8
Assembly Instructions
Earthcore Mortar:
Earthcore Mortar is to be applied to all joints between
Vent-Free fireplace components during field assembly of the
unit. Thoroughly mix the Earthcore Mortar with clean water.
Be sure to eliminate any dry pockets or lumps in the mortar.
The proper finished mixture should be of a “toothpaste”
consistency, suitable for application by use of a standard
mason’s grout bag. If the mixture is too thin and runny then
the mortar cannot reach its full strength.
Note:
When used to assemble the Vent-Free fireplace
components Earthcore Mortar is to be mixed only with clean
water.
Assembling the Vent-Free Fireplace Components:
Once the mortar is mixed and loaded into a grout bag
it can easily be squeezed out and onto all contact surfaces of
the Vent-Free fireplace components as they are fitted together.
A Vent-Free fireplace requires approximately twenty-
five pounds (25 lbs.) of Earthcore Mortar for proper assembly.
Typical grouting procedure is to lay a one half inch (1/2”) bead
of mortar approximately one half inch (1/2”) in from all of the
edges of the contact surface of one component.
The next mating component is then set in place onto the already
grouted contact surface of the first component.
Since some of the component contact surfaces are
broader areas it is advisable to apply several additional half
inch (1/2”) beads of mortar onto these larger contact surfaces
to assure proper sealing. Indication of proper sealing of two
mating components is that some mortar is squeezed out all
along the contact joint of the two components. The excess
grout can be troweled over the face of the joint.
Note:
Do not float Earthcore Mortar over the entire face of any
component.
Leveling and Aligning Components:
Be sure to assemble all Vent-Free fireplace
components flush, level and square. Since it is not intended
that mortar be used to lay a mortar joint of any measurable
thickness as is typical when laying brick or concrete block,
adjustments in component height and level alignments are
accomplished with the use of small plastic shims (supplied
with the unit). These shims can be gently tapped into place to
level and align components. Once the Earthcore Mortar has
set, the small leveling shims can be either nipped off flush at
the insertion point or removed completely.
Be sure to re-grout any and all gaps where shims have
been inserted and then removed or where contact surfaces have
been separated by shim leveling.
Broken Components:
Components that are broken from faulty handling
can be repaired using Earthcore Mortar. The component that is
broken into two pieces and not fragmented along its break line
can be glued together with Earthcore Mortar in the same way
that two mating components are assembled.
Face and Surface Cracks: Should a face crack appear
after the unit is assembled the crack can be repaired in place.
A crack can be “V” notched with a masonry chisel to a depth
of approximately three-eighth inch (3/8”). Earthcore Mortar is
then squeezed into the face crack and troweled smooth to the
surface of the component.
Note:
Badly fragmented components should be discarded and
replaced.
Step 1:
Begin assembly by setting the Vent-Free fireplace’s
three inch (3”) thick base plate flat on a suitable level surface
at zero clearance. This surface can be a concrete slab or a wood
floor system capable of 150 psf loading. The base plate can
also be set on a concrete block raised base or on a raised wood
platform either of which can be built upon a structural slab or
upon a structurally suitable wood floor system.
Step 2:
Next set the first course of back wall and side walls into
place. It may be convenient to scribe the location of the first
layer of side walls and back wall on the base plate and then to
apply Earthcore Mortar to these scribed areas on the base plate
where the side walls and back wall will sit. In this way the first
layer of walls can be set directly into grout already applied to
the base plate. Be sure to grout the vertical joints where the
side wall to back wall connect as each component is joined to
its mate. Look for mortar to squeeze out of all contact joints as
a sign of proper and complete sealing of the joints.
Continue with the sequential assembly of the second
and third courses of the side walls and back wall by first
applying grout to the top of the previous layer, setting the
next course above into grout already applied to the horizontal
contact surface of the component below. Again be sure to grout
the vertical joints of the side wall to back wall connection as
each component is joined to its mate. Look for some mortar to
squeeze out along all joints as a sign of proper sealing of the
joint.
Step 3:
Once the third, or top course of side walls and back
wall are set in place their top surfaces are to be grouted with
mortar to receive the Vent-Free fireplace top plate. Set the top
plate upon the completed side wall/back wall assembly seeing
to it that the grouted contact surfaces are properly sealed. This
completes the assembly of the Vent-Free fireplace rough box
components.
Step 4:
Make sure that the rough box assembly has been set
level and square. Adjust to level and square, as necessary,
while mortar is still wet. Make a final inspection of all contact
joints to be sure they are properly sealed. Re-grout any and all
gaps as necessary.
Step 5:
The manufacturer requires a minimum one and one
eighth inch (1-1/8”) thick fire brick as a liner to the inside of
the Vent-Free fireplace. Thicker rated fire brick may be used as
an option. Also, the pattern for the fire brick interior lining is
not specified and is to be at owner option.
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