12
IBV Assembly Instructions
General Assembly Instructions:
Earthcore Mortar (a thin-set type masonry adhesive) is
used to glue all IBV masonry 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 IBV components by using a masonry grout bag such as the
one 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 IBV components as they are fitted
together. (Figure 2)
It is important that a one-half inch (1/2”) bead of mortar
on all the components’ contact surfaces is applied at about one-
half inch (1/2”) in from all edges of the contact surface of the
component.
When setting a component onto the mortared contact
surface of the preceding 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 one-half inch (1/2”) beads of the Earthcore
Mortar to the area to assure proper sealing of the joint.
Properly mortared firebox and smoke dome requires
approximately 25 pounds (dry measure) of Earthcore Mortar.
Broken Components:
Components broken into two or three
pieces can be glued together along the break line with Earthcore
Mortar 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
IBV components level and flush with adjoining components.
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
IBV components (Figure 3). Be sure to add mortar to all gaps
resulting from shim insertion.
Notes:
1.
Do not mix Earthcore Mortar with spirits or anti-freeze
agents.
2.
The maximum recommended mortar joint thickness at IBV
components is one quarter inch (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 IBV components be completely covered
with the mortar.
Earthcore Mortar
Shim if required
to acheive
correct height
Figure 2
Figure 3
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