DIY Network

Re-facing a Fireplace with Stone Give a fireplace a rugged, rustic look by adding natural-looking stone. From "Man Caves" episode DMCV-109

Materials and tools:

stack stone from Boulder Creek Stone
diamond metal lath
stone type M mortar mix
Tapcon concrete screws or concrete nails
3/4-inch galvanized roofing nails
mason's trowels
angle grinder with diamond blade
hammer drill
mason's hammer
2- or 4-foot level

Note: Quantities of the materials listed above will be determined by the dimensions of your project.

Figure A

Steps:

1. Cut the metal lath to size and attach it to the existing brick with Tapcon concrete screws. Use your hammer drill to pre-drill into the mortar before driving in the Tapcon. Drive a Tapcon in every 6 to 8 inches to hold the lath securely in place (figure A). Make sure the metal lath is secured to the entire surface to which you will be applying the stacked stone. Note: You can also use concrete nails instead of the Tapcon screws to secure the metal lath to the brick façade. Make sure to drive the nail or screw into the mortar and not the brick, as the brick may crack.

advertisement

Figure B

2. Mix a batch of type M mortar that's firm but still moist. Good consistency is important for the mortar to bond properly.

3. Using a square-end trowel, apply the scratch coat by pressing a 1/2" to 3/4" layer of mortar into the lath (figure B). Cover small areas, about 4 to 5 square feet, to ensure that the mortar doesn't set up to quickly. Work with upward strokes with the trowel's leading edge (top edge) held slightly away from the surface, creating an angle that will help push the mortar into the lath. Continue in this manner until the entire area is covered.

4. Starting with the outside corner pieces, wet the backs of each stone with a damp sponge. Next, apply a moderate layer of mortar around the outer edge and press the stone firmly against the scratch coat. You should see some mortar squeeze out. Wipe off the excess. Note: The mortar used to attach the stone to the scratch coat should have a creamy consistency.

5. Work your way in towards the center, stacking the stone as you go. As you work your way in and up, make your cuts as needed using the angle grinder and mason's hammer.

Figure C

Figure D

6. At the fire-box opening, use a scrap 2x4 as a temporary brace to hold up the stack stone until it cures. Cut a piece to the width of the opening and two more pieces to the height of the opening minus 1-3/4 inches. Hold the first piece up to the top of the opening, then place the other two into position to hold it up.

7. Once all the stone is applied, wipe off any excess mortar on the stone. After the mortar has cured, remove scrap wood being used as a brace. Note: Unlike veneer stone, stacked stone does not have mortar joints to fill.