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Instructions on how to install a Pre casted Calabrese oven kit September 2017
Before you start you will need a roll of chicken wire 5 metres, tie wire and aluminium foil x 3 rolls
1.
On your slab roll out the Aluminium foil covering the area of your slab, Do 2 layers of foil ( Picture
1). Lay your insulation board on top of the (aluminium foil ) area in where the oven will be going
keeping centre ( Picture 2 ) . Make sure the board is at least 80mm off the back of your base to
allow for insulation blanket & render (Picture 3).
( the Alumium foil acts as a barrier for moisture between the slab and the insulation board
Picture 1
Picture 3
Picture 2
Once the insulation board is layed out,
place your floor cooking tiles ontop of
the insulation board in the following
order listed on page 2. The tiles may
overhang the insulation board on the
left and right of the tiles. With the
offcuts of the insulation board or
excess fibre blanket pack this under
the tiles that overhang to support tiles.
PLEASE NOTE THE STANDARD
INSULATION BOARD is between 40mm
and 50mm thick for the Courtyard,
entertainer & Grande. IF YOU RECEIVE
4 pieces of 25mm thick board in your
courtyard, Entertainer or Grande kit
PLEASE DOUBLE THE SHEET UP TO
MAKE 50mm..
)
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Summary of Contents for Calabrese ENTERTAINER
- Page 1 Instructions on how to install a Pre casted Calabrese oven kit September 2017 Before you start you will need a roll of chicken wire 5 metres, tie wire and aluminium foil x 3 rolls On your slab roll out the Aluminium foil covering the area of your slab, Do 2 layers of foil ( Picture 1).
- Page 2 Calabrese Courtyard Tile plan Calabrese Entertainer Tile plan Calabrese 800 Tile plan Calabrese Grande Tile plan...
- Page 3 Picture 4 Picture 5 Picture 7 Picture 6 When you lay your floor tiles ontop of the board one is slightly higher than the other you can gently grind this down with an angle grinder to make it smooth. (Picture 4) (if you do this it will leave grind marks in the floor tiles ) Using 4+ people lift the oven into place ontop of the cooking tiles ( please be careful it weighs 220 + kg in 1 piece) The oven should match up to the tiles cut..
- Page 4 Picture 8 Picture 9 With any mortar or Castable that you may have left over ONLY AFTER MORTARING THE FRONT ARCH BRICKS fill the join between the oven and the floor tiles. If you don’t have enough don’t worry. Picture 10 (Picture 9) When you cut the Calsil board to conform to the shape of the floor...
- Page 5 Entertainer , Grande 800*, Courtyard - Calabrese – 63/51/51/51/51/51/51/51/51/51/51/51/51/51/51/63 *Calabrese 800 has smaller 25mm thick front underfloor tile & only a 230 x 115 x 75 brick with no 25mm tile under the front flue arch Entertainer, Grande - Calabrese - 63/51/51/63/51/51/63/51/51/51/51/63/51/51/63/51/51/63 When putting the combination together only use a 3mm thin scrape of mortar to bind the bricks together.
- Page 6 Picture 14 Gently squeeze the flue in and it should sit in there. Tear a small amount of insulation blanket off and pack in around the flue , straighten your flue .. With the castable supplied mix this with water until you obtain a doughy consistency. Then pack this around the flue to seal it in.
- Page 7 For the optional brick trim and stainless cap which is extra we supply mortar them ontop of the flue top 4 x 51mm flue bricks in the following combination and insert the stainless flue ontop. Entertainer / Grande Brick trim...
- Page 8 For the brick trim optional on the entertainer and Grande models when assembling please make sure the face bricks are at the front and the Cut bricks with the grain exposed each side are on the back.
- Page 9 Then once you have mortared the top bricks with any left over mortar spread over the top of the brick trim to make a seal then gently insert the stainless steel cap. When pushing the stainless steel cap down the mortar spread over the top will create a seal.
- Page 10 Place ceramic fibre blanket over the oven (not over the brick front) and make sure it is fully covered tucking it in on the corners around the arch (please use gloves and a mask when handling and cutting the ceramic blanket) and overlapping any joins. Optional: Using Aluminium foil as a secondary barrier cover the ceramic blanket FULLY so you cant see any blanket at all ( this acts as a barrier so no moisture can penetrate the blanket over time.
- Page 11 Picture 21 Picture 22 Once this is done mix your render ( mix below) and form over the top to create a rough layer covering the chicken wire ( Picture 22 ). If you see the chicken wire its not a worry, the first coat is the rough coat. Wait till the render is touch dry say 1hr.
- Page 12 your oven for life. The heat beads are to stay in the oven for a minimum 24 – 48hrs (the longer the better) replacing the heat beads with new ones that are hot to keep the heat at 100 – 150 degrees. This pushes any moisture out of the oven and drys it for LIFE to prevent any issues.
- Page 13 To maintain this heat you will have to keep stoking the fire with timber to keep the temperature up. Please note the door on the oven is not to be used at any stage upon the firing up and cooking. It is only meant to be used to keep the heat in overnight or between use.