Thanks guys for the replies! Way to go!
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0- Can you number your questions? It saves on typing and scrolling
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Absolutely. I usually number my questions for easier answering especially when I have 3+ questions but I forgot to do so this time.. Sorry!
Other weird thing, there is no "Edit Post" button on my first post so adding the numbers is impossible for now...
Anyways, Houston Remodeler:
2- I will look for these Backer-on screws as I already have the impact gun... Thanks for the pointer!
3- I will use whatever Durock suggests.... Otherwise, I imagine the same fastening schedule as a shower wall is OK?
4-OK with fiberglass mesh taope and thinset the corners. Kinda like drywall mudding of corners but with thinset...
5-Yes, the fireplace instruction PDF states non-combustibles materials only. Good point on the ditra... I dont think plastic is combustion proof

I will look at the fusion pro grout. Would you use anything special at all or just: steel stud, cement board, thinset and tile?
6-Absolutely agreed for the expansion joints between floor, wall and fireplace hearth... I was more referring to between the different surfaces of the fireplace hearth than between that one and the wall/floor... For example, should my installation allow for the top of the fireplace to "move" independently from the sides/front? I imagine if the whole box expands/contracts the angle between the surfaces will change and eventually whatever grout line there will crack..
7-I work kinda slowly. I am a perfectionist and very delicate/careful in what I do. Tiling this box may take around 2 days for me as I am not in a rush and I do not tolerate defects at all...
8-Haven't spoke to the tile mfg just yet. As a matter of fact, I havent picked up the tile yet. Most likely it will be Fortiflex 2 as my preferred tile is Ceragres and thats what they recommended last time I used that.
9- All right!!
dhagin,
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Are the steel studs 3-1/2" deep, 20 gauge or heavier, 16" OC max? Looks like you need a few more studs.
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The studs are 3 1/2" deep, 20 gauge but on the front they are not 16" OC.. May have to add a few vertical braces I guess... Easily done
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Is there a header over the f.p. opening to support the weight above?
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I had forgot to mention, the top of the fireplace will not be tiles as I will install a wood shelf. Only sides and front will be tiled. I do not intend to have a heavy load standing on the top of the fireplace box perhaps a flast screen TV but otherwise, not much..
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You have a gas shutoff for the f.p. that will remain accessible once the tile is complete?
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Oh yes! The shutoff (safety valve) is located underneath the appliance behind the lower louver. The tile job wont hide anything that we need access to operate the fireplace or for Code compliance.
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Need to remove the finish flooring in the hearth area and see what you have to go over. EG; what is above the joists and is it installed properly? Plug your floor construction info into the Deflecto and tell us what you get AND what the joist spacing is
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hmmmm.... this is a condo unit with a floating concrete slab. I already tiles onto this slab in the kitchen. Worked flawlessly. Under the slab, I have no idea but the constructors have verbally mentioned that it is a wooden structure (engineered beams) with 1.5in wood substrate. Floor is PLENTY rigid, as a matter of fact, the floating slab is not even cracked.
The finished floor was installed by me a few weeks ago

deflecto tool is not really applicable here... Lack of information over the floor/building construction but history suggests the floor is rigid enough for tiling, especially if it is on a vertical surface (IMO).