The Fire Brick D95 User manual

D95
Brick Oven
D95 PRECUT BRICK OVEN KIT
Instruction Booklet

2
Our Wood Fired Brick
Oven Kits are as
authentic as you can
get. With all the re
bricks cut to size, with
custom formwork and
tooling, building a
quality Brick Oven has
never been so simple.
D95

3
Table of Contents
CONTENTS
INTRODUCTION � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
BEFORE YOU BEGIN � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6
NOTES & UPDATES� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
SAFETY INFORMATION � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8
LIMITED WARRANTY � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 12
LAYOUT DRAWING � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13
WHAT’S IN THE KIT � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 15
ADDITIONAL TOOLS & MATERIALS REQUIRED � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 18
SUBFLOOR INSULATION � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 19
LAYING THE FLOOR TILES� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 20
BUILDING THE DOME� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 23
INSTALLING THE FLUE GALLERY� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 35
INSULATING THE DOME � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 36
OVEN LANDING & SURROUNDS � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 38
PERLITE RENDER � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 39
INSTALLING THE STANDARD FLUE � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 40
FLUE INSTALLATION TIPS � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 41
CURING THE OVEN� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 42
PAINTING� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 43

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You really don’t need to
be a skilled bricklayer
to put this kit together -
we have done all of the
dicult work for you.
You get the fun part, of
putting it all together.
Introduction

5
Introduction
BEN GUILFORD
DIRECTOR
Firstly, our congratulations and gratitude for the purchase of your D95 PreCut Brick
Oven Kit! We have spent years crafting and perfecting our PreCut Brick Oven Kits,
taking suggestions from customers and mentors, to create a product that we are truly
proud of. We’re very blessed to say that we now have thousands of happy customers
around the world, enjoying time with family and friends over meals cooked in the most
authentic way possible.
That is what it’s all about in the end - you’re not just building a Wood Fired Oven.
You’re building something that’s going to bring your family and friends together in a
shared cooking experience. You’re building something that you will spend quality time
with the people that you love around, where you are forced to slow down and just enjoy
what you’ve built. You’re building something that you can use to love and serve others;
it’s rare to see someone re up their oven just to cook for themselves alone. It’s always
about community, it’s about loving and dare I say, spoiling the people closest to you.
If there’s a piece of outdoor equipment that draws people together more than an
authentic Wood Fired Oven, I’m yet to nd it. May your oven bring you, your family and
friends nothing but joy (and the occasional burnt crust) for many years to come.
Introduction
Introduction

6
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.
The refractory bricks and insulation that make up our Wood Fired Oven Kits are very porous, so they will soak
up rain or melted snow that falls on them. This is not a problem in itself - if you re the oven up after the oven
has absorbed some water, the heat will drive the water out and the oven will return to its original state. However,
if your oven has gotten wet and experiences a deep frost, the water held in the re bricks and insulation may
freeze and expand, causing serious damage to the oven.
The sure way to prevent this is to build the oven into an enclosure that keeps it completely dry, so that when
the cold weather comes, it will have no adverse effect on the oven at all. If this is not possible, an alternative is
to re the oven thoroughly before the end of Autumn, then remove the ue and protect the oven with a suitable
weatherproof cover for the winter. The key is to keep the oven completely dry in deep cold conditions.
USING OUR INSTRUCTIONS
Building a Wood Fired Oven is a hugely enjoyable process, providing you take your time and pace yourself.
The best way to prepare for the build is to rst watch through the entire Instructional Video Series, from start
to nish. Then, read through these instructions in full so that you have a clear understanding of the process.
When you actually start building, take 15 minutes and watch the video that covers the part of the build that
you’re up to. These instructions are to help remind you of what you learned and give you more details where
they are needed. Remember, there is information in these instructions that is not in the videos, and vice versa.
That being said, if you’ve watched the videos, read the instructions and still feel even a little bit confused about
something, please call us right away� Part of what you’re paying for when you purchase one of our kits is
quality customer service - we are here to make sure you succeed in your Wood Fired Oven Building adventure!
Before You Begin

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Notes & 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. This is where we will make notes of these changes, where things have evolved
since the instructional videos were recorded.
1. The Refractory Mortar used to lay all of the bricks in the dome of the oven is now a two-part mix (in the
videos it was shown as a one part dry mix). This is to increase the shelf-life of the mortar, by keeping the
active ingredient separate in another bag. Close the tops of these bags after opening to help them keep.
2. The new Refractory Mortar mix used to lay the dome bricks sets far more quickly than its predecessor.
In the video series we suggest waiting until the following day to remove excess mortar from the inside
of the oven dome. We now recommend that you remove excess mortar as soon as possible, as it
will set very hard after 24 hours, particularly if you are building in a warm climate. This is especially
important when you are laying the nal courses of dome bricks on top of the breglass dome
formwork. If you are laying these nal courses over several days, it will be wise to lower the dome
formwork after you lay each course in order to remove excess mortar and clean your brickwork.
3. The D95 PreCut Brick Oven is very similar to its bigger brother - the D105, with one key difference. To
balance the thermal mass of the smaller oven dome with the thermal mass in the oven oor, we have
removed the 25mm Suboor Castable layer, so your 50mm re brick tiles will be mortared down directly
onto the aluminium foil layer that you cover the CalSil board with. This reduces the heat-up time of the
D95, while still giving you more than enough thermal mass in the oor to hold very stable temperatures.
4. If you plan to use your oven at extreme temperatures on a regular basis (in excess of 700°C), or are using
it for commercial purposes, then we recommend using the Refractory Castable to ll in large gaps on the
inside face of the oven. For example, when the dome courses start crossing the Entry Arch there are some
triangular sections that need to be lled in. If you’re using the oven normally, at temperatures below 700°C
then the Refractory Mortar will work perfectly. If you’re going to be using the oven commercially, or running
at extreme temperatures, then replace those sections of Refractory Mortar with Refractory Castable.
Updates

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Fire Safety
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, AN UNINTENDED FIRE MAY RESULT.
TO REDUCE THE RISK OF FIRE, FOLLOW THESE INSTALLATION INSTRUCTIONS.
PLEASE READ THIS SET OF INSTRUCTIONS IN FULL AND WATCH THE INSTRUCTIONAL
VIDEOS BEFORE INSTALLING AND USING YOUR OVEN.
FAILURE TO FOLLOW INSTRUCTIONS MAY RESULT IN FIRE, CARBON MONOXIDE
POISONING OR EXPLOSION LEADING TO PROPERTY DAMAGE, BODILY INJURY, OR
EVEN DEATH.
IF YOU HAVE ANY QUESTIONS AT ALL REGARDING THE SAFE INSTALLATION OF YOUR
OVEN, PLEASE DON’T HESITATE TO CONTACT US, WE’LL BE HAPPY TO ASSIST YOU.
Safety Information

9
Fire Safety
Clearances to Combustible Materials
A major cause of oven-related property re is failure to maintain the required clearances (air spaces) between
the oven and combustible materials. When 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.
If the oven is being built in close proximity to a structure (eg� beneath a pergola), the clearance from
combustible materials to the ue can be reduced by using a twin or triple skin ventilated ue system. If you’re
planning to do this the ue must be specied and installed by a licensed professional to ensure that the ue
system is compliant with the relevant standards and local laws for your area.
If in doubt, contact a qualied plumber or your local re authority for more information.
v
400mm
Above Oven
Clearance
750mm
Flue Clearance
750mm
Flue Clearance
700mm
Vent Brick &
Flue Gallery
Clearance
1200mm
Non Combustible
Floor Material
Clearance Zone
Combustible Material
Non Combustible
Material
Clearance Continues
50mm
Dome
Clearance
MINIMUM CLEARANCES ARE AS FOLLOWS;
50MM CLEARANCE TO COMBUSTIBLES
FROM ALL SIDES OF THE OVEN DOME�
400MM CLEARANCE TO COMBUSTIBLES
ABOVE THE OVEN DOME�
750MM CLEARANCE TO COMBUSTIBLES
FROM ALL SIDES OF THE STAINLESS STEEL
FLUE (UNLESS A MULTI-SKIN FLUE SYSTEM
IS INSTALLED)�
700MM CLEARANCE TO COMBUSTIBLES
FROM ALL SIDES OF THE VENT BRICKS AND
PRECAST FLUE GALLERY�
COMPLETE CLEARANCE ABOVE THE FLUE,
MAINTAINING 750MM RADIUS AROUND IT
(FOR ALL FLUE SYSTEMS)�
NON-COMBUSTIBLE FLOOR MATERIAL
SHOULD EXTEND 1200MM FROM THE
FRONT OF THE OVEN, FOR THE WIDTH OF
THE OVEN DOME, TO PROTECT AGAINST
FALLING HOT EMBERS�

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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 diculties. Repeated exposure to respirable silica may result in pulmonary brosis (silicosis). Silicosis is a bronodular lung
disease caused by deposition in the lungs of ne respirable particles of crystalline silica. Principal symptoms of silicosis are coughing
and breathlessness.
The following materials in your Wood Fired Oven Kit may contain respirable crystalline silica and a suitable dust mask should be worn
while handling them;
• Hybrid Refractory Bedding Mortar (marked Airset Mortar)
• Refractory Mortar Part A
• Refractory Mortar Part B
• Refractory Castable
• Fire bricks (when cutting or shaping them with a grinder)
• Perlite
• Calcium Silicate Board
While the Ceramic Fibre Blanket does not contain respirable silica, the bers are very irritating to the respiratory tract and can cause
irritation in the nose and throat, and chest discomfort. A suitable dust mask should be worn when working with the ceramic bre blanket,
until the rst layer of Perlite Render has been applied to seal the ceramic bre blanket from the atmosphere.
EYE PROTECTION
This is a very hands-on project and you are advised to wear safety glasses when mixing any of the materials or cutting/grinding bricks.
This also applies to applying the ceramic bre blanket insulation, which is irritating to the eyes. If in doubt, wear safety glasses!
SKIN PROTECTION
The mortar mixture that you’ll use to lay the re bricks in your Wood Fired Oven Kit is quite alkaline, and repeated exposure to your skin can
result in chemical burns. The same goes for the Refractory Castable and Perlite Render mixes. This is compounded by having to handle
wet bricks, which (if done without gloves) makes your skin softer and more vulnerable to being attacked by these materials. IGNORE THIS
AT YOUR OWN RISK! THE AUTHOR HAS PERMANENT SCARRING TO REMIND HIM OF THE IMPORTANCE OF WEARING GLOVES�
To avoid this, wear rubber ‘washing up’ gloves underneath ordinary gardening gloves to protect your skin. Rubber gloves alone may not
work well for long, as handling the re bricks can wear straight through them very quickly. There are some heavy duty rubber gloves
available at some supermarkers and hardware stores that work very well by themselves, as you will see in the instructional videos.
The key is to keep your hands dry, and if you notice a hole in the rubber gloves you would be well advised to replace them immediately.
Avoid rubber gloves with an elastic cuff at the wrist – these can rub your skin and leave it exposed to attack from the alkaline material
you’re handling. If your hands get wet inside the gloves, remove the gloves, dry your hands and put on a new pair of gloves, turning the
others inside out to dry so they can be used later. For this reason it’s worth having two pairs of rubber gloves.
The Ceramic Fibre Blanket can be irritating to the skin, with some people experiencing rash symptoms, so we have provided you with two
large plastic gloves that loop over your neck and cover the length of your arms. Wear these when handling the Ceramic Fibre Blanket.

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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 re may result. To reduce the risk of such a re, please follow our installation instructions
carefully. It is critical to use only the materials specied and provided to construct the oven.
Contact your local Building Authority, or Fire Authority regarding local laws for installation of this oven in your area.
OVEN IS HOT WHILE IN OPERATION. KEEP CHILDREN, CLOTHING AND FURNITURE WELL CLEAR. CONTACT WITH UNINSULATED PARTS
OF THE OVEN INCLUDING THE BRICKWORK AND CHIMNEY FLUE MAY CAUSE SKIN BURNS.
DO NOT BURN FLAMMABLE LIQUIDS OR WASTE MATERIALS IN THE OVEN.
DO NOT CONNECT THIS OVEN TO A FLUE ATTACHED TO ANOTHER WOOD BURNING APPLIANCE.
Keep children and pets away from the oven when it is hot, DO NOT leave children near the oven unsupervised.
Use good quality rewood for burning only. DO NOT USE charcoal, pressure treated timber, sappy timber, laminated timber or any material
other than well dried rewood. This does not apply to kindling.
DO NOT USE liquid fuel (relighter uid, gasoline, lantern oil, kerosene or similar liquids) to start or maintain a re.
BEWARE of very high temperatures in the oven and use long oven mitts or welding gloves rated above 400°C to handle pots, pans and
uninsulated tools.
DO NOT put any unprotected part of your body inside the oven while it is hot. The oven can remain hot without a re.
DO NOT close the oven door fully while a re is burning in the oven. Closing the door fully will cut off oxygen to the re, causing the re to
are up violently if the door is then removed. This does not apply to hot coals.
Dispose of ashes using a metal shovel and place in a metal bin with a snug tting lid. The container should be stored on a non-combustible
surface, away from all combustible materials. It is not necessary to empty the ashes from the oven each time it is used, empty as required.
Ensure the ashes are completely cold before disposing of them in an appropriate manner.
VERY IMPORTANT - BEWARE of sparks and embers ying out from the oven opening, as rewood can crackle and pop, sending embers
ying. Ensure no combustible materials are within range of the oven at any time.
DO NOT use water to extinguish the re or cool down the oven.
DO NOT ll the clearance spaces around the oven with sand, insulation or any other material.
Follow the instructions for Curing the Oven with care. Failure to follow these instructions may cause damage to the oven, poses a safety
risk to those nearby, and can void the warranty.
FOR YOUR SAFETY do not store or use gasoline or other ammable liquids or vapours in close proximity to the oven.
Ensure that an able bodied person of suitable age, who’s judgment is not impaired by alcohol, drugs or medication is present to monitor
and control the re from the time that it is lit to the time that it is extinguished.
Ensure that a suitable dry chemical or CO2 re extinguisher is on hand when the oven is lit.
Inspect the ue regularly for any buildup of soot, and remove excess soot if it is found.
If the oven is being built indoors, check with your plumber to ensure that the building has adequate ventilation to feed the re without
lowering the quality of air in the room, or risking a buildup of carbon monoxide.

12
Limited Warranty
The Fire Brick Company, a manufacturer of wood red 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.
QUALIFICATIONS TO THE WARRANTY
The complete Product Warranty outlined above does not apply under the following circumstances:
1. The Oven was not installed in accordance with The Fire Brick Company installation instructions and local building
codes.
2. The Oven has been subjected to non-standard use, such as burning fuels with abnormal burning characteristics including but
not limited to; driftwood, charcoal, plywood and material containing a binder that may burn at excessive temperatures and
cause damage to the Oven.
3. This Warranty does not apply to normal wear and tear.
4. This Warranty does not apply to any cracking caused by over-ring or the failure to follow a proper curing schedule.
5. On parts that would be normally worn or replaced under normal conditions.
6. Normal cracking due to expansion and contraction stress relief in the brickwork, precast ue gallery, render or oor tiles.
LIMITATION ON LIABILITY
It is expressly agreed and understood that The Fire Brick Company’s sole obligation and purchaser’s exclusive remedy under this Warranty,
under any other warranty, expressed or implied, otherwise, shall be limited to replacement, repair, or refund, as specied above, and such
liability shall not include, and purchaser specically renounces any rights to recover, special, incidental, consequential or other damages
of any kind whatsoever, including, but not limited to, injuries to persons or damage to property, loss of prots or anticipated prots, or loss
of use of the Oven.
In no event shall The Fire Brick Company be responsible for any incidental or consequential damages caused by defects in its Ovens,
whether such damage occurs or is discovered before or after replacement or repair, and whether or not such damage is caused by The Fire
Brick Company’s negligence. Some regions do not allow the exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you. The duration of any implied warranty with respect to this Oven is limited to the duration of
the foregoing warranty. Some regions do not allow limitations on how long an implied warranty lasts, so the above may not apply to you.
INVESTIGATION OF CLAIMS AGAINST WARRANTY
The Fire Brick Company reserves the right to investigate any and all claims against this Warranty and to decide upon method of settlement.
HOW TO REGISTER A CLAIM AGAINST WARRANTY
In order for any claim under this Warranty to be valid, The Fire Brick Company must be notied of the claimed defect in writing or by
telephone to The Fire Brick Company, Factory 11/167 Princes Hwy Hallam, Victoria 3803, Australia. Claims against this Warranty in writing
should include the date of installation, and a description of the defect.
Limited Warranty

13
D95 Layout Drawing
115 mm
Fire Brick Dome Wall
50 mm
Ceramic Fibre Insulation
50 mm
Perlite Render Insulation
7 inch
Stainless Steel Flue
950 mm
Internal Diameter
500 mm
540 mm
~ 150mm
Center of Flue
1380 mm
Overall Width
1475 mm
Overall Depth
50 mm
Fire Brick Tile Floor
PreCast Flue
Gallery
50 mm
Calcium Silicate Board
50 mm
Ceramic Fibre Insulation
50 mm
Perlite Render Insulation
115 mm
Fire Brick Dome Wall
1050 mm
Flue Height
695 mm
Oven Height
~ 790 mm
External Dome Height
475 mm
Internal
Dome Height
335 mm 345 mm
Layout Drawing

14
All of the bricks come
cut and ground to
size. We provide you
with templates, CNC
machined formwork, a
trammel tool, breglass
dome form and much
more. Your job is to
assemble the kit like a
big Lego set.
Kit Contents

15
Kit Contents
What’s In the Kit
CALCIUM SILICATE BOARD
3 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.
REFRACTORY CASTABLE
1 x Novaref Refractory Castable 25kg bag
Refractory Castable is premixed high temperature concrete, which you’ll use to pour the dome keystone.
FIRE BRICKS - OVEN DOME
All bricks for the Oven Dome are provided, carefully cut to keep the internal gaps on the inside face of the oven
to a minimum. These re bricks are 38% Alumina, rated to 1350°C and are 115mm thick.
FIRE BRICKS - FLOOR TILES
The Floor Tiles are all cut to size and ready to lay; the center tile has a 3mm hole pre-drilled in the center for
the trammel tool to lock into. The re bricks used in the oven oor are 38% Alumina, rated to 1350°C with an
exceptionally hard wearing surface, and are 50mm thick.
FIRE BRICKS - ENTRY & VENT ARCHES
The bricks for the Entry and Vent Arches that form the mouth of the oven are all cut to size from 38% Alumina
re bricks rated to 1350°C, ready to lay.
The Entry Arch Bricks (the opening into the dome) are machine-ground on their back face to follow the curvature
of the dome, to give you a smooth transition from the dome into the opening.
The Vent Arch Bricks are carefully selected as these will be on display at the front of the oven. They are all cut
to size, and are designed to lock into the Entry Arch for strength and stability.
FORMWORK - ENTRY & VENT ARCHES
We provide CNC machined timber formwork with your kit to construct the Entry and Vent Arches around, to
ensure that your brickwork is exactly as per our design. The Formwork is clearly marked to help you position
the arches accurately, and has machined markings showing the location and thickness of each mortar joint.
TRAMMEL TOOL
The trammel is a tool that you will clamp each dome brick into, enabling you to lay the dome bricks in a perfect
hemisphere. It has a hardened pin in the base that ts into the 3mm hole drilled in the center tile.
What’s Inside the Kit

16
What’s In the Kit
FIBREGLASS DOME FORMWORK
To lay the last few rows of bricks in the dome we provide you with a breglass dome form, made to the same
curve as the oven dome. It comes with a round timber support, to spread the load when you jack it into position.
HYBRID REFRACTORY BEDDING MORTAR
Dry Airset Refractory Mortar: 1 x 20kg bag
This is the mortar you will use to lay the re brick tiles that make up the oven oor. 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. This makes a smooth hybrid mortar mix perfectly suited to bedding down re bricks for
oven oors.
REFRACTORY MORTAR (TWO PART MIXTURE)
Refractory Mortar Part A: 3 x 25kg bags
Refractory Mortar Part B: 1 x 25kg bag
This is the mortar you’ll use to lay all of the remaining bricks in the kit. It is rated to ll joints up to 80mm width.
PRECAST FLUE GALLERY
The PreCast Flue Gallery is the molded section that ts over the brick arches at the front of the oven. Made
from refractory castable and reinforced with stainless steel bres, it’s tted with 7” Stainless Steel Flue sleeve,
ready to attach the ue section onto. A brushed stainless steel ring covers the ue expansion joint.
CERAMIC FIBRE BLANKET
One full roll and one half roll of 25mm thick Ceramic Fibre Blanket are provided, which will give you two full
layers over your brick dome for 50mm coverage which is precisely what we recommend.
PERLITE RENDER
LiteFill Perlite: 2 x 100L bags
This is the material you will use to cover the Ceramic Fibre Blanket layer, which you will be mixing with GP
Cement, Hydrated Lime and Washed Sand* to make a high-build Render mixture. There is enough Perlite in
the kit to build up a 50mm shell of render over the oven dome, with plenty left in reserve if some is wasted on
accident.
* Sand, Hydrated Lime and GP Cement are available at hardware stores and need to be purchased in addition to the kit.
STAINLESS STEEL FLUE & HAT
1 x 7” Stainless Steel Flue - 900mm Length 1 x 7” Stainless Steel Cowling
Kit Contents

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Kit Contents
What’s In 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. It can be tinted at most paint stores.
OVEN DOOR
The nal part of your kit is our Stainless Steel oven door, coated in a satin black nish. The handles are
beautiful oiled hardwood, with solid stainless steel rings top and bottom. The door comes with a vacuum
sealed temperature gauge accurate to 550°C (packed inside the bag of extras within the door box).
EXTRA ITEMS PROVIDED
• Plastic Strips to support the Timber Formwork • 12 x 125mm Nails
• Roll of Chicken Wire & Galv Tie Wire • 25 x 100mm Phillips Head Screws
• 2 x Long Sleeve ‘Vet Examination’ Gloves
OPTIONAL EXTRAS
WATERPROOFING SYSTEM
Roll of 150mm wide Aluminium Flashing and 1 x Cartridge of Sikasil High Temperature Silicone
To prevent rain being drawn into the oven from beneath the outer dome (the perlite render layer), install our
waterproong system around the oven perimeter prior to rendering. Only needed for outdoor installations.
HIGH TEMP SPRAY PAINT FOR PRECAST FLUE GALLERY
Spray can of PPG Temptec 328 in Satin Black. Great for painting the Flue Gallery to make it look sharp.
OVEN WALL TEMPERATURE PROBE WITH THERMOWELL
250mm Temperature Gauge with Stainless Steel Thermowell that can be mounted through the oven wall.
POLISHED GRANITE LANDING
Polished Granite sections cut to t around the Vent area, giving you somewhere to pull out heavy roasting trays
to check on your cooking. Also an important surface to allow you to use your Oven Door as a Draft Door.
STAINLESS STEEL WRAP
2mm thick, brushed Stainless Steel Wrap to cover exposed oor sections around the Vent area.

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Additional Tools & Materials Required
ADDITIONAL MATERIALS REQUIRED
• 3 x 20kg Bags GP (General Purpose) Cement
• 1 x 20kg Bag Hydrated Lime
• 3 x 20kg Bags Washed Sand
• Household aluminium foil
• Masking Tape
We don’t put these items in the kit for several reasons – they add a signicant amount of weight (which takes
the kits over 1000kg, greatly increasing the cost of freight), they’re available at all good hardware stores, and
we nd that some of our customers already have these materials on hand.
TOOLS REQUIRED
• Trowel
• Small Plastic ‘Flexi’ Tub for mixing Mortar & Castable
• Large Plastic ‘Flexi’ Tub OR a Wheelbarrow for mixing Perlite render
• Jigsaw with wood cutting blade
• Drill/driver for putting in screws
• Level
• Straight Edge (can be a straight piece of timber or metal)
• Stanley knife/scissors
• Car Jack
• Sponges, scourers & rags, old towel
• Angle grinder with masonry grinding disk
SAFETY GEAR REQUIRED
• Safety Glasses
• Ear Muffs
• Heavy duty rubber ‘washing up’ gloves (two pairs recommended, so that you always have a dry pair)
• P2 or equivalent rated Dust Mask
• Suitable clothing
• Safe access to climb onto your oven stand & fall prevention if working at height
Addition Tools & Materials Required

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1. Suboor Insulation
The rst step in building your oven is to prevent the heat in the oven oor 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.
1A: MARK CENTER LINE
Draw a line down the center of your top slab, this is
used to make sure your CalSil board and ultimately
your whole oven is positioned correctly, in the center
of your stand.
1B: CUT OUT CALSIL BOARD USING TEMPLATES
Using the provided paper templates, cut out your
CalSil board pieces using a jigsaw. We have provided
you with thumbtacks to hold the templates to the
CalSil surface.
1C: LAY CALSIL BOARD PIECES ON THE SLAB
Using the center line on your slab and the
corresponding line on the templates, position your
CalSil board pieces on your slab. There is no need to
‘glue’ these pieces down as the weight of the nished
oven will hold them in place.
If your concrete slab is at and level, you can lay the
CalSil directly onto the slab. If your slab is uneven use
a thin layer of brickies sand to bed the CalSil down, to
ensure that it’s uniformly supported.
Suboor Insulation
1D: COVER CALSIL WITH FOIL
Cover the top surface of the CalSil board with
aluminium foil, using the drawing pins provided.
Cover the joins with paper masking tape, this makes
the foil surface stronger and less likely to tear.
Transfer the centerlines that you had previously
marked onto your oven stand onto the foil layer.

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2. Laying the Floor Tiles
Fire bricks are very porous and will absorb a signicant amount of water, so if you apply wet mortar to a dry
re brick this mortar will dry out and will not develop a good bond. To overcome this, soak your re bricks in
water for at least 10 minutes before you lay them. Take the bricks out of the water shortly before you need
them, then when you grab a brick to lay, give it a dry on a towel or rag to remove any excess surface moisture.
You’ll be using the Hybrid Refractory Bedding Mortar mix shown below to bed the tiles down and get them at.
Remember - WEAR RUBBER GLOVES. This mortar is alkaline and can cause chemical burns!
HYBRID REFRACTORY BEDDING MORTAR MIXTURE
• 2 PARTS AIRSET REFRACTORY MORTAR
• 2 PARTS WASHED SAND
• 1 PART GP (GENERAL PURPOSE) CEMENT
• 1 PART HYDRATED LIME
These measurements are by volume (i.e. 2 cups Airset, 2 cups sand, 1 cup hydrated lime, 1 cup cement). Mix
well while dry, before adding enough water to make a smooth, thick mixture. Take a small trowel of the mortar
and hold it upside down, it should stick to the trowel. The pot life of this mix is around 20 minutes.
Get all of your oor tiles soaking in water, and mix up some mortar. Only prepare one small area at a time,
enough to lay a single tile. If you try to mortar a large area it will dry out before you have a chance to lay the tiles.
Spread a layer approximately 10mm thick on the top of the heat bank. Use your ngers to notch this mortar
mixture, to bed your tile into.
We designed the layout of the CalSil board to be about 20mm larger than the oor tiles all the way around the
perimeter of the oven oor, so that there is some tolerance on the positioning of your oor tiles. The extra area
extending around the dome of the oven will be covered by the insulating blanket and render layers, while the
sections protruding under the front and sides of the oven oor can either be cut back using an angle grinder if
you’re installing a stainless wrap to the exposed edges, or left in place and covered when a landing is installed.
Reminder - you need to watch the instructional videos to get a full understanding of the process, please don’t
rely on these written instructions alone. Don’t feel like you need to watch them all at once - just watch the
section that you’re about to do before you do it, so that it’s fresh in your mind.
Laying the Floor Tiles