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MANTEL & SHELF INSTALLATION

Installation Instructions for
Wood Fireplace Mantel Surrounds
Installation Instructions for
Wood Fireplace Mantel Shelves
 
THIN CAST STONE MANTELS AND THIN CAST STONE MANTEL KITS Installation Instructions
You will need the following tools and materials to build your mantel:

Power Drill






Fine-toothed
Hand Saw
(if adjusting
height on site)

Tape Measure

3"-long wood
screws

Wood Blocking
2" x 4" x 48"
to support larger
shelves
• Shims to level components
• Thinset for setting the hearth
• Level
• High-strength construction adhesive
• Bracing material
Thin Cast Stone Mantel and Thin Cast Stone Mantel Kit material meets the requirement for non-combustibility when tested in accordance to
ASTM E-136.

Overview

Thin Cast Stone Mantel Kits contain components for a typical installation, and include: mantel components (legs and shelf), facing panels (header, legs) (riser is optional) and a hearth. Facing panels (header and legs) are required to support the bearing surface of the inside edges of the mantel shelf and legs against the wall on the firebox side If facing panels and hearth are not supplied by Mantels Direct, please ensure the non-combustible facing panels located immediately around the firebox opening are built-up to a 1" thickness and extend at least 1" behind the inside edges of the mantel components. Check with your local building code official for clearance and material requirements between mantel components and firebox opening.

Handle products with care to avoid damage to ornamental surfaces and fracturing of components. Avoid unnecessary contact of exposed faces of components with objects that may scratch or scuff surfaces. Carry components on edge and store in original packaging at room temperature.

Mantel components are ideally applied to solid, stable, flat and level substrates such as plaster or drywall. Wood surfaces are typically not stable and may cause cracks in components or filled joints.

Important:Layout and dry fitting of entire mantel is recommended before any adhesive is applied.

Components may be secured using a high-strength construction adhesive that is suitable for plaster or masonry material and potentially high temperature application. Use bracing to secure components tight to the wall until the adhesive sets. Avoid adhesive on exposed component surfaces. Use a finishing nail or a small piece of plastic (shaped like a 'V') to remove excess adhesive at joints. Clean off excess adhesive immediately as required by adhesive manufacturer instructions.

Hearth and Facing Panels Installation
  1. Install the hearth first, centered on the firebox opening and set tight to the wall. Set the hearth level on a bed of thin set masonry material and ensure there are no voids between the floor and underside of the hearth for complete and continuous support throughout its area, especially at the corners. Exposed edges of Thin Cast facing panels and hearth, are beveled to eliminate sharp corners.
  2. Install facing panel legs. Use pencil lines to outline the inside edges of the mantel shelf and legs.

    Note:Thin Cast Stone Mantels require facing panels (header and legs) to support the bearing surface of the inside edges of the mantel shelf and legs against the wall on the firebox side, and to cover the wall area between the firebox opening and mantel components. The cavity behind Thin Cast Stone Mantel components is designed to allow for the position of the facing panels to be adjusted and accommodate a wide range of firebox openings. Cutting is typically required only on the facing panel legs to achieve the desired height.

    Cut facing panel legs as required and ensure the cut sides of Thin Cast facing panels terminate at the hearth and behind mantel components with beveled edges exposed. When set in place, the level height of each facing panel leg must be identical to provide for a level facing panel header. Use shims to level the facing panel legs. Apply a generous and continuous bead of adhesive to ensure continuous contact between wall and bedding surface of the facing panel legs. Brace facing panel legs securely until the adhesive sets.

  3. Install facing panel header. The cavity behind the Thin Cast Mantel components is designed to allow for the position of the facing panels to be adjusted and accommodate a wide range of firebox openings. The Thin Cast facing panel header typically does not have to be cut, however, ensure the beveled edge is exposed when installed. Apply a generous amount of adhesive to ensure continuous contact between wall and bedding surface of the facing panel header. Brace facing panel header securely until the adhesive sets.
  4. If applicable, install the facing riser. The beveled edge of the riser should be exposed and located on the firebox side. Cut the riser panel so that it fits snug between the facing panel legs. The bottom edge may also be cut if a height adjustment is required. Apply a generous and continuous bead of adhesive on the back of the facing panel riser, set in place and brace securely until the adhesive sets.
Mantel Installation
  1. Install mantel legs. Note: The mantel legs can be cut at the base to adjust the overall height of the mantel. Install so that each mantel leg overlaps its respective facing panel. When set in place, the level height of each mantel leg must be identical to provide for a level mantel shelf. Use shims to level the mantel legs. Apply a generous and continuous bead of adhesive to ensure continuous contact between wall and bedding surface of the mantel legs. Brace mantel legs securely until the adhesive sets.
  2. Install mantel shelf last. Note: Larger mantel shelves are cast with a cavity in the back to accommodate wood blocking for support. Locate the wood blocking position by offsetting the material thickness at the top of the shelf from a pencil line indicating the top edge of the mantel shelf when set on the mantel legs. Screw wood blocking with wood screws into wall studs for greatest support. Apply a generous amount of adhesive to the bedding surfaces of the mantel shelf and the top of the wood blocking to ensure continuous contact with the wall. Pile adhesive on top of the wood blocking and continuously along its length so that the mantel shelf will settle into the adhesive as it is lowered onto the mantel legs. Use bracing to secure the mantel shelf tight to the wall until the adhesive sets.

    For additional security on larger mantel shelves, install two (2) - 3"-long wood screws into the top of the mantel shelf and into the wood blocking below. Locate screw holes approx 1" from the wall and 18" on either side of the mantel centerline. Drill pilot holes first and countersink so that screw heads are located below the surface of the mantel shelf. Mix the facing powder provided with water to create a workable paste. Fill screw holes and tool to a smooth finish. Area may be sanded lightly if required.
Finishing

If required, fill any gaps around the mantel with a paintable latex caulk. Thin Cast Stone Mantels are factory treated with a clear water-based sealer, and do not require additional surface treatment.

OPTIONAL OVERMANTEL - NOBLE COLLECTION Installation Instructions

Power Drill





3"-long wood
screws

Tape Measure

• Shims to level components
• High-strength construction adhesive
• Paintable caulk
• Bracing material
Overview
Overmantels are available in White Gypsum or Thin Cast Stone material and are typically installed directly on the top shelf surface of Noble Collection Mantels.

Overmantels are installed AFTER the installation of the mantel is completed. The top of the mantel shelf must be level and secure to support the weight of the overmantel and its bracing.

Note: Make sure the top of the mantel shelf is level, as it will dictate the level of the overmantel that sits directly on top.

Handle products with care to avoid damage to ornamental surfaces and fracturing of components. Avoid unnecessary contact of exposed faces of components with objects that may scratch or scuff surfaces. Carry components on edge and store in original packaging at room temperature.

Overmantels are ideally applied to solid, stable, flat substrates such as plaster or drywall. Wood surfaces are typically not stable and may cause cracks in the product or filled joints.

Overmantel may be secured using a high-strength construction adhesive that is suitable for plaster or masonry material and potentially high temperature application.

Installation
  1. Locate the center of the mantel shelf top and draw a pencil line near its front edge.
  2. Locate the center of the overmantel at the end that will sit on top of the mantel shelf and draw a pencil line at its face near the bottom.
  3. Apply a generous and continuous bead of adhesive to the back perimeter surface area of the overmantel to ensure continuous contact between wall and bedding surface area of the overmantel.
  4. Carefully lift the overmantel over the mantel and gently place it on the mantel shelf top, tight against the wall. Ensure the marked centerlines of the mantel and overmantel are in alignment. Note: Exercise caution to avoid scratching of the top of the mantel shelf by dragging of the overmantel while fitting in place.
  5. Check for full contact between the back perimeter of the overmantel and wall surface.
  6. Use bracing to secure the overmantel tight to the wall until the adhesive sets.
Note: Avoid adhesive on exposed component surfaces. Use a finishing nail or a small piece of plastic (shaped like a 'V') to remove excess adhesive at joints. Clean off excess adhesive immediately as required by adhesive manufacturer instructions.

For additional security install two (2) - 3"-long wood screws on an angle into the top of the overmantel shelf and into wall studs. Drill pilot holes first and countersink so that screw heads are located below the surface of the overmantel. Fill screw holes with paintable latex caulk and tool to a smooth finish.

Finishing
If required, fill gaps around the outer perimeter of the overmantel with a paintable latex caulk and tool to a smooth finish.

Thin Cast Stone Overmantels are factory treated with a clear water-based sealer, and do not require additional surface treatment.

White Gypsum Overmantels will accept lacquers, stains, oil-based or acrylic paints. Apply a drywall primer first, then apply finish in thin coats to avoid filling-up the design details. For best results, use flat or eggshell finishes.

Top of Page

White Gypsum Mantel material meets the requirement for non-combustibility when tested in accordance to ASTM E-136.

Overview

Components for a typical installation may include: White Gypsum Mantel surround components (legs and shelf), non-combustible facing panels (header and legs) and a hearth.

Handle products with care to avoid damage to ornamental surfaces and fracturing of components. Avoid unnecessary contact of exposed faces of components with objects that may scratch or scuff surfaces. Carry components on edge and store in original packaging at room temperature.

Mantel components are ideally applied to solid, stable, flat and level substrates such as plaster or drywall. Wood surfaces are typically not stable and may cause cracks in components or filled joints.

Important:Layout and dry fitting of entire mantel is recommended before any adhesive is applied.

Components may be secured using a high-strength construction adhesive that is suitable for plaster or masonry material and potentially high temperature application.

Use bracing to secure components tight to the wall until the adhesive sets. Avoid adhesive on exposed component surfaces. Use a finishing nail or a small piece of plastic (shaped like a 'V') to remove excess adhesive at joints. Clean off excess adhesive immediately as required by adhesive manufacturer instructions.

Hearth and Facing Panels Installation
  1. Install the hearth first, centered on the firebox opening and set tight to the wall.
  2. Install facing panels.
Note: Some models in the White Gypsum mantel collection may either include a rabbit cut to allow for facing panels or have the option for one along the firebox side of the mantel components. This recessed area may be used to:

a) Accept marble, stone, tile, or other filler (facing panel) material; or
b) Be filled-in with a non-shrinking, non-combustible, sandable wallboard compound, if the recessed area is not required.

Use pencil lines to outline the inside edges of the mantel shelf and legs.

White Gypsum fireplace mantels in the Noble Collection require facing panels to be sized and cut to extend within the 3/4"-wide rabbet along the inside edges of the mantel components.

Note: Layout and dry fit the filler panels before applying adhesive to ensure facing panels extend within the 3/4" x 1" rabbet along the firebox side of the White Gypsum Mantel.

Mantel Installation
  1. Install mantel legs. Note: The mantel legs can be cut at the base to adjust the overall height of the mantel. Install so that each mantel leg overlaps its respective facing panel. When set in place, the level height of each mantel leg must be identical to provide for a level mantel shelf. Use shims to level the mantel legs. Apply a generous and continuous bead of adhesive to ensure continuous contact between wall and bedding surface of the mantel legs. Brace mantel legs securely until the adhesive sets.
  2. Install mantel shelf. Note: Larger mantel shelves are cast with a cavity in the back to accommodate wood blocking for support. Locate the wood blocking position by offsetting the material thickness at the top of the shelf from a pencil line indicating the top edge of the mantel shelf when set on the mantel legs. Screw wood blocking with wood screws into wall studs for greatest support. Apply a generous amount of adhesive to the bedding surfaces of the mantel shelf and the top of the wood blocking to ensure continuous contact with the wall. Pile adhesive on top of the wood blocking and continuously along its length so that the mantel shelf will settle into the adhesive as it is lowered onto the mantel legs. Use bracing to secure the mantel shelf tight to the wall until the adhesive sets.

Note: Place the bracing against the mantels surface gently and make sure that the bracing is padded on the end touching the mantel surface.

Note: Avoid adhesive on exposed component surfaces. Use a finishing nail or a small piece of plastic (shaped like a 'V') to remove excess adhesive at joints. Clean off excess adhesive immediately as required by adhesive manufacturer instructions.

For additional security on larger mantel shelves, install two (2) - 3"-long wood screws into the top of the mantel shelf and into the wood blocking below. Locate screw holes approx 1" from the wall and 18" on either side of the mantel centerline. Drill pilot holes first and countersink so that screw heads are located below the surface of the mantel shelf. Fill screw holes with paintable latex caulk, or non-shrinking compound and tool to a smooth finish.

Finishing
Fill joints between components and any gaps around the mantel with a paintable latex caulk and tool to a smooth finish.

White Gypsum mantels will accept lacquers, stains, oil-based or acrylic paints. Apply a drywall primer first, then apply finish in thin coats to avoid filling-up the design details. For best results, use flat or eggshell finishes.

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