Forno Bravo Pompeii Oven Instructions Manual Download Page 1

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Forno Bravo, LLC

Pompeii Oven™ Plans Version 2.0

Build an Authentic Italian Wood-Burning Oven

A MAJOR CAUSE OF OVEN-RELATED FIRE IS FAILURE TO MAINTAIN REQUIRED

CLEARANCES (AIR SPACES) TO COMBUSTIBLE MATERIALS. IT IS OF UTMOST

IMPORTANCE THAT YOU FOLLOW PROPER SAFETY PRECAUTIONS IN ACCORDANCE

WITH THESE INSTRUCTIONS.

Forno Bravo, LLC

399 Business Park Court, #506

Windsor, CA 95492

(800) 407-5119

[email protected]

http://www.fornobravo.com

Pompeii Oven Instructions

Ver. 2.0

Summary of Contents for Pompeii Oven

Page 1: ...RED CLEARANCES AIR SPACES TO COMBUSTIBLE MATERIALS IT IS OF UTMOST IMPORTANCE THAT YOU FOLLOW PROPER SAFETY PRECAUTIONS IN ACCORDANCE WITH THESE INSTRUCTIONS Forno Bravo LLC 399 Business Park Court 50...

Page 2: ...ratures in the oven and use long oven gloves and mitts to handle pots and tools DO NOT put unprotected hands or arms inside oven while it is lit Dispose of ashes using a metal shovel and place in a me...

Page 3: ...ome 37 8 Building the Oven Opening 41 9 Finishing the Oven Dome 43 10 Oven Vent 46 11 Oven Arch and Door 49 12 Attaching the Chimney 51 13 Oven Dome Insulation 55 14 Enclosure Design Styles 57 15 Iglo...

Page 4: ...high and low heat and it excels at roasting and grilling It heats up quickly and is efficient at holding the high heats required for cooking the perfect three minute Vera Pizza Napoletana The Pompeii...

Page 5: ...p you get off on the right foot One of the great powers of the Internet is that it enables everyone to share ideas so that others can gain from your experience and you can learn from experienced build...

Page 6: ...h and rustic quality The stone cooking floor on these ovens is very uneven making cooking an adventure Like many other things the brick oven took a brief step backward after the fall of the Roman Empi...

Page 7: ...ur fire on one side and your food and pizza on the other side and in the back The entire oven can be easily reached With a 32 x 36 rectangular cooking floor in a barrel vault oven there is not a good...

Page 8: ...r oven More cold spots in a rectangular oven Pizza in a round wood oven Step 1 Pizza in a round wood oven Step 2 Pizza in a round wood oven Step 3 Pompeii Oven Instructions Forno Bravo LLC 2007 2009 A...

Page 9: ...ing in before they are locked in place with a keystone The higher curve of the Tuscan oven A taller first course and steeper lower dome characterize the Naples style oven A sample Naples style oven do...

Page 10: ...the opening between the stand s legs above the wood storage area An insulation layer to stop heat from escaping through the rigid platform and down into the stand legs A smooth surface on which the c...

Page 11: ...lat angle iron or a curved brick arch while the vent opening can be made from a range of decorative materials including brick stone decorative concrete or stucco You can build your own door or if you...

Page 12: ...or finish stucco The finish material must be waterproof The lower half of outdoor ovens that use a metal stand can be finished with metal studs and concrete board and both the metal and concrete block...

Page 13: ...ickness of your dome insulation the thickness of your oven enclosure and the depth of your vent landing and oven landing Use the table below to calculate the stand dimension for your specific oven 42...

Page 14: ...Top Elevation Pompeii Oven Instructions Forno Bravo LLC 2007 2009 All Rights Served Ver 2 0 14...

Page 15: ...Front Oven and Stand Cross Section Pompeii Oven Instructions Forno Bravo LLC 2007 2009 All Rights Served Ver 2 0 15...

Page 16: ...Cross Section Igloo Cross Section Walled Enclosure Pompeii Oven Instructions Forno Bravo LLC 2007 2009 All Rights Served Ver 2 0 16...

Page 17: ...Corner Installation 35 5 external width oven Corner Installation 40 external width oven Pompeii Oven Instructions Forno Bravo LLC 2007 2009 All Rights Served Ver 2 0 17...

Page 18: ...Corner Installation 43 5 external width oven Corner Installation 49 external width oven Pompeii Oven Instructions Forno Bravo LLC 2007 2009 All Rights Served Ver 2 0 18...

Page 19: ...The slab frame for a 5 14 cm foundation is best composed of 2x6 inch lumber set so the top of the form is 2 3 5 8 cm above ground level The longer form boards should sit inside the shorter boards and...

Page 20: ...cavate to a depth greater than the foundation form height you will need to add a material such as thoroughly compacted pea gravel or crushed rock which will allow for the drainage of water from under...

Page 21: ...40 80lb bags or more and mixing it by hand in a wheelbarrow might use up energy and time that will serve you better later in the project Rent a mixer from Home Depot and ask a friend or pay a local t...

Page 22: ...fourth course of blocks Photo 2 1 2 1 Angle iron supports the fourth block course For large commercial ovens it might be necessary to build a third leg supporting column in the center of the stand to...

Page 23: ...laid your first three courses set your two pieces of 2 x2 angle iron across the opening between the two legs of the U shape Note that the back piece of angle iron must be cut to allow clearance for th...

Page 24: ...s for the top course of the stand It provides security that the hearth will never sag causing serious problems to your oven and the added cost and time is low We also recommend dry stacking your block...

Page 25: ...2 8 Filling the cores Pompeii Oven Instructions Forno Bravo LLC 2007 2009 All Rights Served Ver 2 0 25...

Page 26: ...t from 2 8 lumber 38 235 mm and either 3 4 plywood or concrete board to form the bottom of the hearth Thermocouples If you are planning on using one or more thermocouples in the hearth and or cooking...

Page 27: ...oard and the outside edge of the stand to allow concrete to fill into the cores of the stand blocks The concrete hearth will be poured on top of the backer board and the backer board will stay in plac...

Page 28: ...Ready to pour Tips and Hints Cut your frame and plywood for the bottom of the hearth form about 3 8 shorter than the actual opening The concrete will not escape when you pour and it will be easier to...

Page 29: ...care to not reduce your insulating layer to less than 3 1 3 inches Take care with the additional mass under the oven The extra mass is only necessary for very high quantity bread baking All Pompeii Ov...

Page 30: ...ic fiber board in place and you do not have to use adhesive 4 2 FB Board on damp concrete For installations using insulating concrete and a 7 1 2 form draw a line 4 down from the top of the frame to m...

Page 31: ...ere your oven vent will begin and only pour vermiculite directly under the oven chamber and vent area Fill the form under the landing in front of the oven with standard concrete Photo 4 6 4 5 Insulati...

Page 32: ...5 1 A herringbone pattern Instructions These instructions show how to build a cooking floor using firebricks With this method you do not mortar the bricks in place but rather spread a thin layer of p...

Page 33: ...is is your true cooking surface Finally mark the location for the oven dome and landing to prepare for the next step Locate the true center of your oven using a tape measure and chalk line Photo 5 5 U...

Page 34: ...There are three fundamental methods for constructing the oven dome the first is a free standing dome where chains of self supporting brick circles are built on top of one another Photo 6 2 the second...

Page 35: ...m vanes about 8 help in maintaining the profile while not allowing the bricks to rest on the foam This method has been the preferred method of amateur builders To further explore the pros and cons of...

Page 36: ...o sand for firebrick clay Although it won t help at the core of the brick you can also let them soak in a bucket of water for a few minutes before you cut them This will reduce but not eliminate the d...

Page 37: ...ourse a half brick set upright The first course can be oriented in three ways First you can stand a brick cut in half upright 4 1 2 as show in Photo 7 1 Second you can lay a half brick on its side 2 1...

Page 38: ...ut your shim accordingly Photo 7 4 7 4 Cut your shims to match the trial dome layout Do not allow for an inside mortar joint as you will be setting the edges of the bricks facing inside the oven flush...

Page 39: ...ansfer the template to your brick and make your cut The keystone should be tight and require that you lightly tap it into place but not so tight that it causes the rest of the bricks in the chain to s...

Page 40: ...s of bricks round and level Known as The Indispensable Tool this homemade guide attaches to the center of the oven floor and rotates to constantly check the location of each bricks For more informatio...

Page 41: ...ng a metal fabricator build a complete doorframe and vent either from steel or cast iron Frame the opening with a stone or precast lintel The curved arch method is beautiful but difficult to build Hav...

Page 42: ...t fully sealing heat and steam inside the oven chamber and completely cutting off the air supply 8 6 The entry arch and vent has a clearly defined door stop Tips and Hints You can use The Indispensabl...

Page 43: ...e the oven dome Building the Form Because you will set the form in place through the oven opening you need to cut your form into pieces that will fit through it Cut a circular piece of plywood to the...

Page 44: ...lock in the chain Continue with your last few chains until you are down to a single brick that will close in your oven 9 4 Styrofoam forms The Final Keystone The final keystone is the brick that lock...

Page 45: ...t for backyard pizza baking or even restaurant pizza baking for that matter If you plan on baking large volumes of bread and want your oven to retain enough heat to bake multiple batches of bread from...

Page 46: ...it s own decorative arch made from brick or stone The vent itself can be hidden behind decorative material or if you like the metal vent look you can have an attractive vent fabricated and left on dis...

Page 47: ...The upper width of the vent is roughly 14 x14 while the bottom of the vent will depend on the width of your vent landing area Add chicken wire to give the vent structural integrity Pour the vent and...

Page 48: ...can either be attached to the oven enclosure without support walls a style that leaves the landing in front of the oven opening fully open Or it can be fully built in and supported by vent walls made...

Page 49: ...made for a door If a reveal is not made that is fine if you do not leave a reveal however your arch and supports for the arch should be flat so that a door can be accommodated 11 1 A decorative brick...

Page 50: ...door using FB Board be certain to fully enclose the FB Board in another building material FB Board is a ceramic fiber product that you should not come in contact with for long periods of time Other D...

Page 51: ...order to permit the flue liner to expand and contract freely The separation of the flue liner from the surrounding concrete or masonry shall not exceed the wall thickness of the flue liner Where Seis...

Page 52: ...el not less thinner than 26 gage in thickness or non combustible sheet material not more thicker than 1 2 in If it is necessary to pass through combustible walls to connect the oven to a chimney liner...

Page 53: ...t a wall pass through There shall be a minimum 6 152 4 mm separation area containing fiberglass insulation from the outer surface of the wall thimble to wall combustibles Support the wall thimble and...

Page 54: ...on to extend it Spark Arrestor Chimney Caps Use a spark arrestor chimney cap It uses heavy gauge steel and is similar in style to a window screen Its purpose is to trap burning embers that may float u...

Page 55: ...n ceramic products but they will do in a pinch The Forno Bravo Pompeii Oven Kit includes enough FB Blanket to fully insulate the oven dome with 3 of ceramic insulation As a rule of thumb FB Blanket pr...

Page 56: ...of the two 13 4 Loose vermiculite fills a walled enclosure Tips and Hints If your walled enclosure is significantly larger than your oven you can block off the corners with concrete board to minimize...

Page 57: ...stone Basically the style of the enclosure is up to you your imagination and the availability of local materials The examples shown here from around the country will give you a start For other design...

Page 58: ...Igloo Brick House Wall Oven Igloo Stone House Gabled House Pompeii Oven Instructions Forno Bravo LLC 2007 2009 All Rights Served Ver 2 0 58...

Page 59: ...Stone House Corner Oven Gabled Stone House Stone House Pompeii Oven Instructions Forno Bravo LLC 2007 2009 All Rights Served Ver 2 0 59...

Page 60: ...ly from the dome see Photo 15 4 Drill 1 4 holes around the perimeter of the oven hearth the distance you want away from the exterior of your oven to accommodate your insulation thickness Insert pieces...

Page 61: ...olor in stucco for your final Igloo finish coat They are waterproof and crack proof and they will even match a color swatch If you want true old world charm you can still opt for traditional three coa...

Page 62: ...Hardibacker concrete boards Interlock the top two metal stud top plates at each corner to give the structure more strength Set two vertical studs at each corner for a larger face to attach the concret...

Page 63: ...Board and FB Blanket 16 3 The layers of a walled enclosure oven using FB Blanket and vermiculite 16 4 Metal studs and a gabled roof 16 5 Metal studs walls with a shed roof Pompeii Oven Instructions Fo...

Page 64: ...and always center your concrete board seams directly on your vertical studs Use the flat head screws design specifically for attaching concrete board to metal studs as they do a good job of drilling i...

Page 65: ...ou have earned it For additional information on how to get the most from your Forno Bravo Casa oven read our guide to Wood Fired Cooking available on the Forno Bravo CD ROM provided with this oven and...

Page 66: ...plywood and a 2x4 Concrete mixer optional Rent one from Home Depot Tile saw optional You can get by with a diamond blade and a circular saw If you plan on using complicated tile brick or stone trim o...

Page 67: ...bricks depends on style About 50 lb lb masons mortar Chimney 9 round or 6 x10 24 36 clay flue liner Or 8 DuraTech anchor plate 24 36 chimney pipe and cap Material List 36 Oven 71 x 80 Foundation 30 8...

Page 68: ...optional About 30 or more common clay bricks depends on style About 50 lb masons mortar Chimney 6 round or 4 x8 24 36 clay flue liner Or 6 DuraTech anchor plate 24 36 chimney pipe and cap Hints and Ti...

Page 69: ...duty firebrick This is the basic fireplace firebrick stocked by many masonry supply stores They have a lower alumina content than a medium duty firebrick around 30 they have more non refractory impur...

Page 70: ...designed for continual high heat applications such as furnaces They are expensive and will get too hot for cooking food In general pizza wants heat between 750F and 900F while bread and roasts cooks...

Page 71: ...that are used for site built ovens Everyone knows how to install a pizza oven and how to cook in one and the prefabricated ovens are priced fairly The modular pizza oven kits outsell site built brick...

Page 72: ...he oven chamber as fast as you can replenish it With this design it is virtually impossible to maintain the high heat required for the perfect 3 minute pizza At the same time too little thermal mass c...

Page 73: ...hearth FB Board an engineered insulating panel provides an effective layer beneath the thermal layers of the oven floor The graphic below shows how heat is retained in a pizza oven and how it migrate...

Page 74: ...Appendix 5 Wood Fired Oven Anatomy Fig 1 The basic components of a wood fired pizza oven Pompeii Oven Instructions Forno Bravo LLC 2007 2009 All Rights Served Ver 2 0 74...

Page 75: ...at is more heat resistant than basic mason s mortar Portland cement with sand and lime Measure your ingredients by volume use a bucket or shovel to measure and mix only the amount you will us within a...

Page 76: ...While these old fashioned items are functional they are not are durable as modern materials and do not perform or last as well as state of the art materials Finally and perhaps most importantly the Po...

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