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Thanks for your feedback and your contribution to this forum I have read many of your suggestions and advise. I understand, I defiantly got ahead of myself.
The mortar job as you see it was done on Thursday in 4 hours with a break for lunch.
I mixed two batches, I used type S mortar, heatstop50 fireclay and fine silica sand.
I have zero experience with brick and mortar, my friend who happens to be a retired mason helped me mix the mortar and my goal was to finish 3 courses that day.
I was kneeling on the floor as he handed me each brick. The work went fast, the 3 courses were done in the first hour, I had most of the bricks cut in half and the vent arch was not ready when he came over.
Had the vent arch been formed and we had not run out of bricks we would have closed those courses and almost finished the dome.
Another strap of 75 bricks and we will have enough to finish.
The oven floor is 42" in diameter. I'm sure I will have a few bricks left over.
After reading Appendix 6 High Heat Mortar, my friend who happens to be a retired mason, came up with this mortar mix recipe. The type S masonry cement we used has no aggregates so, 1 part type S, 1 part fire clay and 3 parts sand.
This mix is like coolwhip, then once the brick is placed you have less than 10 seconds to position the brick before the mortar bonds, if you try to move the brick after that the bond will break.
Last edited by FrankT; 11-15-2010, 09:08 AM.
Reason: mortar mix recipe...
Just to clarify, for new builders who may be lurking, Heatstop, whether or not it's in a fifty pound bag, is a ready mix refractory mortar. It may have a bit of fireclay in it, but it isn't fireclay. Among other things it's about five times more expensive than fireclay.
FrankT, your oven will be fine. The design that Forno Bravo has put together is almost foolproof, and there is enough margin for error built in that it would be hard to build it such that it WOUDN'T work.
Thanks for the words of encouragement, I needed that.
I will be updating the status of the mortar as I start to use the oven.
The Forno Bravo design is amazing and in my heart I know my oven will stay up.
I will close the dome this week...
I am having a blast constructing this oven.
I just hope the next oven I build will be at a different site.
Ovens are pretty forgiving. Almost all of the ovens have "peculiarities" that reflect material availability and cost, or simple error. And they work anyway. Looking at old ovens in Europe it is obvious that they didn't have standard plans or materials and lots of those have been used for centuries.