The Bakery Project
Maddie sits in the space framed by Bob Streeter,
where the oven will be
Pat Manley arrives, supplies are delivered and acquired.
The basic outline
Three rows of block, three courses high, the spaces between will be wood storage under the oven
the block rows topped with brick, Pat builds the form for the first slab to support the oven
The form for the first slab
The first slab, poured and screed
Form removed, next layer in the morning
The first slab is dry enough, Pat places the Foamglass
The Foamglass in place, separated by strips of Mineral Wool
On top of the Foamglass layer, a slab in four quadrants, each separated from each other by a strip of mineral wool
The base for the oven: a layer review
The arch cross section
So, how did you mix all that cement with no running water?
All the forms removed,
the first two courses of fire brick in place
The saw that Pat uses for cutting the fire brick
The first two courses of fire brick, more waiting to be laid
The Mason happily at work
The beginnings of the side walls
of the innner walls of the oven
Thermocouple hole, there will be one in the arch as well
side view, the oven does start to fill the space...
the top course of bricks in this picture
will support the base of the arch
end view of inner walls
the inner "core" of the oven, when completed, will be wrapped in insulation and then another, outer wall
a look into the cooking area and oven door area
next the floor bricks, where the bread will bake,
and then the arch

The completed floor, moments after the
last brick is laid

inside the oven, with a view of the space around the outside of the floor bricks, to allow for expansion
The oven door opening, with the form
holding the door arch in place
The form for the arch, that cable on the left is connected to the thermocouple in the oven floor
The view into the oven, that straight edge visible below
the door arch is the wooden form for the arch
the arch, 75% finished. the sqare hole on the far side of the yellow level is for the flue; the strip of mineral wool inserted into the arch across the halfway point will allow for expansion,
the pegboard arch form is visible in the empty row
inside the finished oven core
Pat cleaning up inside the finished oven core
the completed oven core; first half of red brick facing;
bluestone slab awaiting placement on the scaffolding
bluestone and oven door in place, harness added
to support the vaulted roof of the oven core
The steel harness in place around the arch
the harness - back view
close up composite, showing the harness bracing the courses of firebrick that support the oven's arched ceiling or "vault"
next, the outer block walls will be built up higher than the top
of the firebrick oven core, with 6 inches of space to fill with insulation all around it, and more on the top.The nice white oven core will be buried in insulation and encased in cement block

The outer block wall, built up within one course of its final hieght,
with the space to be filled with insulation

top view of the oven core, with the outer wall
Pat trowels a slab onto the top of the core

the slab-covered oven core gets wrapped first in aluminum foil,
then with mineral wool, on all sides. The wire leads to the thermocouple, embedded in the top of the core.

on top of the mineral wool, on top of the aluminum foil, on top of the slab on top of the oven core, a thick mix of vermiculite and portland cement
the final layer will be portland cement, but the sand we need to use is frozen in a pick-up, and must be chipped out into buckets, and then thawed on the floor in front of the oven.
the last layer in place - portland cement covers the entire top of the oven.
the red brick face of the oven, with bluestone shelf and keystone
the first fire
Pat shows us how build an "upside down fire" - big logs on the bottom, kindling on the top
as the fire burns, it gets moved gradually to the back of the oven
this is taken through the vent in the steel door
Whole Grain Hearth Loaves
Raisin Cranberry Pan Loaves

These coals are the result of a week of gradually larger fires and higher temps,
it's 479 degrees in the ceiling in this picture -

"There's a Hole! A Hole at Sunnyfield!"
"A Hole? A Hole at Sunnyfield?!"

Word spread fast that a large opening had opened in the earth behind the shed at Sunnyfield. Neighbors stopped by to peer into it, and people who had been contacted about being involved in the bakery project sprang into action....

Birthwise School

Mike Morton dug the hole, and John Gammon set to filling it with the frost walls and foundation we'll need to support the oven.

The finshed slab, reinforced with rebar, awaits the next step, a stucture to shelter the oven site, and oven builder.We still need to empty and finish the shed (to the right).