiln
After repairing kilns for decades, I wanted a simple solution to one of the most common forms of preventable damage.
That's why he created KilnShield.
Rather than asking kiln owners to completely change how they load their kiln, KilnShield protects the area that experiences the most everyday contact.
What Makes KilnShield Different?
KilnShield combines two materials chosen specifically for the job.
Stainless Steel Base
A precision-formed stainless steel shield provides a durable protective barrier over the kiln's vulnerable top brick.
It absorbs the everyday bumps, scrapes, and impacts that would otherwise contact the brick directly.
Soft Silicone Protective Surface
Attached to the steel is a durable silicone foam pad.
The surface is firm enough to protect the kiln, yet soft enough to comfortably lean against while loading and unloading.
It also provides a safe place to temporarily rest kiln shelves, posts, and tools without placing them directly on the brick.
For kilns that already have minor chips or cracks, KilnShield also helps reduce additional wear by protecting those damaged areas from continued impact.
More Than Brick Protection
KilnShield was designed to do more than simply prevent chips.
It helps preserve the condition of one of the kiln's highest-contact surfaces, making everyday loading easier while reducing unnecessary wear over the life of the kiln.
Many customers tell us that once they have a KilnShield, they wonder how they ever loaded a kiln without one.
The protection quickly becomes part of their normal firing routine.
Final Thoughts
Every kiln requires maintenance over time. Elements wear out. Thermocouples eventually need replacement.
But many forms of brick damage are preventable.
Protecting the top bricks helps preserve one of the kiln's most vulnerable areas while supporting the long-term health of your kiln.
After all, every loading session is another opportunity to either wear down your kiln—or protect it.
Small habits make a big difference over the lifetime of your kiln.
