My Barrel Vault Oven Build - Durham

[moonhead]

Finally things have got under way.
Having already dug away the area for the oven, I had the frame for the base constructed, a 10mm re-bar reinforcement grid tied together ready for the concrete pour.
So a damp proof membrane went in under the re-bar supported half way in the 150mm form.
I also want a side table for preparation but more importantly somewhere to put down the beers while cooking So as you can see from the picture I have added a bit to the side as well.
Working out that at 150mm deep I needed about 1 cubic meter of concrete, a quick call to local supplier and hey presto, 2 tons barrowed into the frame last Friday. After another hour of tamping it down & levelling it off with the help of my son who timed his arrival home from school perfectly, it has been left to set over the week.

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[moonhead]

Not having any luck posting multiple images so here is the levelled base.

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[cannyfradock]

Hey Rick

....first talking about it....then doing it!!...can't fault it.

Also love the detail in your base. DPM....re-bar!!....looking forward to seeing your build.

Terry

p.s....we love pics.......post as many as you want....

[turkey]

that is they way to do it, no messing around, mixing that much concrete would have taken a while and left you sore no doubt. Keep the slap well misted with water for a good slow strong cure (with no cracks) .

[nick]

Hey..............

Looking Good

Keep the build going

Cheers

Nick

[moonhead]

Thanks Guys for the encouragement.
I had covered the fresh slab with a tarpaulin on the Friday night and glad I did as we had quite heavy rain over night. Other than a dry layout of the block work, nothing was done through the week. Saving myself for the weekend.





I'm usually working Saturday mornings and after a couple of errands were taken care of it was 2 o'clock before I got a start. Mixed up a batch of mortar and got stuck in. After the first course went down I skimmed the top surface with a thin layer of mortar the laid down the damp course on top and gave it a rub down to make a good contact.





Laying the second course was a lot quicker, especially cutting the blocks before starting to lay them! A step I missed out on the first. Lesson learned Laid in place as I cut them.



The bottom front corner nibs look a little tatty but will be hidden by the facing bricks anyway so not too worried by them. So by 7 I had two courses down no point mixing any more mortar so time to soak my aching back in the tub.
Hopefully the rain will hold back today and progress will continue.



Thanks Terry as well for the help posting multiple images

Rick

[cannyfradock]

Rick

Don't want to sound OTT, but as a bricklayer I truly commend you on the work so far.

It looks very similar to my "Rob's build"...Pompeii oven. I also spent a lot of time dry laying both inter block and external brick before laying my first block. It saved a lot of time and cutting during the build.

Love the rustic brick that you chose.

Terry

[moonhead]

Things are moving along nicely now. Last Sunday started laying bricks around the block work. I didn't want to let that fall behind plus I wanted to put in some wall ties in at the second block level.
the bricks are an Ibstock Northumbrian Cottage pattern. Chosen for their hand throw look. I thought they might hide the faults of a newbie brickie. You can see that the mortar is a bit heavy but getting better I hope
Managed to get my son roped in for some help then early in the afternoon a few of hours additional help arrived via my brother and his son, thanks to him, much appreciated.
So by the end of the day, the front columns were up the the arch height, damp course in on top of the second course, I have also started the side table as I wanted to tie the two walls together, yo can see in one of the pictures where I have laid the bricks across both walls.

Had another good day yesterday. Almost finished the block work. I just want to add a small piece either side of the nibs for the front lintel and the brick work is up to the top of the third block level.
I don't think I'll take this any higher until I have cast the top slab. I'll have an other look at that this morning.

I'm guessing it's probably better to let the blocks set for a few days before putting them under the forces of half a ton of concrete? Better not

[Oven Build_034.JPG]


Days end and a wel learned beer

[rivergirl]

Brilliant build and yes a well deserved beer!!

[petec]

Brilliant - looks like this is going to be a really good build.

enjoy the cold beers - lets hope for warm weather so you can sink a few more at the end of each build session !

Cheers
Pete

[cannyfradock]

Rick

This is turning out to be a brilliant build to follow. All your comments are spot on and your work is tip top.

One tip.....not sure if the props under your arch former are just temporary, but, it's always a good idea to put a couple of folding wedges below your arch former. These can be easily slid out after the arch is built which releases the former from the underside of the bricks, making removal of former easier and safer.

terry

[moonhead]

Thanks all for the comments.

The Sun was shining again yesterday. I hope its saving plenty for the summer too.
Out with the angle grinder and started cutting the bricks where the arch will sit on the columns. I also shortened the lintel. Their tough little sods to cut through. Even with a diamond disc in the grinder the thing was fighting every millimeter of the way. Must get some ear plugs before I cut any more though.
The arch form is cut from a couple of chunks of Kingspan insulating board which I have used as support as well. Its nice and easy to cut so once all is good and set I'll chop out a wedge on side support to allow it to drop. I'm going to use the same form on the side table to match them together only one or two courses lower. I'm aiming for an oven entrance of around 1100mm, a bit high for a table!
I have marked the arch form with the positions for each brick and a square line front to back to help keep things nice and even. I also wrapped it in cling film. I'm hoping that will help it release cleanly.
I'm pretty pleased with my efforts, looks pretty even. I needed a couple more bricks cutting for the next course to level over the arch so back out with the grinder.
Progress seemed slow today. A little more fiddly than the other courses. Unfortunately the key brick I used in the arch is a little taller than any of the others and has made the center brick on the next course sit a little higher. I should have had the arch form maybe 10mm lower. Too late now! I may remove it ( the brick not the arch ) and grind out enough to sit it level. If I leave it as it is it will I'm sure plague me later.


















Must make sure I hide the bottle before taking the last picture of the day!

Rick

[cannyfradock]

....nice work.

I like the way you put a slight catelever on the arched bricks.....nice touch.

Terry

[moonhead]

I have removed the shuttering from the base, re-trimmed it and now it is the shuttering for the top slab. 20mm MDF is sealing things up with 10mm re-bar reinforcement sitting on top of the block work. The top slab will be 130mm thick. I am including an ash slot in the base as well. I have sleeved two bits of the 6"x2" joist timber with a fluted plastic as well a placing a 5mm wedge between the wood at the bottom. This gives a tapered block which will knock out when I remove the front piece of MDF. Wood wedges are placed underneath the four supports of this to aid removal.
After getting the family to sign the MDF, I forgot in my eagerness to take a pic before starting to fill!
Once again my brother turned out to muck in. He's planning his own build, but as he's in the middle of a house build that's having to wait.
So with the aid of a couple of scaffold planks a ramp was improvised. Keeping the barrow loads light to make the transport of the concrete easier on my brickwork.





Eight mixer loads later and the slab is complete. Jewsons all purpose ballast mixed 4 parts to 1 cement.
Pretty pleased with the end result. Shame it will all be hidden from view.





Then it RAINED ! Improvise a cover quick



Phew

Sun was out again Monday, so late afternoon the cover removed and given a good spray with water to keep it damp



That's not a crack around the slab. I had ran a trowel round to release the edge cleanly when I remove the form.

Tuesday the fire bricks have arrived from Kiln Linings, Fantastic.



I have mocked up a template at work and printed a a full size print of the vault arch to check the pattern before I start to build.
Looks pretty good with the bricks in place so I'll continue to build a form pattern to lay on. The arch has an internal diameter of 710mm with a height of 340mm. four of these will give an internal vault length of 920mm.



As long as I keep the fire cement nice and thin it should all come together nicely.
I also opted for the 40mm Cal Sil boards to place underneath the firebrick base ans some fire clay from them which I'll mix with sand to lay them on.
Hoping to get a start this weekend.

[cannyfradock]

Moonhead

Love your workmanship.......nice slab. Nice touch on the ash vent.

I really like the way Liam cuts all the voussoirs for the arches.

Looking forward to following your build.

Terry