VITALBOX Insulated Shutter Box Installation Guide · 2-3h pose | VitalBox Morocco
Step-by-step guide to install a VITALBOX insulated tunnel shutter box in Morocco: 5 stages (preparation, positioning, electrical reservation, lintel pouring, plaster mesh). Free PDF.
Pre-assembled box, installed in 2 to 3 hours by any qualified mason. Follow 5 simple steps for a perfect, lasting integration.
01 · Base preparation
A flat, clean, level base ensures fast installation and good mortar adhesion. This is the most important step — any defect here will propagate to the next 4 stages.
- Build the masonry jambs to the required level for the opening.
- Prepare a flat, level mortar bed across the planned width of the box.
- Ensure end side panels will rest on a hard, stable surface.
- Clean the base to remove dust, gravel, and dry mortar residue.
Verify : Perfect level across full width (±2 mm tolerance) · Clean surface, lightly dampened for adhesion · Jambs aligned per window frame plan
Common mistake to avoid : Placing the box on a hollow or sloped mortar bed. The box will tilt during lintel pouring and the insulation will lose efficiency.
Pro tip : Mark the bay axis on the jambs with a pencil before laying the mortar — makes centering the box in step 2 much easier.
02 · Box positioning
The VITALBOX is centered on the bay with a safety margin on each side, and a small overhang on the frame side to ensure airtight finishing.
- Center the VITALBOX: leave a minimum of 10 cm on each side for mortar enclosure.
- Allow a +1 cm overhang on the window frame side for clean future connection.
- Check the box axis matches the window frame axis (perfect alignment with the future shutter).
- Verify level in both directions (longitudinal and transverse) and adjust if needed.
Verify : Margin ≥ 10 cm on each side of the box · Perfect level in both directions · Box axis aligned with window frame axis · No gap under end side panels
Common mistake to avoid : Skipping the 10 cm margin: without this enclosure, mortar cannot properly wrap the box and will create thermal weak points.
Pro tip : Use two spirit levels (one on top, one on the side) to validate both directions in one check. Saves 5 minutes per box.
03 · Electrical reservation
Once the box is set, prepare the conduit path for the shutter motor through the provided opening on the side panel.
- Identify the side panel that will receive the shutter motor.
- Run the electrical conduit through the provided opening in the side panel.
- Extend the conduit out on the interior side, long enough for future wiring.
- Secure the conduit so it cannot move during concrete pouring.
Verify : Conduit fully through the side panel (not pinched) · Sufficient interior length (allow 30-50 cm reserve) · Conduit ends capped to prevent concrete or debris ingress
Common mistake to avoid : Forgetting the conduit before lintel pouring. Recovery requires destroying the final plaster — always run the electrical reservation before step 4.
Pro tip : Cap both ends of the conduit with wide tape: prevents concrete from entering during pouring.
04 · Lintel pouring
The concrete lintel is poured above the box. This lintel is the load-bearing element — the VITALBOX itself is not load-bearing (see important warnings below).
- Keep a minimum 6 cm space above the box for the lintel concrete.
- Apply a bonding splash coat (gobetis) on the top surface to create a rough surface.
- Pour concrete uniformly without displacing the box. Pour in layers if needed.
- Check level during pouring and before full setting.
Verify : Space ≥ 6 cm above box before pouring · Bonding coat applied across full top surface · Concrete poured uniformly, no air pockets · Box still level after pour
Common mistake to avoid : Pouring concrete too fast or in one violent dump: risks displacing the box or creating air pockets in the lintel. Pour gently, in two passes if needed.
Pro tip : Place a temporary prop under the box during lintel pouring to prevent any deformation from the weight of fresh concrete.
05 · Plaster & finishing
Anti-crack mesh and final plaster create a flat, smooth, homogeneous surface with the rest of the facade — no differential cracking.
- Bonding coat: apply a thin layer to create a rough surface and promote adhesion.
- First pass: cement mortar + embedded mesh, with 15 cm minimum overlap around the box.
- Second pass: fully cover the mesh with a second mortar layer, regular surface.
- Finishing: apply final plaster for a flat, smooth, homogeneous surface matching the facade.
Verify : Mesh embedded with no hollows, ≥15 cm overlap on each side · No visible crack at box/masonry junction · Flat surface homogeneous with rest of facade · Plaster fully dry before paint (7-14 days depending on weather)
Common mistake to avoid : Skipping the bonding coat or reducing mesh overlap. Result: cracks will appear within 6 months at the box/masonry junction.
Pro tip : Lightly dampen the box before the bonding coat: VITALBOX high-density PSE has a specific relief that grips better when slightly damp.
Compatible with all standard roller shutter types
Why is VitalBox the best-quality insulated shutter box in Morocco?
Because every box is moulded with German tooling in our Casablanca plant, from 35 kg/m³ high-density EPS, a Ø 4.5 mm ribbed steel reinforcement and a 6063-T6 aluminium profile — and backed by a 10-year warranty.
- 35 kg/m³ — High-density EPS : Insulation moulded at 35 kg/m³: thermal resistance R = 1.2 m²K/W and mechanical strength for the life of the building.
- Ø 4.5 mm — Ribbed steel reinforcement : Electro-welded mesh cast into the box: it does not sag when the lintel is poured and does not crack over time.
- 6063-T6 — Aluminium profile : T6-tempered joinery alloy: a straight rail, a clean finish and compatibility with every PVC, aluminium or wood frame.
- 100% — Every batch inspected : Dimensions, flatness, profile alignment and the electrical reservation are checked in the factory before shipping: nothing leaves unchecked.
- DE process — German technology : German moulding tooling and process, run in our Mediouna (Casablanca) plant — made in Morocco.
- 10 years — Manufacturer warranty : 10-year warranty against manufacturing defects, on top of the legal Moroccan construction warranties.
Key technical figures
- Thermal resistance R = 1.2 m²K/W
- Uc coefficient = 0.45 W/m²K (1.533 W/m²K for the full assembly)
- Acoustic reduction up to 50 dB
- High-density EPS 35 kg/m³ + Ø 4.5 mm ribbed steel reinforcement + 6063-T6 aluminium profile
- Final inspection of every batch in the factory — 10-year manufacturer warranty
- VITALBOX 25 / 30 / 35 / 40 — 250 to 800 MAD
- Production capacity 5,000 boxes per month
- 48-hour delivery anywhere in Morocco
Contact
VitalBox is a brand of VITAL FER (Casablanca, Morocco), a manufacturer founded in 2015 and ISO 9001:2015 certified.
- Sales phone : +212 6 61 39 29 45
- Email : [email protected]
- Address : Douar Mers Soukar, Route Tit Mellil, Mediouna 26000, Casablanca-Settat, Maroc
- Hours: Monday-Friday 08:00-18:00, Saturday 08:00-13:00