Build a built in bbq Photo: Handyman

 
Build an outdoor cooking area with lightweight concrete blocks.

Download Built-in Barbecue Project PDF

This barbecue originally sat on a wobbly cart, which made the heat uneven and the oil pool in a corner. The new built-in bench is constructed of special concrete and tiled, with meranti doors underneath to hide the gas bottle. A mosaic feature was created to hang above. 

Special Concrete Blocks
The bench is built from Hebel Autoclaved Aerated Concrete (AAC), a lightweight, heat-friendly material. The blocks and panels are easy to lay and after the first course (the first row) is levelled, the rest are secured with a 3mm bed of adhesive.
To Cut: Use a panel saw and wear a respirator, ear and eye protection, sleeves and gloves.
To Tile: Tile the panel and side blocks for heat resistance by spreading tile adhesive and laying the tiles. Mix grout and push into the joints with a squeegee. Wipe clean when dry.

 

STEP 1

Lay a concrete slab 
Excavate the area to 100mm deep and to fit the bench, spacing the formwork to fit rows of blocks to avoid cutting. Mix and pour the concrete slab, screeding using a sawing action across the formwork, float to a smooth finish and leave to dry.

STEP 2

Add damp-proof course
Use a combination square and straightedge to mark out the bench (see Diagram 1). Roll out a layer of aluminium damp-proof course (DPC) where the blocks will lay, creating a slip joint between the blocks and the concrete.

STEP 3

Lay the first course 
Mix and spread the mortar 10mm thick over the DPC with a trowel. To bed the first course, tap the end blocks into position, apply adhesive to the butting ends of the blocks with a notched trowel, position and check with a spirit level.

STEP 4

Lay remaining courses
Position the second course to overlap the vertical joints with a minimum of 100mm (see Diagram 2). Apply adhesive on the first course and to the blocks, tapping to close the vertical joints to 2mm. Lay the third course to match the first course.

STEP 5

Bed the burner panel 
Check the panel against the third course and adjust to fit. Apply adhesive over the third course with a notched trowel, lift and bed the 75mm-thick panel on the adhesive, tapping to make it level.

STEP 6

Add the side benchtops 
Apply adhesive to the panel and along the inside faces of two 600 x 200 x 200mm blocks and secure. Adhere a 100mm-wide block to the other end of the panel.

 

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