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So how do you build your Liberty range wood-fired oven?

The Le Panyol oven kit can be assembled with ease.  We’ve simplified the traditional design, while taking care to keep the same balance of mass, volume and shape:

  • The arch is assembled by putting together a number of “voussoirs” (shaped like orange segments), held together by a keystone.
  • The hearth is composed of several slabs which are just slotted together.  This is where you will build the fire, and then bake your food.
  • The opening, formed by an entrance unit, allows you to insert wood and then your food.
  • The dry assembly system (no joints required between parts) makes assembly much faster.

Assembling the hearth is just one part of the construction process. This hearth must be placed on a support, then insulated and cladded, before it can be used.

The main steps to follow are listed below.

You’ll receive a detailed assembly manual with your oven, or you can download it by clicking here.

FOREWORD

Pallet storage

In order to ensure that your products are kept in the best possible condition, please follow these instructions as soon as you receive your products:

  • Protect your oven from the rain
  • Don’t stack your pallets (except pallets sent with the Crate Packing option)
  • Check the expiry date on the bag of mortar

Choice of location

Before assembling your wood-fired oven, you’ll need to choose your location and accurately assess the usable space (or volume) needed for installation.
In particular, you’ll need to check that the floor can support the total weight of the finished oven (support + oven + insulation + cladding + roof). The floor must be flat and it must not subside under the weight of the construction.

Your oven can be installed either indoors or outdoors, as an independent unit or integrated into an existing building, near a pool, under a veranda or in the kitchen. There are a range of different installation options available to you. Have a look at our gallery or contact us for assistance.

Outdoor wood-fired ovens

Le Panyol ovens must always be protected from bad weather.  Ensure the roof is large enough so that neither the oven nor the hearth slabs will get wet.

Ensure that it remains completely dry in winter.  If it takes on moisture and freezes, this will render the oven unusable.

If the oven in installed as an independent unit, then the duct must be at least a metre long. However, if the oven is built against a wall or built into a house, the duct must extend at least 40cm above the roof ridge (according to the DTU 24.1 standard).

Indoor wood-fired ovens

La Panyol ovens must be connected to an existing or future chimney, according to the DTU 24.1 (Unified Technical Document) standard.  You must not connect more than one device to the same smoke extraction duct.

This must be:

  • 180mm in diameter (the stainless steel throat which comes with the oven has a 180mm diameter)
  • Composed of no more than 2 x 45° elbow joints
  • It must be possible to dismantle it
  • It must have a double skin if installed indoors

In order to ensure that no humidity or water can enter the duct, you must install a rain cover on the top of the outlet pipe.

STEP 1

Building a support and insulating it

Once you have chosen your location, erect a support (at a convenient height) on which to place your oven. The height will normally be between 100 and 120cm, depending on the height of the user and the level of comfort desired.

The support slab, 10cm thick, must be made from reinforced concrete. As this slab will house the oven and its cladding, ensure that it is large enough to do so. See the recommended dimensions for our wood-fired oven models

Insulating the slab:
In order to make the most of your oven, you’ll want to insulate the base.  To do this, we recommend that you insulate the support with 2 materials before laying the hearth slabs:
- thermal insulation panels (siporex type), at least 5cm thick - these do not come with the oven,
- a 2-3cm layer of grog (comes with the oven), onto which you will lay the hearth slabs

STEP 2

Assembling the hearth for your wood-fired oven

This is a dry assembly method.  You don’t have to join the slabs to each other.

Take care to ensure that the hearth is perfectly flat - this is a vitally important part of your oven, especially when using your peel

STEP 3

Assembling the dome for your wood-fired oven

This is a dry assembly method.  You don’t have to join the parts to each other.

Place the voussoirs next to one another and lock them in place with the keystone.

STEP 4

Installing the throat

Attach the throat using the screws which come with the oven.

Drill delicately, using a concrete tip and ensure that you switch the hammer drill mode off.

STEP 5

Applying the refractory mortar

Once you have assembled the hearth and affixed the throat, you’ll then need to pour refractory mortar (this comes with the oven) over the entire dome to make it rigid and provide a seal. This mortar is hydraulic-setting, so make sure that the dome is properly wetted before you apply it. Follow the instructions in the assembly manual.

Leave to dry for a few days, then light a few small fires to drive out any residual humidity before covering the dome with the insulation.

STEP 6

Building the oven walls

If you chose one of the cubic finishes to clad your oven, you’ll need to erect walls all around it (as shown in the diagram).

You can also choose a round finish. In this case, you don’t need to build any walls. You can see the instructions in the downloadable manual by clicking here.

STEP 7

Insulating the dome

Once your oven is dry and in order to get the best results from your oven and the thermal mass it contains, you’ll need to insulate the top of it. There are several solutions available, according to how and how often you want to use your wood-fired oven, its location and the chosen finish (cubic or rounded igloo finish):

Grog insulation (as shown on the diagram): refractory sand made solely from white Larnage clay, which offer extremely high insulation performance and inertia (30% greater than sand). The ideal insulation for bread baking or frequent inertia baking (cooking with the heat accumulated in the clay).

Fibre insulation: High-temperature insulating wool (up to 1100°C): Bio-soluble, extremely pure and non-corrosive fibre. This insulation is good for mixed oven use (with and without flames), for occasional to regular use. Recommended if you want a rounded finish for your oven.

Need more advice? Contact us

 

 

 

STEP 8

Cladding and finishing

You can glue whatever materials you want to your oven.

Let your imagination run wild. Browse our Gallery and be inspired by the various finishes on display.

STEP 9

Installing the smoke extraction duct

You’ll need to call on a specialist to install your duct.

Le Panyol wood-fired ovens must be connected to an existing or future smoke extraction duct, according to the DTU 24.1 (Unified Technical Document) standards.

This must be:

  • 180mm in diameter (the stainless steel throat which comes with the oven has a 180 mm diameter)
  • Composed of no more than 2 x 45° elbow joints
  • It must be possible to dismantle it
  • It must have a double skin if installed indoors

In order to ensure that no humidity or water can enter the duct, you must install a rain cover on the top of the outlet pipe.