Masonry Magazine December 1992 Page. 14
THE FINISHED CHIMNEY in Arizona, one day's work. Total cost $1,200. Out before the framers came in.
Masonry fireplace and chimney doesn't need to cost so much. Let's build them systematically-look at basic design, scheduling and job sequencing, materials handling-and let's advertise an "installed" price.
In the end it's quality and durability that sells masonry. A masonry fireplace and chimney will last 100 years or more. Even if the average family does move every seven years, a masonry fireplace and chimney looks like it will last 100 years while they're there, and adds to the value of the house and the family's sense of well being.
As an industry, to be socially responsible, we should be building houses which last 100 years, anyway. What will happen to our neighborhoods if everything falls apart in fifteen or twenty years?
The Problem:
While over 80% of the new home buyers continue to prefer masonry fireplaces and chimneys, according to the latest NABD research, they continue to lose out to the metal so-called "zero clearance" fireplace units with aluminum sided wooden chimneys.
Last year over 70% of new houses were built with zero clearance rather than masonry fireplaces.
No one is advertising masonry fireplaces. As a recent editorial in a trade magazine pointed out, there were 26 ads for metal zero clearance fireplaces in the July issue of Builder/Architect and no ads for masonry fireplaces.
Some have said that price is the issue. Masonry fireplaces are just too expensive. But there are masonry fireplaces and chimneys being built for under $1,500 and often the real price of the metal fireplace is camouflaged because the extra work to build the chase is not counted.
While price is important, I think it's service that we don't deliver as well as the metal fireplace people do. Decentralized as our industry is, it's just too complicated, from a builder's perspective, to get a masonry fireplace built. He can't find a mason when he needs one, he's not sure the fireplace will be safe and not smoke. It's just plain easier to get the carpenters and drywallers already on the job to frame in a "builders box" (metal fireplace) that is sold "installed" and is guaranteed, than to deal with a masonry subcontractor, especially since masons tend to be messy and the ones who can build fireplaces can't get to it for three weeks.
Solutions:
There's a lot we can do. The masonry fireplace and chimney doesn't need to cost so much. Let's build them systematically-look at basic design, scheduling and job sequencing, on site materials handling-and lets advertise an "installed" price.
Here are some areas I think we, as an industry, can look at to improve masonry fireplaces and make them competitive once again.
The masonry fireplace could be re-designed:
The typical "modern fireplace" is complicated without being well designed nor very effective (see enclosed ASHRAE, BIA and MIA examples). The fireback cants forward and the smoke chamber angles sharply back the other way so that the chimney can be built on the outside of the house-all apparently based on a myth about the anti-down draft function of the smoke shelf.
The fireplace would work better if all those reverses were straightened.
Notes From Phoenix
FOLLOWING ARE MY OBSERVATIONS about the job, made after building our first prototype standard fireplace with a builder who uses both metal and masonry fireplaces and agreed to help me carefully compare the two from his viewpoint. I learned a lot from the Phoenix exercise, and I thought many of the points he made were confirmed by the builders in Columbus.
Masons use 8" hollow block with no wythe or support for flues in chase 3' by 5'.
Used seismic strap even though interior chimney-not required by UBC. CABO lists AZ in Zones 0, 1 or 2 and would not require any seismic reif. Inspector had to see it every 8' lift (holes in block, grout, etc.) required three inspections over as many days, whereas metal has no inspections.
We built box bigger than I'd like to-2.5 brick (22.5") covings and back, instead of two brick.
Problem with throat fiddly at junction with coving. Too many parts with two angle irons and three tiles. We'll redesign it.
Builders Suggestions:
Use cardboard template to lay out firebox on hearth.
Include grate and screen-complete, comparable with metal units.
Big advantage of masonry is timing (only in Southwest where masons are off the job site before the carpenters start-I like it). Masonry goes in early when delays don't cost much. Metal goes in when everything else is happening and has to be carefully coordinated with drywall, roof, stucco. Can't leave units on site or they get stolen. Metal chase cap real problem.
Framers have to know code and dimensions of metal to build chase.
Easier to build around existing masonry chimney-just have to know to stay 2" away.
Can't put chimney tops on metal.
Likes "kit" with all materials and instructions.
14 MASONRY-NOVEMBER/DECEMBER, 1992