Jamesburg, NJ: Custom Brick Commercial Vaulted Wood Fired Oven.

July 31, 2013 by , under Fire Works Masonry News.

Fire Works Masonry latest commercial wood fired oven is a large 48″ x 72″ vaulted brick oven for the Hearthstone Grill in Jamesburg, NJ. The oven will be used for a variety of foods including pizzas, cast iron dishes, roasted meats and vegetables as well as fresh in-house breads. The large oven and newly renovated restaurant are seen in the photo below.

Hearthstone Grill New Jersey Oven Exterior 4402

The oven starts with the firebrick core. The oven was designed by MHA founding member Tom Trout of Vespa Masonry. The photo below shows a view through the loading door into the newly built brick oven. The oven’s firebrick floor is also ready to start cooking. The rough chimney connection is visible in the far back left hand corner.

NJ Custom Wood Fired Vaulted Bread Oven 4176

A strong steel frame permanently supports the outer thrust of the long vaulted span. The completed oven core and steel support structure are pictured below.

NJ Custom Commercial Brick Pizza Oven Core 4191

The photo below shows the top of the oven vault. This oven will be heavily insulated with commercial, high temperature thermal blankets.

New Jersey Custom Commercial Wood Fired Brick Oven Completed Vault 4159

NJ Custom Hand Built Brick Bread Oven Complete Core 4166

The oven facing will be based on steel studs with cement board after the thick insulation for the sides and top. The front of the oven is faced in an additional layer of firebrick. This oven facing can be nicely completed with many options such as thin veneer stone, tile, mosaics, or plaster stucco to match any interior.

The owner and his crew will complete this oven exterior with a cultured stone and tile veneer.

NJ Custom Brick Wood Fired Pizza Oven First Fire 4201

The photo below shows the completed oven core, front brick face and the steel stud frame underway.

NJ Custom Commercial Wood Fired Pizza Oven First Fire 4206

After hours of heat storage, the oven heats up to operating temperatures for cooking pizzas in minutes. The photo below shows the vault burning clean.

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NJ Custom Commercial Wood Fired Pizza Oven 4400

The oven has a custom insulated stainless steel door for use between shifts or overnight to maintain the oven’s heat.

Custom Wood Fired Oven Door_4392

The door fits tightly into the vaulted opening for loading the oven. The owner’s custom stained glass and cultured stone finish is also completed.

Custom Wood Fired Oven Insulated Door_4395

New Jersey Custom Wood Fired Oven Final Exterior 4404

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Phillipsburg, NJ: Outdoor, Wood-Fired 36″ Dome Brick Oven

November 20, 2012 by , under Fire Works Masonry News.

Our latest project is a large backyard wood-fired oven. The hand-built dome oven is constructed entirely of long lasting, high duty firebricks. The oven floor has a 36″ diameter, plenty of room for a large pizza party or an entire Thanksgiving meal. The photo below shows one of the first hot fires rolling over the top of the oven as it heats the firebrick dome.

The tight brickwork is built form free. The every brick is cut to ensure very tight, strong joints. High temperature refractory mortar provides the joint strength between the bricks. The high quality of the firebricks and construction method assure a very functional, long lasting oven. A well made oven lasts for generations. The photograph below shows the dome nearly halfway complete.

The high mass of the oven works great for cooking but requires a masonry foundation to carry the load. A block foundation supports this oven. The oven is insulated from the foundation by 4″ of industrial, load bearing insulation. The dome continues to roll in as the door opening begins below.

The photo below shows the completed wood-fired oven core. The door opening and chimney throat can be seen on the right hand side of the core in the photo below.

The photo below shot through the door opening shows the completed dome from inside the oven. The smooth firebrick floor is also ready to start cooking.

With the core completed, the oven facing can begin. A simple block shell will be constructed around the core. The firebrick core will also be wrapped in 4″ of industrial quality ceramic wool blanket. This helps lock in the oven’s heat for long lasting, efficient cooking.

Finally the oven is fired and the first pizza sizzles on the hot floor.

Once the pizza party is over, the very versatile oven is ready for almost any type of food you can imagine. The oven can roast meats and vegetables as well as bake excellent breads. Fresh pita breads expand on the hearth in the photo below.

NJ Backyard Wood Fired Oven Pita Bread 4409

You can perfectly roast meats as well, such as the tender oven roasted chicken in the photo below.

Wood Fired Oven Roasted Chicken 4410

Oven roasted garlic is another favorite.

Wood Fired Oven Roasted Garlic 4427

Garden tomatoes are roasting in the photo below before they are sauced and canned.

Cast iron cookware gets great results in the oven. A cast iron skillet roasts garden garlic and asparagus in the photo below.

Garden Asparagus Roasted Wood Fire Oven 4457

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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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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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King Of Prussia, PA: Finnish Contraflow Masonry Heater

November 15, 2010 by , under Fire Works Masonry News.

Our clients in King Of Prussia, Pennsylvania have worked for years to retrofit their older home into a modern, zero net energy design. The ambitious plan began with a small addition, improved insulation, and active solar photo-voltaic panels. With these stages complete, it was time to install the clean burning masonry heater into the center of the home.

The homeowner opened the family room floor and built the masonry base to support the masonry heater in the crawl-space below. Once the concrete hearth pad is complete, the masonry heater core and block shell begin simultaneously. The photo below shows the finished high temperature core surrounded by the block heater facing.

The block masonry chimney sits to the left of the Finish fireplace. The masonry chimney transitions to a double wall metal pipe to exit the house.

The block shell is completed after the core. A brick arch spans the bake-oven opening. The travertine bake-oven shelf and mantle are also installed in the block shell. The photo below shows the completed shell and heated bench.

After the heater facing is complete, the two coats of stucco are applied to the heater. Once the stucco sets overnight, the heater door hardware is installed including the loading door, the bake-oven door, ash-box door, and soot clean out doors.

The masonry heater design also includes a large wood storage box to the right of the loading doors.

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Tunkhannock, PA: Finnish Contraflow Masonry Heater

November 15, 2010 by , under Fire Works Masonry News.

This old farmhouse in the rolling hills of Pennsylvania has been in our client’s family for over two hundred years. Updating the home to modern standards has been a work in progress for several years. The family improved the insulation, windows, and building envelope. They also added a small addition to fit their growing family. To update the fireplace, the family decided on an efficient masonry heater in the center of their new primary living space.

The Finnish fireplace core was faced with 4″ masonry blocks. The photo below shows the completed rough shell. The blocks will be faced with a plaster coat then the client will apply natural thin stone veneer produced by  a nearby local quarry.

Tunkhannock, PA masonry  heater

The loading door for the firebox is on the main living room side of the new addition. The rear bake-oven opens into the kitchen space.

Tunkhannock, PA masonry heater, bake-oven side
Once the block shell is completed, the stucco rough coat is applied. The bluestone heater caps, mantle stones, wood-box cap, as well as the bench tops all came from stone on the farm property. The load bearing timber beam also came from the family’s old barn. The photos below show the first curing fire winding through the heater’s extensive internal heat exchange channels.
Tunkhannock, PA masonry heater
Tunkhannock, PA masonry heater
The rear white bake-oven begins to warm as the size of the curing fires increases.
Tunkhannock, PA masonry heater bake-oven
Tunkhannock, PA masonry heater bake-oven
The stucco heater is ready to warm the updated old farmhouse. When the family’s time and budget allow, they will apply the natural thin fieldstone veneer to achieve the final aesthetic look for their masonry  heater.
Tunkhannock, PA masonry heater
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Tannersville, NY: Finnish Contraflow Masonry Heater Core Installation

November 14, 2010 by , under Fire Works Masonry News.

The owners of this new timber frame home high in the Catskill mountains wanted to build a super energy efficient design to stay comfortable in the hard winters. The timber frame, structural insulated panels, and masonry heater allow them to achieve their energy goals while still building a beautiful home. Once the owner completed the timber frame, SIPs, and as well as the roof the masonry heater core is installed.
Tannersville, NY Masonry heater
The photo above shows the completed Finnish Contraflow Heat Kit core in the center of the timber frame. The base for the heated bench and the base of the masonry chimney can also be seen.
Tannersville, NY Masonry heater with bake-oven
The core is wrapped in a fiberglass blanker to provide a slip gap to the masonry heater shell. The firebrick heated bench and completed masonry chimney base are complete in the photos below. The chimney will transition to a double wall metal pipe above the block height below.
Tannersville, NY Masonry heater with bake-oven
Tannersville, NY Masonry heater with bake-oven
The masonry heater will be faced by the client with stones from their new property.

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Pottsville, PA: See-Thru Brick Finnish Contraflow Masonry Heater

July 25, 2010 by , under Fire Works Masonry News.

Pottsville PA Brick Finnish Contraflow Masonry Heater

The owners of this new home discovered the warmth and beauty of a masonry heater while visiting a completed project of their prospective timber framer, Aaron King. They visited Fire Works Masonry’s clients near Kutztown, PA. The new owners wanted a fireplace in their home design and were excited by the prospect of installing a clean burning and efficient masonry heater.

The combination of the open floor-plan and superior insulating properties of the structurally insulated panels (SIPs) wall elements creates an ideal match for the slow and steady energy output of a masonry heater. The open floor plan is ready for the start of the Heat Kit masonry  heater core in the photo below. The concrete pad provides the structural support for the heater and chimney.

Pottsville, PA Masonry Heater with bake-oven

The clients desired a simple, rustic brick fireplace and chimney. The bake-oven side of the heater splits the dining room and kitchen.

Pottsville, PA Masonry Heater with bake-oven

On the opposite side of the masonry  heater is the living room. The heater is see-thru, with large clear loading doors on either side of the firebox. The fireplace is capped with local Pennsylvania bluestone.

Pottsville, PA Brick Masonry Heater with bake-oven

The large open peak of the timber frame highlights the clean run of the brick chimney.

Pottsville, PA Brick Masonry Heater with bake-ovenPottsville, PA Brick Masonry Heater with bake-oven

A small curing fire burns down in the firebox, viewed from the kitchen.

Pottsville PA Brick Finnish Contraflow Masonry Heater

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Carlisle, PA: Natural Thin Stone Veneer Finnish Contraflow Masonry Heater

July 4, 2010 by , under Fire Works Masonry News.

The owners of this new home in Carlisle, Pennsylvania have dreamed and planned for years about building a net zero energy home. The design includes structural insulated panels for very high “R” value walls and ceilings, passive solar home alignment and window design, an active solar system on the roof to generate electricity, geothermal heat exchangers to lower the heating/cooling load on the active system, and a clean burning masonry heater as the warm centerpiece of their home.

Carlisle PA, Finnish Contraflow Masonry Heater

The home was masterfully designed and built by Harrisburg based Bridlewood Builders. They specialize in custom, sustainable, green homes.

The masonry heater thin stone veneer is nearly complete in the photo below.

Carlisle PA, Finnish Contraflow Masonry Heater

The passionate homeowners have a detailed blog of the home’s design and construction as well as the home’s performance: http://carlislegreenbuild.blogspot.com.

The masonry heater is located in the main living area for the new home. The heater also acts as a room divider, separating the family room and the master bedroom.

The heater construction starts with the high temperature core, pictured below. This heater is a Finnish contraflow design. The heater will have two down draft channels on either side of the core as well as a long heated bench wrapping around the front of the core. The exhaust gases will exit into a masonry chimney to the left of the core.

Carlisle PA, Finnish Contraflow Masonry HeaterCarlisle PA, Finnish Contraflow Masonry Heater

The rear wall of the masonry heater core will warm the master bedroom, pictured below.

Carlisle PA, Finnish Contraflow Masonry Heater

After the completion of the high temperature core and heated bench, the masonry facing begins. This heater’s shell consists of bricks and 4″ blocks. The block shell will provide the thermal storage for the fire’s energy and act as the structural base for a natural thin stone veneer application. The shell and chimney are nearly completed in the photo below. The brick facing for the long heated bench is just getting started.

Carlisle PA, Finnish Contraflow Masonry Heater

Below is a view of the nearly completed shell from the open walkway above on the second floor.

Carlisle PA, Finnish Contraflow Masonry Heater

The rear wall of the heater warms the master bedroom. Below we see the completed heater shell from the bedroom doorway.

Carlisle PA, Finnish Contraflow Masonry Heater

Once the masonry shell is completed, a scratch coat of plaster provides the base for the natural thin stone veneer facing.

Carlisle PA, Finnish Contraflow Masonry Heater

Carlisle PA, Finnish Contraflow Masonry Heater

Viewed from the second floor catwalk, the thin stone veneer is nearly complete. The limestone bench and capping stones are in place.

Carlisle PA, Finnish Contraflow Masonry Heater

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