Day 5: Dry Layout

The next day I did a couple of dry layouts to get the dimensions and oven location on top of the slab worked out. I took a lot of photos for future reference. There were two things I needed to work out: The general location of the oven, and the size of the oven floor.

Because of some site limitations, I had planned to place the oven dome back as far as possible on the slab. I wasn't sure how much space I would have for the oven landing. A couple of layouts got me the info I needed.

I had decided to go with the ceramic insulation board for insulating the oven floor, so I measured for that and ordered it from a local oven supply. I also did a couple of layouts with different herring bone patterns for the floor -- I wanted to make sure that the front line of bricks wasn't going to have a lot of awkward cuts.

The final dry layouts were marked in the slab with chalk. Nothing to do now but wait for the slab to dry a bit more.

Day 4: Slab & Block Fill

Day four was a quick, 3-hour work day. Concrete was mixed and poured into the block voids and slab form. At this point had hadn't decided if I should go with ceramic board or vermiculite concrete for the insulating layer. The surface was left rough for application of another layer if needed. The finished slab is 56" square and about 4" thick over the block and 3.5" over the span.. The target is to get the oven floor to 40" above the patio; the existing block base is 32 inches, the slab adds 4 inches, the insulation layer will be 1.5 inches thick and the bricks are 2.5 inches thick. That adds up to 40 inches -- right on target!

I eased all of the edges of the slab -- this isn't really necessary, as this is going to be covered with other materials eventually -- but it's a very satisfying task.

Day 3: Rebar and Formwork

I placed more rebar and mesh. Two #4's in the bottom of the lintel, and #4's at the top pf each wall and in every other core. More #10x8" mesh; this time as bottom reinforcement for the 3.5" slab. The bar across the front opening was bent so it will be one continuous piece for some lateral support.

The 2x6 forms for the foundation slab were modified to make new slab forms.I used some load tie downs to secure the 2x6's and placed scrap pieces at the midpoint of each 2x6 to keep the forms from bowing.

I cut and beveled plywood to support the middle of the slab while it's being placed. The plywood form that covers the middle part is in two pieces that can fit out the "door" once all the concrete sets. All the wood is wedged into place to allow for easy removal and the plywood is covered with plastic to keep it from sticking to the concrete.

Day 2: Laying Block

After letting the slab cure for three days, it was time to lay block. Unfortunately, I chose the hottest day of the year: 106+F! I had a hard time keeping everything wet and workable.
I also miscalculated my block needs and had to run out and buy 9 more blocks! Anyway here is the finished block base.

Day One: Excavation and Slab

First step is to dig out the space for the supporting the slab. The slab is framed from 2x6 so the slab will be 5.5 inches deep. The excavation is about 7" deep. The last inch or so was into sandstone bedrock. I filled the excavation with 1.5 inches of sand, leveled it, placed a vapor barrier, put a little sand on top to keep it in place and then set in the forms.

The slab will be 60" square and be reinforced on the bottom with 2, #4 rebars running underneath where the block walls will eventually go, and #10x8" wire mesh on top.




Here is the slab placed and finished at the end of Day 1. those are #4 dowels placed in what will be every-other block cell (16" o.c.). The slab is broom finished where the block will go and steel troweled smooth in the center, which will remain exposed.

Oh, and pulling out the old fence post was a bear!

Day Zero: Choices

Before I can start I have to make two choices: What kind of oven, and where should it be.

The first choice was pretty simple: I decided to go with a design based on the free Forno Bravo "Pompeii Oven" plans. The plans can be downloaded for free from the Forno Bravo website. The plans have been used by hundreds of oven builders and the site also has a great oven builder forum.

My second choice was: where should I build it?

I had already planned a backyard kitchen area but not planned for an oven, so I spent a little time sussing out the best location. I narrowed it down to two possible locations: In a corner of the existing kitchen, or on a new pedestal where I was originally planning to build a (now banned by AQMD) outdoor fireplace. I sought out my neighbor for the final judgment.

It's going to go here. Just need to remove that old fence post... And build a base...



I put together a materials list for the base and oven. Everything but the special refractory oven items was available from West Los Angeles Building Materials. The refractory mortar and insulation game from Laguna Clay in the City of Industry.

By the way, Forno Bravo has a Pompeii oven "kit" that you can order from them with all the materials that you need. It's a very god deal. I had to run around a lot to find what I needed, and I saved maybe $50-$100 dollars versus the kit. I also had to make due with some less than ideal materials.