Second layer of heat retaining concrete

Another four to six inches of heart retaining concrete (concrete vermiculite mix) was applied to complete the basic dome before a finishing layer will be applied. Before the finishing later I also filled the chimney mold with plain concrete combined with some mortar mix to make it slide down easier.

Fixing the rebar chimney support

Before applying more heat retaining concrete, I covered the rebar of the chimney support with a few inches of plain concrete, as the heat retaining concrete is quite soft. This way the rebar is better locked in place and should not cause cracks in the covering of the some.

Starting the covering of the dome

After the first four inches of concrete vermiculite mix, a fiberglass heart blanket from the kit is placed on the dome. I also added a layer of stucco mesh to help with holding the next layer of concrete and to help even the heat around the dome. A rebar frame is bent to fit over the dome and to have two arms that will be used to secure the chimney. The chimney tube was then surrounded by a rebar net. It was later surrounded by a cardboard column pouring tube.

Assembling the rest of the inside part of the kit

The internal pieces are placed together and the wired to keep them in place during the layering of the outside covering.

Finishing the tabletop

Concrete was poured around the firebricks, with a small box on the side which will be a holder for a pot of basil. Also the for assembly has been placed on the table.

Installation of the under floor firebricks

As mentioned before, this kit came with firebricks for under the floor of the oven, instead of a concrete vermiculite mixture as before.

Finally started pouring concrete

With some help from my son, I was able to start pouring. My previous oven used about 12 80lb bags on concrete in total. This time, for about 3/4 of the table I have already used 36 bags! because of the volume I also used a rented cement mixer this time, it made a great difference. So we are making progress.

In the meanwhile the oven kit also arrived from Italy, via New England (thank you www.TuscanyFire.com). There is a change from the previous version in that there is now a layer of fire bricks below the oven floor, instead of a vermiculite/concrete mix. Luckily I waited for the kit before starting to pour, so I can make allowance for the changed approach.

After a hiatus, work started on the table slab again

Due to some back problems (probably blame that on the 12 80lb bags of concrete that I loaded on to and off the truck) I had to stop work on the oven. However, after some great care from local healthcare specialists, I carefully started on the table again. Building the pouring mould was the first step. I used some leftover plywood, supported on legs made from 2x4 stud lumber to make the bottom of the table slab. I then added a box around the edge of the table, made from 2x8 lumber. I added offcuts of wood to close every other opening in the concrete blocks (saves on concrete), except for the central, thinner leg. Finally I added rebar to the legs that will be filled with concrete, linked to a web of rebar across the table. I also added some PVC pipe for a drain in the back right hand corner, this will be part of a small trough where a basil plant will stand. Nothing like fresh basil on a pizza.

Ready for the first pour

All the blocks are stacked and after some final alignment, tapping them into place carefully with rubber mallet, concrete will be poured into the openings.

Tool storage

To store tools (brushes, ash shovel, peels) I drilled holes one block down from the bottom of the platform and inserted 3/8" rebar sheathed with 1/2" pex tubing