Need some advice on masonry

[Mark42]

I'm going to start the stone fireplace face in a week or so. Have been reading about how to make masonry stone walls. Figure its about the same. I'll be using random sized stones roughtly 6" to 8" thick. They will be stacked on a concrete slab floor and attached to the wall with ties anchored to the studs. The area to be done is 6" wide by 9" tall. The stone yard says I'll need two tons of the stone we picked out.

So, I'm looking for some advice and tips on how to go about stacking the stone.

Thanks

Mark.

 

[burroak]

Re: Need some advice on masonry

I'm going to start the stone fireplace face in a week or so. Have been reading about how to make masonry stone walls. Figure its about the same. I'll be using random sized stones roughtly 6" to 8" thick. They will be stacked on a concrete slab floor and attached to the wall with ties anchored to the studs. The area to be done is 6" wide by 9" tall. The stone yard says I'll need two tons of the stone we picked out.

So, I'm looking for some advice and tips on how to go about stacking the stone.

Thanks

Mark.

What kind of stone are you purchasing?

 

[Mark42]

Re: Need some advice on masonry

This is the display at the stone yard. Called Delaware River Blend. The yard mixes stone from 3 or 4 different piles. After we looked at the piles, we asked that they do include the round boulders in the mix. I want rough irregular shapes, not round shapes. I don't know exactly what type of stone is in the mix.

This is the fireplace that will be faced with the stone. From book case to book case, and floor to ceiling. The black pannels above and below the glass doors have no louvers, and can be covered with stone. The design is to have the entire fireplace covered with stone, excpet for 1" perimeter around the glass doors because there are air gaps that can't be covered.

I saved the L angle iron used to support the old brick work above the firebox. It is 3"x"4x5ft
and I plan on reusing it to support the stone across the top of the doors.

I wonder if 2 tons of stone will have an impact on the foundation or slab floor it rests on? The bricks didn't seem to be a problem, but then their not as heavy as the stone.

 

[rwise]

Re: Need some advice on masonry

nice, are you building the fire box as well? or putting in an insert? I have work with a mason or two, they tell me that the fire box is tricky to get right. if it is no built right it may not draw right or it may not heat good.

 

[burroak]

Re: Need some advice on masonry

Install a vapor barrier on the surround and cover that surface with an expanded metal lath - this will give you a great bonding surface.

Layout your stone on the floor in front of the fireplace site in the pattern that seems pleasing to you. Cut and chip the edges of the stone to make a better fit. An angle grinder and a masons hammer will aid in that. If you work from the back side of the stone, that will leave fewer tool marks on the money side of the wall. When arranging the stone on the floor in your pattern, find out what works best for you, layout rock face down and get a direct reference as to where the next stone will go; or lay them face up and get a friend with dyslexia to place the stone.

Dampen the backs of the rock; this will promote adhesion. Trowel mortar onto the mesh, back butter the stone and set into place. Use small wooden spacers to maintain a consistent joint. Do not be concerned about working the joints between the pieces. Keep that mortar to a minimum; it will be unsightly if you don't. Remove any mortar from the face of the stone immediately.

After the stone has been laid up, mix up mortar for the crevices between the stone. Grout bags can be purchased from the big box stores along with tuck pointing tools. When you work the cracks, it's a lot like decorating a cake. Squeeze the mortar into the joints, use the tuck pointing trowels to embed the mortar and whisk off the small crumbs of mortar with a small brush. Work the joints from the top down; cleanup as you go will be much easier.

Send pics;D

 

[Mark42]

Re: Need some advice on masonry

Thanks Barroak, that's great info.

I have a question about the metal lath: The studs to anchor th metal lath to are 11 inches in from each side of the stone covered area. Should I use something like a toggle bolt to attach the lath to the sheetrock along the edge, or is it OK to leave the edges unattached?

Thanks,

Mark

 

[burroak]

Re: Need some advice on masonry

Thanks Barroak, that's great info.

I have a question about the metal lath: The studs to anchor th metal lath to are 11 inches in from each side of the stone covered area. Should I use something like a toggle bolt to attach the lath to the sheetrock along the edge, or is it OK to leave the edges unattached?

Thanks,

Mark

Hmmmmmmmmm, good question.

After looking at the picture of the fireplace and casework, I see what you mean. If it were me, I would reverse a metal plaster corner bead, attach it to the casework and twist tie the field lath to it. The stone will be more that thick enough to cover the corner bead attached to the casework.

You WILL have mortar shrinkage where the stone meets the casework. Before you install the stone, apply a plastic film to the wood. Use the same stuff home builders use in their model homes to protect the floors in their models. Before the mortar sets completely, back cut the joint running along the bookcases about 1/8"-3/16" at a 45 degree angle. That will give you a bed to apply a mortar colored caulk to bridge the crevice that will be created by the drying of the mortar and score the protective film permitting you to cleanly remove it.

These are the collected musings from lessons that I paid dearly for.

Feel free to use what you are comfortable with.

 

[Mark42]

Re: Need some advice on masonry

Thanks to Burroak's advice, I'm done already! Boy that was hard work, but I got it all done this morning. I was a blur of morter and stone! What do you think?

No, I didn't photoshop the pic. Why do you ask?

 

[burroak]

Re: Need some advice on masonry

Thanks to Burroak's advice, I'm done already! Boy that was hard work, but I got it all done this morning. I was a blur of morter and stone! What do you think?

No, I didn't photoshop the pic. Why do you ask?

Just as a suggestion, you may want to get a helper with a more artistic eye to work on you random symmetry. The eye should mot pick up hard straight lines. I seem to detect one or two. If you are going for that look, it will be quicker and cheaper to use stone patterned vinyl sheet goods.

 

[Coors]

Re: Need some advice on masonry

I'm not sure your slab will hold the weight. I have built several BBQ restaurants, and we had to put a large footer under the pit area, due to the weight; and as, said, if not a prefab, finding a mason that knows about firebox/smoke ledges is the trick. (Whenever I had to use a mason I didn't know, as soon as it was cured, I would be there, starting the first fire, chanting "please draw correctly". And fireclay is needed in the mortar, as regular mortar will expand and pop out with the heat.

 

[burroak]

Re: Need some advice on masonry

I'm not sure your slab will hold the weight. I have built several BBQ restaurants, and we had to put a large footer under the pit area, due to the weight; and as, said, if not a prefab, finding a mason that knows about firebox/smoke ledges is the trick. (Whenever I had to use a mason I didn't know, as soon as it was cured, I would be there, starting the first fire, chanting "please draw correctly". And fireclay is needed in the mortar, as regular mortar will expand and pop out with the heat.

Looking at the pictures, it seems to be a prefab fireplace.

 

[Coors]

Re: Need some advice on masonry

Two tons of stone? That's why a sidewalk will crack when run over buy a truck, alot of times.

 

[Rob454]

Re: Need some advice on masonry

I would rethink the stones. you can get prefab stonet thats light weight and looks just like the real thing. If thats real stone your wall wont support it either and youre gonna run into frame roof wall floor problems. if you plan on doing a pre fab river rock 9 thats what its calle din california_ let me know I can send you some samples of how you need to do the backing the expanded steel mesh mortar etc.
Rob
ss454454@socal.rr.com
I used to be a general contractor so construction was my life for the past 10 years
Rob