February 18, 2013 by Brian Klipfel, under Fire Works Masonry News.
Our latest project is a hand-built, custom 60″ dome brick wood-fired oven. You can find the new restaurant, Johnny’s Wood-Oven Pizzeria, in Chadd’s Ford just outside Philadelphia, PA. The photo below shows the completed oven. The oven exterior is a tile mosaic with a brick base finished by the owner.
The oven is the focal point of the new restaurant, directly behind the bar counter. The photo below shows the view directly through the front entrance.
Once the masonry block base and concrete hearth slab are complete the oven begins. The oven floor and walls are built on top of 4″ of load bearing, commercial grade insulation. The photo below shows the firebrick floor and walls underway. The first course of the form free dome construction has begun.
The dome is built entirely of high duty firebrick. Every brick is cut to achieve tight, long lasting joints. The dome is about halfway complete in the photo below.
The arched door opening in the dome is shown below.
Once the dome is complete, 4″ of commercial ceramic wool insulation covers the oven.
The insulation is covered with a rough stucco coat. The oven is now ready for any type of final facing.
The owner, John, finished the oven in a combination of brick, tile mosaic, and stucco. He’s working the new oven in the photo below.
One of the first hot fires rolls over the dome in the photo below. Notice how clean the oven ceiling is, indicating a hot clean fire burning in the oven.
One a the oven’s first pizzas after just a few seconds in the hot oven cooks on the firebrick floor in the photo below.
In about a minute, the pizza is out and ready to eat.
Fire Works Masonry
June 3, 2012 by Brian Klipfel, 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.
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.
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.
The base firebrick course and oven floor are completed.
The oven walls continue as the vault closes in. Temporary wood forms are inserted to support the vaulted ceiling during construction.
A stainless steel angle iron spans the wide door opening.
The vaulted ceiling approaches the closing final course.
The vaulted ceiling is completed.
The chimney transition is completed. The chimney will transition to a double wall, metal pipe chimney as it exits the restaurants ceiling.
A steel harness is constructed around the oven to resist the outward thrust of the vaulted ceiling.
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.
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.
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.
Below, the oven core and rough shell are ready for the final facing work.
Fire Works Masonry
November 5, 2011 by Brian Klipfel, 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.
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.
The photo below shows the oven dome closing in.
Below is a photo of the same course as above, viewed from inside the dome.
Below, the dome brick coursing and chimney transition are completed.
The completed dome viewed from the inside.
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.
Next the oven is covered with a rough stucco coat over the lathe and insulation.
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.
Fire Works Masonry