aloha pompeii pizza oven assembly
DESCRIPTION
This is how we built our local-fired-clay-bricked-wood-fired-domed-Italian-pizza oven step by step. Get the bricks first! Enjoy! We baked 2x per week for the orphanage and our customers. Sour dough, whole wheat french bread, pan de sal, bagels and pizza galore. We also roast free range chicken, Peking duck, turkey, pork ribs and beef. As the bricks retain heat for days we also dry moringa for our capsuled products as well as artemesia, mint teas and other medicinals.TRANSCRIPT
The Oven of GreatnessThe Oven of GreatnessAA Pompeii OvenPompeii Oven
Bread, Pizza, Roast Poultry and Stews will never be the same
AlohaHouse
AlohaRanchand
OrganicFarm
Appendix 2. Brick PrimerDeciding what type of brick you will use is one of the first choices you will have to make when starting to build a Pompeii Oven. You will use brick in the cooking floor, the oven dome and perhaps for your decorative vent arch, oven landing and other decorative trim.
Medium duty firebrick.We recommend medium duty firebrick for both the cooking floor and dome of the Pompeii oven, and it is the type of firebrick we provide as part of the Pompeii Oven Kit. Medium duty firebricks are comprised of roughly 38% alumina, and are highly compressed and kiln fired. They heat up quickly, easily withstand the 1000oF heat your oven will reach, and are designed for the rapid heat-up and cool down (thermal cycling) that your oven will experience. This type of firebrick will also reach the heat required for baking Pizza Napoletana pizza quickly than clay brick, as they are more efficient at conducting heat.Further, because firebrick is designed to withstand thermal cycling, your oven will last longer, though for most home ovens this is not an important issue, and your oven will probably outlast you—whichever brick you choose.
Low 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% alumina), they have more non-refractory impurities, and they are less dense. That said, low duty firebricks are a good choice for building a Pompeii Oven, and other than considering the Pompeii Oven Kit from Forno Bravo, it is not worth the effort of trying to find a higher quality firebrick in your region.
Red clay brick.Clay bricks are made from clay, and fired in a kiln. They are typically made from local clay, as shipping is too expensive, and fired to between 2000F - 3000F (high enough to fuse the minerals). You can use clay brick in the oven dome, but we would not recommend using them in the oven floor. There are trade- offs to consider.There are two shortcoming to using a clay brick in your oven dome. First, thermal cycling will cause clay brick to spall, where little pieces of the brick flake off, and could cause individual clay bricks to crack. It has happened to us. Second, clay brick is not as good a conductor as fire brick and as a result will take longer to heat up.They are a cost-effective option.however, a 42" oven some has roughly 180 bricks in the dome, so the difference in brick cost should be around $100. In the context of the overall cost of the oven, and large amount of human capital you will be investing in your oven, we think the extra cost of worth it.
If your choice is to build your oven with clay brick or not at all, we would strongly recommend building your oven with clay brick.
Pompeii 110 kit140 9”x4.5”x2.5” firebricks; 20 12”x12”x2.5” floor tiles 165 lbs. high temperature, waterproof mortar (FB Mortar) 80 kiloThree 50 sq ft 1” insulating blankets (FB Blanket) Three 24”x36”x2” insulating boards (FB Board) Weight: about 2,000 pounds
Cooking FloorAbout 65 full firebricks, set on their flat sideFine mesh sand and fireclayOven DomeAbout 135 full firebricks, cut in half About (150-200) lb. FB Mortar high heat mortar
Mix 1
Mix 3
Mix 1
Mix 1
Mix 4
Mix 1 Hearth Insulation1 part Portland cement 6 parts PerliteDry mix then add water
Mix 2 Stove Landing and chimney buffer Insulation½ part Portland cement ½ part Red cement1 part fine sand 1 part PerliteDry mix then add water
Mix 3 Under Brick Oven Floor Paste 1 part fine sand 1 part fireclayAdd water until you reach the texture of a sticky mortar (but without the cement). Spread the under floor using a notched trowel as the ridges will make it easier to get the floor perfectly levelThe process is similar to setting ceramic tiles.
Mix 4 Portland cement Fireclay Mortar Formula 1 part Portland cement 1 part sand 2 parts volcanic rock powder 1 part lime 1 part fireclay
Dome height to opening height ratio for optimum air exchange
hd/w = 32/53 = 61%
The Golden Ratio
Opening height to opening width ratio for optimum air
exchangeho/wo = 32/51 = 63%
42" High Vault Pompeii Oven107 cm Interior Diameter 53 cm hd = Interior Dome Height 51 cm wo = Opening Width 32 cm ho = Opening Height
3D modeling
3D modeling
Mix 1
Mix 3
Mix 1
Mix 1
Mix 4
Mix 0 Hearth Concrete w/steel1 part Portland cement 6 parts sand/gravel
Mix 1 Hearth Insulation1 part Portland cement 6 parts PerliteDry mix then add water
Mix 2 Oven Landing and chimney buffer Insulation1/4 part Portland cement 1/4 part Red cement1 part fine sand 1 part PerliteDry mix then add water
Mix 3 Under Brick Oven Floor Paste 1 part fine sand 1 part fireclayAdd water until you reach the texture of a sticky mortar (but without the cement). Spread the under floor using a notched trowel the ridges will make it easier to get the floor perfectly level
Mix 4 Portland cement Fireclay Mortar Formula 1 part Portland cement 1 part sand 2 part volcanic rock powder, 1 part lime, 1 part fireclay
Mix 0
3D modeling
Mix 0
Hearth Construction Mix 0 Concrete w/steel
1 part Portland cement 6 parts sand/gravel
Hearth Construction
Ash slot
3 days
Mix 1 Hearth Insulation1 part Portland cement 6 parts PerliteDry mix then add water
Insulation slab
3 days
5”
Mix 1 Hearth Insulation1 part Portland cement 6 parts PerliteDry mix then add water
Mix 0 Concrete w/o steel
Insulation slab
Ash slot
3 days
Mix 1 Hearth Insulation
Mix 0 Concrete w/o steel
Oven FloorMix 3 Under Brick Oven Floor Paste 1 part fine sand 1 part fireclayAdd water until you reach the texture of a sticky mortar
Day 1
Oven FloorMix 3 Under Brick Oven Floor Paste 1 part fine sand 1 part fireclayAdd water until you reach the texture of a sticky mortar
Herring bone configurationMinimizes peel snag
Day 1
Dome construction
1st coarse
Mix 4 Portland cement Fireclay Mortar Formula 1 part Portland cement 1 part sand 1 part quartz rock powder 1/2 part volcanic rock powder 1/2 part rock powder 1 part fireclay 1 part lime
Mix 4
Entrance Arch
Dome bricks NOT on floor
bricks
Day 2
Dome construction
1st coarse
Mix 4
Day 2
The plan
Day 2
Ash slot
Insulation slab
Day 2
Dome construction
3rd coarse
Foam guide/support
Plaster as you go every two coursesMix 4
Day 2
Oven Landing Insulation Mix 2 Oven Landing and chimney buffer Insulation1/4 part Portland cement 1/4 part Red cement1 part fine sand 1 part Perlite
Day 2
Ash slot
Oven Landing Insulation Mix 2 Oven Landing and chimney buffer Insulation1/4 part Portland cement 1/4 part Red cement1 part fine sand 1 part Perlite
Day 2
Ash slot
Oven Landing Insulation
Day 2
Ash slot
Oven Landing Insulation
Mix 2 Oven Landing and chimney buffer Insulation1/4 part Portland cement 1/4 part Red cement1 part fine sand 1 part Perlite
Insulation buffer between front arch and dome entrance
Day 2
Front Arch Form
InnerArch Form
Chimney Forms
Day 3
7th course
Dome Entrance Arch
Day 3
Mix 4
Dome Entrance Arch
Front Chimney Arch
Day 3
Dome isolation gap
Dome isolation gap
Dome Arches
Day 3
Top View
Closing In
Day 3
Mix 4
Chimney Form
Day 4
Dome Entrance Arch
Landing and Ash Slot
Insulation buffer between front arch and dome entrance
Day 4
Inner Arch Form
Day 5
Chimney Revealed(and scored for finish plastering)
Day 5
Closing InThe final coarse and keystone
Day 6
Mix 4
Closing InThe final coarse and keystone
Day 6
Closing InThe final coarse and keystone
Day 6
Mock finish 4Simulation 1
Mock finish 4
Today’s Specials
Fresh baked pamdesalPumpkin PieBasil Pizza
Simulation 1
Day 7
Fire clay mortar dome finish
Mix 4
Day 7
3” Insulation coat
Perlite Mix 1
Day 7
Outer wall to retain horticultural Perlite
insulation
Day 8
Insulation coat Perlite
w/cement Mix 1
Outer wall to retain horticultural Perlite
insulation
Day 9
Outer wall to retain horticultural Perlite
insulation
Day 9
Outer wall stone finish
Day 10
Outer wall stone finish
Day 11
Grout
Outer wall stone finish
Day 11
Grout
Outer wall stone finish
Day 11
Outer wall stone finish
Simulation 2
Day 12
Simulation 3
Day 13
Back wallCement boardPlasterRoofBottle light
Oven frontGroutMuriatic acidSealantBlack boardTile and trimWood Beams - Sand finish with coconut oilDoor - frame / hinges
OvenDome cleaning inside
FloorFinish - concretePlaster - Clean out and small wallClean out - cut lid
Work order 2-21-2012
Day 13
Finishing tiles and stone work
Day 14
Finishing wood work
Curing 2 weeks then:First Firing 300 ℉ 148 max. 12 hrs.℃2nd day 350 ℉ 175 max. 12 hrs℃3rd day 400 ℉ 205 max. 12 hrs℃4th day 450 ℉ 230 max. 12 hrs℃5th day 500 ℉ 260 max. 12 hrs℃6th day full firing ready for use
Day 21
Curing 2 weeks then:First Firing 300 ℉ 148 max. 12 hrs.℃2nd day 350 ℉ 175 max. 12 hrs℃3rd day 400 ℉ 205 max. 12 hrs℃4th day 450 ℉ 230 max. 12 hrs℃5th day 500 ℉ 260 max. 12 hrs℃6th day full firing ready for use
Full firing ready for use
Each split and properly dried log contains approx. 15,000 - 25,000 BTU ’s
Thermal Mass
Low thermal mass
quick heating
Less time to use oven Fewer Sessions, 1-2 batches
High thermal mass
slower heating
More time to use ovenMore Sessions, 6-8 batches
200,000 BTU10-12 logs1 hr 10 minutes
500,000+ BTU20-40 logs2-4 hrs
1. radiant heat from the bricks2. convection from the movement of steam3. conduction from the bricks
lbs./cord million BTU
Dogwood, Pacific Cornus nuttallii 3,995 24.8Holly, American Ilex Opaca 3,995 24.8Birch, Black Betula lenta 3,910 24.2Oak, White Quercus alba 3,910 24.2Madrone, Pacific (Arbutus)Arbutus menziesii 3,825 23.7Bamboo Poaceae bambusoideae 1,615 10.0 Firewood: 80 cubic feet per cord
4 feet high, 4 feet deep and 8 feet long, = 128 cu ft, but we deduct for air space
Est 24,000,000 btu/cord / 80 cu ft/cord=300,000 BTU/cu ft
Brick and Mortar BTU Estimate
DimensionsCubic footClay brick
Volume
Wood that has been seasoned for 9-12 months still contains about 20-25% moisture, most of which is wood resins. These resins play an important part in the three stages of wood combustion.
Stage 1 - the kindling fire warms up the fresh load of wood and any remaining water content is removed by evaporation and vaporization.
Stage 2 - As the wood reaches 500 degrees the resins begin to break down chemically, and volatile gases are released which squirt out through the wood fiber and ignite, boosting the temperature of the fire to around 1,100 degrees and producing 50-60% of the heat value from that load of wood.
Stage 3 - As the gases burn away, the flames finally attack the wood fiber itself, and extract the remaining heat value through the process known as charcoaling.
If your firewood has dried to the point where it has lost its resin content, your fire will go directly from Stage 1 (warming up to combustion temperature) to Stage 3 (charcoaling), skipping Stage 2 and missing out on 50-60% of the heat (and burn time) you'd expect to get from that load of wood
Seasoned Wood
Costing
Qty unit cost total Particulars
390 brick 10 3,900.00 bricks - outer
240 brick 16 3,840.00 bricks - fired clay
22 20 L pail 20 440.00 sand
6 large sacks 390 2,340.00 Coolite - Perlite
1 20 L pail 400 440.00 fired clay powder
2 20 L pail 400 800.00 Lava rock powders
1 20 L pail 200 200.00 Fine limestone
1 4 x 8 233 233.00 Cement board
11 40 kl sack 251 2,761.00 Portland cement
1 40 kl sack 290 290.00 Red cement
2 lights 200 400.00 Bottle light
2 qt 623 1,246.00 Sealant
20 30 x 30cm 45 900.00 Tile
3 8 ft strips 120 360.00 Tile and trim
1 6" x 8" x 8' 850 850.00 Wood Beams
4 hinges 200 800.00 SS hinges
2 2' x 3' doors 325 650.00 Cabinet Door
19,800.00 MATERIALS COST
man days daily wage
20 350.00 7,000.00 Labor
26,800.00 TOTAL COST
Italian Noun pizzaiola f (plural pizzaiole) (feminine of pizzaiolo)
1. woman who makes pizzas in a pizzeria
Italian
Nounpizzaiolo m (plural pizzaioli)pit.tsa.ˈjɔ.loman who makes pizzas in a pizzeria
pizzaiola f (plural pizzaiole) (feminine of pizzaiolo)pit.tsa.ˈjɔ.la 1. woman who makes pizzas in a pizzeria2. a pasta sauce made with tomato and oregano
The Vera Pizza Napoletana Guidelines for certification:
1. A Wood-Burning Oven:
Pizza Napoletana must be cooked in a wood-fired dome oven. Gas, coal or electric ovens, while capable of produce wonderful pizza, do not conform to the Pizza Napoletana tradition.
2. Proper Ingredients:
Tipo 00 flour, San Marzano (plum) tomatoes, all natural Fior-di-Latte or Bufala mozzarella, fresh basil, salt and yeast. Only fresh, all-natural, non-processed ingredients are acceptable.
3. Proper Technique
Pizza dough kneaded either by hand, or with a low speed mixer. No mechanical dough shaping, such as a dough press or rolling pin, and proper pizza preparation. Pizza baking time should not exceed 90 seconds.
4. Proper Equipment
A proper work surface (usually a marble slab) and a wood-fired oven operating at roughly 800ºF.
5. The Final Product: Pizza Napoletana
Pizza Napoletana is not larger than 14 with a raised edge crust and thin (.11 inch) center. The pizza should be soft and elastic, and easily foldable, not hard or brittle.
The Vera Pizza Napoletana
San Marzano tomato DOP, grown in the rich soil of
Campania is the perfect pizza sauce tomato. The flesh is
firm, and can be easily worked into a bright and
fresh pizza sauce; perfect for your wood-fired pizzeria.
Palawan Creamery
Take out Or Dine in
Aloha Creamery
Take out Or Dine in
Dome height to opening width ratio for optimum air exchange
h/w = 32/51 = 63%