Lyla Lindsey
A hearth pad is essential when using a wood heater to prevent the floor underneath from catching fire, keeping embers away, and complying with building codes and insurance requirements. While store-bought hearth pads can be expensive, you can create a custom-made hearth pad with basic carpentry skills and knowledge of the required hearth size, which can be found in the installation manual. This paragraph will discuss the process of building a hearth for a wood heater in Australia, including the materials and steps to ensure safety and functionality.
| Characteristics | Values |
|---|---|
| Purpose | To keep the flooring under a wood stove from catching on fire, hold the embers away from the floor, comply with building codes and insurance requirements, and add a decorative touch to the room |
| Materials | Non-combustible materials such as stone, slate, tile, brick, limestone, sandstone, glass, flagstone, granite, steel, and concrete |
| Installation Type | Freestanding or inbuilt; the hearth for a freestanding heater typically sits underneath the wood heater and extends to the front floor section, while an inbuilt heater only needs a hearth on the front floor section |
| Size | Determined by the stove size, distance to flammable walls, and minimum distance from the wood stove to the nearest combustible surface (typically 36 inches to all sides) |
| Thickness | Dependent on the distance from the bottom of the burning chamber to the floor; a 2-4 inch distance requires a 4-inch thick layer of hollow masonry, while 4-6 inches of space cuts the masonry layer to 2 inches |
| Shape | Dependent on the floor space that needs to be protected from heat and embers; typically 18 inches from the front and 8 inches to the side, or 36 inches to each side for certified older stoves |
| Construction | Cut tiles into shape, apply PVA to the bottom surface, bed onto a sand cement mix, grout, and wipe with slate oil or WD40 |
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What You'll Learn
Choosing the right materials
When choosing materials for your hearth, safety should be the top priority. The main purpose of a hearth is to protect your flooring from catching on fire, so all materials used need to be non-combustible. You should also consider the insulative value of the materials, to prevent the materials underneath the hearth from heating up, drying out, and starting a fire.
The thickness of the hearth will depend on the distance between the bottom of the burning chamber of the stove and the floor. A distance of 2 to 4 inches will require a layer of hollow masonry of at least 4 inches thick, covered by a 24-gauge sheet of steel. A distance of 4 to 6 inches will require a 2-inch layer of masonry. Materials other than masonry can also be used to insulate the stove from the floor.
Hearth pads are available in a range of materials, including stone, slate, and tile. Slate is a popular choice, as it is inexpensive, and provides a pleasing, rustic look. Riven slate tiles are available in various hues, usually grey, and are typically 90 x 60 cm in size. Limestone is another option, and is available in black, in sizes of 60 x 60 cm or 90 x 60 cm, and smaller.
If you are tiling your hearth, you will need to cut your tiles to shape, PVA the bottom surface, bed them onto a sand cement mix, leave to set, and then grout. You can use a sand cement mix as grout, or mix in black cement dye for a darker colour. You can also choose not to grout the lines or the gaps underneath the hearth, for a "hovering" look.
If you are using standard off-the-shelf tiles, there is a risk that the heat from the fireplace could damage them. Hearth manufacturers typically use tiles designed for high-temperature applications.
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Hearth pad dimensions
The size of your hearth pad will depend on the type of stove you are using. Wood stoves, for example, require larger pads than pellet, gas, or electric stoves. Specifically, wood stoves typically require pads that are 48 inches or larger to protect from falling embers. This is compared to the smaller pads that can be used for pellet, gas, electric, corn, oil, and propane stoves.
When creating a hearth for a wood heater, you should consult your stove's owner's manual to determine the clearance requirements and choose the most appropriate pad size and shape. You can also consult a hearth pad dealer for advice. Custom sizes are possible but often cannot exceed 60 inches.
The thickness of your hearth pad will also depend on its size. Original Edge framed hearth pads less than 54 inches are 1 inch thick, while those 54 inches and larger are 1.25 inches thick. Ember Defender pads, which provide ember protection, are made with 10-gauge steel and are approximately 0.125 inches thick. Tile and slate pedestals are typically 6 inches high.
If you are installing your wood heater on a carpeted floor, you should be aware that if your stove weighs more than 450 lbs, its weight could cause the hearth pad to bow and crack the grout or tile. Solutions to this include using a Low-Profile Base underneath the hearth pad to compress the carpet evenly and provide a flat surface, or cutting a piece of 0.75-inch particleboard slightly smaller than your hearth pad to support the metal frame.
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Installation type
If you have an inbuilt insert or zero-clearance heater, you can use a diagram to determine the hearth front clearance dimensions and get a better idea of the total clearance dimensions you need. If you have a freestanding wood heater, you will need to check your heater's hearth clearance requirements to understand how much space is required to suit your room. For a corner installation, you will need to account for the distance from the back edges of your heater and the depth.
The shape of the hearth pad is determined by the size of the stove and the distance to flammable walls. Start by determining the floor space you need to protect against the heat coming from the stove and embers. If your stove is not certified, 18 inches from the front and 8 inches to the side of the stove's outside dimensions are a good start. If your stove is certified, you should have at least 36 inches to each side. A stove with a certification sticker will give you more exact numbers.
The thickness of the hearth will depend on the distance from the bottom of the burning chamber of the stove to the floor. A 2 to 4-inch distance will require a layer of hollow masonry of at least 4 inches thick covered by a 24-gauge sheet of steel. 4 to 6 inches of space will cut the masonry layer to 2 inches. Fire resistance is the ability of the hearth to keep itself from catching fire.
It is important to note that you will also need to account for the minimum distance from the wood stove to the nearest combustible surface, which is typically 36 inches to all sides. Insulative value is important to prevent the combustible materials under the hearth from heating up, drying out, and starting a fire.
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Cutting and placing tiles
When cutting tiles, it is recommended to wear protective gear such as gloves, goggles, and a mask. An angle grinder is a suitable tool for the job, but it should be handled with care.
Before placing the tiles, it is important to determine the required hearth size. This can be done by referring to the installation manual of your wood heater. The hearth should be placed on a non-combustible base, such as compressed fibro, and should extend to the front floor section of an open fire.
When laying the tiles, it is suggested to use a tile adhesive and spread it in sections about 5mm thick. You can mix your adhesive with water, using a ratio of one cup of adhesive to about one-third cup of water. After laying the tiles, remove any spacers and wipe away excess adhesive with a clean damp cloth.
To ensure the tiles are flat and even, use a grout squeegee over the surface and leave them to set. You can then apply grout using a grout bottle with a nozzle, smoothing it out with a squeegee. Wipe away any excess grout with a damp sponge and leave it to cure overnight.
Finally, seal the grout with a grout sealer, running the wheel applicator over the grout lines. You can also wipe the new hearth with slate oil or WD40 to make it look better and hide any imperfections and scratches.
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Grouting and finishing
Surface Preparation
Before grouting, ensure that your hearth surface is clean and dry. Remove any debris, dust, or residue left over from the previous construction steps. It's important to provide a smooth and uniform surface for grouting. Use a vacuum to remove any fine particles and then wipe the surface with a damp cloth to ensure it is free of dust.
Grout Selection
Choose a grout that is suitable for the type of tile and hearth you have installed. For a wood heater hearth, a heat-resistant grout is essential to withstand the high temperatures the surface will be subjected to. You can find specific products designed for use with fireplaces and wood heaters, often labelled as "heat-proof" or "refractory" grouts. These grouts typically come in powder form and need to be mixed with water according to the manufacturer's instructions.
Grouting Technique
Use a grout float to apply the grout mixture to the joints between the tiles. Work in small areas at a time, typically starting from the corners and working your way towards the centre. Hold the float at a 45-degree angle and use a diagonal motion to push the grout into the joints, ensuring that the grout fills the spaces completely. Remove any excess grout from the surface of the tiles as you go, keeping the float at a steeper angle to avoid gouging the grout from the joints.
Finishing and Curing
Once you've grouted all the joints, use a damp sponge to wipe away any remaining grout residue from the surface of the tiles. Rinse the sponge frequently in clean water, ensuring you don't overwet the grout joints. This process will help smooth out the grout lines and create a consistent finish. Allow the grout to cure for the recommended time, usually at least 24 hours, before exposing it to heat or heavy use. Refer to the manufacturer's instructions for specific curing times and recommendations.
Sealing (Optional)
Consider sealing your grout to protect it from stains and moisture penetration. Sealing can also make the grout easier to clean and maintain. Choose a suitable grout sealer, following the manufacturer's instructions for application. Typically, you'll apply the sealer with a brush or sponge, allowing it to penetrate the grout lines, and then wipe away any excess sealer from the tile surface. Allow the sealer to dry completely before using your hearth.
Remember that safety should be a priority when working with a wood heater. Always follow the manufacturer's instructions for your specific heater model and adhere to local building codes and regulations.
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Frequently asked questions
A hearth pad is a protective, non-combustible material that shields combustible flooring from catching on fire. It also serves as a convenient place to store firewood and keeps the embers and soot away from the floor.
You can use materials such as stone, slate, tile, brick, limestone, sandstone, glass, or flagstone. All materials need to be non-combustible.
First, determine the floor space you need to protect and the minimum distance from the wood stove to the nearest combustible surface. Then, assemble the platform using 2-by-4s, 6s, or 8s, keeping the distances between the joists at approximately 16 inches. Cut your tiles into shape, apply PVA to the bottom surface, and bed them onto a sand cement mix. Let it set, then grout the tiles using a grout squeegee. Finally, wipe down the tiles with a damp cloth to remove excess grout.
To keep your hearth clean, regularly vacuum or sweep up soot, ash, and wood chips. You can also wipe down the tiles with a warm damp cloth. For decoration, consider using a plant to soften the edges and liven up the space.
