Masonry Basics
When you build with bricks you are creating something that can be cherished for generations. It is not uncommon to find structures in complete ruin except for the masonry, such as a brick chimney or wall.
The reasons for masonry yourself vary, but the main reason seems to be cost. Others include learning a valuable skill to start a new business or simply learning a new hobby. Planning a masonry project begins with gathering ideas and visualizing the end result. Don’t skip this step. Masonry is permanent, so be careful and remember to get it right – the results of your efforts will be out in public view for a long, long time.
When beginning your planning, it is important to consider size and scale, location, material selection, drainage, and appearance. Make detailed drawings of the planned project to eliminate design flaws and help estimate construction costs.
Visit your local home improvement center or hardware store and collect samples of the material you have in mind and evaluate how they blend in with your existing landscape. Depending on whether you plan to pour a small slab or build a brick arch, calculate the dimensions of your project as accurately as possible. This eliminates additional shopping trips. Since you use bricks, your local brickyard is where you’ll find the best supply of masonry supplies. They also carry the tools you will need.
Speaking of the tools, and in order to work effectively, you will have to buy or rent some special tools. I suggest if this is a one time project you rent the tools. The following is a suggested list of masonry tools:
Mortar Hawk – to hold mortar
Wide Pointed Tool – for placing mortar on brick
Articulator – for finishing joints
Brick flip flops – to carry multiple bricks
Narrow pointer – for placing mortar on bricks
Mason’s trowel – for applying mortar
Masonry chisels – for splitting bricks
Mason’s hammers – for chipping bricks
Maul – to drive stakes
Joint chisel – for removing dry mortar
Shop broom – to keep the work area clean
Bucket and scrub brush
Stiff bristle brush: to remove loose material
rubber mallet
Pipe clamp: for marking large amounts of brick
Circular Saw (with masonry blade) – for cutting bricks
Hammer drill with masonry bit
Wheelbarrow – for mixing mortar
shovel
Cement – for mixing mortar
Particle mask, gloves and protective glasses.
A useful tip is to build your project, if possible without using mortar. This allows you to see the finished project, make corrections along the way, and decide if the end result is really what you wanted.
The last thing I’ll cover is choosing, mixing, and pouring the right mortar. Masonry mortar is a mixture of Portland cement, sand, and water. Other ingredients include lime and gypsum to improve workability and control setting time. Believe it or not, the strongest mortar mix is not always the best for the job. Fortunately, gone are the days when DIYers had to mix mortar from scratch, often with disastrous results. Currently, the mortar comes pre-mixed in 50 to 100 pound bags. Today simply select the right mix for the job at hand.
Type N mortar is often requested because it offers a good combination of strength and durability. It is commonly used on non-load bearing projects such as freestanding walls, barbecue grills, and fireplaces.
Type S mortar is a high-resistance mix for exterior use in foundations, brick and block reinforcing walls, driveways, walkways and patios,
Type M mortar is a very high resistance mortar for load-bearing exterior stone walls.
There are other types of special purpose mixes, but for the sake of simplicity I have left them out of this article.
Mixing mortar is simple these days. I dump a bag or two of mix into a large wheelbarrow, push it to the side, and slowly add water until I get the right texture I want. If it’s too thick it will fall off the palette in a bunch and not in the smooth line you want. Add a lot of water and it’s messy and weak. Just follow the manufacturer’s instructions and you should be fine. If you’ve never mixed mortar before, experiment in small batches until you find a mix that works. Make a note of your mix ratios to use later.
Do not mix mortar in large batches unless you are willing to use it all in one application. More than one hobby mason has ended up with a wheelbarrow full of 200 pounds of dry mortar for this reason. It is best to mix the mortar as needed. You can’t anticipate delays like bad weather, running out of daylight, or worse, getting injured.
Seeing a professional mason at work is an impressive sight. I remember when I was a little boy he lived with my grandparents and watched his new home being built. The mortar practically flew off the workers’ trowels and the walls seemed to lift off the ground in minutes. “Throwing Mortars” is an acquired skill that takes years to master, but you can use the basic techniques successfully with just a little practice.
Throwing mortar is a fast and smooth technique. Load the trowel with mortar (how much depends on your comfort level), then set the trowel a few inches above the starting point. In one motion, begin to rotate your wrist and quickly move the trowel across the surface to spread the mortar evenly. Ideally, you should end up with a mortar line about 2 1/2″ wide and about 2′ long.
These are the basics. There are numerous books and how-to videos on countless masonry projects. Just remember to plan accordingly, take your time, and above all, be safe.