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ninesquire · Sep 29, 2006, 09:50 AM

I recently had my chimney swept and was told that I have 2 cracks on the existing panels. He instructed me that the only good fix was to replace them both. The bottom panel has a crack through the center, and the back panel has a vertical crack. I was told that the individual cost of these panels is in the area of $500. Can I repair the existing panels, or perform the work myself? Are there repairs for this? What about placing a steel grate on/over the bottom panel (to prevent fire or heat from passing through and possibly causing the wood support structure to flash)? Can you direct me to where I can find more information regarding this type of repair?

RickJ · Sep 29, 2006, 12:58 PM

What "panels" is he speaking of? Is your fireplace and chimney brick? If you could possibly post a picture of what you're speaking of, that would help. Depending on what he's meaning by "panels" it may or may not be an easy diy project... or even necessary.

ninesquire · Sep 29, 2006, 01:14 PM

The fireplace is pre-fab. The bottom panel is cement and is what the grate sits on. The back panel is 90 degrees to the bottom panel.

RickJ · Sep 29, 2006, 01:24 PM

Sorry; but I'm not familiar with pre-fab fireplaces. In fact I've never heard of it. I would get a 2nd opinion on the repair - asking specifically if the "panels" can be repaired rather than be replaced... and if not, exactly why not. It may very well be that they want to replace them cause they get a big markup on the materials. If it can be repaired and meet code, then I'd definitely look to have it repaired instead of replaced.

skiberger · Sep 29, 2006, 09:08 PM

Is this a zero clearance unit? (metal unit w/ concrete panels at the sides , back and bottom)If it is, the panels are removable. They are held in with clips. You can replace these yourself. You need to remove the front portion of the fireplace to access the panels properly.
A friend was quoted a high price by a chimney sweep for his cracked panels and he replaced them himself for a 1/3 of the cost. ( I forget how much) He got his panels over the internet. Be careful, his first set arrived damaged.

If it is a zero clearance unit, under the firebox where the fan is or should be you'll find the info on the unit. There should be metal info tags or a data plate.

ninesquire · Oct 1, 2006, 10:37 AM

Thanks! You described my set up to a tee. So, I can purchase one back panel and the bottom (cement) panel and do the work myself. That is GREAT! Do you have any recommendations as to where I can purchase these items?

skiberger · Oct 2, 2006, 01:48 PM

You can contact a store that sells the fireplace units or the manufacture.

You'll need the serail # and model # of the unit located on the data plates.

haakon · Oct 11, 2006, 12:58 PM

These are usually firebrick panels. I have a wood burning 0 clearance fireplace insert. It has 4 firebrick panels (3 sides plus bottom). If the cracks have wide cracks (you can stick a toothpick all the way through) you should replace the panels - if you can find them. I cannot find the ones for my fireplace - the manufacturer went out of business and it's 18 years old. You should not use panels from a different manufacturer.

To fix the cracks in my panels, I got hydraulic refractory cement and I parged (layered a thick coat over) the panels. Then I made brick impressions with the back of the trowel. My wife didn't like the looks, but after a few fires it looks bad and aged again (which to her it means nicely rustic..? ). Go to a mason supplies specialty shop. They'll have this type of cement and possibly other options.

Another option is to get a mason to remove the panels and build a firebox from firebricks from scratch. This look better than the parging method I used. If you decide to replace the panels, I would suggest you consider replacing the whole insert instead, particularly if your insert is oer 15 years old. Chances are a good new wood insert will be more energy efficient and safer than what you got.

Some links of interest:
http://www.rumford.com/store/cms.html
http://www.rumford.com/articleRefmortar.html

Cheers!

ChimneyTechTX · Jan 11, 2011, 09:12 PM

Fact: Even though the unit may be called a "zero clearence", it still requires you to maintain at least 1/2" to combustibles during installation... I prefer to call these units prefabricated boxes or PRE-FABS. I can tell you that most pre-fab manufacturers quit selling and making replacement panels for units over 10 years old. Manufacturers do this because of new styles, improvements,etc. It's no different than a 1955 Chevy bel-air. Chevrolet only made parts for it for so long. After so long, you have to find someone that specializes in fabricating special or custom parts. Getting back to Pre-Fabs... No matter what, you CAN NOT change, add, subtract or modify a pre-fab unit in anyway, form or fashion. You will void the UL listing and if you are a professional working on a customers fireplace and change, add, subtract or modify the pre-fab in any form or fashion and lose of property or life results, than you may be held liable! Also, cracked panels can never be repaired!! They should be replaced with the same manufacturers replacement panel. IF for some reason they are no longer available through the manufacturer, they can be made by a company that specializes in making custom/specific refractory panels.
I'm a Professional Chimney Sweep and have been, now, for 18 years. I can tell you that if you are paying over $400 per panel installed, than you may very well be over paying for that service and product. Shipment of this particular product should not be taken lightly... it pays to get it shipped un-damaged that first time... I recommmend The UPS Store, they can pick-up the panels and pack them securely and it will be insured. You can add extra insurance to it, if you feel that you need to! Unfortunately, I can not divulge the information of where my custom refractory panels come from, but I assure you that such a place exists! They do it full time and professionally using the same materials that the manufacturer of your pre-fab fireplace used in the first place! Hopefully this will be of some help to whoever may end up with these same issues! Bill Jr.

ballengerb1 · Jan 12, 2011, 05:09 PM

Good start Chimneytechtx, one post one greenie. Keep up the great answers

corawhite · Jan 13, 2011, 06:35 AM

I have a insert in my home , The back firebrick or a little shot well big shot
How do I go about repairing these in the Back?:I haven't the first Clue:confused:

fireplaceguy · Oct 11, 2012, 09:05 AM

You most likely have found an answer by know but for anyone else having this same probllem, try this site: http://www.woodstoves-fireplaces.com/hargrove-fireplace-refractory/

RYAN279 · Oct 30, 2012, 10:43 PM

I bought a house recently that already has a pellet stove insert. The pellet stove quit working and was looking to replace it with a wood insert. After removing the pellet stove I found that the heat shields on both sides of the fire box are bent, I'm guessing someone tried to remove them or maybe the whole box itself. Can thesepanels be hammered back into place or does the whole box need to be replaced?