System

Installation

The materials used are durable, long lasting and energy efficient. Comfort Block has adopted the latest efficient European construction methods while keeping current American construction codes in mind. Build with Comfort Block today and rediscover how wonderful masonry construction can be! FOLLOW OUR STEP-BY-STEP GUIDE BELOW.

We’ve made every effort into creating a wall system that is easy to construct!  Accurately level the first course and then the rest of the blocks simply stack and remain level throughout the rest of the wall!

Because the blocks are all exactly the same height only adhesive is needed.

Follow our step-by-step guide below:

Wall Block Installation: Step-by-step video

Step 1: Layout

Before construction of the Comfort Block wall, ensure that all wall dimensions conform to the block dimensions to reduce gapping and cutting.  All steel reinforcement should be located according to engineering recommendations before the base course is constructed.

step-2-imgStep 2: Preparing the base

The preparation of the base course is the most critical stage of building with the Comfort Block System.
Before beginning construction, all coursing requirements should be considered.  Coursing Blocks made with Comfort Block units should be used in the base course.  When laying the first course, standard mortar may be used to overcome any excessive variation in foundation levels.  This should be used between the foundation and the first course of Comfort Block units.

Block layers must ensure that the base course is level horizontally along and across each block and that there are no steps between each block.  Once the block layers have the base course leveled, the highly engineered blocks combined with good craftsmanship will ensure that the walls are plumb and maintain a consistently even height.

Step 3: Mixing the mortar

Comfort Block mortar has been tested specifically for the Comfort Block system.  A single 50 pound bag of Comfort Block mortar mixed with water will lay approximately 200 blocks when applied by roller.

The mortar may be mixed in small quantities near the work area, which reduces the need for jobsite forklifts, noisy cement mixers, and storage of bulk sand.

Step 4: Mortar rolling technique

A special roller has been designed for use with the Comfort Block system.  The roller is fast and easy to use.  It provides an even spread of mortar along the block work, reduces waste, and limits skin exposed to any activated cement.

Pour the required amount of Comfort Block mortar into the roller, and roll it along the wall.

Step 4: Optional Gluing technique

An optional mortar adhesive to glue the blocks together is also available to construct the Comfort Block wall system.  Due to the precision of the Comfort Block wall system, the wall remains level during the entire construction so all that is needed is adhesive to glue the blocks together.  A special adhesive specifically developed for gluing masonry products together is available from Comfort Block.

step-5-imgStep 5: Laying the blocks

Once the base course has been prepared, laying Comfort Block units is a simple process.  Once a layer of mortar has been applied, lay the blocks next to each other using the interlocking design. The block should be positioned and struck with a mallet to ensure that the blocks are seated correctly.  The accuracy of the Comfort Block units combined with the correct standards of workmanship ensures the walls are vertically level.

Where string lines are used, they’re for range only.  The level is maintained due to the accuracy of material and good craftsmanship.  The Comfort Block system incorporates a place to insert line pins for such a purpose.

Step 6: Cutting Comfort Blocks

Mechanical cutting is recommended when cutting Comfort Block units.  The block cutter can use water suppressed disk cutters, chop saws, or appropriate bench cutting saws.

Step 7: Grouting

Grouting the Comfort Block wall should be done when the wall is no higher than 7 courses.  Horizontal grouting may also be done as required on any course necessary.  Steel may be laid into the lowered web locations to ensure that grout covers the steel properly.  Corners must be cut to ensure steel intersects with the vertical grout.  It is recommended that concrete sand be used for grout as it flows better and has additional strength.  However, mortar sand may be used if that is what is available on the job site.

Where do I put electrical work?  No problem.  The Comfort Block wall system has areas specifically designed for electrical work on either side of the wall!  Simply cut out where you would like an electrical box and locate it on the second wall of the block.  They fit perfectly!  No need to fur out an interior wall and use sheetrock.

Follow our step-by-step guide below:
Step 1: Locating the Electrical Box

Begin by measuring over 1 ¾” over from either side of a Comfort Block unit.  This is where the edge of either a 2” or 4” electrical box can be located.

Place the desired electrical box on both the edge of the mark and in line with the bottom of the block.

Trace around the electrical box with a permanent marker to mark a guide line to cut around.

Step 2: Cutting the Electrical Box hole

Using a tool specifically designed to cut concrete such as an Arbortech saw or a masonry blade on a skill saw, cut out the hole where the box will be placed into.  Cut the hole a bit larger than the traced area in order to more easily install the electrical box.  Do not cut into the Comfort Block unit below.  This unit will be used to hold and level the electrical box.  Next, cut a small notch where the electrical wire will emerge from the box.  This will make running the wire into the box easier as well.

Step 3:  Installing the Electrical Box

Place a 2 ¼” deep Electrical Box in the hole and let it rest on the Comfort Block unit immediately below the unit with the cut.  Since the Comfort Block unit is level there is no need to level the electrical box.

Using an appropriately sized masonry drill bit and a rotary hammer drill, locate a mounting hole on the back of the electrical box and drill into the second wall back on the Comfort Block unit.  Install a concrete fastening screw such as Tap Con to hold the box to the wall.  Plastic anchors and screws may be used as well.

Step 4: Running the Wire

Run the wire down from the top of the block wall to the electrical box.  A fishing wire may be needed to assist.

If electrical wire must be run horizontally, Comfort Block units must have a channel cut deep enough to accept flexible conduit.

Step 5: Tape the box and fill with plaster

Tape over all electrical boxes and trim tape properly so that plaster work be finished neatly to the box.

Using base coat plaster, fill in all deep holes around the box as well as any horizontal channels or holes created during electrical installation.  The wall is now ready for plaster work.

Using an appropriately sized masonry drill bit and a rotary hammer drill, locate a mounting hole on the back of the electrical box and drill into the second wall back on the Comfort Block unit.  Install a concrete fastening screw such as Tap Con to hold the box to the wall.  Plastic anchors and screws may be used as well.

Once the Comfort Block Wall System has been constructed, an exterior finish must be applied in order to create an air barrier as well as protect the blocks from the weather.

The Comfort Block Wall System may be finished with a two part Synthetic waterproof coating. Various colors and textures may be chosen. Different EIFS systems and siding may be also fastened onto the wall system. However, an initial air and water sealing base coat must be applied first.

New generation synthetic stucco coatings are nearly self-cleaning and offer superior waterproofing. Stucco is also excellent in high wind areas as it is not apt to be blown off like other types of siding.

Comfort Block Exterior Coating
Exterior Coating
Exterior Finish
Comfort Block Waterproof Exterior
Exterior Finish

Once the Comfort Block Wall System has been constructed, an interior finish must be applied in order to create a good air barrier as well as a smooth and desirable surface.

The Comfort Block Wall System may be finished with either one or two coats of gypsum plaster.  Interior furring and sheetrock is not needed due to the fact that the wall system has an incorporated utility space on both sides of the block.  Gypsum plaster works naturally with the block.  It is a durable and chemical free product that also works to balance the humidity levels in a home as well as add additional thermal mass.

Comfort Block Interior Wall
Interior Sample Wall
Comfort Block Interior Wall
Interior Finish
Comfort Block Interior Wall
Interior Finish

Installation Resources:

Download Construction Details PDFs:

Foundation Detail

House Floor to Garage Detail

Roof Truss Connection

Whole Wall Section

Download Engineering PDFs:

Section Properties