How To Make Fireplaces A Statement. Successfully

Overview

How to make Fireplaces a statement because they are usually the focal points of a room they adorn no matter what country it is. The more common differences relate to their overall size, the firebox size and fuel type.

Throughout the ages, the fireplace with its mantel & surrounds has been produced with many different products and design elements.

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Modern Day & How To Make Fireplaces A Statement

Today, modern fireplaces are seeing a resurgence in the UK and are driven by the spiralling cost of fossil fuels that are normally used for heating systems.

Many of these are in the form of a log burner which can be a compact and efficient source of heat. But these are not as homely as an open fire with the crackle of logs burning. Sadly, they are just not as efficient as the smallish multifuel burners. Many of these new burners are placed in the same area of the old fireplace using a custom-made fireplace mantel.

Safety Regulations Are Inplace In Most Countries

Most countries have many regulations for the building of fireplaces and parts of the surrounds to the firebox. The primary reason for this is safety, the saving of lives and the destruction of property. In today’s world, even technology plays its part with fire and CO2 detector systems, remote controlled fireplaces that can even be operated from your phone.

How To Make Fireplaces A Statement Is Helped By Choosing Cast Stone

Architectural cast stone is a great choice for today’s fireplaces, mantels and upper or lower surrounds. It’s non-combustible and there is an inexhaustible and flexible choice for designs.

In many areas of the States like North Carolina, especially in country or golf club settings, I have seen monstrous natural stone fireplaces & mantels, 25’-30’ tall. But many of these it turns out were not real stone. They were cast stone products, like Eldorado or Cultured Stone veneers. Very convincing and I will detail this type of stone in a later article.

My company, from the early 90s to 2011, had a huge involvement in the fabrication and installation of many fireplaces. We were either asked how to make fireplaces a statement with design suggestions or to work with an interior decorator to achieve the same result. And some of these were large and grand fireplaces, some being 10m (30’) tall, and even the same in width, although these did include other usable side niches in the design.

Early Involvement

We were nearly always asked to become involved at an early stage. This would allow us to advise the client, decorator or builder of the best way to achieve the design. And it also allowed us to inform them of any changes to the on-site conditions required to achieve the client’s vision.

How To Make Fireplaces A Statement Begins Choices and Designs

A good starting point was always to ask the client if they had seen anything in a magazine, or if they had a photo of anything that had caught their eye. We used to show our portfolio of past projects or new major elements we now could provide. It was always important to get a feel for the client’s tastes and preferences early in the process.

Firebox Selection Is Part Of How To Make Fireplaces A Statement

In how to make fireplaces a statement has many important points at this first meeting. And if it wasn’t already in place, a choice of the firebox was made and its position off the floor and its position on the wall where it was being built.

Choosing a firebox is a really important part of the puzzle in how to make fireplaces a statement, and not just because of the fuel choice. Size and color play a big part in the overall design concept as well. If it’s too small it could look out of place and limit the size of the fireplace. Also, some fireboxes, even if they have the same finish sizes, any buildout could be different. Firebox options may have considerations too, access for any service, ventilation requirements are just 2 that spring to mind.

Most of these boxes were of metal designs and used gas and artificial logs and embers, Electric, very effective for looks and no mess. Others could be of fire brick or a special concrete liner and flue kit construction and could be used for solid fuels.

These choices were important for installing the gas supply or any electrical requirements, and for us to draw the designs up. All field measurements were taken if the structure or walls were already built, while noting the type and position of the firebox, and any obstacles or other potential issues.

How To Make Fireplaces A Statement By Design Parameters

Some questions were always raised about basic design parameters. What would you prefer the height of your mantel to be? What is your preference for your mantel support, column(s), corbels or a pilaster? How much display space would you like on top of your cast stone mantel for display usage? Do you have any artwork, mirror or TV that needs to fit in the upper cast-stone surround?

Texture And Type of Cast Stone

How to make fireplaces a statement would not be possible without the last part of the puzzle. Always part of the first meeting was the type, texture and colour of the cast stone. This part was always easier when an interior decorator was involved. It was normally down to 2 choices for the type of cast stone, limestone or coral stone. The texture was always smooth for limestone, but coral stone could be produced in 3 very different textures, heavy random, medium and light.

How To Make Fireplaces A Statement By The Cast Stone Color

When it came to colour, we always offered 5 standard colours or the choice of a custom colour at additional cost. Anyone considering enquiring with a cast stone company about a fireplace should have the following readily available.

• . Have your ideas ready, photos, and magazines.
• . Any fire box picked out.
• . The type of cast stone you would like.
• . The colour and finish of your cast stone.
• . Your preferred height of the top of your mantel
• . How much display space on your mantel is needed?
• . What style of mantel support is preferred?
• . Information on any item you want incorporated.

Moving On To Production

Over time I developed a system that was based on ease of installation and to eliminate much of the additional costs associated with complex buildouts/structures required for these behemoths or even the smaller designs.

This situation with buildouts was a challenge that was encountered 80% of the time before my new design system was implemented. Because it created many more possibilities for mistakes with the buildout. These mistakes could then lead to the potential for an unsatisfactory installation of the cast stone.

Large Territory

As we could be working on as many as 5 of these projects at any given time. In a territory stretching from Key West to the Hamptons in New York State, my goal was to change things fast. This would make it easier all around and cut out the possibility of potential mistakes throughout the process.

So with all field measurements to hand, the client’s design and choices met, signed off paperwork for all elements, and the process of producing the cast stone fireplace, mantel & surrounds began. It was always wise at this point to check with the builder or designer, one last time, that there had been no changes. Even if we did have all the sign-offs.

Creating Shops & Tags.

The first step in production was to create the individual shop drawings With Corel Draw, for each part of the assembly. Our custom-built software would at the same time produce thermal tags for the No of pieces, job ID & location with barcodes for tracking.

With the tags attached, these were then passed through to our mould shop where they checked for a mold availability or if a new mold was required.

Allowances & Compensating With Design.

Each one of the pieces was made to fit together in the field, so at the shop drawing stage, again using Corel Draw, and practical knowledge, the many calculations made to enable this. Allowances for grout joints and any returns were 2 of the many considerations. But the overall design was that the installers had no cuts to make and they could stack the install like a “Lego” kit.

Once the mold shop work was done, the mold(s) would be sent to production. After production, each piece went through quality control. Dry setting the pieces of the assembly to check for tolerances was standard on fireplace assemblies. And then onto packing and palletising, and storage ready for the future delivery.

Installation.

As the scheduled installation date became closer, our design office would prepare an installation package. Drawings of the overall fireplace with part locations noted, which pallet they were on. Also details of colour, address and contact information. Transport was arranged and then on the day, along with the installers, they converged on the project. Complete with all the information, setting and grouting materials, all tools and equipment to finish the project.

Prior Skills.

Because I was previously a mason and cast stone installer the implementation of my “Lego” design method, made installation simple and fast, and my installers were very keen to work with my cast stone fireplace mantels and upper surrounds. And most importantly the contractor and the client were extremely pleased with the overall finished item.

In later articles, I will go into a more detailed description of the various processes mentioned above.

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Author Rob