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Project 2:  Re-facing Existing Fireplace with Stone

Materials & Tools: 

• Stack Stone from Boulder Creek Stone
• Diamond Metal Lath 
• Stone Type M Mortar Mix
• Tapcon Concrete Screws or Concrete nails
• Masons Trowels & Angle Grinder W/ Diamond Blade
• Hammer Drill & Masons Hammer
• 2’ or 4’ level
  

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

Step by Step:

Applying the Diamond Lath...

1. Cut the metal lath to size and attach it to the existing brick, using the tapcon concrete screws.  Use your hammer drill to pre-drill into the mortar before driving in the tapcon.  Drive a tapcon in every 6˝ - 8˝ to hold the lath securely in place.  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.

Applying the Scratch Coat...

1. Mix a batch of type M mortar that’s firm, but still moist.  Good consistency is important for the mortar to bond properly.
2. Using a square-end trowel, press a ½˝ to ¾˝ layer of mortar into the lath.  Cover small areas, about 4–5 s/f, to ensure that the mortar doesn’t set up to quickly.  Continue in this manner until the entire area is covered.
   

Applying the Stacked Stone...

1. Start by wetting the backs of each piece with a damp sponge which will improve the bond.  Next, apply a moderate layer of mortar around the outer edge and press it firmly against the scratch coat.  You should see some mortar squeeze out. Note:  The mortar used to attach the stone to the scratch coat should be a creamy consistency.
2. If you have outside corner pieces, install those first.  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.
3. In the case of the fire box opening, use a piece of scrap wood, like a length of 2x4, as a temporary brace to hold up the stack stone until it cures.  Secure the scrap wood in place using the tapcon concrete screws.
4. Once all the stone is applied, wipe off any excess mortar on the stone.
5. Once the stone has cured, remove the piece of scrap wood being used as a brace, and the job is done    

Note:  Unlike veneer stone, stacked stone does not have mortar joints to fill.