StoneAge SA 48 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, manufactured

by Stone Age Manufacturing, Collinsville, Oklahoma.

Three generations of fireplace knowledge and experi-

ence have gone into the design and construction of the

Standard series fireplaces. Standard Fireplaces are cer-

tified to UL127 for the US, and ULCS610 for Canada.

Assembly and Cutaway views of a SA48 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 ar-

rangements are shown in Figure 2. Components are

listed in Table 1. Specifications and installation dimen-

sions 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 instal-

lations, 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 separately

- 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

SA48

Front View Side

Cutaway

iew

Figure 1. SA48 Fireplace Assembly

& Cutawa

View

Table 1. Fireplace Components

Item Description 48”

1 Riser Legs 18” x 40”

1A Riser Leg-Cross 18” x 51”

2 Base Plate 33” x 58”

3 Sidewall 11” x 33”

4 Back Plate 22.5” x 52”

5L/5R Slanted Sidewall 11” x 26”

6 Back Header 11” x 58”

7A/7S Lintel, Arch/Straight 11” x 58”

8 Throat 11.5” x 30”

at top

9A Flue (Note 2) 23” x 23” x 6”

10 Hearth 11” x 5” x 58”

11 Throat to Flue Adapter 23” x 30”

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”

Chimney flue (All Sides) 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.

5L 6

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 acceptable.

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 in-

stalled 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 Ta-

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

Numbers in ( ) are item numbers from Table 1 and Fig-

ure 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 installers

review local building codes, consult with local building

officials and/or a structural engineer before beginning

the construction of any Stone Age product.

Pad or footings for outdoor installations should be a

monolithic pad constructed of steel reinforced concrete.

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

Figure 3. Clearances (Use with Table 2)

require a deeper footing or the addition of piers, to

reach more stable subsoil or bedrock. Areas with cold-

er 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 overall

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

materials. If custom hearths or additional masonry

structure is to be attached to the fireplace kit, the foot-

ing dimensions should be adjusted to include these cus-

tomizations.

If local building code exceeds the manufacturer’s speci-

fications for footings, follow the local code.

Table 3. Minimum Footing Specifications

Minimum Requirements for Footing 48”

Thinner Finishes-

Fabricated Stone, Stucco, Stain or Tile

8” - 10”

48”

64”

Thicker Finishes-

Full Veneer Natural Stone or Brick

18” - 24”

54”

70”

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 require-

ments based on the overall height, and the weight of

fireplace, chimney, and finish materials. If custom

hearths or additional masonry structure is to be attached

to the fireplace kit, the footing dimensions should be

adjusted to include these customizations.

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

high temperature fire clay or refractory cement suitable

for indoor or outdoor use, and mix according to manu-

facturer’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 using

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 Riser

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 suggested

that you first assemble the components without mortar

to familiarize yourself with how the components 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), ensur-

ing 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, ensur-

ing 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.

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

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

procedure will be the same for indoor or outdoor

applications.

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

position 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.

Figure 11. Lower Sidewalls

Figure 15. Upper Sidewalls

Figure 12. Middle Sidewalls

Figure 13. Back Plate

5L 5R

Figure 14. Upper Sidewalls –Top View

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

J. 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.

K. 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 Figure 19.

Figure 19. Sidewall Firebrick

Figure 18. Back Wall Firebrick

ure 17. Floor Firebrick

ure 16. Back Header

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

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

20.

M. Install the tapered front and rear throat pieces (8).

See Figure 21.

N. Install the flue adapter piece (11). See Figure 22.

O. 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 23.

7 A

Figure 20. Front Lintel

Figure 21. Throat Pieces

Figure 22. Flue Adapter

Figure 23. Chimney Flue

P. 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 24. If additional chimney is required to

penetrate a roof or structure, refer to Section 4.0

for more detailed instructions.

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

nent, and any hearth extension. See Figure 25.

R. 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 installa-

tion 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 Par-

agraphs 4.0 and 4.1 before beginning the finish appli-

cation.

If installing a mantel and side trim, particularly if it is

wood or other combustible materials, ensure the min-

imum distances shown in Table 2 and Figure 3 are

met.

Figure 25. Hearth

Figure 24. Chimney Complete

3.3 Exterior finishing

The exterior of the fireplace may be finished in any

masonry-compatible material. Mantle and exterior ve-

neers 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 using

concrete nails, tapcons, masonry or concrete anchors.

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 chimney

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 sup-

porting the weight and height of the chimney. Never

exceed more than a 30 degree angle when offsetting a

chimney.

B. If chimney exit opening does not already exist lo-

cate 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 center.

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 Figure

26.

D. Frame the opening in the roof, maintaining the

required minimum 2” clearances to combustibles

around the chimney. See Table 2. When the chimney

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 ac-

ceptable 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 pro-

vide 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 27.

Figure 26. Roof Penetration

Table of contents

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