Building up a hearth on a cement floor

Hi folks,

I'm looking at designing and building a tile (or maybe stone) hearth for my wood stove. Right now, it is resting on a cement floor and I would like to put laminate floor down. So I figure it would be best at this time to build the hearth, then the flooring can butt up against the hearth rather than the hearth sitting on the laminate.

It is in the middle of the wall, not in a corner. So the hearth would have a floor portion and a flat wall portion - no corners, yay! I think that's most of the big picture... Here are the main steps I'm looking at for this project. I want to make sure I'm not missing any big pieces before I start into this. So any feedback on this plan would be hugely appreciated!


Starting on the floor, working up:

1. Start with a layer of vapor barrier, resting on the cement. I read somewhere that this will prevent any moisture from rotting the wood. Not sure where the moisture would come from, but I figure it can't hurt.
   
   
2. Resting on the vapor barrier, a 2x4 frame (2x4's on edge), with interior "studs" 2x4's, 8" OC. I figure with the weight of the stove, my interior 2x4's should be this close together. Any thoughts on if this should be further/closer than 8"? Then fasten this frame to the adjoining wall studs/bottom plate using screws. I figure with plywood, Durock, tile/stone, and a nearly 200lb wood stove on top of it, this platform isn't going anywhere. So I'm considering foregoing cement nails at this stage to fasten it to the cement floor. This whole frame would be designed, of course, with the appropriate clearances in the manual for my wood stove.
   
   
3. 1/2" plywood on top of the 2x4 frame, fastened to the 2x4's using 2" nails.
   
   
4. 1/2" Durock on top of the plywood using Backer-On screws.
   
   
5. Put on grout, tile/stone. As you can see, I've been thinking more about the first few steps... I figure whatever I use in this step, it will need Durock or something of the sort as a backing. Is there anything else I should be considering on the floor platform?
   

On the wall:

1. Cut out drywall where I want the hearth. Again, check manual for clearances. Patch/replace any cuts that I make in the vapor barrier behind it.
   
   
2. Replace drywall with 1/2" Durock. Again, what should I use as a fastener here? And should I build out a 2x4 frame at this stage? Or can the Durock be flush with the existing drywall?
   
   
3. Grout, tile or stone. Is there anything else I should be considering on the wall portion?
   

So that's what I'm planning for now... I've never worked with Durock, tile, grout, or stonework before but am excited/nervous to try it. Does anyone have any recommendations for what I should look for in a stone (material = granite?), or tile (tile that is sufficiently heat resistant?).

Again, never tiled anything before... any tips on working with these materials?

A huge thanks in advance!
-Matt

electrathon said:

Are you wanting to raise the stove up? If not, why are you not just going to tile the concrete floor? A lot less work and a better finished product.

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Good point... hadn't thought of it! That sounds quite a bit easier, especially since I'm going to try to do this by loosening the screws in the adjustable stove pipe and jacking the stove up and working around/underneath it. I'm only one man, so I don't want to bother trying to move it laterally.

So you're talking just plywood, then Durock, then tile/stone on the floor? Would you even bother trying to fasten the plywood to the floor? Or just have the weight of the stove hold the whole thing in place (plus the laminate butting up close on either side).

What about the wall portion? Could my Durock be flush with the existing drywall? Or should I build out a bit? I have probably ~14" to work with between the stove and the wall. So I think I've got plenty of room to build a 2x4 half-wall, but if I could avoid it I would.

Thanks!

electrathon said:

The floor is concrete, you have no fire safety issues with it. Put down thin set and put your tiles on it, grout, done (sort of). Adding plywood and other stuff would only be done if you want to raise your stove.

What is on the wall now? Is it legal or are you trying to fix an issue?

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I guess I didn't think tile could sit directly on a cement floor. Thought you needed something underneath... But that makes life a lot easier.

I'm mainly looking to do the wall for aesthetic purposes, to match the floor. I've got lots of room in my clearances according to my wood stove's manual.

DougA said:

I laid 6" cinder block on their sides mortared right onto the cement floor. That gives you a smooth surface to lay ceramic tiles or stone on. If I had to do it again, I would use 8" cinder block to get another few inches up. Raising the hearth is much easier for loading your stove, for viewing and it helps keep small kids away from the hot stove. Don't use plywood at all for a hearth if you already have a cement floor - not needed.

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I like that. I was trying to think of other reasons why I would want it raised! But definitely makes loading it a lot easier. So avoid flammable wood in making a hearth. Makes sense.

Any thoughts on my original idea to do Durock on the wall? I'd like to do it as well for aesthetic purposes, to match the floor section. Cut out drywall, then replace with Durock? Or should I build out?

Thanks for the help!

Thanks for all the great responses everyone... I'm contemplating all of the stubbed toes with a raised hearth and am leaning towards putting tile directly on the slab. It's very level (great work from the crew that poured it) and would be a nice option considering we're tight on space in that area around the stove. And the more I think about it, Bob, the more it looks like moving it is going to seem exceedingly necessary. Before I get going with the rest... any tips on moving a heavy wood stove (and then back onto the new hearth, without scraping across and disturbing newly installed tile)?