How to Build an Outdoor Fireplace BBQ
Whether you are grilling at a pool party, for a family dinner or before the big game, an outdoor barbecue is appropriate any time of year. Although some might prefer a manufactured grill, others may want to have an exterior fireplace barbecue. Because the fireplace barbecue grill is masonry, a great deal of time and preparation are necessary for its construction. Furthermore, the grill should meet local building codes as an interior fireplace would; try not to cut corners. Does this Spark an idea?
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Things You'll Need
- Grill grate
- 4 steel reinforcing bar pieces, #4
- Standard brick
- Concrete masonry units
- Mortar
- Aggregate
- Concrete
- 10-inch brick or 8-inch firebrick
- Masonry grout
- Masonry clips
- Noncombustible lintel
- Manufactured chimney assembly
Instructions
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Sketch out the design before constructing your fireplace barbecue. Because the grill grate is precast and is the heart of the barbecue, start with its dimensions, and draw a 12- to 14-inch masonry wall on three sides of the grate. This gives the minimum dimensions for the firebox of the fireplace barbecue. Draw a surface 16 inches beyond the open, front side of the grate. This extension is a hearth sill, which is important to keep the hot ashes and coal from contacting flammable surfaces.
The grate should be 36 to 40 inches above the ground, and the firebox floor should be 10 to 12 inches below the grate (a minimum of 24 inches above the ground). The grate, firebox and masonry should rest on top of a 12-inch-deep masonry footing that extends 6 inches beyond the faces of the fireplace grill.
Above the grill grate, the ceiling of the fireplace barbecue should extend 12 to 18 inches, creating an opening at least 22 inches from firebox floor to ceiling. Above the ceiling, the fireplace chimney should extend 36 inches, or 24 inches above any structure within 10 feet.
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Feel free to be creative with the form of the fireplace beyond the firebox and grate. For example, a preparation area might be helpful when grilling large meals. Work such features into your design.
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Construct the 12-inch masonry footing. Evenly place four #4 steel reinforcing bars on the centerline of the proposed masonry wall and anchor these into the masonry footing. These pieces of rebar should extend the height of the masonry. Use standard brick or concrete masonry units (CMUs) for the foundation's construction, and follow the curing and application instructions given with the mortar.
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Lay and mortar the grill base using a double wythe of standard brick or concrete masonry blocks. Remember to follow the instructions given with the mortar. The masonry should be 6 inches from the edge of the foundation and follow the drawn dimension of the fireplace.
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Backfill the cavity within the masonry walls 10 to 12 inches below the floor of the firebox stop, using aggregate. Tamp the aggregate 3 inches below the top of the brick or CMU walls.
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Pour concrete over the aggregate and trowel a smooth surface that is even with the top of the masonry wall. Allow the concrete to cure.
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Begin placing the 10-inch brick or 8-inch firebrick for the firebox walls. Grout and mortar appropriately. If facing brick is to be applied to the outside of the firebrick, use masonry clips. Follow the instructions provided with the masonry clips. Also, don't forget to create a ledge 12 inches above the floor of the firebox for the grill grate. Continue placing the brick until you have reached the desired height.
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Place a noncombustible lintel over the firebox walls, leaving at minimum a 6-inch throat for the chimney assembly. Attach the manufactured chimney assembly, following the manufacturer's specifications. Remember, the chimney must extend 36 inches above the firebox or 24 inches above any structure within 10 feet.
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If desired, continue laying brick around the chimney assembly. Again, follow the guidelines given by the chimney's manufacturer.
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Before using the fireplace barbecue, allow the mortar and concrete to cure for a week or more.
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Tips & Warnings
When calculating the amount of brick needed, it is helpful to know that there are seven bricks per square foot. Also, it may be preferable to design the fireplace barbecue in 8-inch modules - the brick is 8 inches wide and 4 inches deep, and three layers of bricks equals 8 inches. If desired, a manufactured firebox can be used in place of firebrick.
Consult local ordinances and building codes before constructing a fireplace barbecue.
