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Le Panyol Liberte Series Assembly Instructions Manual

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LIBERTE RANGE
Model 120
ASSEMBLY INSTRUCTIONS
14/01/2020

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Summary of Contents for Le Panyol Liberte Series

  • Page 1 LIBERTE RANGE Model 120 ASSEMBLY INSTRUCTIONS 14/01/2020...

  • Page 2: Oven Parts List

    Refractory terracotta tiles 33x33x6cm – White color Oven-entry 1 in 2 parts (left and right) Smoke throat 1 in 3 parts (left, central, right) Pediment Le Panyol Voussoirs n°1 (120N1) Voussoirs n°2 (120N2) Voussoirs n°3 (120N3) Voussoirs n°3A (120N3A) Wood templates to place the voussoirs...
  • Page 3 TOOLS • Spirit level • Tape mesure • Spatula • Trowel • Rubber Mallet • Jack • Wood specer • Iron wire • Drill • Gloves...
  • Page 4 FOREWORD Le Panyol ovens are made exclusively of Refractory White Earth, a 100% natural clay from our own quarry. As the material is irregular by nature and the production methods are based partly on craft skills, you may find that there are gaps between the parts when it comes to assembling them.
  • Page 5 THE KEY STAGES OF ASSEMBLY 1. Choose a site for the oven 2. Build a base on which to sit the oven 3. Insulate the base 4. Assemble the oven floor – see also the video 5. Assemble the oven dome - see also the video 6.

  • Page 6: Step 1 : Choosing A Site

    Outdoor Installation The Le Panyol oven must be protected against bad weather by a roof wide enough to prevent the oven and hearth tiles from getting wet. It must be kept dry in winter as, if it absorbs water, frost would make it unusable. If the oven is stand-alone, the pipe must be approximately 1m long.
  • Page 7 STEP 1 : Choose the final shape of the oven There are 2 kinds of shape for the oven : cubic and rounded. In terms of the shape, the insulation materials and the size of the base are different. For a rounded shape, there’s no need to build a surrounding wall and therefore the size of the base is smaller. Cubic shape Rounded shape...
  • Page 8 STEP 2 : Building a base to support the oven Foreword : Before building the base, it is important to define the oven floor height (where the fire will be laid and the cooking done). This height defines the pillars’ height of the base. The oven floor is generally between 100 and 120 cm high, depending on the user’s height and comfort requirements.
  • Page 9 STEP 2 : Building a base to support the oven Cubic shape Build : • 3 breeze-block pillars 20 cm thick • 1 reinforced concrete slab 10 cm thick • 1 level (14 cm) of surrounding wall on the 3 sides using Siporex- type insulation blocks 10 cm thick if cubic shape and 5 cm thick if rounded shape.
  • Page 10 STEP 3 : Insulating the base Warning : Once you have built the base : The photos are matching the model 83. For the model 120 there are 30 tiles but the process is exactly the same. 1/ Insulate the reinforced concrete slab using dry Siporex-type insulation blocks 5 cm thick. Do not seal. 2/ Draw a line at 21 cm from the edge of the base and place siporex block 3 cm thick in order to contain the grog.
  • Page 11 STEP 4 : Assembling the oven floor The tiles must be laid against each other without sealing. Handle gently. Draw the axis of the base. Begin with the tiles with stone color . Draw the axis of one tile. Match the 2 axis. Warning : there is a way for the tiles.
  • Page 12 STEP 4 : Assembling the oven floor Finish the first row. Then place the other tiles (white) on the same process. Once all the tiles are placed, check the level with your hand. Check that the oven floor is as flat as possible to avoid the pizza peel bumps during charging.
  • Page 13 STEP 5 : Assembling the oven dome...
  • Page 14 STEP 1 : Placing the smoke throat pieces Left pillar Central piece Right pillar Draw the central axis of the oven floor. Place the 2 pillars with equal distance from the axis. Place them with an overflow (1 cm) from the table. Place the central piece.
  • Page 15 STEP 2 : Placing the oven entry The entry is made of 2 pieces (Right (D) and Left (G)) Place these 2 pieces behind the smoke throat as below. Entry With a string and a nail, draw a circle as shown – 62 cm radius. This circle will help you to place the voussoirs (arch stones).
  • Page 16 STEP 3 : Placing the voussoir row N°1 Front perspective: Back perspective : 1/ Place 1 voussoir N°1 (stamped 120N1) as shown in the picture. 2/ Adjust the same voussoir as shown in the pitcure. 3/ Place 7 voussoirs N° 1 following the circle. 4/ To secure the construction, a strap should be Do not tighten the voussoirs.
  • Page 17 STEP 4 : Placing the wood templates Place the wood templates (1 per voussoir) in the wooden Protect the oven floor with paper or cardboard. disc. Place the jack in the center. Black marking should be on the top and visible. Place the wooden disc on the top of the jack..
  • Page 18 STEP 5 : Placing the voussoir row n°2 et n°3 N°1 Place 4 voussoirs N°2 stamped 120N2 as shown in N°2 : When row N°2 is finished, make sure tenons are the picture. aligned. Then complete the row with voussoirs N°2. N°4 : Place the last front voussoirs stamped N°3 Place the third row of voussoirs, 120N3A.
  • Page 19 STEP 6 : Placing the keystone Place the keystone on the top of the dome. The keystone can be a few centimetres higher than the Do not drop it in yet. As you let the jack down cupola. slowly, settle the different oven pieces tightly The oven is made with handmade refractory.
  • Page 20 STEP 7 : Placing the smoke adaptor Seal the central piece of the smoke throat with some provided refractory mortar. • Place the smoke adaptor above the doorway, where there is a hole for evacuating smoke. • Slide the edge of the smoke adaptor under the small arch stones on the dome. •...
  • Page 21 STEP 8 : Placing the pediment Place the pediment in the middle. Fix it PROPERLY with the mortar CR25H. This piece will be still apparent when the oven will be insulated and decorated.
  • Page 22 View STEP 9 : Applying the mortar the video The aim of applying the mortar is to consolidate the whole of the dry assembly and to fill the gaps The mortar is hydraulic, so you’ll need to wet the dome regularly. For the proportions, please refer to the instructions on the bag.
  • Page 23 View STEP 9 : Applying the mortar the video Wet again the dome. Pour the mortar over the dome and spread with a trowel over a minimum thickness of 1 cm. Proceed like this until completely covering the dome. Work quickly enough because the mortar dries quickly. Finish around the smoke adaptor.
  • Page 24 STEP 10 : Insulating the dome The insulation materials and the insulation techniques are different if the final shape of the oven is CUBIC or ROUNDED. Read the next pages which concern you. Before you fit any insulating materials, we recommend that you light a few small fires to remove any residual moisture, as this will be more difficult to get rid of once the oven is insulated.
  • Page 25 Insulating the dome for a CUBIC shape oven 1/ Building walls aroung the dome Build a wall at the back, on the right and left, with aerated concete 10 cm thickness and with a height you have chosen. For the front wall : On each side of the oven entry, build walls 10 cm thickness.
  • Page 26 Insulating the dome for a CUBIC shape oven 2/ Place the GROG Once your flue chimney installed, shed the grog on the oven dome until it is no more visible. The number of provided bags has been studied to get a performing insulation. Advice : to prevent the grog from accumulating unnecessarily in the corners, build walls at each corner of the surrounding wall (see draw above).
  • Page 27 Insulating the dome for a ROUNDED shape oven 1/ Place the blanket 38 mm Recover the dome with refractory blanket (Surperwool 1100°C kind) « without humping ». Advice : cut triangles in the blanket. 2/ Place a chicken fence (non provided) Recover with chicken fence / frame (same method as the blanket).
  • Page 28 Insulating the dome for a ROUNDED shape oven 3/ Applying a refractory Mix : refractory cement + vermiculite + water (materials non provided) Recover all with a refractory MIX very wet : ➢ Mix dry the refractory cement with vermiculite (1 dose cement for 3 doses vermiculite) ➢...
  • Page 29 STEP 11 : The chimney pipe In accordance with DTU standard 24.1 (Unified Technical Document), you must not connect more than one apparatus to the same chimney pipe. The pipe should be: • 180 mm in diameter (the stainless steel smoke adaptor supplied with the oven is 180mm in diameter) •...
  • Page 30 STEP 12 : Surround / decoration You can use a wide range of materials to suit the style you’re looking for: • Earthenware, • Decorative stone • Bricks, • Rendering, etc. They must be class M0 (French legislation which classifies materials according to their reaction to fire - M0 = non-combustible) Stick the chosen material on the surrounding wall or insulated dome (if the rounded shape).

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