Casa90 Build

[Paul in Rockwall TX]

Re: Casa90 Build

I would think 4 anchors per side to hold the track down would be fine. I would also use a 3/8 anchor, if you can get it long enough. go at least 2 inches deep, preferably deeper into the substrate.

here's a sample:
Wedge Anchor, Stl, Zinc, 1/2x7 L, PK10 - Wedge Anchors - Anchors - Fasteners : Grainger Industrial Supply

McMaster-Carr

If you can't get an anchor long enough, you can have a local place cut a threaded stud to length and set it into the hole with an epoxy or chemical anchoring adhesive.

Kind of a lot of work, but that's where' you are.

Pal

[Cdubs]

Re: Casa90 Build

Paul - You are full of great info. Even though all of your solutions will absolutely work, I have to think that there is an easier way. I reaally prefer using metal studs but the more I think about it, it may be easier to use 4x8x16 block. I reaally dont want to do thaat for several reasons but it may be the only way.

[Paul in Rockwall TX]

Re: Casa90 Build

I considered the same thing, but ended up going with metal studs. I didn't trust my ability to mortar the joints, and I didn't want to dry stack.

I think you're in the same place though. the vermicrete is probably not strong enough around the edges to support a 4" wide block wall on top of it.

you'd still need to cut away a reveal, which is pretty easy. a little messy, but you could accomplish it quickly.

[Cdubs]

Re: Casa90 Build

Being able to mortar the block correctly is also worrying me. I have heard that they make some pretty strong adhesive that some pro's have been using. In regards to the edges being weak, I think that my 3to1 ratio may hold up. I was looking at it today and it seems to be pretty strong. If I was going to cut into it, what tool would you suggest?

[Paul in Rockwall TX]

Re: Casa90 Build

you could use an angle grinder with a masonry wheel. I used a 4-1/2 for cutting most of my bricks. with a small diameter wheel you'd have to make a couple of passes and it might not be perfectly plumb, but it doesn't really matter. I think it might be softer than you think, too. mine was 5:1, and you can trim it back with a good chisel and hammer.

you could certainly experiment and do no real harm.

[Cdubs]

Re: Casa90 Build

I took your advice Paul. I wish I had a grinder but the chisel and hammer did the trick. I was able to get through two side with ease but it seems hard to keep things clean. Hopefully I'll be able to put the dome together tomorrow..it's all going to depend on the weather.

[Paul in Rockwall TX]

Re: Casa90 Build

looks good - I (like most others here) made lots of miscalculations and subsequent adjustments. I wish I'd started asking questions sooner so that I could've avoided some.

I think you've made a good move here.

Paul

[Cdubs]

Re: Casa90 Build

To be honest I usually "do" before I ask, but decided that this time I was going to suck up my pride and ask for advice. Without people like you I would be completely lost...thanks for all your help.

[Cdubs]

Re: Casa90 Build

So I was finally able to put the oven together and plan on putting the insulation blanket on tomorrow. Ill be honest, I'm not very happy with the way the oven looked when i took it completely out of the crate. At first inspection everything looked great but after taking all 4 sides of the crate off it was a different story. I understand that there may be some small cracks but i have one going through the entire front piece (front and back). I think this is the down fall of having concrete shipped across country. Anyway, the build must go on.

Tomorrow will start my insulation phase with the blanket and two inches of vermiculite/cement mix. Does anyone have any good ideas on keeping the blanket down. How do you guys tie it all together?

[Les]

Re: Casa90 Build

I sat in some tapcon's and used bailing wire. Are you doing an enclosure or an igloo? From my experience you will not be able to apply the vermiculite mix on top of the blanket - it wants to slump WAY too much.

[david s]

Re: Casa90 Build

Stick to the installation instructions.

[Cdubs]

Re: Casa90 Build

Les - I will be doing an enclosure but won't be able to build it right away. I figured if I put the vermicrete on top it would be able to hold up to some rain. Btw what is bailing wire?

David - I understand the guide has great info but Im looking for more detail. At this point I have memorized the guide and it says you should use A metal band or wire mesh. I have used mesh before and that is not what I'm looking for. I want something that hugs the blanket and compacts it. Also, what is a metal band..if I walk into HD will they know what that is?(probably not) It actually looks like the picture shows rebar..not what I want to use.

[Cdubs]

Re: Casa90 Build

I meant to post some pictures of the oven install yesterday but it was too late. Here are a couple from this morning. We are finally getting somewhere.

[SableSprings]

Re: Casa90 Build

I used metal lathe sheets to hold my dry insulation in place and to provide a base for my perlcrete insulation coating. Home Depot carries the sheets, as I understand it they are used as the base for cultured stone facades on the outsides of buildings. One caveat that's been noted elsewhere...this metal has some very sharp edges and if you cut it to fit, it has MORE sharp edges. Be very careful, go slow, and wear leather gloves.

I found that fitting the cut sheets into place worked pretty well by cutting instead of folding and using small pieces of wire ties to hold sheets together at "joints" as tightly as possible. Try to avoid any bounce/give between the lathe and insulation blankets. The cement insulating mixes will go through the holes in the lathe if you have open spaces or press too hard. A thin paper or foil layer between the provided blanket insulation and lathe would probably work well to eliminate that problem. I found out that it's better to do small concentric rings 10-12" high around the base and let it set for an hour or two. Next, do another ring on top and let it set. If you don't, the lathe will deform with the added weight and you start losing the dome shape. You might also consider leaving the a spot in the back open for a while to help the dome's "extra masonry insulation" vent/dry through at least 5-6 full oven firings.

I would not trust a perlcrete or vermicrete mix to shed water...my experience with my oven, was that the mix absorbs and holds water really well. You'd be best served to set up an "over dome" canopy to protect against rain. I borrowed a small picnic canopy from a friend and it worked pretty well to keep things dry while I continued to work on the enclosure/insulation/facade.

[Cdubs]

Re: Casa90 Build

Thanks Mike...I wish I would have seen your post before I got started today. I would have reconsidered and used the metal lathe like you suggest. I ended up covering the oven with 3 inches of fire blanket and wrapping bailing wire (Thanks Les) around the oven to keep it all tight. After that, I mixed up some vermiculite and cement to a 10 to 1 ratio and started spreading. I will say that it was much harder then I thought it was going to be. Getting the consistancy right was tough and this stuff just did not want to stick.

A few hours, a sore back, and some cut hands and this is what it looked like......