etex Promat PROMAFOUR boards Installation and user guide

How to:
Line a masonry replace
with PROMAFOUR®
PROMAFOUR® re surround lining systems

TECHNICAL SERVICES EMAIL: technical.proma[email protected]
2
Promat | How to Line a masonry replace
If you are installing a new stove,
stove surround or updating an
existing one you must ensure that
the wall lining in the replace is
safe and doesn’t pose a re risk.
You must ensure that the board
has the legal certication that it
canboth:
• Withstand temperatures of up
to 1000°C; and
• Is classied A1 non-combustible
and will not catch re or
contribute to a re
Promat PROMAFOUR® meets
these criteria. It has been
fully tested and classied to
international re standard,
BSEN13501-1 and carries
a CEMark which is the
manufacturers declaration
thatPROMAFOUR® meets
EUsafety requirements.
Whilst there are other boards on
the market which are classied
A1 non-combustible, they are
not designed to withstand the
intense heat of a replace or the
continuous ongoing strain that is
unique in this environment.
Gypsum plasterboards – including
the re-rated pink boards – are
combustible and should not be
used for replaces.
In contrast, Promat PROMAFOUR®
has been specically designed
to be used for the installation
of a false chimney breast for an
inset type replace and for walls
surrounding free standing stoves.
It will provide a clean, pre-
decorative nish for your replace
and as it requires no plaster it will
not crack under pressure from the
most intense heat.
PROMAFOUR®
The re surround lining system

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Promat | How to Line a masonry replace
Why PROMAFOUR®
Benets for installer and homeowner
SAFE AND RELIABLE
PROMAFOUR® boards are
classied A1 non-combustible in
accordance with BS EN 13501-1
and resistant to very high
temperatures up to 1000°C
duringprolonged exposure.
Theboards are composed of
calcium silicate and don’t contain
any bonding agent which could
emit an irritating odour.
AESTHETICS AND COMFORT
PROMAFOUR® has good heat
permeability and very good
thermal storage capacity. This
ensures less heat loss and uniform
heat emission into your home even
after the re has gone out.
PROMAFOUR® boards have a
naturally smooth surface which
is ideal for painting without
additional plastering, leaving
your stove to be the feature in
thereplace.
QUICK AND EASY TO INSTALL
PROMAFOUR® boards can
easily be cut with traditional
woodworking tools and installed
using masonry screws, staples,
nails and PROMAFOUR® Glue,
a refractory silicate based glue
which resists temperatures up to
1000°C.
FINISHING
The high quality smooth surface
nish of PROMAFOUR® is ideal
for painting without the need for
plastering.
PROMAFOUR® can also be tiled,
supporting a maximum weight of
30kg per m².
PEACE OF MIND
As PROMAFOUR® boards
minimally expand and contract
during and after heating, the
risk of cracks, splitting or the
board deforming is reduced to
an absolute minimum – giving
reassurance that your replace will
require no future maintenance.
In order to build a secure
and aesthetic PROMAFOUR®
encasement, we advise you to
follow the instructions described
and utilise the PROMAFOUR®
product range, which has been
developed specically for use
with res and stoves.

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Promat | How to Line a masonry replace
TECHNICAL SERVICES EMAIL: technical.proma[email protected]
1 PROMAFOUR® boards are
mechanically strong and easy
to work with.
Board dimensions are
2500mm x 1250mm and
1250mm x 1250mm
Available in thicknesses of
12mm and 15mm.
2PROMAFOUR® GLUE 1000 is
a refractory silicate based glue
which resists to temperatures
up to 1000°C.
Available in 310ml cartridges.
PROMAFOUR® GLUE 1000
3PROMAFOUR® Primer is a
non-combustible and vapour
permeable primer, which
has been designed for use
atelevated temperatures.
Available in 3 Litre and
1Litretubs.
PROMAFOUR® Primer
4PROMAFOUR® HT Joint Filler
for nishing.
Available in 1.5kg tub
Getting started
Equipment required
5Promat PROMASEAL®
SILICONE SEALANT is a
silicone based re protection
sealant.
Available in white or grey
colour.
OTHER ITEMS YOU MAY NEED
• Dust and Plastic
Sheeting/Matting
• Appropriate PPE – Glasses,
gloves, dust masks
• Countersunk wood screws
and metal plugs
• Spatula
• Hand Saw
• Sponge
• Right angle / set square
• Nail Gun
• Spirit level
• Knee pads / air masks
with lters
• A circular saw or jigsaw with
dust extraction device or with
separate dust extraction
(The one seen in this guide is
a Festool Plunge Saw with dust
extractor) other plunge saws
are available
• Cutting Table
• Hand saw (If required for
shaving boards to t)
• Buckets ( for mixing
compounds)
• Cleaning spatula to wipe the
excess glue off before it sets
• If Painting – Paint and roller
• Countersunk concrete/
masonry screws
BEFORE YOU BEGIN
Before you begin to install
your PROMAFOUR® lining it
is important to carefully read
the following safety measures
and instructions;
• Always observe the safety
instructions of the stove
manufacturer
• Always ensure safe working
conditions and a safe
working environment
• Take the necessary
precautionary measures
to prevent possible injuries
• Always use the correct
equipment as described
in this installation
manual and stove
manufacturers guidelines.
This is not a guide on how to
install a stove – please ensure
you meet building regulations
and follow all of the procedures
for the stove installation in
addition to this process.

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Promat | How to Line a masonry replace
1 Cover the surrounding area to the installation
with dust sheets to ensure any dust is contained.
2 Review the opening of the replace and look
to see how uneven the surfaces are. For new
properties this should not be an issue but older
properties can have uneven surfaces. You can
check how straight by using a right angle set
square. As shown opposite.
3 Large protrusions on the surface should be
removed to make the surface as level/even
aspossible.
Stage 1
Preparing the existing replace
Some older properties might have hooks inside the replace
– these should be removed.
Using a right angle set square to check for uneven surfaces
THERE ARE 4 STAGES FOR THE LINING OF A FIREPLACE;
Stage 1: Preparing the existing replace
Stage 2: Installing PROMAFOUR®
Stage 3: Fixing PROMAFOUR®
Stage 4: Finishing PROMAFOUR®

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Promat | How to Line a masonry replace
TECHNICAL SERVICES EMAIL: technical.proma[email protected]
1 Measure the three surfaces of the replace.
With older properties take several measurements
at different levels just to check how uneven the
wall might be.
2 You will need to cut the rear panel rst as this is
the rst one to be installed.
TIP Always carry and stack PROMAFOUR® boards
carefully. Two people should carry a full board.
Each board should be carried on it’s edge, taking
care not to bend it as this can cause internal cracks
which may not show in normal conditions but when
heated the crack can expand. PROMAFOUR®
should be stored on at surface in a well ventilated
room. NEVER store the boards on their side.
Carefully place your measurements on the
board prior to cutting.
3 Cut the PROMAFOUR® to the measurements
marked on the board for the three faces
of replace.
The installers in this guide have used a Festool
Plunge Saw with dust extractor which we
recommend for a straight cut but you can also
use a Jigsaw with woodworking saw blade.
TIP We advise leaving a 2mm gap from the left and
right rear panel boards to allow for expansion when
heating. Please take this into consideration when
cutting.
Also leave a gap of between 1-2mm for the left and
right hand side panels from the back panel as this
will be glued later.
Stage 2
Installing PROMAFOUR®
Measuring the surfaces of the replace.
Place your measurements on the board prior to cutting.
Using a Festool Plunge saw to cut.
Fitting the board.

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Promat | How to Line a masonry replace
Stage 2
Installing PROMAFOUR® (continued)
The rear PROMAFOUR® board is held in place
using Flamebond 9 as a bonding compound.
Check to ensure it is level and the surface is even.
When screw xing into the the masonry you
would need to use a suitable metal wall plug
and countersunk wood screw.
TIP As is common with older properties some
of the walls might be uneven – if this is the
case you could use a PROMAFOUR® wedge as
shown opposite to pack out behind the board to
overcome any unevenness on their side.
Now apply the PROMAFOUR® pieces you have
measured for the left and right of the re place in
the same way as rear board but you do not need
to use compound to hold into place.
TIP If you have uneven walls that the board
needs to be corrected for, you can use a hand
saw to ‘shave’ the board to ensure a good t.
Checking the board is level.
4
Using a PROMAFOUR® wedge to correct uneven walls.
Fixing the left and right pieces.
5
‘Shaving’ PROMAFOUR® with a hand saw to ensure a good t.

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Promat | How to Line a masonry replace
TECHNICAL SERVICES EMAIL: technical.proma[email protected]
Stage 3
Fixing PROMAFOUR®
Pre-drill and countersink oversize screw holes in
the rear board and at the back of the left and right
boards at a maximum of 300mm centres. This is to
allow for heat expansion. See diagram opposite.
Screws should be loosely tted to the boards and
xed into metal plugs. If they are too tight they
can put additional tension on the board when the
screw expands with the heat, which can lead the
board to crack.
Alternatively, you can use countersunk concrete/
masonry screws but do not over-tighten.
PROMAFOUR® Glue is applied in the back left
and right corner to help support the left and
right boards. Excess should be cleaned with a
spatula and a sponge.
TIP The glue dries very quickly to a hard nish
so clean any excess before it dries as removing
when dry can be difcult.
TIP Water can collect in the top of the glue. When
opening glue for the rst time snip of the top and
hold over a bucket for example to allow excess water
to be released.
Fixing centres.
1
Screw being loosely xed to the rear board.
2
Min 40mm
Min 12mm from edges
Max 300mm
Pre-drilling screw holes in the rear board.
Applying PROMAFOUR® Glue to the back left and right corners.
3
Min 12mm from edges

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Promat | How to Line a masonry replace
Stage 3
Fixing PROMAFOUR® (continued)
PROMAFOUR® Glue being applied to between the joints.
4PROMAFOUR® Glue is then applied between
the joints of the left and right boards to the rear
board.
In most installations the edge of the Promafour®
boards will be hidden by a hearth. Here we show
a way of nishing the boards into the surround
if this is not possible. If there is no surround you
may want to use the joint ller to blend into the
wall. If this area gets too hot the non Promafour®
components, such as beading and plaster, may
expand or contract with heat and lead to cracking.
Fixing using a nail gun.
5
TOOLS NEED FOR INSTALLATION
Power equipment required for installation. Other items required for installation.

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Promat | How to Line a masonry replace
TECHNICAL SERVICES EMAIL: technical.proma[email protected]
Stage 4
Finishing PROMAFOUR®
PROMAFOUR® Joint Filler is applied to ll the screw heads.
1Apply PROMAFOUR® Joint Filler to the screw
heads to make an even surface. Once ller has
dried you will need to sand it down for a
smooth surface.
The ller may contract overnight and require re-
applying and re-nishing the following day. This
should be done before decorating.
Apply PROMAFOUR® Primer and paint using
a suitable paint if painting.
Allow 24 hours for the re place to
dry before painting.
TIP Most other primers contain water, if you paint on to
this primer, the water content can turn to steam and the
paint can ‘blister’ - PROMAFOUR® Primer contains no
water - it is silica based and is ideal for this application.
Applying PROMAFOUR® Primer.
2
Once dry PROMAFOUR® Joint Filler can be sanded down.
3

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Promat | How to Line a masonry replace
Stage 4
Finishing PROMAFOUR® (continued)
Painting PROMAFOUR®
4If required PROMAFOUR® can be painted
with specialist high temperature paint, such as
Keim Paint. Please refer to paint manufacturer
guidelines.
TIP We have only discussed a paint nish but if you
prefer a tiled nished, install with rough side facing
the room and prime the rough surface and x tiles to
PROMAFOUR® using PROMAFOUR® glue.
PROMAFOUR® can be tiled with a minimum
board thickness of 12mm. The boards should
be sealed on both faces with PVA or watered
down tile adhesive and allowed to dry.
The boards should be xed with the textured
face outwards, to the supports at 200mm centres.
The screws should be countersunk and corrosion
resistant. The tile should then be xed using
Promafour® Glue.
Maximum tile weight: 30kg/m2
Allow 24 hours for the re place to dry before
lighting the stove for the rst time.
TIP PROMAFOUR® needs to be gently warmed up.
If the re becomes over heated by turning too much
wood in one go, this may damage not only your
appliance but may also cause cracks to appear in the
boards at rst heating, as all refractory material will
shrink and expand at high temperature and therefore
need time to be settled. Therefore we recommend at the
beginning to heat up slowly to the required maximum
temperature, by burning at a low primary air level and
not too much wood in one go. High moisture content
can lead to cracking if heated up too quickly.
Allow 24 hours for the paint to dry.
5
6
A completed clean and aesthetic replace.

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Promat | How to Line a masonry replace
TECHNICAL SERVICES EMAIL: technical.proma[email protected]
Frequently
asked questions
CAN I PLASTER PROMAFOUR®?
We do not recommend this.
The board nish is smooth and
ready to be painted once primed.
Even high temperature plaster is
not guaranteed against cracking
and the plaster accessories, such
as metal beading, expand with
high temperatures which makes
an unreliable nish for replaces.
CAN I JOIN PLASTERBOARD/
PLASTER SURFACE TO A
PROMAFOUR® IN ONE
CONTINUOUS LINE?
Whilst PROMAFOUR® offers a
high quality nish, it looks slightly
different to a plastered one,
even with the same paint on both
surfaces, therefore we wouldn’t
recommend this approach.
I HAVE A LARGE FIREPLACE, CAN
PROMAFOUR® BE USED IN THIS
INSTANCE?
Yes it can - The maximum height
for use with inset res is 3.5m. This
is due to the fact that it will be a
false wall and any higher you would
need a solid structure to build off.
In the case shown we are xing
PROMAFOUR® to a solid wall.
Please contact the
Promat Technical Services
[e-mail]
or 0800 145 6033 (Option 2)
if you have any enquiries.
WHAT TYPE OF PAINT SHOULD I
USE ON PROMAFOUR®?
A Silicate/non-organic content
paint (such as Keim Paint) Always
check with the manufacturer that
it is suitable for the application
and never use a paint with an
alkyd content.
CAN I TILE PROMAFOUR®?
Yes - See section on how to tile
PROMAFOUR®.
HOW DO I DISPOSE OF ANY
PROMAFOUR® WASTE?
PROMAFOUR® may be disposed
of with ordinary building material
waste (always observing local and
national legislation).
CAN I WALLPAPER ON TO
PROMAFOUR®?
Yes – please ensure any wallpaper
and adhesive is suitable for this
application before installation.
WHERE CAN I BUY
PROMAFOUR®?
Stockist information can be found
on www.promat.co.uk on the
PROMAFOUR® product page.

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TECHNICAL SERVICES PHONE: [phone]
GB ORDER LINE
For placing orders, delivery enquiries,
local stockists etc.
T: 0800 373 636
F: 01275 379 037
E: [e-mail]
RESOLUTIONS
For any problems with invoices or deliveries.
T: 01275 379 031 or 0800 373 636
F: 01275 379032
E: [e-mail]
TECHNICAL SERVICES
For technical support and advice.
T: 0800 145 6033
E: technical.proma[email protected]
KEIM PAINTS
T: 01952 231 250
W: www.keim.com
FORTAFIX
Flame Bond Range
T: 1429 273 252
W: forta[email protected]
PROMAT
Gordano House
Marsh Lane
Easton-in-Gordano
Bristol
BS20 0NE
T: 0800 373 636
F: 01275 379 037
E: [e-mail]
www.promat.co.uk