FireRock FIREROCK CONVENTIONAL User manual
IMPORTANT: This manual contains product usage guidelines infield application rules installation steps and operating and
maintenance instructions for the FireRock Conventional/California Conventional preengineered masonry fireplace kit and
LiteRock installation method This manual should become the property of and be reviewed by all current and future users of this
product It is the responsibility of the general contractor and the installer to ensure that the instructions set forth in this manual
are followed exactly It is also the responsibility of the general contractor to provide adequate clearance to combustibles see page
from all fireplace surfaces as specified herein
Before installing this product please consult with local building and zoning authorities regarding the need for proper permitting
If the information in this manual including installation instructions is not followed exactly a fire or explosion may result causing
property damage personal injury or loss of life
IMPORTANT: Read the entire manual before beginning construction.
Contents of this manual may change without prior notification
Installer: Leave this manual with the appliance.
Consumer: Keep these instructions for future use.
MANUFACTURING:
Avenue C
Birmingham AL
ADMINISTRATIVE:
st Ave N #
Birmingham AL
PHONE FAX TOLLFREE
LISTED MASONRY FIREPLACE SYSTEM
MODEL FIREROCK CONVENTIONAL/CALIFORNIA CONVENTIONAL
” ” ” ” MODULAR FIREPLACE
UL 127 COMPLIANT
CONVENTIONAL/CALIFORNIA CONVENTIONAL FIREPLACE
INSTALLATION, SPECIFICATION AND OPERATION MANUAL
THIS PAGE INTENTIONALLY LEFT BLANK
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TABLE OF CONTENTS
Important Safety Information
Materials and Equipment List
Intended Use Statement
Installation Considerations
Warnock Hersey Listing Label
Fireplace Dimensions
Clearance to Combustibles
Rough Framing Dimensions
Fireplace Installation
Foundation
Mixing and Applying Mortar
Firebox Assembly
Throat and Damper Assembly
Smoke Chamber Assembly
Chimney Assembly
Firebrick Installation
Brick Flange
Outside Air Kit
Typical Gypsum Board Application
MultiFloor Stacking Diagram
Metal Chimney Installation
LiteRock Installation Method
Operating Instructions
Parts Dimensions
Terms and Conditions
4
IMPORTANT SAFETY INFORMATION
The FireRock Conventional/California Conventional fireplace is a modular system designed to be assembled in field using
FireRock Adhesive Mortar Each component is designed for a specific part of the firebox smoke chamber and flue design and
therefore only one means of assembly is possible A minimum ¼” thick firebrick lining is required compliant with ASTM
Any application other than the “intended use” stated herein is in violation of the manufacturer’s instructions and is hereby
prohibited Such violations may cause immediate hazard property damage or loss of life and will void all liabilities to the
manufacturer and will void all warranties explicit or implied
Read the installation and operating instructions carefully and in full to be sure you understand them prior to installation If the
information in this manual including installation instructions is not followed exactly a fire or explosion may result causing
property damage personal injury or loss of life
Check local building codes pertaining to fireplaces and fireplace installation All installations must comply with local
regional state and national building codes and regulations
Maintain the stated minimum clearance to combustibles see page and do not violate any specific installation
requirement
Do not pack required air spaces with insulation or other materials
Foundations and footings must meet local building code and be approved by the local building authority For any
foundation design and load requirements check with a structural engineer
This fireplace is not designed to sit directly on or abut a combustible surface or floor system except when using the
LiteRock Installation method See pages for specific installation requirements
Ensure that an adequate supply of replacement air from outside of the house is accessible to the fire to support normal
combustion It is the responsibility of the builder or contractor to supply adequate combustion air
Do not use a fireplace insert or other product not specified for use with a fireplace with the reflective properties of this
product
This fireplace has not been tested for use with doors To reduce the risk of fire or injury do not install doors
Do not burn construction debris of any kind in this fireplace
Do not burn small branches or twigs that exceed the volume of a normal fire see page Overfiring can permanently
damage the system
Only vented gas logs that are listed by ANSI Z can be used in this fireplace
This fireplace has not been tested with an unvented gas log set Do not install an unvented gas log set in this fireplace
NOTE: This is important safety information for the installation of this fireplace
For safety information regarding the operation of this fireplace see pages
5
MATERIALS AND EQUIPMENT LIST
NOTE: Some of the components of this fireplace are extremely heavy and should not be lifted by one person Because of this
realize that building this fireplace is at minimum a twoman job
30” 36” 42” 48”
” Base Plate
” Base Plate
” Base Plate
” Base Plate
Firebox side
Back Wall ” Courses &
Back Wall ” Course
Back Wall ” Course
Back Wall ” Courses &
Back Wall ” Course
Back Wall ” Course
Back Wall ” Courses &
Back Wall ” Course
Back Wall ” Course
Back Wall ” Courses &
Back Wall ” Course
Back Wall ” Course
” Radius Throat Front
” Throat Back
” Radius Throat Front
” Throat Back
” Radius Throat Front
” Throat Back
” Radius Throat Front
” Throat Back
Throat Side
” Smoke Chamber Front/Back
” Smoke Chamber Front/Back
” Smoke Chamber Front/Back
” Smoke Chamber Front/Back
Smoke Chamber Side
Chimney Base Large
Chimney Base Small
Angle Steel
TOTAL 23 27 27 31
REQUIRED MATERIALS & EQUIPMENT
Concrete for pad/foundation
Clean water
Trowel
gallon bucket
Level
Plastic shims
FireRock Adhesive Mortar
Damper for interior applications
Firebrick
Masonry chimney block or UL metal
pipe with required accessories
OPTIONAL MATERIALS & EQUIPMENT
Rebar to fill hurricane holes in masonry
chimney blocks
CMU block
LiteRock riser kit
Outside air kit
Log lighter
Noncombustible stone or veneer for
outdoor applications
CONVENTIONAL/CALIFORNIA CONVENTIONAL*
MASONRY FIREPLACE SYSTEM COMPONENTS
See pages 34-40 for component specifications
*For all sizes, the California Conventional model will have 2 additional back wall (courses 1 & 2)
pieces, which replace the 2 angled back wall (course 3 and course 4) pieces of the Conventional model
6
INTENDED USE STATEMENT
NOTE: Illustrations in this manual are not to scale and are intended to show “typical” installations The FireRock ”
Conventional model is shown throughout this manual Nominal dimensions are given for designs and framing reference only
since actual installations may vary due to job specific design and preferences Always maintain the stated minimum clearance to
combustibles and do not violate any specific installation requirement
The fireplaces and chimney system are tested and listed by Intertek Testing Service to UL and UL
The FireRock fireplace is designed to burn wood gas or coal Use solid wood processed solid fuel fire logs natural gas propane or
coal fuel only Only vented gas logs that are listed by ANSI Z can be used in this fireplace
Burning some fuels such as charcoal can be hazardous due to the possibility of producing carbon monoxide which is both
invisible and odorless Overexposure to carbon monoxide can lead to illness and death It is strongly recommended to install
smoke and carbon monoxide detectors wherever fireplaces are in use
This fireplace is intended for use as a supplemental heat source only and is not intended for heavy use as a primary heating system
Overfiring abusive burning or mistreatment will void any warranty claims
Do not use a fireplace insert or other product not specified for use with a fireplace with the reflective properties of this product
The fireplace must sit on a concrete pad or slab that is designed to bear the total weight of the fireplace and chimney This pad
or slab should provide for the noncombustible hearth extension substrate needed to support the code required noncombustible
hearth extension finish materials This fireplace is not designed to sit directly on or abut a combustible surface except when using
the approved LiteRock installation method see pages Installing this fireplace directly on a combustible surface may result
in a fire or explosion causing property damage personal injury or loss of life
This product is designed to work with the FireRock Solid Block masonry flue system or any appropriately sized UL compliant
metal prefabricated flue system The metal flue system manufacturer must offer an anchor plate specifically designed for the
purposes of attaching the metal flue to the masonry fireplace Installation of the chimney must conform to the manufacturer’s
installation instructions
Recommended minimum overall height for the Conventional/California Conventional fireplace and FireRock masonry chimney
system for an indoor application is ’ for a straight vertical chimney Maximum overall height is ’
For heights above ’ consult a structural engineer for additional structural support These heights do not reflect information
regarding metal flue Any UL metal flue can be used on FireRock fireplaces See metal flue manufacturer’s installation
instructions for information relating to height requirements/restrictions For outdoor applications there is no minimum height
requirement
Any fireplace insert must be approved in writing by FireRock Products LLC Failure to heed this warning could result in failure of
this product and/or the insert product
Always obtain necessary permits from proper authorities in local jurisdictions and comply with all local building codes
All work performed on near and adjoining the fireplace and chimney installation must meet or exceed the specifications and
requirements in this manual and the prevailing local building code Subsequent renovations and/or additions of cabinets and
storage spaces in the enclosure surrounding the fireplace are also limited to the specifications in this manual and to the prevailing
local building code
7
Modifications to fireplace components not mentioned in this manual may void warranty claims listing and approvals and could
result in an unsafe and potentially dangerous installation Alterations to the firebox are allowed with prior written approval and
instruction from FireRock The installer indemnifies will defend and hold harmless the manufacturer from all claims and losses
and under no circumstances will manufacturer be liable for damages of any kind or nature whether foreseeable or not arising out
of or relating to any modifications of the fireplace by the installer
This fireplace has not been tested for use with doors To reduce the risk of fire or injury do not install doors Using this fireplace
with doors installed may result in a fire or explosion causing property damage personal injury or loss of life
The FireRock Conventional and California Conventional fireplace is approved for Indoor and Outdoor use Maintain stated
clearance to combustibles for indoor and outdoor use
INTENDED USE STATEMENT
(CONTINUED)
8
INSTALLATION CONSIDERATIONS
A. COMBUSTION AIR + SMOKE DRAW
Always ensure that an adequate supply of replacement air from outside of the house is accessible to the fire to support normal
combustion Fireplaces consume large volumes of air during the normal firing process and will only draft properly when they are
installed according to the instructions in an appropriate location and with the proper chimney height Installing the fireplace
according to the installation instructions choosing a proper location and determining an appropriate chimney height is the
responsibility of the designer and the general contractor
Outside air kits can be installed in all FireRock fireplaces to supplement combustion air Determining that the building’s internal
air pressures are conducive to positive fireplace drafting and whether an outside air kit should be included in the installation is the
responsibility of the designer and the general contractor
In the event the home is tightly sealed ie spray foam insulation or house wrap an outside air kit may not provide all the air
required to support combustion and the proper flow of combustion gases up the chimney The manufacturer is not responsible for
any smoking or related problems that may result from the lack of adequate combustion air supply flowing into the house It is the
responsibility of a builder/contractor to ensure that adequate air supply has been provided for the fireplace
Avoid placing a fireplace in an area near tall trees or buildings that can reduce air flow pressure and/or produce down drafts
FireRock Products LLC does not warrant drafting and is not responsible for it
Refer to page for more information on using an outside air kit with a FireRock preengineered masonry fireplace kit
B. TERMINATIONS
The termination of the chimney above the roof must extend at least ’ above the highest point where it passes through the roof
and at least ’ higher than any portion of a building within ’
The FireRock Solid Chimney Block system is approved for use with properly sized rain caps chimney pots and other decorative
features
If using a UL listed metal chimney refer to the metal flue manufacturer for approved chimney caps shrouds and covers and
rain caps FireRock does not manufacture these components and therefore defers to the manufacturer’s instructions
C. BROKEN COMPONENTS
Components that become broken due to poor handling or shipping should be mortared back together providing the breaks or
cracks are clean and original alignment and dimension can be maintained Components broken into multiple pieces or fragments
must be discarded and replaced When in doubt about a component’s usability consult your FireRock distributor or authorized
FireRock representative for advice You may also call the FireRock Technical Support Desk tollfree at
Failure to provide an adequate air supply for the unit can result in the emission of smoke sparks or hazardous gases into the
house and in some cases may result in a fire or explosion causing property damage personal injury or loss of life
9
D. GAS LINE APPLICATIONS
The FireRock fireplace may be drilled through with an ordinary masonry drill bit to accommodate a natural gas connection
This natural gas connection may be used to incorporate an automatic shutoff device and/or comply with the Standard for
Decorative gas appliances for installation in Vented Fireplaces ANSI Z The decorative gas appliance should be installed in
accordance with the National Fuel Gas Code ANSI Z
E. LOG LIGHTER
A log lighter can be used with your FireRock fireplace as either a flush mount installed before the firebrick or top mount
FireRock recommends the log lighter be installed by a professional plumber See manufacturer’s instructions for directions on how
to install
HINTS
If this is your first FireRock installation it would only take a few extra minutes to “dry stack” erect without mortar your
firebox to gain a better understanding of how the components go together Then disassemble and erect using FireRock
Adhesive Mortar
Use a level to ensure all components are level by course and plumb as you erect your fireplace and chimney
Ensure your base plate is level and at a proper elevation so the finished hearth height including firebrick lining is correct
in relationship to your finished floor height
Realize that this is at minimum a twoman job Some of these components are too heavy for one person to lift
5. Always install in accordance with local codes.
INSTALLATION CONSIDERATIONS
(CONTINUED)
Only vented gas logs that are listed by ANSI Z can be used in this fireplace This fireplace has not been tested with an
unvented gas log set To reduce the risk of fire or injury do not install an unvented gas log set into this fireplace
10
LISTED MASONRY FIREPLACE SYSTEM MODEL FIREROCK
CONVENTIONAL 30 36 42 48 INCH MODULAR FIREPLACE
CALIF CONV 30 36 42 48 INCH MODULAR FIREPLACE
CERTIFIED TO UL 127
CLEARANCE TO COMBUSTIBLES
UNIT TO SIDE ENCLOSURE 1” UNIT TO BACK ENCLOSURE 1”
UNIT TO FACE ENCLOSURE 1” UNIT TO CEILING JOISTS 1”
OPENING TOP TO COMBUSTIBLE MANTLE 16” OPENING TO SIDEWALL 28”
OPENING TO COMBUSTIBLE FACEWALL 12”
HEARTH EXTENSION BEYOND FRONT: 20”
HEARTH EXTENSION BEYOND SIDES: 8”
INSULATION FROM FIREBOX: 3”
***WARNINGS*** XXXXXXXXXXXXXXXXXXXXXX
MANUFACTURED BY: FIRE ROCK PRODUCTS, LLC; 3620 AVENUE C; BIRMINGHAM, AL 35064
USE SOLID WOOD, PROCESSED SOLID FUEL FIRE LOGS, NATURAL GAS, PROPANE, OR COAL FUEL ONLY
DO NOT USE A FIREPLACE INSERT OR OTHER PRODUCTS NOT SPECIFIED FOR USE WITH THIS PRODUCT
THIS FIREPLACE HAS NOT BEEN TESTED WITH GLASS DOORS TO REDUCE RISK OF FIRE OR INJURY DO
NOT INSTALL GLASS DOORS
WHEN BURNING GAS IN THE FIREPLACE, ADJUST DAMPER TO FULLY OPEN POSITION
ONLY VENTED GAS LOG SETS WHICH ARE LISTED ARE TO BE INSTALLED IN THIS FIREPLACE. DO NOT
OPERATE AN UNVENTED GAS LOG SET IN THIS FIREPLACE.
W/N 13350
SEE FIRE ROCK’S INSTALLATION AND OPERATING INSTRUCTIONS FOR THIS MODEL
REFER TO THE INTERTEK DIRECTORY OF BUILDING PRODUCTS
(HTTPS://BPDIRECTORY.INTERTEK.COM) FOR DETAILED INFORMATION.
WHI-
SIZE: 3-7/8” x 6”
NO HOLES OR ADHESIVE
PLEASE PROOF COMPLETELY -
THE NAMEPLATE WILL PRINT
EXACTLY AS IT APPEARS HERE.
SIGN AND RETURN IF OKAY
TO PRINT, THANK YOU
X
WARNOCK HERSEY LISTING LABEL
11
FIREPLACE DIMENSIONS
DIMENSION ” ” ” ”
AOVERALL WIDTH ” ” ” ”
OVERALL DEPTH ” ” ” ”
CFIREBOX HEIGHT ” ” ” ”
DSMOKE CHAMBER HEIGHT ” ” ” ”
EOPENING WIDTH ” ” ” ”
FOPENING HEIGHT 33.75” 33.75” 33.75” 33.75”
GWIDTH AT CHIMNEY BASE ” ” ” ”
HFIREBOX DEPTH ” ” ” ”
JWIDTH AT REAR ” ” ” ”
*before firebrick lining
A
J
E
F
G
C
D
H
FIGURE 1.1
3’-8”
3 -2 1/2”
2’-4”
2’-10 1/2”
2’-3 1/2”
0’-4”
0’-3”
0’-2” 0’-2”
0’-9”
0’-3” (TYP.)
1’-10”
2’-2”
FIGURE 1.2
36” CONVENTIONAL
4’-2”
3’-8 1/2”
2’-10”
0’-3”
2’-10 1/2”
2’-3 1/2”
0’-4”
0’-5” 0’-5”
0’-9”
0’-3” (TYP.)
1’-10”
2’-8”
FIGURE 1.3
42” CONVENTIONAL
4’-8”
4’-2 1/2”
3’-4”
0’-3”
2’-10 1/2”
3’-0 3/4”
0’-4”
0’-5” 0’-5”
1’-0”
0’-3” (TYP.)
1’-10”
2’-8”
FIGURE 1.4
48” CONVENTIONAL
12
CLEARANCE TO COMBUSTIBLES
Opening to Side wall ”
Opening to Combustible Trim ’
Opening to Combustible Mantle with ” Depth ”
Noncombustible Hearth Extension ” front ” each side
Firebox and Smoke Chamber
to Combustibles or Framing ”
Smoke Chamber to Front Wall
and Smoke Chamber Top to Wood Framing ”
MANTLE
TRIM
HEARTH EXTENSION
SIDEWALL
TILE/MARBLE 16”
28” 12”
8”
FIGURE 2.1
Failure to maintain stated minimum clearance to combustibles may result in a fire or explosion causing property damage
personal injury or loss of life
FIGURE 2.2
1”
Do not pack required air spaces with insulation or other
materials Using insulation or other materials in required
air spaces may result in a fire or explosion causing property
damage personal injury or loss of life
NOTE “Combustibles” are defined as “normal construction
materials” and are considered to be wood framing materials
particle board mill board plywood subflooring plywood
paneling wood flooring and drywall
The fireplace must sit on a concrete pad or slab that is designed to
bear the total weight of the fireplace and chimney This pad or slab
should provide for the noncombustible hearth extension substrate
needed to support the code required noncombustible hearth
extension finish materials
This fireplace can be installed on a combustible surface only when
using the LiteRock installation method refer to pages
All fireplaces should have a noncombustible hearth that extends
” beyond the front of the firebox and ” to either side Approved
noncombustible materials include brick tile or stone that is
properly supported with no combustible material against the
underside
13
ROUGH FRAMING DIMENSIONS
A
B
C
The numbers listed are the framing dimensions recommended by FireRock which add ½” of air space to the required clearances
Always maintain the stated minimum clearance to combustibles for this unit
For ease of installation it is recommended to not install framing header until after firebox is installed
Rough framing dimension “A” includes the ³₄” thick base plate Dimension “A” should be reduced by ³₄” if the base plate is
eliminated to create a “flush hearth” A raised hearth requires additional rough opening height for dimension “A” equal to the
height of the raised hearth detail
FIREBOX SIZE
” ” ” ”
A47.5” 47.5” 47.5” 47.5”
B30” 30” 30” 30”
C41” 47” 53” 59”
FIGURE 3
Failure to maintain stated minimum clearance to combustibles on page may result in a fire or explosion causing property
damage personal injury or loss of life
14
The FireRock fireplace must be erected on a
noncombustible base with a noncombustible ” hearth
extension in front of the firebox opening and at least ” on
either side of the firebox opening Figure on page
There are types of foundations that can be used in this
type of installation
Concrete Slab Figure
Concrete Pad Supported by Masonry CMU
Tower Figure Typically used when the
fireplace is placed over a basement or crawl space
The noncombustible pad is best made from a ”
thick concrete slab with # rebar tied together at
maximum ” intervals center poured on top of
corrugated metal Concrete pad must be supported
by a full masonry tower with no combustible
underpinnings to withstand the weight of the
firebox and flue system
NOTE Use of the FireRock base plate is optional for either
of the above foundation types concrete slab or concrete
pad
FireRock fireplaces can be installed directly on a
combustible floor or a limited loadbearing floor using our
LiteRock system See pages for installation method
UL listed metal pipe is required for this installation Use
of the FireRock base plate is required for this installation
FIREPLACE INSTALLATION
STEP 1: FOUNDATION
DEPTH WIDTH
” 50” 46”
” 50” 52”
” 50” 58”
” 50” 64”
CONCRETE PAD WITH HEARTH EXTENSION DIMENSIONS
FIGURE 4.1
CONCRETE SLAB
FIGURE 4.2
CONCRETE PAD SUPPORTED BY MASONRY (CMU) TOWER
This fireplace is not designed to sit directly on or abut a combustible surface Installing this fireplace directly on a
combustible surface may result in a fire or explosion causing property damage personal injury or loss of life
Foundations and footings must meet local code and
be approved by the local building authority For any
foundation design and load requirements check
with a structural engineer Failure to ensure adequate
foundations can cause significant property damage
It is the responsibility of the general contractor to
ensure adequate foundations
15
FIREPLACE INSTALLATION
STEP 2: MIXING AND APPLYING MORTAR
FIREROCK ADHESIVE MORTAR
FireRock Adhesive Mortar must be used when building the
FireRock fireplace for your FireRock warranty to be valid
Use of other mortar will void your FireRock warranty
This mortar is available from your FireRock dealer or
distributor This specially formulated mortar is a low
sand polymer modified with heat resistant additives and
is designed to work as a “glue” rather than a typical joint
provider
MIXING THE MORTAR
Mix FireRock Adhesive Mortar with clean water
according to the instructions on the bag until it results in
a “toothpaste” consistency free of lumps or dry pockets
Be sure it is not too thin or runny to ensure maximum
strength Use only clean water when mixing FireRock
Adhesive Mortar Do not use spirits or antifreeze agents
Do not apply if temperatures are below F or will be
within a hour period
APPLYING THE MORTAR
It is appropriate to use a trowel or grout bag to apply the
mortar to firebox and smoke chamber joints These joints
should be COMPLETELY COVERED BY ¹₂” ” OF
MORTAR Figure and the components stacked so
as to result in a ¹₁₆” to ¹₈” joint The excess mortar should
push ooze out and be scraped away
BUTTERING THE JOINTS
At each level of the firebox smoke chamber and masonry
chimney it is important to go back and “butter” all joints
This procedure involves a final smoothing of any excess
mortar inside and out sealing all joints and ensuring a “no
leak” installation Figure
FIGURE 5.1
SIDE BLOCK WITH MORTAR APPLIED TO TOP FACE
FIGURE 5.2
FIREBOX WITH BUTTERED JOINTS
16
FIREPLACE INSTALLATION
STEP 3: FIREBOX ASSEMBLY
BASE PLATE
The base plate must be placed on a level noncombustible
surface It is very important that your base plate be square
to the room properly centered and level Mark out the
position of the base plate on the supporting floor system
Apply a layer of mortar to the area and set the base plate
Figure
Whether using a flush hearth or a raised hearth a
noncombustible hearth must extend at least ” out in
front of the finished firebox opening and ” beyond the
finished sides of the opening Figure on page
FLUSH HEARTH (FIGURE 6.2)
If the design calls for a flush hearth you can omit the base
plate from the assembly instructions and build the side
walls directly on the concrete pad or slab In the event you
opt not to use the base plate carefully chalk lines where the
base plate would be to ensure proper placement of your
firebox
With a flush hearth the firebrick floor of the firebox will be
applied directly to the concrete slab or pad This makes the
finished firebrick floor approximately ¹₂” above the top of
the slab or pad
RAISED HEARTH (FIGURE 6.3)
If the design calls for a raised hearth the base plate should
be set on a noncombustible platform that is built up to the
desired hearth height
When calculating the hearth height be sure to account for
both the ³₄” base plate and ¹₂” thick firebrick floor in
addition to the height of the platform
FIGURE 6.1
BASE PLATE ON CONCRETE SLAB
FIGURE 6.2
FLUSH HEARTH
FIGURE 6.3
RAISED HEARTH
17
FIREPLACE INSTALLATION
STEP 3: FIREBOX ASSEMBLY (CONTINUED)
BACK WALL AND SIDE BLOCKS
Side blocks and back blocks are next Completely cover
each component with mortar ¹₂” ” thick where it will lie
or butt up against another component You will begin by
placing a back block on the base plate Figure Next
place the corresponding side blocks Figure again
completely covering each edge of a component that butts
up to another component including the base plate with
¹₂” ” of mortar Use your level to ensure level and plumb
placement of each component
Continue to build each course of the firebox making sure
all surfaces are plumb and level and firebox position is
correct Figure
NOTE: The Conventional model has an angled back wall
The first courses of the firebox use identical straight back
blocks followed by angled back wall pieces for course
Figure and course Figure The back wall pieces
can only be positioned one way
The California Conventional model has a straight back wall
made of identical back wall pieces for all courses
Butter all joints inside and out see page
LEVELING AND ALIGNING COMPONENTS
It is important that each course of the firebox is level
and flush with adjoining components FireRock mortar
is not intended to create a mortar joint of any thickness
for leveling purposes Leveling and alignment adjustments
should be made by the use of small shims Be sure to re
mortar any gaps resulting from the shims to maintain a
leakfree seal
FIGURE 6.5
1 COURSE
FIGURE 6.4
BASE PLATE + 1 BACK BLOCK
FIGURE 6.7
FULLY ASSEMBLED FIREBOX
FIGURE 6.6
3 COURSES WITH ANGLED BACK WALL
18
FIREPLACE INSTALLATION
STEP 4: THROAT AND DAMPER ASSEMBLY
THROAT (FIGURE 7.1)
Begin building the throat by placing the radius throat front
and square throat back Remember to completely cover
each component with mortar ¹₂” ” thick where it will lie
or butt up against another component Given the curvature
of our radius throat front to aid in smoke draw be careful
when placing this piece as it can roll Mortar and place the
throat left and throat right pieces to secure it in place
A piece of angled steel ” x ” x ¼” thick has been
provided with your FireRock fireplace kit The length of
this angled steel piece corresponds with the overall width
of your firebox model It should be installed beneath the
radius throat front across the top of the firebox opening
angle up for maximum firebox opening or angle down for
additional “smoke lip” Figure
SETTING THE DAMPER
Upon setting the throat components a recess Figure
is formed for the purpose of locating the damper
Place the damper in the recess and over the smoke
chamber opening The damper’s operating plate should
face toward the rear of the fireplace If necessary use
mortar to tack the four corners of the damper into place
Do not mortar all the way around the damper to create
an air tight seal as it is important the damper be able to
expand and contract
Each fireplace uses a different size damper
” firebox ” damper
” firebox ” damper
” firebox ” damper
” firebox ” damper
NOTE A damper is not required for outdoor installations
FIGURE 7.2
DAMPER RECESS + ANGLED STEEL
FIGURE 7.1
ASSEMBLED THROAT
19
SMOKE CHAMBER
The smoke chamber components can only be positioned
one way The fronts and backs are identical above the
damper
Remember to completely cover each component with
mortar ¹₂” ” thick where each edge of each component
will lie or butt up against another component
Align the smoke chamber flush with the back wall of the
fireplace leaving an approximately ” “ledge” on top of the
radius throat front This ledge allows space for a framing
header to maintain the required ” clearance
Be sure to check for and maintain plumb and level
installation of these components
“Butter” all joints to give a smooth appearance and ensure a
leakfree joint
The final component of the smoke chamber is the chimney
base Completely cover the tops of all smoke chamber
components with ¹₂” ” of mortar before placing this final
component and be sure it is level fronttoback and sideto
side
“Butter” all joints to ensure a noleak seal
FIREPLACE INSTALLATION
STEP 5: SMOKE CHAMBER ASSEMBLY
FIGURE 8.1
SMOKE CHAMBER ASSEMBLY
FIGURE 8.2
COMPLETED FIREBOX AND SMOKE CHAMBER
20
FIREPLACE INSTALLATION
STEP 6: CHIMNEY ASSEMBLY
SOLID BLOCK CHIMNEY
FireRock Solid Block Chimney Figure may be
installed from this point Completely cover each chimney
block component with ¹₂” ” of mortar resulting in a ¹₁₆”
¹₈” joint “Butter” all joints to give a smooth appearance
and ensure a leakfree joint The inside face of the chimney
should also be “buttered” to ensure a noleak seal as well
as to prevent smoke obstruction caused by excess mortar
build up
For masonry chimney mortar should be used at a rate of
bag for every blocks
SOLID BLOCK CHIMNEY SPECIFICATIONS
Overall width ” x ”
Overall height ”
Weight lbs
UL compliant
” clearance unless offset then ” clearance above
offset
To increase the solid block chimney’s strength even more
insert rebar and mortar into the “hurricane” holes see
Figure
NOTE Solid Block Chimney is required if your plans call
for a Brick Flange see page Refer to local building
codes for minimum and maximum height requirements
REQUIRED CLEARANCES: The FireRock Solid Block
Chimney system is listed for ” clearance to normal
construction materials and may be enclosed in a wood
chimney chase at ” clearance to wood framing members
FIGURE 9.2
CONVENTIONAL FIREPLACE WITH 4 CHIMNEY BLOCKS
HURRICANE HOLES
FIGURE 9.1
SOLID BLOCK CHIMNEY
If using a metal chimney refer to page
This manual suits for next models
1
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