Brick Oven Build (Pic heavy)

[jonumberone]

I'm currently attempting to build a brick oven in my yard.
Currently 5 weeks in, and would say I'm 75% done with the project.
There's a lot of waiting for things to dry and cure in between steps, and the crazy heat has slowed me down too.
I'm halfway through the oven construction, which I'm hoping to finish this coming weekend, then I'll need to insulate and render the dome, and finish the stand.
Before this project, I never mixed a bag of cement, mortared a block, or laid a brick in my life, and I thought cinder blocks were for smashing storefront windows.
That said, I'm pretty satisfied with how things are coming along.

Here's some photos of the process:

Blank slate
https://i.postimg.cc/wvyfR473/1593642803113.jpg

I had to pour a foundation slab. After talking with some people that know what they're doing I poured a 6 inch slab on 6 inches of crushed and compacted stone. Reinforced the slab with 3/8 inch rebar on 6 inch centers.

https://i.postimg.cc/TwzkVjD0/20200707-070315.jpg

https://i.postimg.cc/bvvFpwPx/20200707-115842.jpg

After the slab cured for a week, I mortared and laid the block.

https://i.postimg.cc/8P83MGdG/20200714_144508.jpg

https://i.postimg.cc/FF0xSz0x/20200715_225305.jpg

Once the mortar dried, the cores of the block needed to be filled with cement.
I ran 1/2 inch rebar through every other core to tie in to the suspended slab.

https://i.postimg.cc/667JCzDr/20200716-165228.jpg

Next I had to form up and pour the suspended slab.

https://i.postimg.cc/8cxZbRfw/20200719-202337.jpg

Added a second grid of 3/8 rebar to reinforce the slab.

https://i.postimg.cc/cJdXT46q/20200721-113754.jpg

Finished product

https://i.postimg.cc/mrVVnfFP/20200730-131915.jpg

After another week of curing, and roughly 4 weeks total I was finally able to start the oven.

Started with 2 inch calcium silicate board to insulate the floor, then formed up and poured a 1 inch refractory castable base.

https://i.postimg.cc/QMkX5px3/20200731_205014.jpg

https://i.postimg.cc/SNzTxvHP/20200803-194544.jpg

Next I mortared and laid the floor tiles.

https://i.postimg.cc/BbdWR6Qp/20200805_070531.jpg

And then, finally started work on the dome!

https://i.postimg.cc/mgLqxzH2/20200809_123004.jpg

https://i.postimg.cc/Wb6Kf6tH/20200809_122827.jpg

https://i.postimg.cc/qByF6z5k/20200809_082040.jpg

I haven't gotten much done since I took these pictures Sunday morning
Took Sunday to point the mortar joints, and scrub the brickwork clean, and this morning I laid the first of 2 arches across the opening of the oven.

[Brlesq]

Wow, Dom, that's a lot of work, but it looks great! I know you said that you had no experience with this, but you must have been a mason in a past life.

[IrishBoi]

That looks awesome

[Steve]

Very nice Dom!

[elderboy02]

Very cool! :tu

[GreekGodX]

I can't even hang curtains so this is incredible. Great work, Dom! Can't wait to see it in action :ss

[yourchoice]

Fantastic, Dom!

[mosesbotbol]

Quite handy! Well done. Is this for pizza's or just general cooking?

[BigAsh]

"Meh...probably going to burn waaaaay too thick pizza anyway"...(posting for a friend..)
:r:r

Nice work my brother!

[markem]

Amazing, Dom!

[SSDVC]

Real nice work. If all else falls by the wayside, you can always use it as a bomb shelter !! That thing is built stout !!

[8lug]

Great job so far. Keep the pic's coming

[Havanaaddict]

:cl great work Dom!!!

[EricF]

That's amazing Dom!!!

[Chainsaw13]

Looking good so far. Can’t wait to see the finished product.

[T.G]

Pretty damn impressive, Dom. I can see why you decided to ruin your nipples for this.

[CigarNut]

Very cool, Dom! I am so impressed with all the thought and effort that you have put into this project! You should be very proud of your accomplishment!

[Old Sailor]

Awesome work!!:salute:

[jonumberone]

Thanks, guys.

Great job so far. Keep the pic's coming

Thanks for all your help!!

Quite handy! Well done. Is this for pizza's or just general cooking?

Little bit of this, little bit of that.
With the thermal mass of the oven it should stay warm enough to cook in for 3 days from a full firing.

[icehog3]

That's incredible, Dom, although little surprises me with your outdoor cooking masterpieces. Can it toast pretzels? :D

[Black Coral]

Great work Dom looks awesome can’t wait to see it in true cooking form

[Buckeye Jack]

Dude..thats awesome!!

[AdamJoshua]

Kind of short for a walk-in oven.... didn't know umpa lumpas came in Jew mode.

[Porch Dweller]

Wow!

[Mr.Maduro]

Wow. Amazing. Well done.

[jonumberone]

Can it toast pretzels? :D

You might want to stay away from the pretzels.
Usually the handle breaks, and they fall all over the floor.
We pick them up, put the box in front of Roger, and merrily giggle as he stuffs his pie hole. :D

[CEC_Tech]

That's coming out amazing. I would never have known this was your first attempt with Masonry.

[BigAsh]

You might want to stay away from the pretzels.
Usually the handle breaks, and they fall all over the floor.
We pick them up, put the box in front of Roger, and merrily giggle as he stuffs his pie hole. :D

Ahhhhh.....memories of simpiler times.....

[icehog3]

You might want to stay away from the pretzels.
Usually the handle breaks, and they fall all over the floor.
We pick them up, put the box in front of Roger, and merrily giggle as he stuffs his pie hole. :D

Ahhhhh.....memories of simpiler times.....

https://i.imgur.com/22B9cWf.gif

[cort]

That's Bad A$$, Bro!!

[jonumberone]

Got some work in on Saturday, but Sunday was a washout with rain, so I haven't finished the dome yet.
It was a little slow going as the walls got steeper because the bricks want to fall in.
I had to wait a few minuets for each brick to set, and use some wood to prop them up and hold them in place.
I'll be using a domed fiberglass form for the next few rows to prevent this.
I also botched the section where the ring crosses over the entry arch for the first time.
I didn't build it up enough, and turned my ring into a teardrop.
Of course I didn't notice until after the bricks had set up so it took some time to fix.
I had to build up and shape up the mortar in that spot to get the next row back in a ring.

You can see the dip here. The brick that is in the tool, and the one to the right of it

https://i.postimg.cc/g2jJxM69/20200815_160545.jpg

Back to a ring

https://i.postimg.cc/rs9mr3JT/20200815-201053.jpg

You can see here how steep the sides are getting.

https://i.postimg.cc/g062DnDN/20200815_181911.jpg

https://i.postimg.cc/v87DkxdK/20200815_201142.jpg

Where I'm at currently

https://i.postimg.cc/NfgLcGsj/20200816_140251.jpg

https://i.postimg.cc/vH3THRTL/20200816_140301.jpg

[Porch Dweller]

:cl

[8lug]

excellent work Dom

[icehog3]

It just gets better and better. :)

[markem]

Wow! That's getting more and more amazing. The Taj Mahal of backyard ovens.

[Snook]

Amazing build man! Can't wait to see pics of that oven in action.

[jonumberone]

I've finished the dome. :banger

Inserted the fiberglass form which is held in place with a car jack.

https://i.postimg.cc/3xPnNmMF/20200817_162050.jpg

https://i.postimg.cc/y85rR2R9/20200817_162119.jpg

Working up the dome

https://i.postimg.cc/G2n77Yqm/20200818-104412.jpg

https://i.postimg.cc/x80sYQrr/20200818-132750.jpg

https://i.postimg.cc/yNM5M2YB/20200818-135555.jpg

And then poured my keystone with refractory castable.

https://i.postimg.cc/52jR6fXb/20200818-143134.jpg

https://i.postimg.cc/x8YZCHz4/20200818_143457.jpg

Once the keystone is set hard I get to remove the form and crawl in the oven on my back to clean and point the joints. :hn

Going to spend the time waiting for the castable to set building up a landing around the door for the granite to sit on.
Still have a lot of work to do, but the hard part is done.

[markem]

Sweet bajeebuz but that's amazing!

[icehog3]

Cooler as you go, Dom! :tu

[BigAsh]

Sooooooo...what's a "carjack"??

[heyferg]

Outstanding, Dom. Well done!!

:tu

[RevSmoke]

Wow! You said you are not a mason?
That is incredible!

God's blessings on the project!

[CigarNut]

Awesome, Dom!

[Havanaaddict]

This is all Greek to me, very interesting! I have some questions!
Why on the bottom structure are there 2 sides?
Is it for storing wood?
Is there going to be a chimney or vent?

[The Poet]

Got some work in on Saturday, but Sunday was a washout with rain, so I haven't finished the dome yet.
It was a little slow going as the walls got steeper because the bricks want to fall in.
I had to wait a few minuets for each brick to set, and use some wood to prop them up and hold them in place.
I'll be using a domed fiberglass form for the next few rows to prevent this.
I also botched the section where the ring crosses over the entry arch for the first time.
I didn't build it up enough, and turned my ring into a teardrop.
Of course I didn't notice until after the bricks had set up so it took some time to fix.
I had to build up and shape up the mortar in that spot to get the next row back in a ring.

You can see the dip here. The brick that is in the tool, and the one to the right of it

https://i.postimg.cc/g2jJxM69/20200815_160545.jpg

Back to a ring

https://i.postimg.cc/rs9mr3JT/20200815-201053.jpg

You can see here how steep the sides are getting.

https://i.postimg.cc/g062DnDN/20200815_181911.jpg

https://i.postimg.cc/v87DkxdK/20200815_201142.jpg

Where I'm at currently

https://i.postimg.cc/NfgLcGsj/20200816_140251.jpg

https://i.postimg.cc/vH3THRTL/20200816_140301.jpg

Nice, Dom. As for your issues with the dome, Filippo Brunelleschi had the same one when he built the dome for the Florence Cathedral. But he solved that in the mid-15th Century, so you have no excuse. :r

[jonumberone]

This is all Greek to me, very interesting! I have some questions!
Why on the bottom structure are there 2 sides?
Is it for storing wood?

Yes, it's for wood storage.
The bottom is 7 feet long. I segmented it and left it open on both ends so I wouldn't have to crawl in to get at the wood stored in the back.


Is there going to be a chimney or vent?


I have to lay another arch at the front, and install the chimney.
That's the plan for today.

[CigarNut]

Forgive a stupid question (or four):

So the wood fire and the cooking food both go in the dome?

If so, I assume that it takes a bit for the oven floor to get hot?

How much wood will it take to get the oven hot?

How long do you think it will take to get it hot?

[jonumberone]

Forgive a stupid question (or four):

Ask away :D

So the wood fire and the cooking food both go in the dome?

Yes. After the oven comes to temp, I'll move the fire to the back of the oven for cooking, and over to the side when doing pizza.

If so, I assume that it takes a bit for the oven floor to get hot?

Yes

How much wood will it take to get the oven hot?

Roughly 90 pounds

How long do you think it will take to get it hot?

3+ hours. It should take over 3 days for the oven to cool down

Obviously this is all based on what I've read. No real world experience..... Yet :D

[BigAsh]

Obviously this is all based on what I've read. No real world experience..... Yet :D

Tic tock... tic tock....Looking forward to seeing it in action!!....Morning gents!

[Havanaaddict]

Yes, it's for wood storage.
The bottom is 7 feet long. I segmented it and left it open on both ends so I wouldn't have to crawl in to get at the wood stored in the back.

I thought that would have been the trick to get Adam to crawl in:r

[yourchoice]

This is a great thread, Dom. That's all, carry on! :D

[jonumberone]

Busy weekend here.
I got a lot of work done.
Crawling into the oven to clean and point the joints took way longer than I expected Thursday, so I wasn't able to actually build until Friday evening after work.

Friday night I put up the vent arch

https://i.postimg.cc/X7hhjH9D/20200821_195959.jpg

Saturday I put up the flue gallery and covered the dome with the remaining mortar mix.

https://i.postimg.cc/DybT7gQw/20200822_102701.jpg

And made sure the door fit

https://i.postimg.cc/SsKB37Nq/20200822_171632.jpg

Sunday I added two inches of ceramic fiber blanket for insulation, lashed it all down with chicken wire, and put on a waterproofing flashing
I also installed a thermowell through the brickwork so I can monitor oven temps when the door isn't in.

https://i.postimg.cc/y8mCZ8bq/20200823_145412.jpg

Thermowell is more visible here

https://i.postimg.cc/pLbtrFkY/20200823_145420.jpg

All that's left to finish the oven is to put on a perlite shell over the blanket.
However, I need to get the granite for the stand cut before I can do this, so I can bring the shell over the granite and eliminate the seam.
Hopefully he doesn't take too long.

[8lug]

Coming along nicely.

[CigarNut]

Truly amazing, Dom!

[icehog3]

Wow! Just wow!

[Black Coral]

Amazing

[longknocker]

Excellent Work, Dom!:D:tu

[markem]

Wow, that is turning out amazing, Dom. You should be quite proud of the result.

[DBall]

This is seriously an incredible build!

[Dave128]

Looking good!

[Scottw]

Amazing

[EricF]

Looking real good Dom!

[jonumberone]

Thanks for the kind words, fellas.

Installed the landing in the front of the oven opening.
This will make the granite sit flush and make it easier to get food in and out.

https://i.postimg.cc/KvQYrS48/20200825-095013.jpg

https://i.postimg.cc/SNmsMNSP/20200825_095005.jpg

[markem]

Just keeps getting better and better, Dom. A piece of art.

[Havanaaddict]

Thanks for the kind words, fellas.

Installed the landing in the front of the oven opening.
This will make the granite sit flush and make it easier to get food in and out.

https://i.postimg.cc/KvQYrS48/20200825-095013.jpg

https://i.postimg.cc/SNmsMNSP/20200825_095005.jpg

I was Wonderding if you were going to do something like granite in front! You are going all out, and I would not expect anything less!!! Any plans for the cinderblock base:confused: Maybe some nice ledge stone, Brick or thin stone veneer to face!!!

[Brlesq]

That oven door is sexy.

Looking good, but you forgot to put in a couple of beer holders :D

[icehog3]

That oven door is sexy.

Looking good, but you forgot to put in a couple of beer holders :D

That's what Roger and Vin are for. :D

[jonumberone]

I was Wonderding if you were going to do something like granite in front! You are going all out, and I would not expect anything less!!! Any plans for the cinderblock base:confused: Maybe some nice ledge stone, Brick or thin stone veneer to face!!!

Brick Veneer is the plan for the base. It ties in nicely to the granite and other stone I have in my yard.

https://i.postimg.cc/Xq2mYXZy/20200830_085107.jpg

[Havanaaddict]

Nice I like it:banger Were going to have to get you a gig on HGTV:) Just need a catchy name!
"Dom the no pants pit master"

[jonumberone]

I've finally finished with the oven construction.
Now I just have to finish the skim coat and brick veneer on the stand, do a series of curing fires. Once I'm done with that, I can paint the oven. :hn

Took some time to get the granite installed.
It finally went in last Sunday.

https://i.postimg.cc/y8nCvLNy/20200906-182912.jpg

Once the granite went in it was time to apply the perlite render shell.

https://i.postimg.cc/j5nVqK4M/20200907_120522.jpg

Once the shell was dry, I Installed the chimney and I was finally done with the oven part of this.

https://i.postimg.cc/RCL9ZZvp/20200913_090457.jpg

https://i.postimg.cc/Y9nBzxMs/20200913_090450.jpg

After a few days, I lit the first of a series of small curing fires.

https://i.postimg.cc/BbpGYMhf/20200913_113427.jpg

https://i.postimg.cc/fyDNf6fv/20200913_113708.jpg

I still have some work to do, but hopefully I'll end up cooking something by the end of the week.

[Porch Dweller]

:cl That's great work!

[markem]

Wow! That is more and more incredible each time you post pics, Dom. A true work of art.

btw, do you deliver? Asking for a friend.

[Steve]

Awesome Dom!

[BigAsh]

Got to see it in person this weekend....and I have to say....it's still unfinished! :r:r The photos don't do it justice, it's massive! Impressive build

[icehog3]

Like Keith said, pics don't do it justice! Really amazing, and I got to witness the first "firing". Like seeing a baby takes its first step. :D

[Havanaaddict]

Dom you rock:banger

[markem]

The photos don't do it justice, it's massive!

So, google maps in about 3 months, you think?

[massphatness]

I would have paid good money to see Dom, on his back, inside that teeny tiny opening putting the final touches on the interior of the oven. Why is there no video?

[8lug]

Nice work Dom. Congrats and good eats

[jonumberone]

Used the tail end of one of the curing fires to cook a Lasagna.
Still a few fires away from getting it hot enough for pizza.

https://i.postimg.cc/x1GxxFkg/20200917_171715.jpg

https://i.postimg.cc/pLMcBtdp/20200917_172632.jpg

[longknocker]

Awesome, Dom!:tu

[AdamJoshua]

I've seen better.

[icehog3]

Gettin' closer! :D

[markem]

Wow! Do you do takeout?

[CigarNut]

Do you ship? :D :D

[sigsauer]

unbelievable......
I have no talent

[8lug]

Wait a minute. Where's the garlic bread and wine?

[Snook]

Amazing build. Your neighbors will have their mouths watering.

[jonumberone]

So, I never got around to doing the veneer on the stand last season, and had to cover the oven for the winter.
Finally got a window of warm temps and no rain which allowed me to get it done.
I just have to scrub the brickwork clean tonight and I'll finally be finished.

https://i.postimg.cc/KYZ5WFjh/20210427-195727.jpg

https://i.postimg.cc/qM3QhjSS/20210427-195717.jpg

https://i.postimg.cc/NjvD1RwM/20210427-195741.jpg

[massphatness]

Your backyard is a veritable Disneyland for chefs
Posted via Mobile Device

[longknocker]

Beautiful Workmanship, Dom!:D:banger:noon:tu

[8lug]

Great Job!

[Steve]

Very impressive Dom!

[icehog3]

Pepperoni and sausage please. :D

[retired]

Outstanding!!!

[markem]

Beautiful, Dom!

[The Poet]

Adam's seen better. Me, I haven't.

[Porch Dweller]

I have a man crush on it. :D

[jonumberone]

Thanks, guys!

[Brlesq]

Great job!

[Havanaaddict]

Have you done any baking in it yet?

I have become an avid baker since covid started.

Here are a few recipes i found that looked and sounded good?

https://www.brickovenlifestyle.com/brick-oven-lifestyle/brick-oven-recipes/

BUTTERY HONEY BEER BREAD
Ingredients 3 C all-purpose flour
1 T baking powder
1 tsp salt
1/4 C honey
1 bottle (12 oz) beer
4 T melted butter

Steps

In a large bowl, whisk together flour, baking
powder, and salt. Slowly pour beer (it will foam)
and honey into the flour mixture. Next, stir 1/3 of
the butter into the mixture until combined.
Lightly oil a cast iron bread loaf pan (9 x 5 x 3 in)
and preheat for about 5 min in the 350° brick
oven. Take pan out of oven and pour 1/3 of the
melted butter into the bottom of the pan. Then
add the batter to the pan in an even layer and
pour the rest of the melted butter evenly over the
top of the batter. Bake in 350° brick oven for 40-
50 min. When top of bread is golden-brown, and
a toothpick inserted into the middle of bread
comes out clean, bread is done! Serve while still
warm!

     Notes
• I recommend warming the honey in the brick oven just a few seconds before pouring
into the flour mixture. It will stir in so much easier!
• Use your favorite beer for this recipe. I prefer a lite fruity beer!
• The bread can be frozen and then thawed when ready to use at a later.
• Toasting this bread in a toaster is one of my favorite ways to eat this bread!


PEACH COBBLER

Ingredients                   
Fruit Mixture:
8 fresh peaches
1/4 C white sugar
1/4 C brown sugar
1/4 tsp ground cinnamon
1/8 tsp nutmeg
2 tsp cornstarch
1 tsp lemon juice (mix with sliced peaches before adding to dry ingredients!)

Batter Topping:
1 C all-purpose flour 1/4 C white sugar 1/4 C brown sugar 1 tsp baking powder 1/2 tsp salt 6 T chilled butter (small cut pieces) Final Sprinkle Topping: 3 T white sugar 1 tsp cinnamon

Steps
Fruit Mixture:
8 fresh peaches
1/4 C white sugar
1/4 C brown sugar
1/4 tsp ground cinnamon
1/8 tsp nutmeg
2 tsp cornstarch
1 tsp lemon juice (mix with sliced peaches before adding to dry ingredients!)

Batter Topping:
1 C all-purpose flour
1/4 C white sugar
1/4 C brown sugar
1 tsp baking powder
1/2 tsp salt
6 T chilled butter (small cut pieces)
Final Sprinkle Topping:
3 T white sugar
1 tsp cinnamon

Steps
Slice an ‘X” into the bottom of each peach using a pairing or serrated knife edge. In a large pot boil peaches 1-3 min. just until skin begins to show signs of pulling away from edges of the “X” created on each peach. Remove and when cool to touch Peel peaches. Then cut in halves. Cut halves then into quarters. In a bowl gently mix lemon juice with peach slices. In another bowl mix together all dry fruit ingredients. Add to peaches and coat evenly. Pour mixture into a warm 10- inch cast iron skillet and bake for 10 min. in 425° brick oven. Meanwhile, in a bowl, combine batter topping ingredients using a pastry cutter to cut and create a crumble. Also, in a small bowl mix together sprinkle topping mixture and set aside. After removing skillet from oven drop spoonful’s of topping evenly over peaches. Then add sprinkle topping evenly over top and bake for 30 min. or until bubbly and topping turns a golden color. Wow! the peach cobbler will melt in your mouth!

And of course

Calzone Wood Fired Oven Dessert Recipe

Ingredients

6-8 oz. pizza dough!
Nutella
2 cups your favorite sliced fruit – try bananas or strawberries
Powdered Sugar

Preparation

1. Heat your wood-fired pizza oven to 600 degrees Fahrenheit. You can accurately measure the oven's temperature with an infrared temperature gun.

2. Use a rolling pin to work your pizza dough into a quarter-inch thick square.

3. The best part... coat the middle of the dough with Nutella, and top it with the sliced fruit of your choice.

4. Fold the dough in half, and pinch the edges together to seal.

5. Place the calzone directly on the oven floor and bake in your pizza oven for 2-3 minutes, until they are a beautiful golden brown. Don't forget to turn the calzones during cooking to prevent burning any side.

6. Remove from your wood fired brick oven

7. Dust with powdered sugar prior to serving, and enjoy!

[jonumberone]

No baking yet aside from garlic knots with leftover pizza dough.
I have done ribs, wings, lobster, baked potatoes , and prime rib.

https://i.postimg.cc/J0jqtW25/20200927-155251.jpg

https://i.postimg.cc/tgft5T0z/20200927-151336.jpg

https://i.postimg.cc/9MR159PS/20201010-181724.jpg

https://i.postimg.cc/Bn0zTm5v/IMG-20210404-223406-985.jpg

https://i.postimg.cc/QM6nrs2B/IMG-20210404-223407-051.jpg

https://i.postimg.cc/nhGP0qTG/IMG-20210404-223407-065.jpg

[icehog3]

Christ, now I'm hungry Dom. :lr

[jonumberone]

Christ, now I'm hungry Dom. :lr

Come on by. You know you're always welcome here. :tu

[CigarNut]

That is AWESOME, Dom!!