Step 1  Preliminary considerations, tools, materials

 

Before getting started with the stove it’s important to check a few things: the supporting floor needs to be strong enough, the chimney should be okay, and volume and insulation of the space to be heated should be in such a way the Roquetinho can do the job.

As much as possible the stove should be in the centre since it’s mainly a radiation heater. Further: the ventilation of the room has to be sufficient. There's no need for a separate air supply.


    Foundation

A wooden floor does not have the strength needed to support the Roquetinho. A foundation is then a necessity. A connection with the nearest wall can be a solution. This works with a console (for example steel T-profiles inserted in the wall). Let only a professional do it!


    Chimney

You need a chimney of at least 4 meter high, calculated from the stove bottom. Inside the room a singular inox tube of Ø 10 cm will do. Up from 30 cm under the ceiling and outside, the tube has to be double and insulated. Normal chimney rules are applicable such as having the top of the flue above of the roof.



Tools


    Vibration table




To cast forms out of refractory concrete you need a (simple) vibration table. As soon as the concrete mixture goes into the mould, it needs to be vibrated to condense the material and force the air bubbles out.

Here's a simple vibration table that you can put on a Workmate. A thick plywood board of 40x60 cm is attached to two 40 cm beams by four springs that you fasten with bolds and nuts. A 60 cm beam, fixed onto the two 40 cm beams, is clambed in the workmate. To stabilise the workmate, you put 2 concrete tiles on it. You shake the table using a hammerdrill, hitting a thick metal plate. On the top board you fasten the mould with clambs. Make sure the mould is level.


For a more regular use it's easier to have a motor attached to the table. In the video here below a motor is attached to the top board. An excentric weight has been fixed to the axle of it. There's an infinite diversity of designs that you can use, a lot of them are on YouTube.





Other tools you need are:


   Metal work:

metal cutter

tig welder

grinder

table drill

folding tool

clambs


   Masonry:

trowels

filling knife

buckets



   Cutting bricks and blocks:

• grinder

• safety mask

• clambs

• workmate

• ruler, pencil


   Making moulds:

• saw table

• saw

• drill

• screwdriver

• paint brush

• sandpaper




List of materials


  1. Solid refractory concrete, e.g. Calderys F50

  2. Insulating refractory concrete (for the riser castings), e.g. CaldeCast MW StrongLite

  3. Firebricks (220 x 110 x 30 mm) for the fire box

  4. Firebricks (220 x 110 x 50 mm) for the bottom of the core

  5. Firebricks (220 x 110 x 60 mm) for the upper section of the bell

  6. Refractory glue (e.g. Moviset)

  7. Portland cement (cimento)

  8. Builder’s sand (areia grossa)

  9. Gravel

  10. Clay powder and fine sand to make cob

  11. Superwool 100x61 cm

  12. Vermiculite

  13. Stainless steel flue outlet (∅100 mm)

  14. Steel tube for upper riser insulation (∅200 mm x 420 mm)

  15. Rectangular-section steel tube for floor channel (40 x 20 x 1,5 mm)

  16. Rectangular-section steel tube for floor channel (25 x 25 x 1,5 mm)

  17. Steel L-profile (40 x 40 x 4 mm) and other metal parts for the frame and door

  18. A 185 x 185 mm piece of fire glass (for the door)

  19. Steel plate (475 x 475 x 8 mm) for the top of the bell

  20. Steel L-profile (30 x 30 x 3 mm) for the top of the bell


  Various materials for temporary works – such as a transport board, various laths

  and battens, etc.