Pallet boards are a great choice for this type of use since they are short and easily fit the dimensions of fireplace surrounds with minimal cutting required. But there are many other sources of wood that is distressed and weathered.
How to Find Reclaimed Wood
There are many sources for finding reclaimed wood. Some of the makers in this gallery were fortunate enough to have access to barn wood at relatives’ farms. Much reclaimed wood—the most desirable kind that comes from warehouses, barns, bowling alleys, and school gyms—is costly to purchase from retailers. However, some reclaimed wood from online retailers can be fairly affordable. Reclaimed paneling from distributor Elmwood Reclaimed Timber typically costs $6 to $10 per square foot range, though that does not include shipping and handling.
Pallet Wood
Wooden shipping pallets are generally built from rough-sawn hardwood or softwood lumber. They are sometimes manufactured right at lumber mills for sale to shipping companies, but there are also specialty manufacturers that build wooden pallets to specifications from buyers. It’s becoming steadily more common for pallets to be recycled to manufacturers for reconditioning and resale, but you can still find pallet wood being given away for free. The advantage of pallet wood is that it is prestressed and the pieces come in short lengths, many of which require no cutting as you assemble a fireplace surround. All that’s needed to “harvest” such wood is a tarp, hammer, pry bar, and a reciprocating saw to disassemble the pallets where you find them.
Outside businesses: Before taking a pallet you see discarded behind a company’s loading dock, always speak to the business owner. Pallets are not always free for the taking. Sometimes they are rentals, slated for return; or the owner may have plans to reuse or sell them. A pallet ownership stamp (CocaCola, USPS, etc.) is usually a tip-off that the pallet is not fair game. Pallets weathered outside have an attractive, weathered look. However, pallets that have been outdoors for too long tend to break down when you disassemble them.Craigslist: Some businesses charge a nominal fee of $5 to $7 per pallet to customers willing to come and pick up old pallets. It is well worth going through Craigslist or other similar websites to look for these offers. Paying this fee ensures that there will be no problems with taking the pallet, and you may get to see photos ahead of time to verify their condition.Pallet manufacturers: The businesses that sell shipping pallets to warehouses and shipping companies may offer both new and recycled, weathered pallets. Knowing the growing market for pallet wood in decorative applications, some of these companies now welcome business from individuals, even those wanting just a pallet or two for a small project. If there is a wood pallet company in your area, a quick call to the order desk will determine if they are willing to sell old pallets to individuals.
“Manufactured” Reclaimed Wood
New wood that is either factory- or DIY-distressed can sometimes be cheaper than authentic reclaimed wood. You can build a fireplace surround for less than $100 by using new wood from a home improvement store and then distressing it yourself. Stikwood is one brand of factory-made replica reclaimed wood that sticks directly on the wall with pull-tab adhesive strips. Other companies specialize in salvaging, cutting, and packaging reclaimed wood, offering it for sale by the square foot. Buying weathered wood in this way is not a money-saving option (these boards sometimes cost more than new wood), but it can be a good option if you have no free or low-cost sources for pallet wood and other types of reclaimed wood.
Safety Concerns
The International Residential Code, a model code adopted by many municipalities, does allow for combustible materials, such as wood sheathing, to be placed directly on fireplace surrounds. However, all combustibles must remain at least 6 inches from the fireplace opening. Many people create a frame of ceramic tile or firebrick around the fireplace opening to create this 6-inch buffer between the fireplace and wooden surround. If you have an electric (non-flammable) fireplace, you do not have these clearance restrictions. If you have a particular model, consult your local permitting office or municipality rules to learn if there are any restrictions on your fireplace. Be aware that some of the following examples may use reclaimed wood in a way that is restricted in your community. She accomplished this by:
Being highly selective about the palletsCutting nails off with the reciprocating sawStacking pallet boards of varying textures and colorsUsing a vintage beam from a relative’s old barn to create the wood mantle.
