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The Fire Brick P85 Instruction Booklet

Pre-cast oven
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P85
PreCast
Oven
P85 PRE-CAST OVEN KIT
Instruction Booklet

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Summary of Contents for The Fire Brick P85

  • Page 1 PreCast Oven P85 PRE-CAST OVEN KIT Instruction Booklet...
  • Page 2 The PreCast Oven Kit is a great design; we’ve done all of the hard work - you get the fun of putting it together.

  • Page 3: Table Of Contents

    Table of Contents CONTENTS INTRODUCTION � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5 BEFORE YOU BEGIN �...
  • Page 4 Our PreCast oven is easy to assemble, fits into a small space and heats up quickly. Perfect for the spontaneous entertainer.

  • Page 5: Introduction

    Introduction Introduction Firstly, our congratulations and gratitude for the purchase of your P85 PreCast Oven Kit! We have spent years crafting and perfecting our PreCast Oven Kits, taking suggestions from customers and mentors, to create a product that we are truly proud of.

  • Page 6: Before You Begin

    Before You Begin Before You Begin COLD CLIMATES - WARNING If you’re building a Wood Fired Oven in a region that experiences ‘freeze-thaw’ conditions, where the frost is so severe that it penetrates deep into the ground, this is something that you need to be aware of when deciding on where and how to build your Wood Fired Oven.

  • Page 7: Updates

    Updates Updates We are on a continuous search for ways to improve our products, so that we’re always giving our customers the very best product that we can. These changes are always small and incremental - tested by us before being rolled out to our customers.

  • Page 8: Safety Information

    Safety Information Safety Warning A MAJOR CAUSE OF UNINTENDED OVEN-RELATED FIRE IS FAILURE TO MAINTAIN REQUIRED CLEARANCES (AIR SPACES) TO NEARBY COMBUSTIBLE MATERIALS. IT IS OF THE HIGHEST IMPORTANCE THAT THIS OVEN BE INSTALLED ONLY IN ACCORDANCE WITH THESE INSTRUCTIONS. IF THIS OVEN IS NOT PROPERLY INSTALLED, A FIRE MAY RESULT.
  • Page 9 Clearances to Combustible Material A major cause of oven-related property fire is failure to maintain the required clearances (air spaces) between the oven and combustible materials. When you’re planning the location for your oven, ensure that you maintain clearances to all combustible materials, including but not limited to nearby walls, posts, ceiling structures and vegetation.
  • Page 10 Safe Installation Instructions DUST EXPOSURE – RESPIRABLE CRYSTALLINE SILICA Inhalation of airborne dust may cause irritation to the mucous membrane and upper airways. Symptoms can include coughing, sneezing and breathing difficulties. Repeated exposure to respirable silica may result in pulmonary fibrosis (silicosis). Silicosis is a fibronodular lung disease caused by deposition in the lungs of fine respirable particles of crystalline silica.
  • Page 11 Safe Usage Instructions WARNING: PLEASE READ ALL OF THE INSTRUCTIONS BEFORE INSTALLING AND USING YOUR WOOD FIRED OVEN� FAILURE TO FOLLOW INSTRUCTIONS MAY RESULT IN FIRE, CARBON MONOXIDE POISONING OR EXPLOSION LEADING TO PROPERTY DAMAGE, BODILY INJURY, OR EVEN DEATH� SAVE THESE INSTRUCTIONS� If your oven is not installed properly, an unintended fire may result.

  • Page 12: Limited Warranty

    Limited Warranty The Fire Brick Company, a manufacturer of wood fired ovens, warrants its ovens (henceforth referred to as the Oven) to be free from defects in materials and workmanship for a period of (1) one year from the date of purchase.

  • Page 13: Layout Drawing

    Layout Drawing P85 Layout Drawing 50 mm Perlite Render Insulation 50 mm Ceramic Fibre Insulation 65 mm Cast Refractory Dome Wall PreCast Flue Gallery 400 mm Internal Dome Height 265 mm 320 mm 50 mm 50 mm Fire Brick Tile Floor...
  • Page 14 Our PreCast Oven Kit is the result of years of design and development and is something that we at The Fire Brick Company are immensely proud of.

  • Page 15: What's Inside The Kit

    What’s Inside the Kit What’s Inside the Kit CALCIUM SILICATE BOARD 2 x Calcium Silicate Boards 1000x615x50mm This is the 50mm thick insulation board layer that you will install underneath your oven; it comes with printed paper templates & drawing pins so that you can pin the templates onto the CalSil board and cut out the pieces you need, following the lines shown on the paper templates.
  • Page 16 Dry Airset Refractory Mortar: 1 x 10kg bag This is the mortar you will use to lay the fire brick tiles that make up the oven floor. Please be aware that you will need to mix the Airset mortar with General Purpose Cement, Hydrated Lime and Washed Sand* in the ratio shown on the bag.
  • Page 17 What’s Inside the Kit ACRYLIC ROLL-ON BASECOAT RENDER 1 x 5L MAC ‘Rustic Roll-On’ Acrylic Render (White Basecoat) This is the membrane coating that you will apply over the outer dome, once the oven has been completely cured and all moisture has been driven out. It gives the dome a good waterproof basecoat which can be rolled over with more roll-on render, or other similar exterior acrylic coating.
  • Page 18 Additional Material Required ADDITIONAL MATERIALS REQUIRED • 2 x 20kg Bags GP (General Purpose) Cement • 1 x 20kg Bag Hydrated Lime • 2 x 20kg Bags Washed Sand • Household aluminium foil • Masking Tape • Cling wrap We don’t include these for several reasons – they add a lot of weight which would increase shipping costs, they’re available at all good hardware stores, and many of our customers already have these on hand.

  • Page 19: Subfloor Insulation

    Subfloor Insulation 1. Subfloor Insulation The first step in building your oven is to prevent the heat in the oven floor from being conducted into your concrete slab, and from there into the surrounding air to be lost forever. We use Calcium Silicate (CalSil) board to do this, as it has excellent insulating properties, great compressive strength and is easy to work with.

  • Page 20: Laying The Floor Tiles

    Laying the Floor Tiles 2. Laying the Floor Tiles Fire bricks are very porous and will absorb a significant amount of water, so if you apply wet mortar to a dry fire brick this mortar will dry out and will not develop a good bond. To overcome this, soak your fire bricks in water for at least 10 minutes before you lay them.
  • Page 21 2. Laying the Floor Tiles 2A: LAY THE FRONT CENTER TILE Lay the front-center tile, making sure it’s level with your stand so that the other tiles can be laid flush and level with it. Spread a layer approximately 10mm thick on the top of the foil layer.

  • Page 22: Building The Dome

    Building the Dome 3. Building the Dome The dome of the oven is made up of four PreCast sections, which lock together using ‘tongue & groove’ joints. In your kit you will find the Entry Arch and three Shell Sections, with a number painted onto the back of each shell section, to ensure the castings are placed in order.
  • Page 23 3. Building the Dome The PreCast sections are somewhat porous, and just like the fire bricks will absorb a significant amount of water, so if you apply mortar to the dry PreCast sections this mortar will dry and harden very quickly. To overcome this, soak the base of the PreCast sections in water before you lay them.
  • Page 24 3. Building the Dome 3B: INSTALLING THE ENTRY ARCH As discussed on the previous page, soak the brick tiles on the left and right-hand side where the Entry Arch section is going to land. Ensure the base of the PreCast Entry Arch Section is also thoroughly soaked in water. Mix a small batch of mortar &...
  • Page 25 3. Building the Dome 3C: INSTALL DOME SECTION 1 Soak the base of all of the PreCast Shell sections in water, and apply 5-10mm of mortar to the area on the floor that PreCast Section 1 is going to land on, then place the section (you need someone to assist with the lifting). Do not use any mortar inside the tongue and groove joint, this will make it very difficult to fit the pieces together as they are designed as a dry interlocking joint.
  • Page 26 3. Building the Dome 3D: INSTALL DOME SECTION 2 Repeat the process with PreCast Section 2, ensuring the floor tiles are wet before you put down the mortar bed. Place the section and move into place using a rubber mallet or dead-blow hammer around the base of the section, until the joint with PreCast Section 1 is fairly close (don’t try to get it perfectly into position yet as you will need to ‘open out’...
  • Page 27 3. Building the Dome 3F: BRING THE DOME SECTIONS TOGETHER Note in the image below that on placing Section 3 you will have a large gap between the sections. As mentioned on the previous page you now need to shift the sections using a rubber mallet or dead-blow hammer to bring the sections together as tightly as you can.
  • Page 28 3. Building the Dome 3G: INSTALL FIBERGLASS FORM Take the fiberglass dome that is included in your kit and use a car jack to push it firmly against the keystone hole at the top of the oven dome. Prior to inserting the dome, wipe the surface with vegetable oil to help it release from the castable that will be poured on top.
  • Page 29 3. Building the Dome 3H: POUR THE KEYSTONE Mix around two thirds of the bag of castable with water to a very thick porridge consistency. You want it to be wet through, but as thick and ‘stodgy’ as you can make it, so add water slowly and mix throughly. Fill the keystone void with the wet castable mixture immediately after mixing it.

  • Page 30: Building The Vent Arch

    Building the Vent Arch 4. Building the Vent Arch 4A: POSITION FORMWORK Position the timber formwork at the front of the oven, laying flat as shown, lined up with the Entry Arch. Mark the edges of the formwork onto your fire brick floor with a pencil.
  • Page 31 4. Building the Vent Arch Please note that if you make these joints too thick you will have to grind the Vent Spring Bricks slightly to make them fit into the angled rebate in the Entry Arch PreCast Section. You may also need to raise the formwork slightly when you lay the Vent Arch, if you find that the Vent Arch bricks seem too tight when you dry-fit them, this is because the formwork is sitting too low.

  • Page 32: Installing The Flue Gallery

    Installing the Flue Gallery 5. Installing the Flue Gallery 5A: ADD PACKERS & DRY FIT THE FLUE GALLERY Place packers 3mm to 10mm thick on top of your Vent Springer bricks, you could use the plastic spacers that come with the kit as temporary packers that you remove once the PreCast Flue Gallery is set in place.
  • Page 33 5. Installing the Flue Gallery 5E: REMOVE THE VENT ARCH FORMWORK Fill in any gaps on the front and sides of the joint between the Flue Gallery and the Vent Arch Bricks. Hold the base of the formwork in place while pulling out the plastic strips.

  • Page 34: Insulating The Dome

    Insulating the Dome 6. Insulating the Dome You’ll now wrap the Oven Dome in Ceramic Fibre Blanket, which is the insulation material to prevent heat escaping from your brick dome. We provide you with green ‘Vet Exam’ gloves to protect your arms from the itchy fibres, also remember to wear the appropriate safety equipment.
  • Page 35 6. Insulating the Dome 6D: TIE WIRE Use the 125mm nails, hammering them into the CalSil board around the perimeter, 25mm above the base at roughly 300mm spacing. Leave about 20mm hanging out, as a fixing point for your tie wire. Use the heads of the nails as tie points to lash the blanket down against your dome using the tie wire provided.

  • Page 36: Oven Landing & Surrounds

    Oven Landing & Surrounds 7. Oven Landing and Surrounds Before you render the dome, finish the top of your concrete slab with tiles or stone, and seal off the exposed CalSil board at the sides and front of the Vent area using either our Stainless Steel Wrap, or an Oven Landing. If you do this now, it will be much easier to cut the tiles to fit as they don’t have to be cut very accurately.

  • Page 37: Perlite Render

    Perlite Render 8. Perlite Render To render over the Ceramic Fibre Blanket you’ll be using LiteFill Perlite – this is a lightweight aggregate that you’l use to make an insulating render mixture. The Perlite render layer serves two purposes – it forms a thick, hard shell over the insulation blanket, and it provides additional insulation to your oven dome.

  • Page 38: Installing The Standard Flue

    Installing the Standard Flue 9. Installing the Standard Flue If you’ve built your oven outdoors and the flue will be well clear of any combustible materials as per the diagram on page 9, you can install the standard flue for the oven following the steps detailed below. 9A: INSTALL THE FLUE Place the flue cowling (hat) on the plain end of the flue pipe, this is meant to be a snug, tight fit.

  • Page 39: Flue Installation Tips

    Flue Installation Tips Flue Installation Tips EXTENDING THE FLUE It’s very common to need to make your flue higher, and there’s no problem with that, in fact it will make the flue draw even better! Something to consider is how you will support the extra lengths.

  • Page 40: Curing The Oven

    Curing the Oven 9. Curing the Oven CURING THE OVEN Regardless of the weather conditions during your build, when you are finished your oven will still be holding water. Each brick was soaked before being laid, so your oven will be holding water in the walls, floor and CalSil board.

  • Page 41: Painting

    Painting 10. Painting PAINTING THE FLUE GALLERY The PreCast Flue Gallery comes in the kit in a plain cast finish, which is a light grey colour. You can leave it in this finish if you want a more natural look, or coat it with high temp paint which sets it off against the bricks. Make sure the oven is fully cured before you paint the flue gallery, to avoid blistering when the oven is fired.
  • Page 42 Examples...
  • Page 43 Examples...
  • Page 44 From the whole team at The Fire Brick Company, thank you for choosing us. You’re not only a customer, you’re now a part of The Fire Brick Co. family and we’re here to support your wood fired endeavours in whatever way we can. We have a number of videos and other resources to help you with using your oven, now that you have it built, and will be adding to them on a regular basis.
  • Page 45 Contact THE FIRE BRICK CO. 11/167 Princes Highway Hallam, Victoria Australia Ph: (03) 9703 1758 Email: sales@melbournefire bricks.com.au www.melbournefire bricks.com.au...

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Precast p85

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