Cast stone mantel Kits contain components for a typical installation, and include: mantel components (legs and shelf), facing panels (header, legs) and a hearth (included on builder kits, optional on others).We also include a patch kit that can make repairs to cracks and chips as well as fill screw holes and seams.
If you choose your own facing panels and hearth, please ensure the non-combustible facing panels located immediately around the firebox opening are built-up to a .75" thickness and extend at least 1" behind the inside edges of the mantel components.
You will need the following tools and materials to build your mantel:
- 3"- long wood screws
- Bracing material
- Caulk Gun
- Circular Saw with diamond masonry blade
- High-strength construction adhesive
- Power Drill
- Shims to level components
- Tape Measure
- Thinset for setting the 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
- If any facing or hearth piece is bowed or warped following shipment, simply lay flat (face up) and mist with water using a spray bottle. Repeat if necessary after allowing time to dry
Prepping both the mantel and and wall to which it will be applied is an important first step. 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.
Layout and dry fit all parts of the mantel before any adhesive is applied. This will help you identify any missing pieces, tools, or other things you may need.
Ensure you have appropriate high-strength construction adhesive (available from mantelsdirect.com) or most home centers). The construction adhesive should be suitable for plaster or masonry material and high-temperature application.
Have bracing prepared to secure components tight to the wall until the adhesive sets. Avoid adhesive on exposed component surfaces and use caution not to apply too much.
Have a finishing nail or small piece of plastic handy to clean off excess adhesive immediately as required by adhesive manufacturer instructions.
Hearth and Facing Panel Installation
Step 1 - Hearth Installation
Install the hearth first, centered on the firebox opening and set tight to the wall (Fig. 1). Set the hearth level on a bed of thin set masonry material. 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. Apply construction adhesive. (Fig. 1.1)
Step 2 - Install Facing Panel Legs
The following instructions are for adjustable surround facing that contains three pieces. Custom one piece facing will simply fit over your firebox opening.
- Adjustable Surround Facing: The cavity behind a cast stone mantel is designed to allow for the position of the facing panels to be adjusted and accommodate a wide range of firebox openings. Measure for the legs, and check both sides of the firebox; it may be necessary to cut the height of the legs. Cut the legs as required with a circular saw with a masonry blade. Always make your cuts on a level surface; never let the piece you are cutting fall free. Apply adhesive on the back of each leg and place into position. (Fig. 2)
Step 3 - Install your Facing Header and Optional Riser
Apply adhesive on the back of the header and place into position. (Fig. 3) It is usually okay if your header extends beyond the outside of each leg – our fireplace mantels are designed to overlap facing material and can accommodate up to 5" on each side in most cases.
If you are using a riser panel, simply cut the panel to fit between the two facing legs, apply adhesive and place into position. (Fig. 3.1)
Step 1 - Install Mantel Legs
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. (Fig. 4) and (Fig. 4.1) Brace mantel legs securely until the adhesive sets. If necessary, the mantel legs can be cut at the base to adjust the overall height of the mantel.
Step 2 - Install Mantel Shelf
Your mantel shelf should be set so that there is equal distance on the outside of each leg. After locating this position, mark with pencil. Apply adhesive to the back of the shelf as well as the top of each leg. (Fig. 5 and Fig. 5.1) Set the shelf. For additional security, install two (2) - 3"-long wood screws into the top of the mantel shelf and into the wood blocking below. Locate screw holes approximately 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.
Step 3 - Screw Hole and Seam Repair
Mix a small amount of the facing powder provided with a few ounces of the white liquid to create a workable paste (peanut butter consistency). Fill screw holes and seams with a knife or small putty tool to a smooth finish. Area may be sanded lightly, after it dries, if required.
Step 4 - Sealing Your Fireplace Mantel
All cast stone mantels (polished and honed) require a sealer as recommended by the manufacturers. Use a clean cloth and apply sealer on all components.
Step 5 - Wait To Use
After installing any of our cast stone mantels, wait 30 days to use your fireplace. Our Classic, Majestic, and Builder Series use a high heat formula that can withstand up to 300 degrees Fahrenheit