Why I Oughta...

With the foundation and stand complete for our diy'd wood-fired pizza oven, I recently started turning to building the *actual* oven by cutting bricks last week.   The process of starting the actual oven begins with prepping the top of the hearth to accept the calcium silicate insulation boards.  Cal Sil boards are water-resistant, but you want to keep it as dry as possible so the mass of insulation works as ACTUAL insulation under the oven floor.   The latest innovation for dealing with water penetration that has been driven through the community over at Forno Bravo is the addition of mats of mosiac tiles - set upside down - on top of the reinforced hearth and under the insulation boards.  The idea is that by setting the mosiac tile upside (with the mesh/glue pieces facing up), you create little channels that any surface water that hits the hearth can find its way to the drain holes. I went up to a closeout flooring store on North Avenue in Northlake recently a...

Last week, I completed the concrete pour of the raised (reinforced with rebar) hearth for our DIY pizza oven build project.  After a few days of allowing the concrete to cure (wet curing), I stripped the forms and was able to see the final product.  Good news, all around.  The backer rod, caulk and sand held and the forms didn't leak.  The concrete also settled down into the Pressed Bond Beam blocks and filled all the available space.   Below is a look at the fresh concrete right after stripping the forms: The first thing I did was to put a couple of levels on the surface: And...more good news:  dead perfect level.  Both directions: Other good news include the hearth being square, fully-formed.  And all six drainage pipes clear and useful.   With the forms removed, I'm now DONE with the stand construction and can move on to the actual oven build. It has been quite a journey. January 2024 -  Location decision in our backyard ....

Yesterday, I showed how I built a platform for the Mudmixer in order to pour the raised hearth in our backyard wood-fired oven stand construction project.  Today, we show the details of the actual pour.  Using the Mudmixer and 35-or-so 60# bags of 4K PSI concrete mix, I was able to complete the job in just about an hour of run-time.  I spent quite a bit of time trying to make sure the forms were level and square and using a mix of sand (to fill cores), caulk and backer rod, I filled as many of the gaps in the forms as I could to keep the slab from leaking too much. The good news - the forms held.  They didn't bow.  And...they didn't leak that much.  Same with the supports under the Densshield boards.  Below are a few photos showing the raised, reinforced hearth pour.  The first one shows the platform and the poured hearth: Below, you can see the drain pipes that were able to sit right at the surface of the hearth: Below are a couple of shots showi...

A few days ago, I shared an update on our DIY backyard wood-fired pizza oven build that showed the latest progress:  the installation of the final rebar and bracing (wires) for the raised, reinforced concrete hearth.  I'm set to pour that 4.5" thick hearth (plus the filling of the pressed bond beam block cavities (so...around 8" deep around the perimeter and 12" deep across the opening spans), but the forms of the heart sit 42" above grade.   Like I did with the foundation slab, I'm planning on using the MudMixer to help pour the concrete.  The problem that I'm facing is that the Mudmixer's chute stands just 16" from the ground.  That means....that I have to either use buckets to lift the mixed concrete up from the Mudmixer chute or....raise the Mudmixer to allow it to 'POUR' directly into the raised hearth. If you look back at this post where I showed the foundation slab pour, you can see that I made a platform for the Mudmixer to allow...

The last I posted about my DIY backyard wood-fired pizza oven, I shared how I made and mounted the forms for the reinforced hearth on top of my cinder block stand.  With the forms set-up and square (and level), I began to finalize the rebar setup.  I ran a couple of rows around the flow-thru bond beam blocks that made-up the top row of the stand.  Before doing the rest of the rebar, I laid down a couple pieces of vapor barrier on TOP of the tile backer board segments.  Once in place, I ran vertical rebar up the filled cores from the foundation slab, through the block stand and out the top.   I tied a grid of 1/2" rebar together and spanned the hearth with seven pieces each direction.   I used zip ties to tie them together and some block fragments to elevate the center part of the grid.  On the edges, I tied this rebar grid directly to the vertical posts.   Once that was done with the rebar, I cut up some one-foot segments of 1/2" p...

Busy week with the pizza oven.  First, the bottom trays and supports were put in-place .   Then, I cut, bent and placed some rebar into the top of the stand - via the bond beam blocks .  I also cut most of the grid of rebar.   That meant that I could move-on to creating the hearth forms.  I used 1/2" trays and I'd like the hearth to be 4" or so thick, so that means I need 4.5" of height on-top of the stand.  Because of the Bond Beam blocks and their openings, I also need the forms to cover 1.5" of the stand.  That's 6" of form - which means I can't use a 2x6, but had to upgrade to 2x8's. I cut the 2x8's to length, then affixed a 2x4 to the face of them to stiffen them - and prevent bowing.  I used various pieces of lumber to create legs that were just a tiny bit short.  I put the forms together, stood-it-up on the legs and then shimmed in one side for the final height.   Moving around the stand, I leveled up each side usin...

Earlier this week, I updated my wood-fired pizza oven build progress with some photos showing the bottom trays and their supports/bracing cut to size .  I have a couple of things that I need to do (I lifted eight steps - bracing for trays shimmed, rebar to bond beam blocks, fill gaps, cut rebar for grid, set up 2x8 forms, wire them, add drainage pipes and fill remaining cores with sand ) and most of those can go in any order.    Once I had the trays in place, I decided to see if I had enough rebar on hand to complete the job.  That started with bending some of the 1/2" steel rebar for around the bond beam blocks.  Then, I cut the rest for across the top in a grid pattern. Below is a photo showing the rebar bent and laid into the bond-beam blocks.  I'm doing curved rebar at every corner and doubling-it-up with 90-degree corners on top of those curves.   On top of this will be a 4.5" thick hearth, so the rebar you see running across the top of the s...

The next step after filling every-other-core in my DIY wood-fired oven build is to create the support that goes *under* the hearth that can support the concrete pour.  I've made three areas for storage in the stand, so each of those need a cover (or lid) and some support bracing to keep the concrete from sagging through the openings.  I opted to use 1/2" DensShield board and various 2x4's and 2x6's to create the supports under the openings.  Below are a few photos showing how I cut the board (1/2" thick) and then used the legs to support/span the openings. Below is a peek at the INSIDE of one of the storage bins and you can see the legs/supports laying this-way-and-that.  Why?  Because...I cut them just a little bit short of the length needed.  My plan is to use a bunch of wood shims under these so once the pour is complete, I can pull the shims out and the supports will fall away.   Without the shims, the supports might not come out so easily....

Last week, my pizza oven build update included how I had purchased a 10" wetsaw and mortared in the first course of the cinder block stand .  On top of that first course of block sits the rest of the stand, but I opted to simply dry-stack them in place.  The height of the oven floor is one of the biggest build considerations and I'm aiming for between 44 and 46 inches in height.  Based on some tests, that's where I'm comfortable and want to aim to hit when I build the stand, add the insulation and place the floor.   The floor is made of medium-duty firebricks that are 2.5" thick.  Set on a thin base of high heat mortar and/or sand.  Call it 1/4".  4" of insulation below that puts me at 6.75" of height.  The hearth has a little bit of flexibility in it - thickness-wise.  But, call it about 4 to 5 inches thick.  That means, I needed to do a little math to figure out how many courses I needed to build.   46 inches minus 6.75...