There are many oven shapes, ranging from rectangular ovens with sprung arch roofs (which require external steel support for the arch) to barrel arches with vertical end walls and various dome or igloo shapes.
The sprung and barrel arch designs can be constructed entirely with medium- or high-duty firebrick for the hot face. The dome type can use either firebrick (which requires a lot of cutting) or can be cast utilizing high-temperature concrete, appropriately called castable. A firebrick is still required for the hearth when casting an oven.
One needs a form made from wood, styrofoam, or compacted wet sand to cast a dome. Cover the form with polyethylene sheeting to keep the water from the castable from being absorbed by the form.
The insulating layer is typically a lightweight insulating castable (25 to 120 pounds per cubic foot density) rated to 1800 to 2000 degrees Fahrenheit. This castable should be used on the concrete block or poured concrete base. It is also used over the outside walls and roofs built with firebrick or dense castable. To minimize potential cracking of the lightweight castable over the outside walls and ceiling, first, using a 1” layer of 6# density ceramic fiber blanket and then putting the lightweight castable on top is a good solution.
The hot-face hearth can be constructed with larger firebrick tiles to minimize joints in the cooking surface compared to regular firebrick. Note: Refer to Firebrick 101 and Economical Composition for Kilns on our website to further understand the available sizes and shapes.
All mating brick surfaces should be mortared using a refractory air-set mortar. The joints are thin, typically 1/16th to 1/8th inches thick.
Larkin Refractory Solutions is your trusted source for all the materials needed to build durable and efficient outdoor ovens of any type. Whether you’re constructing a pizza oven, bread oven, or custom outdoor kitchen, we offer a full range of refractory supplies to ensure optimal heat retention and performance. From dense and insulating firebrick to ceramic fiber products and castable refractories, we provide high-quality materials designed to withstand the high temperatures and environmental conditions outdoor ovens face. With our extensive inventory and fast, reliable service, Larkin can help you build the perfect outdoor oven, ensuring long-lasting results and consistent heat performance.
