Aloha Pompeii assembly

The Oven of Greatness
A Pompeii Oven
Bread, Pizza, Roast Poultry and
Stews will never be the same
Aloha
House
Aloha
Ranch
and
Organic
Farm

Pulled coals for rocket stove and Dutch oven

Appendix 2. Brick Primer
Deciding 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 quicker 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 dome 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.

Cobb
Sand clay chopped straw
Rammed earth
Sand clay ricehull stabilizer
Clay fired brick
Local compressed bentonite and sand
Refractory brick
Commercial high alumina brick
Inexpensive  more expensive  most expensive
Short lasting  longer lasting  longest lasting

Cooking Floor
About 65 full firebricks, set on their flat side
Fine mesh sand and fireclay
Oven Dome
About 135 full firebricks, cut in half
About (150-200) lb. FB Mortar high heat mortar
Portland cement Fireclay Mortar Formula
• 1 part Portland cement
• 1 part non silica sand
• 2 parts rock powder - volcanic, granite
• 1 part hydrated lime
• 1 part fireclay
42" High Vault Pompeii Oven
107 cm Interior Diameter
53 cm Interior Height
32 cm Opening Height
52 cm Opening Width
Pompeii 110 kit
140 9”x4.5”x2.5” firebricks;
20 12”x12”x2.5” floor tiles
165 lbs. high temperature, waterproof mortar (FB
Mortar) 80 kilo
Three 50 sq ft 1” insulating blankets
(FB Blanket)
Three 24”x36”x2” insulating boards (FB Board)
Weight: about 2,000 pounds

Mix 1
Mix 3
Mix 1
Mix 1
Mix 4
Mix 1 Hearth Insulation
1 part Portland cement
6 parts Perlite
Dry mix then add water
Mix 2 Stove Landing and chimney buffer Insulation
½ part Portland cement
½ part Red cement
1 part fine sand
1 part Perlite
Mix 3 Under Brick Oven Floor Paste
1 part fine sand
1 part fireclay
Add 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
level
The process is similar to setting ceramic tiles.
Mix 4 Portland cement Fireclay Mortar Formula
1 part sand
2 parts volcanic rock powder
1 part lime
1 part fireclay

Low dome
Pizza mainly
Dome Options
1 Bread loaf

Low dome
Pizza mainly
Mid dome
Pizza and bread
Dome Options
1 Bread loaf 2 Bread loaves

Low dome
Pizza mainly
Mid dome
Pizza and bread
High dome
Bread
and Pizza
Dome Options
3 Bread loaves

Low dome
Pizza mainly
Mid dome
Pizza and bread
High dome
Bread
and Pizza
High dome
Bread and Pizza with
replaceable floor
Dome Options
3 Bread loaves Turkeys, hams, roasts

Fire Brick
Oven Floor Paste
Insulation
Hearth
Insulation
Refractory Grout
Build Order
Igloo style

Hearth
Insulation
Façade type

O2
CO2
Opening height to Dome height ratio for
optimum heat retention
ho//hd = 63%
hohd
Opening
and door

O2
CO2
ho//hd = 63%
Low
Opening
and door

O2
CO2
High
Opening
and door
ho//hd = 63%

O2
CO2
Start up T.L.U.D.
(Top Light Up Draft)
Appropriate Technology
Make Fuel Cell Cube
H = L = W
Low smoke / maximum heat

O2
CO2
CO
Volatile oils
Syngas
No insulation

O2
CO2
Ash slot
Chimney cross section should be at
least ½ oven opening area
Optional ash slot for
ease of cleaning

The Golden Ratio
Flame roll
(torus)

The Golden Ratio
Opening height to opening width
ratio for optimum gas exchange
63%

Opening height to Dome height
ratio for optimum heat retention
ho//hd =63%
The Golden Ratio
Opening height to opening
width ratio for optimum air
exchange
ho/wo = 32/51 = 63%
42" Wide Vault Pompeii Oven
107 cm Interior Diameter
53 cm hd = Interior Dome Height
51 cm wo = Opening Width
32 cm ho = Opening Height
a/a + b/a=a/b

Golden Angle
137.5˚
Golden Ratio
A/B = B/(A+B)
The smaller to the larger is equal to the larger to the whole
(sum of the two)
Approx. 63%

PHILIPPINES
Puerto Garden Resort
PHILIPPINES

Width does not equal interior dome height
PHILIPPINES
Puerto Garden Resort
PHILIPPINES

Oven opening too high plus chimney too small
Small chimney
releases smoke
outside chimney
Italian built
PHILIPPINES
Farah Lily Resort

Small chimney
releases smoke
outside chimney
Italian built
PHILIPPINES
Sheridan Beach Resort
PHILIPPINES

Small chimney
releases smoke
outside chimney
Italian built
PHILIPPINES
Hibiscus Resort

Small chimney
releases smoke
outside chimney
No insulation
High opening

Chimney inside
dome loses heat
Cement structure
never heats up?!?
Spaniard built
PHILIPPINES
Qi Resort, El Nido
Palawan

Cob oven without
chimney releases
smoke and heat
into restaurant
Hippy built
MAUI, HAWAII

Small chimney
releases smoke
outside chimney
Neva’s Pizza
Palawan

Commercial bread in Palawan
Side fed fuel
separate from
product door
Clogged ash slot

3 burner rocket stove with
cover removed
Consumes more fuel than
necessary without insulation bricks

Bench Mark
3 stone fire
Water Boil Test
Wood weight fired
to boil 2 liters of
water
BTUs to rolling boil
Many designs are less efficient than the 3 stone fire
http://www.lowtechmagazine.com/2014/06/thermal-efficiency-cooking-stoves.html

Bench Mark
3 stone fire
Many designs are less efficient than the 3 stone fire
For three-stone fires, thermal efficiency is stated to be as low as 10 to 15%.
Water Boil Test

0
20
40
60
80
100
120
Willingness to Share Knowledge
Zero Knowledge Little Knowledge Some Knowledge Growing Knowledge
“Advocacy”
Mount Stupid
Actual Experience and growing success

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20
40
60
80
100
120
Mount Stupid
Actual Experience and growing success

Ovens can be rated on thermal efficiency
Suggested ratings
1.Dough baked / firing 11 kgs.
2.Time to fully charge 105 min.
3.Baking time 300 down to 150º C 300 min.
4.Temp. after 24 hrs. (door closed) 105º C
5.Quantity wood / firing 80 kgs.*
6.Energy / firing 250,000 BTUs

Mix 1
Mix 3
Mix 1
Mix 1
Mix 4
Mix 0 Hearth Concrete w/steel
6 parts sand/gravel
6 parts Perlite
Mix 2 Oven Landing and chimney buffer Insulation
1/4 part Portland cement
1/4 part Red cement
1 part fine sand
1 part Perlite
1 part fine sand
1 part fireclay
Add 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 sand
2 part volcanic rock powder,
1 part lime, 1 part fireclay
Mix 0

Mix 0
Hearth Construction
Mix 0 Concrete w/steel
6 parts sand/gravel
Hearth Construction
Ash slot
3 days

6 parts Perlite
Insulation slab
3 days
5”

6 parts Perlite
Mix 0 Concrete w/o steel
Insulation slab
Ash slot
3 days

1 part fine sand
1 part fireclay
Add water until you reach the
texture of a sticky mortar

Mix 0 Concrete w/o steel
Oven Floor
1 part fine sand
1 part fireclay
Day 1

Oven Floor
1 part fine sand
1 part fireclay
Herring bone configuration
Minimizes peel snag
Day 1

Dome construction
1st coarse
Mix 4 Portland cement Fireclay
Mortar Formula
1 part sand
2 parts volcanic 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

Ash slot
Insulation slab
Day 2

Dome construction
3rd coarse
Foam guide/support
Plaster as you go every two courses
Mix 4
Day 2

Oven Landing Insulation
1/4 part Red cement
1 part fine sand
1 part Perlite
Day 2

Ash slot
1/4 part Red cement
1 part fine sand
1 part Perlite
Day 2

Ash slot
Day 2

Ash slot
1/4 part Red cement
1 part fine sand
1 part Perlite
Insulation buffer between front
arch and dome entrance
Day 2

Front Arch Form
Inner
Arch 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

Top View
Closing In
Day 3
Mix 4

Dome Entrance Arch
Landing and Ash Slot
Insulation buffer between front
arch and dome entrance
Day 4

Chimney Revealed
(and scored for finish plastering)
Day 5

Closing In
The final coarse and keystone
Day 6
Mix 4

Closing In
The final coarse and keystone
Day 6

Mock finish 4
Today’s Specials
Fresh baked pamdesal
Pumpkin Pie
Basil 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
insulation

Day 9
insulation

Day 10
Outer wall stone
finish

Day 11
Grout
Outer wall stone
finish

Day 11
Outer wall stone
finish

Day 13
Back wall
Cement board
Plaster
Roof
Bottle light
Oven front
Grout
Muriatic acid
Sealant
Black board
Tile and trim
Wood Beams - Sand finish with coconut oil
Door - frame / hinges
Oven
Dome cleaning inside
Floor
Finish - concrete
Plaster - Clean out and small wall
Clean out - cut lid
Work order 2-21-2012

Day 13
Finishing tiles and stone 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 oven
More Sessions,
6-8 batches
200,000 BTU
10-12 logs
1 hr 10 minutes
500,000+ BTU
20-40 logs
2-4 hrs
1. radiant heat from the bricks and flames
2. convection from the movement of steam
3. conduction from the bricks

lbs./cord million
BTU
Dogwood, Pacific Cornus nuttallii 3,995 24.8
Holly, American Ilex Opaca 3,995 24.8
Birch, Black Betula lenta 3,910 24.2
Oak, White Quercus alba 3,910 24.2
Madrone, Pacific (Arbutus)Arbutus menziesii 3,825 23.7
Bamboo 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
Dimensions
Cubic foot
Clay 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
Noun
pizzaiolo m (plural pizzaioli)
pit.tsa.ˈjɔ.lo
man who makes pizzas in a pizzeria
pizzaiola f (plural pizzaiole) (feminine of pizzaiolo)
pit.tsa.ˈjɔ.la
1. woman who makes pizzas in a pizzeria
2. 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.

Dome height to opening width
ratio for optimum air exchange
h/w = 32/51 = 63%

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