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ASSEMBLY AND INSTALLATION INSTRUCTIONS
1.
Carefully remove all components from the shipping cartons and inspect for damage. If any damage is noted contact
the shipping company or your dealer immediately. DO NOT INSTALL THIS UNIT IF DAMAGED OR MISSING PARTS.
2.
Protect the fl ooring near the intended place of installation with an old rug, blanket, or cardboard. Place the fi rebox
on this material.
3.
Mix and install the Malmcrete hearth refractory as follows:
a. Obtain a sturdy water-tight mixing container such as a wheelbarrow or large wash tub, a bucket or can for
transporting the mixture, a cement trowel, and a source for clean mixing water. It is suggested that the
Malmcrete be mixed outside to avoid spillage or splatters in the dwelling.
b. Pour the dry Malmcrete mixture into the mixing container.
c. Use 1 quart water for each bag.
d. Add 1/2 to 3/4 of the water to the dry mix and mix thourghly. Add additional water in small increments, mixing
throughly between additions. Do not add more water than is necessary to get a somewhat dry mixture; to much
water in the mix may cause the refractory to crack excessively, and will reduce the strength of the refractory.
To test for proper water content, cut vertically into the mixture with the trowel, push the trowel sideways to open
a 3 inch deep by 2 inch wide cut in the mixture, then slide the trowel back up out of the cut. The cut should
stay open with very little "slumping" back into the cut. Next, run the trowel over the surface of the mixture with
the blade at a slight angle to the surface of the mixture, like spreading butter. The mixture should become
relatively smooth with few voids after 6 or 7 passes of the trowel using moderate pressure. Water should not
fl oat to the top of the mixture.
e. Transfer the mixture to the hearth (fl oor) area inside the fi rebox, spreading the mixture out as it is added. Use
the trowel to spread the mix into the fi rebox area. Continue to add refractory until there is a minimum of 2 inches
thick over the entire hearth area. To measure the depth of the mix, place a piece of tape 2 inches from the pointed
end of a long nail. Insert the nail vertically through the mix every 6 inches (front to back and side to side) across
the hearth; the mix should come to a uniform height up the nail, at or slightly above the tape. Trowel in the nail
holes when completed.
f.
Allow the mix to cure at least 48 hours. Additional curing time is necessary in cool temperatures. The longer
Malmcrete is allowed to cure before the fi rst fi re is lit, the stronger and more durable it will become.
g. Make the fi rst 3 or 4 fi res very small and of short duration to allow the refractory to adjust to the high temperature
of a fi re.
Hearth Requirements
A fl oor protector is required to protect the fl oor in front of the fi replace opening from sparks. The fl oor protector must
be a minimum of 3/8 inch thick non-combustible material such as brick, concrete, slate, ceramic tile, or a listed fl oor
protection board such as Wonderboard or Homosote.
The fl oor protector must extend a minimum of 16 inches in front of the fi replace opening and 8 inches to either side of
the fi replace. The Zircon has been designed to provide fl oor protection allowing for fl exible design of the hearth setting.
Clearance to Combustibles
The Zircon requires a clearance to combustible walls of 10" measured from the back of the unit. For locating the center
of the chimney the measurement is 15 1/2" from the backwall and 47" to the sidewall. See fi gure 1, page 3. For corner
installation the center of the chimney is 19". See fi gure 2, page 3.
Clearance to Non-combustibles
The Zircon clearance to a combustible wall may be reduced with proper wall protection. Accepted methods for wall
protection would allow reduction of the wall clearances. For appearance if desired a non-combustible wall covering can
placed on the wall. The covering should consist of a listed wall protection board installed to the manufacturer's
specifi cations. Approved protection boards at the time of this publication are Wonderboard, Dura Rock and Homosote.
A non-combustible material can then be placed over the wall protection board. With most of the protection boards the
clearance can be reduced to 8 inches from the original combustible wall. Be certain to check with your local building
offi cials and or fi re inspector for accepted methods in your area. Refer to NFPA 211.
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Zircon 30 8/20/15
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