Here, I will record my progress in making my first cast oven, having spent many, many hours exploring this forum and others in order to identify the best construction methods....
My plans are for:
A concrete slab, with a brick built base, supporting a 100mm (4") reinforced concrete slab
A 100mm (4") thermolite block floor insulation layer, surrounded by concrete to the edge of the formwork
A 1" ceramic board (CaSi) insulation layer above the thermolite block (to reduce direct heat on thermolite which has an unknown extreme heat tolerance)
An oven base constructed of 64mm deep firebricks, insulated peripherally with vermicrete, with concrete to edge of base formwork
A heat retaining dome constructed over a sandcastle of 800mm internal diameter (32"), approx 5cm thickness, (sand, fireclay, lime, cement, polypropylene screed fibres, stainless needles)
A flue gallery, entrance of 450mm width, 250mm height (62% dome radius), with flue partially in dome area, and ridge for internal door to sit against positioned to enable flue to be isolated from oven when door closed.
A stainless flue 150mm (6")
A 1-2 inch ceramic blanket, possibly secured with chicken wire
A 5cm vermicrete layer
Render
Waterproofing (paint or tiles) to dome
Waterproofing to top of base (tiles)
Oven Costings:
Oven:
Brick Base (concrete foundation, brick wall and reinforced slab with thermolyte topping):
Timelapse of building sand-castle, cast dome, and vermicrete insulation
Time lapse of scratch coat and final render top coat
My plans are for:
A concrete slab, with a brick built base, supporting a 100mm (4") reinforced concrete slab
A 100mm (4") thermolite block floor insulation layer, surrounded by concrete to the edge of the formwork
A 1" ceramic board (CaSi) insulation layer above the thermolite block (to reduce direct heat on thermolite which has an unknown extreme heat tolerance)
An oven base constructed of 64mm deep firebricks, insulated peripherally with vermicrete, with concrete to edge of base formwork
A heat retaining dome constructed over a sandcastle of 800mm internal diameter (32"), approx 5cm thickness, (sand, fireclay, lime, cement, polypropylene screed fibres, stainless needles)
A flue gallery, entrance of 450mm width, 250mm height (62% dome radius), with flue partially in dome area, and ridge for internal door to sit against positioned to enable flue to be isolated from oven when door closed.
A stainless flue 150mm (6")
A 1-2 inch ceramic blanket, possibly secured with chicken wire
A 5cm vermicrete layer
Render
Waterproofing (paint or tiles) to dome
Waterproofing to top of base (tiles)
Oven Costings:
Oven:
- Stainless flue 6" 1m + 0.5m = £58 (ebay)
- Fireclay 25kg bag £30 (inc delivery) valentines clays
- Firebricks x 30 £75 Vitcas
- ceramic blanket 7.3m x 1" £65 Vitcas
- ceramic board 1x1x1.2m £60 Vitcas
- delivery from Vitcas (pallet) £40
- Cement 25kg x 2 £10 Selco
- hydrated lime 25kg x 1 £12 Selco
- Sharp sand (from bulk bag costed in base)
- Stainless needles 3kg £50 Rockbond (inc delivery)
- Polypropylene fibres 900g £11 ebay
- vermiculite 100l £24 ebay
- perlite 100l £24 ebay
- blue quartz glass (arch) £4 ebay
Brick Base (concrete foundation, brick wall and reinforced slab with thermolyte topping):
- Cement 25kg x 10 £40 Selco
- OSB board for formwork £20 Selco
- builders sand (mortar) 6 bags £15 Selco
- Ballast (for concrete) 1xbulk bag £50 Selco
- Sharp sand (for sandcastle/dome casting) £50 Selco - used less than 1/2 and got most back after sand castle
- blue bricks £100
- thermolyte blocks x 10 £12 Selco
- rebar mesh 3.6x2m - £20 Selco
Timelapse of building sand-castle, cast dome, and vermicrete insulation
Time lapse of scratch coat and final render top coat
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