Finally completed and painted

After a couple of months "seasoning", the oven has received its final coat of paint. In the mean time we have been using it, and learning a lot. Actually we found that the trickiest is getting the oven just right for pizzas, mainly in trying to cook them too soon, before the oven is ready.

Start of the journey

I put this blog together to show how I built my own backyard wood-fired oven. Rather than start from scratch I decided to use a kit, and from the many different ones found in a Google search we choose a model 6/B (Piccolo) from Tuscany Fire. Below are picture after the delivery of the kit. But this was just the start!

I also needed other materials, to build a counter on which to install the oven, and cement to mix with materials sent with the kit for covering the oven.

Preparing for the countertop

First step was to build a wall on which the countertop will rest. For this I used hollow concrete blocks, stacked mortarless, and then filled with concrete. They were stacked in a "U" form, to make a counter big enough to take the oven (and then some).

Framing the counter-top

before pouring the countertop I built a wood frame around the wall, and a sheet of wood under the counter. To allow for a coating on the blocks, I allowed for a 1/2" overlap of the counter-top. This required adding some strips of wood under the 2 x 8 planks that I used for the sides of the counter mold. The outside frame was supported by 4 legs and kept in place by 3 side supports. The sheet was supported by 6 legs, however Once pouring I noticed some bowing, so I added a couple of extra legs. If I were to redo this I would make a 2x4 frame to support the sheet with cross bars to prevent sagging. Once the frame was installed, a 12" x 12" grid of 1/2" rebar was added to reinforce the first layer of concrete (4").

Pouring the counter-top

The counter is poured in two sections. The first half (4") is normal concrete, I actually used high strength concrete mix, in which the reinforcing bars (rebar) are embedded. The top layer is a mix of cement and vermiculite. The latter is a mineral derived from mica which holds heat, The recommended mix is 3 parts vermiculite to 1 part cement. I used this mix for the edges of the counter top, but in the middle added more vermiculite to closer to a 4:1 mixture, for more heat mass. All concrete and cement was mixed by hand!

Removing the counter-top pouring frame

After letting the counter cure for a week, during which the concrete was sprayed with water two or three times daily, the time came to dismantle the pouring mold.

Assembling the refractory oven parts

The cast refractory oven parts were assembled on the counter top. Note that these parts are not mortared together, they are just dry assembled. the top is wired to the door holder with masonry wire. The floor of the oven sits on a layer of sand and vermiculite (1:1) to bring its top above the bar at the bottom of the door.

First heat mass layer

The oven is now ready to receive its first layer of heat mass - 3:1 mixture of vermiculite and portland cement. This layer must cover the oven to a depth of 4". To strengthen this layer I added some chicken wire at a depth of 2".