PRECUT WOOD FIRED BRICK OVEN KITS
Wood Fired Ovens have been steadily gaining in popularity for the past 15 years, and rightly so. Not only are they wonderfully versatile for cooking, they are a beautiful centrepiece for any alfresco. As a piece of outdoor furniture, nothing else comes close. Our customers tell us the same thing - when their family and friends arrive and see the oven burning, they gravitate towards it.
We established our company in 2011, with the goal of supply high quality refractory bricks, mortar and insulation to customers who were wanting to build a brick oven. It quickly became clear that building a brick oven from scratch was a very difficult task, even for the most seasoned DIYer. We found that while there were plenty of Pizza Oven Kits available, they didn't grab us.
The idea of creating a PreCut Brick Oven Kit was born, and it's been the mainstay of our business ever since. We put together a timelapse of the building process to explain how our oven kits go together, which you can see below.
PRECUT BRICK OVEN RANGE
THE DIFFERENCES BETWEEN OUR BRICK AND PRECAST OVENS
INSIDE A KIT
Our DIY PreCut Brick Oven Kits have been designed to make the process of building your own brick oven as easy as possible. They come with a set of detailed written instructions to follow, as well as a series of videos to watch in which we walk you through the process of building the oven from start to finish. As a customer recently posted to our Facebook page;
"It feels like we have bought a great big Lego kit with everything we need, video instructions and expert advise a phone call away. Loving the experience."
You really don't need to be a skilled bricklayer to put this kit together - we have done all of the difficult work for you, leaving you with the fun part of assembling it. We've made 3D CAD models of each of our Brick Oven Kits in order to determine the size and shape of each brick, to give us the tightest possible mortar joints on the inside face of the oven.
The Kit comes with high temperature Calcium Silicate (CalSil) Insulation board and templates for cutting and positioning it. CalSil stops the heat in the thermal mass of the floor of your oven from escaping into the supporting structure beneath, keeping the heat in the floor where you need it
To increase the thermal mass in the floor of the oven we include enough Refractory Castable and the required formwork to create a 25mm thick slab on top of the insulation board. This layer will store extra heat, and gives you a smooth, flat surface to bed your floor bricks down onto
The kit includes precision-cut refractory bricks to make up the floor of your oven which are 50mm thick. These bricks are made with a 38% Alumina Fireclay, with incredible surface hardness and density. You'll bed these bricks down into a layer of refractory mortar to get your floor perfectly flat and level
The Brick Oven Kits come with CNC Machined formwork for the inner and outer arches. The formwork comes with the mortar joints marked to make sure the brickwork that makes up the front of your oven is laid neat and tidily
A key element of the PreCut Kit is our Trammel Tool. Bricklayers have been using this concept to build wood fired ovens for hundreds of years; we've just taken it to another level. The Trammel will lay each brick in the dome for you, all you need to do is clamp the brick into the Trammel and it will help you place it in the perfect position
The Entry Arch bricks in our PreCut Kits are carefully cut to size, and the curve of the dome is hand-ground into the back edge of them so that the Entry Arch merges beautifully into the dome of the oven
The Vent Arch bricks in the PreCut Kit are cut to fit perfectly across the face of the oven, and are numbered to make them easy to place. There's a separate set of CNC machined formwork for the Vent Arch to make laying these bricks a breeze
We include plenty of Refractory Mortar so that you can assemble your brickwork, with Refractory Castable included to allow you to fill in bigger sections, such as the dome keystone
This is where our PreCut Brick Oven kits shine - the refractory fire bricks for the dome of the oven are carefully cut to size such that all of the internal joints are as close to brick-on-brick as possible
To finish the brickwork at the top of the dome, you'll put in your Fibreglass Dome Formwork and raise it into place using a car jack. Each of our PreCut Brick Oven Kits comes with a hand-made fibreglass dome designed to match the exact curvature of the dome you're building. Lay the last few rows of bricks on this formwork, and pour the dome keystone using the Refractory Castable provided. Once the keystone has set, the fibreglass dome formwork can be removed through the oven mouth
When you reach the final row in the dome you have a choice; you can cut special keystones using the extra bricks provided in the kit, or you can simply pour the keystone using the high strength refractory castable provided. We recommend pouring the dome keystone, as the refractory castable is just as strong and durable as the firebrick. With the fibreglass dome in place you can pour the castable and know that it will fill the entire void, making the perfect keystone
The PreCast Flue Gallery is a critical part of our kit, made from high grade refractory castable, reinforced with stainless steel fibres. It comes fitted with a stainless steel flue stub with an expansion joint around it to allow for the expansion of the flue when it heats up. The PreCut Kit comes standard with a single length of flue and a cowling; if you need to run the flue through a ceiling or up the side of a structure we recommend contacting a local plumber to supply and fit a suitable system for you
Ceramic Fibre Blanket is an incredibly efficient high temperature insulation material, preventing heat escaping from the oven dome. The combination of the CalSil board under the floor and the Ceramic Fibre Blanket over the dome means the thermal mass of the oven is cocooned in high temperature insulation. This is why a D105 Oven heated to 350°C can take 72 hours to cool to 70°C
To cover the Ceramic Fibre Blanket, the kit comes with enough LiteFill Perlite for a 50mm thick shell of strong, lightweight render. This layer is in essence a structural basecoat, ready for finishing. Once the oven is cured and dry, you can cover this render layer with a coat of roll-on render to give it a waterproof membrane, and colour.
Once the render layer is complete, the sky is the limit when it comes to finishing your oven! The insulation system that we use is so efficient that you can coat the dome with just about anything you want - roll-on render, river pebbles, mosaic tiles, the choice is yours.
We include a Stainless Steel Oven door in the PreCut Kit, finished in a satin-black powdercoat. The door comes with a temperature gauge, and is fitted with beautiful oiled hardwood handles.
There are so many ways you can trim your Wood Fired Pizza Oven, you're only limited by your imagination. From vintage pressed brick surrounds to ovens built into old sea-mines, we've seen it all!
We've seen our PreCut Brick Ovens built into some incredible backyards, and we're looking forward to seeing what you do with yours...