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.
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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.
Fire Works Masonry
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).
Fire Works Masonry
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.
Fire Works Masonry
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.
Fire Works Masonry
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
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.
Below, the first flames roll over the oven vault. The spacious oven floor will toast the bagels, as well as other wood fired cuisine.
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.
Fire Works Masonry
Fire Works Masonry’s client in Rock Hill, NY recently posted some great praise for his masonry heater on his blog:
“Artic Air/ Nordic Heat
The weather has been pretty cold of late. Below zero for the past 4 nights. The masonry heater keeps the place around 60+ degrees with 2 good sized fires per day. This morning it was a 70 degree temperature difference between inside (60) and outside (-10)… and that was 12 hours after last night’s fire had burned out. I’m beyond impressed”.
Thanks, John! Check out his blog and custom home project, WatchTheHouseGrow.Blogspot.Com.
Fire Works Masonry
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.
Fire Works Masonry
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.
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.
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.
The rear white bake-oven begins to warm as the size of the curing fires increases.
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.
Fire Works Masonry
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.
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.
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.
The masonry heater will be faced by the client with stones from their new property.
Fire Works Masonry