Mattone Barile Ovens

Mattone Cupola Ovens

  • How is the Mattone Cupola, that I pour and pack myself, different from the prefabricated ovens on the market?

    Prefabricated ovens are made by blending Castable Refractory with water and stainless steel fibers in a large mixer housed in an expensive factory (usually in California or Italy).  It's then poured into a large dome shaped mold by expensive factory workers and allowed to dry for several days.  It's then crated and placed on a hard-bouncing cargo truck and shipped across the country.  Cross your fingers and hope that your oven arrives on that heavy pallet with no damage!  Once it arrives, you call your friends and neighbors over to help you carry it to the backyard.

     

    BrickWood Ovens Mattone Cupola dome-shaped foam oven molds provide homeowners and contractors the ability to make the same size oven (28", 36", 40" and 46") using the same high-quality Castable Refractory that you purchase locally from a nearby Castable Refractory dealer.  After mixing the refractory with water and stainless steel fibers (included in kit), simply pour and pack the refractory in your dome shaped oven mold.  After the oven is dry, simply strip the foam off the oven and follow the 7-day curing instructions.  Easy Peasy!  You now have a super-awesome, high-quality wood fired oven that you built yourself.

     

    Now reach your hand in your pocket and pull out a wad of all that green paper.. That's the HUNDREDS if not THOUSANDS of dollars you'll be saving by building the oven yourself!  No experience necessary and it takes LESS than 2 hours to build a 36" Mattone Cupola!  Click here to watch a Mattone Cupola DIY video.

  • Can you make a custom size Mattone Cupola?  Can you make a 50" or larger?

    At this time, we only offer the 28", 36", 40" and 46" models as these dimensions are the most popular ovens sizes ovens on the market.  The 28" is perfect for small families while the 46" model is a huge monster that can cook a ton of pizza for large, hungry crowds.. like at the Somerset Amphitheater in Wisconsin!

     

    Another reason we don't offer custom size ovens is due to Quality Control and Testing.  We've tested all 4 sizes of our Mattone Cupola ovens for several years now and all 4 sizes have MET and EXCEEDED our strict oven requirements.  If we made a custom size, we wouldn't feel comfortable putting the BrickWood Ovens logo on one of our units until we've had time to fully test an oven with custom dimensions.

  • Why is there such a price jump between the 28" and the 36", 40" and 46"?

    Great question!  It does seem odd doesn't it.

     

    Actually, it all boils down to freight and the high cost associated with it.  Our 36", 40" and 46" oven forms are too large to be shipped via FedEx Ground.. so these forms get to ride in a freight truck to your destination.

     

    The 28" on the other hand is just the right size to travel on a lower-cost FedEx Ground truck.  In fact, we used every square inch allowed by FedEx Ground when designing our 28" Mattone Cupola.  If it were 1 square inch larger, it would have to be shipped via Freight Class.

     

    So instead of charging more for the 28" and pocketing the difference, we pass the savings on to you!  How nice is that!

  • How close to my house can I build the oven?

    First and foremost, ALL BrickWood Ovens are for OUTDOOR & NON-COMMERCIAL USE ONLY!

     

    Secondly, the placement of your oven really depends on your local building codes.  Many codes & HOA’s state that all “solid-fuel burning devices” be placed within “X” number of feet from any structure.  Before you build your oven, check with your local municipalities and/or HOA’s to verify you build to the standards of your code.  And let's not forget your homeowners insurance policy requirements (Allstate, AmFam, Farmers, etc..).  They may have rules on how close an oven can be to any structure that is covered under one of their policies.

     

    In addition, you must remember that no wood burning oven manufacturer can guarantee 100% smoke capture.  For this reason, we do not recommend placing your BrickWood Oven within 5 feet of any ceiling or covered structure.  We also recommend leaving a distance of 3 feet between the oven and any structure like walls, fences, trees, etc..

     

     Also, make sure that the front / opening of your oven faces the direction of the oncoming wind.  If the wind hits the rear of the oven, it can create a small vacuum which will pull the smoke out the front of the oven.

  • After reading the instructions and watching the video.. I'm assuming you can't use the mold over again?

    Sorry.. You'll need to destroy the foam mold to get the dry oven out.  But we do give discounts to repeat buyers if you want to buy another form :)

  • Could I put this oven on a trailer / mobile oven?

    Absolutely!  If you are aiming to build a mobile wood fired pizza oven, the Mattone Cupola is the oven kit for you!

     

    Unlike our Mattone Barile (with 700+ brick and mortar joints which is not great with road vibration or speed bumps) and our Cortile Barile (too small for mobile cooking), our Mattone Cupola ovens are ready to hit the road running!  Built in ONE solid monolithic form (not 5 or 6 pieces like other brands), our Cupola dome ovens can withstand many, many years of road trips on a properly built trailer.  (See trailer info below).

     

    Not sure what size you need?  Be sure to sit-down and factor all the pros and cons of each oven size based upon your needs.  Here's a little cheat sheet to help guide your decision..

     

    28" or 30" - Too small for a mobile unit.. you can only make one pizza at a time.

     

    36" - A great size for the person that likes to occasionally provide mobile events.  Perfect for catering weddings, birthday parties, corporate events, kids school events.. and especially church potlucks!  Anywhere 80 - 100 hungry people are lurking about, there should be a 36" Mattone Cupola oven.

     

    40" - Our personal favorite!  You can't go wrong with a 40"!  If your not ready to throw in the corporate 9-5 towel, but would still like to make a extra little dough on the weekends, than this oven size is for you!  Easily cook 3 or 4 pizzas and calzones at the same time and breeze through that line of people in front of your oven lickety-split!  Great for Farmer's Markets, Wineries, small fairs and the like.  Easily feed around 200 - 300 a day!

     

    46" -  This ain't no backyard oven.. This bad boy is HUGE!  When you have to feed a large number of people, the 46" Mattone Cupola is a great oven to have behind you!  With it's generous cooking surface, 3.5" thick walls for superior heat retention and ability to cook 6 pizzas at one time, the 46" is more oven than you will ever need!  The next time you are at the Sommerset Amphitheater in Wisconsin, look for a line of hungry concert goers in the concession area.. their probably lining-up for a slice of pizza from our 46" Mattone Cupola!

    While we make awesome pizza oven kits.. we don't make pizza oven trailers.  We leave that to the experts in trailer industry as there is a bit of science behind weight distribution and balancing, state and federal DOT regulations, permits, countless design options, etc..

     

    The best recommendation we can make about trailers - seek assistance from your local trailer fabricator.  And with today's technology, you can find a trailer fabricator in your area in about 3 seconds..  Simply Google Map "Custom Trailers" and your Zip Code.  Provide them with instructions of the oven you choose and they will have all the weights and dimensions they need to build you a stylin' mobile wood fired oven trailer!

  • Where do I find castable refractory and / or other refractory materials?

    You would be surprised at how many locations sell Castable Refractory!  Odds are, you drive near a location on your way to work. Click here to locate a Castable Refractory dealer near you.

     

    Orrr.. you can purchase the Castable Refractory off our website / store - but please keep in mind, we HIGHLY encourage you to purchase your refractory locally so you don't have to pay freight charges.

     

     

  • How do you pronounce Mattone Cupola?  What does that mean in Italian?

    Mattone Cupola is pronounced Matˈtone ˈKupola and it means "Brick Dome" in Italian.

  • What is the purpose for the stainless steel fibers that are mixed with the castable refractory?

    You could build your oven with just Castable Refractory and it would be rock solid.  But our stainless fibers are the secret ingredient for a bulletproof wood fired oven!  These jagged little 2" fibers act like thousands of tiny little rebar when they are mixed with the Castable Refractory.  So if your oven should happen to get a hairline crack, the stainless steel fibers will hold the oven firmly together and keep the expansion to a microscopic level.

  • Can I put this oven on a mobile cart to wheel around my house and neighborhood?

    Absolutely.. kinda..

     

    You can put our 28" Mattone Cupola on a cart with no problem.  It will weigh less than 600lbs and you can roll it all over the neighborhood to your neighbors delight!

     

    Our next size up is the 36" and that will take a bit more muscle to move as it weights in at 1000+ lbs.  Not something you want to be rolling around on a cart.

     

    Your next question will probably be, "Great!  Where can I get a cart?".  While we don't fabricate / sell carts for our ovens at this time, your local Metal Fabrication shop can make one for you.  Simply Google Map "Metal Fabrication" and your Zip Code and several shops in your area will appear.  Call around - get the best price!

  • Any tips and / or advise you can give me about building the Mattone Cupola?

    1.  DO NOT OVER PAY FOR CASTABLE REFRACTORY!!  We have spoken with almost every castable dealer in the US and we can tell you prices range from $35 a bag to $80 a bag!  $80!  Castable Refractory should be around $35 - $45 a bag.. anymore than that and you should call the manufacturer direct.

     

    2.  Mix the castable refractory and the water to the manufacturers specifications!  Castable isn't like cement you use to pour a sidewalk - it's much more dry and firm.  The proper water ratio is VERY important when mixing the refractory and packing the oven mold.

     

    3.  Pack the refractory SLOWLY yet FIRMLY!  This is probably one of the most important parts of building the oven.  When packing the refractory with a wood dowel, you will notice that the castable is very sticky.  If you pack too quickly the refractory will stick to your dowel and create an airpocket in the refractory - and this is bad!  Pack the refractory slowly and firmly.. it's not a race and it will save you a lot of headaches down the road!

     

    4.  You may have some foam sticking to the finished parts of the oven when stripping the foam away.  Try to get off as much as possible, but don't put too much effort into getting every little bit off.  The foam on the outside of the oven won't be seen.. and the foam on the inside will not withstand the test fires.  Just remove as much as possible, but don't waste too much time trying to get every little foam bead off the finished oven parts.

  • How do I repair small gaps and/or pinholes in the dry castable refractory?

    When you remove the foam mold, you may see some small "pinholes" in the refractory and this is okay!  Since this is merely a cosmetic nuisance and not a structural issue, you can put your worries aside.  Very soon, you will be wrapping the oven with ceramic fiber blanket and then applying an exterior finish, you won’t see those pesky pinholes for very long.

     

    If you have a larger hole or gap (greater than the diameter of a pin / pencil), then you might want to apply a small patch.  Simply mix a small batch of refractory and press it into the hole with putty knife or with the palm of your hand.  Preferably, you should use the Castable Refractory, but if you are out, you can use the Refractory Mortar.

     

    The best way to prevent pinholes is to pack your castable refractory SLOWLY yet FIRMLY as you are building the oven.  The majority of all holes are due to rapid packing during the construction stage.  As you are packing the castable refractory with a wood dowel, the castable refractory can stick to the dowel and create an unseen vacuum which will create a holes and gaps

  • Can I use natural gas / propane to heat the oven?  Do you sell burner kits?

    Yes and No..  You can use burner kits in the Mattone Cupola ovens, but no, we don't sell these kits.  We have had several customers purchase the Drago P1 Burner and they had nothing but glowing reviews about the burner.  BUT.. they aren't cheap!

     

    Another approach to installing a natural gas burner is to contact your local propane tank installer or your HVAC supply and see if they can recommend a Master gas technician that can custom build / install a burner for you.

Cortile Barile Ovens

Oven Bases

Firebrick & Standard Size Brick

Fireclay, Silica Sand, Lime & Portland Cement (High-Temp Mortar - Common Blend)

Vermiculite & Perlite

Insulating Castable

High Temperature Mortar  (Factory Blend - Bag / Pail)

Castable Refractory

  • What is Castable Refractory?

    Castable Refractory is a mixture of refractory aggregate and heat resisting hydraulic cement or other suitable binder.  Another definition is: A special type of concrete that can take extreme heat temperatures over and over again.

  • What is a decent / average price for a bag of Castable Refractory?

    When buying from a manufacturer, you should pay around $30 - $40 a bag.

     

    If buying from a distributor, you should ONLY pay around $40 - $50 a bag.

     

    If you are ever quoted more than $50 a bag, you should consider looking at other distributors (see our Castable Refractory Dealers List), or you can buy the Castable Refractory from our store and have it delivered directly to your jobsite!

  • Should I buy from the Castable Refractory manufacturer or one of their dealers?

    Either.  If you have the luxury of living near a manufacturer, you will save a few dollars buying direct.  If you don't have a manufacturer nearby, you can purchase the Castable Refractory from an authorized dealer, but they usually charge a few dollars more than the manufacturer would charge.

     

    But again, DO NOT pay more than $50 per bag!

  • How do I mix it?  In a cement mixer or by hand?

    Almost all of the Castable Refractory manufacturers recommend using a Paddle Mixer when mixing castable.

     

    While we agree, we also recommend using a Cement Mixer as well.  Since you will be mixing over  60 bags of concrete and mortar when building the base, you might as well continue using the cement mixer when mixing the stainless steel fibers and castable refractory with water for your oven.

     

    Just be sure to immediately clean your tools and clean your mixer when you are finished using the mixer as the castable will dry quickly on the blades.  It is very hard to remove cured castable.. you will need a hammer and chisel.

  • It looks like regular concrete.. How is it different?

    Castable Refractory does look like regular concrete mix, but they are definitely different beasts!

     

    Unlike regular 'ol concrete mix, Castable Refractory can withstand temperatures up to 3000 degrees.  And that's about 2000 degrees hotter than you will ever get your oven!  Regular concrete would crumble under those extreme temperatures.

     

    On the flip side, Castable is not as forgiving, nor as easy to use as regular concrete mix.

     

    With concrete mix, you can typically eye-ball the consistency of the water-to-mix ratio as the concrete is mixing in a wheelbarrow or mixing machine.  If you need to add more water, you just spray it in, but if you add too much, you just add more cement mix to thicken it up a bit.

     

    Castable Refractory on the other hand has a very strict water-to-castable ratio that is set forth by the manufacturer (so be sure to ask for mixing directions when you purchase your Castable).

  • How much time do I have to work with the Castable?  Can I add more water if it starts to get firm?

    One you mix the water, stainless steel fibers and Castable Refractory together, you have a limited amount of time to put the mix in the mold before it starts the curing process.  After you mix your materials together, you have about 15 minutes to before the curing process begins.

  • Any tips you can give me on working with Castable Refractory?

    Working with Castable Refractory is not like working with regular cement mix.  If you add too much water when working with cement, you just add more dry cement mix.  If you didn't add enough water, you just spray more in.  Easy Peasy.

     

    Castable Refactory on the other hand requires an exact amount of water to be mixed per bag to ensure the Castable cures properly.  Too much water and the Castable will be weak.  Too little water and the Castable will be too dry to pack.  Both can result in possible hairline cracking.

     

    The first tip is to follow the mixing instructions set forth by the Castable Refractory manufacturer!

     

    The second tip is to pack the Castable Refractory slowly yet firmly.  Castable is a fairly sticky and as you are packing it in the foam forms, the Castable will tend to stick to your wood dowel (the stick you are using to pack the Castable).  If you are packing the Castable loosey-goosey, the Castable will stick to your dowel and leave an air pocket and/or not pack properly.  IT IS VERY, VERY, VERY IMPORTANT THAT YOU FOCUS WHILE PACKING THE CASTABLE!!  MAKE SURE YOU ARE PACKING IN SMALL BATCHES AND ENSURE THAT THE CASTABLE IS PACKING FIRMLY AND THERE ARE NO AIR POCKETS.

Ceramic Fiber Blanket

  • I see some ovens built with Ceramic Fiber Blanket and some without.  What are the benefits of the blanket?

    1.  Wrapping your oven with Ceramic Fiber Blanket will allow your oven to heat quicker and retain the heat longer than without Ceramic Fiber Blanket.

    2.   If you get a hairline crack on the inside of your oven, the blanket prevents the hairline crack from showing on the outside of the oven.

    3.  2 layers of blanket costs less than a 2nd row of firebrick (each box contains enough blanket for 2 layers).

    4.  Your oven can be 900 Degrees inside.. and be cool to the touch on the outside!

    5. The blanket can be applied and secured in about 30 minutes while a 2nd layer of firebrick takes 4 - 5 hours..

    6.   COUNTLESS finishing options can be applied to an oven with the blanket / stucco shell..

    Thin Brick / Brick Veneer

    Stone Veneer

    Painted Finish

    Ceramic Tile

    Fireplace Combo

    Almost any type of Finish!

    We would HIGHLY encourage you to build your oven with Ceramic Fiber Blanket!

  • You suggest 2 layers of Ceramic Fiber Blanket.  What are the benefits of 3 or more layers?

    If you plan on using your oven for 6+ hours / 5 days a week (or more) then 3 or 4 layers of blanket will be beneficial.  If you are like 98% of our customers and use your oven for about 4 - 5 hours at a time, then 2 layers will be more than adequate.

     

    If you are building the 40" or 46" Mattone Cupola dome oven, we recommend 3 or 4 layers of Ceramic Fiber Blanket since ovens that size are normally used for a little more than the typical backyard event.

  • Can I use regular house insulation to insulate the oven?  The Pink Panther kind?

    House insulation is for houses.. Oven insulation is for ovens.

     

    The oven insulation we sell is manufactured by Harbison Walker and HeatStop.. the big boys of the Ceramic Fiber Blanket & Castable Refractory industry!

     

    While there are several blends and thicknesses of CFB (1" or 2".. 4lb, 6lb, 8lb..), we only stock and sell the 1" x 24" x 25' - 6lb Inswool by Harbison Walker.  This blend is super-thick and provides the most amount of insulation for the least amount of $$$.

  • Why do you recommend chicken wire instead of metal lath?  Isn't metal lath better?

    It costs more, so it must be better right?  That's not always the case..

     

    The reason we recommend inexpensive Galvanized Chicken wire (or poultry netting) is threefold.

     

    1. Chicken Wire holds the blanket firmly against the the oven while you apply the first stucco layer.

     

    2. Chicken wire supports the stucco as it is being applied over the blanket.

     

    3. You can easily shape the chicken wire by shaping it into place (like bending a paper clip).  Simply stick your fingers into each opening and squeeze the wire into shape.  The tighter you squeeze, the tighter the chicken wire gets around the blanket!

     

    NOTE:  DO NOT use plastic chicken wire (plastic and heat do not play well together).

     

    So why do we dislike metal lath?  Metal late is not user friendly.. it's not pliable.. and you can't simply press it into shape by squeezing or bending the wire.

Top 15 Questions

Shipping

Returns

  • Can you ship to other countries besides the US and Canada?

    Absolutely!  Please visit our International Orders page for more information.

  • What days do you ship on?  How soon will my order ship?

    We ship every Monday, Wednesday & Friday.

     

    Due to the large size of the ovens, we can only ship via FedEx Ground.  If you live on the West Coast, it takes about 3-4 business days for order delivery. If you live on the East coast, it takes about 6 business days.

  • My entire order hasn't arrived yet.  Do deliveries occur on different days?

    Yes.  Depending on what products you ordered, the delivery dates of each item may vary as several products are drop-shipped from the manufacturer.  Since we work with regional distributors, our delivery date and their delivery date may differ.

  • How do I track my order?  Where is the Shipping / Tracking Number?

    When we process your order, we auto-generate your FedEx Ground shipping labels.  After we place the labels on your product(s), our super-cool FedEx rep pulls up to the warehouse and scans the labels on each box before delicately placing your order in their truck.  When this scan occurs, you are automatically sent an email with your tracking numbers from FedEx.  To track your packages, simply open the email from FedEx that reads "FedEx MPS Shipment Notification" and click on the link that reads "Tracking Number" or "Master Tracking Number".

     

    Once you click on the link, you will see the status of you order and an ETA of when your packages will arrive to your requested Ship-To address.

  • I needed the kit yesterday!  Can you overnight or 2-day the order?

    Shipping the Mattone Barile Grande from our warehouse to Pittsburgh via our standard shipping method (FedEx Ground) costs about $60!  If you were to overnight that box, you are looking at $400.. and $300 for 2 day!  YIKES!

     

    We ship within 24-48 hours of receiving your order, so if you can, please readjust your schedule so your order can ship via standard FedEx Ground.  Your wallet will thank you!

  • Can you ship the oven via USPS instead of FedEx or UPS?

    BrickWood Ovens boxes are BIG... USPS trucks are small...  It's a No-Go...

     

    Most of our oven forms, molds and accessories are shipped in boxes that are larger than USPS size limits.

Returns

  • 30 Day Refund Policy

    Items can be returned for a refund within 30 days of your order date if items are unused and in re-sellable condition.

     

    Before you return your order, we will need for you to request an Return Merchandise Authorization number (RMA).  This can be done by emailing our Shipping & Receiving department by clicking on this link - Returns.  Be sure to include your order number with your return request.

     

    After you receive your RMA number, write the number on the outside of all the boxes you are returning.   Take those boxes to your local Authorized UPS or FedEx shipper and send the boxes to the address on your RMA.  BrickWood Ovens is not responsible for return shipping charges.

     

    Once we receive the return and verify that the items are unused and in re-sellable condition, we will process a credit / refund in the form of payment used to make your purchase.  You can expect to receive your refund within two weeks of shipping your package back to us.

     

    Please Note – While we do offer “Free Shipping” on many of our products, shipping is not free for us.  In fact, shipping our products across the country is quite expensive!  To offset the costs of shipping your products, we do charge “FedEx Surcharge” up to 25% on all returned items.  This charge basically helps us recover the costs of the actual shipping charges of the initial shipment.

Mattone Barile Ovens

Back To Top

Cortile Barile Ovens

Construction Materials

Castable Refractory

Ceramic Fiber Blanket

Fireclay, Silica Sand & Lime

Firebrick and Standard Brick

General Questions

Returns

Shipping

Vermiculite / Perlite

High-Temperature Mortar

Oven Bases

Top 15 Questions

Insulating Castable

Mattone Cupola Ovens

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