Author Topic: Finally starting my build! (Read 15350 times)

Tscarborough · « **Reply #120 on:** June 24, 2018, 11:59:48 AM »

You add vermiculite/perlite to concrete to make it lighter, but it also reduces the strength by a significant amount. The purpose of the grog is to prevent cracking, and to reduce the amount of paste needed to make the concrete. It will increase the strength.

BANTAR1000 · « **Reply #121 on:** June 24, 2018, 05:46:52 PM »

Well crap... lol now I have to go take out some aggression!

BANTAR1000 · « **Reply #122 on:** June 27, 2018, 06:57:30 PM »

I think I'm gonna look for one of these! lol

BANTAR1000 · « **Reply #123 on:** June 22, 2019, 05:55:58 PM »

So I'm back to work again! But I'm not using a hammer, I'm using a big hammer drill to make grog with my fire bricks. My plan is a 2" wall all the way around the first sailor course up to the top of the first bricks. Is the mix for this concrete the same as usual just with fire brick rocks instead of regular aggregate? Also, how can I tell how much grog I'm gonna need? Yes, the hammer drill is easier than the metal plate and hammer posted before but it still sucks! LOL Thanks guys! -John

Jon in Albany · « **Reply #124 on:** June 22, 2019, 09:03:13 PM »

The mix I used was homebrew plus grog.

1 part hydrated lime, 1 part fireclay, 1 part Portland cement, 3 parts sand plus grog.

No idea how much you will need. I had a good sized box full of it it and thought I could have used some more. As the making of the grog continued, the size of the pieces got bigger out of laziness and possibly grog making fatigue.

BANTAR1000 · « **Reply #125 on:** June 22, 2019, 11:14:50 PM »

Wow, Jon I had this all wrong. I thought it was the

3 aggregate, 2 sand, 1 portland mix and I was just going to use firebrick grog instead!

How big was your box? I was planning on using 5, 5 gallon buckets full of grog!

Jon in Albany · « **Reply #126 on:** June 24, 2019, 12:16:05 AM »

I can't speak to that mix. I followed Tscarbough's lead from when he built and oven for Gene. You can see what he did in this area of the thread.

https://www.pizzamaking.com/forum/index.php?topic=20117.msg201915#msg201915

My oven is 42 inch diameter. I poured a 2 inch thick ring around the walls. I also added a little more to add mass to the dome.

BANTAR1000 · « **Reply #127 on:** February 15, 2020, 06:56:54 PM »

Again, I’m back at it this time hopefully for good. I’m still stuck at the refractory concrete for reinforcing the “Sailor” walls. I’ve found an easier way to make the firebrick grog, but I don’t know how much to make!

For a 2” thick wall all the way around 42 diameter I’m gonna use:
1 part Portland
1 part fireclay
1 part hydrated lime
3 parts sand
2 parts crushed fire brick
How much crushed fire brick will I need to have? I have one and a half 5 gallon buckets at the moment but plan to spend tomorrow making more. Thanks for checking on me!

BANTAR1000 · « **Reply #128 on:** May 08, 2020, 10:18:46 AM »

I need clarification. This is taking me so long because of work and kids. I took my tarp off the other day to start mortaring new bricks and several bricks fell over. It's very possible it was a very hot day when I did it and the mortar dried too fast. So, Is this correct:

homebrew refractory Concrete
1 portland, 1 fireclay, 1 hydrated lime, 3 sand, 2 crushed fire brick

Homebrew refractory Mortar
6 sand, 1 portland, 1 lime, 1 fireclay

Masonry is WAY too complicated for this banjo player!

Jon in Albany · « **Reply #129 on:** May 08, 2020, 11:35:58 AM »

In my build I used HeatStop 50 for mortar so I don't have hands on homebrew mortar experience. But the way I did it was the only difference between homebrew mortar and homebrew refractory concrete was the grog.

Homebrew mortar

1 Portland
1 Fireclay
1 Hydrated Lime
3 sand

Add grog to make it a concrete.

The 6 parts sand seems high, I'm wondering if you are crossing a perlcrete formula which I have seen have 6 to 10 parts of perlite in it.

BANTAR1000 · « **Reply #130 on:** May 08, 2020, 12:10:08 PM »

Thank you again Jon! That may have been an issue before. But now I feel better about it. I’m hoping to mortar the last of the low bricks today or tomorrow, then set my form for the concrete early next week!

BANTAR1000 · « **Reply #131 on:** May 08, 2020, 12:16:58 PM »

How far did one 50lb bag get you?

Jon in Albany · « **Reply #132 on:** May 08, 2020, 01:12:40 PM »

Quote from: BANTAR1000 on May 08, 2020, 12:16:58 PM

How far did one 50lb bag get you?

I think I used 3 bags plus some of a 4th on the build. If I was a better mason, it would have taken less than 3 bags. I had a plastic cup that I kept in the bag of heatstop. I'd scoop some into a plastic bowl and then add some water from a liter sport water bottle. Made what felt like a million small batches. Only make you need right away.

BANTAR1000 · « **Reply #133 on:** November 08, 2022, 11:24:48 PM »

Figured I'd keep to my original post for progress posts. I'm not happy that this proves it's taken me at least 5 years... But It's SO close! I will finish the roof this week, put the rest of the batten boards on the box, put in the perlite and ceramic blanket, then seal it and seal the concrete, then clean out the oven and start heating it up. Thanks for all the help!

BANTAR1000 · « **Reply #134 on:** November 12, 2022, 10:46:08 PM »

Super happy I got my lights installed. I'll post a pic of the new lights in the daytime. One of my friends gave me an old barn light that someone shot down from the front of his barn. It has a bullet hole in it! LOL I love the way this looks with everything on. I know it's a mess, but I'm not cleaning it up until I'm done with the oven!

BANTAR1000 · « **Reply #135 on:** December 01, 2022, 11:40:31 PM »

FIVE YEARS! And tonight my neighbor helped me clean out the inside with a portable dust collector, a wire brush and a great attitude. When we finished we decided to light a small fire just to watch it. I have a lot to learn about how to start and maintain a fire! I would love any suggestions anyone has for some videos on fire! Thanks

BANTAR1000 · « **Reply #136 on:** December 01, 2022, 11:42:06 PM »

I owe this guy a LOT of pizza!

BANTAR1000 · « **Reply #137 on:** December 28, 2022, 11:55:00 PM »

I used it finally! Cured it and had it up to 1075 on the first cook night. I decided to leave an access hatch in the back, so I could see the dome and really the huge pile of perlite on top of it. On top of the dome I have 4" of the ceramic fiber blankets, then on top of that I have about 3 inches of perlite. Once the oven got to around 1,000, I noticed either smoke or steam rising inside on top of the perlite pile. It wasn't much of either, but it was noticeable. Should I be concerned? Is there anything that I can do? Or, could this just be steam from the first big firing? Thanks for all y'alls help! -John

Jon in Albany · « **Reply #138 on:** December 29, 2022, 09:16:07 AM »

Not a lot of smoke at 1000 degrees so my guess is steam. When I built, I did have one spot where the chimney met the dome that had a little smoke come out that I patched up with mortar. It was noticeable, smelled of smoke, and was at low temps. If your hatch is still open, my guess is that this will be reduced during the next firing.

BANTAR1000 · « **Reply #139 on:** December 29, 2022, 10:51:18 AM »

Thanks Jon! I really appreciate it!