The Oven of GreatnessThe Oven of GreatnessAA Pompeii OvenPompeii Oven

Bread, Pizza, Roast Poultry and Stews will never be the same

AlohaHouse

AlohaRanchand

OrganicFarm

Appendix 2. Brick PrimerDeciding what type of brick you will use is one of the first choices you will have to make when starting to build a Pompeii Oven. You will use brick in the cooking floor, the oven dome and perhaps for your decorative vent arch, oven landing and other decorative trim.

Medium duty firebrick.We recommend medium duty firebrick for both the cooking floor and dome of the Pompeii oven, and it is the type of firebrick we provide as part of the Pompeii Oven Kit. Medium duty firebricks are comprised of roughly 38% alumina, and are highly compressed and kiln fired. They heat up quickly, easily withstand the 1000oF heat your oven will reach, and are designed for the rapid heat-up and cool down (thermal cycling) that your oven will experience. This type of firebrick will also reach the heat required for baking Pizza Napoletana pizza quickly than clay brick, as they are more efficient at conducting heat.Further, because firebrick is designed to withstand thermal cycling, your oven will last longer, though for most home ovens this is not an important issue, and your oven will probably outlast you—whichever brick you choose.

Low duty firebrick.This is the basic fireplace firebrick stocked by many masonry supply stores. They have a lower alumina content than a medium duty firebrick (around 30% alumina), they have more non-refractory impurities, and they are less dense. That said, low duty firebricks are a good choice for building a Pompeii Oven, and other than considering the Pompeii Oven Kit from Forno Bravo, it is not worth the effort of trying to find a higher quality firebrick in your region.

Red clay brick.Clay bricks are made from clay, and fired in a kiln. They are typically made from local clay, as shipping is too expensive, and fired to between 2000F - 3000F (high enough to fuse the minerals). You can use clay brick in the oven dome, but we would not recommend using them in the oven floor. There are trade- offs to consider.There are two shortcoming to using a clay brick in your oven dome. First, thermal cycling will cause clay brick to spall, where little pieces of the brick flake off, and could cause individual clay bricks to crack. It has happened to us. Second, clay brick is not as good a conductor as fire brick and as a result will take longer to heat up.They are a cost-effective option.however, a 42" oven some has roughly 180 bricks in the dome, so the difference in brick cost should be around $100. In the context of the overall cost of the oven, and large amount of human capital you will be investing in your oven, we think the extra cost of worth it.

If your choice is to build your oven with clay brick or not at all, we would strongly recommend building your oven with clay brick.

Pompeii 110 kit140 9”x4.5”x2.5” firebricks; 20 12”x12”x2.5” floor tiles 165 lbs. high temperature, waterproof mortar (FB Mortar) 80 kiloThree 50 sq ft 1” insulating blankets (FB Blanket) Three 24”x36”x2” insulating boards (FB Board) Weight: about 2,000 pounds

Cooking FloorAbout 65 full firebricks, set on their flat sideFine mesh sand and fireclayOven DomeAbout 135 full firebricks, cut in half About (150-200) lb. FB Mortar high heat mortar

Mix 1

Mix 3

Mix 1

Mix 1

Mix 4

Mix 1 Hearth Insulation1 part Portland cement 6 parts PerliteDry mix then add water

Mix 2 Stove Landing and chimney buffer Insulation½ part Portland cement ½ part Red cement1 part fine sand 1 part PerliteDry mix then add water

Mix 3 Under Brick Oven Floor Paste 1 part fine sand 1 part fireclayAdd water until you reach the texture of a sticky mortar (but without the cement). Spread the under floor using a notched trowel as the ridges will make it easier to get the floor perfectly levelThe process is similar to setting ceramic tiles.

Mix 4 Portland cement Fireclay Mortar Formula 1 part Portland cement 1 part sand 2 parts volcanic rock powder 1 part lime 1 part fireclay

Dome height to opening height ratio for optimum air exchange

hd/w = 32/53 = 61%

The Golden Ratio

Opening height to opening width ratio for optimum air

exchangeho/wo = 32/51 = 63%

42" High Vault Pompeii Oven107 cm Interior Diameter 53 cm hd = Interior Dome Height 51 cm wo = Opening Width 32 cm ho = Opening Height

3D modeling

3D modeling

Mix 1

Mix 3

Mix 1

Mix 1

Mix 4

Mix 0 Hearth Concrete w/steel1 part Portland cement 6 parts sand/gravel

Mix 1 Hearth Insulation1 part Portland cement 6 parts PerliteDry mix then add water

Mix 2 Oven Landing and chimney buffer Insulation1/4 part Portland cement 1/4 part Red cement1 part fine sand 1 part PerliteDry mix then add water

Mix 3 Under Brick Oven Floor Paste 1 part fine sand 1 part fireclayAdd water until you reach the texture of a sticky mortar (but without the cement). Spread the under floor using a notched trowel the ridges will make it easier to get the floor perfectly level

Mix 4 Portland cement Fireclay Mortar Formula 1 part Portland cement 1 part sand 2 part volcanic rock powder, 1 part lime, 1 part fireclay

Mix 0

3D modeling

Mix 0

Hearth Construction Mix 0 Concrete w/steel

1 part Portland cement 6 parts sand/gravel

Hearth Construction

Ash slot

3 days

Mix 1 Hearth Insulation1 part Portland cement 6 parts PerliteDry mix then add water

Insulation slab

3 days

5”

Mix 1 Hearth Insulation1 part Portland cement 6 parts PerliteDry mix then add water

Mix 0 Concrete w/o steel

Insulation slab

Ash slot

3 days

Mix 1 Hearth Insulation

Mix 0 Concrete w/o steel

Oven FloorMix 3 Under Brick Oven Floor Paste 1 part fine sand 1 part fireclayAdd water until you reach the texture of a sticky mortar

Day 1

Oven FloorMix 3 Under Brick Oven Floor Paste 1 part fine sand 1 part fireclayAdd water until you reach the texture of a sticky mortar

Herring bone configurationMinimizes peel snag

Day 1

Dome construction

1st coarse

Mix 4 Portland cement Fireclay Mortar Formula 1 part Portland cement 1 part sand 1 part quartz rock powder 1/2 part volcanic rock powder 1/2 part rock powder 1 part fireclay 1 part lime

Mix 4

Entrance Arch

Dome bricks NOT on floor

bricks

Day 2

Dome construction

1st coarse

Mix 4

Day 2

The plan

Day 2

Ash slot

Insulation slab

Day 2

Dome construction

3rd coarse

Foam guide/support

Plaster as you go every two coursesMix 4

Day 2

Oven Landing Insulation Mix 2 Oven Landing and chimney buffer Insulation1/4 part Portland cement 1/4 part Red cement1 part fine sand 1 part Perlite

Day 2

Ash slot

Oven Landing Insulation Mix 2 Oven Landing and chimney buffer Insulation1/4 part Portland cement 1/4 part Red cement1 part fine sand 1 part Perlite

Day 2

Ash slot

Oven Landing Insulation

Day 2

Ash slot

Oven Landing Insulation

Mix 2 Oven Landing and chimney buffer Insulation1/4 part Portland cement 1/4 part Red cement1 part fine sand 1 part Perlite

Insulation buffer between front arch and dome entrance

Day 2

Front Arch Form

InnerArch Form

Chimney Forms

Day 3

7th course

Dome Entrance Arch

Day 3

Mix 4

Dome Entrance Arch

Front Chimney Arch

Day 3

Dome isolation gap

Dome isolation gap

Dome Arches

Day 3

Top View

Closing In

Day 3

Mix 4

Chimney Form

Day 4

Dome Entrance Arch

Landing and Ash Slot

Insulation buffer between front arch and dome entrance

Day 4

Inner Arch Form

Day 5

Chimney Revealed(and scored for finish plastering)

Day 5

Closing InThe final coarse and keystone

Day 6

Mix 4

Closing InThe final coarse and keystone

Day 6

Closing InThe final coarse and keystone

Day 6

Mock finish 4Simulation 1

Mock finish 4

Today’s Specials

Fresh baked pamdesalPumpkin PieBasil Pizza

Simulation 1

Day 7

Fire clay mortar dome finish

Mix 4

Day 7

3” Insulation coat

Perlite Mix 1

Day 7

Outer wall to retain horticultural Perlite

insulation

Day 8

Insulation coat Perlite

w/cement Mix 1

Outer wall to retain horticultural Perlite

insulation

Day 9

Outer wall to retain horticultural Perlite

insulation

Day 9

Outer wall stone finish

Day 10

Outer wall stone finish

Day 11

Grout

Outer wall stone finish

Day 11

Grout

Outer wall stone finish

Day 11

Outer wall stone finish

Simulation 2

Day 12

Simulation 3

Day 13

Back wallCement boardPlasterRoofBottle light

Oven frontGroutMuriatic acidSealantBlack boardTile and trimWood Beams - Sand finish with coconut oilDoor - frame / hinges

OvenDome cleaning inside

FloorFinish - concretePlaster - Clean out and small wallClean out - cut lid

Work order 2-21-2012

Day 13

Finishing tiles and stone work

Day 14

Finishing wood work

Curing 2 weeks then:First Firing 300 ℉ 148 max. 12 hrs.℃2nd day 350 ℉ 175 max. 12 hrs℃3rd day 400 ℉ 205 max. 12 hrs℃4th day 450 ℉ 230 max. 12 hrs℃5th day 500 ℉ 260 max. 12 hrs℃6th day full firing ready for use

Day 21

Curing 2 weeks then:First Firing 300 ℉ 148 max. 12 hrs.℃2nd day 350 ℉ 175 max. 12 hrs℃3rd day 400 ℉ 205 max. 12 hrs℃4th day 450 ℉ 230 max. 12 hrs℃5th day 500 ℉ 260 max. 12 hrs℃6th day full firing ready for use

Full firing ready for use

Each split and properly dried log contains approx. 15,000 - 25,000 BTU ’s

Thermal Mass

Low thermal mass

quick heating

Less time to use oven Fewer Sessions, 1-2 batches

High thermal mass

slower heating

More time to use ovenMore Sessions, 6-8 batches

200,000 BTU10-12 logs1 hr 10 minutes

500,000+ BTU20-40 logs2-4 hrs

1. radiant heat from the bricks2. convection from the movement of steam3. conduction from the bricks

lbs./cord million BTU

Dogwood, Pacific Cornus nuttallii 3,995 24.8Holly, American Ilex Opaca 3,995 24.8Birch, Black Betula lenta 3,910 24.2Oak, White Quercus alba 3,910 24.2Madrone, Pacific (Arbutus)Arbutus menziesii 3,825 23.7Bamboo Poaceae bambusoideae 1,615 10.0 Firewood: 80 cubic feet per cord

4 feet high, 4 feet deep and 8 feet long, = 128 cu ft, but we deduct for air space

Est 24,000,000 btu/cord / 80 cu ft/cord=300,000 BTU/cu ft

Brick and Mortar BTU Estimate

DimensionsCubic footClay brick

Volume

Wood that has been seasoned for 9-12 months still contains about 20-25% moisture, most of which is wood resins. These resins play an important part in the three stages of wood combustion.

Stage 1 - the kindling fire warms up the fresh load of wood and any remaining water content is removed by evaporation and vaporization.

Stage 2 - As the wood reaches 500 degrees the resins begin to break down chemically, and volatile gases are released which squirt out through the wood fiber and ignite, boosting the temperature of the fire to around 1,100 degrees and producing 50-60% of the heat value from that load of wood.

Stage 3 - As the gases burn away, the flames finally attack the wood fiber itself, and extract the remaining heat value through the process known as charcoaling.

If your firewood has dried to the point where it has lost its resin content, your fire will go directly from Stage 1 (warming up to combustion temperature) to Stage 3 (charcoaling), skipping Stage 2 and missing out on 50-60% of the heat (and burn time) you'd expect to get from that load of wood

Seasoned Wood

Costing

Qty unit cost total Particulars

390 brick 10 3,900.00 bricks - outer

240 brick 16 3,840.00 bricks - fired clay

22 20 L pail 20 440.00 sand

6 large sacks 390 2,340.00 Coolite - Perlite

1 20 L pail 400 440.00 fired clay powder

2 20 L pail 400 800.00 Lava rock powders

1 20 L pail 200 200.00 Fine limestone

1 4 x 8 233 233.00 Cement board

11 40 kl sack 251 2,761.00 Portland cement

1 40 kl sack 290 290.00 Red cement

2 lights 200 400.00 Bottle light

2 qt 623 1,246.00 Sealant

20 30 x 30cm 45 900.00 Tile

3 8 ft strips 120 360.00 Tile and trim

1 6" x 8" x 8' 850 850.00 Wood Beams

4 hinges 200 800.00 SS hinges

2 2' x 3' doors 325 650.00 Cabinet Door

19,800.00 MATERIALS COST

man days daily wage

20 350.00 7,000.00 Labor

26,800.00 TOTAL COST

Italian Noun pizzaiola f (plural pizzaiole) (feminine of pizzaiolo)

1. woman who makes pizzas in a pizzeria

Italian

Nounpizzaiolo m (plural pizzaioli)pit.tsa.ˈjɔ.loman who makes pizzas in a pizzeria

pizzaiola f (plural pizzaiole) (feminine of pizzaiolo)pit.tsa.ˈjɔ.la 1. woman who makes pizzas in a pizzeria2. a pasta sauce made with tomato and oregano

The Vera Pizza Napoletana Guidelines for certification:

1. A Wood-Burning Oven:

Pizza Napoletana must be cooked in a wood-fired dome oven. Gas, coal or electric ovens, while capable of produce wonderful pizza, do not conform to the Pizza Napoletana tradition.

2. Proper Ingredients:

Tipo 00 flour, San Marzano (plum) tomatoes, all natural Fior-di-Latte or Bufala mozzarella, fresh basil, salt and yeast. Only fresh, all-natural, non-processed ingredients are acceptable.

3. Proper Technique

Pizza dough kneaded either by hand, or with a low speed mixer. No mechanical dough shaping, such as a dough press or rolling pin, and proper pizza preparation. Pizza baking time should not exceed 90 seconds.

4. Proper Equipment

A proper work surface (usually a marble slab) and a wood-fired oven operating at roughly 800ºF.

5. The Final Product: Pizza Napoletana

Pizza Napoletana is not larger than 14 with a raised edge crust and thin (.11 inch) center. The pizza should be soft and elastic, and easily foldable, not hard or brittle.

The Vera Pizza Napoletana

San Marzano tomato DOP, grown in the rich soil of

Campania is the perfect pizza sauce tomato. The flesh is

firm, and can be easily worked into a bright and

fresh pizza sauce; perfect for your wood-fired pizzeria.

Palawan Creamery

Take out Or Dine in

Aloha Creamery

Take out Or Dine in

Dome height to opening width ratio for optimum air exchange

h/w = 32/51 = 63%