Masonry Introduction
Masonry is a foundational element in the world of construction, known for its strength, durability, and timeless aesthetic appeal. In this masonry guide, we will walk you through the step-by-step process of installing various types of masonry, including brick, concrete block, and stone.
Each type of masonry presents their own types of unique challenges, and by the end of this guide, you'll have the knowledge and confidence to tackle any DIY masonry project.
Materials and Tools
Depending on the project, whether preparing to install bricks, blocks, or stone, your material and tools may differ slightly. However, for most masonry projects you will need the following tools, supplies, and materials:
- Brick or block trowel
- 2 foot and 4 foot levels
- Jointers and pointers
- Mortar (mud) boards
- Scaffolding (depending on job scope)
- Gauge tape
- Clean rags
- Empty pails
- Access to clean water for mixing
- Type S Mortar
- Diamond blade saw
For your safety and protection, you should also have the following Personal Protective Equipment (PPE) readily available:
- Hard hard
- Safety glasses
- Face shield
- Gloves
- Hearing protection (ear plugs or earmuffs)
- Steel toe boots
- N95 dust mask or half mask with P100 filters
Preparing the Surface
Preparing the surface is a crucial first step in any masonry project. It sets the foundation for a sturdy and long-lasting structure. For brick, block, stone, and natural stone installations, the surface preparation involves cleaning the substrate thoroughly to remove dirt, dust, and debris. Ensure the surface is level or plumb and free from any obstructions. A properly cleaned and prepared surface will not only enhance the bond between the masonry material and the substrate but also contribute to the overall integrity.
Mixing Mortar
When it comes to mixing mortar for masonry projects, you have two primary options: manual mixing in a pail or using a standalone electric or gas mixer.
Pail Mixing (Ideal for Small Home DIY Projects): Pail mixing is suitable for smaller-scale projects such as a DIY home renovation or repair. Start by wearing appropriate safety PPE, then combine the mortar mix and water in a clean pail following the manufacturer's recommended ratio usually found on the bag. Using a trowel or electric handheld mixer, mix the components until you achieve a uniform consistency similar to peanut butter. Pail mixing is convenient for projects with limited mortar requirements and offers control for precise mixing.
Standalone Electric or Gas Mixer: For larger projects involving extensive masonry work, utilizing a standalone electric or gas mixer is the preferred choice. These mixers are designed to handle larger quantities of mortar efficiently. Follow the manufacturer's instructions for the correct mortar mix ratio and operate the mixer until the mixture reaches the desired consistency. For DIY home projects that are of larger scale, you could look at the option of renting a smaller standalone mixer from your local tool rental shop to help reduce labor and save time.
Installing Brick
Bond Layout
Begin by planning the layout and bond of the brick wall. Measure and mark the starting point, corners, and endpoints to ensure a straight and level installation. Use strings and gauge sticks to create guidelines.
Cutting Bricks
When laying out your brick bond, you will likely need special cuts or half bricks to fit at the ends or around obstacles. Use a brick saw with a diamond blade to carefully cut the appropriate sizes for your project needs.
Lay Bricks
Carefully set each brick into mortar, pressing them firmly while maintaining uniform gaps for mortar joints. Use a level to ensure the bricks are plumb and level.
Fill Mortar Joints
Using a brick jointer or pointer trowel, fill in the gaps between each brick. Ensure smooth and consistent joints.
Clean Excess Mortar
While the mortar is still fresh, clean off excess mortar on the brick faces using a jointer or a wet sponge.
Cure and Brush Finish
Allow the mortar to cure for at least 24 hours before further handling. Finish by brushing or washing the brick surface to remove any remaining mortar residue.
Installing Concrete Block
Bond Layout
Similarly to laying bricks, plan the layout and bond of the block wall. Measure and mark the starting point, corners, and endpoints to ensure a straight and level installation. Use strings and gauge sticks to create guidelines.
Cutting Blocks
Cut blocks as needed to fit at the ends or around obstacles. Use a block saw with a diamond blade to carefully cut the appropriate sizes based on the project scope.
Lay Blocks
Place each concrete block into a mortar bed, pressing it down firmly and ensuring it's level and plumb. Start by building the corner leads and fill in between afterwards using a string line as a guide.
Install Reinforcements
Insert rebar into cores as required, and use horizontal reinforcement ladder wire as required by specs.
Fill Mortar Joints
Fill the gaps between blocks with mortar, using a pointing tool to create smooth, consistent joints.
Concrete Core Filling
After completing several courses of blocks and allowing them to cure, fill cores with concrete to enhance stability and strength.
Cure and Finish
Allow the mortar and core fill to cure for at least 24 hours before further handling. Finish by brushing or washing the block surface to remove any remaining mortar residue.
Installing Manufactured Cultured Stone
Concrete Core Filling
After completing several courses of blocks and allowing them to cure, fill cores with concrete to enhance stability and strength.
Surface Preparation
Begin by cleaning the wall surface where you plan to install the cultured stone veneering, and ensure it is structurally sound.
Wall Prep Work
Securely install a heavy duty tar paper to the surface prep area, which provides a moisture barrier and helps promote adhesion. Next, install diamond mesh lath over the tar paper. The mesh lath offers support for the masonry material and enhances its bond with the substrate. Make sure it is securely fastened to prevent any movement during the installation process.
Applying Scratch Coat
Spread a scratch coat of mortar onto the substrate using a trowel. Create grooves or scratches using a firm brush to enhance adhesion.
Install Stone
Apply mortar to the back of each cultured stone veneer piece and press it firmly onto the scratch coat. Ensure to maintain consistent spacing and patterns.
Fill Mortar Joints
Fill the gaps between veneer pieces with mortar using a pointing tool. Aim for uniform and aesthetically pleasing joints.
Masonry Maintenance
Maintaining your masonry work is essential to ensure its longevity and visual appeal. Regularly inspect your masonry for any cracks or damage and address any issues promptly to prevent further deterioration. If you find any deteriorated mortar joints, clean out the loose pieces and repoint with new mortar. By performing regular maintenance, you can preserve the beauty and durability of your masonry work for years to come.
Potential Hazards
Ensuring safety in home construction or any building projects should always be a top priority. Even on the cleanest work sites, potential hazards may exist. Start by conducting a thorough assessment of your surroundings to identify and mitigate potential risks. Be aware of hidden hazards, such as slips and trips over cords or items that may be in walkways, and be aware of any pinch points or crush hazards. Remember, working safely is not just a task, it's a responsibility that should never be compromised.
Summary
Whether installing bricks, concrete blocks, or manufactured cultured stone, it is important to remember safety and quality.