AB Courtyard Weekend Projects: Outdoor Kitchen or BBQ Grilling Station
Outdoor Kitchen
By following the pre-set patterns, this kitchen goes up quickly. Adjustments can be made to accommodate larger grill sizes, or a longer counter top space to allow for shelving or a refrigerator.
To build an Outdoor Kitchen you will need AB York, AB Dublin, AB Corners, Wall Caps and counter top material.
Step 1 - Determine layout and location.
Step 2 - Layout the first course, cutting blocks as needed.
Step 3 - Layout the next 5 courses per the pattern, cutting blocks as needed.
Step 4 - Install the top course following the pattern. This course needs to be installed with the raised rings down to allow placement of the Wall Caps and the counter top material.
Step 5 - Install Wall Caps and chosen counter tops; secure with adhesive.
Step 6 - Move the grill into place and you are ready to entertain in style.
See How-to Sheet #340 and How-to Sheet #341 for complete details.
How to Build an Outdoor Kitchen
Dine out more often with a beautiful and functional outdoor kitchen. An Outdoor Kitchen made with AB Courtyard Collection is an impressive application that can easily be added to any backyard. You can build it on an existing surface like a patio or pavement, as well as on soil. If you will be building in an area that does not have an existing patio or pavement, see How-to Sheet #120 Building Wall Panels and How-to Sheet #220 Building Posts for more information. Take a look at the different options we have here, or get creative and design your own.
Outdoor Kitchen For a Standard Gas Grill - Option 1
The dimensions for this outdoor kitchen are 6.5 ft. wide and 5.5 ft. deep (2 m by 1.7 m ). This example shows the installation steps for a 7 course high bar area with a 6 course high grill area, built on an existing patio surface. The grill used in this example is 30 in. wide and 28 in. deep (760 mm by 710 mm) with height of 4 ft. (1.2 m).
Option 1
Option 2
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How-To Sheets
Outdoor Kitchen Layouts
Step 1: Find the Right Location
Determine the location of the kitchen. Remember to leave enough space around the kitchen area to accommodate for the chef and any additional seating. Then draw a guideline using chalk or tape where the wall panels of the kitchen will be constructed.
Figure 1: Cut Corner Block
Layout the First Course
Step 2: Layout the First Course
Layout the first course of blocks as seen in (Pattern 1). Use a square to line up the blocks to ensure your corners are square. An AB York Block and an AB Dublin Block will need to be split for this course. Save the second half of the AB York to use on the next course. A corner block in this pattern will also need to be cut at an angle so that the blocks match up on the end (Figure 1). Learn more about splitting and cutting blocks.
Step 3: Install the Second Course
Begin laying out the second course as seen in Pattern 2. Next remove the raised rings and split two AB Dublin center-split blocks. See (Pattern 2) for placement of the blocks. Removing the raised rings will create a smooth surface for the next course to be placed on top of. If there are any additional pieces left over they can be used when this pattern repeats.
Pattern 1: First Course Layout
Place the Second Course
Stack the Third Course
Step 4: Continue Stacking Courses
Continue stacking courses by repeating Steps 2-3 until the desired height is achieved. In this example the wall panel behind the grill is one course lower than the bar area panel to allow for movement of the grill hood.
Step 5: Finish With a Countertop
Once you have reached your desired height, it is now time to finish with a countertop. Choose a countertop material to fit your design. In this example we used concrete slabs that are cut to size. Set your countertops in place and check for level. Shims may be used if adjustments are necessary. Secure the countertops in place with masonry adhesive. Move your grill into place and you are ready to fire up the BBQ!
Pattern 2: Second Course Layout
Install Additional Courses
Allow room for the grill hood to move
**NOTE: A larger opening will be needed if your grill is a larger size than the one shown in this example. To increase the width of the grill area opening, add additional AB Yorks, AB Dublins and or split blocks to your wall panel to enlarge the grill area. The minimum increment you can increase your width by is approximately 4 in. (102 mm).
Add the Countertop
Tools Needed
- Square
- Measuring Tape
- Level
- Chalk or Tape
- Hammer & Chisel
- Saw with a Masonry Blade
- Safety Glasses
- Work Gloves
Materials Needed
- 30 in (760 mm) Grill
- 63 Corner Blocks
- 23 AB York Blocks
- 28 AB Dublin Blocks
- Outdoor Countertop
- 4 Tubes of Masonry Adhesive
These are the exact numbers based on our installation. We would recommend purchasing additional block to accommodate for design changes, shipping or breakage.
Outdoor Kitchen with Gas Grill & Side Burners - Option 2
The dimensions for this outdoor kitchen are: 9.4 ft. wide and 5.6 ft. deep (2.9 m by 1.7 m ). This example shows the installation steps for a 7 course high bar area with a 6 course high grill area.
Step 1: Choose Your Location
Determine the location of the kitchen. Remember to leave enough space around the kitchen area to accommodate the chef and any additional seating. Then draw a guideline using chalk or tape where the wall panels of the kitchen will be constructed.
Video: How to Build an Outdoor Kitchen
Option 2
Step 2: Layout the First Course
Lay out the first course of blocks as seen in Layout 1. Use a square to line up the blocks to ensure your corners are square. An AB York Block and an AB Dublin Block will need to be split for this course. Save the other half of the split AB Dublin for use on the third course. A Corner Block will also need to be cut at an angle so that the blocks match up on the end (Figure 1).Learn more about cutting and splitting blocks.
Figure 1: Cut Corner Block
Layout 1: First Course Layout
Layout the First Post
Complete the First Course
Step 3: Build the Second Course
Begin laying out the second course as shown in Layout 2. You will need to split two AB York Blocks and an AB Dublin end-split block to complete this course. Save any remaining split pieces to be used on the next course.
Layout 2: Second Course Layout
Place the Second Course
Stack the Third Course
Step 4: Build the Third Course
Construct the third course as shown in Layout 3 , splitting the AB York and AB Dublin Blocks as needed. A corner block will again need to be cut at the end of the wall, see(Figure 1). We recommend measuring the distance on your project before cutting to make sure you have a proper fit.
Layout 3: Third Course Layout
Build the Fourth Course
Build the Fifth Course
Step 5: Build the Fourth Course
Install the fourth course in the same manner as the previous courses following the pattern in Layout 4, splitting blocks as needed.
Step 6: Build the Fifth Course
Install the fifth course in the same manner as the previous courses following the pattern in Layout 5, splitting blocks as needed. This is the last course to be built in this manner. The next two courses will have additional modifications to complete the project.
Build the Sixth Course
Layout 4: Fourth Course Layout
Layout 5: Fifth Course Layout
Layout 6: Sixth Course Layout
Step 7: Install the Last Course of Blocks
In this example the wall panel behind the grill is one course lower than the bar area panel to allow for movement of the grill hood. On this course you will need to flip the blocks over along the first post/pillar and the back wall of the grill area**. This will allow the countertop to be flush and level when installed.
** This is done by knocking the rings off with a hammer and chisel, or simply flipping the blocks over so that the raised rings go into the holes on the previous course.
Step 8: Complete the Raised Bar
Once you have reached your desired height of the grilling area, it is now time to finish the raised bar. Underneath the bar is a perfect spot to place a mini refrigerator or add shelves for storage. To build the top course of the bar, you will need to flip these blocks over to create a level surface for the courtertop. Install the blocks using the pattern in Layout 7.
Step 9: Add Your Countertop
Now that the construction of the kitchen frame is complete, it is time to install your countertop material. In this example we used concrete slabs that are cut to size. However any outdoor countertop material will work that is outdoor rated like concrete, granite or quartz, etc. So choose a countertop that fits your design and measure the area where it will be needed.
Allow room for the grill hood to move
Layout 7: Raised Bar Layout
Finish the Last Course
Add Your Countertop
Set your countertops in place and check for level. Shims may be used if adjustments are necessary. Secure the countertops in place with flexible concrete adhesive. We recommend allowing for overhang of the countertops on the seating and countertop sides of the kitchen.
*NOTE: A larger opening will be needed if your grill is a larger size than the one shown in this example. To increase the width of the grill area opening, add additional AB Yorks, AB Dublins and or split blocks to your wall panel to enlarge the grill area. The minimum increment you can increase your width by is approximately 4 in. (100 mm).
Countertop layouts
Tools Needed
- Square
- Measuring Tape
- Level
- Chalk or Tape
- Hammer & Chisel
- Saw with a Masonry Blade
- Safety Glasses
- Work Gloves
Materials Needed
- 30 in (760 mm) Grill
-
73 AB York Blocks
- 8 AB Dublin cut in half
-
30 AB Dublin Blocks
- AB Dublin cut at raised ring
- 4 AB Dublin cut in half
- 67 Corner Blocks
-
3 Outdoor Countertops
- 1 - 24 in. x 32 in. (60 cm x 80 cm)
- 1 - 66 in. x 8 in. (168 cm x 20 cm)
- 1 - 80 in. x 36 in. (205 cm x 90 cm)*
- Flexible Concrete Adhesive
These are the exact numbers based on our installation. We would recommend purchasing additional block to accommodate for design changes, shipping or breakage.
BBQ Grilling Station
In just a few hours, you can be sitting in front of a roaring fire, with your feet up, enjoying the evening. Using the AB York and Wall Caps from the AB Courtyard Collection, you can add a beautiful accent to your landscape.
To build a BBQ Grilling Station you will need AB York, AB Dublin, AB Corners, Wall Caps and counter top material.
Step 1 - Determine layout and location.
Step 2 - Build first post/pillar following pattern.
Step 3 - Build back wall panel.
Step 4 - Build 2nd post/pillar.
Step 5 - Build additional courses.
Step 6 - Install Counter tops and Wall Caps.
See How-to Sheet #290 and How-to Sheet #290A for complete details.
How to Build BBQ Grilling Station
Grill out more often with an attractive and functional BBQ Grilling Station. Learn here just how easy it is to build. This project demonstrates how to build on a hard,level surface, such as concrete or pavers. You can build it on an existing surface like a patio or pavement, as well as on soil. If you will be building in an area that does not have an existing patio or pavement, see How-to Sheet #120 Building Wall Panels and How-to Sheet #220 Building Posts for more information.
Option 1
Option 2
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How-To Sheets on
BBQ Grilling Stations
Step 1: Build the First Post/Pillar - Option 1
Mark out the location of your grilling station. Draw an 87 in. (2.2 m) minimum guideline where the back of the BBQ grilling station will be constructed.
Place the first Corner Block on the guideline where you want to begin. Then place 3 more Corner blocks and 2 AB York blocks (Figure 1).
Video: How to Build BBQ Grilling Station-VS 1
Use a square to line up the blocks to ensure your post/pillar is square. Remove the raised ring on one of the AB York Blocks using a hammer and chisel. This will provide a flat surface for the next course of blocks.
On the second course, place 4 Corner blocks so that they offset the blocks beneath them. Split an AB Dublin end-split block and place the large piece with the raised rings facing down and the split side against the Corner block (Figure 2). Save the smaller piece to be used at the end of the wall panel.
Figure 1: First Post/Pillar Base Course Pattern
Mark the Location
Place the First Corner Block
Step 2: Build the Wall Panel
Begin the wall panel by installing the first 2 courses at the same time, using the patterns shown (Figure 3), or one you have chosen. In this example we are alternating between AB Dublin and AB York blocks.
Building the first 2 courses at the same time will ensure that the blocks line up properly. End the base course of the wall panel with a Corner block. End the second course of the wall panel with the remaining small piece of the AB Dublin end-split block used on the post/pillar (Figure 3).
Figure 3: Wall Panel Course Patterns
Figure 2: First Post/Pillar 2nd Course Pattern
Align the Blocks with a Square
Remove the Raised Rings
Step 3: Build the Second Post/Pillar
Continue building the second post/pillar by placing 3 additional Corner Blocks and 1 AB York block as shown (Figure 4).
Use a square to position the blocks. Remove the raised ring on the AB York block with a hammer and chisel. Build the second course of the post/pillar by placing 4 Corner blocks starting with the first Corner block against the small piece of the AB Dublin end-split block (Figure 5).
Figure 4: 2nd Post/Pillar Base Course Pattern
Figure 5: 2nd Post/Pillar 2nd Course Pattern
Finish with an AB Dublin
End-Split Block
Build Wall Panel
Step 4: Continue Building
Continue stacking courses by repeating Steps 1-3 until the desired height is achieved. This example uses a total of 5 courses, plus one additional course of 5 Corner blocks to each post/pillar. The wall panel is one course lower than the posts/pillars to allow for movement of the grill hood (Figure 6).
Figure 6: Hood Movement
Start the Second Post/Pillar
Remove Raised Rings & Build Second Course
Step 5: Finishing the BBQ Grilling Station
Place Wall Caps on top of the wall panel by alternating the caps to keep a straight line. Secure the caps in place with masonry adhesive. Choose a countertop material to fit your design (Figure 7). Set your countertops in place and check for level. Shims may be used if adjustments are necessary. Secure the countertops in place with masonry adhesive, move the grill into place and you are ready to fire up the grill!
The dimensions of this BBQ grilling station used in this example are 36 in. H x 30 in. D x 87 in. W (0.9 m H x 0.8 m D x 2.2 m W) using a 39 in. (1.0 m) wide grill. To build using a different size grill, see (Figure 8) for information on other grill widths.
Figure 8: Block Counts for Common Grill Widths* |
|||
|---|---|---|---|
| Block Type | 30 in. (762 mm) |
39 in. (0.99 m) |
48 in. (1.2 m) |
| AB York | 26 | 21 | 26 |
| AB Dublin | 7 | 12 | 12 |
| Wall Caps | 4 | 5 | 6 |
| Corner Blocks | 50 | 50 | 50 |
Figure 7: Countertops
Continue Stacking Blocks to the Desired Height
Set Wall Caps in Place
Add Countertops to Posts
Tools Needed
- Square
- Measuring Tape
- String Line
- Level
- Hammer & Chisel
- Safety Glasses
- Work Gloves
Materials Needed
- 39 in(0.99 m) Grill
- 50 Corner Blocks
- 21 AB York Blocks
- 12 AB Dublin Blocks
- 5 Wall Caps
- 2 Outdoor Countertops
24 in x 32 in. (600 mm x 800 mm) - 2 Tubes of Masonry Adhesive
These are the exact numbers based on our installation. We would recommend purchasing additional block to accommodate for design changes, shipping or breakage.