Archive for 'Fire Works Masonry News'

Reading, PA: Fieldstone, Double Bell, See-Thru Masonry Stove

November 18, 2012 by , under Fire Works Masonry News.

When our clients in Reading, Pennsylvania planned their energy efficient addition to their home, a masonry stove was in the center of their plans. A clean burning masonry heater replaced a drafty, traditional masonry fireplace. The masonry heater sits between the existing living room and new addition, diving the man living space. Their kids stand safely on the heated bench in the photo below as their project nears completion.

At the heart of the masonry heater is the double bell core. It stands completed in the photo below. The masonry heater has a see-thru firebox and heated benches.

The masonry heater core is faced with masonry blocks, filled solid for heat transfer and storage.

The new addition side of the fireplace has an extended heated bench, a long stone mantle and a panoramic door for viewing the fire.

The living room side of the see-thru masonry heater will also have a heated bench as well as a bake-oven above the loading door.

Once the masonry block shell is completed around the core, the natural thin veneer stone facing begins.

The Pennsylvania fieldstone facing is finished and grouted.  The photo below shows the completed fireplace warming the nearly finished new addition.

The heater is complete and warming the new addition.

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Galax, VA: Brick Faced, Double Bell Masonry Heater.

July 19, 2012 by , under Fire Works Masonry News.

Our most recent project is a double bell masonry heater installation in scenic Galax, Va. The owners of this new project in the rolling Blue Ridge Mountains were determined to build an efficient home. They decided on a masonry heater for the heart of the design. With no local masons certified in heater building, the owners reached out to Fire Works Masonry. The picture below shows a small curing fire in the nearly complete fireplace.

The double bell masonry stove was sized and designed for the new home. The design includes a spacious firebox and a black-oven for cooking. The completed core is pictured below.

The photo below shows a view of the core during the construction process. The black bake-oven has been completed and is ready to be capped. A temporary form supports the freshly laid arch bricks over the oven door opening. The up and down-draft heat exchange channels are also visible.

The second, or double, bell is then completed above the oven.

Once the core is completed the brick facing began. The photos below show the nearly completed brickwork. A small curing fire begins to dry the new fireplace.

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Hudson, Massachusetts: Custom Commercial Wood-Fired Pizza Oven

June 3, 2012 by , under Fire Works Masonry News.

Fire Works Masonry working with friends at Iron Hammer Stoneworks recently completed a large, custom wood-fired commercial pizza oven in Hudson, MA. The picture below shows the completed oven firebrick core.

Massachusetts Wood Fired Pizza Oven Complete Core

The oven begins with an insulated base pad, followed by the start of the firebrick core. The large oven floor measures 9ft wide by 5ft deep.

Hudson Massachusetts Wood Fired Pizza Oven Base

The oven floor is built using 12″x12″ firebrick tiles. The photo below shows the floor tiles cut to size before installation inside the oven core.

Hudson Massachusetts Wood Fired Pizza Oven Firebrick Floor Tiles

The base firebrick course and oven floor are completed.

Massachusetts Wood Fired Pizza Oven Firebrick Floor

Massachusetts Hand Built Wood Fired Pizza Oven

The oven walls continue as the vault closes in. Temporary wood forms are inserted to support the vaulted ceiling during construction.

Massachusetts Wood Fired PIzza Oven Firebrick Core

A stainless steel angle iron spans the wide door opening.

Massachusetts Commercial Wood Fired Pizza Oven Core

The vaulted ceiling approaches the closing final course.

Massachusetts Commercial Wood Fired Pizza Oven

The vaulted ceiling is completed.

Massachusetts Commercial Wood Fired Oven Complete Core

The chimney transition is completed. The chimney will transition to a double wall, metal pipe chimney as it exits the restaurants ceiling.

Massachusetts Commercial Wood Fired Oven Complete Core

A steel harness is constructed around the oven to resist the outward thrust of the vaulted ceiling.

Massachusetts Commercial Wood Fired Oven Complete Core Steel Harness

Once the steel harness is completed, the wooden forms are removed from inside the oven. Below is a view into the spacious oven from the door opening.

Massachusetts Commercial Wood Fired Oven Inside Complete Core

The picture below shows the large oven floor space, shot from one end of the oven. The door opening and chimney throat can be seen on the right.

Massachusetts Wood Fired Commercial Pizza Oven

The firebrick core is tightly wrapped with 4″ of ceramic wool insulation. The insulation retains the heat of the fire within the oven core. The ceramic wool blanket is wrapped with metal lathe and then a rough coat of stucco is applied.

Massachusetts Commercial Wood Fired Oven Insulation and Rough Stucco Coat

Below, the oven core and rough shell are ready for the final facing work.

Massachusetts Commercial Wood Fired Oven Complete Stucco Core

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Marlboro, Maryland: Finnish Contraflow Masonry Stove Core Installation

June 1, 2012 by , under Fire Works Masonry News.

We recently completed a Heat-Kit masonry heater core installation in eastern Maryland. Our clients wanted the clean, comfortable efficient heat of a masonry heater in their existing home’s living room. The core is a corner unit: the side heat exchange channels are at 45˚ angles to the front. The core also has a pre-cast white bake-oven. The high temperature core is completed in the photo below, ready for the final facing stone veneer.

The core construction begins in the photo below. The inner wall of the double wall firebox has just begun.

After the firebox is completed, the pre-cast white bake-oven is installed. The hot exhaust gases warm the oven chamber from all sides as they exit the fireplace.

Once the center of the core is finished, the side downdraft heat exchange channels are installed.

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Basking Ridge, NJ: Outdoor 27″x36″ Vaulted Wood-Fired Oven

May 11, 2012 by , under Fire Works Masonry News.

Fire Works Masonry recently completed an outdoor wood fired oven for a bread and cooking enthusiast. One of the first curing fires begins to warm the oven in the photo below.

Th oven firebrick core and insulation are faced with a combination of bluestone and limestone facing.

The wood fired oven compliments our clients new pavilion and outdoor kitchen.

The oven firebrick core has a 27″ x 36″ rectangular cooking floor. The ceiling of the oven is a vaulted arch, with a steel frame for reinforcement.

The picture below shows the firebrick floor and vaulted arch ceiling.

The oven has custom redwood doors for the lower wood storage area as well as for the oven. The upper door is insulated to lock heat into the oven after the fire is out.

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Bridgewater, NJ: Natural Thin Stone Veneer, Dry Stacked Ledgestone Entryway

April 14, 2012 by , under Fire Works Masonry News.

Our clients in Bridgewater, NJ were looking to update their home’s entryway. Our friends, Patullo Brothers Builders in Somerville, NJ, designed and built the addition on the existing home. They also installed the custom wood door. Fire Works Masonry then set the colorful natural thin stone veneer ledge-stone veneer in a dry stack style (no visible mortar between the stones).

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New City, NY: Thin stone veneer, double bell masonry heater.

January 3, 2012 by , under Fire Works Masonry News.

The owners of the new home pictured below in the Hudson Valley were interested in taking advantage of their ample wooded lot by designing their floor-plan around a clean burning, efficient wood burning masonry. The masonry heater’s chimney exit can be seen exiting the center roof line.

The completed, see-thru heater seen in the photo below divides the kitchen and the main family space.

All masonry  heaters start with the high temperature core. This heater has a double bell core designed by Alex Chernov, of Stovemaster. The photo below shows the kitchen side of the core underway. A white bake-oven sits above the see-thru firebox design.

Once the core is completed, the external facing of the masonry heater begins. This heater will be faced by a firebrick shell, then a natural thin stone veneer will be applied. The two photos below show the living room and kitchen side of the rough shell. A mixture of red and buff firebricks are used for the facing. The soapstone mantle and bake-oven shelf are also installed at this point in the construction.

Once the shell is completed, the thin stone field stone veneer begins. Below the living room side of the heater is nearly complete.

The veneer stone is grouted and the soapstone accent pieces are installed. All the benches, shelves, and capping stones are beautiful soapstone slabs. Below we see the kitchen side of the masonry heater ready for the door hardware installation.

A thin veneer chimney rises above the masonry heater. The final chimney connection will be a double wall insulated stainless steel chimney. The photo below shows the completed stonework from an upstairs bedroom.

Below the chimney is seen from the second floor catwalk.

The heater also has a large wood-box. The photo below shows the masonry  heater from the garage entrance to the house.

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Centerville, MD: Stucco Faced, Contraflow, See-Thru Masonry Heater

December 4, 2011 by , under Fire Works Masonry News.

Our clients in Centerville, Md were building their custom, dream home. A clean burning, efficient masonry  heater was central to their desires and blueprint. The whimsical, energy efficient home was built on a scenic corner of the family’s horse farm.

The home’s interior reflects the artistic exterior. The timer frame, post and beam construction is entirely built using timbers harvested from the farm property. Structural insulated panels (SIPs) compose the walls exterior walls, providing superior insulation for the new home. To warm the new home, a Finnish contraflow masonry heater is central to the energy design and floorplan. The heater is faced with simple 4″ masonry blocks. The both the living room as well as kitchen side rough block shell is seen in the pictures below.

 

Once the block masonry shell is complete, a rough stucco facing is applied. The living room side of the heater includes a warm, heated bench detail. The double wall, insulated metal pipe chimney exits the fireplace to the top left in the photograph below.

Below the kitchen side of the heater is shown. The optional bake-oven is directly above the firebox doors. Below the firebox doors are two clean-out doors and the center ash clean-out door.

The final heater facing will be a mixture of American Clay stucco and tiles, applied by the homeowner and his family. The first coat of clay is applied to the kitchen side and pictured below.

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Manhatten, New York: 60″ Dome Custom Commercial Wood-Fired Brick Pizza Oven

November 5, 2011 by , under Fire Works Masonry News.

Our latest project is the construction of a hand-built, site constructed domed wood-fried pizza oven in New York City. The Oven has a 60″ diameter floor. The oven design is based on the impeccable work of Alex Chernov of Stovemaster.

The photo below shows the completed oven firebrick core with a stucco shell exterior. The oven is ready for the chimney exhaust connection as well as final external tile detailing. The opening in the block foundation will be used for wood storage when the kitchen work is complete and the restaurant is up and running.

The large working space and completed dome for the wood-fried pizza oven are shown below. The dome construction consists of all high temperature firebricks cut for very tight, strong joints.  The oven floor is constructed of 12″ by 12″ firebrick tiles. The fire will be constructed on these tiles to heat the floor of the oven as well as the dome. The restaurant’s delicious pizzas will cook directly on these heated tiles.

Below is a photo of the start of the oven construction. The oven walls and first course of the dome have been set. The oven is constructed on top of load bearing, high temperature insulation. This insulation layer supports the weight of the oven while also isolating the heat of the oven, keeping the energy of the fire inside the cooking area.

New York City Wood-Fired Pizza Oven First Course

The construction of the dome continues. All the brick courses are cut with a compound miter to ensure very tight, interlocking joints. Every brick acts like a keystone, locking every course in place.

New York City Wood-Fired Oven Course #8

New York City Wood-fired Oven Eleventh Course

New York City Wood-Fired Oven Eleventh Course

The photo below shows the oven dome closing in.

New York City Wood-Fired Oven Thirteenth Course

Below is a photo of the same course as above, viewed from inside the dome.

New York City Wood-Fired Oven Thirteenth Course

Below, the dome brick coursing and chimney transition are completed.

New York City Domed Wood Fired Oven Completed Core

The completed dome viewed from the inside.

New York City Wood-Fired Pizza Oven Core Complete.

Once the firebrick core is complete, the oven is wrapped in high temperature ceramic wool insulation and metal lathe wire. The ceramic wool insulation keeps the intense heat of the fire inside the oven dome, working on cooking the pizza.

New York City Wood-Fired Pizza Oven Insulation

Next the oven is covered with a rough stucco coat over the lathe and insulation.

New York City Wood-Fired Pizza Oven Rough Stucco Coat

The wood-fired pizza oven is then covered with a colored stucco coat. The oven is ready for the chimney connection and final tile detailing. A soapstone transition piece is set on the oven opening, ready to receive the new restaurant’s pizzas.

New York City Wood-Fired Pizza Oven Stucco Shell.

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Brooklyn, NY: Wood-Fired Montreal Style Bagel Oven

March 22, 2011 by , under Fire Works Masonry News.

Fire Works Masonry recently completed a wood-fired commercial oven in Brooklyn, New York. The large oven will crisp Montreal-style bagels for the new B&B Empire cafe located at 200 Clinton St. in downtown Brooklyn. You can learn more on their new website, B & B Empire.com.

A small curing fire starts the process of warming the oven mass in the photo below.

Brooklyn New York Wood Fired Montreal Style Bagel Oven

Below, the first flames roll over the oven vault. The spacious oven floor will toast the bagels, as well as other wood fired cuisine.

Brooklyn New York Wood Fired Montreal Style Bagel Oven

Special thanks to our associates in the Masonry Heater Association: Alex Chernov of Stove Master, the designer of the complex wood-fired oven, as well as Chris Springer of Iron Hammer Stone Works and Antoine Guerlain of Old Stone Heat for assisting with the oven construction.

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