StoneAge SA 24 User manual

Report 307-F-01b-2

Installation and Operation

Instructions

Stone Age Outdoor Fireplace

1.0 Introduction

The following provides instructions for the installation

and operation of the Stone Age Fireplace, manufac-

tured by Stone Age Manufacturing, Collinsville, Okla-

homa.

Three generations of fireplace knowledge and experi-

ence have gone into the design and construction of the

Standard series fireplaces. Standard Fireplaces are

certified to UL127 for the US, and ULCS610 for Can-

ada.

Assembly and Cutaway views of a SA24 fireplace are

shown in Figure 1.

Because of structural modifications required in an ex-

isting home, it is recommended that this fireplace be

installed by a professional installer, or by a builder in

new construction. Installation by a non-qualified per-

son may negate the warranty.

Keep these instructions for future reference.

2.0 Description

The fireplace is delivered as a kit with all components

necessary to complete the installation. Component

arrangements are shown in Figure 2. Components are

listed in Table 1. Specifications and installation di-

mensions are shown in Table 2.

A completed installation should include the following:

A. Fireplace items shown in Figure 2 and listed in

Table 1.

B. Top Mount Damper (Optional for Outdoor in-

stallations, sold separately) (Shown in Figure 28).

C. Chimney Cap (sold separately) (Shown in Figure

26).

D. Fireplace Grate (sold separately) (Shown in Fig-

ure 31).

E. Split firebrick (may be included or sold separate-

ly - confirm with your dealer)

F. Stone Age Multi-Purpose Ready-Mix Cement

(sold separately).

The Stone Age Fireplace has been tested and listed in

accordance with UL 127 and ULC S610 standards for

indoor or outdoor use, and is listed by OMNI-Test La-

boratories, Inc. for installation and operation in the

United States and Canada as described in this manual.

This fireplace is designed to supplement your current

heating system. It is not designed to be used as a pri-

mary heat source.

Ensure that appropriate building permits required by

local codes are obtained before installation in an exist-

ing home.

Ce manuel est disponible en français à www.stoneagemanufacturing.com.

This manual is available in French at www.stonea

emanufacturin

.co

SA24

Front View Side

Cutaway

iew

Figure 1. SA24 Fireplace Assembly

& Cutawa

View

Table 1. Fireplace Components

Item Description 24”

1 Riser Legs 18 x 40

1A Riser Leg-Cross 18 x 27

2 Base Plate 33 x 34

3 Sidewall 11 x 33

4 Back Plate 22.5 x 27

5L/5R Slanted Sidewall 11 x 26

6 Back Header 11 x 34

7A/7S Lintel, Arch/Straight 11 x 34

8 Throat 19 x 19

at top

9A Flue (Note 2) 19 sq

10 Hearth 11 x 5 x 34

Note 1: Item numbers refer to component numbers in Figure

Note 2: Flue sections are available but not provided in suffi-

cient quantity to reach a height of 16 feet. Flue sections

must be purchased separately.

Note: Drawings of the fireplace components,

with dimensions, are shown on page 15.

2.1 Specifications

Table 2: Clearances (See Figure 3)

Item Clearance Figure 3

Reference

Sidewall to Opening 18”

Top Trim to Opening 17” A

Side Trim to Opening 3”

Mantle to Opening 25” B

Floor to Opening 7”

Front Hearth Extension 24” C

Side Hearth Extension 12” D

Opening to Combustibles 48”

Minimum Ceiling Height 7’6”

Clearance around Chimney

flue

2”

Chimney Height from floor 16’

Note 1. This Fireplace is intended for use with solid wood fuel

or vented gas logs

Note 2: This fireplace has not been tested for use with glass

doors. To reduce the risk of fire or injury, do not install glass

doors.

Note 3: Do not use fireplace insert or other products not speci-

fied for use with this model. Use a fireplace grate when burning

wood.

Note 4: This fireplace has not been tested with an unvented gas

log. Do not install an unvented gas log set into this fireplace.

Note 5: Clay flue liners installed in flue section (item 9A, Figure

2) meet the specifications of ASTM Section C315-02.

Note 6: Make sure installation complies with local building

codes.

Note 7: Thermal Floor Protection of ½ “ of k=0.84 thermal

protection

Note 8: Floor under unit must be non-combustible to earth

Note 1: This Fireplace intended for use with solid wood

fuel or vented gas logs.

CAUTION: When using this appliance, the fireplace

damper (if present) must be set in the fully

open position.

Note 2: This fireplace has not been tested for use with glass

doors.

Note 3: Do not use fireplace insert or other products not

specified for use with this model. Use a fireplace grate

when burning wood.

Note 4: Clay flue liners installed in flue section meet the

specifications of ASTM Section C315-02.

Note 5: Ensure installation complies with local building

codes.

Figure 2. Fireplace Components

2.2 Installation of Additional Equipment

WARNING: THIS FIREPLACE HAS NOT

BEEN TESTED FOR USE WITH

DOORS. TO REDUCE THE RISK

OF FIRE OR INJURY, DO NOT

INSTALL GLASS DOORS.

A. Do not install a fireplace insert unless it is tested

with this fireplace.

B. Cutting or drilling a hole into the floor or walls

for gas supply for a vented decorative gas appliance

(log), fresh air venting, or an ash dump, is accepta-

ble.

C. If a decorative gas appliance is installed, it must

be installed in accordance with the National Gas Fire

Code, ANSI Z223.1.

D. It must incorporate an automatic shutoff device.

E. Installation must comply with the Standard for

Decorative Gas Appliances in Vented Appliances,

ANSI Z21.60 (1991) or American Gas Association

draft requirements for Gas-Fired Log Lighters for

Burning Fireplaces, Draft No. 4 dated August 1993.

3.0 Installation of the Fireplace

WARNING: DO NOT USE SUBSTITUTE

MATERIALS IN THE

ASSEMBLY, INSTALLATION OR

OPERATION OF THIS

FIREPLACE. TO DO SO WILL

VOID THE WARRANTY AND

MAY RESULT IN FIRE AND

PERSONAL INJURY.

It is most important that the Stone Age fireplace be

installed according to the following instructions. It is

also important that local building codes be consulted

and followed. Improper installation could result in:

• Overheating, leading to fireplace failure

• Leakage of rainwater through and around the

chimney

• Cracks and settling because of poor founda-

tions

• Emission of smoke, sparks and gases into the

living area

• Combustion of materials adjacent to the fire-

place.

WARNING: THIS FIREPLACE HAS NOT

BEEN TESTED WITH AN

UNVENTED GAS LOG SET. TO

REDUCE THE RISK OF FIRE OR

INJURY, DO NOT INSTALL AN

UNVENTED GAS LOG SET INTO

THIS FIREPLACE.

Do not install this fireplace in a manufactured or mo-

bile home.

3.1 Preparations

Select a location in the home plans or outdoor living

area where all the minimum distances, as shown in

Table 2 and Figure 3 can be met. Proceed as follows.

Numbers in ( ) are item numbers from Table 1 and

Figure 2. Ensure the base on which the fireplace is to

be installed is a solid and level foundation and is com-

posed of non-combustible material, such as concrete.

Due to varying climates, soil conditions, building

codes, construction methods and materials in different

geographical regions, Stone Age recommends install-

ers review local building codes, consult with local

building officials and/or a structural engineer before

beginning the construction of any Stone Age product.

Figure 3. Clearances (Use with Table 2)

Pad or footings for outdoor installations should be a

monolithic pad constructed of steel reinforced con-

crete. Minimum footing specifications for fireplaces

built on stable soil, with overall height not exceeding

10 feet, are listed in Table 3. Locations with unstable

soil may require a deeper footing or the addition of

piers, to reach more stable subsoil or bedrock. Areas

with colder climates may also require deeper footings

or piers that reach below the frost line to prevent frost

heaving. Piers should include steel reinforcement that

extends into the footing above. See Figure 4.

For taller applications, consult with an engineer to de-

termine the structural requirements based on the over-

all height, and the weight of fireplace, chimney, and

finish materials. If custom hearths or additional ma-

sonry structure is to be attached to the fireplace kit, the

footing dimensions should be adjusted to include these

customizations.

If local building code exceeds the manufacturer’s

specifications for footings, follow the local code.

Table 3. Minimum Footing Specifications

Minimum Requirements for Footing 24”

Thinner Finishes-

Fabricated Stone, Stucco, Stain or Tile

4” - 6”

48”

40”

Thicker Finishes-

Full Veneer Natural Stone or Brick

8” - 12”

54”

46”

See Figure 5.

Footing requirements for indoor installations should

be determined based on local building code. Consult

with a structural engineer to determine the footing re-

quirements based on the overall height, and the weight

of fireplace, chimney, and finish materials. If custom

hearths or additional masonry structure is to be at-

tached to the fireplace kit, the footing dimensions

should be adjusted to include these customizations.

Use Stone Age’s Multi-Purpose Ready-Mix, or anoth-

er high temperature fire clay or refractory cement suit-

able for indoor or outdoor use, and mix according to

manufacturer’s instructions.

Once the fireplace is constructed you must wait at least

28 days before building a fire to give adequate time to

cure. This will provide ample time for any water resi-

due to evaporate, eliminating the adverse reaction of

the combination of water and fire.

Stone Age products are designed to be assembled us-

ing a 3/8” fully bedded mortar joint for the kit pieces.

Do not “butter the edges” of the kit pieces.

If the unit is to be installed indoors, do not use the Ris-

er Legs (items 1 and 1A, shown in Figure 2 and Table

1). Instead, install the fireplace on a solid base, such

as a cement pad or concrete blocks. Two courses of 8”

tall block will be slightly shorter than the riser legs of

the kit.

WARNING: DO NOT USE RISER LEGS FOR

AN INDOOR INSTALLATION. IN

THIS INSTALLATION, THE

VOID BELOW THE FIREBOX

COULD INADVERTANTLY BE

USED FOR THE STORAGE OF

COMBUSTIBLE MATERIALS,

WHICH COULD CREATE A FIRE

HAZARD.

Figure 4. Footing with Piers - Cutaway View

Figure 5. Footing with Piers

Front

Piers

3.2 Assembly of Components

Components that become broken during shipment and

handling can be mortared back together providing the

breaks or cracks are clean and the original alignment

can be maintained. Components broken into multiple

pieces must be replaced.

If this is your first Stone Age installation, it is suggest-

ed that you first assemble the components without

mortar to familiarize yourself with how the compo-

nents fit together. See Figure 2.

During the actual assembly with mortar, ensure each

layer of the kit is plumb, level, and square before pro-

ceeding to the next step of the assembly.

A. For Indoor installations, determine the height

above the floor you want to place the base plate (2).

The base plate, plus firebrick, will be approximately

4 1/2 inches thick. Mortar and set concrete blocks

into place to reach the desired height. Ensure the

block base is level and square. Set the base plate (2),

ensuring it is level and square. See Figures 6 & 7.

B. For Outdoor installations, align and set a Riser

Leg (1) and the Cross Leg (1A) on the footing, en-

suring they are plumb and level. See Figure 8.

C. Install the second Riser (1), ensuring it is plumb,

level and square. See Figure 9.

D. Set the base plate (2), ensuring it is level and

square. See Figure 10.

Note 6: From Step E to Step Q, the installation

procedure will be the same for indoor or outdoor

applications.

Figure 8. Riser Leg & Cross Leg

Figure 9. Riser Legs & Cross-Leg

Figure 10. Base Plate

Base Plate

Concrete Block

Base

Figure 6. Block Base

For Indoor Use

Figure 7. Kit Base Plate

E. Install the lower sidewalls (3), ensuring they are

level and square. See Figure 11.

F. Install the middle sidewalls (3), ensuring they are

level and square. See Figure 12.

G. Install the back plate (4). See Figure 13.

H. Install upper sidewalls (5L) and (5R), ensuring the

correct piece is placed in position. The correct posi-

tion is when the inner wall, outer wall and front are

parallel with the middle wall pieces. Place each so

the front is set back 3½ inches from the front of the

middle wall piece below. See Figures 14 & 15.

H. Install Back Header (6). See Figure 16.

Figure 11. Lower Sidewalls

Figure 15. Upper Sidewalls

Figure 12. Middle Sidewalls

Figure 13. Back Plate

3 3

5L 5R

Figure 14. Upper Sidewalls –Top View

ure 16. Back Header

I. Line the firebox, using split firebrick and 1/4-

inch mortar joints. Install firebrick on the floor first,

with 1/4-inch of Stone Age Multi-Purpose Ready-

Mix or other high temperature mortar. See Figure

17.

J. Install firebrick on the back wall, with the brick

laid on edge. See Figure 18.

K. Install firebrick on the side walls, with the brick

laid on edge. The brick lay up on approximately 1/3

of the upper sidewall, and a notch should be cut in

the front brick on each side, to allow them to clear

the front lintel piece (to be installed later). See Fig-

ure 19.

L. Install the front lintel piece, (7A, for arched lintel,

as shown) or (7S, for straight lintel kits). See Figure

20.

7 A

Figure 19. Sidewall Firebrick

Figure 18. Back Wall Firebrick

Figure 20. Front Lintel

ure 17. Floor Firebrick

M. Install the tapered front and rear throat pieces.

See Figure 21.

N. Install the first Stone Age masonry chimney sec-

tion (9A), with the tile extending upward. Fill the

void on the bottom with mortar to create a smooth

transition. See Figure 22.

O. Install the remaining chimney sections (9A), fully

bedding each piece in mortar, and filling in the gap

between the clay tiles in each section. Parge the

joints to create a smooth transition between each

chimney section. Note that if a tile is chipped or

slightly out of square, it may be used as long as it the

joints are filled and smoothed with high temperature

mortar. See Figure 23.

If additional chimney is required to penetrate a

roof or structure, refer to Section 4.0 for more

detailed instructions.

P. Install the hearth piece (10) if using this compo-

nent, and any hearth extension. See Figure 24.

Figure 23. Chimney Complete

Figure 21. Throat Pieces

Figure 22. Chimney Flue

Q. Ensure the Table 2 and Figure 3 clearances and

distances are maintained. Ensure that the hearth and

flooring under and in front of the hearth are made of

fully non-combustible materials, not just a non-

combustible floor covering. When the hearth instal-

lation is complete, if the chimney complete and is not

continuing through a roof or structure, you are ready

to install the exterior finish. If the chimney will be

continuing through a roof or structure proceed to

Paragraphs 4.0 and 4.1 before beginning the finish

application.

If installing a mantel and side trim, particularly if it

is wood or other combustible materials, ensure the

minimum distances shown in Table 2 and Figure 3

are met.

3.3 Exterior finishing

The exterior of the fireplace may be finished in any

masonry-compatible material. Mantle and exterior

veneers may be fabricated stone, thin veneer or full

bed depth natural stone, tile, brick or stucco.

If the exterior finish will be stucco, stain, tile or manu-

factured thin stone, wrap the outside of the firebox

with metal lathe. Attach metal lathe to the firebox us-

ing concrete nails, tapcons, masonry or concrete an-

chors. Natural stone veneers (whether full bed depth

or thin veneer), full size brick, concrete pavers, CMU

block, etc., do not require metal lathe. Ensure the

same refractory mortar used to build the kit is used to

install these materials.

4.0 Installation of Chimney Through a

Roof or Structure

A. The chimney is completed by stacking as many

flue sections as necessary to reach the desired chim-

ney height. Chimney plumbing can either be straight

through the ceiling and through the roof, or if the fire-

place is installed on an outside wall, the chimney can

be external to the house. When needed, offset blocks

can be used for the chimney and should be engineered

to structurally support the offset with CMU or custom

fabricated steel posts and/or angle iron capable of

supporting the weight and height of the chimney.

Never exceed more than a 30 degree angle when off-

setting a chimney.

B. If chimney exit opening does not already exist

locate the point where the chimney will exit the roof

by plumbing down to the center of the fireplace

chimney. Drive a nail into the roof to mark the cen-

ter.

C. Measure to all sides of the nail and mark the re-

quired opening, and then cut a hole in the roof. Re-

member that the hole is measured on the horizontal,

and then projected to the roof. The hole may then be

larger, depending on the pitch of the roof. See Fig-

ure 25.

Figure 24. Hearth

Figure 25. Roof Penetration

D. Frame the opening in the roof, maintaining the

required minimum 2” clearances to combustibles

around the chimney. See Table 2. When the chim-

ney passes through a ceiling to an upper floor, make

sure the 2-inch clearance is maintained with framing

where it passes through the ceiling. Exterior veneer

attached directly to the chimney measuring 2” or

more is acceptable for needed clearance.

WARNING: DO NOT PACK REQUIRED AIR

SPACES WITH INSULATION OR

OTHER MATERIALS.

E. Continue to add flue sections, extending the

chimney through the roof.

F. As the chimney extends through the attic to the

roof, attach securing straps to rafters and joists to

provide stability if required by local building code.

G. Install roof flashing appropriate to the roof pitch.

H. At the top of the chimney, use mortar to create a

cap, sloping away from the clay flue and running out

to the edge of the finish material, to assist with water

drainage. Install the chimney cap following instruc-

tions provided. This will protect the chimney from

rain, birds, animals and leaves. See Figure 26.

4.1 Height of Chimney

Figure 27 illustrates the proper height of the chimney

top. Correct height depends on the chimney’s location

on the roof and distance from the peak of the roof.

Surrounding trees, other buildings and hills may also

be a consideration.

If the chimney top is not high enough, unusual

downdrafts may occur, resulting in undesired smoke

spillage. For a more thorough explanation of the fig-

ure 27 illustration, this is the traditional 2/10 rule. The

center of your chimney should be a minimum of two

feet higher than any roof or projection within ten feet

horizontally from the chimney center. This means the

chimney does not have to extend above the peak of the

roof if the peak is more than 10’ away horizontally.

Once the chimney is ten feet away and extended two

feet above roof structure at that distance, the height is

sufficient, but it should never be less than three feet

taller than the point where it penetrates the surface of

the roof.

Figure 26. Mortar Cap and Chimney Cap

Figure 27. Chimney Height

2’ Higher

Chimney Must be at Least 2’ Taller

Than Anything Within a 10’ Radius

10’ Radius

Chimney Must be at Least 3’

Above The Roof Penetration Point

3’ Above

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