Starting new build in Dallas

[Dwatkins]

I picked up a load of cedar to start the extension. Got the two posts set and set the two beams and once I have the two ends tied together I will start the joist.

[Dwatkins]

After for two days I pulled the forms and the oven floor foundation is ready. I plan to complete the pergola extension before I start the dome just to keep it dry so I will be working on the pergola for a while. The last pic shows the pergola pre-oven and where the round table sits is the oven location. The pergola will extend to the fence, about another 14'.

[Dwatkins]

The wood blocks did come out as I filled in with cement. Just used them for temporary stilts.

[Dwatkins]

OK, using my handy dandy Harbor Freight mixer in 70 minutes I had 24 50lb bags of quikrete poured. Wait two days and will pull the forms.

[Dwatkins]

Thanks David, it actually has worked very well but now that I am at the dome floor I will be using a level.

Over the long weekend I started framing for the oven dome slab which will be 5” thick. I added in two 2 ½” angle iron supports to add strength to the center while pouring. I used my angle grinder to cut slots in the brick so the angle iron would lay flat. I will then lay ½” wonderboard over this to pour the slab. It took two 3 X 5’ sheets of wonderboard which I laid on top of the forms, crawled underneath and scribed the inside of the forms. I used the angle grinder with a masonry blade to cut them to fit. Worked great.

[shanxk8]

That is looking excellent so far Dan! The bricks you picked to build the support structure look beautiful.

Looks like you created a simple IT tool for a cylinder . I could have used something similar to keep my decorative brick exterior level (which they are not), but I built mine using concrete/cinder blocks and then brick outside.
I'll have to keep checking in on your build, as it looks very well executed so far.
David

[Dwatkins]

More progress the past two weeks. Got both the inner and outer walls bricked up to 34", pickup the 3" angle iron for the wood storage opening and framed up for the oven floor slab.

[Dwatkins]

I made a little headway this past week on the build but it is tough trying to do a project with a full time job always taking my time. Anyway, I made two different jigs that are working very well; the first is this piece of 2 x 8 cedar with a slight angle for cutting each end of the bricks in order to form the circle. I am not like some of the engineers on this site that I have seen that calculate out the exact degree, I use the TLAR theory, “that looks about right” and it works pretty well although I will probably be a little more detailed once I get to bricking the oven. Since the walls are round and it is critical that the walls are plumb it was going to be a challenge to hold a level to every brick going around and especially with each joint where two brick come together forming a point, so I came up with this jig. I got a 5/8” x 72” all thread and anchored it to the slab with two pieces of 5/8” plywood and then braced it off at the top so it was level. I then cut a 2 x 4 to 67 inches which is the diameter of the outside wall and drilled a 5/8 hole in the center. Slid it down the all thread where it sits on a nut and flat washed and now I can raise it up with each course of brick and as I lay each brick I can spin it or move it to line up the end of the 2 x 4 with the face of each brick. Now the face of each brick will be 33 ½” from the center and should be completely plumb. Once I get to the oven floor height naturally this will no longer work but it is working well now. The interior wall is not as critical but I am following closely to the outside wall leaving a small gap.

[Dwatkins]

Russell, appreciate the response.

[UtahBeehiver]

Forno Bravo actually provides AiSi with their kits. IMHO, here are the two critical specs you need for either AlSi or CaSi, compressive strength of about 70 PSI or more at 5% deformation (abt 0.5MPa) and 0.07-08 w//m.k at 400C thermal K factor. You could try looking for Thermal Gold 12 (CaSi) from Distribution Internation, think their corporate office is in Houston with a branch in Dallas or Austin. Some recent builders have been asking about InsBlok 19 but IMHO it is on the low side at 38 PSI compressive strength. The ovens we build are really really heavy.

[Dwatkins]

Is there any difference between Aluminosilicate Ceramic Fiber Insulation Board and Calcium Silicate Insulation Board? The Calcium board that I found is 2", has a 370 PSI and rated to 1800F. Cost is about $10 sq ft.

[UtahBeehiver]

The circular base will give you good practice on the saw for your dome work. Being under cover will go a long way to keeping the oven dry. Dry pour over blanket will work great. You should have a very well insulated oven around the dome and with 4" of floor insul. the oven heat will last for days. Looking forward to seeing your build. I used the old cheap HF saw for my build and it is still hanging in there after a oven, patio and stone work. I needing to sell it off to make garage space but hard to let it go, right tool for the right job.

[Dwatkins]

Russell,
Just a follow up to the previous post and I need to do a better job proofreading before sending.
My plan is to extend our pergola over the oven which will add a 14' x 12' roof over the oven. The interior brick wall will come up approx. 36" which will support the oven floor and plan to add angle iron with a center post for added support. The oven floor will stop at the center of the two rows of brick allowing the exterior to continue up to the pergola roof. I had mentioned that I did not believe moisture would be an issue but adding some weep holes in the floor just in case moisture does get under the insul board will not be a problem. I also was not planning to do stucco over the blanket/ chicken wire because I intend to add a loose fill to cover the oven once I have bricked the outer wall up to at least the height of the top of the dome. The other pics are my first load of old Chicago bricks (250 of about 1400), my new 10" Harbor Freight wet saw, and the starting lay out. For $250 w/ tax the wet saw performed exceptionally well for the few hours that I used it over the weekend. Considering that almost every brick will have at least two cuts to form the circle, it will get a workout.

[Dwatkins]

Mongo,
Saw the post of your build.
Looks incredible!
Dan

[Dwatkins]

Russell,
Yes figures are accurate. It will be close but do believe that I have some room if needed. I drew it out and have measured many times and do not believe that I have missed anything. The exterior will brick all the way up. I will extend the pergola to completely cover the oven so not worried about moisture. If it is just for good measure to leave so holes just in case than can easily do so once I get ready to pour the floor and hearth.
Thanks for the response.
Dan