There is nothing quite like the experience of cooking outdoors over an open flame. A permanent brick barbecue not only becomes a stunning focal point for your backyard but also elevates your grilling game to a whole new level. While a store-bought grill is convenient, building your own masonry barbecue creates a durable, high-performance outdoor cooking station that will last for decades. Many people feel this project is beyond their skill set, but it’s more achievable than you might think.
Learning how to build brick barbecue with chimney is a rewarding project that combines basic masonry skills with a love for outdoor living. The addition of a chimney is crucial, as it provides excellent smoke ventilation, pulling smoke up and away from the cook and your guests. This guide will walk you through the process step-by-step, from laying the foundation to setting the final brick on the chimney.
Why Building a Brick Barbecue Is a Great Backyard Upgrade
Building your own brick barbecue creates a robust and permanent outdoor cooking feature that adds significant value and appeal to your property. Unlike portable metal grills that rust and degrade over time, a masonry structure is incredibly durable and can withstand the elements for years. It offers superior heat retention and distribution for more consistent cooking. Furthermore, the chimney provides effective smoke ventilation, ensuring a more pleasant cooking environment. It’s a project that allows for full customization, enabling you to design a barbecue that perfectly fits your space and your outdoor entertaining style.
8 Step-by-Step Guide: How to Build Brick Barbecue with Chimney
Step 1: Design Your Barbecue and Choose the Location
Before you lay a single brick, it’s essential to have a clear plan. Decide on the size and design of your barbecue, considering how much cooking space you need and whether you want to include areas for storage or food preparation. The location is equally important. Choose a level spot in your yard that is a safe distance from your house, fences, trees, and any other flammable structures. Also, consider the prevailing wind direction to ensure the chimney will effectively direct smoke away from your home and any outdoor seating areas. Sketch out your design with precise measurements.
Step 2: Lay a Concrete Foundation
A solid foundation is critical to prevent your barbecue from shifting or cracking over time. Mark out the dimensions of your barbecue’s base on the ground and excavate the area to a depth of about 6 to 8 inches. Fill the bottom few inches with hardcore or gravel and compact it firmly to create a stable sub-base. Build a simple wooden frame (formwork) around the perimeter of the excavation. Mix concrete according to the package directions and pour it into the frame, ensuring it is level. Smooth the surface with a trowel and let it cure completely, which can take several days.
Step 3: Lay the First Courses of Brick
Once the foundation has cured, you can begin laying the bricks. Start by doing a “dry run”—lay out the first course of bricks on the foundation without mortar to check your spacing and alignment. Aim for a consistent mortar joint of about 3/8 of an inch (10mm). Once you are happy with the layout, mix your mortar to a smooth, workable consistency. Apply a layer of mortar to the foundation and begin laying the first course, pressing each brick firmly into the mortar. Use a spirit level constantly to ensure the bricks are perfectly level and straight.
Step 4: Build Up the Barbecue Walls
Continue building up the walls of your barbecue, course by course. Apply mortar to the top of the previous course and to the end of each new brick before placing it. Stagger the joints in a running bond pattern for maximum strength. As you build, use your spirit level to check that the walls are plumb (vertically straight) and level. Use a trowel to scrape off any excess mortar that squeezes out of the joints. For the area that will hold the charcoal, be sure to use fire-resistant bricks, as they are designed to withstand the high temperatures of a fire.
Step 5: Incorporate Supports for the Grill Grate
As you build up the walls to the desired cooking height, you will need to create ledges to support the charcoal tray and the grill grate. A simple way to do this is to turn some of the bricks on their side so they protrude into the cooking area. Plan for at least two levels: one for the charcoal and a higher one for the cooking grate. This allows for some temperature control. Ensure these support bricks are laid level and are securely embedded in the mortar so they can safely hold the weight of the grates.
Step 6: Begin Constructing the Chimney Base
The chimney construction begins by “corbelling” the brickwork. This technique involves gradually stepping in the bricks on the back and sides of the barbecue to narrow the opening, which funnels the smoke upwards. Start this process a few courses above the cooking area. Each corbelled course should overhang the one below it by only a small amount—no more than an inch—to maintain structural integrity. This transition from the wide barbecue body to the narrow chimney flue is a crucial part of learning how to build brick barbecue with chimney.
Step 7: Build the Chimney Flue
Once you have narrowed the opening to the desired size of your chimney flue (a square of about 12×12 inches is common), you can begin building the chimney stack vertically. Continue laying courses of bricks in the same running bond pattern, checking for level and plumb with every course. The height of the chimney is important for good smoke ventilation; it should be tall enough to draw smoke effectively and direct it above head height. A height of about 2 to 3 feet above the cooking grate is usually sufficient for most backyard designs.
Step 8: Finish the Mortar Joints and Clean Up
After you have laid the final brick, you need to “point” the mortar joints for a clean, professional look and improved weather resistance. Use a pointing trowel or a specialized jointing tool to press and smooth the mortar in the joints. This compacts the mortar and creates a neat, concave profile. Once the mortar has had some time to set but is not fully hard, use a stiff-bristled brush to clean off any dried mortar smudges from the face of the bricks. This final step in how to build brick barbecue with chimney makes a huge difference in the finished appearance.
Frequently Asked Questions
What Kind of Bricks Should I Use for a Barbecue?
For the main structure, standard clay engineering bricks are suitable. However, for the immediate area that will be exposed to high heat (the firebox where the charcoal sits), it is essential to use fire-resistant bricks (also known as refractory bricks). These are specially designed to withstand very high temperatures without cracking or degrading, ensuring the longevity and safety of your barbecue.
What Type of Mortar Is Best for a Brick Barbecue?
You should use a dedicated fire cement or a refractory mortar mix for the fire-resistant bricks in the firebox area. For the rest of the structure, a standard mortar mix of building sand and cement (typically a 4:1 or 5:1 ratio) is sufficient. You can also buy pre-mixed mortar bags where you just need to add water, which is a convenient option for beginners.
How High Should the Cooking Grill Be?
The cooking grill height should be comfortable for the primary user. A good standard height is around 30 to 36 inches from the ground, which is a comfortable working height for most adults. It’s a good idea to create multiple levels of support for the grill grate, which will allow you to adjust the cooking temperature by moving the grate closer to or further from the hot coals.
Does a Brick Barbecue Need a Concrete Foundation?
Yes, a solid concrete foundation is absolutely essential. A brick barbecue is extremely heavy, and without a proper foundation, it will settle, shift, or sink into the ground over time. This can cause the structure to become unstable and develop serious cracks in the brickwork and mortar joints. The foundation distributes the weight evenly and provides a stable, level base to build upon.
How Long Should I Wait Before Using My New Barbecue?
You need to allow the mortar to cure completely before you light your first fire. This can take anywhere from one to two weeks, depending on the weather and humidity. Lighting a fire too soon can cause the moisture trapped in the mortar to turn to steam and expand, which can crack the joints. Be patient and allow the structure to gain its full strength before its first use.
Conclusion
Mastering how to build brick barbecue with chimney is a project that provides immense satisfaction and results in a stunning, permanent feature for your backyard. While it demands careful planning and physical effort, the process is built on basic masonry principles that are well within the reach of a dedicated DIY enthusiast. This guide breaks the project down into clear, logical steps, from laying the foundation to finishing the joints.
The final result is more than just an outdoor cooking station; it’s a testament to your hard work and a gathering place for friends and family for years to come. Now that you have the knowledge, it’s time to start planning and get ready to enjoy the unmatched flavor of food cooked over a fire in a barbecue you built yourself.