39 inch - 1000mm corner brick WFO build - Newcastle au

[Newie newby]

Just filled up the backs of the dome bricks tonight with a different mortar supplied with kit called "fondu mortar". Still high temp rated but supposed to be better for larger gaps. Mixed with washed brickies sand 1 part dry mortar to 3 parts sand, just enough water to make mortar like consistency when mixed. Much easier to fill the gaps than laying the bricks, especially when outside will be covered later anyway...

[david s]

The wet ready to go mortar in the bucket sounds like a sodium silicate based mortar. The “fondu mortar” sounds to me more like Ciment Fondu which is calcium aluminate cement, not a premixed mortar. It requires the addition of a fine aggregate to create a mortar and what you have described that you did by mixing the 3 parts washed sand to it. Because it reacts far faster than Portland cement there is no need for extended damp curing.

[Newie newby]

I noticed an earlier pic of the footing, blockwork and slab sizing is not showing from earlier post, so additional copy attached FYI.

[Newie newby]

Few more progress pics of the build. Had a little mate helping for a while .....

[Newie newby]

Gravity started to work against me as courses got higher, ended up propping bricks to stop the droop. Premixed Airset mortar on inside, then mixed up fondu cement for outside as courses continued up.

[Newie newby]

More help from feline friend...

[Newie newby]

Now up to plug layer. Added some plastic to capture waste, then added bricks and template, finished course of bricks then added sand to form shape of top of dome.

[Newie newby]

Up she goes, much easier with form under bricks

[Newie newby]

Decided to not cast the keystone tonight, hopefully when I remove the form and get the sand out from inside the dome tomorow I can stick my hand in and clean up the excess mortar then pour it later. Good feeling to have the dome closer to finished. Now to clean inside, do the flue arch and chimney and get the dome insulated...

[Newie newby]

Cleaned up inside oven and keystone poured.

[Newie newby]

Mocked up flue arch and chimney housing fire bricks. There won't be gaps once mortared in.

[SableSprings]

Get some shims under that arch form support. Mortar not only adds "extra spacing between bricks but it will set down tight on that form piece and can make it difficult to remove. We have had builders struggle to remove the form and actually loosen/damage their newly laid arch. Oven is looking great, you've done an excellent job on this build!

[UtahBeehiver]

Plus one Mike's shim comment, at least a 1/2" worth of shims or you won't get the form out without damaging the arch.

[Newie newby]

Will do and thanks for the feedback. Cheers, Brad

[Newie newby]

Made some more progress on the entry/flu arch, also added some bricks forward of the oven for a landing.