Making a brick oven is a home project that will cost both time and money. However, this brick oven is well worth making for delicious food and a happy heart. First, find a brick oven design that fits your needs and budget. Next, prepare the foundation for the oven by digging a hole and filling it with mortar. Once the foundation is completely dry, start building a brick oven. Follow the design as you gather materials and build bricks. Finally, use the brick oven to bake pizza, bread, and other delicacies.
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Part 1 of 5: Choosing a Design
Step 1. Find a brick oven design
Making a brick oven is a project that costs both time and money. If you make the wrong one, the oven can crack and you'll have to redo all the previous hard work. If you want to build your oven properly, follow the design. Brick oven designs can be found for free or purchased online. Some good designs include:
- Free brick oven designs from Forno Bravo (https://www.fornobravo.com/pompeii-oven/brick-oven-table-of-contents/)
- Free brick oven designs from Makezine (https://makezine.com/projects/quickly-construct-wood-fired-pizza-oven/)
- Brick oven designs you can buy from EarthStone (https://earthstoneovens.com/)
Step 2. Consider the size of the oven
The design you choose will depend on how much space you allocate to the oven. For example, if you have a small garden, the size of the oven you make must fit it. Other considerations are:
- If you are making your oven under a patio shade, the oven should be short enough to fit under the patio roof. However, make sure the chimney sticks out from under the roof to release the smoke.
- If you want to bake a large pizza, the floor of the oven must also be wide enough.
- In addition, the budget limit must be taken into consideration. If your budget is small, make a smaller oven.
Step 3. Choose a domed oven design
The vaulted oven is an igloo-shaped brick oven with a wooden door. This oven has a simple but elegant appearance so it can add visual appeal to the backyard. In addition, an oven like this can bake food evenly and can be heated to very high temperatures.
- Domed ovens are difficult to build. Some designs even involve woodworking.
- This type of oven takes a long time to heat properly.
Step 4. Consider the design of the oven from the barrel
A barrel oven is a brick oven built around a large iron barrel. Ovens like this heat up very quickly and are more energy efficient than dome ovens. This type of oven is a great choice for hobbyists who want to bake food quickly.
- Ovens from barrels are usually sold in sets consisting of a stove and a large iron barrel.
- These sets usually have to be purchased online and shipping tends to be expensive.
Part 2 of 5: Building the Foundation
Step 1. Design the foundation
Most brick oven designs will include instructions for creating a concrete foundation. A concrete foundation will withstand the weight of the oven and keep it level for years. The foundation slab should be at least as wide as the brick oven. However, if the size is made much larger, you can at the same time make a patio or a seat near the oven.
If you create a larger patio area, more materials will be needed and the foundation will take longer to build
Step 2. Create the foundation frame
Instructions for this frame will be listed on the brick oven design. Follow these instructions to make a wooden frame. The frame will be laid in the ground and filled with cement mortar to create the foundation.
Use a spirit level to make sure the frame is completely level. The flatter the frame, the flatter the foundation will be
Step 3. Dig the area for the foundation
Measure the foundation for a brick oven using a small flag or chalk powder to mark the edges. Next, remove any boulders or other debris before using a tool such as a tiller or hoe to lift the soil. Most foundation designs recommend digging to a depth of 25 cm. Digging machines such as tillers (or cultivators, i.e. hand tractors) can be rented or purchased at garden hardware or supply stores. When using the tiller, note the following:
- Follow the manufacturer's instructions on the tiller.
- Don't dig too deep too soon. Lift about 3 cm at a time.
- Water the area a few hours before using the tiller to loosen the soil.
Step 4. Install the foundation frame
Once the soil is removed and the hole is formed, place the foundation frame in it. Press each side of the frame firmly to sink it into the ground. If you have difficulty installing the foundation frame, dig and lift the soil that is stuck on the side of the frame. Once placed, fill all the blanks outside the frame with soil.
Step 5. Place the pebbles
Pour a layer of pea gravel or crushed stone into the hole. Continue to add until the gravel layer reaches a height of about 8 cm. Next, use a tamper to compact the gravel. Tampers can be rented or purchased at a hardware or material store.
If you don't have a tamper, you can use your feet to compact the gravel. However, the results will not be as dense as with tamper
Step 6. Lay the wire mesh
Cover the gravel with a layer of wire mesh. If necessary, use strong wire cutters to cut or shape the mesh. You can install 6 MIL brand polyethylene tarpaulin over the gravel, but under the wire mesh. This tarpaulin serves to prevent water from seeping from the ground onto the foundation slab. In fact, it's even better if you add Xypex (a water-repellent chemical) to the cement while mixing it. Xypex is inexpensive and will help keep the concrete or rebar from rusting. Rust will cause the metal to swell and eventually crack the foundation slab.
Wire mesh can be purchased at a hardware store, local hardware store, or online
Step 7. Install the concrete frame
The installation of cast iron will help strengthen and stabilize the cement foundation. Check out the brick oven design to find out how much cast iron you'll need. Usually, you'll need to attach the metal to the sides of the wooden frame. Use wire to tie the overlapping rods together.
Some people consider the installation of a concrete frame unnecessary and you can skip this step. However, without a concrete frame, the cement base may crack after several years of use. Most small foundation slabs are made without a concrete frame, but still use wire mesh to strengthen them. The concrete frame or wire mesh should be poured over the gravel using stones or bricks to blend into the concrete mortar
Step 8. Pour the concrete. Mix one part cement-concrete (with the recommended amount of Xypex added) and pour into the wood frame until the concrete frame is completely submerged. Concrete frames laid on gravel foundations must be held in place by rocks or bricks, not wood. Once the wood frame is fully loaded, use a straight piece of wood, such as a 2x4, to level the cement surface. Allow the foundation slab to dry and solidify for a few days before building a brick oven.
- The amount of mortar you need will vary depending on the size of the foundation. For complete information, use the oven design as a reference.
- Mixers (cement mixers) and other cement mixers (such as mixers) can be rented at your local hardware or materials store.
Part 3 of 5: Reading Design
Step 1. Follow the design exactly
You can easily make mistakes when building a brick oven. This error could result in the oven cracking, collapsing, or with poor insulation. If you follow the design exactly the same, these mistakes can be avoided. Don't be tempted to cut corners or improvise. If you do, you might have to redo all this hard work from scratch.
Step 2. Learn basic woodworking techniques
The design of the oven will likely require wood molding. If that's the case, you'll need to know how to use basic wood tools. Some of the basic equipment includes:
- Circular saw, for straight wood cutting
- Jigsaw, for cutting wood into certain shapes
- Electric drill, for screwing nuts into wood
- spirit level
Step 3. Use the right type of brick
The design of the oven will require several different types of bricks. You may be tempted to ignore the advice and use the cheapest brick or one that happens to be available. However, each type of brick has a different important function that will extend the life of the oven. For example:
- Refractory brick or fire brick is used to coat the inside of the oven. This brick can withstand damage caused by heat. Fire bricks are also resistant to exposure to high temperatures.
- Red bricks are usually used for the exterior of the oven. This type of brick helps insulating the refractory brick and can withstand heat as well.
- Other types of brick, such as concrete block or paving block, can be used as the foundation for the oven. This type of brick is chosen based on its durability and stability.
Step 4. Use the right type of mortar
Usually, when building a brick building, you will use concrete mortar to hold it together. However, if you use cement concrete for a brick oven, the cement will actually crack the bricks when exposed to heat. Instead, use a mixture of clay and sand to hold the bricks together in the oven. This type of mortar will expand and contract at the same rate as brick.
- Follow the mix ratio ratio as recommended on the design. Typically, oven designs will instruct to mix 6 parts clay with 4 parts sand.
- For advice on bricklaying, ask a builder or the person at the material store. They can advise you on the right tools and equipment.
Part 4 of 5: Building a Brick Oven
Step 1. Make the oven stand
Use concrete bricks to make the oven stand. Lay the first layer of concrete brick in a rectangular shape with an opening in the front. Use a spirit level to make sure the layers are even. Continue laying concrete bricks until the oven is waist level.
- After the concrete bricks are stacked, fill each hole in the center with concrete mortar to hold it all together.
- The space in the oven stand can be used to store firewood.
Step 2. Install the core of the oven
Make a heart-shaped wooden frame. Next, place the wooden frame on the oven stand and fill it with concrete mortar. Use a long, straight wooden plank to spread the cement and let the mortar sit for a few days to dry.
Place the concrete frame into the wood frame as additional reinforcement before the cement mixture is poured
Step 3. Cover the core of the oven with refractory bricks
Lay a layer of refractory brick according to the shape of the oven in the design. Adhere with a thin layer of mortar made of 1 part sand and 1 part fire clay. Add water until the mixture becomes a thick slurry.
Ignore the temptation to use mortar to glue the fire bricks together. The cement mortar will not expand and contract with the bricks and will eventually crack
Step 4. Make the oven dome
Place the refractory bricks in a circular shape to make the walls of the oven. While installing, slowly tilt the row of bricks inward to form a rounded dome. You may have to cut the bricks into smaller sizes using a ceramic saw.
- Let the sand and clay mixture in each layer dry before you move on to the next step.
- Leave a hole in the back of the dome. This hole will be the exit of the smoke to the chimney.
Step 5. Build the chimney
Circle the hole behind the dome with a layer of refractory brick. Stack the bricks in a rectangular shape to make a tall chimney. The smoke from the oven will flow out the back and the chimney will direct it into the air.
You can also make the base of the chimney with refractory bricks and then buy a tall chimney tube made of iron. Install the chimney with cement mortar
Step 6. Create an oven opening
Use red clay bricks to make oven openings. This is where you put firewood and food. Traditionally, the opening of a brick oven is usually made in a curved arc. However, you can also create a rectangular opening if you want.
- Use a cement mortar to hold the clay bricks together.
- You can make the oven door out of wood or just use brick to cover the opening if necessary. Remember, closing the fireplace opening while the oven is in use will cut off the oxygen supply and allow the oven to cool, or even extinguish the fire.
Step 7. Cover the oven with insulation
Cover the entire oven with vermiculite-based insulating concrete cement. Allow the concrete insulation to dry according to the instructions on the product. Once dry, add a layer of red clay brick around the oven for a traditional oven look.
Part 5 of 5: Using the Oven
Step 1. Review the brick oven design
The design will tell you where and how to light a fire in a brick oven. Make sure you fully understand the process before starting the fire. If you try to cook without reading the instructions, the food may be scorched or undercooked.
Step 2. Purchase an infrared thermometer
Different foods require different cooking temperatures. An experienced brick oven expert can tell the oven temperature just by looking at it. However, if you are not experienced, just buy an infrared thermometer. It's a bit pricey, but it's an important investment for your cooking experience.
Follow product instructions when using an infrared thermometer
Step 3. Cook the pizza
Make delicious pizza in a brick oven using the “fire in the oven” method. First, light a big fire. Let the fire burn until it licks the oven ceiling. After that, push the flame to the back to make room for the pizza. Place the pizza directly on the bricks and bake with the oven door open for 1-3 minutes.
- The oven must be at 340-370 °C for the pizza to cook perfectly.
- You may have to add firewood every 15-20 minutes to keep the fire burning while the oven is heating.
Step 4. Bake the food overnight
Add firewood to the oven for a large fire that will burn slowly. Once it reaches a temperature of 260 °C, the oven is ready to be used for baking food. First, remove the charcoal from the oven to turn off the heat. Next, put the food to be baked and close the oven door. The residual heat from the fire will slowly roast the food over the course of the night.
- This method is best suited for grilling meat in large pieces.
- Food should be placed in a baking sheet and wrapped in aluminum foil.
Step 5. Bake a conventional dish
You can use the oven to bake at temperatures below 260 °C. First, turn on the heat in the oven. Once the temperature is right, remove the charcoal to turn off the fire. Put the food in the oven and close the door. The residual heat in the oven will roast the food.
