Assembly instructions Le Panyol wood fired oven– Model 83 Page 2
FOREWORD
• Le Panyol ovens are made exclusively of Refractory White Earth, a 100% natural clay from
our own quarry.
• As the material is irregular by nature and the production methods are based partly on craft
skills, you may find that there are gaps between the parts when it comes to assembling
them. These will be filled in when you apply the refractory mortar.
• These gaps allow the oven to expand.
• The keystone may be slightly higher or lower than the dome of the oven.
• The edges of the parts may crumble slightly if they are handled repeatedly.
THESE DIFFERENCES WILL IN NO WAY IMPAIR THE OPERATION OF YOUR OVEN
OR SHORTEN ITS LIFE
The oven must be built under cover.
THE KEY STAGES OF ASSEMBLY
0. Choose a site for the oven
1. Build a base on which to sit the oven
2. Insulate the base
3. Assemble the oven floor
4. Assemble the oven dome
5. Build an enclosing wall around the hearth – If the final shape of the “traditional” oven
6. Insulate the oven dome
7. Connect the oven to a chimney pipe
8. Surround / decorate the oven
Assembly instructions Le Panyol wood fired oven– Model 83 Page 3
CHOOSING A SITE
Before you start to assemble the oven, you’ll need to decide where you’re going to place it and work
out exactly how much space you’ll need to install it.
Check in particular that the floor can bear the weight of the finished oven (base + oven + insulation +
surround + roof). The floor must be flat and should not subside under the weight of the construction.
The oven may be installed indoors or outdoors, stand-alone or incorporated into an existing building,
near the pool, under a veranda or in the kitchen. A wide range of installations are possible. See our
“Gallery” page on our website or ask the retailer in your region.
Outdoor Installation
The Le Panyol oven must be protected against bad weather by a roof wide enough to prevent the
oven and hearth tiles from getting wet. It must be kept dry in winter as, if it absorbs water, frost
would make it unusable. If the oven is stand-alone, the pipe must be approximately 1m long.
However, if the oven is backed on to a wall or built into the home, the pipe must be long enough to
go 40cm beyond the roof ridge (in accordance with DTU standard 24.1).
Indoor Installation
The Le Panyol oven must be connected to an existing or future-build chimney pipe, in accordance
with DTU standard 24.1 (Unified Technical Document). Do not connect more than one apparatus to
the same chimney pipe.
The pipe should be:
• 180 mm in diameter (the stainless steel smoke adaptor supplied with the oven is 180mm in
diameter)
• Made up of a maximum of 2 x 45° bends
• Removable
• With a double skin if an indoor installation
To prevent moisture and rainwater from getting into the pipe, you’ll need to fit a rain cap on the top
of the stack.
Assembly instructions Le Panyol wood fired oven– Model 83 Page 4
BUILDING A BASE TO SUPPORT THE OVEN
Materials
• Generally 2 breeze-block pillars and 1 reinforced concrete slab 10 cm thick.
• The base could also be a sufficiently strong steel table.
Base width and depth
The size of the base will vary according to 2 criteria:
1/ The final shape of the oven:
o Traditional shape (fairly cubic): you’ll need to include the thickness of the surrounding wall
in your size calculations.
o Rounded shape: here there’s no need to build a surrounding wall– see “Advice on insulation
and surrounds for a rounded-shape oven” which you can download from
www.lepanyol.com/documentation
2/ The surround materials : the thickness varies depending on whether it is a rendering, decorative
brickwork or natural stone. You’ll need to include this thickness in your size calculations.
The instructions are based on the following sizes:
Surrounding walls : 10 cm thick (for the sides and back of the oven) and 7 cm thick for the front of
the oven.
Surround : rendering (i.e. a few millimetres thick)
If the surround material is more than 2 cm thick and you have planned to use it to surround the
whole oven (base + oven), you must build the surround on the base before you assemble the oven.
Height of the base
• The oven floor (where the fire will be laid and the cooking done) is generally between 100
and 120 cm high, depending on the user’s height and comfort requirements.
• As the hearth tiles in the oven are 6 cm thick and the insulation under the hearth is
approximately 7 cm thick, subtract approximately 13 cm to obtain the height of the base (see
diagram on page 8).
Assembly instructions Le Panyol wood fired oven– Model 83 Page 5
For the 83 model, the recommended base size for a standard installation is:
Width : 155 cm - Depth : 170 cm - Height : 107 cm
Once you have built the base, build up one level (20 cm) of surrounding wall on the sides and at the
back using Siporex-type insulation blocks 10 cm thick on which the decorative material will be fixed
(diagram page 5).
Note: you may also build a surrounding wall using other materials, e.g. bricks 22x22x5.5cm.
Measurement in cm
Standard construction on a standalone platform
(Other types of installation are possible)
Assembly instructions Le Panyol wood fired oven– Model 83 Page 7
INSULATING THE BASE
Good floor insulation is essential if you’re to get the best use out of your oven.
Once you’ve built the base, insulate the reinforced concrete slab using dry Siporex-type insulation
blocks 5 cm thick.
107 cm
FLOOR
Siporex-type insulation block 5 cm
Surrounding
wall : side
Surrounding
wall : side
Surrounding wall : back
Front view
Reinforced concrete slab – 10 cm thick
Assembly instructions Le Panyol wood fired oven– Model 83 Page 8
ASSEMBLING THE OVEN FLOOR
The oven floor is where the fire will be laid and the cooking done.
For a 66 model, it is made up of 16 white tiles, 33x33x6 cm
Place the tiles against each other dry on a bed of grog 2 to 3 cm thick.
Use a level and mallet to ensure that the tiles are laid flat.
If necessary, even out the differences in thickness of the tiles by placing a bit more grog where
required.
Place the 1st row of tiles 21 cm from the edge of the base (diagram page 9)
Then place the other rows.
FLOOR
Surrounding
wall : side
Surrounding
wall : side
107 cm
120 cm - adapt to the user’s requirements
Grog 2cm
Floor tiles 6 cm
Siporex-type
insulation block 5
cm
Surrounding wall : back
Front view
Reinforced concrete slab – 10 cm thick
Assembly instructions Le Panyol wood fired oven– Model 83 Page 10
ASSEMBLING THE OVEN DOME
1/ Placing the oven entry
Centre the oven entry on the floor tiles
2/Placing the « voussoirs » (arch stones)
Place a straight voussoir (non conical) on each side of the oven entry. Spot the Bottom of the
voussoir thanks to the letter B marked on it.
Wedge the 2 voussoirs in position.
Adjust their inner faces to that of the oven entry.
Photo 1
Photo 3
Photo 2
Assembly instructions Le Panyol wood fired oven– Model 83 Page 11
Position the keystone on a stable base.
Place the 4 small voussoirs on the oven entry and squeeze all the pieces together.
Adjust the height of the 2 large voussoirs (placed in photo 4 and 5) to the height of the 4 small
voussoirs so that they are at the same height around the keystone.
The keystone should ideally be at the same height, but it may sometimes stick out slightly.
Place 2 other straight voussoirs (non conical) on the opposite side of the keystone.
Photo 4
Photo 5
Photo 6
Assembly instructions Le Panyol wood fired oven– Model 83 Page 12
Complete the assembly with the other voussoirs.
Adjust the keystone so that it is centred.
Remove the base supporting the keystone and the wedges.
Adjust the whole construction.
Circle the whole construction with metal wire (to be left in place).
Photo 7
Photo 9
Photo 8
Photo 10
Assembly instructions Le Panyol wood fired oven– Model 83 Page 13
ASSEMBLING THE FRONT OF THE OVEN
The front of the oven is made up of the parts marked with an orange dot on the above photo:
3 shelves boards
2 pillars (right and left)
1 central pediment
These parts remain visible once the oven has been insulated and surrounded.
Order in which they are installed:
1/ shelves boards(page 14)
2/ pillars (page 15)
3/ pediment (page 16)
Assembly instructions Le Panyol wood fired oven– Model 83 Page 14
Placing the shelves boards
The shelves boards are placed at the front of the oven, extending out from the oven floor tiles (see
diagram below) and overhanging the base.
They must be sealed to the base using the refractory mortar supplied with the oven.
Placing the 1st shelf board:
Start with the middle shelf board (the 3 shelves boards are the same).
Prepare a small amount of mortar
Mark the centre of a shelf board.
Align the centre with the centre line of the floor.
Using the mortar, place the shelf board at the same height as the floor tiles for a perfectly flat
surface. The amount of mortar you use should allow you to achieve the same level as the floor tiles.
Maintain a very slight slope towards the front.
Place shelves boards 2 and 3 in the same way.
There’s no need to seal the shelves boards together.
Leave to dry for 24 hours
Centre line of the oven
floor
15 cm overhang
Surrounding
wall
Dalles de sole
Shelves boards
Oven entry
2
3
1
Assembly instructions Le Panyol wood fired oven– Model 83 Page 15
Placing the front pillars
Place the 2 oven front pillars on the shelves boards and against the oven opening.
Centre them (in relation to the centre line of the oven floor).
Check that the oven door can be inserted easily and fits correctly against the oven opening. (Rim of
approximately 3cm).
The gaps between the different parts will be filled with mortar during the “Applying the mortar”
stage.
Oven front pillars
Hole for
evacuating
smoke
15 cm overhang
Surrounding
wall
Shelves boards
Oven entry
Assembly instructions Le Panyol wood fired oven– Model 83 Page 16
Placing the smoke adaptor
• Place the smoke adaptor above the doorway, where there is a hole for evacuating smoke.
• Slide the edge of the smoke adaptor under the small arch stones on the dome.
• Make sure the smoke adaptor is facing the right way!
• The inclined face should be on the dome side (so that it hugs the rounded shape)
• Mark the holes with a pencil for drilling.
• Remove the smoke adaptor and drill carefully (use an 8mm concrete bit without the
‘hammer’ mode)
• Insert the plugs provided.
• Reposition the smoke adaptor and tighten the screws.
• Make sure that the edges are flat. The joint will become watertight when the mortar is
applied.
Placing the pediment
Centre the pediment in the space provided. Seal it in place with 2 to 3 mm of mortar.
This stage must be carried out with care as the pediment will remain visible. Do not let the mortar
run.
Assembly instructions Le Panyol wood fired oven– Model 83 Page 17
Applying the mortar
The aim of applying the mortar is to consolidate the whole of the dry assembly and to fill the gaps.
The mortar is hydraulic, so you’ll need to wet the dome thoroughly.
Mix the mortar according to the instructions on the bag: 5 litres of water per 25 kg bag.
Wet the dome with a sponge or small watering can, having first protected the inside of the oven with
newspaper.
Apply the mortar from the top downwards.
Fill all the gaps thoroughly and carefully cover the base of the smoke adaptor.
Leave to dry for approximately 2 to 3 weeks until all the moisture has gone.
The drying time varies according to where the oven is sited (indoors or outdoors), the ambient
temperature, the amount of water used to apply the mortar, etc.
The main thing is that the mortar and the oven should be properly dry before adding the insulation.
Assembly instructions Le Panyol wood fired oven– Model 83 Page 18
Finalizing the surrounding wall
Finish building the surrounding wall on the sides and back to a suitable height, which will depend on
the final shape of your oven.
For the front: build a wall 7 cm thick around the doorway.
The doorway remains visible. Do not cover it.
Assembly instructions Le Panyol wood fired oven– Model 83 Page 19
INSULATING THE DOME
To get the best performance out of your oven and a maximum energy output, the upper part of the
oven needs to be thoroughly insulated (to prevent the heat from dispersing outwards).
Before you fit any insulating materials, we recommend that you light a few small fires to remove
any residual moisture, as this will be more difficult to get rid of once the oven is insulated.
For a “traditional” (cubic) oven shape:
Depending on the insulation you choose:
Refractory fibre: cover the whole oven with the fibre.
OR
Grog (refractory sand): fill the area within the surrounding wall with grog until the whole oven is
covered above the keystone.
Pour the bags over the dome and let the grog flow around the edge of the dome. The number of
bags supplied has been calculated to provide effective insulation.
Advice : to prevent the grog from accumulating unnecessarily in the corners, build walls at each
corner of the surrounding wall.
Cubic shape example
Top view
Surrounding wall
Oven
Assembly instructions Le Panyol wood fired oven– Model 83 Page 20
For a rounded-shape oven:
If you have chosen to keep the rounded shape of the oven, see the “Advice on insulating and
surrounding a rounded-shape oven” document, which you can download from
www.lepanyol.com/documentation
This must be built under cover.
Whatever the final shape of the oven, if it is installed outdoors, it must be protected against bad
weather by a roof wide enough to prevent the oven getting wet in bad weather.
To ensure that any residual moisture can be evacuated, the roof (or shelter) should not hermetically
seal the top of the oven (build in an access hatch).
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