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Drain Water Pipe Smoker
Smoker-barbecue-grill combination.
A drain water pipe is used to build the smokehouse. Such pipes are laying around wherever new housing projects are built in developing areas. They come in 10' length and are made of reinforced concrete about 3" thick. Inside diameters vary from 12" to 40" in 2" increments.
Due to its length and size, an average pipe weighs about 800 lbs, its transport is one of the most difficult parts of a project. The pipe will have to be cut down to size and the openings for a smoke delivery channel and clean out access have to be made. That can be accomplished with a portable motorised saw with a 12" diamond blade. A saw can be rented out or a paving contractor can perform the service.
When cutting a pipe down to size the cut section can be saved to be used as an inside part of the fire pit, although an opening will have to be made for the smoke delivery channel. This way we can eliminate laying down the fire bricks. It is recommended to place masonry bricks on the outside of the fire pit and the smoker for a more elegant look.
This smoker has many advantages:
Smoke flows evenly inside due to its round shape (no blind pockets).
Smoker has a very good natural insulation due to its very thick walls.
Neither a meat loading door nor fire box door are needed.
It is very simple to build, there are no precise measurements or difficult hardware or hinges to install.
Due to its massive weight a solid 6" reinforced concrete foundation has to be poured down. Using concrete pipes for making smokehouses is quite common.
In place of smoke channel "B" the round pipe 6" in diameter may be installed.
Smoker-barbecue-grill combination.
Description
The beauty of this design is that both a smoker and a grill use the same fire pit. The amount of smoke or heat going into the smoker is adjusted by moving burning wood towards or away from the entrance to the smoker. This is accomplished by burning an open fire right on the concrete foundation floor. A metal grate with short legs can be placed in the fire pit and the wood will be burning faster and at a higher temperature having an extra supply of fresh air from below. The fire pit can be covered with a metal cover that will send all available heat to the smoker. Neither the smoker nor the fire pit employ any doors which greatly simplifies construction. Instead, a round metal cover is placed on top of the smoker. By moving this cover a smoke draft control is established. Smoke sticks can be easily mounted by drilling with a masonry drill right through the pipe walls. This is inconvenient when loading many small items such as sausages and impossible to hang a long rope sausage. A more professional solution is to install smokestick supports that allows for loading smokesticks outside. Supports for a safety screen can be drilled right through the concrete pipe wall. It is a wise precaution to install a safety screen to prevent the possibility of meats falling down on the floor during smoking.
A good idea is to make the outside bricks about 2" longer than the pipe. Metal rebars may be used as smoke sticks and the cover will sit on top of the bricks above them. A crossbar with three arms separated by 120 degrees can be constructed and will permit to hang more meats in the lower part of the smokehouse.
Smoke stick support.
A cross bar support.
Brick support over smoke channel.
Grill/Fire Pit
A grill is nothing more than a metal screen suspended on supports inside of the fire pit. Such round screens are available in standard sizes at all department stores.
Grill screen support.
Left-Three metal supports embedded between bricks and spaced equally every 120 degrees.
Right-Firebricks used as a grill screen support. The easiest approach.
The supports can be 4" long pieces of rod or flat metal and should be inserted into damp mortar between the bricks. They can go on top of vertically standing firebricks which determines the height of the screen that is 9". The screen is surrounded by an additional 8" of bricks and that will confine heat in the grill area. When cutting the pipe down to size it is a good idea to cut another section for the inside wall of the fire pit, providing that fire pit and smokehouse are of the same diameter. Remember to also cut an opening for the smoke channel. This way the smoker and the fire pit will be of the same diameter. This is not a rule and the fire pit can be made wider than the smokehouse. The smoker is top loaded and at first it may seem too high and awkward but the top of the smoke delivery channel "B" serves as the 11" high step ladder and loading the smokehouse becomes quite easy.
Using the smoke delivery channel as a step ladder is the reason why the smoke sticks should be installed perpendicular to the smoke delivery channel. This provides a strong grip and facilitates their insertion or removal. There is a 8" x 8" clean out access "A" to facilitate cleaning the smoker or recovery of the fallen items. An electric heating element can be inserted through this hole when wood is in a short supply. It is a very unusual looking smoker which works very well.
There is no need to buy sawdust or wood chips. Logs of wood are used and smoking can continue for days or weeks with little supervision. If it stops at night, it can be very easily re-ignited the following morning.
Laying bricks around concrete pipe.
Building fire pit
Smoke delivery pipe.
Laying firebricks inside fire pit.
Finished smokehouse.
Concrete Block Smoker
An excellent smoker can be built in no time by using standard 8”x 8” x 16” concrete blocks. A firm support base is required and square patio stones of 12”, 16”, or 18” that are available at garden centres can be successfully used. Even bigger prefabricated concrete slabs 30” x 30” that are used to support outside air-conditioning heat pumps are commonly available in warehouses with building supplies. They may make an installation look prettier but are not necessary, a bare ground is fine. Just grade it well so it is levelled.
The construction does not include using mortar, just arranging blocks in the manner that will be most practical and a separate fire pit built from blocks is provided. This way the entire smoking chamber can be utilised for smoking meats and the entire process will be easy to control and more enjoyable. Nothing stops you from using mortar and making it a permanent structure but a strong suggestion will be to try it out a few times and make some observations that may help you with any future decisions regarding building a permanent smoker
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Easy to build concrete block smoker
Smoking chamber
This is a totally flexible design and imagine that you are building a smoker like a child who is erecting a house using little building blocks. This is how this smoker is built and the only difference is that our concrete blocks are slightly bigger: 8’’ x 8” x 16”. The needed materials are available from a building supply store and the final cost will be incredibly low.
Smoke sticks support
The easiest and fastest way to support the smoke sticks (not the screens) is to place them directly on the top of the smoker. The sticks should be 1” in diameter as they act as spacers now, separating the top of the smoker from the cardboard or wooden cover that rests on it. This creates an ample space for the smoke to exit from the smoker. This also limits us to two smoke sticks (one level). An old potato burlap sack has been used for that purpose for hundreds of years. Of course a flattened piece of cardboard or a piece of plywood can be used as well.
Smoke sticks on top of the smoker
Smoke sticks on protruding blocks
Top side and front views
Construction Details
The block laying style repeats itself, uneven layers 1, 3, 5 have one pattern, even layers 2, 4, 6 have another one. There are 5 blocks in #1 level, all others require 6 blocks. In a six floor configuration a total of 36 blocks are used for the smoker and 7 blocks for the fire pit. Neither masonry bricks, mortar, half blocks or any tools are needed. As the fire pit is on the same plane as the smoker, in order to achieve enough draft, the smoker is built of six floors and is 48" high which makes it a comfortable height to work with. It will also work if the height is limited to 5 block levels (40") and if more draft is needed, an extra floor can be added in a matter of minutes. The blocks can be spaced so that every other row can have two blocks projecting inward from the wall on each side of the smoker. This arrangement creates support for the smoke sticks, screens or racks.
Fire Pit
There are only 7 blocks needed to construct the fire pit which is freely attached to the front wall. Any little smoke coming from the connection is negligible as long as there is smoke coming out of the chamber. A wet towel can be placed over the connection where the fire pit and smoker come together. A fire pit may be attached to the smoker with a mortar. As the concrete block is not designed to withhold high temperatures it is to be expected that once in a while one of the fire pit concrete blocks might crack. Obviously, the most practical solution is to replace it with a different one and go on happily smoking like before.
A long stem thermometer can be inserted between blocks or through the top cover. The temperature control and amount of heat generated is obtained by moving burning wood closer or away from the entrance to the smoker. This is a fully functional and easy to operate smoker capable of producing smoked meats of the highest quality and it should not be judged by its looks. Its useful inside space is only 0.7 cubic foot (0.18 cubic meter) smaller than that of a typical metal drum, providing that we could use all of the drum's space for smoking. Resting smoke sticks on two separate levels creates enough capacity to smoke about 22 lbs (10 kg) of meats.
Smoker with attached fire pit
Frame Smokehouse # 5351
The following smokehouse was used for smoking meats and sausages. It was designed in 1933 by the North Dakota State University and the U.S. Dept. of Agriculture. This is a big walk-in smokehouse requiring a foundation reaching below the frost line. This is the depth where water can still be found frozen depending on a particular geographical location.
Description of the Smokehouse
This is a frame smokehouse built from standard size wood beams and panels. It is covered on the outside with 6" drop siding. The 6" x 14" vent at both ends (front and back) is screened on the outside. The minimum distance between the fire pit and the smokehouse is 4'. This is a big smokehouse and there is a room for a removable utility bench and a barrel with salt. There are 2" x 4" beams with round movable hangers placed every 24". The roof is covered with tight sheathing and the frame is secured to the foundation with 5/8" x 12" anchor bolts.
Floor plan.
Fire Pit
This plan incorporates a rather unusual design of a fire pit as the smoke pipe is going down into the ground and then up again into the smokehouse. Although the smoke delivery pipe is going down into the ground and then up again through the smokehouse floor, there is enough draft as the smokehouse is over 8' high.
The firebox is made of concrete that should be reinforced with woven wire fencing and additional rods around metal doors. The top should also be reinforced with 3', 1/4" rods or their equivalent in addition to woven wire fencing. The doors can be made of sheet metal. Doors from an old heating stove can be used. Grates can be made of pipes, rods or old stove or furnace grates. A hole may be made in the top slab to heat water for feed or butchering.
Cross section.
Masonry Smokehouse # 5352
The following smokehouse was used for smoking meats and sausages. It was designed in 1933 by the North Dakota State University and the U.S. Dept. of Agriculture. This is a big walk-in smokehouse requiring a foundation reaching below the frost line. This is the depth where water can still be found frozen depending on a particular geographical location.
These plans have a great value from an educational point of view and can be easily adapted to an existing shed or other already erected structure. The smokehouse can also be built up right from the beginning.
Description of the Smokehouse
The smokehouse is entirely built from commonly available concrete blocks ( 8" x 8" x 16"). The 5" thick roof slab is made from concrete that is reinforced with # 9 fencing wire. Meats hang on 2" x 6" hangers that are placed 6" apart in slots of the 2" x 8" wall plates (2). One wall plate is located on the front wall just above the door and the other is on the back wall. The wall plates are secured every 12" with ½" bolts and washers on both sides of the concrete blocks. That will require drilling holes through the blocks and the bolts will have to be about 14" long to accommodate the 8" block, 2" wall plate and washers. See detail A and B. There is a concrete lintel (8" x 8" - 4'1") above the door to provide support for the upper 3 levels of concrete blocks. Lintel is reinforced with two 3/8" - 3'10" steel rebars. The door frame is attached to the blocks with six (3 on each side) ½" countersunk bolt anchors. The 2'6" x 6'6" built-up door is covered with a tin sheet on the inside. See detail B. The smoke exit and ventilation are provided by four screened vents attached on the outside - detail E.
Fire Pit
What separates this smokehouse from others is its original fire pit design. In almost all traditional smokehouses smoke delivery is provided by an underground pipe connecting the fire pit with a smoking chamber. In this design a fire pit is an integral part of the smokehouse and the smoke is delivered through the opening in the wall that is situated above the ground level. The fire pit and its vertical safety baffle are made of reinforced concrete to prevent flames from reaching the inside of the smoking chamber. There is a cast iron ring and cover on top of the fire pit and water may be heated for butchering or cooking. The cover can be removed altogether and the cooking vessel can be placed directly over the fire. A cast iron door is provided for ash removal. Due to the height of the smokehouse (10') there is a sufficient draft for smoking.
Floor plan.
Cross sections A-A and B-B.
Detail E, smoke exit and ventilation
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Detail B, door and wall plate support.
Details C and D, fire pit.
Frame Smokehouse # 5695
The following smokehouse was used for smoking meats and sausages. It was designed in 1965 by the North Dakota State University and the U.S. Dept. of Agriculture. This is a big walk-in smokehouse requiring a foundation reaching below the frost line. This is the depth where water can still be found frozen depending on a particular geographical location.
General view.
Description
This is a classical design of a smokehouse that has been used in Europe and later in the USA for centuries. About 10' high, ventilation on both sides, # 30 mesh screen on the inside and a hinged door on the outside. Roof covered with tight sheathing and the frame secured to the foundation with ½" anchor bolts. A removable utility bench inside and the barrel with salt in the corner.
Floor plan.
Fire Pit
The firebox in best of tradition is placed below the smokehouse floor and the smoke delivery pipe is pitched up towards the smokehouse. The minimum distance between the firebox wall and the smokehouse's wall is 4' and the pipe has a perfect length of 7 feet. There is a wood plug with a ring covering the smoke pipe when not in use. The firebox is made of reinforced concrete (rods and wire mesh). There is a 24" tapered concrete plug on top of the firebox that when removed will allow the placement of a large vessel for heating water or cooking.
Cross section.
A simple but functional sliding metal door is secured by pipe uprights. The door will be hot and it should have hook holes or handles. Earth mound over the pipe completes construction.
Masonry Smokehouse #5695
The following smokehouse was designed in 1965 by the North Dakota State University and the U.S. Dept. of Agriculture. This is a big walk - in smokehouse requiring a foundation reaching below the frost line. This is the depth where water can still be found frozen depending on a particular geographical location.
General view
Description
This plan is very similar to the # 5695 Frame Smokehouse, the difference being in the materials used for construction. This is a classical design of a smokehouse that has been used in Europe and later in the USA for centuries. About 10’ high, ventilation on both sides, # 30 mesh screen on the inside and a hinged door on the outside. A removable utility bench inside and the barrel with salt in the corner.
Floor plan
The smokehouse is built using standard size concrete blocks 8” x 8” x 16” which make the project inexpensive and easy to complete. It is almost like building a small house – foundation, concrete walls and a wooden roof that can be covered with shingles. The floor is made of 4” concrete, the door covered on the inside with sheet metal.
Cross section
The advantage of this design is an excellent insulation and a very strong design. Using gas for fuel and placing two strong burners inside it will make it possible not only to smoke products inside but cook them as well to the required inside meat temperature of 152° - 160° F.
Supports for hangers
This type of smokehouse is an overkill for a home sausage maker but becomes a very attractive proposition for someone who wants to make products for sale. Commercially made smokehouses of this capacity will be very costly and the main difference will be in used materials-stainless steel, computer control, automatic showering and all types of advanced settings.
All those functions can be easily accomplished by using a few thermometers and obeying the basic rules of smoking meats. The proper curing of meats before smoking is more important than all the bells and whistles that come with an expensive industrial unit. Another advantage is that there is almost no maintanance as the smokehouse is so simple. If including this type of smokehouse in a regular meat processing operation it would be a good idea to submit the plans to the local fire department to see what changes may be needed. They may require a concrete slab roof instead of the framed one, different thickness of the floor, or some additional drain to be installed. This type of design has proven itself for hundreds of years and cannot be beaten. Many professional butchers use their own brick layered smokehouses with a great deal of success.
Hangers
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