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Installing the Flue Gallery
4. Installing the Flue Gallery
Now, it's time to install the PreCast Flue Gallery. This is a job for two, due to the weight. Take your time and get
this right, it's hard to remove and do again. We recommend doing a dry run first.
4A: Wet the upper surfaces of the Vent Arch and Entry Arch bricks where the PreCast Flue Gallery is going to
land. Also soak the underside of the PreCast Flue Gallery in water so that the mortar will bond properly to it.
4B: ADD SPACERS & DRY FIT
Put plastic packers 3mm to 10mm thick on top of your
Vent Spring bricks and do a dry fit of the PreCast Flue
Gallery to check the mortar joint thickness across
the Vent Arch. You're aiming for between 5mm and
10mm. The plastic strips that held your #1 formwork
in place can be cut up to use for this purpose.
4C: APPLY MORTAR
Trowel Refractory Mortar around the packers and
across the top of the Vent Arch bricks (you will fill
the gap between the Entry Arch and the Flue Gallery
next). Be sparing with the mortar, aim to apply just a
little more than the final joint thickness, so that you
don't have to force much out when the Flue Gallery
is installed.
4D: PLACE FLUE GALLERY
Quickly, while the mortar is still wet, lower the Flue
Gallery onto the mortar and 'wriggle' it into place until
it rests on the packers. Leave the gap between the
Entry Arch and the PreCast Flue Gallery for later.
Carefully remove the #2 formwork. Hold the base of
the formwork in place while pulling out the plastic
strips. If the formwork gets stuck, don't panic! Just
undo the screws that hold it together and tap the
pieces until they loosen and come out.
4E: FILL GAPS WITH MORTAR
With the formwork removed you can fill the gap
between the PreCast Flue Gallery and the Entry Arch
with Refractory Mortar, smoothing off the inside face.
Remove the plastic packers and fill in the resulting
voids with mortar. Scrape off any excess mortar on
your Vent Arch brickwork and fill in any voids.
Congratulations - the brickwork is complete!
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