THIN CAST STONE MANTELS - Installation Instructions

You may require the following tools and materials to install your mantel:

• Power Drill
• Fine-toothed Hand Saw (if adjusting height on site)
• Tape Measure
• Stud finder
• 3"-long woodscrews
• Wood Blocking 2" x 4" x 48" to support larger shelves
• Shims to level components
• Thinset for setting the hearth
• Level
• High-strength construction adhesive, such as Liquid Nails or Bulldog Grip
• Bracing material, such as 2” x 2”

Overview

Thin Cast Stone Mantel Kits contain components for a typical installation, and include: mantel components (legs and shelf), facing panels (header, legs) (riser is optional) and a hearth. Facing panels (header and legs) are required to support the bearing surface of the inside edges of the mantel shelf and legs against the wall on the firebox.

Check with your local building code official for clearance and material requirements between mantel components and firebox opening. Handle products with care to avoid damage. 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

Important: Layout and dry fitting of entire mantel is recommended before any adhesive is applied.Components may be secured using a high-strength construction adhesive that is suitable for plaster or masonry material and potentially high temperature application. Use bracing to secure components tight to the wall until the adhesive sets. Avoid adhesive on exposed component surfaces. Use a finishing nail or a small piece of plastic (shaped like a 'V') to remove excess adhesive at joints. Clean off excess adhesive immediately as required by adhesive manufacturer instructions.

Hearth and Facing Panels Installation

1. Install the hearth first, centered on the firebox opening and set tight to the wall. Set the hearth level and 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
2. Install facing panel legs. Use pencil lines to outline the inside edges of the mantel shelf and legs. Cut facing panel legs as required and ensure the cut sides of Thin Cast facing panels end at the hearth and behind mantel components. When set in place, the level height of each facing panel leg must be identical to provide for a level facing panel header. Use shims to level the facing panel legs. Apply a generous and continuous bead of adhesive to ensure continuous contact between wall and bedding surface of the facing panel legs. Brace facing panel legs securely until the adhesive sets.
3. Install facing panel header. The Thin Cast facing panel header typically does not have to be cut. Apply a generous amount of adhesive to ensure continuous contact between wall and bedding surface of the facing panel header. Brace facing panel header securely until the adhesive sets.
4. If applicable, install the facing riser. The beveled edge of the riser should be exposed and located on the firebox side. Cut the riser panel so that it fits snug between the facing panel legs. The bottom edge may also be cut if a height adjustment is required. Apply a generous and continuous bead of adhesive on the back of the facing panel riser, set in place and brace securely until the adhesive sets.

Mantel Installation

1. Install mantel legs.  . Use shims to level the mantel legs, if necessary. Apply a generous and continuous bead of adhesive to ensure continuous contact between wall and bedding surface of the mantel legs. Brace mantel legs securely until the adhesive sets.
2. Install mantel shelf last.  Apply a generous amount of adhesive to the bedding surfaces of the mantel. Pile adhesive on top of the wood blocking and continuously along its length so that the mantel shelf will settle into the adhesive as it is lowered onto the mantel legs. Use bracing to secure the mantel shelf tight to the wall until the adhesive sets. For additional security on larger mantel shelves, install two (2) - 3"-long wood screws into the top of the mantel shelf and into the wall stud. Locate screw holes approx 1" from the wall and in the center of a wall stud. Drill pilot holes first and countersink so that screw heads are located below the surface of the mantel shelf. Mix the facing powder provided with water to create a workable paste. Fill screw holes and tool to a smooth finish. Area may be sanded lightly if required. FinishingIf required, fill any gaps around the mantel with a paintable latex caulk, taking care not to get the caulk on the surface of the mantel.

OVERMANTEL - Installation Instructions

You may require the following tools and materials to install your overmantel:

• Power Drill
• 3"-long woodscrews
• Tape Measure
• Shims to level components
• High-strength construction adhesive
• Paintable caulk
• Bracing material

Overview

Overmantels are installed AFTER the installation of the mantel is completed. The top of the mantel shelf must be level and secure to support the weight of the overmantel and its bracing.
Note: Make sure the top of the mantel shelf is level, as it will dictate the level of the overmantel that sits directly on top. Overmantels are ideally applied to solid, stable, flat substrates such as plaster or drywall. Wood surfaces are typically not stable and may cause cracks in the product or filled joints. Overmantel may be secured using a high-strength construction adhesive that is suitable for plaster or masonry material and potentially high temperature application.

Installation

1. Locate the center of the mantel shelf top and draw a pencil line near its front edge.
2. Locate the center of the overmantel at the end that will sit on top of the mantel shelf and draw a pencil line at its face near the bottom.
3. Apply a generous and continuous bead of adhesive to the back perimeter surface area of the overmantel to ensure continuous contact between wall and bedding surface area of the overmantel.
4. Carefully lift the overmantel over the mantel and gently place it on the mantel shelf top, tight against the wall. Ensure the marked centerlines of the mantel and overmantel are in alignment. Note: Exercise caution to avoid scratching of the top of the mantel shelf by dragging of the overmantel while fitting in place.
5. Check for full contact between the back perimeter of the overmantel and wall surface.
6. Use bracing to secure the overmantel tight to the wall until the adhesive sets. Note: Avoid adhesive on exposed component surfaces. Use a finishing nail or a small piece of plastic (shaped like a 'V') to remove excess adhesive at joints. Clean off excess adhesive immediately as required by adhesive manufacturer instructions. For additional security install two (2) - 3"-long wood screws on an angle into the top of the overmantel shelf and into wall studs. Drill pilot holes first and countersink so that screw heads are located below the surface of the overmantel. Fill screw holes with paintable latex caulk and tool to a smooth finish.
7. Finishing If required, fill gaps around the outer perimeter of the overmantel with a paintable latex caulk and tool to a smooth finish.