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Maine Wood Heat Company LE PANYOL 66 Construction Manual

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Construction of the
Le Panyol Wood-Fired Oven

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  • Page 1 Construction of the Le Panyol Wood-Fired Oven...
  • Page 2 All inquiries should directed to: Albie Barden, Maine Wood Heat Company, Inc., 254 Fr. Rasle Rd., Norridgewock, Maine 04957 Book Design: Joseph Conway Cover Photo and oven: Scott Barden, Michael Scholz Albion Bread Co.

  • Page 3: Table Of Contents

    Table of Contents Preface Introduction Le Panyol ovens and the legacy of the Roman Empire Le Panyol “Core” Values The Le Panyol Oven cores The Domestic ovens cores; Model 66, 83, 99 and 100 Design and Construction Calculating the height of your oven hearth Hearth slab depth Footings and Foundation Oven stand...
  • Page 4 Assembly of the Le Panyol oven core: Models 99 and 100 Step - by - Step assembly Variations for the Model 100 Model 99: plan and sections Model 100: plan and sections Appendixes Appendix A...

  • Page 5: Preface

    As the exclusive North American Le Panyol creation of any of the individual all-natural importer, the Maine Wood Heat Company is earthenware oven elements. For as the French proud to bring an authentic, artisan crafted, say, “Du feu sort le four, Du four sort le...

  • Page 7: Introduction

    Introduction LE PANYOL OVENS AND THE and hot exhaust gasses fully and evenly over the LEGACY OF THE ROMAN EMPIRE dome, warming it to provide reflective and radiant heat for cooking and baking. The heat then rushes Fire: The most primal element of the human along the ceiling, coming forward in order to vent experience.
  • Page 8 Chapter 1: Introduction and conduct thermal energy simultaneously. A modest fire in a Le Panyol initially warms the oven cavity while also charging the masonry mass surrounding it with stored energy for prolonged discharge. As a result, your Le Panyol comes to temperature quickly and delivers enough extended heat to cook multiple course dinners and bake several rounds of bread per firing.

  • Page 9: Le Panyol "Core" Values

    Chapter 1: Introduction Chapter 1: Introduction Chapter 1: Introduction Le Panyol “Core” Values The Le Panyol wood fired oven is ideal for cooking truly exceptional pizzas, meats, vegetables, stews, and of course, baking the best artisan breads and pastries. Using the oven is easy! The process is simple: 1.

  • Page 11: The Le Panyol Oven Cores

    Le Panyol Ovens cores The domestic ovens are designed for passionate home bakers and gourmets. Models 66, 99, 83 and 100 offer the performance of professional grade ovens in a size that can be easily integrated into any kitchen or backyard.

  • Page 12: Specifications

    Chapter 2: Le Panyol Ovens M o d e l Specifications Inside Diameter 26" Weight 838 lbs Hearth 39 3/8" x 39 3/8" Total Height 19 5/8" Inside Height 12 1/4" Cooking Surface 3.68 ft2 Dome Thickness 4 1/8" Door Opening 8 5/8"...
  • Page 13 Chapter 2: Le Panyol Ovens M o d e l Specifications Inside Diameter 32 5/8" Weight 1234 lbs Hearth 52" x 52" Total Height 19 5/8" Inside Height 12 1/4" Cooking Surface 5.8 ft2 Dome Thickness 4 1/8" Door Opening 8 5/8"...
  • Page 14 Chapter 2: Le Panyol Ovens M o d e l Specifications Inside Diameter 26" x 39" Weight 1124 lbs Hearth 39 3/8" x 52" Total Height 19 5/8" Inside Height 12 1/4" Cooking Surface 6.03 ft2 Dome Thickness 4 1/8" Door Opening 8 5/8"...
  • Page 15 Chapter 2: Le Panyol Ovens M o d e l 1 0 0 Specifications Inside Diameter 39 3/8" Weight 1805 lbs Hearth 66" x 66" Total Height 19 5/8" Inside Height 12 1/4" Cooking Surface 9.9 ft2 Dome Thickness 4 1/8" Door Opening 8 5/8"...
  • Page 16 Notes...

  • Page 17: Design And Construction

    Design and construction What your wood fired oven will look like is 100% up to your imagination. In this chapter you will learn the basics of oven design and how to get the most from your Le Panyol.
  • Page 18 Chapter : Design and construction Square vs. Domed Facade: It’s best to first determine the basics of your oven’s appearance. The two traditional designs are the square façade and the domed façade.

  • Page 19: Calculating The Height Of Your Oven Hearth

    Chapter : Design and construction CONSTRUTION: CALCULATING THE HEIGHT OF YOUR UNDERSTANDING THE HEARTH FUNDAMENTALS The first step in building the ideal oven This section covers the construction of stan- is to determine the perfect hearth height for dard masonry foundations and oven stands the chef or baker.

  • Page 20: Hearth Slab Depth

    Chapter : Design and construction THE HEARTH SUPPORT SLAB The dimensions of the oven core, hearth In almost all scenarios the length and tiles, insulation, hearth support slab and veneer width of the support slab are equal to the relate to the size of your oven footprint, stand, corresponding dimensions of the oven stand foundation and footing.

  • Page 21: Footings And Foundation

    Chapter : Design and construction FOOTINGS AND FOUNDATION measure 12” thick with 2 parallel layers of 1/2” rebar laid within the upper and lower third of the concrete mass. Corner junctions of rebar Footing Options: Outdoors should be secured with tie wire. Additionally, L- shaped sections of 1/2”...

  • Page 22: Oven Stand

    Chapter : Design and construction concrete. Some jurisdictions may require (please see below). that vertical and horizontal rebar be carried Allow 24 hours of cure time prior to throughout the entire foundation structure-- continue work atop the support slab. Slabs please consult with your local contractor spanning large distances may require interme- Below grade foundation applications...

  • Page 23: Smoke Throat Adaptors

    Chapter : Design and construction AFTER CONSTRUCTING THE CORE: over the throat and then rest on the refractory elements. Flue tiles should be set with refractory SMOKE THROAT ELEMENTS AND mortar and be free to move relative to the ADAPTORS surrounding masonry.
  • Page 24 Notes...

  • Page 25: Assembly Of The Le Panyol Oven Core

    Assembly of the Le Panyol oven core: Models 66 & 99 The Domestic family of le Panyol oven cores are exceptionally quick and easy to assemble.

  • Page 26: Models 66 And

    Chapter : Assembly of the Le Panyol Oven core: Models 66 and 8 First, debur the pieces of the  oven with a grinding stone.   Then place the hearth tiles and  ensure that they are level.             Center the oven entry 5 1/8  inches from the front edge of the  hearth (to accomodate the smoke  throat elements and 1/8” mortar  joint added later).
  • Page 27 Chapter : Assembly of the Le Panyol oven core: Models 66 and 8 Chapter : Assembly of the Le Panyol oven core: Models 66 and 8 Starting on one side of the  oven entry, place the voussoirs.  Support each voussoir as  necessary with a piece of wood.  Chock these two voussoirs with  12” pieces of wood first. The inside surface should be flush with the inside surface of the ...
  • Page 28 Chapter : Assembly of the Le Panyol Oven core: Models 66 and 8 Put the key stone in place on top  of a stable 12 1/2”-13” support.  In order to ensure that the lower  surface is at the same level as the  inside of the roof, use a support  of fixed length on top of a few removable pieces (shown here)  to allow for keystone height  adjustments. The pieces of each Le Panyol  oven core are handcrafted and  thus vary slightly in size and  orientation.  When stacking the  core, structural integrity is much  more important than a perfect fit and “seamless” oven cavity.  ...
  • Page 29 Chapter : Assembly of the Le Panyol oven core: Models 66 and 8 Chapter : Assembly of the Le Panyol oven core: Models 66 and 8 Place the 4 half-voussoirs on the  doorway piece. Place two voussoirs opposite the  full voussoirs already in place. www.mainewoodheat.com for the latest step-by-step oven installations.
  • Page 30 Chapter : Assembly of the Le Panyol Oven core: Models 66 and 8 Place the other voussoirs.  It  may be necessary to shim the  elements with pieces of masonry  at the top and bottom in order to  ensure proper fit at the keystone. Again, a sound structure is more  important than a perfect fit. The voussoir positioning can be  adusted from inside by gently  tapping with a wood pole or  stick.
  • Page 31 Chapter : Assembly of the Le Panyol oven core: Models 66 and 8 Chapter : Assembly of the Le Panyol oven core: Models 66 and 8 A rubber mallet can be used to  adjust the outside. The dome structure. www.mainewoodheat.com for the latest step-by-step oven installations.
  • Page 32 Chapter : Assembly of the Le Panyol Oven core: Models 66 and 8 Insert the two included metal  screws into the doorway as  shown.  Cirle the construction  with wire (baling wire, etc.).  The  wire should be snug, not tight. Layer the hearth with newspaper.  to protect it from the mortar.  As  an alternative, the vertical joints  in the dome can be stuffed with  paper towels, which will later  burn away during the first fire. Wet the dome with a sponge and  clean water, making sure that all  of the joints and dome surface  are thoroughly wet.
  • Page 33 Chapter : Assembly of the Le Panyol oven core: Models 66 and 8 Chapter : Assembly of the Le Panyol oven core: Models 66 and 8 Take 1/4 of the refractory mortar  from the bag provided with the  oven kit and mix just enough water to create a thin paste. Pour  this around the keystone and  down along the joints make sure  all opening have been sealed. With the remaining portion  of the refractory mortar, mix enough water to create a slighly ...

  • Page 34: Variations For The Model 83

    Chapter : Assembly of the Le Panyol Oven core: Models 66 and 8 VARIATIONS FOR THE MODEL 83 Put the key stone in place on  top of a stable 13 1/2” support.  In order to ensure that the  lower part is at the same level  as the inside of the roof, use a  support of fixed length on top of a few removable pieces (shown  here) to allow for keystone  height adjustments. Place two voussoirs opposite the  full voussoirs already in place. The dome constructed.

  • Page 35: Model 66: Plan And Sections

    Chapter : Assembly of the Le Panyol oven core: Models 66 and 8 Chapter : Assembly of the Le Panyol oven core: Models 66 and 8 www.mainewoodheat.com for the latest step-by-step oven installations.

  • Page 36: Model 83: Plan And Sections

    Chapter : Assembly of the Le Panyol Oven core: Models 66 and 8...
  • Page 37 Chapter : Assembly of the Le Panyol oven core: Models 66 and 8 Chapter : Assembly of the Le Panyol oven core: Models 66 and 8 Notes www.mainewoodheat.com for the latest step-by-step oven installations.
  • Page 38 Notes...

  • Page 39: Models 99 And

    Assembly of the Le Panyol Oven core: Models 99 & 100...
  • Page 40 Chapter 5: Assembly of the Le Panyol Oven core: Models 99 and 100 First, debur the pieces of the  oven with a grinding stone.  Then place the hearth tiles and  ensure they are level. Center the oven entry 5 1/8  inches from the front edge of the  hearth (to accomodate the smoke  throat elements and 1/8” mortar  joint added later).
  • Page 41 Chapter 5: Assembly of the Le Panyol oven core: Models 99 and 100 Starting on one side of the  oven entry, place the voussoirs.  Support each voussoir as  necessary with a piece of wood.  Chock these two voussoirs with  12” pieces of wood first. The inside surface should be flush with the inside surface of the  doorway piece. www.mainewoodheat.com for the latest step-by-step oven installations.
  • Page 42 Chapter 5: Assembly of the Le Panyol Oven core: Models 99 and 100 Put the key stone in place on  top of a stable 12 1/2”-13”  support. In order to ensure that  the lower surface is at the same  level as the inside of the roof,  use a support of fixed length on top of a few removable  pieces (shown here) to allow for  keystone height adjustments. Place the 4 half-vousoirs on the  doorway piece.
  • Page 43 Chapter 5: Assembly of the Le Panyol oven core: Models 99 and 100 Place and center 2 straight  voussoirs on each side of the  keystone. Place the other voussoirs.  It  may be necessary to shim the  elements with pieces of masonry  at the top and bottom in order  to center the keystone.  Again,  a sound structure is more  important than a perfect fit. www.mainewoodheat.com for the latest step-by-step oven installations.
  • Page 44 Chapter 5: Assembly of the Le Panyol Oven core: Models 99 and 100  9 The voussoir positioning can be  adusted from inside by gently  tapping with a wood pole or  stick. A rubber mallet can be used to  adjust the outside.
  • Page 45 Chapter 5: Assembly of the Le Panyol oven core: Models 99 and 100 The dome structure. Insert the two included metal  screws into the doorway as  shown.  Circle the construction  with wire (baling wire, etc.).  The  wire should be snug, not tight. Layer the hearth with newspaper  to protect it from the mortar.  As  an alternative, the vertical joints  in the dome can be stuffed with  paper towels, which will later  burn away during the first fire. www.mainewoodheat.com for the latest step-by-step oven installations.
  • Page 46 Chapter 5: Assembly of the Le Panyol Oven core: Models 99 and 100 Wet the dome with a sponge and  clean water, making sure that all  of the joints and dome surface  are thoroughly wet. AVOID CONTACT WITH THE REFRACTORY MORTAR OR ANY CEMENT BASED PRODUCT AS THEY ARE CAUSTIC AND CAN CAUSE DAMAGE. Take 1/4 of the refractory mortar  from the bag provided with the  oven kit and mix just enough water to create a thin paste. Pour ...
  • Page 47 Chapter 5: Assembly of the Le Panyol oven core: Models 99 and 100 Add the smoke throat pieces to  the doorway, flush with the edge of the hearth. Affix with a 1/8” mortar joint (Heat Stop 50 or  other commonly available high- temp refractory mortar). The smoke throat adapter will be  installed above the rectangular  openening. www.mainewoodheat.com for the latest step-by-step oven installations.
  • Page 48 Chapter 5: Assembly of the Le Panyol Oven core: Models 99 and 100 VARIATIONS FOR THE MODEL 100 Place a straight voussoir on  either side of the doorway,  chocked with a 12” piece of  wood.  A 12 1/2”-13” table  support should be used for the  keystone, placed at an angle  to meet the tops of the straight  voussoirs.  The two halves of  the keystone fit together as shown. Place the four half voussoirs on  the doorway piece.  7 Place 8 straight voussoirs  as shown in relation to the  doorway. Place the other voussoirs.  It  may be necessary to shim the  elements with pieces of masonry ...
  • Page 49 Chapter 5: Assembly of the Le Panyol oven core: Models 99 and 100 www.mainewoodheat.com for the latest step-by-step oven installations.
  • Page 50 Chapter 5: Assembly of the Le Panyol Oven core: Models 99 and 100...
  • Page 51 Chapter 5: Assembly of the Le Panyol oven core: Models 99 and 100 Notes www.mainewoodheat.com for the latest step-by-step oven installations.
  • Page 52 UL & ULC Information Le Panyol Wood-Fired Oven Models: 180 and 180 Stretch (with 10” (25.5 cm) diameter chimney) 120 and 120 Stretch (with 8” (20 cm) diameter chimney) 100 (with 8” (20 cm) diameter chimney) 83, 66x99, and 66 (with 7” (18 cm) diameter chimney) 75 – Outdoor Installation Only READ ALL INSTRUCTIONS BEFORE INSTALLING AND USING THE OVEN When this oven is not properly installed a fire may result. To reduce the risk of fire, follow the installation instructions. Please read this entire manual before you install the oven. Failure to follow instructions may result in property damage, bodily injury, or even death.
  • Page 53 UL & ULC Information Oven is to be installed using the minimum diameter UL 103 HT (ULC S629 in Canada) listed chim- ney specified or a code approved masonry chimney with a flue liner. The oven is required to be installed with a vertical flue and without a hood. Contact local building or fire officials to determine if there are any installation restrictions or the need for inspection of the oven installation.
  • Page 54 UL & ULC Information burning fire. As a result, creosote residue accumulates on the flue lining and exhaust hood. When ignited, this creosote makes an extremely hot fire. The oven flue should be inspected at least twice a year to determine when creosote buildup has oc- curred.

  • Page 55: Appendixes

    Appendixes A...

This manual is also suitable for:

Le panyol 99Le panyol 100Le panyol 83

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