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1. Standard cement base was built then lifted into place on top of some brickwork.
2. Sandbags were placed in the center to make a dome, with yellow sand filling the gaps to make the dome nice and round. There is no opening for a flu/chimney. The sand was covered in wet newspaper to make the shape for the dome.
3. Clay was built up around this shaping dome. I think it was standard terracotta clay that is usually used for art purposes?
4. Normal house bricks were built up around the clay dome, I think using normal mortar/cement to join. (not fireproof).
5. Chicken wire was placed over this so that it could be rendered.
6. Sheep’s wool was layered over this for insulation, and rendered to finish.
Unfortunately, it was not fired straight away, and the terracotta clay layer has absorbed moisture and shrunken away from the brick layer, and much of it has fallen inwards, so that the raw house bricks are currently exposed bare to the cooking chamber, with a bare cement floor.
Is it possible to get some flat/thin fire bricks for the base (heat absorbing ones) for cooking on, and lay them loosely on top of a 1 inch layer of double-washed river sand for insulation to protect the cement base, then render the inside face of the house bricks with some castable? Or do we need to put some insulating firebricks around the inside edges of the house bricks as well? Do you have any ideas/advice?
We just need to get it finished ASAP, with as little work and as cheap materials as possible (approx $300 or less). We wont be using it all the time, maybe 2-3 times a term, so 8-12 times a year, so it doesn’t need to be indestructible, just usable for the next 5-10 years at that rate (if possible). Any advice /costings you could give would be greatly appreciated!
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