This 100-year-old fireplace had been removed and walled over sometime in the past. The hearth had been removed and the old fireplace had been framed and the floor had been repaired with hardwood flooring.
PHASE I
Today's codes requires a hearth to be on a base of non-combustible material so all of the combustible materials had been removed and replaced with sturdy steel angle iron. The footings of the new hearth were concrete precast pillars. A base was laid inside the angle iron reinforced with rebar and a concrete base was poured.
PHASE II
The next phase of the restoration was to position the base of the liner at the correct termination height for the new firebacks dimensions then to terminate the liner and to insure the correct clearances around the liner for our zero clearance insulation (thermix). Another concern at this time was the failed masonry products where the old fireplace had been removed. The bricks and mortar showed sign of heat failure and we had a fireplace that was completely inside the house it was necessary to zero clearance the new firebox as well. A one inch thick ceramic blanket was used to achieve this safety barrier. The blanket was held in place with a wire mesh that gave us the surface to build the smoke chamber with a refractory cement. This process had to be built in several layers to achieve the shape of the new smoke chamber each time having to cure the refractory.
PHASE III
The mason was brought in to build the firebox, replace the breast wall and install two lintels to adequately support the structure and the restoration then build the new brick facia for the firebox. All of the masonry work was done with lime mortar and fire clays where needed in keeping with the original structure. The brick were hand made brick to match the era of the original property. NOTE: Modern firebrick were used in the fireplace to meet modern code and to insure safety. Great care was taken to insulate behind all of this brickwork to insure no heat transfer to the old timbers of the house. A new hearth extension was laid on the concrete substructure to complete the appearance. Again great pain was taken to choose the materials with consideration for the overall appearance of the finished restoration.
NOTE: Customer had found an old period mantel that had to be slightly altered to fit between the bookcases.