Reconstructed Natural Stone Fireplace
GENERAL INSTRUCTIONS FOR THE INSTALLATION AND USE
PLEASE READ CAREFULLY BEFORE COMMENCING INSTALLATION AS WE CANNOT ACCEPT RESPONSIBILITY FOR ANY DEFECTS CAUSED BY NON COMPLIANCE WITH THESE INSTRUCTIONS
THESE INSTRUCTIONS MUST BE LEFT WITH THE USER TO COMPLY WITH CURRENT BUILDING REGULATIONS
Before installing this fireplace, please make the time and the effort to read these instructions. Allowing five to ten minutes now will make the job of installing the fireplace much easier. We have taken considerable care to ensure that the fireplace is delivered to you in first class condition. To avoid damage during unpacking and installation please handle the components with care. Please check all components prior to installation to ensure that no damage has occurred whilst in transit. DO NOT INSTALL THE FIREPLACE IF ANY SECTIONS ARE DAMAGED OR INCORRECT Once the fireplace is installed, no claims or responsibility will be accepted by the manufacturers relating to chips or other damage to the material. With the exception of certain designs*, these fireplaces are suitable for installation with standard 16/18" B.S. firebacks with solid fuel or inset gas fires, or for other types of gas fires without B.S. firebacks, or for all types of electric appliances. Specific designs can also be used with fire chambers and other larger fire-openings with noncombustible interiors. Some of the sections are very heavy and may require two people to lift/carry them. Always take extreme care when lifting heavy or awkward objects. During manufacture the components are made and marked as a set ensuring that each part fits flush with another. Do not mix the components of one surround with another. Carefully unpack all components and check for any damage or missing parts. Small chips or marks can be sanded out using the 60grit silicon carbide paper provided. Take care not to sand out moulded edges. If there are any large chips or other damage contact the manufacturer before commencing installation. DURING OFFERING UP AND INSTALLATION ADEQUATE PROTECTION MUST BE USED FOR ALL SECTIONS AND JOINTS. ENSURE CORK SPACERS ARE USED IN ALL JOINTS BETWEEN ALL COMPONENTS TO ALLOW FOR NATURAL SHRINKAGE AND MOVEMENT DO NOT USE CEMENT BASED OR HARD SETTING COMPOUNDS TO INSTALL THE FIREPLACE
THESE INSTRUCTIONS COVER THE FOLLOWING FIREPLACE DESIGNS
SUFFOLK, CAMBRIDGE, KENT, HERTFORD, NORFOLK ESSEX*, DORSET, DORSET REGIS, SOMERSET, DEVON, WARWICK, CANTERBURY*,GLOUCESTER, DURHAM ,LINCOLN*& YORK Versions
The fireplaces marked * are not specifically designed for use with solid fuel fires/appliances, in some cases it may be possible to make alterations to the hearth so that they can be used with solid fuel. Please consult our technical department if in doubt.
Each fireplace design comprises of a combination of sections, some designs may not include certain sections and the reference to their fitting should therefore be ignored. The following tables indicate what components are supplied with each design. For fireplaces that are supplied with fire chambers, no standard interior head and slips are supplied.
SUFFOLK long legs (carved& plain)
Mantel Shelf 1
Head Section 1
Interior Head 1
Interior Slips 2
Leg Plinth Blocks 2
SUFFOLK (plain & carved) NORFOLK CAMBRIDGE SOMERSET HERTFORD DORSET DORSET REGIS ESSEX
3 piece Norfolk has corbels attached to top of legs 4 piece
1 upper hearth Leg & slip combined 1 upper hearth
3 piece 3 piece
Leg & slip combined
Leg & slip combined Hearth plinth as option
The YORK style fireplace has various modules that can be arranged to give alternative styles of fireplace. Our standard versions comprise of the following
Extra shelf forms raised hearth on 2 2 2 1 0 2 0 1Piece leg plinths The Fireplace comprises of a combination of components generally as below. Certain designs may not include all of these components (see above) (A) – MANTEL / SHELF (B) – HEAD SECTION (C) – LEGS (D) INTERIOR HEAD SECTION (E) - SLIPS (F) - PLINTHS
V1 V2 V3 V4 V5 V6 V7 V8
1 1 1 1 1 1 1
2 2 2 2 2 2 2
1 1 1 1 1 1 1
0 0 1 1 1 1 1
2 2 2 2 2 2 2
0 1 0 1 2 1 2
3 piece 3 piece 3 piece 3 piece 3 piece 0 0
A B C D E F
(F) - HEARTH IN 1 to 3 OR MORE SECTION S
Plus a fixing Pack Comprising – 1.Cork Tile (for spacers), Tube of pointing mastic, Tin of stone sealer, 60grt silicon carbide paper . Plus heat tiles when ordered for solid fuel. Certain fireplace styles may also include 1 or more upper hearths
These instructions are written in accordance with standard building practice, Building Regulations and the relevant British Standards. The constructional part of the chimneybreast, flue and hearth MUST comply with the current Building Regulations, and must be suitable for the appliance that is to be installed. For installation with other appliances i.e. convector boxes, fan flue systems, and back boilers, which require different construction within the recess, refer to appliance manufacturers own instructions. The general principles outlined regarding protection and expansion will still apply. Any building work involved, such as reducing the builders opening, holes for fan flued appliances or alterations to the flue must be carried out before the fire surround is fitted. These instructions have been compiled to illustrate the essential features of installation to prevent excessive heat transference through the components and to provide expansion joints to accommodate differential thermal movement.
The notes apply to new installations to prepared builders openings. If the fireplace is a replacement, the existing surround, hearth, fireback and any rubble must be removed first. It is preferable but not essential to cut the fireplace into the plaster and fix to the actual brickwork. The plaster should therefore be removed from the face of the chimney for an area of at least 25mm larger all around than the actual fireplace. It is also recommended that the flue is swept & checked for soundness and draught before proceeding.
Preparing to fit the fireplace
You will need to have the following items (not supplied with your fireplace) Bonding medium such as bonding/multi plaster or non hard setting mastic fixative such as NAIL & SEAL Packing pieces, protective covering Spirit level & plumb line Clean water and sponge for cleaning fireplace upon completion Lime / sand / cement Leca / Vermiculite or similar backfill insulation Bricks or blocks Fibreboard or corrugated cardboard (to use as expansion materials)
Ensure that the constructional hearth / concrete floor is level and the chimneybreast / wall is flat and plumb. Make allowances for any variations.
For installations with firebacks go to section 1 For installations without chimneys or with chimneys but without firebacks and for installation with Class II gas flues, go to section 2 For installations with firechambers go to section 3
SECTION 1 – Installation with fireback
1.1 The builders recess should have a Minimum opening approx. 600mm wide by 800mm or higher depending on the height the fire / appliance is to be set at. There should be a precast or support lintel at the top of the opening inserted at least 100mm into each side of the chimney breast brickwork. (Fig 1)
If a preformed gather unit such as the Constructa is used, the height of the opening can be reduced to approx. 675mm (depending on desired height of appliance) from finished floor level. This will then allow the fireback throat unit to be omitted. However the exposed back of the fireplace head section will require protection from heat.
1.2 Place fireback into builders recess on pieces of tile or cut brick with bottom edge set at approximately 65mm above
finished floor level or at same height as thickness of the hearth (fig 2). The front edges of the fireback should be set back 10mm from the face of the brickwork and central to proposed hearth position.
Place a piece of corrugated cardboard around the back of the fireback, this will allow the fireback to expand and contract during use. A purpose made throat unit should be set on top of the fireback with the front face flush with the front edges of the fireback. Check the height of the fireplace slips and ensure that the throat unit is set at a height that it will not show below the fireplace head section. The space between the sides of the recess and fireback should now be closed with brickwork. (Fig. 3)
1.4 Back fill behind the fireback with a suitable solid insulation material such as Leca or Micafil mixed with cement on a 6 – 1 ratio. The top of the fireback should then be sloped off with a lime/sand/cement mix. Finish off closing in area above throat unit. (Fig. 4) Fig 1 Fig 2
SECTION 2 - Installation without chimneys or firebacks and Class II gas flues (including Hole in the Wall designs)
2.1 Where the fireplace is to be installed with an appliance where no chimney exists, i.e. Fan Flued or Balanced Flued, all cutting of walls and other associated building work must be carried out prior to starting the fireplace installation. Where a chimney exists, the builders recess should have a maximum opening approx. 600- 650mm wide by 700mm or higher depending on the height the fire / appliance is to be set at Where a raised fire, i.e. Hole In The Wall style, is to be installed, the base under the appliance should be constructed of solid non combustible material. There should be a precast or support lintel at the top of the opening inserted at least 100mm into each side of the chimney breast brickwork. Larger openings must be reduced in size to allow the fireplace to be installed against a solid supporting structure. The exposed back of the fireplace head section will require protection from heat. For installations with Class II gas flues check all joints around base blocks are sound and install the fireplace as you would in front of a fireback. Take care not to drill into flue way when drilling for brackets
SECTION 3 - Installation with Firechambers
Larger size fire openings normally require larger size flues to ensure safe evacuation of the flue gases. The flue size must be checked prior to installation and a satisfactory smoke test should be carried out. The Halstead COLLECTION of fireplaces (without interior panel) has fire-openings of the following sizes. When installed with stone chamber panels or tiles, nominal 50mm thick, they require a minimum builders opening to the dimensions stated. Larger builder’s openings should be reduced prior to installation.
All dimensions are in millimetres and may vary +/- 5mm Fire-opening Builders opening (min) width - height width - height - depth 875 935 900 940 900 680 870 x x x x x x x 715 840 900 795 900 720 790 975 x 815 x 350 1035 1000 1040 1000 780 970 x x x x x x 940 1000 895 1000 820 970 x x x x x x 350 350 350 350 350 350
Suffolk Cambridge Sussex Norfolk Kent Dorset Regis Somerset
If other chamber interiors/linings are to be used, these must be of a suitable fire resistant material. Allowances must be made in the builders opening size to accommodate the thickness of the proposed interior/lining. It is not recommended that standard house bricks are used for firechambers as prolonged exposure to direct heat can cause deterioration. 3.1 If supplied, set firechamber base on lime/mortar mix with top edge either at the same level as the top of the hearth, or for added effect approximately 15 – 20mm above the hearth. The base is purposely thinner than the main hearth to allow for unevenness in builders opening . The front edge of the base should be flush with the face of the brickwork or face of wall. (Fig.5) 3.2 Set the firechamber back panel in position on firebase with cork spacers between joint. If no firebase is used, then panels should be set on pieces of tile or cut brick with the bottom edge at the level of the top of the hearth. If back panel is against the rear wall of the recess,it should be bonded to the wall with either lime- mortar or some non hard setting bonding medium If there is a large gap, between the walls of the builders opening and the Chamber panels, this can be reduced With block/brickwork or the panels can be fixed in position with fixings or Brackets and then back filled later. (Fig 6 ) Fig 5 Fig 6 Fig7
Ensure the bonding medium is spread evenly across the panel and there are no large gaps that could become air pockets.
3.3 Set the firechamber side panels in position as for the back panel. The front edges should be flush with the face of the brickwork/wall. Check the panels are at the same width as the fireopening. Fix back as for back panel. (Fig.7) 3.4Install a large throat lintel across the top of the side panels to protect the back of the fireplace head from heat. If a proper throat lintel cannot be fitted, the head must be protected with a heat proof board or similar. The lintel should be set approx. 10mm above the height of the fireopening. (Fig. 8 ) 3.5Any space above the throat lintel should be filled in and gaps or voids behind the panels should be back filled with either Leca or Vermiculite / cement (or similar) on a 6–1 ratio. Again ensure there are no air pockets. The top edges of the panels should be sloped off using a lime, sand and cement mix
SECTION 4 INSTALLING THE FIREPLACE
Referring to pages 4 & 5, different styles of fireplace comprise of various components.
We suggest you layout all the components for the fireplace you are installing to familiarise yourself with them. Ignore the sections below where components are not included in your fireplace.
REMEMBER DO NOT USE HARD SETTING COMPOUNDS OR MASTICS TO INSTALL THIS FIREPLACE
4.1 HEARTH Lay the hearth centrally to the fireback/builders opening, on thin dabs 5 – 10mm thick of 6 to 1 mix lime mortar or bonding plaster, if the floor is flat and level, you may fix the hearth with a soft setting silicon mastic. Level accurately from side to side and front to back. There should be a 3-4mm joint between each section. (Fig.9)
Solid fuel Hearths Hearths that have been supplied for solid fuel have had the centre section
Cut down and heat tiles supplied. This form heat plate Just in front of the fire opening (Fig.9.1) To avoid settlement during the rest of the installation, you can if needed, place temporary soft wood wedges under the hearth sections. (Be sure to remove them carefully upon completion) The surround is designed to sit on the hearth, therefore allow only a small gap (approx. 2-3mm) from the rear wall.
Place a protective cover / blanket over the hearth ensuring no grit or particles are under it that could damage the surface.
Insert a thin layer of expansion material (approx. 3-5mm) along the back edge of the hearth and then screed base of fireback/builders opening level with the top of the hearth using a weak sand, lime & cement mix. If a firechamber base is used, place a thin strip of corrugated cardboard along back edge of hearth then fill remainder of gap with weak mortar mix. Measure overall width of head section, (except Dorset) working from a centre line over fire opening, mark wall equal to width of head. Using vertical level or plumb line, draw lines on wall from hearth up to approx. 900mm. (this will give setting line for legs and head section).
4.2 UPPER HEARTHS
Where applicable the upper hearth should be set centrally at the back edge of the hearth using cork spacers and a soft setting compound. Interior slips are designed to sit on the upper hearth. It will also act as a spacer to set the legs in the correct position later. Complete fireplaces (not chamber models) are produced with interiors that either set in rebates in the legs or that butt up to the inside of the legs. For those styles with rebates, continue as follows. For styles without rebates you can either install the slips and header now or fit them in after the main head has been fitted.
4.3 INTERIOR HEAD & SLIPS
When supplied, the interior head and slips should be offered up allowing for joints. The slips should be placed equal distance from the centre of the hearth with cork spacers underneath, check fire opening is correct width. Using a non hard setting bonding medium, set the side slip sections in place do not fix permanently at this stage. Check they are plumb and square to hearth and fire opening, the face of the slips should be 50 – 52mm from face of wall, this allows about 3mm gap between leg and interior for pointing. Extra brackets can be attached to interior head if necessary, take care when drilling not to drill through section, do not use hammer action, ensure drill, screws and plugs are all correct size. Place cork strips on top of slip sections. Trowel a thin layer of bonding medium across the top of the fire opening or across the back of the interior head section, set section in position on top of slips. Again check it is plumb and square to the slips, again check the face of the interior head is 50 – 52mm from face of wall, to allow about 3mm gap between leg and interior for pointing. (fig. 10)
4.4 PLINTH BLOCKS
Only supplied separately on certain styles of fireplaces, on other models they are either cast as part of the leg, or they do not have them. Place cork spacers on hearth, set plinth blocks on back edge of hearth Measure width of blocks and width at base of legs, divide the difference by two, this will give the amount that the outside edge should extend approx. beyond the vertical lines on wall. Check they are set equal to the ends of the hearth, there should be a 3mm gap (approximately) between slips and plinth blocks for pointing. They should be fixed with a non hard setting medium. (Fig. 11)
4.5 LEGS If required extra brackets can be fixed to the legs, we recommend they are used for large or heavy legs. Offer up legs with cork spacers between them and plinth blocks or hearth, check they are vertical on the front and sides. Check they are set equal on the hearth and where appropriate central on the plinth blocks and they line up with the vertical lines on the wall. If brackets are used, mark the wall for the fixing screws. To ensure leg sits back against the wall, it may be necessary to chase the surface/plaster of the wall to allow the brackets to be slightly recessed. Remove the legs carefully then drill and plug the wall. Trowel a thin layer of bonding medium on the back of the legs and set them in position. Screw back to secure again checking they are vertical. (Fig 12) 4.6 MAIN HEAD SECTION The head section is fitted with either wire tags or brackets, check these are in the right position for fixing, offer up head with cork spacers on top of legs, mark the wall for the fixing screws Again as in section above, to ensure head sits back against the wall, it may be necessary to chase the surface/plaster of the wall to allow the brackets to be slightly recessed. Remove the head carefully then drill and plug the wall. Trowel a thin layer of bonding medium on the back of the head or face of the wall and set the head in position. Check head lines up with legs and is plumb and level, screw back to secure, again checking it is plumb and in line with slips. (Fig 13) 4.7 MANTEL SHELF Extra fixing plates are provided for fixing the mantel shelf. (If required) They should be fitted to the back of the shelf with the screws and plugs provided (DO NOT USE HAMMER ACTION ON DRILL). With cork spacers on top of the head /legs, offer the shelf into position, mark the wall, remove the shelf, drill and plug the wall. Trowel a thin layer of bonding medium onto the top of the head/legs and on the back of the shelf. Set shelf in place, level side to side and front to back and screw back. (Fig.14) 4.8 POINTING AND FILLING Fill in the gaps around the fire opening between the head, the slips and the fireback / builders opening using fireproof mortar and/or fibre rope. There must be no gaps between the back of the surround and the facing wall/chimney that products of combustion could seep into. (Fig 15) Using the soft cream mastic provided, point all the joints. Application should be made using a mastic gun, applying a thin bead evenly along the joints, scrape off the excess and clean with a damp sponge, rinse the sponge between each application so as not to spread mastic over stone. Ensure all mastic is removed from the surface of the stone. Should any mastic be visible on the stone after the surround has dried, this can easily be removed with the abrasive paper provided. Make good any plaster around the surround.
Wash and clean the complete surround with warm water and sponge. Any marks on the stone can be removed by gently sanding with abrasive paper provided. A LITTLE EXTRA TIME SPENT NOW CAN SAVE A LOT OF PROBLEMS IN THE FUTURE CARE AND CLEANING INSRUCTIONS FOR THE USER
We hope that you are pleased with the product and the installation of your Fireplace. If you do have any concerns please contact your supplier, or our Office for advice.
Do Not:Use the fire for at least 7-10 days. Then only low fire settings should be used for the next few days, this allows for the installation to dry out. Place any object on the hearth or shelf until after the fireplace has dried out and been sealed, otherwise staining may occur. Drag or drop heavy objects such as metal coal scuttles on the hearth surface Stand on the hearth, this is not only dangerous, but it will disfigure the surface texture
You should be aware that
The product is made from natural materials, we do all we can to ensure that colour variation does not occur within a complete fire surround and hearth, but over a period of time there may be variation between batches of stone received for the manufacture process. Occasionally specks of darker stone occur; this is a natural occurrence in the stone. 1) The surround and hearth have been made for at least 2 weeks, but an allowance of an additional 6 – 8 weeks should be made for them to dry out completely. In new buildings this allowance may need to be increased. Do not seal the fireplace until it has completely dried out. During the drying out period, the stone may appear to be different colours. As the components are of various thicknesses, the drying occurs at different rates. The product is made from natural materials, we do all we can to ensure that colour variation does not occur within a complete fire surround and hearth, but over a period of time there may be variation between batches of stone received for the manufacture process.
2) Occasionally specks of darker stone occur; this is a natural occurrence in the stone.
3) The surround and hearth have been made for at least 2 weeks, but an allowance of an additional 6 – 8 weeks should be made for them to dry out completely. In new buildings this allowance may need to be increased. Do not seal the fireplace until it has completely dried out. During the drying out period, the stone may appear to be different colours. As the components are of various thicknesses, the drying occurs at different rates. Should you notice a dusting of the surface when the fire surround is new, this can be perfectly normal as the minute pores of the stone may hold some dust particles. These are normally removed during final cleaning. When the fire surround has dried out completely, we recommend that you seal it with a recommended stone sealer. We enclose a tin for this use, which will protect the stone surface from the majority of stain marks As the fireplace is made from natural stone products, occasionally small hairline cracks may appear, these are not detrimental to the product, and they can be caused by thermal movement during heating up and cooling down.If these are considered unsightly, they can be filled with a stone repair kit.
Cleaning & Stain Removal
To generally clean your fire surround, always use warm water and a sponge, not a cloth. A small amount of detergent may be used if required. Always wash with steady wipes right across the components rather than a circular movement. If necessary the fire surround may occasionally be scrubbed with a clean brush and afterwards sponged down with clean warm water. Any soot or carbon stains can usually be removed using warm water with a mild detergent, gently scrubbing with a soft brush. If a stain is particularly stubborn, then special chemical cleaners are available. Alternatively white vinegar or clear diluted bleach can be used, again washing down afterwards with clean warm water. Very bad marks may require rubbing down with 60 to 80 grit silicon carbide paper but be very careful not to rub out any feature lines.
Note: If the fire surround is not sealed, the colour may change slightly over time with use and frequent cleaning / washing Guarantee 1) Your Fireplace is guaranteed for one year from date of purchase 2) The guarantee is given subject to the following provisions; a)The installation is carried out in accordance with these Installation Instructions . b) That our instructions regarding cleaning and handling are adhered to. This guarantee does not cover mishandling. c) That any part or parts on which a claim is made are returned to us. If we agree with the claim the parts will be replaced free of charge. d)That our liability is limited to the free replacement of the parts affected