Berkshire Corner Pompeii - First Time Build

[bento]

Rather than posting different questions throughout the forum, maybe best I start a build thread and I can post all relevant ones here!

Was meant to start building my oven last year but left it too late, and this year I completely forgot. So rather than take time planning everything out ahead of time and never getting round to doing anything, I just ploughed straight in and am planning as I go along (started beginning July this year - evenings and weekends only).



Unexpectedly, underneath the gravel was a layer of brick hardcore - probably had to shift a tonne and a half of rubble and hardcore before I could start digging the foundation are out.





Ground was heavily compacted and too hard to dig out so hired a tiller.

[bento]

All dug out, but ground is way out with the soil line.





Front of the drive (closest I can get any materials delivered), to the oven location is about 60 meters - and two offset doors only 1 cm wider than my wheelbarrow and a nightmare run to negotiate.



Had to hire a compactor to tamp down the sub base.

[bento]

Frame built and reinforcements laid.





Cement mixer died two mixes in - couldn't handle a full load (6 Ballast 1 Cement), so had to manually turn the drum for the next 4 hours to allow it to at least partially assist with mixing without burning out.





Form removed, fairly happy with the outcome.



Blocks arrived - an absolute back and forearm killer shifting over 40 25kg and a dozen 15kg blocks through to the back of the garden (don't know if I could have used lighter ones?)!

[bento]

And that's where I'm up to.

Trying to stick to a budget, hiring of the tiller and whacker were unexpected costs but fairly essential as I don't really have free time outside of evenings and weekends.

Question - the blocks fit perfectly leaving a 4" perimeter (see last pic), in most places to allow the width of a brick finish.
Do I need to leave a cavity and use brick ties (meaning I will have to cut the blocks down by an additional 4"), or can I face the blocks directly with bricks (I will most likely use reclaimed bricks or tan/yellow facing bricks)?

[spider44]

Hi Bento, great to see your build coming along. I used similar blocks as you and can vouch for how heavy they are! I'm going to render my blocks and then use bricks over the dome so can't really give you any advice about tieing in the bricks around the base but whatever you decide it seems worthwhile putting in DPC under the blocks and under the hearth if you can.

[darrellme]

Hi Bento

I had the same question and while and ago and you will need to tie the bricks to the blocks using brick ties. I don't think there is a need for a cavity though

D

[bento]

Hi darrellme, did you cement the back of the bricks to the blocks also (did you use 'any' cavity/gap)?

I have time to adjust what I do as per picture below, as I haven't concreted the cores yet I can adjust the tie locations.

Also, adjusted the oven size to allow a 6" perimeter so there can be a 50mm cavity if needed.

[darrellme]

Hi, sorry, I haven't actually gotten around to doing the actual brick laying part yet but I wasn't planning on applying the mortar to the side of the bricks that face the blocks, although that's not to say that you couldn't do that, I don't have the expertise on that part yet. As far as I understand it the simple fact of having the brick ties should be enough to tie the outer skin to the blockwork, so you shouldn't really have to mortar them to it, but perhaps someone with more experience than I can comment

D

[bento]

Slowly getting there...

The two front corners are heavily patched, but the cores will be filled on these corners making it solid.

[bento]

Question:

Am starting to look at firebricks.

What is the recommended size brick for the floor and then for the dome?

Am looking at potteryprouk on ebay - www.ebay.co.uk/sch/potteryprouk/m.html?item=301687936093&hash=item463e00945d&rt=nc&_trksid=p2047675.l2562 and the sizes differ quite a lot - they go up and down a large amount with only small differences in size (as do the Kiln Linings ones).

Undecided if I can afford to go firebrick for the dome, depends on recommended size as price seems to vary between 99p to 2.99 per brick!

All advice welcome.

[bootsyb]

Looks pretty good - something like what I am planning - did you get inspiration from the Birckwood oven Facebook site - something very similar on there.
How are you going to do your counter top?  Are you going to cast it in place or make it in sections and lift it into place when it is dry?  Im keen to see how you get on before I commit to my design.

[bento]

No inspiration for the Brickwood oven site, just using the forno bravo plans as a guide and kind of making it up as I go along.








Hoping to pour the hearth at the weekend.

[bento]

Update over the last couple weeks...

Frame built, rebar laid

  

Poured and oven location planned out.

     

[bento]

Had cut the first layer of calsil board, and then may have made a bit of an error of judgement!

The calsil board is maufactured with a compacted outer shell making it a bit harder wearing on the outside than the inside.

Cutting the board exposes the inside which is a lot softer.

Having read up on how absorbant this board was, I stored it under the oven stand (once cut), knowing that it couldn't wet, but didn't account for how much moisture in the air it was going to suck up (it rained that night).

Next evening I checked the board to take a measurement and the exposed part where I had cut felt very damp and scratched off in (not quite soggy), lumps.

I've now stored this in a drier environment (and may actually bring it indoors for a bit).

I will be getting a few more sheets of this board and may replace the cut ones just in case I have done long term damage to their heat integrity.

[bento]

Oven floor cut and laid, now just experimenting with layout.


     

Q. The soldier course sits directly on the oven floor - does this soldier course get cemented down as looking at lots of build pictures it looks like not all of them are cemented down?

Also, is it best to raise the IT to be level with the top of the soldier course or do you measure your second course from the bottom of the soldier course?