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Hi everyone just wanted to share my build so far. Took me around 4 weeks from start to finish.
Base was constructed from concrete landscape wall blocks that when put together form a circular shape. I used around 80 blocks glued together with P&L polyurethane glue. It has a total of 11 layers. The first 9 create a circle with a 36" diameter and the last 2 top layers were held out 1.5" creating a top ring with a 40" diameter and a lip inside to pour a concrete layer before moving forward with the oven floor. The top layer of rock all have tapcon screws drilled in side which stick into the concrete ensuring they never move. I left specific blocks out to create the opening below for wood storage.
Once this was complete I cut a piece of dura rock board and fit that in bottom against lip. I then poured a 2" layer of high strength concrete with rebar inside. This gave 6" remaining inches of space within the top 2 layers which was filled with 6" of 5:1 perlite concrete to bring everything even with top of the top block layer. I added 1/8-1/4" layer of mason sand on top to allow firebrick to site even with each other. I used red medium duty firebrick in a herringbone pattern. In order to create an entrance I was able to get a piece of granite which can be seen in the pictures. This was secured with P&L polyurethane glue and high heat mortar.
I then created a mold for 6" walls around the dome 2" thick. I added 2" of perlite 5:1 in mold first to ensure dome walls made no contact with concrete base in any way. I poured Heat Cast40 castable refractory mortar into the mold. Once dry I removed only the inside form and the filled the entire oven with mason sand to create the dome. I poured the remaining castable refractory on top of the sand mold. It took a total of 320lbs of heat cast with 10lbs of stainless fibers for added strength. The oven has a 28" inside diameter which will be perfect for 10" pizza at home. The dome height is 15" with a 9.45" door height.
Once this was complete I removed the sand and sealed seam between dome and walls with high heat mortar. I decided to use a 24" clay flue with inside diameter of 6". To avoid cracking from expansion and contraction I first wrapped entire flue with 1" ceramic blanket from FB. This was followed by chicken wire and stainless wire. I placed it on top of oven and secured with high heat mortar. I made sure mortar was only between the ceramic blanket and dome. This will hopefully allow and expansion to be absorbed by blanket.
I covered the entire dome with 2 layers of 1" ceramic blanket. I chose 1" because this allows seams to be covered by second layer. The top of the dome has 3 layers to help with shape and insulation. I secured this with chicken wire and stainless wire.
I then covered the dome with 1/2" of polymer based scratch coat. Followed by 1/8-1/4" final stucco color coat.
I will add pictures below.
Base was constructed from concrete landscape wall blocks that when put together form a circular shape. I used around 80 blocks glued together with P&L polyurethane glue. It has a total of 11 layers. The first 9 create a circle with a 36" diameter and the last 2 top layers were held out 1.5" creating a top ring with a 40" diameter and a lip inside to pour a concrete layer before moving forward with the oven floor. The top layer of rock all have tapcon screws drilled in side which stick into the concrete ensuring they never move. I left specific blocks out to create the opening below for wood storage.
Once this was complete I cut a piece of dura rock board and fit that in bottom against lip. I then poured a 2" layer of high strength concrete with rebar inside. This gave 6" remaining inches of space within the top 2 layers which was filled with 6" of 5:1 perlite concrete to bring everything even with top of the top block layer. I added 1/8-1/4" layer of mason sand on top to allow firebrick to site even with each other. I used red medium duty firebrick in a herringbone pattern. In order to create an entrance I was able to get a piece of granite which can be seen in the pictures. This was secured with P&L polyurethane glue and high heat mortar.
I then created a mold for 6" walls around the dome 2" thick. I added 2" of perlite 5:1 in mold first to ensure dome walls made no contact with concrete base in any way. I poured Heat Cast40 castable refractory mortar into the mold. Once dry I removed only the inside form and the filled the entire oven with mason sand to create the dome. I poured the remaining castable refractory on top of the sand mold. It took a total of 320lbs of heat cast with 10lbs of stainless fibers for added strength. The oven has a 28" inside diameter which will be perfect for 10" pizza at home. The dome height is 15" with a 9.45" door height.
Once this was complete I removed the sand and sealed seam between dome and walls with high heat mortar. I decided to use a 24" clay flue with inside diameter of 6". To avoid cracking from expansion and contraction I first wrapped entire flue with 1" ceramic blanket from FB. This was followed by chicken wire and stainless wire. I placed it on top of oven and secured with high heat mortar. I made sure mortar was only between the ceramic blanket and dome. This will hopefully allow and expansion to be absorbed by blanket.
I covered the entire dome with 2 layers of 1" ceramic blanket. I chose 1" because this allows seams to be covered by second layer. The top of the dome has 3 layers to help with shape and insulation. I secured this with chicken wire and stainless wire.
I then covered the dome with 1/2" of polymer based scratch coat. Followed by 1/8-1/4" final stucco color coat.
I will add pictures below.
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