Instructions for retroactively installed horizontal insulation using the saw method and placement instructions for the placement of insulating foil and masonry wedges.
The cut is performed, using a carbine-tipped chain saw or a diamond wire saw in sections of max. 1 m (40 inches) length. In some cases, if the wall structure is very loose or jagged, a shorter cut is necessary. Prior to any cutting, pipes or wiring inside the wall must be located, any plaster or joints in the area of the cut must be removed (it reduces wear and increases working speed). When applying the foil and wedges, the cutting must be stopped and as a safety precaution, the saw must be shut off.
Insulating foils must always overlap 10 cm (4 inches) min. Prior to placing the foil, the saw cutting area must be cleaned using a special joint cleaner, removing any debris or loose joint material. A severely jagged wall surface can be levelled off with a thin layer of cement mortar before the foil is placed. When cutting the foil the required thickness of the plaster (1-2 cm) must be taken into consideration. The end of one foil is always overlapped by another foil. Therefore, wedges must never be placed at the end/beginning of a foil but always on top of an overlap!
To grout the remaining soil voids within the saw cutting area, the voids are first packed inside and outside with mortar, whereby small tubes for packing the mortar are inserted from one side and between the wedges. After solidifying of the grout a non-shrinking, hardening mortar is forced through the tubes and into the wall, using a suitable mortar press. Subsequently the wall’s interior structure is re-established.
Masonry wedges (wedge plates) are force-fit into the whole thickness of the wall (hammer weighing approx. 1,500g) and embedded approx. 2-3cm. Ideally, this is done from both sides of the wall. However, if the wedges are being forced in one after the other (due to inaccessibility from one side), the following wedge thicknesses are to be used (1st wedge 8mm – 2nd wedge 9mm and so on). The wedge plates can also be placed rotated 90° or can be split. Wedges must always be placed on top of an overlap.
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