PLOURDE STONE MASONRY
How to Build Brick Patio and Stone Fireplace
Acquiring the Basic Do-It Yourself Knowledge
James S Plourde
4/23/2012
English 101 College Composition
John Goldfine
Why I Am Writing
I chose this topic because it is something I would like to do myself. I could easily hire a contractor to
come in a do it but I don’t think it would give me the same feeling of gratification I will get if it’s done
with my two hands. I have thought this project through extensively for about two years and have many
ideas on what I would like our dream patio to look like. I want the base to be a brick style paver probably
a traditional red. I plan to build a bar across the back. Not just any bar but a bar made with a 1950’s 16
foot old town canoe as a top. I picked this canoe up at an auction for twenty bucks toward the end of
the summer last year and new it was the perfect piece to add to the patio. The gunnels are broken and
there are no seats left but the ribs are perfect and gorgeous to look at. They were made with such
beautiful wood back then! I think I can make a cool and unique piece of furniture that will fit nicely with
the whole camp theme. Across the front overlooking the water will be the spot for the fireplace. I want
it to be set up so all of the seats face the fireplace giving everyone setting around the feeling that the
fire is right on the water. Hopefully with what I learn in my research I will be able to create the fireplace
that is the focal point of the property.
Some of the questions I am hoping to answer are:
1) What do I use for the base of my patio?
(a) Is there special sand or crushed rock etc.
2) How do I level the base of the patio?
(a) Do I need a tamper?
(b) Do I need a border and level from side to side?
3) How do I lay the pavers?
(a) Do I use a pattern or just lay them as they fall?
4) How do I grout the pavers after they have been laid?
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5) What do I use for the base of my fireplace?
(a) Is there a heat retardant material that should be used?
(b) Are there drainage issues that need to be addressed?
(c) How big should I build it to fit the top structure?
6) What are the steps to building a fireplace?
(a) Do you build the rock structure first and then line it with fire brick?
(b) Again what style of mortar do I use?
(c)How does it cure?
7) How do choose the style of rock to use?
8) How do I build a chimney?
(a) Is there a special liner? (b)How to form rock around the liner?
(b) How to form rock around the liner?
9) How do I build a cooking area?
(a) What do I use for a grill?
(b) How do make it so I can easily put in and take out?
(c) Can I build it to have adjustable heights?
10) Are there steps that need to be taken to preserve it so it lasts a lifetime?
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What I Know And Don’t Know
1. What do I use for the base of my patio?
(a) Is there special sand or crushed rock etc.
(b) I think for the base of the patio I would use a beach style of sand but my question would be
if a stone dust would be better and if so where to get it. I know that these style of patios are
prone to move and shift in northern Maine and I want it to stay together as long as possible.
2. How do I level the base of the patio?
(a) Do I need a tamper?
(b) Do I need a border and level from side to side?
(c) I know I need to compact whatever I use for a base I just don’t know if it is imperative to use
a gas style of tamper or can I get by with a manual style.
(d) It would make sense to me that the outside edge would need to be bordered somehow I am
just not sure if it should be wood or if they sell an edging, maybe plastic?
3. What I know about leveling is when I have helped with pouring cement you level from side to
side across the forms with a long board that can touch both sides. You slide it back and forth
down the forms until everything levels off. I would think this method would work just as well
with sand or stone dust.
4. How do I lay pavers?
(a) Do I use a pattern or just lay them as they fall?
I know that I have seen them in many patterns I just don’t know if I would be getting in deeper
than I want trying to get fancy. I don’t want to get into a job that takes me all summer so if it’s
too intense I would go with a more basic layout that would be less time consuming
5. How do I grout the pavers after they have been laid?
Again it would make sense to me that you would use whatever you use for the base and broom
it into the pavers to fill around them using the same concept as grouting tile.
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6. What do I use for the base of my fireplace?
(a) Is there a heat retardant material that should be used?
(b) Are there drainage issues that need to be addressed?
(c) How big should I build it to fit the top structure?
My thought would be to pour a slab, probably 6inches thick, and a little bigger that the
structure. I know that sense heat rises fireplace bases last longer than the walls. I know that if
concrete has any air in it that it will crack easier with the heat of a fire as the air holes hold
moisture.
It would seem that you should build it with a slight slope so that water would not puddle up on
your burn area. I was thinking it should have drain holes somewhere in the back but I am not
sure how that would work.
7. What are the steps to building a fireplace?
(a) Do you build the rock structure first and then line it with fire brick?
(b) Again what style of mortar do I use?
(c) How does it cure?
I really don’t know anything about this. It makes sense to me to build the outside structure and
then line it but just a guess.
It would seem to me there would be a special cement that is made for high heat but again just a
guess and what I am hoping to find out.
8. How do you choose the style of rock to us?
I don’t know if you should use a bigger rock on the bottom and work up to smaller rocks at the
top but that would make sense. I have seen them built with round rock and more cement and I
have seen them built with flat rock and less cement. I am not sure what way I will go until I
research it
9. How do I build a chimney?
(a) Is there a special liner?
(b) How do you form the rock around the liner?
I have heard that people use large pipes, like culverts, and then build around them. The bigger
the pipe the bigger the fire! Fire needs air. Again I want to do whatever is easier. Although I
want to have a beautiful piece I don’t want to get in over my head. Been there and done that!
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10. How do I build a cooking area?
11. What do I use for a grill?
(a) How do I make it easy to put in and take out?
(b) Can I build it to have adjustable heights?
I know I want to be able to put a grate in and take it out as needed. I know I would like to
have different height settings depending on the coals. I have seen them built with diamond
grate and a solid steel surround and I like the looks of that.
12. What are the steps I need to take to preserve it and make it last a lifetime?
(a) There must be an acid to clean it with?
(b) Is there a sealer that I can use to keep the moisture away?
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The Search
I choose the topic of a fireplace and patio because it was something I wanted to do myself and I felt
there would be enough easily available information to sort through. I have to admit I have found it
harder than I expected. First I did the obvious and googled outdoor stone fireplace which brought up
many sites that I found interesting and helpful. One of the better sites I found was a site called
Hubpages how to build an outdoor fireplace a step by step guide. It breaks every step pretty well but I
found it a little bit vague. I found other pages like Ehow Home how to build a simple fireplace with
information pertaining to what I wanted but none of it seemed complete. I tried many different ways of
searching from basic stone mason to outdoor fireplace and everything in between. If I wanted to do a
basic fire pit there was plenty but I want my fireplace to have a chimney and be built out of rocks (not as
popular as I thought). There was definitely enough information to help me build the patio and a fair
amount of information on building the fireplace but it just felt incomplete or not spelled out enough for
my abilities. I just couldn’t grasp enough from it that I would want to start building. The thing with the
internet is a lot of the available information is from someone trying to sell you something like a fireplace
kit.
In the past when I was doing a project I found YouTube to be a great source of information so that is
where I headed next. There were a few videos showing people building different styles of fireplaces like
http://www.youtube.com/watch?v=k_FK8bt1rQU with information ranging from basic pits to elaborate
fireplace but again I didn’t feel the breakdown was enough for me to feel comfortable that I knew what I
was doing. The best videos of fireplaces like I want were just frame by frame shots of the building
projects and not actual directions how to build it.
Okay let’s go back to basics so I went to my local library and found the stone mason section. Our library
when I was younger was a very nice library and still has a lot of the same qualities but unfortunately still
has a most of the same books as well. I found a couple of time life how to books that seemed to help
and a few general guides on masonry. I checked them out, brought them home and pulled out any
information I thought might give me some of the tools I needed. Most of what I found wasn’t exactly
what I was looking for but it was solid information I could to build the base of my fireplace and the
bottom structure.
My wife had an appointment in Bangor so I thought surely the Bangor library would have everything I
needed to know so I dropped her off and headed to over. They did have a larger selection than our
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library and I was able to pull out some different information than I was able to obtain anywhere to this
point. A couple of books I found helpful where Practical Stone Masonry by Stephen Kennedy and How to
build and repair concrete, brickwork and stone by John Corinchock. I think if I where to put all the
information gained to this point and just started building I could probably pull it off but I have to admit I
still felt unsure of myself. I don’t know if the information I was getting was just too vague or if I am just
not smart enough to put it all together but I still felt just a little lost and not as comfortable as I had
hoped.
The last step I took to obtain information was to set-up an interview with a good friend Adam Cyr who is
a carpenter/mason. His dad was a mason and he also has two brothers doing the same kind of work.
Adam set down with me and broke everything down in a way I could understand it. Listening to him
helped to make sense of all the other information I had obtained. He explained every step I needed to
make in both the patio process and the fireplace process and threw in some things the books had not
explained. This was extremely helpful to me and I feel it was the turning point in what will create the
area I hope to make. Thank You Adam!
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What I Have Learned
Building My Patio
1) What do I use for the base of the patio?
A) For some reason I thought I might need to use a crushed rock under sand for good drainage
but my research and my interview with Adam taught me different. As I stated before the
area I am using for my patio is one that I created for this purpose so the ground has already
been prepared with gravel and leveled to where it needs to be creating a firm base to build
on. (Rodriguez). My research also says to create boundaries using wood or plastic edging but
the way my area was created most of the retainer is rock and I will hopefully be able to
follow suite with more rock. I will need to add a layer of landscape fabric to stop the weeds
and then cover with around two inches of sand (Rodriguez). I can purchase sand at Lee’s
cement. I will need about 3 yards at $15 per yard and I will1 haul it with my dump trailer.
B) How will I level my patio: I will use a 2x4 to level the sand and create a 1” to 4” slop across
the top for drainage. (Rodriguez) Most of what I read does not call for tamping but my
interview with Adam leads me to believe it would be best to tamp the sand with a hand
tamper and level the area again using the same method as before.
C) Laying my pavers: For pavers I decided to use a low end 12”x12” red paver from The Home
Depot for $1.90 apiece. I will need about 400 Sq. Feet with a total cost of about $720. Price
is a concern to me and from my research this seems the cheapest way. I did look at using
slate but the inconsistence in thickness was going to make it a lot more work as each piece
would need to be leveled separately and in my mind not worth the minimal savings it would
bring.. My patio area is essentially a 20’x20’ but not perfectly square. I will need to lay my
pavers in a square pattern leaving a gap between of 1/8” or less, (Rodriguez) suggest using
slices 0f wood to create the gap, using a rubber mallet to gently tap and level them. I will
need to periodically drag my 2”x4” across the top to check for high and low spots. After the
center is laid I will go back and fill in the large gaps around the edges making a template
with paper of the space and using a grinder to cut the pavers to fit the area.
(http://www.youtube.com/watch?v=9tLDa7OX-QE) and fill in the smaller areas with sand to
level.
D) Grouting my pavers: To grout pavers you simply sprinkle sand across the top and sweep the
sand around until the cracks are full. Use a light mist with a garden hose to wet and settle
the sand let dry and repeat the process.(Rodriguez)
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Building my Fireplace
1) Steps to building my fireplace:
A) Building a cement base: I intend for the outside diameter of my fireplace to be 46”x46.5” so I
will need to build a pad of this size. I will need to pour a 4” thick pad. First I will need to build a
form out of 2”x6”boards to hold the cement. (How to Build and Repair Concrete, Brick and
StonePg.271). The book does not say to use rebar but Adam said if he were building it he
would. It gives the concrete a sturdiness to help it last and not crack. I will use a mixer that I
will borrow from Adam and 1to 1.5 bags of Portland type N cement for around twelve dollars a
bag. The mixture is 4 parts sand to 1 part cement. Most of the prices I got for my fireplace
came from Levasseur’s True Value. They are our local hardware store where I do a lot of
business.
B) The next step is to start the actual fireplace: After you have let your base cure for at least three
days you can start the building process. There are different approaches to the next steps from
building with firebrick first and work out, start with your cement block and work your way in or
not even using any cement blocks and just building a rock frame and lining it with fire brick
(Mueller). My preference will be to start with my cement block frame. This is the way Adam
thinks I should go so I will trust his opinion. I will to start from the inside dimensions of the
actual fire box. The size of my fireplace is based on the fact that cement blocks are
7.5”x7.5”x15”at a cost of $2.09. Building to the size of the block hopefully sets me up for
minimal cutting. I would like my firebox to be two feet wide by three feet deep so I need to
start there and measure back on all three sides the width of my fire brick, which is 1.25,” to
where I will lay my first cement block. I will lay my cement block on three sides, leaving the
front open, using about one half inch of mortar between each block and on the base. Mortar is
more like glue than cement so it is used in the building process and the mixture is 3 to 1. Adam
thinks it is a good idea to use 1 part cement in with it to strengthen it so again I will take his
advice. I will build my blocks up 4 blocks high which will be about thirty two inches including
cement.
C) Lining the firebox: I will line the inside of the firebox with fire brick. Fire brick is brick that is
denser than regular brick with no air pockets so it can resist cracking under high heat it’s
dimensions are 1.25”x4.5”x9” and cost $4.19 each,. I will line the entire box with fire brick
again using about ½” of mortar to hold them together. I will drill and mortar in 5” long pieces of
rebar, I will use six of them, two on each side, to hold a cooking grill. (How to build repair
concrete, Brick and stone Pg. 271) (Adam Cyr)
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D) Creating a chimney: I had a very hard time to find any information pertaining to building a
chimney. Hub pages were the closest I have come to useful information in this area and
basically they say to frame it up with 2”x4” and install a premade chimney. The books I have all
talk about indoor chimneys but not outdoor stone chimneys so I will use an Adam design. I
want the outside dimensions of my chimney to 12” wide x 46”long and 36”Tall. I use steel in my
business all the time so I have ¼” steel plate at my shop as well as the welder, torches and
grinder needed to create what I need. The steel cost my $143.00 an 8’x4’ sheet and I will use
about half a sheet. The base piece will be 43”x12” and will create a base for my 8”x10”
chimney liner. I need to taper the steel up to the base of the flue. If smoke hits a flat surface it
will not slide over to the opening of the chimney and will come out the front of the fire.
Therefore I will create a hole in a 43”x12” steel plate 17.5”x8”. I will create a tapered edge of
four inches high on each side of the base of the flue the with a 2”pitch. My goal is to have the
flue set 4” higher than the base sheet of steel tapered in on the sides 4” on each side and weld
it together to form a stand for my chimney flue. Once I have set my flue I will cement a row of
filler block on each side and us it as an anchor for my flue.
E) The last step is to line the outside with rock: My goal is to pick rocks for the outside of the
fireplace I understand that a flat rock works better for this but I am really attracted to the look
of smaller round rock so that is what I intend to use. The rock will be attached to the outside of
the concrete block using mortar on the bottom and block side at least 1/2” or as needed to fill
in the gaps. I will stack them all the way up using flat ones across the top flat surface and
surrounding the chimney with a uniform tapered edge.
F) Cleaning the rock: After the cement has set for a day I will need to clean the rock with a brush
and Muriatic acid to remove the excess mortar from the rock and give a clean finished look. I
will need to apply a 2 to 1 mixture of Turpentine and Linseed oil to help preserve the finish.
(Time Life Pg. 56) (Adam Cyr)
G) Let the fireplace cure: Adam suggest letting the fireplace harden for a couple of weeks before
use. Build fires small at first to give the cement a chance to harden solid before the more
serious late night Bon-Fire!
H) Cooking grate: I have a piece of cooking grate cut to fit a 2’x2’ cooking area that I will install as
needed on top of the rebar pins that I cemented in place.
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The Future
My goal for this Isearch was to find enough information to build my own fireplace and patio area
for our camp at the lake. Using the knowledge I have gained I hope to start this project in the next few
weeks. At this point I am not sure how far I will be able to go this year as I didn’t realize the price of
some of the materials needed.
Before I started researching the patio area I had a general idea what I was in for but I learned a lot of
little things I didn’t know. I had done some research in the past and it is possible that I can complete at
least this phase by the end of summer with some help from friends and family. Doing this Isearch has
given me a better idea of price and I think with sand and pavers I should be in the $800.00 range by the
time this stage is completed. I watch for sale sites like Uncle Henry’s and Craig’s List in hopes of finding
cheaper used materials with some character that I would use instead of new if possible but I have not
found what I am looking for yet. Keeping my fingers crossed.
As for the fireplace my goal will be to complete it by the end of summer. If my calculations are correct I
think I can complete this phase of the project for a little under $500.00 and a lot of manual labor. Again I
am hopeful to find some reclaimed materials and already have a lead on fire brick which at $4.17 per
brick for 70 bricks is the most expensive part of the project.
The last step for me is one that is not part of my Isearch but is one I talked about earlier. I didn’t include
this because I already do a lot of my own carpentry and know how to complete this phase. I would like
to build a bar on the back side of the patio facing toward the camp. I was able to obtain some 100 year
old Douglas Fir from a friend. This wood used to be in the ceiling of the grinder room of the Great
Northern paper mill in Millinocket and was taken out a few years back during an update of the area. My
plan now is to use this as the bar top and face. I will need to spend some time with a plainer to get it
usable but it is beautiful when finished. As I said earlier I have a 1950’s Old Town canoe that I originally
planned to somehow use as the top but have now decided to turn upside down over the bar and use it
as a roof. This way you get to enjoy the beauty of the inside and still see the outside of the canoe. I truly
love reclaimed material and wish I could find more to use for this whole project. If I could find the right
old bricks I would probably use them for everything from the patio to the fireplace. The problem with
reclaimed brick is they have to be cleaned and that takes a lot of time! Something I am commonly short
on.
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Bibliography
Kennedy, Stephen M. Practical Stonemasonry Made Easy 1988
I found a lot of information in this book that coupled with other sources was helpful. All a little bit too
vague for a beginner.
Corinchock John A. How To Build And Repair Concrete, Brickwork And Stone 1991.
Again I found good tips on building my fireplace but I would not be able to build anything close to what I
want using just this book.
Time Life home repair and improvement book Masonry. Copy write 1995
Good basic information with tips about other subjects that I can apply to what I need.
Time Life home repair and improvement. Verginia Alexandria copy write 1997
This book was more useful in building that patio than the fireplace. Again good helpful insite.
Audet Mary How to build an outdoor fireplace a step by step guide www.hubpages.com
http://maryeaudet.hubpages.com/hub/How-to-Build-an-Outdoor-Fireplace---A-Step-by-Step-Guide
Morrisan Jonah How to Make an Outside FireplaceEhow September 11 2010 www.ehow.com
http://www.ehow.com/how_6982880_make-outside-fireplace.html
Smith Steve Building a Fireplace Chimney February 18, 2009 www.ehow.com
http://www.ehow.com/how-does_4797340_building-fireplace-chimney.htm
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Rodriguez Gene,III: How to Build a Patio www.Life123.com`
http://www.life123.com/home-garden/landscaping/walkways/How-to-Build-a-Patio.shtm
This is the site I got my best information out of. Again extremely incomplete but tied with Adam’s input
it works.
Mueller Annie: How to Build a Stone Outdoor Fireplace March 4, 2009 www.ehow.com
http://www.ehow.com/how_4829905_build-stone-outdoor-fireplace.html
ewilder105:Outdoor Stone Fireplace Homemade Project Final October 1, 2010 wwwYoutube.com
http://www.youtube.com/watch?v=k_FK8bt1rQU
I like anything I can watch and see how someone else does it. I have always had good luck with youtube
but I was surprised to find that there were not many videos to watch on this subject.
carlfxy: How to cut concrete pavers with a grinder September 16, 2011 www Youtube.com
http://www.youtube.com/watch?v=9tLDa7OX-QE
Again a great tool for finding out how to cut pavers.
Adam Cyr Personal interview Millinocket, Maine March 28, 2012
The best information I found.
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