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General Isokern Assembly Instructions:
Earthcore Mortar (a thin-set type masonry adhesive) is
used to glue all Isokern components together during field assembly
of the unit. The mortar is supplied dry, in either 15 pound or 50
pound pails.
Earthcore mortar is mixed with clean water to a smooth,
workable texture (without lumps or dry pockets) of a “toothpaste”
consistency. This mixture is suitable for application onto Isokern
components by using a masonry grout bag supplied with the unit.
Attention should be paid that the mortar mixture is not too
thin or runny, as this will not allow the mortar to reach its maximum
bonding strength.
Earthcore mortar is squeezed from a grout bag onto the
contact surfaces of the Isokern components as they are fitted
together.
It is important that a 1/2” bead of mortar on all the compo
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nents’ contact surfaces is applied at about 1/2” in from all edges of
the contact surface of the component.
When setting the next component onto the mortared con
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tact surface of the first component, some mortar should squeeze out
along the face of the entire joint as a sign of complete and proper
sealing of the joint.
On broader contact surfaces it is advisable to apply several
additional 1/2” beads of the Earthcore Mortar to the area to assure
proper sealing of the joint.
Properly mortared firebox and smoke dome assembly re
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quires approximately 25 pounds (dry measure) of Earthcore mortar.
Broken Components:
Components broken into 2 or 3 pieces can be repaired by
using Earthcore mortar along the break line as the component is set
into place. Components broken into multiple small pieces should be
discarded and replaced.
Leveling and Aligning Components:
Be sure to assemble all Isokern components level and flush
with adjoining components.
Earthcore mortar is not intended to create a mortar joint
of any thickness for leveling purposes. Therefore, leveling and
alignment adjustments are made by the use of small plastic shims
supplied with the unit.
The shims can be inserted under a component to level and
align it with adjacent Isokern components. Be sure to re-grout any
and all gaps resulting from shim insertion to maintain components
to full bearing.
Notes:
1. Do not mix Earthcore mortar with spirits or anti-freeze agents.
2. The maximum recommended mortar joint thickness at Isokern
components is 1/4”.
3. Earthcore mortar can be troweled over the face of a joint where
it has squeezed out while setting components. It is not intended that
the exposed faces of the Isokern components be completely covered
with the mortar.
Assembly Instructions - 36 C
Earthcore Mortar
Shim if required
to acheive
correct height
