How to Reface a Fireplace Surround and Hearth

Chipped bricks, a stained hearth, and years of accumulated soot can turn what should be the focal point of a living room into an eyesore. Replacing a hearth and surround—either with seamless tone slabs or with ceramic or stone tiles—makes a big difference in the way a fireplace looks.

Below, Dan McLaughlin, with help from carpenter Thad King, shows how to replace an old quarry tile hearth and cover a brick surround with four sleek granite slabs, each 1¼ inches thick. It took McLaughlin and King just a few days of work to rejuvenate this fireplace and reinstall the existing mantel. Installing a tile surround might take a bit longer, but there’s less heavy lifting than with stone.

Steps for Refacing a Fireplace Sound and Hearth

Step 1: Pry off the mantel

• If the mantel is to be reused, mark its outline on the wall and floor.
• Use prybars to gently remove the mantel from the wall.
• Make sure all wood framing and lath are at least 2 inches away from the firebox opening, as required by code.

Tip: This is a good time to consider building or buying a new mantel.

Step 2: Remove the old hearth

• Tape thin plywood or cardboard to the floor around the hearth to protect floor from scratches and debris.
• Use demolition hammer with a chisel bit to chip away old hearth and the mortar underneath (as shown). Leave concrete hearth base and firebox floor in tact.
• Brush and vacuum debris and dust from hearth base.

Tip: Wear eye and ear protection and a dist mask when using a demolition hammer.

Step 3: Prepare the hearth base

• Notch the ends of a 2×4 to make a screed that’s a foot longer than the hearth; its bottom should fit easily in the excavated area. For the flush hearth, cut the notch depth equal to the thickness of the new hearthstone, plus 3/8 inch (for thinset).
• Wet the hearth base. Mix and pour concrete topping.
• Set ends of screed on the floor, notch down. Pull it across the hearth while moving it quickly from side to side (as shown).
• Add or remove the topping mix and continue to pull the screed across it until the base is flat. Smooth with a trowel.
• Let the mix set overnight.

Step 4: Spread the thinset for the hearth

• Stick suction cups to the new hearth slab and test fit on the hearth base.
• Mix enough thinset mortar to cover the hearth base.
• Pour thinset onto the base.
• Comb the toothed trowel through the thinset to raise evenly spaced furrows across entire surface.
• Save leftover thinset for next step.

Step 5: Set the hearth in place

• Use suction cups to lift and set the slab (as shown).
• Press down firmly on the hearth to adhere the stone to thinset.
• Check that the hearth does not rock. If it does, lift the hearth and add more thinset.
• If the hearth is meant to be flush with the floor but is too high, tap on the stone with the rubber mallet; if the hearth is too low, lift it and add thinset.
• Fill the joint between the firebox and hearth with thinset. Scrape off the excess and tool smoothly.

Step 6: Set the surround pieces

• With a trowel, comb thinset onto the backs of side pieces.
• Set each piece in place on top of the hearth and press against the brick. Make sure the inside edges slightly overlap the sides of the firebox.
• Lay straightedge across tops of side pieces. Check that they align. If not, pivot slightly.
• Butter thinset on the top of the piece. Set it on the side pieces. Press tight to the brick. Check that joints are flush.
• Allow thinset to harden overnight.

Step 7: Fit wood mantel

• Set mantel on the hearth, tight against new surround. Align with the outline on the wall.
• Measure from the back of the mantel to the wall. Cut wood filler strips to that thickness.
• Glue and nail the filler strips to the back of the mantel, flush with its edges. Glue and nail molding extensions to strips.
• Using a compass, scribe the strips where they touch the wall (as shown). Cut along scribe lines with a jigsaw.

Step 8: Fasten the mantel to the wall

• Mark the locations of the wall framing.
• Set the mantel so it’s centered on the surround.
• Push the mantel tight to the wall and the surround.
• Toenail mantel into framing with 8d finish nails.

Materials

• Masonry brush
• Suction cups

Tools