One Meter Internal Dome Oven AVERAGE GUIDE

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1 FIELD FURNACE REFRACTORIES Pty Ltd. 8 Arnott Place Wetherill Park NSW 2164 Phone: Fax: One Meter Internal Dome Oven AVERAGE GUIDE Quantity Description Unit price Total 192 Tapered Half brick $2.40 $ Fire brick. 230 x 115 x 75mm $3.65 $ Floor tile 50 x 300 x 300mm $16.40 $ High temperature mortar. 25kg bag $46.00 $ Insulation brick (I.F.B) 230 x 230 x 60mm $5.50 $ Ceramic fibre roll 25 x 600 x7200mm 128kg/m3. $ $ Door Arch Brick 230 x 115 x 75/63mm $4.65 $ Door arch brick 230 x 115 x 75/51mm. $4.65 $ Flue arch brick 345 x 115 x 75/51mm. $6.65 $ Flue arch brick 345 x 115 x 75/63mm $6.65 $ Flue brick 345x 115x 75mm $6.65 $ Pallet charge (Refundable on return) $33.00 $33.00 EXTRAS 1 Chimney cap 300 x 300 x 40mm $12.80 $ Hollow Chimney Blocks 240 x 240 x 150mm $16.50 $ Stainless steel ash rake $79.90 $ o C Thermometer (Dial or T-Gun) $72.60 $ Pizza oven 3 piece set + Wall bracket $ $ (Large peel, turning peel and brass brush) 1 Oven door $ BASIC $ COMPLETE $

2 PRODUCT INFORMATION When using high temperature mortar, mix with water only to a trowel able consistency. Soak each brick in water for 10 minutes minimum as this gives a better bond with the mortar. When using ceramic fibre ware long sleeves and a mask in case of allergies or irritation. The render on top of the ceramic fibre blanket should be 20-30mm or thicker to have sufficient strength. Use wire mesh for reinforcing. FORMULA TO BUILD A DOME OVEN All ovens from 1meter to 2meters should never be higher than 540mm from cooking surface. Ovens under 1meter internal should be half their width in height. The door height should be 63% of the ovens height (this is just a guide). WAYS FOR BUILDING A DOME OVEN A wooden template which can be moved around gradually as the dome is created. A 50mm piece of conduit which is secured to the centre of where the oven will sit. Every brick that is laid must touch the end of conduit. By using this method you can create a near perfect dome. The length of the conduit is determined by the size of oven you wish to build e.g., to build a one metre internal oven the conduit must be 500mm long (half the width). TIPS To build a dome oven cut your bricks in half then by having a very thin joint on the inside and opening the joints up at the back, you can create a dome effect. To speed up the heating and slow down the cooling of the oven, cover the dome with ceramic fibre 75mm thick. This prevents massive heat loss, in turn allowing the oven to heat up quicker and stay hot for longer. Building the oven on top of insulation fire brick (I.F.B) also makes the oven more efficient and prevents damage to the concrete slab (cracking and spalling). The flue is placed in front of the oven door, drawing the smoke away from your face. When the oven door is placed up against the door arch sealing the main chamber, this create maximum heat storage with the only loss of heat through the steel plate door (4-6mm preferably). Floor tiles should be placed inside loose so over time with wear and tear, any cracked or broken tiles may be replaced. Ash after a few uses will fill any gaps and act as an expansion joint.

3 This base is a 20mm cement sheet with 2 layers of 75mm Hebel, glued together with Hebel glue. The size of the base is 1500mm in width and 1800mm in length. You may also use a concrete slab 100mm thick minimum. Lay the internal insulation brick in position, note these are not glued or fix into position. Cut and lay the floor tiles on top of the insulation brick When in position grind any high lips down leaving a smooth joint, this will stop the peel catching on any tiles. Your ready to position the door arch template and lay the first corse of insulation brick in the dome.

4 If you build the door arch first it s always good to lay 3 or 4 course s either side for support. By using a length of conduit you re able to build the dome 5 or 6 course high before the bricks start to slide. Measure the width of the opening left in the dome, then by cutting 2 to 3 pieces of wood you can create a plug. By using a level make sure the height of the sand from the floor tile is at the correct height, this is governed by the width of the oven. Once you have the desired height compact and shape the sand, brickie sand is best for this as the clay in it gives a dense and firm surface. Begin to lay the rest the half s cutting the halves when needed. Once you have finished building the dome, leave the brick work for an average of 4 hours. Pull the sand plug out and now you need to clean the inside while it s not rock hard, a scraper, sponge and buck of water is easiest way.

5 You re ready to build the flue arch, there are a couple ways to go about it here are two examples. With the brickwork in the oven complete it s time to insulate the oven, ceramic blanket is the most efficient and cost effective way. Covering the dome with 3 layers of 25mm thick ceramic blanket, with a total thickness of 75mm. Make sure that the joints don t line up, The insulation will reduce the ovens temperature from 400 degrees to 35 degrees. Using bird wire wrap the oven keeping it firm to the ceramic blanket, by not allowing the mesh bulge it will make the render easier to apply. Render the oven 20 to 30mm an easy mix is (1 Bag of cement, 2 bags Sydney sand, 1 bag of brickie sand) you may also add a liquid hardener for superior strength. Make sure the mix is thick and you are able to make a peak from it this will insure sufficient strength, leave the render for 20mins to an hour depending on the weather With a damp sponge rub it back smoothing out trowel marks, where the render meets the flue arch allow 2mm for expansion and contractions of the oven, this will avoid cracking as the blanket will absorb any movement of the brick oven. Your ready now for the first firing.

6 DRYING OUT YOUR OVEN When firing the oven for the first time heat beads are best. It is important to avoid flame impingement to the brick work. Light 3-5kg bag of heat beads outside the oven to avoid the flames touching the brick work. Once lit, using a shovel, toss them in spreading them around the perimeter. After 20minutes you can repeat the process 4 more times, tapping the heat beads with a bar or stick every 30 to 60 minutes will ensure good radiant heat. Allow about 6-8 hours before tossing in the first pieces of wood. Do Not let the oven cool, it is important to reach cooking temperature during the dry out. You are now ready to cook otherwise put the door on and let the oven bake in the retained heat for the next 2 days.

7 TIPS TO MAKING THE DOOR AND FLUE ARCH TEMPLATES To create the wooden templates needed you must first lay the desired shape, (combination of bricks) on top of a sheet of plywood with wooden or plastic packers 5mm thick to mimic the mortar joints. Once the desired shape has been created and checked for alignment and centre, mark the shape out labelling each brick as well as mortar joints on plywood. By placing two pieces of plywood together then cutting it out with a jigsaw will give you matching pieces. Prop up the template with wedges at its base. Once the brick work has dried you can remove the wedges so the template may drop and be removed easily. With the door and flue arch the height can be adjusted by adding or removing standard straights (75mm thick brick). This must be taken into account as each individual tends to make their mortar joints different thickness and this affects the width and height of each arch. Door Arch Flue Arch 51 = 230 x 115 x 75/51mm arch brick 51 = 345 x 115 x 75/51mm arch brick 63 = 230 x 115 x 75/63mm arch brick 63 = 345 x 115 x 75/63mm arch brick The information provided in this pamphlet is for guidance only. FFR shall not be held responsible for any loss, damage or delay arising from its use. The user of this data is required to determine the suitability and accuracy of any information supplied.

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